DUBAI MUNICIPALITY

DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 19

MECHANICAL WORKS

DM/DNID Section 19 Mechanical Works Rev 00 June 2016 Page i of 1

 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

DM/DNID Section 19 Mechanical Works Rev 00 June 2016 Page i of iv

 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

SECTION 19 – MECHANICAL WORKS

CONTENTS
19 MECHANICAL WORKS ....................................................................................... 1
19.1 METAL AND PLASTIC MATERIALS ................................................................... 1
19.1.1 Aluminium Alloy .............................................................................................. 1
19.1.2 Steel ................................................................................................................ 1
19.1.3 Stainless Steel ................................................................................................ 1
19.1.4 Reinforced Thermosetting Plastics ................................................................. 1
19.2 METAL AND PLASTIC PREFABRICATED ITEMS ............................................. 5
19.2.1 Ladders and Safety Hoops ............................................................................. 5
19.2.2 Open Mesh and Chequered Plate Flooring .................................................... 6
19.2.3 Stainless Steel Open Mesh Flooring ............................................................... 6
19.2.4 Aluminium Guard railing.................................................................................. 7
19.2.5 Stainless Steel Guard railing ........................................................................... 7
19.3 FINISH ................................................................................................................... 7
19.4 MATERIALS ......................................................................................................... 7
19.5 SETTING OF MACHINERY .................................................................................. 8
19.6 VALVES ................................................................................................................ 8
19.6.1 General ........................................................................................................... 8
19.6.2 Non-Return Valves.......................................................................................... 9
19.6.3 Gate Valves for Sewage and Related Fluids ................................................ 11
19.6.4 Air Valves ...................................................................................................... 11
19.6.5 Back Pressure Valves ................................................................................... 13
19.6.6 Flap Valves ................................................................................................... 13
19.7 PENSTOCKS ...................................................................................................... 18
19.7.1 General ......................................................................................................... 18
19.7.2 Stainless Steel Penstocks ............................................................................. 19
19.7.3 Plastic Penstocks .......................................................................................... 20
19.7.4 Actuators ....................................................................................................... 21
19.8 PRESSURE AND COMPOUND GAUGE FOR SEWAGE .................................. 21
19.9 MECHANICALLY CLEANED BAR SCREEN (GENERAL FOR
SEWERAGE AND DRAINAGE APPLICATION)................................................................... 22
19.9.1 Description .................................................................................................... 22
19.9.2 Performance and Design Requirements ....................................................... 23
19.9.3 Coarse Screen Design Specifications........................................................... 23
19.9.4 Controls and Instrumentation ........................................................................ 25
19.9.5 Spares........................................................................................................... 27
19.9.6 Installation and Testing ................................................................................. 27
19.10 SCREENS AND SCREENINGS HANDLING EQUIPMENT FOR
SEWAGE PUMPING STATION ............................................................................................ 28

DM/DNID Section 19 Mechanical Works Rev 00 June 2016 Page ii of iv

 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.10.1 Materials ....................................................................................................... 28

19.10.2 Item Description ............................................................................................ 28
19.10.3 Washpactor Performance Guarantee ........................................................... 30
19.10.4 Shop Tests .................................................................................................... 30
19.10.5 Spare Parts ................................................................................................... 30
19.10.6 Installation ..................................................................................................... 30
19.10.7 Field Performance Tests ............................................................................... 30
19.10.8 General requirements for all screening and compaction equipments ........... 31
19.11 BAR SCREEN AND SCREENINGS HANDLING EQUIPMENT FOR
DRAINAGE PUMPING STATION ......................................................................................... 31
19.11.1 General ......................................................................................................... 31
19.11.2 Materials ....................................................................................................... 32
19.11.3 Description .................................................................................................... 32
19.11.4 Operation for Automatic Raking Machine ..................................................... 34
19.11.5 Unit Control Panel ......................................................................................... 35
19.11.6 Shop Tests .................................................................................................... 35
19.11.7 Spare Parts ................................................................................................... 35
19.11.8 Field Performance Tests ............................................................................... 36
19.11.9 General requirement for all screening and compaction equipment .............. 36
19.12 PUMPS ................................................................................................................ 36
19.12.1 Pump Performance ....................................................................................... 36
19.12.2 Pump Casing ................................................................................................ 37
19.12.3 Casing Wear Rings ....................................................................................... 38
19.12.4 Bearings ........................................................................................................ 38
19.12.5 Sealing .......................................................................................................... 40
19.12.6 Pump Shaft ................................................................................................... 41
19.12.7 Centrifugal Sewage Pumps .......................................................................... 42
19.12.8 Horizontal Mounting ...................................................................................... 44
19.12.9 Vertical Mounting .......................................................................................... 44
19.12.10 Couplings .................................................................................................... 46
19.12.11 Installation .................................................................................................. 46
19.12.12 Sump Pumps / Drain Pumps ...................................................................... 46
19.12.13 General Requirements................................................................................ 47
19.12.14 Submersible Pumps ................................................................................... 48
19.12.15 Axial Propeller Pumps ................................................................................ 51
19.13 ODOUR CONTROL EQUIPMENT ...................................................................... 54
19.13.1 General ......................................................................................................... 54
19.13.2 Ventilation and Odour Treatment .................................................................. 54
19.13.3 Materials ....................................................................................................... 55
19.13.4 Enclosures and Covers ................................................................................. 56
19.13.5 Ductwork (Incorporating Dampers) ............................................................... 57
19.13.6 Carbon Deodoriser Units .............................................................................. 60
19.13.7 Bio filter Units ................................................................................................ 61
19.13.8 Chemical Absorption Units ............................................................................ 62
19.13.9 Two-Stage Odour Control System ................................................................ 70
19.13.10 Hoses ......................................................................................................... 73
19.13.11 Drench Showers ......................................................................................... 73
19.13.12 General requirements for odour control units for main sewage pumping
stations ....................................................................................................... 73

DM/DNID Section 19 Mechanical Works Rev 00 June 2016 Page iii of iv

 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.14 VENTILATION .................................................................................................... 74

19.14.1 Wall Mounted Air Conditioning Units ............................................................ 74
19.14.2 Centralised Air Conditioning Systems........................................................... 75
19.14.3 Split Unit Air Conditioners ............................................................................. 76
19.15 CENTRIFUGAL FANS (AIR BLOWERS) ........................................................... 76
19.15.1 General Construction .................................................................................... 77
19.16 LIFTING EQUIPMENT ........................................................................................ 77
19.16.1 Electrically Operated Traversing Cranes ...................................................... 77
19.16.2 Manually Operated Lifting Equipment ........................................................... 79
19.16.3 Lifting Frames ............................................................................................... 80
19.16.4 Lifting Davits ................................................................................................. 80
19.17 GAS DETECTORS ............................................................................................. 80
19.17.1 Portable Gas Detectors: General ................................................................. 80
19.17.2 Portable Gas Detector .................................................................................. 81
19.18 SURGE SUPRESSION & CONTROL ................................................................. 81
19.18.1 General ......................................................................................................... 81
19.18.2 Intersection of Welds .................................................................................... 82
19.18.3 Vessel Geometry .......................................................................................... 83
19.18.4 Sight Glasses ................................................................................................ 83
19.18.5 Inspection Port .............................................................................................. 83
19.18.6 Main Access Flange ...................................................................................... 83
19.18.7 Safety Relief Valves & Pressure Gauge ....................................................... 84
19.18.8 Bolting & Gaskets ......................................................................................... 84
19.18.9 Radiographic Testing .................................................................................... 84
19.18.10 Welding ....................................................................................................... 84
19.18.11 Marking of Vessels ..................................................................................... 84
19.18.12 Compressors .............................................................................................. 85
19.18.13 Automatic Air Volume Control System........................................................ 85
19.19 SUPPORTS AND FIXINGS................................................................................. 86
19.20 SUPPORT FOR PIPEWORK AND VALVES ...................................................... 86
19.21 SUPPORTS AND ANCHORS ............................................................................. 87
19.21.1 Process Piping .............................................................................................. 87
19.21.2 Building Services Piping ............................................................................... 90
19.21.3 Execution ...................................................................................................... 93
19.22 VENDOR LIST .................................................................................................... 97

DM/DNID Section 19 Mechanical Works Rev 00 June 2016 Page iv of iv

 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19 MECHANICAL WORKS
19.1 METAL AND PLASTIC MATERIALS
19.1.1 Aluminium Alloy
Aluminium alloys shall be selected as having properties appropriate to the duty of the
unit, the method of fabrication and the environmental conditions.

The materials shall be manufactured in accordance with an approved International

Standard and shall be anodised when specified.

Alternative alloys may be proposed by the Tenderer if the manufacturer considers its
properties more appropriate to the application, the environmental or the physical
conditions prevailing.

19.1.2 Steel
Steelwork shall be manufactured / fabricated in accordance with an approved
international standard. Where specified or detailed steel work shall be hot dipped
galvanised in accordance with an approved International Standard at the place of
manufacture / fabrication.

19.1.3 Stainless Steel

Stainless steel shall have the following composition with mechanical properties to the
appropriate approved standard.

Table 19-1 Required Properties for Stainless Steel

Element Percentage Chemical Composition
Welded Fabrication Cold Fabrication
% minimum % maximum % minimum % maximum
Carbon - 0.03 - 0.07
Silicon 0.20 1.00 0.20 1.00
Manganese 0.50 2.00 0.50 2.00
Nickel 11.00 14.00 10.00 13.00
Chromium 16.50 18.50 16.50 18.50
Molybdenum 2.25 3.00 2.25 3.00
Sulphur - 0.03 - 0.03
Phosphorous - 0.045 - 0.045

Alternative, higher grade, stainless steel may be proposed by the Tenderer if the
manufacturer considers its properties more appropriate to the environmental or
physical conditions.

19.1.4 Reinforced Thermosetting Plastics

Reinforced plastic shall be as follows unless otherwise agreed in writing by the
Engineer.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 1 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

1) Manufacturing Standards
The specification for design, materials, construction, inspection and testing of plant
manufactured from reinforced plastics shall conform to the appropriate sections of the
approved standard.

2) Resins
a) Isophthalic, Terephthalic, Bisphenol and Vinyl Ester resins may be specified
and they shall comply with the approved standard. The resins used shall
have a minimum strain to failure of cured cast resin of 2%.
b) Pigments or fire retardant resins (or fillers) shall only be used when specified
or ordered in writing.
c) Additives shall not be included in the resins unless they are required for
viscosity control.
d) Due attention must be paid to preclude the possibility of air inhibition
occurring on the laminate surfaces. The inclusion of paraffin wax, etc., must
be in accordance with resin suppliers’ recommendations.
e) Where protection against Ultra Violet light degradation is required, a
translucent UV inhibitor shall be included in the outer layers of the laminate.
3) Curing
Curing systems shall be in accordance with the Resin Manufacturer's
recommendations. The manufacturer of the laminate shall demonstrate that the
laminate has been adequately cured prior to its acceptance at the laminator's works.

4) Reinforcement
a) 'E' type glass chopped strand mat reinforcement shall be to the approved
standard and shall be to a maximum unit weight of 600 gm/m².
b) 'E' type glass woven roving fabrics shall be to the approved standard and
shall be to a maximum unit weight of 800 gm/m².
c) 'C' type glass veil (or synthetic fabric veil, where use is agreed by the
Engineer), shall be used to reinforce all surface sealing resin layers on
laminates.
d) Use of 'ECR' Corrosion Resistant glass will be permitted.

5) Structural Design
a) The laminate shall be designed to withstand all the loadings normally carried
by the laminates.
b) Under the worst combination of loading conditions, a maximum strain of
0.2% shall be permitted in the laminate.
c) A minimum laminate thickness of 6 mm shall be maintained for all GRP
laminates including the facings over or under stiffener sections.
d) Stiffener sections may be used to increase the rigidity of a structure. The
minimum glass reinforcement content shall be 1.2 kg/m² in these areas.
Depending upon the application, stiffener sections may be manufactured
from the following materials :
i. Polyurethane Foam

DM/DNID Section 19 Mechanical Works Rev 00 June Page 2 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

ii. Marine Plywood

iii. Other material agreed in writing
Stiffener sections shall not be made from steel or metal sections unless written
consent has been previously obtained. Where stiffening sections are employed they
shall not be construed as adding to the strength of the section to which they are
added. Plywood stiffeners shall not be acceptable for access ladders.

6) Moulds
Moulds shall be of adequate rigidity to retain dimensional stability and permit a high
level of laminate consolidation. The mould surfaces shall be of a quality which will
ensure the surface finish of the product.

7) Fabrication Methods
Manufacture shall be by approved mechanical methods wherever possible. Items
produced by hand lay-up processes will only be permitted if a suitable mechanically
manufactured product is not available. If deposition of resin by gun is used, this must
be carried out by airless spray technique.

a) Unreinforced gel coats shall have a maximum thickness of 0.5 mm.

Unreinforced flow (top) coats shall be fully brushed out to remove resin rich
areas. The flow coat shall not exceed 0.3 mm in thickness.
b) Surface veil or synthetic fabric reinforced layers shall consist of
approximately 90% resin by weight. The thickness of this reinforced layer
shall not exceed 0.5 mm.
c) Chopped strand mat layers shall have a resin content of between 65% and
75% by weight.
d) Woven roving glass fabric layers shall have a resin content of between 40%
and 60% by weight.
e) Where edges of laminates are cut or exposed these shall be sealed with a
continuous layer of fully cured resin.
f) Bisphenol or vinyl ester protective layers to isophthalic / terephthalic
laminates, shall be applied with a 'C' type glass veil (or synthetic fabric veil)
reinforcement after hardening of the substrata. When this has sufficiently
cured to prevent movement, a continuous flow (top) coat of bisphenol or vinyl
ester resin shall be applied and fully cured. In such cases it is anticipated
that an appropriate paraffin wax additive will be required to prevent air
inhibition of the surface.
8) Samples
a) A sample measuring 1 metre square and typical of each different laminate
proposed shall be submitted for approval together with a detailed descriptive
specification at least 4 weeks prior to the commencement of manufacture.
b) Production samples measuring 300 mm square and typical of each different
section of laminate shall be submitted to the Engineer's duly authorised
Inspecting Engineer throughout the period of manufacture for the purpose of
testing.
c) Samples of liquid and cast resin together with reinforcements and surfacing
veils (or fabrics) required to manufacture the samples indicated in (b) above

DM/DNID Section 19 Mechanical Works Rev 00 June Page 3 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

shall also be made available to the Engineer.

d) Failure to provide any of the samples designated in (a), (b) and (c) above
shall be construed as representing a delay in completion of the Contract
under the terms and conditions contained therein.
9) Tolerances for Moulded GRP

Table 19-2 Thickness Tolerances for Moulded GRP

Nominal thickness Moulding from Moulding from Matched metal
(mm) open mould. closed mould mouldings
(mm) (mm) (mm)
Up to but not p 0.50  0.20  0.18
including 1.5
1.5 to but not  0.75  0.30  0.20
including 3.0
3.0 to but not  1.10  0.50  0.30
including 6.0
6.0 to but not  1.50  0.75  0.40
including 12.0
12.0 to but not  2.00  1.40  0.50
including 25.0
25.0 and over  3.00  1.90  0.65

10) Quality Control and Testing

a) The following tests for inspection and quality control shall be carried out:-
i. The laminate shall be fully cured and shall show full resistance to a
commercial acetone sensitivity test.
ii. The laminate shall give Barcol Hardness of at least 90% of the resin
manufacturer's recommendations. The measurement of hardness by
means of a Barcol Impresser shall be carried out in accordance with the
approved standard.

b) Resin burn off tests shall be performed on cut-outs, where no such cut-outs
exists the Engineer reserves the right to have 50 mm diameter cut-outs for
checks to be made on local glass reinforcement content. The tests shall be
conducted in accordance with the approved standard and the result shall
define glass content.

c) The following strengths of the laminate shall be determined in accordance

with the approved standard.
i. Ultimate tensile unit strength
ii. Flexural strength
iii. Lap shear strength
iv. Shear and Peel strength of bond between thermoplastic linings and
laminate shall be at least 95% of the minimum value specified by the
laminate manufacturer.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 4 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

d) Where a laminate has been designed to take bolts in the makeup of the
structure tests for bolt bearing strength shall be performed. Bolt bearing
strength tests shall be performed in accordance with the approved standard.
e) Where a laminate is to be used in conjunction with electrical control
equipment all or part of the following additional tests may be called up which
shall be carried out in accordance with the approved standard.
i.
ii. Electrical strength of sheet parallel to the plane of the sheet.
iii. Electrical strength of sheet normal to the plane of the sheet.
iv. Electrical strength of casting laminating resin system.
v. Insulation resistance of laminated sheet using IEC taper pins.

f) Additional tests may be called up at the discretion of the Engineer.

g) Certificates of Inspection and Testing
i. Test Certificate shall be obtained from the resin supplier for the heat
distortion temperature of resin and the unreinforced resin extension to
failure.
ii. Test Certificates shall be obtained from the glass reinforcement
manufacturer for each grade and type of glass employed in the fabrication
of the laminate.
All the tests referenced in (a) to (f) above shall be witnessed by the Engineer or his
Representative unless waived in writing by the Engineer.

11) Trial Election

A sufficient proportion of the fabricated sections of the structure must be trial
assembled to demonstrate the correctness of fit of the various sections.

19.2 METAL AND PLASTIC PREFABRICATED ITEMS

19.2.1 Ladders and Safety Hoops
Ladders and safety hoops shall be manufactured from either stainless steel or
approved glass reinforced plastic, as specified in the contract documentation.

The materials of ladders and safety hoops shall be in accordance with an approved
international standard.

Stringers of stainless steel ladders shall be 65 mm by 12 mm and spaced 375 mm

apart. The rungs shall be 25 mm dia. reduced to 20 mm dia. at the ends and welded
on both sides of the hole in the stringer and shall have an approved antiskid surface.
Rungs shall be spaced at 225 mm centres. The ladders shall be provided with fixing
brackets or the ends of the stringers shall be turned over to form fixings. The fixings
shall be drilled for 16 mm diameter bolts. Spacing between fixing brackets shall not
exceed 1200 mm.

Stainless steel safety hoops shall be of circular pattern fabricated from 50 mm by 10

mm flats and shall be provided at centres not greater than 900 mm and distance from
floor to safety hoop shall not exceed 2500mm. Fixing shall be by 12 mm dia.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 5 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

countersunk screws with washers and nuts, the screws being inserted from the inside
of the ladder stringers. Vertical straps for safety hoops shall be 5 in numbers of 50
mm x 10 mm S.S flats to an approved International Standard fixed to safety hoops
with M12 countersunk screws inserted from inner side of the hoop.

Dimensional details of GRP ladder shall be similar to stainless steel ladder.

All fixing brackets, screws, bolts and nuts, etc. shall be SS grade 316 S16.

Ladders shall be fixed to the structure using Resin Anchors S.S Grade 316, size
M12 minimum.
All ladders shall have proper hand holds.

19.2.2 Open Mesh and Chequered Plate Flooring

Open mesh and chequer plate flooring shall be of mild steel, aluminium or reinforced
plastic.

Bearing bars for metal flooring to be serrated to form an antiskid surface.

Alternatively, twisted cross bars may be welded on top bearing bars to achieve the
required antiskid property. Reinforced plastic flooring shall have a similar non slip
tread surface.

Bearing bars shall be designed to achieve a loading capacity of 500 kg / m2

minimum.

Deflection under a concentrated load of 100kg shall not exceed span/200 for metal
flooring and span/100 for reinforced plastic flooring.

Unless a higher grade of protection is detailed, all mild steel flooring shall be hot dip
galvanized after fabrication.
All anchor bolts used for fixing the frame for flooring to structure shall be S.S 316
resin anchors

19.2.3 Stainless Steel Open Mesh Flooring

Open type flooring shall be of stainless steel grade 316L complying with the
requirements of BSEN ISO 14122-2001 (BS5395:Pt 3: 1985 and BS4592: Pt 1 2006),
Suitable for a super imposed loading of 5kN/m.sq. The flooring shall be rectangular
pattern type constructed from main span bars designed to suit the loading and made
up of suitable size panels for ease of handling and complete with welded on nosing
bars. The mass of any individual panel shall not exceed 40kg. Where floor panels are
supported on structural members, adjustable type fixing clips or shot fired fixings shall
be provided with a minimum of 2 clips per panel, securing each corner with 2
additional clips for end panel covers. Where floor panels are contained within angle
curbing, fixing clips are not required. Where angle curbing is provided, this shall
complete with bent flat lugs welded on for grouting into the surrounding concrete at
maximum 900mm centres and at a maximum of 150mm from each end or corner.
Flooring shall be of such depth to ensure that deflection does not exceed span/200 or
10mm whichever is lesser when fully loaded. Support beams of grade 316 stainless

DM/DNID Section 19 Mechanical Works Rev 00 June Page 6 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

steel shall be provided, including all cleats and fixing bolts to facilitate easy removal
where necessary. Fixing clips shall be stainless steel grade 316 material. Where cut
outs are required in flooring around pipe work or other obstructions, a continuous
nosing bar shall be fully welded to all load bearing bars around the cut out. The
clearance around the obstruction shall not exceed 30mm.

Flooring shall be untreated mill finish (welds as laid), pickled clean or electro-polished.

19.2.4 Aluminium Guard railing

Unless otherwise specified or ordered, aluminium guard railing shall be constructed
with tubular rails fixed to double ball pattern solid forged standards. Both rails and
standards shall have a minimum outside diameter of 38 mm.

The rails and standards shall be of aluminium alloy anodised after fabrication. The
standards shall be fitted with base plates approximately 150 mm x 65 mm x 16 mm
thick.

Heights of rails, overall dimensions and details of the bases for the standards, fixing
bolts and any other special requirements relating to the guard railing are shown on
the drawings.

19.2.5 Stainless Steel Guard railing

Tubular handrails and standards shall be constructed of schedule 40, stainless steel
tubes of 32 mm nominal internal diameter. The ball on the standards shall be of
adequate size to accommodate the rails which shall be fixed by grub screws or by
approved fixings.

Height of rails, overall dimensions and details of the bases for the standards, fixing
bolts and any other special requirements relating to the guard railing shall be as
shown on the drawings.

All guard railings shall have approved toe plates, 6 mm thick and 150 mm wide, or
to an approved size at the base of standard, irrespective of the material of railing .
Toe plates shall be fixed to the standards with suitable clamps. Standards shall not
be drilled for fixing toe plates.

19.3 FINISH
All covers flanges and joints shall be properly faced, bored, fitted, fixed, hollowed
moulded or chamfered as the case may be according to the best approved practice.
All working parts of the plant and other apparatus shall in like manner be well and
accurately fitted, finished, fixed and adjusted.

19.4 MATERIALS
All materials incorporated in the works shall be the most suitable for the duty
concerned and shall be new and of first class commercial quality, free from
imperfection and selected for long life and minimum maintenance.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 7 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.5 SETTING OF MACHINERY

The machinery shall be mounted on flat steel packing of thickness selected to take up
variations in level of the concrete foundations.

The packing shall be bedded by chipping or grinding of the concrete surface.

Packing shims of approved material and of the appropriate thickness shall be located
adjacent to each holding down bolt. The number of shims shall not exceed three at
each location.

The machinery shall be aligned, levelled and pulled down by the nuts of the holding
down bolts with a spanner of normal length. No grout shall be applied until the
machinery has been run and checked by the Engineer for stability and vibration.

Where specified an approved high performance non shrink grout shall be poured to
bed the equipment.

19.6 VALVES
19.6.1 General
Valves and penstocks shall be capable of withstanding corrosion in the ambient
conditions.

Nylon or other thermoplastic materials liable to attack shall not be used where
hydrogen sulphide is likely to be present.

All valve waterways shall be coated internally with a solvent free epoxy or polyester
lining of 100% solid content to be applied at the place of manufacture. The lining
shall be of 300 micron nominal thickness and holiday free.

All valves and penstocks will normally be witness tested at works.

Unless otherwise specified all valves and penstocks shall be anti-clockwise opening
and the maximum effort required, applied at the circumference of the hand wheel to
operate the valves against the maximum unbalanced head shall not exceed 55kg.

Valves, 400 mm and above in nominal diameter shall have a suitable gear box

All hand wheels shall have the words “open" and “close" in Arabic and English with
arrows indicating the direction of rotation cast on and shall be coated in plastic, nylon
or other approved materials in order to withstand the ambient conditions.

Unless otherwise specified or agreed spindles and extension spindles shall be of

stainless steel Grade 316 S16.

Extension spindles, where required, shall be connected by suitable muff type

couplings manufactured from stainless steel grade 315S16. The muff couplings shall
be supplied drilled with nuts and bolts for connection to the spindles.

A clear polycarbonate tube shall be securely fitted to protect the thread of rising
spindles for penstocks.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 8 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

The nuts shall be of gunmetal or synthetic material and mating surfaces of gates and
bodies shall be of gunmetal, copper alloy or approved synthetic material.

All construction bolts, nuts and washers shall be in S.S grade 316.

Valve bonnet shall be fixed to valve body with bolts and nuts; fixing bonnet with bolts
screwed into drilled and tapped holes in valve body not acceptable.

All fixing brackets, bolts and nuts, washers, etc. shall be SS grade 316 S16.

All valves shall have the following embossed in casting:

a) Manufacturer’s badge
b) Type of casting/ material code
c) Nominal diameter
d) Pressure rating /Flange drilling
e) Year of Manufacture

Where "Operation by Tee Key" is specified the valve or penstock shall be supplied
with a suitable yoke with a squared cap of standard size to receive the tee key.

The key shall be supplied at the rate of one key per two valves or two penstocks
unless the valve or penstock is to be installed in an isolated location in which case
one key shall be supplied for each fitting location.

Before delivery to site all working surfaces shall be thoroughly cleaned, and, if metal,
protected by grease.

Packing must be sufficient to ensure complete protection of the fitting during transit
and storage.

Valves under 300 mm diameter together with all hand wheels and other easily
detachable items on both valves and penstocks are to be packed in timber packing
cases and properly bound with steel packing bands.

All valves of 300 mm and over are to be protected with wood or plywood discs or
flanges together with straw rope and hessian wrapping.

All valves shall be open–end tested and copies of manufacturer’s test certificates shall
be submitted to the engineer prior to installation of the valves

19.6.2 Non-Return Valves

Unless higher pressure ratings are required for the pipelines non-return valves shall
have a pressure designation of 10 bar which shall be marked on the valve body.
Unless detailed to the contrary to suit existing pipe work, flanged valves shall have
their flanges to a pressure of 10 bar and be drilled accordingly. The face to face
lengths of the valves shall be either 2 x ND + 100 mm or to an approved international
standard, the longer length to be allowed for in all cases using make up pieces where
necessary to achieve the required lengths.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 9 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Non-return valves shall be manufactured to conform to the requirements of an

approved international standard. Valves shall be of the single door swing check type
and shall have bodies of ductile iron or cast iron with copper alloy / gun metal
seating for body and the swing door for sewerage application and with resilient
faced disks for irrigation application. Valve spindles and all construction bolts shall be
stainless steel grade 316 S16. Door to spindle connections shall incorporate a
keyway.

All valves shall be clearway, and lugs provided on screwed seats, etc., for assembly
purposes shall be removed.

Wafer type valves are not acceptable for sewage application.

In sewerage, the valves shall be constructed to allow solid matter to fall clear of the
valve flap and shall have 90 mm solid passing capacity unless impracticable for the
specified size of the valve.

Valves shall be provided with a removable cover on top of the body casting, to
enable the hinge and door to be inspected or removed. Valves of sizes ND 400 mm
and above shall have at least 2 numbers of jacking screws of suitable sizes for
easy removal of the cover from the body casting.
The door opening shall be restricted to a maximum angle of 70° at the hinge,
measured from a plane passing through the hinge at right angles to the axis of flow.
Swing Check Valves shall be of anti-slam type and valve shall be provided with
extended door spindles fitted with lever arms suitable for balance weights.

Wherever specified, non return valve shall be provided with limit switch, operated by
external cams rigidly attached to the door spindle. The limit switch shall operate
when the valve door has moved through an angle of approximately 10°. The switch
shall be suitable for the environment in which it is installed.

All components of the valve shall be suitable for highly saline ground water and / or
for sewage of high concentration of hydrogen sulphide in dissolved or gaseous state

Valve shall be suitable for continuously fluctuating flow as well as steady flow and
swing door shall be suitable for frequent closing and opening without any undue
strain on door – seat or hinge pins.

Pressure rating for swing door-seat also shall be 10 bars and any leakage across door-
seat shall not be acceptable. Valve shall not leak across swing door at back pressure
as low as 0.1 bar or even lower.

Valve spindle/shaft to be lavishly sized and easily removable . Stuffing box and
gland arrangement for shaft sealing shall be extremely reliable and free from leakage.

Protective coating for inner and outer surfaces, shall be fusion bonded epoxy or
approved two component epoxy and shall be to 300 micron DFT and holiday- free,
and application of coating to be at place of manufacture. Construction bolts shall
be Stainless Steel Grade 316 and shall not be coated. Coating shall be guaranteed for

DM/DNID Section 19 Mechanical Works Rev 00 June Page 10 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

a period of five years from the date of commissioning and acceptance of the
pumping system by the employer unless otherwise detailed elsewhere and approved
by the engineer /employer

19.6.3 Gate Valves for Sewage and Related Fluids

Unless higher pressure ratings are required for the pipeline, gate valves shall have a
nominal pressure designation of 16 bar which shall be marked on the valve body.
Unless detailed to the contrary to suit existing pipe work, flanges shall have a nominal
pressure designation of 16 bar and shall be drilled accordingly. The face to face
lengths of the valves shall be in accordance with an approved international standard.

Gate valves shall be manufactured to conform to the requirements of an approved

international standard and shall be metal seated, for sewerage application, with valve
bodies of ductile iron or cast iron and the seatings copper alloy faced. The gates shall
be of wedge pattern, copper alloy faced with inside screw non-rising stems of forged
bronze or stainless steel grade 316 S16. Valves shall have a packed stuffing box and
gland. Alternatively bolted glands with nitrile rubber O-rings / Sealing rings to an
approved international standard will be acceptable for valves 300 mm or less in
nominal diameter.

Where resilient seated gate valves are detailed(for TSE network only ) the valve
bodies shall be ductile iron or cast iron. The gates shall be of ductile iron or cast
iron and wedge pattern with vulcanised (firmly bonded) nitrile rubber or EPDM lining
and with inside screw non-rising stems of stainless steel or forged
Actuator operated valves larger than 300 mm dia. shall have copper alloy faced
guides and slippers. 300 mm dia. and smaller actuator operated valves installed
other than in a vertical position shall have machined guides and gates.

Whenever the valve is specified or shown on drawing to be installed at different

positions than stem in the vertical up-right position shall be provided with special fit to
achieve guiding between surfaces of disc and body. The manufacturer shall
guarantee for the minimum torque and function of the valve when it orients from
vertically installed positions.

Valves shall be provided with drain plugs.

All cast iron and ductile iron used for the manufacture of valves shall be to an
approved international standard.

19.6.4 Air Valves

Unless higher pressure ratings are required for the pipeline, or otherwise indicated in
the Contract Documentation air valves shall have a nominal pressure rating of 10 bar
which shall be marked on the valve body and shall be designed for a liquid
temperature of 52° C and air temperature of 70° C.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 11 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Air valves for pumped pressure pipelines shall be the special high pressure ‘Dual’
large orifice type. The following shall be used as a guide for the general sizing of
large orifice air valves:

Pipeline Bore Air Valve size Ball size

200 20 100
300 25 100
350 50 100/125
450 80 100/125
600 100 125
900 150 125/200
1000* 200 150/200
*For larger mains air valves may be fitted in clusters of two or more as required.

For other duties, such as distribution mains single, small orifice type standard air
valves having a nominal 25mm male thread inlet and with a ball size of 100 mm shall
be used.

The test pressure for different components of the air valves shall be as follows:-

Body 20 bar
Seat 16 bar
Ball/Float 16 bar

All components shall be highly resistant to corrosion due to sewage and very high
concentrations of H2S and other gases. The air valve for sewerage application shall
consist of a compact body, all stainless steel SS 316L fabricated or properly
protected cast iron / ductile iron of approved International standard, hollow direct
acting spherical or concave float in S.S 316 or grade higher in corrosion resistance
and solid large orifice float in HDPE - stainless steel nozzle and woven dirt inhibitor
screen, EPDM rubber seals and seat.

The valve shall have an integral "Anti-Surge" Orifice mechanism which shall operate
automatically to limit transient pressure rise or shock induced by closure to less than
1.5 x valve rated working pressure.

The intake orifice area shall be equal to the nominal size of the valve. Large orifice
sealing shall be affected by the flat face of the control float seating against an EPDM
rubber 'O' ring housed in a dovetail groove circumferentially surrounding the orifice.

Discharge of pressurized air shall be controlled by the seating & unseating of a small
orifice nozzle on a natural rubber seal affixed into the control float. The nozzle shall
have a flat seating land surrounding the orifice so that damage to the rubber seal is
prevented. The valve construction shall be proportioned with regard to material
strength characteristics, so that deformation, leaking or damage of any kind does not
occur by submission to twice the designed working pressure. Connection to the valve
inlet shall be facilitated by flanged ends conforming to PN 16 rating of BS4504.
Flanged ends shall be supplied with the requisite number of stainless steel screwed
studs inserted for alignment to the specified standard.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 12 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

The access cover for air valves shall be in such a position that the valves could be
easily removed for repair/maintenance.

Installation of the air valves shall be at locations shown on the drawings, as

recommended by the pipeline surge analysis or as decided by the Engineer on site.

19.6.5 Back Pressure Valves

The valve body shall be of ductile iron or cast iron with flanges to ISO 5752 series 16.
The valve shall be extra heavy construction with bronze seats, SS 304 stem, nitrile
seals and membrane, bronze and ductile iron closing system, bronze pilot and
strainer, brass accessories, internal and external epoxy paint coating.

The valve controls and maintains a minimum preset upstream pressure regardless of
variance in downstream demand and the throttling of the main valve closing system is
controlled by an adjustable pilot valve operating in conjunction with a needle valve.
The valve is to be provided with a setting range of 1.37 bar to 8.6 bars or as per the
project requirement.

19.6.6 Flap Valves

19.6.6.1 Metal Flap Valves

Flap valves shall be designed for a nominal pressure rating of 10 bar which shall be
marked on the valve body, and a liquid temperature of 520C.
Flaps and frames shall be of ductile iron or cast iron to an approved international
standard with end flange faced and drilled to an approved international standard.
Mating surfaces of flaps and frames shall be of an approved non-ferrous metal
machined to ensure a watertight fit in the closed position.
Hinge pins shall be robust in design and of stainless steel Grade 316 or phosphor
bronze to an approved international standard; all flaps shall be double hung and
seated off the vertical to assure positive closure

Springs shall be of stainless steel, Grade 316 S16.

All cast iron surfaces shall be cleaned by grit or shot blasting to be free from grease,
then coated as specified for the environment. Hinge pins and mating surfaces shall be
smeared with grease.

A positive stop shall be included to avoid over-opening of the flap.

A cast-lifting eye for flap shall be included for manual lifting of the flap.

19.6.6.2 S.S Flap Valves

DM/DNID Section 19 Mechanical Works Rev 00 June Page 13 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Flap valves shall be designed for a nominal pressure rating of 10 bar which shall be
marked on the valve body, and a liquid temperature of 52° C.

Flaps and frames shall be of all stainless steel construction in Grade 316 or higher
with end flange faced and drilled to an approved international standard. Mating
surfaces of flaps and frames shall be of an approved non-metallic material to ensure
a watertight fit in the closed position.

Valve shall be double hinge type for optimum sealing, hinge pins shall be of Stainless
steel grade 316; flaps shall be double hung and seated off the vertical.

19.6.6.2 Plastic Faced Flap Valves

Flap valves shall be faced in an approved synthetic material so as to be corrosion-

free in the ambient conditions. The flap shall be weighted to assist closing and shall
be suitably braced and reinforced.

Hinge pins shall be of stainless steel and all flaps shall be double hung and seated off
the vertical.

Mating surfaces shall be accurately moulded or machined to ensure a watertight fit in

the closed position.

19.6.6.3 Butterfly Valves

Butterfly valves shall comply in all respects with approved International standards.
Body shall be with all flanges faced and drilled to PN 10 or PN16, as detailed, and
face to face length to ISO 5752-Series 13 or 14 as recommended by the engineer and
approved by the employer. Inner face of valve body shall have vulcanized (firmly
bonded) liner of 6 mm thick( minimum), hard rubber or EPDM, whichever is most
suitable for the flow medium, extending seamless over body seat face, bearing bore
and sealing faces of connecting flanges. The disc shall be made of Ductile Cast Iron,
Aluminium Bronze, Stainless Steel Grade 316 or Duplex Stainless Steel complying
with approved international standards and depending on the application. Discs of
ductile iron shall have vulcanized, firmly bonded, 6 mm thick(minimum), seamless
lining of hard rubber or EPDM whichever is most suitable for the flow medium.
Valves with discs of aluminium bronze or stainless steel shall have the inner face of
valve body lined with suitable material, of sufficient thickness, highly resistant to
mechanical stresses due to possible dragging of disc on the sealing seat during
operation. Liner shall be integral part of the body/disc and shall be durable for the life
of the valve. Valves with alternative coating or lining for the inner face of the body
and disc may be acceptable on submission of data sheets and all other documents, to
the engineer, confirming the suitability of the proposed coating material for the flow
medium.

Disk shall be mounted on stainless steel shafts located in PTFE lined self lubricating
bearings with synthetic nitrile rubber shaft seal.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 14 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

The valve disc shall be generally double offset eccentric type fitted with a non-ageing
sealing element of EPDM (EPDM Profile Seal) or similar approved material held in
place by an adjustable one-piece stainless steel clamping ring secured with Stainless
Steel adjusting set screws mechanically locked in place (not resin bonded). The
profile seal shall provide a bi-directional tight shut off in accordance with ISO 5208
Cat.A.

The valve disc shall be as streamlined as possible to ensure lowest head losses and
secure movement without disk flutter. Disc shall be designed for optimum hydraulic
flow pattern with negligible swirl and turbulence of water at two stub ends on
opposite sides of the disc.

The disc shall be designed to withstand maximum specified differential pressure

across the valve in either flow direction. The valve shall be suitable for throttling
operation. Valves shall be suitable for downstream dismantling and dead-end-service.

Mill certificate records, for the body and the disc, detailing mechanical properties,
chemical composition etc. as per EN 10204 3.1B or any other approved international
standard shall be submitted with the valve.

The disc stub shafts shall be manufactured from Stainless Steel, and positively keyed
to the valve disk and incorporate a key securing device (valve discs pinned to stub
shafts are not acceptable).The shafts shall be designed to withstand the maximum
torque that will be imposed by the operator.

The stub shaft bearings shall be of maintenance-free self-lubricating PTFE lined

bushes, and shaft seals of EPDM or equivalent.

The epoxy coated valve gearbox shall be fitted with a sealed for life maintenance-free
travelling fork and nut gearbox, suitable for buried service duty and capable of easy
operation at full pressure differential equal to nominal pressure, embossed in cast iron
casing, grease packed, with ball thrust bearings coupled with hand wheel and position
indicator. Gear box enclosure shall be of protection class IP67 minimum.

Travelling fork and nut gearboxes or slider crank gear boxes shall be used depending
on the size of the valve and according to the pressure rating.

Hand wheels / extension spindles foot brackets etc.shall be provided as standard

wherever detailed. Headstock, if detailed, shall incorporate a valve position indicator
Body seat ring, if applicable, shall be replaceable and of stainless steel Grade 316.
Clamping ring (retaining ring) for rubber profile seal for disc to be of
Stainless Steel 316.

Requirement of double eccentricity for disc shall be waived and centred disc
butterfly valve shall be acceptable under the following conditions:

a) Disc shall be encapsulated in(firmly bonded) or vulcanized with suitable

DM/DNID Section 19 Mechanical Works Rev 00 June Page 15 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

abrasion resistant material of sufficient thickness or shall be of stainless

steel, duplex steel or aluminium bronze to an approved international standard
and replaceable sealing ring is not required.

b) Body shall be lined (firmly bonded) or vulcanized with an appropriate

material and liner shall be an integral part of the body; thickness of liner
generally varying from a minimum of 8 mm to 20 mm in disc sealing area
and 6 mm to 15 mm in other noncritical areas for valves of diameters vaying
from 100mm to 2000 mm. The liner shall be thick enough in shaft sealing
area to guarantee positive sealing in all disc positions.

c) Body liner shall be highly resistant to mechanical stresses due to possible

dragging of disc on the sealing seat during operation. Body liner shall be
guaranteed for long service life without any replacement

d) Valve shaft (two piece shaft) shall be inserted into the disc hubs for a distance
of atleast 150% of the shaft diameter.

e) There shall not be any contact of the pumping medium with the valve shaft
and shaft sealing shall be positive and long lasting.

f) Dismantling of shaft and disc shall be easy.

g) Positive sealing ( tight shut-off) with no leakage in either flow direction shall
be guaranteed.

Protective coating shall be 300 micron DFT fusion bonded epoxy and holiday- free,
and application of coating to be at place of manufacture. Construction bolts to be
S.S.316 and shall not be painted. Transit/ installation damages of protective coating
shall be made good using site repair pack supplied by the manufacturer. If coating /
lining on the inner face of the valve is found damaged the valve shall be rejected and
no field repair of the inner face will be allowed.

19.6.6.4 Knife gate valve

Valve shall be suitable for bidirectional flow and shall guarantee zero leakage shut
off against the full unbalanced head acting on either side of closed slide.

Valve shall have full bore opening available for flow in the fully open position

Valve body shall be nodular cast iron ( Ductile Iron) GGG50 or duplex stainless steel
depending on the application and the body shall incorporate specially contoured
flush-out corners in the invert, such that all solids in the blade guides pushed down
to the invert as the slide is closed are flushed into the flow by the increased velocity
of the medium. The valve body shall have increased clearance in the chest area to
minimise the possibility of solid material causing the valve getting jammed.

The valve slide shall be grade 316L stainless steel, ground on its faces and two long
edges, and shall have a leading edge radius larger than the valve bore radius,
incorporating a single chamfer to give a cutting action through solids in the line onto

DM/DNID Section 19 Mechanical Works Rev 00 June Page 16 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

the body flush invert, ensuring at all times a complete zero leak shut off.

The body/slide sealing system shall be outside the fluid flow path through the valve
so that it is protected from damage due to abrasion caused by solids and grit in the
flow and to ensure long, maintenance-free seal life.

Sealing to atmosphere shall be with replaceable elastomer sealing elements in the

chest of each side of the body, protected against damage by abrasive material in the
fluid.
Pressure Test :Pressure test at 1,5 times maximum allowable working pressure for valve
body. Pressure for seat tightness : 1,1 times maximum allowable differential pressure for
closed valve-No visible leakage allowed.

Knife gate valve for saline ware application shall be of full S.S construction

Pressure rating and flange drilling shall be PN10 unless otherwise specified

19.6.6.5 Plug Valves

Plug valves shall be of the non-lubricating, eccentric type and shall be designed
for a working pressure of 16 bars unless otherwise specified. Valves shall
provide tight shut-off at 1.1 time rated pressure.

Valves shall be of round port design; larger valves with rectangular port design
shall have shorter sides rounded to form semicircles. Plug valves shall have fluid
flow area 95 to 100 % of pipe bore the area being calculated by considering the
distance from plug edge to seat on opposite side with valve in fully open position.
Calculating the bore by considering the distance from seat to seat not
acceptable.

The plug valve body shall be cast iron / ductile iron of approved international
standard with welded-in overlay of 99% nickel alloy content on all surfaces in
contact with the face of the plug. Sprayed, plated, or seats screwed into the body
are not acceptable.

Valve flanges shall be rated to PN16 unless otherwise specified and drilled
accordingly for nut and bolt connection to mating flange.. Drilled and tapped
holes for flanges for connection to mating flange of pipe line not acceptable.

Plug valve shall be furnished with permanently lubricated sleeve type bearings
conforming to approve International standard. Bearings shall be of sintered, oil
impregnated type 316 stainless steel or bronze.

Valves shaft seals shall be of the “U” cup type, in accordance with approved
international standard and seals shall be self-adjusting and repack able without
moving the bonnet from the valve.
Valve shall be with suitable gear box
Valve shall have suitable end stops for full open and full close positions
External position indicators for plug shall be incorporated with the valve.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 17 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Valve shall be suitable for operation with electrical actuators

19.6.6.5 Elastomer check valves

The valve shall be suitable for highly saline ground water.

The valve shall be suitable for frequent opening and closing.
Connection to the pipe shall be with integral elastomer flange drilled to PN 10. Slip-
over pipe type of elastomer check valve not acceptable.

Retaining ring to be S.S 316, to right thickness and shall have a lifting eye welded to
it.
Suitability of the offered valve for the available maximum and minimum flow velocity,
maximum and minimum inlet pressures and maximum back pressure to be confirmed
by the manufacturer.
Valve shall resist “retraction” into the pipe under any situation.

19.7 PENSTOCKS
19.7.1 General
Fixings shall be of the drilled anchor type and made of stainless steel.

All penstocks shall be suitable for an on/off seating head of 10m minimum but in no
instances shall be less than 1.5 the maximum working head.

Penstocks shall conform to the following specifications:

a) Austenitic Ni Resist Cast iron

b) Stainless Steel
c) Plastic
The size of penstock to be used in any particular location shall be as described in the
Contract Documentation and Drawing and shall be approved by the Engineer.

The frame, doors, sealing faces and spindles of each type of penstock shall be as
specified in the appropriate clauses herein.

Unless otherwise described in the Contract Documentation all penstocks shall be

provided with hand wheels of adequate diameter with suitable gearing where
necessary to ensure that the required operating force applied by hand does not
exceed 220 KN.

Hand wheels shall have the words “Open” and Close” in Arabic and English with
arrows indicating the direction of rotation cast on them. The direction of closing shall
be clockwise and a vandal/weatherproof, clear polycarbonate tube cover shall be
securely fitted to protect the thread of rising spindles. The tube shall be clearly and
permanently engraved to indicate the position of the penstock.

Spindles shall have machine cut robust trapezoidal or square form threads as
necessary. They shall be of stainless steel. Extension spindle coupling shall be of
the muff type and they shall be drilled and provided with a stainless steel nut and bolt

DM/DNID Section 19 Mechanical Works Rev 00 June Page 18 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

for securing the spindle to the penstock spindle head which likewise be drilled to take
the bolt.

All penstocks shall be of the rising spindle type unless otherwise stated. Headstocks
shall be provided except in cases where the hand wheels can be mounted on the
penstock frames. Unless otherwise specified, penstocks in general to be designed
without thrust tubes and thrust in both directions of operation shall be absorbed by
the structure. For motorised /actuator operated penstocks, thrust tubes, if specified,
shall be provided between the penstock frame and headstock in order to absorb the
thrust in both directions of operation. Thrust tubes shall incorporate all necessary
fixing brackets and spindle guide plates

Permissible rates of leakage under the specified testing head shall be as follows:

On seating installation - 5 litres per meter of slide perimeter per hour.

Off seating installation - 30 litres per meter of slide perimeter per hour.

The slide perimeter shall be measured as the total length of contact faces between
the gate and frame in the closed position.

All materials used in the manufacture of penstocks shall conform to the approved
international standards.

19.7.2 Stainless Steel Penstocks

The frames and doors of stainless steel penstocks shall be of Grade 316 S31 or SS
316 Ti (DIN 1.4571) The design of the doors shall be such that the required working
pressures can be withstood without deflection or distortion that would affect the
operation of the penstocks. Any strengthening of doors by the provision of ribs and
gussets shall be carried out by welding and not by bolting.

Penstock door shall be designed with deflection not exceeding 1/600 of the width of
opening , deflection being measured at the bottom most edge of the door under 1.5
times working head or 10 metres of water, whichever is higher. Door shall be of
maintenance-free design and plate thickens shall not be less than 6 mm

Penstock shall be designed to achieve 1.5 time safety factor.

The side sealing faces may consist of simple metal to metal contact between the door
and frames or by synthetic rubber seals and plastic guides as necessary to withstand
the required working pressure without leakages.

Spindles shall be manufactured in stainless steel grade 316 S31. Spindle shall be
designed with a safety factor of 3.5 times, to avoid buckling on closing. The hollow
type spindle shall not be acceptable. The penstock shall be generally rising spindle
type (spindle nut shall not be located in penstock door) unless otherwise detailed. The
spindle nut shall be of high tensile material free from dezincification, lavishly sized to
avoid fatigue failures and nut, drive sleeves, and screw threads shall be easily
accessible for inspection and re-greasing. All the components of the penstock shall
be suitable for brackish water of very high salinity and also for sewage with

DM/DNID Section 19 Mechanical Works Rev 00 June Page 19 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

considerable quantity of hydrogen sulphide in dissolved or gaseous state.

The penstock shall be totally surface mounted on the wall and bottom of frame shall
not be embedded in concrete. The frame shall be fixed to the wall using Stainless
steel grade 316 resin anchors of suitable size. Penstock seating (seal) shall be easily
replaceable.

Adequate number of spindle support brackets (S.S 316) to be provided. Spacing of

brackets shall not exceed 2 metres and all stem guides shall have teflon bushes for
friction-less sliding motion of the stem.

Penstock shall be close frame type and soffit member of the frame shall be rigid
enough to resist distortion during transportation and handling.

Detailed drawing showing all structural dimensions for the penstock proposed
shall be approved by the engineer. General specimen drawing shall not be acceptable.

All nuts and bolts shall be in metric standard sizes only. All screws used for fixing
sealing strips for doors shall be easily accessible and sealing strips shall be easily
replaceable.

Penstock shall be suitably rated for minimum on and off seating head of 10 metres
and shall satisfy 1.5 times maximum working head requirement.

Head stock or pillar for penstock shall be robust in design and shall be made of
stainless steel Grade 316 or 316 Ti. The base plates shall be sized and re-inforced
with 4 numbers of gusset plates.

The penstock shall be tested on site for the leakage rates at specified rated head. The
contractor shall make all temporary arrangements for testing the penstock on site.
Leakage rate shall not exceed the specified volume. Each penstock shall be suitable
for both on -seating and off -seating installation.

Guarantee: Penstocks shall have a comprehensive guarantee for a period of 10 years

for material and workmanship and if the material of any component of the penstock is
not in total compliance to the specification for the project and / or if material of any
component is inferior in quality, the manufacturer / supplier and the contractors shall
be responsible for replacement of the penstock at their own cost.

19.7.3 Plastic Penstocks

The frames of plastic penstocks shall be made from continuously welded stainless
steel grade 316 or higher. Frames shall be reinforced and gusseted to ensure rigidity
without dependence upon the bridge which shall be bolted for ease of removal.

The doors of plastic penstocks shall be made from sheets of approved rigid cellular
polymer sandwiched between sheets of approved rigid compressed composite
plastics. The linear coefficient of thermal expansion of the material shall not be

DM/DNID Section 19 Mechanical Works Rev 00 June Page 20 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

greater than 1.6 x 10 per o C. No PVC or GRP materials shall be used. The doors
thus formed shall have sufficient strength to withstand the required working pressures
without deflection, distortion or that would affect the water-tightness of the penstocks.
Totally enclosed steel matrices shall be incorporated in the door construction to
ensure adequate rigidity.

The sealing faces and side guides shall be to the approval of the engineer and shall
consist of plastic strips having a high resistance to sliding wear and a coefficient of
friction of less than 0.10. The sealing strips shall be securely fixed to the inner faces
of the frames and shall incorporate removable stainless steel adjusting devices.

Spindle operating nuts shall be of gunmetal or manufactured from an approved ultra

high molecular weight polyethylene material. The operating nuts for the spindle
retaining blocks shall be fixed in a visible position inside a separate gate lifting
bracket bolted on to the top of the door with stainless steel fasteners. The operating
nut or spindle retaining block shall not be contained within the door.

All plastic materials shall be nontoxic ultraviolet stabilized and shall have fire
resistance in accordance with an agreed internationally approved standard.

19.7.4 Actuators
Where electric actuators are required for valves or penstocks they shall comply with
the requirements of Section 18 the Electrical & Instrumentation Specification.

19.8 PRESSURE AND COMPOUND GAUGE FOR SEWAGE

Pressure gauges for use with sewage and sludge shall be Bourdon gauges. The
pressure transmission system shall be of the air-filled or oil-filled stainless steel
capillary tubing sleeved with suitable reinforced plastic tubing and diaphragm
transmitter. Pressure gauges for submersible pump installations shall be fixed in
control panel room and diaphragm transmitters in valve chambers unless otherwise
detailed.

For the air-filled system, the diaphragm shall be mounted in a clean-out housing. The
transmitter housing shall be mounted directly onto a 25 mm or greater bore straight
through diaphragm type isolating cock. The cock shall be mounted directly onto the
pressure tapping.

Where the gauge is mounted directly on the pressure tapping a Schaffer diaphragm
gauge may be used. Schaffer diaphragm gauges shall be fitted with 20 mm or
greater bore straight through diaphragm type isolating cocks.

All construction bolts for isolation valves and pressure transmitters shall be Stainless
steel grade 316.

All internal components of the gauge shall be robust in design and in stainless steel or
other suitable corrosion resistant material.

Pressure transmitters and directly mounted gauges shall be resistant to high

Vibrations and instrument connection for pressure transmitters shall have integral

DM/DNID Section 19 Mechanical Works Rev 00 June Page 21 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

vibration dampers wherever applicable.

All liquid filled (Glycerine filled) gauges shall have very effective sealing to prevent
liquid leakage from the gauge.

Transmitter body and diaphragm assembly shall be stainless steel grade 316. The
diaphragm assembly shall be durable and replaceable
Gauges shall be graduated in metres of water and bars gauge, together with vacuum
where appropriate. The accuracy of the system shall be 1.50% of range or 2.50m
bar.

Gauges shall have 150 mm diameter circular faces and it shall be made of stainless
steel body. Gauge graduations shall be such that the gauge is never used
continuously beyond 60% of the maximum graduation.

The gauges shall not be connected to air release pipes or auxiliary suction pipes.

The gauges shall be fitted with a pressure snubber to dampen pressure pulsation.

The face shall have a warning label marked in red “IMPORTANT - TURN OFF WHEN
NOT IN USE” both in English and Arabic.

Before delivery, each gauge shall be tested and calibrated in accordance with an
approved international standard and the test certificate/calibration report to be sent to
the Engineer.

Alternatively, digital transmitters and display units of approved model and suitable
range may be used instead of mechanical transmitter and Bourden gauges

19.9 MECHANICALLY CLEANED BAR SCREEN (GENERAL FOR SEWERAGE

AND DRAINAGE APPLICATION)
19.9.1 Description
The Tenderer shall furnish and install mechanically cleaned coarse screens with
multiple rake blades at the locations shown on the drawings. Each screen shall be
manufactured from AISI 316L stainless steel shapes. Fabrication and assembly shall
be in conformance with these specifications.

Each screen shall be furnished complete with bar rack, dead plate, discharge chute,
side frames, covers, rake blades, drive chains, sprockets and bearings, scraper
assembly, drive motor, gear reducer, anchor bolts, controls and all accessories and
appurtenances specified or otherwise required for a complete and properly operating
installation.

The Tenderer shall coordinate all details of the equipment with other related parts of
the work. The Tenderer shall verify that all structures, piping, wiring, and equipment
components are compatible. The Tenderer shall be responsible for all design
including dimensions and structural requirements.

The power supply is 400 Volts, 50 Hz, 3-phase.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 22 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.9.2 Performance and Design Requirements

The screen rake speed should not be less than 6 m/min.

Screen shall be designed for a screenings load of minimum 0.01 m3/m of rake blade
width on all rake blades.

All components shall be so designed that jamming at any point will not result in
structural failure, but will cause the drive motor to stall. All components, including the
gear reducer, shall be designed to withstand, without damage or permanent
distortion, the full stalling torque of the drive motor and/or the maximum differential
head at any channel water depth.

19.9.3 Coarse Screen Design Specifications

19.9.3.1 Material

Screen shall be manufactured from AISI 316L stainless steel shapes (rods, angles,
and channels), pipes, and sheets. In particular, side frames and guides, bar rack,
rake assembly, scraper assembly, shafting, discharge chute, fasteners and anchor
bolts shall be made of this material.

All stainless steel components and structures shall be submerged in a chemical bath
of nitric acid and hydrofluoric acid (pickling bath) to remove any residues that may be
present on the material as a result of forming, manufacture, or handling. After
removal from the pickling bath, the equipment must be washed with a high-pressure
wash of cold water to remove any remaining surface debris and promote the
formation of an oxidized passive layer which is critical to the long life of the stainless
steel.

Chains shall be made of hardened stainless steel. Chain rollers shall be made of
polyamide.

Sprockets shall be made of stainless steel type 316L.

Lower sprocket bearings shall have a stainless steel casing including a shaft made of
white abrasion resistant chromated chilled cast iron and a friction bushing made of
zirconium oxide.

Upper sprocket bearings shall have a paint coated cast iron casing and include ball
bearings that are greased for life and shall be double-sealed with Nilos rings to
achieve protection IP67.

Safety stop mechanism shall be made of a special designed torque control by a

spring package system made in stainless steel. The control must be done for the
forward and backward operation of the screen. Electronic Safety Stop Mechanism
shall be provided as an added protection.

19.9.3.2 Construction

The bar screen shall remove debris (screenings) from the incoming wastewater by
means of a positively cleaned bar rack that is installed in a concrete channel. The
screen shall retain debris at the bar rack. A multitude of rake blades shall remove and

DM/DNID Section 19 Mechanical Works Rev 00 June Page 23 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

lift the debris to a discharge mechanism. Screens with single rakes shall not be
approved. Screens make use of brushes and spray water for screenings removal
shall not be approved.

The bar rack shall consist of equally spaced, straight bars that are inclined from the
horizontal with the inclination specified angle. The lower ends of the bars shall be
provided with a 8mm thick curved base plate such that the rakes positively remove all
screenings from the bottom of the bar rack. Rectangular bars shall have a minimum
10mm x 60mm cross section and shall be equal spacing of 40 mm centre to centre
between the adjacent bars. The bar rack shall be securely fastened to the frame of
the screen and be readily removable.

The bar screen shall be provided with a dead plate extending from the bar rack to the
discharge chute. The dead plate shall be made of a minimum 8 mm thick stainless
steel plate and shall be stiffened by structural members so that it is flat without
undulation so that the tips of the rake’s teeth ride at a distance between 2 and 6 mm
over the dead plate. The dead plate shall be securely fastened to the side frames.
Sides of dead plate shall be 100 mm lip in order to prevent screenings from dropping
off sides of the rake.
A discharge chute shall be provided that fully encloses the discharge section of the
screen. An access hatch with hinges and handle shall be provided in the chute
permitting easy access. The discharge chute shall be mounted to direct screenings
into the appropriate receiving container or conveyor. The chute shall have a slope of
minimum 45 degrees. The screenings shall discharge into the screw compactor. A
pivoting lip plate supported on bearings shall prevent material from re-entering the
channel. The pivot shaft shall include a stainless steel hydraulic shock absorber.
The rake, apron, wiper and chute shall be so designed to avoid screenings from
dropping off from the rake while transporting screenings up and discharging into
discharge chute.
A frame shall be provided supporting all required loads. Side frames shall be made of
316L stainless steel plates and a minimum of four edges and shall have a suitable
width for the size of the screens. The side frames shall be connected to support
frames. The support frames shall be securely anchored onto the operating floor.

The screen shall be provided with easily removable covers made of stainless steel
plates. The covers shall be provided with turn locks and handles.

Neoprene strips shall be fastened to the side frames to seal the lateral gaps between
the side frames and the channel walls.

Each side frame shall include separate roller tracks to guide the rakes. The roller
tracks shall be bolted to the frame so that they can easily be replaced.

Drive chains for the rakes shall be roller type chains and shall be made of hardened
stainless steel. Drive chains, chain guides, sprockets and their bearings shall be
replaceable without removing the screen from the channel.

Chain rollers shall be made of polyamide.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 24 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Upper bearings shall be ball bearings, shall be greased for life and shall be double-
sealed with Nilos rings to achieve protection IP67.

Lower bearings shall be slide bearings in a stainless steel casing. They shall include
white abrasion resistant chromated chilled cast iron shafts and zirconium oxide slide
bushings. Bearings employing slide bushings made of plastic or metal material shall
not be accepted.

The rake blades shall each consist of several segments with teeth/tynes such that
only one of the segments needs to be replaced in case that a tooth is be damaged.
Rake teeth / tynes shall be of curved stainless steel construction and teeth shall not
be less than 18mm thick and shall be of tapered self-relieving design.

A pivoting scraper mechanism shall be positioned at the point of discharge and shall
be attached to the side frames. The scraper shall clean the rake on each pass and
return to its rest position with minimal shock.

The gear reducer shall be a totally enclosed unit. The gear reducer shall be of the
helical worm type and have a service factor rating of 1.25 based on the design
running load. Gear reducer shall have ball or roller bearings throughout with all
moving parts immersed in oil and bearing enclosure to be to IP67 rating. Gear
reducers which require periodic disassembly of the unit and manual re-greasing of
bearings are not acceptable. During continuous operation the oil temperature shall
not exceed 200 degrees F (95 °C).

The rake assembly shall be driven by an electric motor. The motor shall be UL rated
for operation in Class 1, Div 1 environment. The drive motor for each unit shall be
400 V, 3Ph, 50 Hz, severe duty, squirrel cage induction brake motor, with a 1.15
service factor at 52C ambient temperature. The motor shall be closed coupled to the
reducer gear assembly. The motor shall have Class F insulation with Class B
temperature rise and shall be adequately rated (kW) and shall be explosion proof and
with protection IP68 even if not submerged. Cog wheel and pin rack assembly shall
have a minimum service life of 5 years in severe operating conditions in a space of
high concentration of H2S. Chain drives speed reducer and head shaft shall not be
acceptable. The gears on each drive unit shall be enclosed in stainless steel safety
guards. Motors, limit switches, isolators etc shall be rated to IP 68 and shall be
explosion proof. Bearings shall be sealed for life and shall be enclosed to IP67
rating.

19.9.4 Controls and Instrumentation

19.9.4.1 General

The control system shall be designed by the screen supplier.

The screen shall be pre-wired so that it only requires making the electrical
connections from the control panel to a junction box at the screens.

Local controls on screen:

a) One (1) NEMA 4X proximity switches for monitoring of the shaft’s rotation

DM/DNID Section 19 Mechanical Works Rev 00 June Page 25 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

speed.
b) One (1) NEMA 4X frame mounted junction box. The electrical components of
the rake shall be pre-wired to the junction box.
c) Screen shall be retuned back to parking position upon completion of full
cycle or when it shall be stopped as per PLC programme.
d) The machine shall be provided with local control station which should include
lockable LOR selector switch, forward-off-reverse”, spring return to “off”
selector switch and mushroom head emergency stop push button.
e) All cubicles for local controls installed in Screen house shall be in S.S, IP67
and shall be suitable to be installed in hazardous area - Class 1, Division 2.
f) It is preferred to include starters and control of screen in main MCC. The
manufacturer shall provide softcopy of PLC control algorithm to incorporate
within the station main PLC. The manufacturer shall also coordinate with the
MCC vendor till successful commissioning is achieved and required
functionality is implemented.
g) Torque overload limit switch shall be provided to restrict the screens from
overloading due to mechanical or electrical or any other forces.
h) Where a considerably large screening system with multiple machine are
specified the manufacturer could supply a freestanding MCC to be installed
remotely in station MCC room with its own control system encompassing
PLC and HMI. The screen PLC shall communicate with the station PLC/RTU
and eventually configured at local/central remote SCADA system.

19.9.4.2 Water level sensors and float switch

Coarse screen manufacturer shall provide one ultrasonic transmitter with two
separate transducers and electronics package for continuously monitoring of the
upstream and downstream levels for control of screen operation. The transducers
shall be rated for Class 1, Division 2 hazardous locations and shall be intrinsically
safe without the use of additional barriers, complete with built-in temperature
compensation and submerged shield. The transmitter shall be mounted in the control
panel (free-issued by the screen manufacturer). Tenderer shall install the transducers
and provide wiring to the control panel.

Coarse screen manufacturer shall provide a float switch with intrinsically safe relays
and submersible cable for backup control and alarm. Tenderer shall install the float
switch and provide wiring to the control panel.

19.9.4.3 Control Panel

Refer to specification Section 17 – General Mechanical and Electrical Works &

Section 18 Electrical and Instrumentation Works.

19.9.4.4 Sequence of operation

In AUTO position the screen shall be controlled by the water level sensors. Screen
operation shall be started when the water level sensors monitor a certain water level

DM/DNID Section 19 Mechanical Works Rev 00 June Page 26 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

difference, when the float switch senses high water level, or when a certain time has
passed since the last operation of the screen. Screen operation shall be stopped with
an adjustable delay time after the water difference is below a certain value and after
the float switch ceases to indicate high water alarm, or after a certain run time has
expired (if operation was started by timer).

If the proximity switch senses a movement of the upper frame part while the motor is
running forward, the motor direction and therewith the rake movement is
automatically reversed for an adjusted period of time. Then the motor direction and
rake movement is reversed again to forward movement. If the upper frame moves
again during the forward movement, return is repeated one more time. If the upper
frame moves a third time, the screen is shut off an alarm is rendered.

Reset is manually performed after correction of any cause for a trip-out.

In HAND position the operator shall be able to run the rake assembly by pushing the
respective FORWARD or REVERSE tip button.

19.9.5 Spares
The following Spare Parts shall be included for each of the upstream and
downstream coarse screens upon obtaining the Engineer approval and shall be
supplied together with the equipment:

a) 1 set of rake plates

b) 1 set of chain
c) 1 upper bearing
d) 1 lower bearing
e) 1 wiper for scraper
f) 2 shock absorbers for scraper
g) 1 proximity switch
h) 1 set of spares required for screens PLC (as applicable)
i) 1 set of spares required for screens Local control panel
j) And any other item recommended by screens manufacturer as operational
spares 2 years of trouble free operation.
Spare parts shall be packaged with labels indicating the contents of each package,
and shall be delivered to Owner as directed. Tenderer shall include the spare parts
price under mechanical screens in the Bill of quantities and the list of spares required
shall be approved by the Engineer.

19.9.6 Installation and Testing

The equipment shall be factory assembled and witness shop tested. Shop test
reports shall be submitted to Engineer for review.

Installation of the equipment shall be in strict accordance with the contract documents
and the manufacturer’s instructions.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 27 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Supplier shall furnish the services of a factory-trained Service Engineer for one (1)
trip to inspect the installation, observe start up, and provide operator training.

The Service Engineer shall make all necessary adjustments and settings to the
controls and demonstrate proper and sequential operation of the screen. The screen
shall operate automatically based on the water level differential.

The screen shall operate automatically based on the water level differential.

Screens control philosophy shall be submitted to the Engineer for his approval prior to
placing the order of PLC system.

19.10 SCREENS AND SCREENINGS HANDLING EQUIPMENT FOR SEWAGE

PUMPING STATION
The Screenings Handling Equipment for Sewage Pumping Station includes the
conveyor, washpactor, motors and other appurtenances.

Washpactors are normally to be operated automatically and provided with a manual

control device. Washpactor shall be interlocked with screen PLC.

19.10.1 Materials
Design washpactors and appurtenances for long, continuous, and uninterrupted
service; easy adjustment and replacement of parts.

Structural Steel: Provide in accordance with ASTM A36.

Iron Castings: Provide in accordance with ASTM A48 Class 30.

Provide Type 316 L stainless steel for fasteners and hardware.

Stainless steel in accordance with AISI 329, AISI 410.

Provide finish coats for all materials except stainless steel in accordance with this
specification documents.

19.10.2 Item Description

The Washpactor shall be capable of subjecting all incoming sewage screenings to
liquefaction, separation from dirty water, rinsing with clean water and final compaction
to achieve a clean de watered disposable end product. The product shall have
remaining moisture content in the range of 45-55%. Liquefaction shall take place
within a purpose designed tank allowing sufficient retention to achieve maximum
separation of faecal solids from other materials prior to the compaction process.

The dirty washing water and solids are to be separated within the integral Screw
Compactor. Wash water shall be introduced within the Screw Compactor chamber to
provide a final rinsing of separated screenings prior to compaction.

Maceration and disintegration of the total solids will not be accepted.

A screw conveyor shall transport screenings from the mechanically raked screens to
the washpactor. The length of the conveyor shall be in accordance with the Tender

DM/DNID Section 19 Mechanical Works Rev 00 June Page 28 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Drawings. The screw housing for conveyor shall be in stainless steel grade 316.The
screw flights shall be 10 mm stainless steel, minimum, with torque tube of 50 mm or
more and of 4 mm thickness. The screw shall have replaceable wear shoes. The trough
shall have a 80 mm drain to remove the excess water. The bearing for the screw shall
be part of the drive system.

Drive motor shall be suitable for 400 v/3Ph/50 Hz supply and shall be IP68 and
explosion proof.
The screenings shall discharge from the washpactor via a flanged stainless steel
tubular chute(s) with sufficient length to discharge directly into the required collection
receptacle.

A flanged/valved tank drainage point(s) shall be provided at the base of the

Washpactor tank to allow for collected grit flushing and drainage of the tank prior to
maintenance operation.

The complete Washpactor assemblies shall be manufactured from a grade 316 L

stainless steel. All internal small bore pipe work shall be stainless steel or ABS
plastic. The impeller and impeller housing shall be manufactured from a high grade
cast stainless steel and suitably treated to withstand an abrasive condition.

The Impeller(s) shall be directly coupled to the drive motor and sealed on the rotating
shaft by a silicon carbide/carbon mechanical seal. The impeller shall be purpose
designed for the liquefaction of the faecal solid within the Washpactor Tank.

The compactor screw(s) shall be supported at the drive end by an independent self-
aligning thrust and radial load bearing, the screw shall be driven by a shaft mounted
helical geared motor unit. It is not acceptable to support the compactor screw shaft
from the gearbox bearings.

The compactor screw(s) shall be fitted with a hard wearing nylon brush on the
periphery of the screw blades. The brush shall be fixed to the screw blades with
special clamps to allow adjustment of the brushes onto the compactor trough when
wear occurs.

A hinged assembly shall be fitted to the impeller housing(s) to allow for simple
removal of the unit from the Washpactor body.

The Washpactor shall be fitted with low level electrodes of the conductive type to
prevent the unit from operating in a dry condition.

The Washpactor tank roof shall be manufactured from glass reinforced plastic. The
compactor tank covers shall be manufactured from either glass reinforced plastic or
black RPC.

The Washpactor shall be fully electrically wired to a machine mounted junction box.

The Washpactor discharge chute(s) shall be fitted with a hinged extension unit.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 29 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.10.3 Washpactor Performance Guarantee

1) The minimum dry solids content of the Washpactor’s washed screenings
product is 40%.
2) The maximum BOD5 of the Washpactors washed screenings product is 20
mg/g of dry solids.
19.10.4 Shop Tests
1) Motor Tests:
Standard commercial test.

2) Washpactor Tests:

a) Provide check list showing that materials, types and ratings of the screws,
motors and electrical connections and shop test are in accordance with the
contract documents.
b) Test for correct rotation and current draw.
c) Provide certified test data confirming performance guarantees.
d) The equipment shall be shop tested in the presence of the Employer and the
Engineer at the discretion of the Engineer the cost of which shall be borne by
the Tenderer.
19.10.5 Spare Parts
Furnish a list of spare parts items required for washpactor and deliver to Employer:

1) One set of manufacturer’s spare parts for each size of washpactor with all
parts identical and interchangeable for similar equipment.
1) One set of special tools.
2) Any other item recommended by screens manufacturer as operational spares
2 years of trouble free operation.
3) The tenderer shall include these items under the washpactor price in the Bill of
quantities and the list of spares required shall be approved by the Engineer
prior to ordering.

19.10.6 Installation
Install items in accordance with manufacturer's printed instructions.

19.10.7 Field Performance Tests

After installation and services of manufacturer's factory trained engineer, operate
each unit to demonstrate ability to continuously operate without vibration, jamming,
and overheating.

Make all adjustments necessary to place equipment in working order at time of

testing.

Remove and replace equipment at no additional cost to the Employer if unable to

demonstrate to the satisfaction of the Engineer that the mixer assemblies perform the

DM/DNID Section 19 Mechanical Works Rev 00 June Page 30 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

services specified and that they will operate free from vibration and overheating and
that the hoist system operates properly.

19.10.8 General requirements for all screening and compaction equipments

i. All anchor bolts used for installation shall be SS 316 resin anchors.
ii. All construction bolts including those for Carriage motor, gear box and
Plummer blocks shall be SS 316.
iii. Protective coating for motor, gear box and Plummer blocks shall be approved
two component epoxy to thickness 300 micron DFT.
iv. All limit switches shall be IP 68 even if not submerged and shall be easily
accessible.
v. Radial guide / cog wheel and bearing at the bottom and drive chain for raking
mechanism submerged in sewage shall be protected from fibrous materials,
timber logs , even metallic objects, sand and solids in flow stream by suitable
flow deflectors. Guaranteed service life for bottom bearing shall not be less
than 5 years.
vi. Raking mechanism shall be heavy duty and suitable to handle the larger
objects/rubbish like GRP sealing plates in sewage.
vii. The torque limiter shall be suitable for the limited number reverse / forward
operation of rake in the event of such heavy blockages. Electronic Torque
limiter suitable for highest ambient temperature and corrosive environment
specified shall be provided in addition to the mechanical torque limiter to
guarantee additional protection to raking mechanism and this device shall
activate on failure of the mechanical torque limiter in the event of heavy
blockages.
viii. All metal surfaces (except machined mating surfaces and stainless steel) shall
be blast cleaned as specified and coated with two component epoxy to 300
micron DFT
ix. Screening Equipment shall have all local control boxes of appropriate IP65
protection rating in S.S 316

19.11 BAR SCREEN AND SCREENINGS HANDLING EQUIPMENT FOR

DRAINAGE PUMPING STATION
The Screens and Screenings Handling Equipment for Drainage Pumping Station
includes the Bar screen, Raking machine, overhead monorail system, travelling
trolley, grab unit, portal frame structures, trash collection skips and other
appurtenances.

19.11.1 General
All equipment and components shall be designed for the Dubai, UAE climate having
salt laden dusty atmosphere.

Only tropical grade materials shall be used throughout the installation.

Sun shading shall be provided for all outdoor installations to ensure that plant and
equipment operates satisfactorily in the specified ambient conditions.

De-rating of electrical equipment and cables shall be done in accordance with the
specified climatic conditions.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 31 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Electrical panel and equipment shall be suitable for continuous operation in an

ambient temperature. The fact that control room be air conditioned shall not be taken
into account.

Upon the commissioning, the raking machine shall be tested and certified by
competent authorities (third party inspection) for SWL of 500 Kg.

19.11.2 Materials
Bar screens : Stainless Steel Gr.316L
Monorail Track : Hot Dipped Galvanised Mild Steel
Structural Columns : Hot Dipped Galvanised Mild Steel
Trolley Enclosure : Stainless Steel Gr.304
Trolley Frame : Hot Dipped Galvanised Mild Steel
Grab : Stainless steel Gr.316L
Hydraulic hose drum : Stainless Steel Gr.304
Cable Drums : Hot Dipped Galvanised Mild Steel
Fixings & Fastenings : Stainless steel Gr.A4
Hydraulic Tank : Carbon Steel Epoxy Painted
Hydraulic Oil : As per vendor recommendation
Hoist Cable : Stainless Steel Gr. 316L
Cable Trolley : Stainless Steel Gr. 304
Sprockets : Carbon Steel epoxy coated
Chains : Stainless steel Gr. 316L
Dome Nuts : Stainless steel Gr. A4
Cases for External Switches : GRP or thermoplastic (UV resistant)
Cable Ducting : Stainless Steel Gr. 304
Cable Clamp : Aluminium
Structural Steel: Provide in accordance with ASTM A36.

Iron Castings: Provide in accordance with ASTM A48 Class 30.

Provide Type 316 L stainless steel for fasteners and hardware.

Stainless steel in accordance with AISI 329, AISI 410.

Provide finish coats for all materials except stainless steel in accordance with the
specifications.

19.11.3 Description
The screening handling equipment (Raking Machine) includes the overhead monorail
system, a travelling trolley, a grab unit and other appurtenances. The screenings skip
of minimum 6 m3 volume shall be provided and is shall consist of heavy duty wheels

DM/DNID Section 19 Mechanical Works Rev 00 June Page 32 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

and perforated at the bottom. The make & material of construction shall be as per
Dubai Municipality approved make for the skips.

The overhead monorail shall be formed from minimum 10 mm thick single plate to the
required section. The overhead monorail shall include a track for the drive and
support wheels fitted to the top of the travelling trolley.

The single overhead track shall be supported on hollow steel columns and extend
over the width of the bar screen and the screenings unload / dump area, where
screenings collection skip is located.

The trolley unit shall contain the hoisting unit for the grab and the hydraulic power
pack for the operation of the hydraulic cylinder on the grab itself. It is traversed by a
geared motor unit mounted on top of the trolley at one end. Polyurethane coated
heavy duty wheels fitted directly to the gearbox output shaft, run on the inside of the
monorail sections. A second pair of free running support wheels keeps the trolley
parallel with the track.

Power to the trolley will be supplied by a trailing cable (festoon cable and track
system) which contains both power and control leads and is supported on cable
carriages also running in the monorail sections.

The grab unit shall consist of a series of fingers which are opened or closed by a
hydraulic ram. The hydraulic hoses, carrying power to the ram from the power pack in
the trolley, shall wound on one spring tensioned drum which will operate in sequence
with the hoisting drums for the grab support ropes. The grab is laterally held in the
upper position by spring loaded swing restrictor plates.

In operation, the trolley and grab with the fingers open, moves out along the monorail
until it is in the first raking position. Here a proximity switch on the trolley senses a
position plate on the monorail, the trolley stops and the grab is lowered.

As the grab descends, the downstream fingers engage with the screen bars and top
bars on the grab push any accumulated debris to the screen invert. At the invert, the
grab stops and the fingers are closed by the hydraulic rams. The grab is then raised,
together with any collected debris.

When the grab reaches its top position, the trolley is traversed back to the selected
dump position (skip location position / area) where the fingers are opened and the
debris is deposited. The trolley and grab then return to the next raking position.

The raking system should have minimum three raking position (or as required for the
screen width) for the overall width of the bar screen. Each raking position shall be
controlled by a proximity plate on the monorail and the position selected is
determined, in automatic mode, by a Programme Logic Controller (PLC). When all
positions have been raked, the trolley returns and stops at a pre-determined park
position.

If a large amount of debris or other obstruction prevents the grab reaching the screen
invert, slack rope devices on the trolley stop the lowering motion, the fingers are

DM/DNID Section 19 Mechanical Works Rev 00 June Page 33 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

closed and the grab lifted. The collected load is taken to the dump area and
deposited. The trolley then travels to the next raking position and continues its cycle.

The top and bottom hoist limits shall be determined by a rotating cam switch unit. In
addition to the switches for determining the raking and dump positions, limit switches
shall be provided to each end of the trolley to prevent it from contacting the end of the
monorail.

The hoist and slack rope proximity switches shall be backed up by direct contact
mechanical limit switches, as a safety precaution.

The hydraulic power to the grab shall be supplied by an electrically driven pump
directly mounted on a tank in the travelling trolley.

When the grab reaches the screen invert, the downward travel is stopped by the
preset limit switch, the hydraulic pump motor shall starts and a spool valve should
directs the oil to close the hydraulic ram.

The electrical controls then continue the sequence until the trolley is in the dump
position where the spool valve moves to the open position and the hydraulic pump
motor is again started.

As soon as the ram is fully open, the hydraulic pump motor should stop and the
electrical sequence controls shall be re-activated.

In addition to the pressure and spool valves mentioned above, a controlled return flow
valves in the lines to the hydraulic ram and a pressure safety valve to the pump
discharge shall be provided.

A return filter with a renewable element shall be provided on the tank cover. The filter
element shall be spring loaded to facilitate bypass in the case of blocked element.

A timer shall be included in the PLC circuit to prevent loss of oil in the event of a pipe
fracture. A pressure gauge and oil level sight glass are also fitted.

19.11.4 Operation for Automatic Raking Machine

Manual Control at the Machine

With the selector switch on the control panel set to “Remote Manual”, the Raking
Machine to be operated locally by a pendant type push-button station which will be
plugged into a socket on the local control panel.

Push-buttons will be provided on the pendant to operate the traverse, hoist and
cylinder controls individually.

Automatic Control

With the selector switch on the control panel set to “Automatic”, the Raking Machine
to be operated by either of the following methods.

 By depressing the “start ” push-button on the interface

DM/DNID Section 19 Mechanical Works Rev 00 June Page 34 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

 By variable periodic timer control

When the start command is given, the trolley/grab will travel from the parked position
to the first screen raking position and commence automatic cycle as described.

19.11.5 Unit Control Panel

Electrical controls for the automatic operation of the raking machine shall be
contained within a single compartment wall mounting unit control panel.

i. Construction : 2 mm thick 316 stainless steel, folded and

welded, wall mounted enclosure
ii. Cable Ducting : Stainless Steel Gr. 304
iii. Protection : IP65
iv. Finish : Milled finish
v. Dimensions (each control panel) : 900mm high, 600mm wide, 320mm deep
vi. Locking Mechanism : Spanner locks

The unit control panel components and starters shall comply with electrical
specification. The unit control panel shall be provided complete with 24vdc power
supply, PLC, communications module and human machine interface.

Pendent control station for field manual operation.

Audible and visual warning device to indicate that the machine is operating, mounted
on the leg of columns.

Junction boxes, power, control and signal cables complete.

19.11.6 Shop Tests

Provide check list showing that materials, types and ratings of the equipment, motors
and electrical connections and shop tested in accordance with the manufacturer
standard.

Test for correct rotation and current draw.

Provide certified test data confirming performance guarantees.

The equipment shall be shop tested in the presence of the Employer and the
Engineer and the cost shall be borne by the Contractor.

19.11.7 Spare Parts

Furnish a list of spare parts items required for screening handling equipment and
deliver to Employer:

i. One set of manufacturer’s recommended spare parts for screens and screening
handling equipment.
i. One set of special tools.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 35 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

ii. Any other item recommended by screening handling equipment manufacturer

as operational spares 2 years of trouble free operation.
iii. The Contractor shall include these items under screening handling equipment
price in the Bill of quantities and the list of spares required shall be approved by
the Engineer prior to ordering.
19.11.8 Field Performance Tests
After installation and services of manufacturer's factory trained engineer, operate
each unit to demonstrate ability to continuously operate without vibration, jamming,
and overheating.

Make all adjustments necessary to place equipment in working order at time of

testing.

Remove and replace equipment at no additional cost to the Employer if unable to

demonstrate to the satisfaction of the Engineer that the mixer assemblies perform the
services specified and that they will operate free from vibration and overheating and
that the hoist system operates properly.

19.11.9 General requirement for all screening and compaction equipment

All general requirements for screening and compaction equipment detailed for
sewerage are applicable for drainage also.

19.12 PUMPS
This Specification shall be read in conjunction with Section 17 & Section 18.

19.12.1 Pump Performance

a) The pump head versus flow characteristic shall be stable and rise continually to
close valve head and be non-over loading.
b) Pump testing to be in accordance with BS EN ISO 9906.
c) The closed valve head shall be a minimum of 110% of the duty head.
d) The motor shall have a continuous maximum rating which shall be 10% greater
than the maximum absorbed power at any point in the operating range of the
pump within the system characteristics. In each case the de-rating will be
sufficient to maintain the class B temperature rise in accordance with BS 4999
and PD 5000.
e) The net positive suction head (NPSH) required shall be compatible with that
available to enable the pump to operate without cavitation, over the full range of
flows at all sump liquid levels.
f) Contractors shall select the most economic pumps given the constraints of the
operating parameters, as operating costs will be considered in association with
the capital costs in the evaluation.
g) The Contractor shall carry out a feasibility study to determine the best capital
investment with respect to the hydraulic performance. OPEX (Operational costs)
i.e. pump running costs including power and whole life costs shall also be
considered and shall be issued to the Engineer / DM for approval.
h) Pump speeds shall not exceed 1500 rpm for pumps delivering less than 30 l/s

DM/DNID Section 19 Mechanical Works Rev 00 June Page 36 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

and shall not exceed 1000 rpm for pumps delivering greater than 300 l/s.
i) Contractors shall provide technical brochures, for the plant proposed and this
shall include full technical details of thrust bearings, lubrication, and sealing and
protection devices.
j) Where forced ventilation is necessary in order to maintain the design output,
details of the rating of fan motors used for this purpose shall be included in the
tender document. The additional loading represented by forced ventilation fans
will be taken into account when calculating overall system operating efficiency.
k) The velocity through the eye of the impeller shall not exceed 3 metres per
second. Although this does not apply for pumps with “free-flow” vortex type
impellers, it shall be used as a guide to prevent pump selection with excessive
velocities through the pump.
l) Minimum or maximum size impellers for the casing are not permitted. The
Contractor must confirm duty diameters as well as maximum and minimum
diameters in the pump technical schedule.
m) For pumping stations delivering flows in excess of 10m3/Sec, the Pump Supplier
shall cooperate with the Principal Contractor to construct a fully operational
1/10th scale model of the installation to determine the pumping station
performance at a range of flows.
n) This model shall be utilised to specifically determine the following:
iii. Grit deposition.
iv. Screenings settlement.
v. Initiation of eddy currents in the pumping station under all combinations of
pump operations.

19.12.2 Pump Casing

19.12.2.1 Material

a) The pump casing shall be high grade cast iron and be abrasive resistant, capable
of taking shock loads and incorporate lifting eyes located for removal of the
pump. However, for some applications stainless steel will be specified in the
technical schedules.
b) Pump casings and discharge pipe work, up to and including the isolation valves
and non-return valves, shall be rated for the maximum closed valve head
developed; inclusive of the maximum suction pressure or 16 Bar, whichever is
the greater. Pump casings shall be tested to twice the working pressure, or the
maximum surge pressure, whichever is the greater.
c) Pipe work including inline equipment downstream of the isolating valve shall also
be rated for the closed valve head developed unless it is open to atmospheric
conditions.
d) Collared lifting eyes shall be provided for each pump set in accordance with
Lifting Equipment Specifications.

19.12.2.2 Tappings, Hand holes & Drains

a) Tappings for pressure gauges shall be incorporated in the casing except for

DM/DNID Section 19 Mechanical Works Rev 00 June Page 37 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

submersible pumps. The drain plugs shall be provided at the lowest point of the
casing and automatic air release valves from the top of the casing except for
submersible pumps. Each shall be complete with isolating cocks and bleed lines,
to the bedplate tundish (for water pumps), to the pump sump for sewage pumps,
and shall be provided on each stage of the pump. The air release pipe work
shall be not less than 15mm bore, shall be of stainless steel, and shall be fitted
with crosses and couplings to facilitate rodding. A shut off valve of Saunders full
bore straight through type or similar shall be fitted at the high point(s) and a
check valve of approved manufacture shall be fitted above this. Drainage pipe
work shall be fitted as close to the lowest point of the pump suction as is
practicable. The minimum size drainage pipe work and valves shall not be less
than 50mm bore for sewage pump sets. Pipework shall be led to the drainage
system and shall not discharge direct to the floor.
b) For large sewage pumps which are not submersible, hand holes shall be
provided in the pump casing and suction bends to facilitate the clearance of
obstructions which may occur. The hand hole covers shall be shaped so that the
interior profile of the waterway conforms when the cover is in place.
c) Pump inlet and outlet flanges shall be rated to 16 bar as a minimum.
d) Clean water and irrigation pump sets shall be fitted with pressure gauges with
minimum 3/8” BSP fittings on the suction (except submersible) and delivery
branches, complete with stainless steel or brass isolating cocks and snubbers.
For sewage pump sets tappings shall be 50mm NB and fitted with a diaphragm
seal between the sewage and the pressure gauge. Pressure gauges shall be
150mm nominal diameter “Industrial” type. Pressure gauges shall comply with
Section 16690: Pressure Gauges, Dial Thermometers and Pressure Switches.
e) Except for submersible pumps, pump casings shall be specifically designed for
bed plate mounting using support feet machined to a finish to suit its intended
bed plate and incorporating holes drilled and spot faced for holding down bolts.
The feet shall accommodate and transfer all loads to the supporting bed plate.
f) The casing halves shall be accurately aligned during assembly to match the
volute profiles and be doweled to ensure certain repositioning after disassembly.
Means shall be provided to facilitate the separation of the casing halves. On
larger castings this shall be by two or more jacking screws.
g) A separate removable suction casing shall be provided, to gain access to the
impeller without dismantling the discharge pipe work.
19.12.3 Casing Wear Rings
Casings wear rings shall be locked to prevent rotation by dowel or similar approved
method. Ease of replacement shall be a major design criterion. The wear rings shall
be of bronze for potable water or cast iron for sewage and designed such that
hydraulic pressure aids the sealing of the ring into the pump casing. Stainless steel
may be used. Casing wear rings shall be incorporated on all rotating / stationary
interfaces, except for low head sewage pumps such as Vortex types
19.12.4 Bearings
a) The pump shaft shall be supported at both ends by single row bearings with an
option to fit a pair of angular contact thrust bearings if required. Bearing
housings shall have the ability to be retrofitted with a pair of angular contact
bearings without re-machining. All vertical pumps shall be fitted with a pair of

DM/DNID Section 19 Mechanical Works Rev 00 June Page 38 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

angular contact thrust bearings at the drive end.

b) Bearings shall be either oil or grease lubricated, and shall comply with the
bearings section of this specification. Oil lubricated bearings shall be fitted with a
constant level oiler. “V” ring seals shall be provided on the bearing housings.
c) Except for submersible pumps, bearing housings shall be a separate component
and not integral with the casing, to allow replacement of bearings, seals and
sleeves without removing the top half casing when fitted with a spacer coupling.
d) Bearing housings shall have full flange bolting to bottom and top half casings with
a full registered fit. Except for submersible pumps, bosses shall be provided for
vibration monitoring transducers.
e) Where bearing lubrication is by oil, suitable means of filling and draining it shall
be provided together with a suitable means of level measurement.
f) Bearing temperature measurement / protection shall be as specified by DM for
certain non-immersible applications.
g) For aggressive sewage environments, stainless steel bearings shall be offered
as an alternative, for consideration by DM.

19.12.4.1 Thrust Bearing

a) The axial thrust generated shall be taken by an appropriate thrust bearing

arrangement.
b) Thrust bearing arrangements incorporated into the motor housing are not
permitted.
c) Setting of thrust bearings shall account for dynamic loading albeit setting is
carried out with the machinery stationary.

19.12.4.2 Rolling Element Bearing

Ball or roller bearings shall be sealed for life. They shall be rated to give a minimum
life of 100,000 hours at maximum load without replacement. Bearings shall be
protected by water throwers and lip seals.

19.12.4.3 Water Lubricated Submersible Bearings

a) Submersible bearings in shaft driven pumps, such as for irrigation, shall be of the
water lubricated type with corrosion resisting outer shell and internal lining of high
resilience and abrasive resisting properties. The shaft should be protected
locally with shaft sleeves to ensure that particles in suspension in the water do
not cause premature wear.
b) Intermediate support bearings shall be housed in a spider arrangement spigotted
to the discharge column flanges to ensure concentricity. The upper water
lubricated bearings shall be maintained in a lubricated condition particularly on
pump start up, in order to avoid dry running of the bearing.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 39 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.12.4.4 Plain/Bush Bearings

Bush bearings, where utilised, shall be in bronze or as otherwise specified in the

technical schedules, split for easy maintenance, and positively locked to prevent
rotation.

19.12.5 Sealing
19.12.5.1 General

a) The means of sealing shall be dependent upon the application and unless
otherwise required by the Contract shall be as follows:
i. Raw Water : Mechanical Seal
ii. Final effluent/irrigation: Mechanical Seal
iii. Potable Water/Irrigation Water: Mechanical Seal
iv. Sewage: Mechanical Seal
v. Sludge: Soft Packed Gland

b) Adequate access shall be provided to allow maintenance of the shaft sealing

arrangement together with drainage facilities to allow the piped waste of any
sealing lubrication water.

19.12.5.2 Soft-Packed Gland

a) Gland packing shall be graphite impregnated PTFE, of approved

manufacture. Asbestos based packing will not be permitted.
b) The gland design shall incorporate the following:
i. A tapered “lead-in” at the mouth of the gland entry to facilitate packing
replacement and obviate the risk of damage on assembly.
ii. The surface finish of the adjacent metal parts shall be 0.4µm CLA on the
shaft gland sleeve and 1.6µm CLA on the stuffing box bore.
iii. Where running clearances are excessive, the packing shall be protected
by an independent ring of suitably robust material which reduces the
clearance to a minimum.
iv. The packing must not be used as a bearing.
v. All studs, dowels and adjustable nuts shall be manufactured from stainless
steel.
vi. Lantern rings shall be of gun metal or bronze or stainless steel for irrigation
and shall be split for ease of removal. Stainless steel lantern rings will be
used for all aggressive applications.
vii. Pumped water supplies to the lantern ring shall be free from abrasive
solids.

19.12.5.3 Mechanical Seals

a) Mechanised seals shall be designed to operate with a positive suction head and
delivery head as specified. The seals shall, not under normal conditions permit
any controlled leakage from the pump.
b) The Contractor shall specify the type, size and material of the mechanical seal he
intends to supply. It shall be the responsibility of the pump manufacturer to

DM/DNID Section 19 Mechanical Works Rev 00 June Page 40 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

ensure, and to demonstrate in supporting technical information submitted for

design approval, that the tolerances required by the seal manufacturer are not
exceeded. Checks shall be carried out on the pump casing and shafting for:
i. Shaft straightness
ii. Rotational balance
iii. Shaft run-out
iv. Bearing clearance – lateral and radial movement
v. Shaft tolerance and ovality
vi. Concentricity
vii. Seat squareness
viii. Coupling alignment

c) The Contractor shall ensure and demonstrate in supporting technical information

submitted for design approval, that the seat, face and component materials of the
mechanical seal are suitable for the media being sealed. Under operational
conditions thermal loading of the seal components shall be within the capacity of
the seal to ensure that wear rate is minimised.

19.12.5.4 Seal/Gland Drainage

a) Except for submersibles, seal/gland drainage shall be collected in a collecting try

formed integrally with the pump casing stuffing box. The tray shall not extend
high enough to submerge the gland in the event of drain, hole blockages.
Drainage shall be piped to the bed plate tundish located at the non-driven end of
the pump. A water thrower shall be fitted to the shaft between the pump seal and
the motor.
b) The final discharge shall be piped individually from each pump to the drainage
channel in the pump house basement. The drain pipes shall be 38mm dia
stainless steel tube fitted with couplings so as to facilitate removal of any
possible blockages. The tundish opening should be protected with a stainless
steel mesh insert.

19.12.6 Pump Shaft

19.12.6.1 Shaft Sleeves

a) Where shafts are exposed to the process fluid and where they pass through the
sealing gland they shall be fitted with keyed sleeves of bronze or stainless steel,
positively driven and which extend through the stuffing box. The finish of the
sleeve at the seal faces shall be highly polished (15 microns). Where a pump is
drawing water containing suspended solid material then stainless steel sleeves
shall be fitted. The sleeves shall be sealed with an “o” ring and keyed to prevent
rotation. The sleeve shall terminate in the cradle area, to prevent any water
ingress into the buildings.
b) The diameter of the sleeve shall not be taken into account when calculating shaft
stiffness.
c) Shafts shall be of stainless steel. The lower section of any shaft drives shall be
designed to be readily removable to facilitate maintenance.
d) In a dry shaft arrangement a lower grade of shaft material may be used with a

DM/DNID Section 19 Mechanical Works Rev 00 June Page 41 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

duplex stainless steel shaft protecting sleeve.

19.12.6.2 Balance

a) The whole of the rotating assembly, including impeller locking key(s) but
excluding the impellers shall be dynamically balanced as an integral component.
b) The impellers shall be dynamically balanced separately and then assembled to
the shaft, to form without further adjustment, a dynamically balanced whole.
19.12.7 Centrifugal Sewage Pumps
19.12.7.1 General

a) Submersible pumps shall be capable of running partially or totally submersed in a

wet well configuration without overheating. They shall also be capable of
withdrawal from the wet sump without the requirement for entry to the wet sump
for disconnection by maintenance personnel.
b) Pump and motor units shall be designed for a working life of 100,000 hours with
overhauls at not greater than 20,000 hour intervals. All components shall be
capable of renovation during overhaul making maximum use of readily
replaceable parts.
c) Pump motors shall be of premium efficiency.

19.12.7.2 Casing

a) Except for submersibles, the pump casing shall be provided with adequate
access for internal inspection with the minimum of dismantling. External hand
hole covers shall be provided and the contour of the internal volute should not be
affected when the cover is in place.
b) The external surface of the pump casing shall be fusion bonded epoxy coated,
with a minimum thickness of 300 micron.

19.12.7.3 Impeller

a) The Impeller shall be selected by the manufacturer for its ability to handle
sewage. The impeller shall be of the screw, torque flow or semi-open mixed flow
types and made from high grade cast iron, or duplex stainless steel. Ni-hard cast
iron shall be used where high grit content is likely. Provision shall be made to
prevent the build-up of solids behind the impeller. Hydraulic balance holes are
not permitted.
b) Each pump shall be capable of passing a 100mm minimum diameter spherical
solid through the impeller and associated passages without , and be designed for
the sewage and conditions of Dubai. In exceptional circumstances where the
passage size has to be reduced to meet the duty then smaller passages down to
80mm shall be approved by DM.
c) The leading edges of the impeller shall be capable of shearing any rags or
plastics within the pumped media without chipping or splitting.
d) The impeller shall be positively secured to the high tensile steel or stainless steel
pump shaft and dynamically balanced as a whole.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 42 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.12.7.4 Pump Inlet and Outlet

The inlet of the pump must be positioned so that the circulation of fluid to the intake
is not impaired by benching in the sump.

19.12.7.5 Submersible Pumps

Seals Design

a) The pump motor shall be protected by a tandem mechanical seal arrangement.

Lip seals are not permitted. The Contractor shall provide complete data on the
seal materials, seats, faces etc., and ensure suitability for the medium being
sealed.
b) On pumps greater than 5kW the mechanical seal performance shall be by
monitoring equipment to detect the following:
i. Moisture within the oil chamber.
ii. Moisture/water or oil within the motor casing.
iii. Temperature rise of the hydraulic driven end bearing.
iv. Loss of oil from the oil chamber.

Cooling

Cooling of the motors shall be provided by one of the following methods with the
Contractor supplying and installing all of the necessary equipment:

i. On units of less than 7kW cooling may be provided by the casing provided
that the application meets the manufacturer’s requirements for heat
dissipation. Cooling must be sufficient when pumping at sump levels at
top of pump volute.
ii. Oil cooled motor with a heat exchanger in the base plate to the pump bowl.
iii. Water jacket utilising sewage as the cooling medium. A filtering gap shall
be provided to prevent large solids blocking the cooling passages. This
cooling method is not permitted for sludge pumps.
iv. Air cooled for immersible pump sets installed in dry well conditions.
Motors shall be suitable de-rated for the maximum ambient air
temperature.
v. Motors provided with variable speed drives shall not be operated at a
speed below which heat dissipation is reduced below the manufacturer’s
recommendations.

Pedestal

a) The pedestal shall be manufactured from cast iron / stainless steel and shall
incorporate a boltless automatic connection between the pump and the discharge
pipe work and provision for locating and retaining the lower ends of the pump
guide system.
b) The outlet flange of the pump shall seat firmly on the outlet flange of pump stool
with the weight of the pump, and shall not leak when the pump is operating at
maximum pressure.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 43 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

c) Where submersible pump sets are utilised in a drywell situation, the pump inlet
bend / duckfoot support shall include a quick release hand access to facilitate
impeller eye clearance.

Guide Rails

A guiderail system of stainless steel Grade 316L, schedule 80, tubing shall be provided
to ensure simple and effective removal and reinstallation of the pump set. The system
shall be vertical over its entire length, be retained at the bottom by fixings forming part
of the discharge connection and at the top by a bracket / access frame arrangement.
The guide system shall be retained at the lower end by the pump pedestal and at the
upper end by mounting brackets. Guide wires are not permitted.

Guides

The pump body shall be provided with either detachable or integral guides. The guides
shall be accurately manufactured to permit the lowering of the pump without swing or
seizure until connection is made with the pump discharge connections.

19.12.8 Horizontal Mounting

a) Horizontal pump sets shall have the pump and motor mounted on a common
bedplate of cast iron or fabricated steel which shall incorporate machined
reference surfaces to permit levelling of the assembled pump set on its
foundation. The bedplates shall be fully supported on sets of steel packers and
shims which shall be not less than 80mm wide or twice the width of the bedplate
frame drilled for positive location by the same. Not more than three packers shall
be used.
b) The pump shall be mounted on and bolted to the bedplate and unless positively
located be dowelled in its final position with not less than 0.75mm of brass
shimming between the pump and bedplate. The motor shall not be dowelled until
after final alignment on site has been subject to a pre-construction review by the
DM. Dowel pins shall be Grade A in accordance with BS 1804 Part 3 or
equivalent.
c) Back pull out pumps shall comply with is EN 25199.

19.12.9 Vertical Mounting

19.12.9.1 Close-Coupled

Close-coupled pump sets complete with motor shall be mounted on a rigid stool
incorporating the coupling, coupling guards and thrust bearing where applicable.

19.12.9.2 Shaft Driven

a) Where the design requires the pump to be mounted on a separate floor below
the drive motor because of the possibility of pump room flooding or for the
purposes of locating motors adjacent to switchgear, shaft driven pumps shall be
provided. The shaft may be open or enclosed and shall incorporate intermediate

DM/DNID Section 19 Mechanical Works Rev 00 June Page 44 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

steady bearings as determined by the transmitted power, speed, length and

diameter. Intermediate shaft lengths shall not exceed 3m and shall run below
their first critical speed, and be vibration free. Shafting shall be of high tensile
steel adequate to avoid the possibility of fatigue failure and flexible joints of the
“Hardy Spicer” or constant velocity joint type shall be provided.
b) Couplings shall be provided to permit the removal of drive shafts, bearings, etc
without removing the pump or motor. Couplings between the thrust bearing and
motor shall be accommodated within motor support stools.

19.12.9.3 Support

a) The shaft shall be supported such that the weight of the shaft is not transmitted
to the pump and motor bearings. A thrust bearing assembly shall be
incorporated into the drive motor stool to take the weight of the shaft and include
all necessary ventilation and cooling coils if required.
b) Each intermediate shaft shall be independently supported and designed such
that there is no transmission of vibration between supports via walkways, support
steelwork, etc.
c) The Contractor shall be responsible for the design, provision and erection of all
support steelwork for the support bearings.
d) The Contractor shall provide balancing test sheets for the balancing of the
complete fabricated shafts at the Works, for approval under the submittals
section of the general workmanship section of this specification.

19.12.9.4 Support Stool

The support stool shall be manufactured from either close grained cast iron, ductile
iron or fabricated steel. The stool shall be founded on a separate foundation plate
permanently bolted and grouted to the structural floor. The motor stool shall be
located relative to the motor by a machined spigoted flange and to the foundation
plate by the same or dowel pins together with the necessary number of securing
bolts. The upper face of the motor stool shall not be less than 600mm above the
finished motor room floor level.

19.12.9.5 Bearings

a) The intermediate bearings shall be self-aligning ball or roller type housed in

plumber blocks fixed and dowelled to the supporting steelwork, complying with the
bearing section of this specification. Bearing support steelwork shall be sufficiently
rigid to contain any vibration.
b) Bearings lubrication shall be by refillable lubricators giving indication of lubricant
content.

19.12.9.6 Lubrication

Lubrication points or support bearings, universal joint sliders, etc shall be readily
accessible from permanently fixed access platforms provided under the contract or
piped to ground level unless otherwise specified.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 45 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.12.9.7 Balance

After manufacture and assembly, including setting pre-load in the universal coupling
bearings, the shaft assembly shall be dynamically balanced. Completed balancing
records shall be submitted for approval.

19.12.10 Couplings

19.12.10.1 General

a) Couplings shall be provided to permit the independent removal of the pump

or motor.
b) Couplings shall be of the flexible multi-pin and bush type, having not less
than six pin-bushes. Each bush shall have an inner sleeve to allow rotation
on the pin. Bushes shall not be in direct contact with the pin. All pins shall
have shoulders to allow positive location and securing to the bosses.
c) Bosses shall be a tight fit on the shafts and secured with fitted keys.
d) Couplings shall be supplied in matching balanced sets and shall be
machined, balanced and marked before leaving the manufacturer’s
premises.
e) Couplings and all other exposed rotating parts shall be enclosed by guards
and comply with the general workmanship section of this specification.
Guards over couplings shall be designed to be readily removable without
dismantling any other item or accessory.

19.12.10.2 Coupling Alignment

After coupling alignments the DM shall witness and review the machine alignments
which shall be recorded.

19.12.11 Installation
a) The layout of the pump sets shall take into account access to the rotating
elements with adequate clearance between adjacent pumps, pipe flanges,
valves etc. to allow easy access to all parts of the installation for
maintenance.
b) The pipe supports shall be so arranged so that the pump flanges are relieved
of all external loadings from the pipe work. During site erection the
Contractor shall take particular care to ensure that none of the component
parts are stressed due to misalignment of the pipes of other items.
19.12.12 Sump Pumps / Drain Pumps
a) Where specified, sump pumps shall be provided in dry wells where natural
drainage is not possible and in wet sumps which are required to be fully
drained down after a pump cycle, for example, storm pump sump.
b) Sump pumps shall be fully automatic with integral non-mercury level control

DM/DNID Section 19 Mechanical Works Rev 00 June Page 46 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

switches. Integral level float switches shall not operate on mains voltage.
They shall be free standing and suitable for use with 300mm x 300mm x
300mm drainage sumps.
c) Delivery pipe work shall be ABS terminating with a check valve and isolating
valve adjacent to the drainage sump. For dry well applications, a flexible
hose 3000mm long shall connect the pump to the pipework, complete with
hand tightened threaded pipe union to facilitate removal of the pump without
affecting the pipe work.
d) Sump pumps mounted in wet sumps shall be guide rail mounted and comply
fully with the submersible pump specification.
e) Sump Pumps / Drain pumps shall include complete with all the pipe
supports, electrical power supply, cabling, trunking, ducting and starters,
controls as necessary for proper operation as required by Engineer.
19.12.13 General Requirements
Rotary Pumps are required to pump storm/groundwater or raw sewage containing
rags, fibrous material and general waste matter including grit and other abrasives,
partially treated sewage, sewage sludge and/or grit laden sewage.

Pumps shall be designed to pump satisfactorily solids of 90 mm diameter unless

otherwise specified. Freedom from choking is essential and is more important than
high pumping efficiency.

Pumps unless otherwise specified shall be designed to have stable head/quantity

characteristics, so as to avoid large changes of quantity with small changes of head.
The pumps shall be capable of operating with the sump surcharged to its maximum
level and the Pump motors shall be rated accordingly.

The fluid velocity at entrance to pump impellers shall not exceed 3.6 m/s for pumps
with suction pipework larger than 200 mm dia. nor 5.5 m/s for smaller pipework. The
fluid discharge velocity shall not exceed 3.6 m/s for all pumps.

Pump bodies, covers, brackets, bearing housings, wearing plates, eye rings, support
brackets, etc., shall be manufactured from close-grained cast iron or nickel iron.

Pump castings shall be of substantial construction to give long life under abrasive
conditions and to enable them to withstand shock loads caused by solids in
suspension.

Impellers shall be of duplex stainless steel for sewage and storm/groundwater

pumps.

Impellers shall be keyed onto shafts.

Shafting shall be of stainless grade 316 S16 or equal of adequate size to avoid the
possibility of fatigue failure. The duty speed range shall be well below the first critical
speed. At any change in diameter of the shaft the shoulder shall be generously
radiused to reduce stress concentration.

The rotating elements shall be dynamically balanced before final assembly.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 47 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Pump casings shall be hydraulically tested before assembly to a pressure of 1.5

times the closed valve head of the pump plus the maximum suction pressure.

Cathodic corrosion protection shall be provided for the storm/ground water pumps.

Pumps shall be performance witness tested at the manufacturer’s works by the

Engineer in accordance with the appropriate standard using clean cold water. Unless
otherwise specified pumps shall be tested with the motor which will drive them after
installation.

Mass produced pumps shall be tested at factory or at site or required both (as per
Engineer discretion) to prove the duty/guarantee point of pumps.

Special pumps (i.e. those for which the impeller is specially trimmed or otherwise
designed) shall be tested to prove the duty/guarantee point and to develop
Quantity/Head, Quantity/Power, Quantity/Efficiency curves for the pump at operating
speed, or if the pump is multi or variable speed, at maximum and minimum speeds.

19.12.14 Submersible Pumps

Submersible pumps shall comply with the General Requirements for Pumps.

They shall be close coupled units comprising a single, stainless shaft, a squirrel cage
electric motor and a single entry, end suction pump.

Stainless steel lifting frames or eye bolts shall be fitted to casings for connection of
lifting chains.

The motor shall be induction type with squirrel cage rotor, housed in an air filled
watertight chamber. The motor shall have IP 68 protection, the stator winding and
stator leads shall be insulated with moisture resistant class H insulation, rated for
180°C but with Class-B temperature rise. The motor shall be specifically designed for
continuously submerged pump usage and shall be rated for operation both when
submerged in sewage or ground water at ambient temperature and when in air The
motor shall be designed for a minimum of 10 starts per hour.

Over temperature sensors (thermal switches or/and thermistors) shall be embedded

in stator coils to monitor the temperature of each phase winding. These sensors shall
be set to open at 140 C° and shall be used in conjunction with and supplemental to
external motor over load protection and shall be connected to the control panel. In
addition, at least one analogue sensor shall be embedded in one of the phase
windings to enable continuous measurement and recording of winding temperature.
Motor shall also have leakage sensor for stator housing for motor-capacity 7.5 kW
and above

Motors above 30 kW rating shall also be fitted with a lower bearing temperature
monitor and stator housing liquid level monitor. The monitoring equipment shall be
designed and installed so that automatic re-starting of the motor is not possible in the
event of a fault. The monitoring units shall be manufactured by the pump supplier

DM/DNID Section 19 Mechanical Works Rev 00 June Page 48 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

and supplied as free issue to the control panel manufacturer to form part of the
control panel.

Motors shall have a voltage tolerance of plus or minus 10 %.

The power and monitoring cables for motors shall be sized to IEC standards and shall
be of sufficient length to reach the control panel without joints. The motor and cables
shall be capable of continuous submergence without loss of watertight integrity to
depth of at least 30 metres. The cables shall be tough-rubber–sheathed insulated
flexible, highly resistant to heavy mechanical stresses and each core shall be of tinned
copper wires. Pump cables shall be SIEMENS / PIRELLI types N SS HOU-J /
S1BN8-F depending on the size of motor, or equivalent Suspension of cables shall be
with stainless steel cable socks from stainless steel suspension brackets, each cable
shall have separate cable socks.
Two mechanical seals shall be fitted on the shaft between the electric motor and the
pump impeller. The space between these two seals shall be oil filled.

Performance chart shall be provided showing curves for torque, current, power factor,
input / output KW, NPSH required and efficiency. This chart shall include data on
starting and no load characteristics.

Discharge bends shall be of close grained cast iron or stainless steel and shall
provide both pump support and lower guide rail/rope location. The pump discharge
connection system shall be designed so that the weight of the pump provides a
clamping force. Sealing between the pump and bend shall be achieved by the weight
of the pump and there shall be no leakage at the joint between the faces.

Mounting brackets for the pump shall be of Grade 316 S16 Stainless Steel or close
grained cast iron to an approved international standard.
Guide rails and holders shall be manufactured from stainless steel grade 316 S16
rigidly supported at both ends.

Lifting chains shall be of stainless steel, shall be rated for overhead lifting and shall
include shackles for connection to pump lifting points. They shall be at least 1.50 m
longer than the guide rails. Suspension of chains shall be from stainless steel
suspension brackets.

The lifting chain shall be fitted with a stainless steel tag detailing the safe working
load, the test load and the date of testing and the name of the testing authority.

Pumps in general shall be compliant to the following requirements:

Pump shall be suitable for minimum 10 starts an hour.

Protective coating shall be of 300 micron DFT, holiday-free and shall be suitable for
highly saline ground water and also for sewage with high concentration of hydrogen

DM/DNID Section 19 Mechanical Works Rev 00 June Page 49 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

sulphide. The coating shall be guaranteed for a minimum period of two years from the
date of commissioning and acceptance by the employer.

The pumps and ancillaries to be in total compliance to specifications in all respects

other than any deviation, due to technical reasons, agreed by the engineer and
approved by the Employer.

Pumps shall operate at best efficiency at the specified duty point.

Pumps shall be suitable for healthy operation over a wide area on the performance
curve without any abnormal vibration or symptom of cavitation. Pumps with operating
point at lower part or higher part on performance curve at the specified duty point
shall not be acceptable.

Pumps shall be designed to pump satisfactorily sewage with a large fibrous materials
and rags without clogging ; impeller shall be non-clogging type .

Pumps shall have suitable wear rings for the impeller and the volute casing.

Pump / Motor protection sensors shall have all wire leads brought out separate using
suitable multi core cable up to the monitoring unit fixed in the control panel. Provision
of integrated sensor module in the terminal box for pumps with common wire leads to
the monitoring unit in the control panel shall not be acceptable. Sensors and
monitoring / control unit shall be totally reliable with longer service life in ambient
temperature of 52 degree celsius in the Emirate of Dubai.

Pumps shall be quite in operation free from cavitation and vibration /rattling over
entire path of performance curve and shaft speed shall not exceed 980 RPM unless
otherwise specified for any particular application.

Pump guide system: Guide rails longer than 6 metres shall have suitable intermediate
supports; guide rails shall not be supported on riser pipes.

Pump cables shall have suitable additional S.S support bracket to protect the cables
from sharp bend at cable entry on terminal box for motor and brackets shall not
have sharp edges which could damage cables. All propeller pumps with cables in the
flow stream shall have proper cable suspension arrangements to protect the cables
from rubbing against any portion of the discharge column while the pumps are in
operation. Pump cables shall not be tied to lifting chain or rope.

Pump materials shall be according to Table 19-3

Table 19-3 Schedule of Pump Materials

Cast parts Cast iron
Studs, nuts, screws and washers Stainless steel Grade 316 S16
Lifting handle Stainless steel
O-rings Nitrile rubber (700 IRH)
Stationary wear ring Nitrile rubber-clad steel
Rotating wear ring Stainless steel

DM/DNID Section 19 Mechanical Works Rev 00 June Page 50 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Upper Mechanical shaft seals Tungsten carbide/Tungsten carbide

Lower mechanical shaft seals Tungsten carbide/Tungsten carbide
Impeller for Storm/Ground water Duplex Stainless steel
Impeller for Sewage Duplex Stainless steel / Close grained Cast
Iron / High chromium Cast Iron (Hard Iron
EN 12513:2011)
Shaft Stainless steel

19.12.15 Axial Propeller Pumps

19.12.15.1 Materials

The pumps shall be of at minimum, the following grades of materials:

i. Impeller (Propeller) Duplex Stainless Steel.
ii. Diffuser Casing: Grey cast iron EN-JL1030 (A 48 Class 30B)/
Stainless steel Grade 316
iii. Casing Wear Ring: Stainless steel EN-1.4571 (A 276 Type 316 Ti)
iv. Inlet nozzle: Grey cast iron EN-JL1030 (A 48 Class 30B) /
Stainless steel Grade 316
v. Shaft: Stainless steel EN-1.4021+QT800 (A 276 Type
420)
vi. Bearing cover: Grey cast iron EN-JL1030 (A 48 Class 30B)
vii. Cable sheath: Waterproof synthetic rubber compound
viii. Elastomer components: Nitrile rubber (NBR)
ix. Lifting clamp at stopper: Stainless steel EN-1.4462 (A 182 Grade F51)
x. Motor casing cover: Grey cast iron EN-JL1040 (A 48 Class 35)
xi. Lifting clamp: Non-alloy structural steel EN-1.0038
(A 283 Grade B)
xii. Bolts, nuts: Stainless steel A4 (EN-1.4571) (A 276 Type 316)
19.12.15.2 Pump Construction

a) The pump shall be of submersible centrifugal, single stage pumps for installation
in a discharge column driven directly by a fully submersible dry squirrel cage
induction motor. The pump shall be suited for continuous operation in a
submerged condition.
b) The head-capacity curve shall have a single flow rate for each pumping head
value and have a continuously rising head characteristic from the specified
design point to the minimum flow rate so as to ensure stability and control in
individual and/or parallel operation. The operating range of the pump, as
specified, is defined by the maximum and minimum operating heads against
which the pump will be required to operate. At no point within the operating range
shall the pump’s power demand exceed the rated power of the motor.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 51 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.12.15.3 Casing

a) A diffuser casing with a self-centring, force-locked seating for installation in a

discharge column shall be used. Designs requiring additional anchoring or
rotational protection shall not be acceptable. Perfect sealing between the casing
and the discharge column shall be accomplished by an O-ring seal. The single
piece pump casing shall be made of suitable thickness to allow for long pump
life. The inlet nozzle shall have baffle plates for a vortex free inflow. The external
diameter of the pump shall be preferably small in order to minimize discharge
column diameter and friction losses.
b) Critical mating surfaces where watertight sealing is required shall be machined
and fitted with O-rings. Fittings will be the result of controlled compression of
rubber O-rings in two planes and O-ring contact of four sides without the
requirement of a specific torque limit. Rectangular cross-sectioned gaskets
requiring specific torque limits to achieve compression shall not be considered as
adequate or equal. No secondary sealing compounds, elliptical O-rings, grease
or other devices shall be used.
19.12.15.4 Wear Ring

The pump shall be provided with a replaceable wear ring in the pump casing to insure
efficient sealing between the volute and suction inlet of the impeller. It shall be firmly
secured to prevent rotation or displacement.

19.12.15.5 Impeller

The axial propeller shall be of a centrifugal, fiber repellent and self-cleaning, design
for high efficiency pumping of surface water and groundwater. The free passage of
the pump shall be not less than 75 mm. The propeller hub and the 4 blades of fixed
angle of attack shall be a one piece casting of the material as specified. It shall be
smooth, well finished, free from blowholes and imperfections, and be dynamically
balanced. The impeller shall be positively locked to the shaft with a key and lock nut
designed not to loosen, but be easily removed for maintenance.

19.12.15.6 Pump Shaft

The common pump/motor shaft shall be of sufficient size to transmit full driver output
with a maximum deflection of 0.05 mm (0.002 inches) measured at the lower
mechanical seal. The pump/motor shaft shall be of stainless steel or be completely
isolated from the pumped media through the use of a stainless steel shaft sleeve.

19.12.15.7 Bearings

The shaft shall rotate on at minimum 3 / 1 antifriction bearings. The bearing system
shall be adequately designed so as to be capable of handling all axial thrust loads
plus any and all radial loads. The pump bearings shall be regreasable.

19.12.15.8 Shaft Seal

a) Each pump shall be provided with two totally independent, mechanical seals,
installed in tandem, each with its own independent single spring system acting in
a common direction. The sealing shall not depend on the direction of rotation.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 52 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

b) The primary, impeller-side seal shall operate in a large flooded chamber formed
by cast recesses in the impeller and backplate. The impeller-side seal shall be of
bellows type mechanical seal.
c) The primary and the secondary seal faces shall operate in a generously
proportioned lubricant chamber that hydrodynamically lubricates the seal faces to
allow for extended periods of dry-running operation without the need for external
seal lubrication or cooling systems.
d) The lubricant chamber liquid shall be an environmentally friendly and nontoxic.
e) The seal face material of the primary seal shall be of at minimum Silicon Carbide
versus Silicon Carbide (SiC/SiC) for excellent hardness and chemical resistance
across the entire "pH" range. The secondary seal shall be of Carbon versus
Silicon Carbide (Carbon/SiC) for best emergency running properties. The seal
faces must be of a solid material capable of being re-lapped. The seals shall
require neither routine maintenance nor adjustment, but capable of being easily
inspected and replaced.
f) Mechanical seal metal parts shall be of CrNiMo-stainless steel.
g) Seals shall be non-proprietary in design, and shall be available from another
vendor in addition to the pump manufacturer.
h) Conventional double mechanical seals with a single or multiple springs acting in
opposed direction, cartridge-type mechanical seals; seals with materials other
than those specified; shall not be considered as adequate for this critical sealing
area.
19.12.15.9 Bolts and Nuts

All nuts or bolts exposed to the pumped media shall be of stainless steel grade 316
as specified.

19.12.15.10 Nameplate

Each pump shall be provided with a stainless steel nameplate firmly attached to the
pumping unit. It shall be clearly and durable inscribed with the manufacturer's name,
year of manufacture, pump-type, serial number, and principal rating data. For easy
identification of the submerged pumping unit, a second equal nameplate shall be
supplied along with its documentation for attachment outside the wet well.

19.12.15.11 Protective Coating

a) All exterior metal surfaces of the pump shall be subject to following preparation
and coating procedure except name plates, bright parts and stainless steel parts.
b) The preparatory treatment of cast and welded components shall be
accomplished in accordance to Sa 2 1/2 to SIS 055 900. (Identical to ISO 8501-1
/ ISO 12 944-4 and DIN 55928, Part 4).
c) Scale, rust and coatings shall be removed by steel grit blasting to such an extent
that that any residues on the surface remain visible only as a light tinge due to
shaded pores. Cleaning of the sandblasted surfaces shall be done by vacuum
cleaning, blasting or brushing off.
d) The primer when using Zinc dust or Zinc phosphate base shall have a dry film

DM/DNID Section 19 Mechanical Works Rev 00 June Page 53 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

thickness of not less than 50 microns.

e) An abrasion and shock-resistant, non-porous 2 component epoxy resin base
coating shall be used. It shall be resistant against many diluted acids and brines
as well as grease, oil, solvents and seawater and especially suited for use in
hydrous media. The solids content shall be not less than 82%.The shop-applied
top coat shall have a dry film thickness of not less than 320 microns. The colour
shall be as approved by the Engineer.
f) Name plates shall be masked or removed prior to surface preparation and
coating. Polished parts and surfaces (shafts, couplings) shall be preserved /
protected against corrosion.

19.13 ODOUR CONTROL EQUIPMENT

19.13.1 General
Odour problems are typically associated with the development of anaerobic
conditions (septicity) in sewage or sludge resulting in the formation of a range of
malodorous compounds by the action of bacteria. The main compound associated
with sewage and sludge odours is hydrogen sulphide (H2S), which is also a toxic and
corrosive gas.

Odorous compounds cause a problem if they are released to atmosphere and if there
are residential/trafficked areas close to the site that may be affected. An assessment
shall be taken of the likely impact the pumping station/treatment works shall have on
the locality and the deodorisation requirements fitted/sized accordingly to DM’s
approval.

19.13.2 Ventilation and Odour Treatment

a) All buildings containing sewage or sludge processes will need some form of
ventilation to avoid build-up of potentially hazardous (explosive or toxic)
atmospheres.
b) The odour control system shall be designed for removal Sulphide Odour up
to 99.99%(minimum) at the discharge of the odour removal unit stack.
c) The design of the ventilation and odour control system shall take in to
account the handling of potentially hazardous gases, and the zone
requirements of the area in which it is installed.
d) Odour releasing units (such as screens or belt presses) within a building
shall be locally enclosed, and a proportion of the required ventilation air
drawn from the body of the building towards the odorous unit to ensure
odours do not escape into the body of the building.
e) Siting of stacks and emergency vents shall be away from potential
complainants.
f) The choice of odour treatment process and the number of treatment stages
depends on:
i. Flow rate of air to be treated.
ii. The strength and composition of the incoming air and whether intermittent
or continuous.
iii. The percentage removal required (the standard of odour treatment

DM/DNID Section 19 Mechanical Works Rev 00 June Page 54 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

required to avoid an odour problem shall be derived from odour dispersion

modelling).
iv. Space availability and zoning requirements of the proposed location.

g) The design of odour control unit, ductwork, chemical storage and associated
equipment shall take into account expected temperatures:
i. 25 - 35ºC sewage.
ii. 0 - 55ºC ambient.
iii. 90ºC maximum radiating temperature (surfaces).
iv. Up to 30ºC air vented from the sewerage system to an OCU.

h) Preferred odour treatment technology is:

i. Two stage odour control system comprising of bio scrubber / bio trickling
filter as Stage 1 and Wet chemical scrubber as Stage 2, using
alkali/oxidant such as sodium hypochlorite with sodium hydroxide.
ii. Polishing treatment or treatment at small or remote sources (such as
subsidiary sewage pumping stations) shall be achieved with activated
carbon odour control units. In cases, where activated carbon is used,
carbon shall suitable for re-generation with water.
iii. Post treatment of vented air or lightly odorous air by ducting to the
activated sludge process shall be considered.
iv. Post treatment of ventilation air, for example using carbon, shall be
considered at sensitive sites and at pumping stations.

i) The same technology shall be used throughout a site, for ease of

operation. At existing sites, existing technology shall be duplicated unless
agreed otherwise by DM.
j) Several sources should be combined to a single odour control unit, possibly
providing more than one stage of treatment
k) Odour control units shall be designed and sized to maintain negative
pressures within the space housing the odorous gases
l) Odour control equipment shall be designed to remove the range of odorous
compounds expected. The treatment process, the number of units and the
number of stages of treatment required shall be based on the inlet / feed
characteristics of odorous gases to the odour removal system and the
desired outlet characteristics of treated air from the odour removal system

19.13.3 Materials
a) Ductwork, casings, sun covers and louvres shall be constructed of
chemically reinstated glass reinforced plastic.
b) Glass Reinforced Plastic (GRP) shall meet the following specification:
i. Polyester Resin – ortho and isophthalic chemical resistant grades to
BS3532.
ii. Glass Reinforcement - water resistant E Type chopped strand mat or
woven glass fabric to BSEN14181 and BS3749.
iii. Surface Finish - Gelcoat - Flowcoat isophthalic resin to BS3532.
iv. All drilled, cut or otherwise exposed edges are to be sealed with polyester

DM/DNID Section 19 Mechanical Works Rev 00 June Page 55 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

resin.
v. Any non-GRP materials are to be fully encapsulated within the GRP
laminate.
vi. BS4994 and DIN DVS 2205.

c) Materials requiring corrosion protection shall be in accordance with Section

7.
19.13.4 Enclosures and Covers
a) In some instances to contain and collect odours covers, or an enclosed
building, are only way to ensure that odour release can be controlled. If
processes are enclosed within a building, additional local covering is likely to
be necessary to ensure that the working atmosphere is safe. Processes that
are commonly provided with local covering are:
i. Inlet works (may also be within a building).
ii. High rate filters.
iii. Sludge storage tanks.
iv. Sludge liquor sumps.
v. Sludge import facilities.
vi.
b) Provision of covers will create a confined space where high concentrations of
potentially hazardous gases may develop, requiring appropriate measures in
terms of zoning (including for ventilation fans and/or odour treatment) and
personnel access. Fan-assisted extraction/ventilation may be needed to:
i. Inlet works (may also be within a building).
ii. Convey odours to an odour treatment system.
iii. Prevent the accumulation of high levels of odours that could be displaced
during operations.
iv. Reduce the level of corrosion below covers.
v. Reduce condensation and consequent corrosion.
vi. Prevent the accumulation of high levels of potentially hazardous
chemicals.
vii. Ensure that working conditions meet Health and Safety requirements.
c) Choice of materials for covers will need to take into account: strength,
thickness, durability, weight, cost, aesthetics, supplier and operational
requirements.
d) Covers shall be resistant to corrosion, both from external forces such as
weathering and UV radiation, as well as internal chemical attack due to the
hydrogen sulphide, sulphuric acid or organic acids below covers.
e) Fibre reinforced plastic (with appropriate choice of resin, UV absorbers and
light stabilisers) and aluminium are commonly used. Vinyl ester resin is
considered to have excellent corrosion resistant properties. Aluminium with
the correct choice of alloy is also corrosion resistant, although susceptible to
corrosion if splashed with sewage.
f) Covers shall withstand wind loadings and static loads.
g) Materials for covers and supports, and any equipment below the cover shall
be resistant to corrosion. Where possible, motors, etc., shall be located
outside the cover.
h) Suitable platform access and walkways shall be provided to any equipment.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 56 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

In general, facilities to allow access of personnel onto covers shall not be

provided.
i) Inspection and access hatches will be required for repair and maintenance
purposes. Alternatively, cover sections may be designed to be removable.
j) Where possible, design shall be such that equipment below covers can be
easily and quickly removable.
k) Covers shall be sealed as far as possible. Inspection/access hatches shall
be sufficiently durable so that they continue to be effectively sealed for the
design life of a piece of plant.
l) Overflow and discharge pipes shall be designed and constructed to prevent
a route for air under covers being discharged to the atmosphere.

19.13.5 Ductwork (Incorporating Dampers)

19.13.5.1 Ductwork

a) Ductwork, in general, shall be designed and installed in accordance with

Heating and Ventilation Contractor’s Association (HVCA) Specifications
DW144 (sheet metal ductwork) and DW154 (plastic ductwork).
b) Ductwork shall be designed in accordance with duct pressure Class B
(medium pressure) with respect to static pressure and air leakage (refer to
DW/154), however, the maximum ductwork gas velocity shall be 10 m/s. For
the critical leg, the maximum pressure drop shall be 2 Pa/m.
c) Ductwork shall not be installed underground unless otherwise approved.
Similarly, inverted sections of ductwork shall not be incorporated, unless
otherwise approved.
d) Unless otherwise specified, ductwork installed outdoors shall be made from
PVC-U reinforced with GRP.
e) Ductwork for foul air draw off and all foul air ducts interconnecting the
scrubbers shall constitute standard GRP pipes rated for 6 bars and drilled
to PN6 from DM approved suppliers. All bends and other fittings
incorporated in ductwork shall be standard , factory built,GRP fittings flanged
and drilled to PN6 .Insitu drilled flanges will not be acceptable.
f) All joints in ductwork/manifold shall be effectively sealed. Gasket shall be full
face and made of an approved material.
g) Flexible connections of appropriate material shall be provided, where
necessary, to accommodate differential movement and prevent the
transmission of vibration.
h) Flexible connections / dismantling joints shall be incorporated with all volume
and control dampers in foul air pipe work.
i) All flexible connections and dismantling joints shall be double flanged and
drilled to suit the related flanged draw off pipes and fittings; wraparound type
of flexible connections will not be acceptable.
j) All ductwork shall be provided with flanged connections at all joints and at its

DM/DNID Section 19 Mechanical Works Rev 00 June Page 57 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

termination points unless otherwise approved for any particular joint due to
technical reasons.
k) Ductwork shall be securely fixed to rigid supports. All ‘secondary’ fixtures and
fixings shall be made of stainless steel (grade 316) unless otherwise
specified.
l) Ductwork shall be designed to prevent the accumulation of windblown sand
or rainwater on its upper surfaces.
m) Ductwork shall incorporate all necessary drain points to allow removal of
condensate. Drain traps shall be rated for a minimum of 1.5 times the
ductwork pressure differential.
n) Ductwork shall incorporate all necessary access ports for the connection of
pressure gauges, gas velocity sensors, etc. and for sampling. If
practicable, access ports shall be positioned in straight lengths of ductwork,
at least 3 ductwork diameters from dampers. Access ports shall be provided
with facilities to prevent ingress of air when not in use and shall be located so
that monitoring instruments are easily accessible/ visible from ground level.
o) The ductwork colour shall be as specified on the Technical Schedule. Colour
shall be provided by non-degradable pigments in the ductwork external
surfaces. Ductwork shall be colour banded in accordance with BS 1710.
p) Ductwork shall be earthed to prevent the build-up of static electricity and
have a maximum resistance of 108 Ω in accordance with BS 5958 1 and 2.
Any equipment operating procedures or precautions required to prevent the
build up of static electricity shall be provided with the Tender.
q) Ductwork shall be provided with all necessary access ports/hatches to
facilitate cleaning of interior surfaces.

19.13.5.2 Control, Balancing and Isolating Dampers (Incorporating Non-Return Flaps)

a) All necessary control, balancing and isolating dampers shall be provided to

ensure effective, fail-safe equipment operation.
b) All isolation dampers shall guarantee effective sealing on closure and shall
be leak tight.
c) Non-return flaps shall be effectively sealed in their closed position and offer
minimum resistance to gas flow in their open position.
d) Damper and non-return flap spindles shall be made of stainless steel (grade
1.4401 to BS EN 10088-1).
e) Damper blades > 400mmm in diameter shall be made of stainless steel
(grade 1.4401).
f) Where possible, damper position shall be clearly visible from ground level.
Dampers shall be lockable and their blade positions clearly indicated so
that settings can be recorded during commissioning.
g) Dampers used for bypass purposes or for isolating ductwork for man-entry
shall be completely leak-proof (i.e. butterfly-type dampers shall not be
used).

DM/DNID Section 19 Mechanical Works Rev 00 June Page 58 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.13.5.3 Fire Dampers

a) All necessary fire dampers (electrically actuated and non-electrically

actuated) shall be provided to prevent/control the spread of fire.
b) Fire dampers shall have at least the same standard of fire resistance as the
building element through which the ductwork passes, subject to a minimum
rating of 2 hours, in accordance with BS 476: Part 20-23.
c) Fire dampers shall be of the folded, interlocking blade, shutter type.
d) The fire damper operating mechanism shall be one of the following:
- Steel retaining strap with fusible link
- Fusible phial in cartridge housing
- Bi-metallic thermal release
e) Access facilities shall be provided in the damper casing/adjacent ductwork to
allow safe inspection/maintenance access to the damper blades and
operating mechanism.
f) Damper position shall be clearly visible from ground level.
g) Fire dampers to be fitted in walls/floors shall incorporate suitable casing
fixtures (lugs, etc.) for attachment to the building structure.
h) Fixtures shall be provided with facilities to accommodate differential
movement between the damper and building structure.

19.13.5.4 Pre-filters (e.g. Dust Filters, Grease Filters and De-misters)

a) Pre-filters shall be designed to enable easy/safe access to all

components/systems requiring inspection/maintenance and
removal/replacement.
b) Pre-filters and their housings shall be made from SS316L or better corrosion-
resistant materials.
c) Pre-filters shall be securely fixed in their housings. Seals shall be provided to
prevent leakage of air between pre-filters and housings.

19.13.5.5 Odour Control Unit Housings

a) GRP housings shall comply with the relevant category of BS 4994.1987 Cat
1
b) All joints in housings shall be sealed to prevent the leakage of fluids
c) All fixtures and fixings shall be made of SS316L or an appropriate corrosion
resistant polymeric material.
d) Housings shall be designed to enable easy/safe access to all
components/systems requiring inspection and maintenance and
removal/replacement.
e) Housings shall be provided with suitable flanged connections for connecting

DM/DNID Section 19 Mechanical Works Rev 00 June Page 59 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

to inlet/outlet manifolds, outlet stacks, ductwork, drainage facilities and/or

monitoring instruments, as appropriate.

19.13.6 Carbon Deodoriser Units

a) Carbon deodoriser units shall be based on the use of Activated Carbon
suitable for re-generation without removing carbon from the deodoriser
housing.
b) They shall be of the carbon filter type. Housings shall be manufactured from
a chemically-resistant grade of glass reinforced polyester and fittings shall be
stainless steel grade 316L, unless otherwise stated. Seals and gaskets shall
be PVC or neoprene.
c) The filters shall be single- or double-pass, as required for the areas to be
controlled, to provide efficient use of carbon and to promote life expectancy.
The media shall be provided in disposable cells to allow easy replacement
and disposal. Should pre-filters be used, they shall be manufactured in
resilient plastic random mesh which are washable and long lasting.
d) A full specification of the type and grade of activated carbon proposed
together with automatic regeneration process shall be included with the
Tender.
e) Design Parameters are as follows:
viii. Concentration of H2S gas in wet well: 250ppm static (Sulphide gas
concentration).
ix. Sulphide concentration in solution: 50 mg/l.

f) The type of activated carbon selected must be effective in dealing with

odours arising from maximum concentrations of hydrogen sulphide and other
sewer gases.
g) The Tenderer shall state the expected life of the activated carbon and
guarantee sufficient supplies for the first year of operation. Offered carbon
shall have guaranteed service life of 5 years inclusive of re-generation. The
cost of the activated carbon shall be entered in the appropriate schedule.
h) The activated carbon shall be packed in disposable cells for ease of
maintenance.
i) Fan motors shall be direct coupled and suitable for installation within a Zone
1 potentially explosive hazardous area and shall comply with Electric Motors
Specifications.
j) Where the odour control system is fan-assisted all parts exposed to the
fumes shall be stainless steel construction, heavy gauge and resistant to
attack or of approved non-metallic material and the motor and drive shall be
sealed from the exhaust gas path.
k) Each deodoriser unit shall be installed complete with adjustable dampers
and isolation valves. Multiple inlets shall each have individual valves and
dampers.
l) Each odour control unit shall have at least two numbers (1 duty/1standby) of
foul air draw off fans of totally S.S.316 construction. Approved isolation

DM/DNID Section 19 Mechanical Works Rev 00 June Page 60 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

dampers shall be provided at inlet and out let of each fan to facilitate removal
one fan for maintenance while the other fan is working. Suitable backflow
preventers shall be provided at outlet of each fan. Suitable flanged flexible
dismantling joints shall be incorporated with all dampers and backflow
preventers.
m) Suitable flap valves shall be provided to allow the circulation of fresh air into
the well as necessary, so that the deodoriser can operate.
n) The deodoriser shall be supplied with a differential pressure gauge and a
visible indicator to show the level of H2S contamination in the activated
carbon.
19.13.7 Bio filter Units
a) Biofilters shall utilise peat media for the bio-oxidation of H2S. Peat is a typical
lignitic material which is capable of absorbing large quantities of water and
has with good compaction resistance. Alternatives may be offered as options
for consideration at the tender stage.
b) The filter shall be manufactured from GRP with rigid polyethelylene foam
infill, boltable sectional panels, removable cover and base. Polyethelylene
foam (25mm thickness) shall be fully-encapsulated and provide thermal
insulation for site conditions.
c) Shading may be necessary to protect the biofilter from direct sunlight.
d) The GRP panels shall be suitable for outdoor locations, UV stabilised with a
colour-impregnated gel coat finish. Sectional panels shall be provided with
substantial flanges utilising stainless steel fittings. Panels shall be formed
with 100mm deep internal webs to prevent short-circuiting of air and
incorporate suitably reinforced external base flanges capable of withstanding
wind loadings on the unit arising from wind speeds up to 50m/sec.
e) The bases shall be provided with adequately sized effluent drains.
f) A sprinkler system shall be sized to maintain the required filter bed media
humidity. The sprinkler system manifold branches shall be fitted with isolation
valves, suitably sized externally located strainers, union connections and
spray heads. An overlapping sprinkler spray pattern shall be provided and on
large installations, zoning may be provided, controlled via solenoid timer
switches.
g) Pipework shall be PVC-U, ABS, or where necessary for superior mechanical
strength, stainless steel.
h) Final effluent shall be utilised for the wetting of the media, where available.
Alternatively, potable water with necessary pH chemical dosing control shall
be provided.
i) The media support decking shall be manufactured from injection-moulded
polyethylene to provide a substantial deck designed to accommodate the
media loading. A plenum chamber (500mm minimum depth) shall be
provided to enable the installation of an air ductwork manifold system
providing a uniform flow rate with minimum pressure drop through the
support decking. The minimum support deck aperture size shall be 25mm x
25mm, rigidly interconnected and supported, with a minimum decking free
area of 40%. Air shall be passed through the media in either "upward or

DM/DNID Section 19 Mechanical Works Rev 00 June Page 61 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

downward" flow pattern.

j) The Bio filter panel sections shall be rigidly secured, where necessary, by a
tie bar system to adequately resist the internal load of the peat media. Tie
bars shall be installed in a square matrix configuration with necessary
diagonal bracing connected via stanchion heads. Tie bars shall be stainless
steel grade 316L and be bolted to enable tensioning after assembly to
accommodate pressure and wind loadings.
k) A suitable bulking material shall be provided to allow for air percolation
through the peat bed media and assist in reducing the resistance to the air
flow. Heather is a preferred material which shall be capable of lasting the life
of the bed and be resistant to rotting. The media shall be bio-degradable and
non-hazardous, being suitable for safe site disposal.
l) Interconnecting ductwork shall be provided in accordance with the Section
19.14.5: Ductwork. Control dampers shall be fitted in ductwork branches,
main extract branches and on the fan inlet side as an integral part of the
ductwork system.
m) Condensate shall be drained from all low points within the system and
adequately sized inspection hatches shall be provided wherever access is
required for periodic maintenance of internals.
n) Exhaust air shall be discharged through a vertical chimney terminating with
accelerating cone designed to provide dilution and dispersion.
o) The chimney shall be fitted with eddy shedders and shall be restrained by
steel guy wires. The chimney design shall be approved by DM.
p) H2S and methane monitoring shall be provided to control automated
dampers and the provision of alarm situations at times of excessive
saturation and potentially explosive mixtures. Monitors shall be provided in
all buildings where access is required.
19.13.8 Chemical Absorption Units
19.13.8.1 General

a) Chemical filters shall be suitable for treating sources of malodour to below

the perception threshold levels associated with sewage gas.
b) The odour control plant shall be of a packed tower of two- or three-stage
chemical type.
c) For smaller plants or lower concentrations, a two-stage scrubber system
comprising of sodium hydroxide (caustic soda, NaOH) and sodium
hypochlorite (NaOCl) shall be used.
d) For some installations or higher concentrations, a three-stage scrubber
system, with the addition of a sulphuric acid (H2SO4) stage, will be
necessary.
e) All Air Handling Units (AHUs) shall be designed to provide negative pressure
within the conditioned space, which shall be achieved by a balanced
ventilation system.
f) The minimum design parameters are as follows:
i. Concentrations of H2S in wet well: 500ppm,

DM/DNID Section 19 Mechanical Works Rev 00 June Page 62 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

ii. Mercaptans: Trace only.

iii. Amines (mono/di/tri): 10ppm.
iv. Ammonia: 50ppm.
v. Concentrations of H2S in solution: 50mg/l.
vi. Number of air changes per hour in sump 4 minimum. (More if the
Contractor deems it necessary)
vii. Removal of mercaptans: No requirement.
viii. Pressure drop per scrubber stage: No greater than 28mm Wg.

19.13.8.2 Component Parts

The complete unit shall comprise the following:

a) Duty/standby extract and supply fans.
b) Scrubber towers:
i. Sulphuric acid (as required) dosing pumps, duty/standby.
ii. Sodium hydroxide (as required) dosing pumps, duty/standby.
iii. Sodium hypochlorite (as required) dosing pumps, duty/standby.
iv. Recirculation pumps dosing pumps, duty/standby.
v. Water supply pumps dosing pumps, duty/standby.
c) Regenerable water softener.
d) Sulphuric acid storage tank of 1 weeks storage at maximum usage.
e) Sodium hydroxide storage tank of 1 weeks storage at maximum usage.
f) Sodium hypochlorite storage tank of 1 weeks storage at maximum usage.
g) Drench showers and hose supply.
h) Electrical equipment, including instrumentation and control.
i) Access platforms, ladders, etc.

19.13.8.3 General Mode Of Operation

a) The units shall be self-contained and be provided with a spun stainless steel
wire type pad and capable of operating at a minimum face velocity of 2 m/s.
The removal efficiency shall be 99% for all aerosol droplets above 15
microns.
b) Gases shall be extracted and ducted to the inlet of the first stage scrubbing
tower passing vertically through a packed bed section complete with a
recirculation system set above the packing elements.
c) This liquid shall flow downward, counter-current to the gas flow.
d) In the packed bed section, the gas constituents shall be dissolved and
diffused into the scrubbing liquid by means of the large liquid/fume interfacial
surface contact area provided by the packing elements.
e) The treated gas air stream shall then flow through the knitted pad type mist
eliminator. The entrained liquid droplets removed from the air stream
agglomerate in the knitted fibres are returned to the recirculation system.
f) Liquid to the spray headers shall be recirculated from the base tank with
evaporation losses and a continuous overflow, from the discharge side of the

DM/DNID Section 19 Mechanical Works Rev 00 June Page 63 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

duty pump, replaced by water make up via a ball float valve. The bleed off
rate will be determined by site operating conditions.
g) Liquid level in the recirculation tank shall be monitored by a level element,
using conductivity rods, providing a low liquid level alarm signal and a low
signal to stop the pumps, to avoid a condition of dry running. High liquid level
alarm shall also be provided.
19.13.8.4 Stage 1 Operation (Sulphuric Acid)

a) The chemical condition of the recirculation liquid of this stage shall be

monitored by a pH probe, enabling the bleed-off rate to be adjusted to
maintain the liquor within limits and control the addition of 20% sulphuric
acid.
b) Treated gases shall then pass from the side exit of the scrubber to the inlet
of the adjacent second stage scrubbing tower.
19.13.8.5 Stage 2 Operation (Sodium Hydroxide and Sodium Hypochlorite)

a) Here a similar course of events to the first stage shall occur, but an additional
Redox probe shall be provided in the sump to control the addition of sodium
hypochlorite.
b) The pH probe in this secondary tower shall control the addition of 50%
sodium hydroxide solution.
c) The final treated gases shall then be ducted to the inlet of the duty/standby
extraction fans for discharge via the exhaust stack, or via suitable louvres if
the extract fans are fitted on the scrubber inlet.
19.13.8.6 Scrubbing Tower Ancillaries

a) The scrubbing towers shall include conductive resin strips behind weld lines,
nozzle fitting joints in vessel shell, etc. to enable a full spark test to be carried
out. This will permit checks to be made on the integrity of the inner
thermoplastic shell after installation and at any time during the lifetime of the
vessel.
b) Scrubbing towers shall have uniform wall thickens and each scrubbing tower
shall have a corrosion-resistant thermoplastic liner, wrapped externally with
glass reinforced UV-stabilised white pigmented polyester resin. It shall be
designed in accordance with BS 4994 and consist of a vertical cylindrical
tower to be manufactured in flanged sections with flat base. Flanges drilled
in-situ not acceptable.
c) The sump section of the units shall hold recirculating scrubbing liquor pumps
and be complete with internal baffle, flanged connections and water level
measurement.
d) A recirculation pump feed to include:
i. Overflow.
ii. Make-up water inlet, incorporating float valve,
iii. Drain outlet.
iv. Chemical dosing points.

e) A gas bed section comprised of:

DM/DNID Section 19 Mechanical Works Rev 00 June Page 64 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

i. Support plate and support ring.

ii. Packed bed of random packed cascade mini rings (if required).
iii. Flanged access cover, to permit removal/replacement of packed bed rings.
iv. pH probe
v. Redox probe (if required).

f) A spray assembly system fitted with:

i. Flanged connections for spray bar assemblies.
ii. Lower and upper inspection doors.
iii. Spray system with spiral type non-clogging nozzles.

g) A mist eliminator section comprised of:

i. Demister ring support;
ii. Horizontally mounted aerofoil blade mist eliminator.
iii. Drain back to sump.

h) A conical transition section with discharge outlet to be mounted onto conical

transition section. (This may comprise a separate stack, or outlet louvres.)
i) Gaskets shall be from flexible EPDM sheet.
j) All materials shall be chemical resistant with support plates and fasteners
etc. in 316L stainless steel. i.e. high chloride-resistant stainless steels are
required because of the high salinity levels.
k) Design calculations shall be submitted in respect of the discharge height
required to prevent downwash of H2S occurring due to the effects of adjacent
structures.
l) An automatic condensate drain and trap shall be provided.
m) A self-contained pre-filter unit shall be provided with synthetic panel filters to
40% ASHRAE standard. The filter shall have continuous bonding between
the periphery edges of the filter pack and the inside of the enclosing frame to
eliminate any possible air bypass.
n) The enclosing frames shall be constructed of rigid, water-resistant waxed
board. Units shall be securely loaded in side access frames which will assist
access for maintenance.
o) The filter thickness shall be 50mm minimum with a free open area of 96%.
p) The chemical filter section shall contain media in vertical beds which shall be
suitable for horizontal air flows. Overall bed depth shall be adjustable from
200mm minimum up to 750mm in 250m increments.
q) The air flow rate shall be designed in order to achieve a dwell time of two
seconds over the media section.
r) The media shall be capable of providing adequate odour control for peak
loadings of hydrogen sulphide up to 500 ppm whilst the average loading is
anticipated to be 50 ppm.
s) An adequate means of access for inspection and replacement of the media
shall be provided.
t) A media analysis service shall be provided in order to determine the life

DM/DNID Section 19 Mechanical Works Rev 00 June Page 65 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

expectancy and replacement frequency date (twice annually) for a five year
period.

19.13.8.7 Air Fans and Associated Plenum

a) Duty/standby air fans shall be installed and sized to maintain negative

pressure within the odour space.
b) Extract fans shall be sized to provide the minimum number of Air Changes
Per Hour (ACPH) for the area specified:
a. Toilets 12 ACPH
b. Stores 6 ACPH
c. Workshops 15 ACPH
d. Garages/Car park areas 8 ACPH
e. Messes (two speed) 6 20 ACPH
f. Motor Room 10 – 20 ACPH
g. Dry Well 20 ACPH
c) They shall be suitably rated for their duty and be selected to operate at or
near their best efficiency point.
d) Foul Air draw off fans shall be totally of S.S 316 construction or they shall be
constructed of approved materials that are not susceptible to attack by the
component gases to which they are exposed. Each odour control unit shall
have sufficient number of foul air draw off fans to work on duty /stand by
operation philosophy. Actuated, isolation dampers shall be provided at inlet
and out let of each fan to facilitate removal of one fan for maintenance while
the other fans are working. Suitable backflow preventers shall be available at
outlet of each fan. Suitable flanged flexible dismantling joints shall be
incorporated with all dampers and backflow preventers.
e) Fresh Air feed fans shall be of S.S 316, Aluminium or GI construction or they
shall be constructed of approved materials that are not susceptible to attack
by corrosive environment to which they are exposed. There shall be
sufficient number of fresh air feed fans to work on duty /stand by operation
philosophy. Isolation dampers shall be provided at out let of each fan to
facilitate removal of one fan for maintenance while the other fans are
working. Suitable backflow preventers shall be available at outlet of each fan.
Suitable flanged flexible dismantling joints shall be incorporated with all
dampers and backflow preventers. Fresh air feed fans shall have heavy duty
washable filters at inlet to the fans.
f) Fans and their drive systems shall be securely fixed to rigid supports.
g) Where the odour control system is fan-assisted all parts exposed to the
fumes shall be non-metallic or stainless steel grade 316 construction, heavy
gauge and resistant to attack.
h) The impeller shall be secured to the impeller shaft and shall be secured
against circumferential movement. The impeller shall not be pinned to the
shaft nor shall shaft movement be relied on to ensure that the impellor is
locked in position.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 66 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

i) Pulley and V-Belt transmissions shall incorporate a minimum of two belt

drives. V-belts shall be designed with a service factor of 1.6, based on the
minimum absorbed power of the fan.
j) The motor and drive shall be sealed from the exhaust gas path.
k) Substantial outlet and inlet plenums with external stiffeners and flanges shall
be provided for connection to the external ductwork.
l) Ventilation ducting shall be of GRP, Stainless Steel any other approved
corrosion resistant material. Material thickness, stiffening and joint
arrangements for all fabricated ducts shall be in accordance with an
approved International Standard to provide adequate strength and to assure
rattle free operation and to prevent air leakage. Suitable noise attenuators
shall be incorporated in ducting wherever necessary. Insulation shall be
provided as required.. All duct work joints shall be flanged joints and GRP
ductwork shall constitute standard GRP pipes rated for 6 bars and drilled to
PN6 from DM approved suppliers. All bends and other fittings incorporated in
ductwork shall be standard , factory built,GRP fittings, flanged and drilled to
PN6 .Insitu drilled flanges shall not be acceptable.
m) Ducting shall be complete with all necessary supports. Stainless steel nuts
and bolts shall be used for all ducting joints and all supports and brackets .All
supports and brackets, in general, shall be hot dip galvanized except in
locations otherwise specified. All anchor bolts for fixing brackets and
supports to the structure shall be resin anchors S.S Grade 316. Ducting shall
be in suitable sections to facilitate removal, repair and replacement, if
required. All ducts, supports, brackets and fixings in wet wells for pumping
stations shall be stainless steel.
n) Ducting shall be sized so that the air velocity within the main ducts shall not
exceed 5.5 m/s and 3.0 m/s at the outlet louvers.
o) Flexible connections and anti-vibration mountings shall be provided as
necessary between the ductwork and fans and provision shall be made for
thermal expansion.
p) Where ducts pass through walls roof or floor slab the gap shall be sealed
with a non degradable approved material.
q) Condensate shall be automatically drained from all low points.
r) Inspection panels shall be provided wherever access is required for periodic
maintenance of mechanical plant.
s) Test holes for commissioning purposes shall be provided on each ductwork
branch.
t) Ductwork shall be tested for gas tightness.
u) Supply and extract four-way type diffusers shall be installed complete with
balancing dampers and be suitable for corrosive atmospheres. Suitable
mounting supports shall also be provided.
v) Fan motors shall be direct-coupled units suitable for installation within the
Zone 2 potentially explosive hazardous area.
w) Dual-speed motors shall be provided for all fans. They shall be controlled via
gas sensors that switch to low speed setting to minimise running costs. High

DM/DNID Section 19 Mechanical Works Rev 00 June Page 67 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

speed operation shall be initiated on recording of high gas level

concentrations and thermostats located within the conditioned space.
x) The fan units shall be supplied with anti-vibration mounts incorporating
efficient impeller design to ensure minimal noise levels.
y) Regulation of the air flow shall proceed on satisfactory operation of the fan
sets. Balancing of air flows within the ventilating duct system shall be carried
out to the satisfaction of DM. Adjustment of regulating dampers to achieve
the specified air flow rates shall be completed prior to locking.

19.13.8.8 Outlet Stack

a) The Exhaust air shall be discharged through a vertical chimney terminating

with accelerating cone to provide dilution and dispersion.
b) The outlet stack shall be designed to withstand wind loadings in accordance
with BS6399-2.
c) The stack shall be provided with an accessible sampling point.
d) The stack shall be provided with an accessible access ports/hatches to
facilitate the cleaning of the internal surfaces.
e) Lightning protection requirements shall be assessed in accordance with the
DM Specifications.

19.13.8.9 Chemical Dosing Pumps

The Chemical Dosing pumps shall be of the double diaphragm type and have as a
minimum standard:

i. Hypalon chemical diaphragm.

ii. uPVC metering head.
iii. Viton valve seats.
iv. PTFE faced working diaphragm.
v. Caustic soda - stainless steel valve balls.
vi. Sulphuric acid and sodium hypochlorite - glass valve balls.
vii. Capability of altering dosing rate from 10-100%.
viii. Integral pressure relief valve.
ix. Pulsation dampers.

19.13.8.10 Water Softener

The water addition/softening systems shall each incorporate the following, as a

minimum:

i. Break tank with air gap or approved double-acting check valve, complete
with isolating valve.
ii. Softener isolating valves.
iii. Duplex style non-return valves.
iv. Dual cylinder style water softeners, rated for continuous output with
integral meter initiated water power regeneration.
v. The softener shall use a fine bead resin bed in conjunction with a brine

DM/DNID Section 19 Mechanical Works Rev 00 June Page 68 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

solution.
vi. The softener shall be rated for 28 days use without the salt storage being
replenished.
vii. Flow regulating ball type valves.
viii. Flow indicator sensors, variable with adjustable high and low sensor.

19.13.8.11 Chemical Storage Tanks

The storage tanks shall conform to BS 4994 and each incorporate the following
features, as a minimum:

i. Double barrel type tank designed to contain leakage of chemical between

barrels.
ii. Visual cat-and-mouse style contents gauge.
iii. Level transducer (low/high).
iv. Tanker Fill Panel.
v. Bulk fill lines consisting of manual plug valves, and connections suitable
for bulk tanker filling.
vi. Lined plug outlet valve.
vii. Diaphragm drain valve.
viii. Overflow pipe, to direct chemical into bund in a safe manner which avoids
splashing of operators or equipment.
ix. Vent pipe.
x. Covered top.
xi. Construction:
xii. Sodium hydroxide - polypropylene/GRP.
xiii. Sodium hypochlorite - polyvinyl chloride/GRP.
xiv. Sulphuric acid - polypropylene/GRP.
xv. Each tank shall be contained in a separate bunded area, which shall
provide containment for 110% of the tank volume.

19.13.8.12 Instrumentation

a) pH transmitters shall be provided with 230V high and low alarm contacts,
range 0-14 pH, fully programmable complete with electrodes and dip probes.
b) Redox transmitters shall be provided with 230V high and low alarm contacts,
range 0-14 pH, fully programmable complete with electrodes and dip probe.
c) One conductivity type level measurement device of the 24V rod type shall be
provided in each scrubbing tower.
d) One recirculation flow meter with 230V magnetic low flow switch shall be
provided.
e) One bleed flow meter shall be provided.
f) One differential air pressure switch for extract fans shall be provided.
g) One pump pressure gauge and switch shall be provided for each pair of
dosing pumps.
h) One hydrogen sulphide monitor shall be provided in the inlet to system.
i) One hydrogen sulphide monitor shall be provided in the outlet to the system.
j) An ultrasonic level sensor shall be provided for each of the storage tanks.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 69 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

k) All pipework shall either be of polypropylene or PVC material, flanged or

solvent welded.
l) The following valves and accessories shall be provided as a minimum:
i. Hand-operated uPVC (ball) isolation valves on each side of the
recirculation pumps.
ii. Hand-operated uPVC (ball) isolation valves on each side of the dosing
pumps.
iii. Non-return valves at pump outlets.
iv. Injection valves on recirculation line dosing.
v. Strainers on inlets to all pumps.
vi. Isolation valves for all pump outlet pipework.
vii. Pulsation dampers in the dosing pump outlet pipework.
viii. Drain and flushing facilities at all low points in the pipework.
ix. All pipework shall be contained so that in the event of a burst or leak the
chemicals are directed into the secondary containment.
m) Hydrogen Sulphide and methane monitoring shall be provided to control
automated dampers and the provision of alarm situations at times of
excessive saturation and potentially explosive mixtures. Monitors shall be
provided in all buildings where access is required.
n) Toxic gas detection unit shall be capable of detecting Hydrogen Sulphide
levels in the range of 0-1000ppb (minimum range) prior to discharge.
o) The detection unit principal operation shall consist of a dry colorimetric
cassette system providing quick responsive indication (10 sec) dependent on
tape stain. Colour changes shall be measured by an electro-optic detection
system. Microcomputer control resulting in a digital signal matched to preset
alarm programme relayed to the telemetry unit via 4-20mA signal (Audio and
Visual).
19.13.9 Two-Stage Odour Control System
Essentially, the system will comprise of a two stage process – Bio trickling filter /
Bioscrubber followed by a Caustic-Hypochlorite /Peroxide scrubber operating in
series. The inlet concentration and minimum over-all contaminant removal rates shall
be as in Table 19-4

Table 19-4 Typical Odour Quality Standards (approximate)

Ave Outlet
Inlet Concentration % removal rate concentration
Compound (ppm) (across the 2- (ppb)
stage process)
Avg. Peak Avg.
Maximum Odour
< 500 OU/m3
Discharge
Hydrogen
100 250 99.99 10
Sulphide, H2S

Mercaptans, R-SH 2 5 99.5 10

Ammonia, NH3 1 4 95 50

DM/DNID Section 19 Mechanical Works Rev 00 June Page 70 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Dimethyl Sulphide,
1 4 99.5 5
DMS
To achieve < maximum odour
VOC 20 40
discharge

19.13.9.1 Performance Specification

The odour level shall not exceed 5 OU/m³ at 100%ile on 1 hourly averaging basis
measured at the site boundary, based on ‘BS EN 13725:2003 standard odour control
method’. Odour dispersion modelling shall be used to verify that this standard can be
achieved at the site boundaries. The Tenderer shall guarantee that there will be no
malodours perceived beyond the site boundaries.

Guaranteed overall H2S removal across the 2-stage treatment process shall be
>99.99% based on average inlet concentration.

19.13.9.2 Process Description

Odorous air shall be extracted via new GRP ductwork and collected for treatment into
the odour control unit (OCU)

The incoming gas flows upward through the biotrickling filter / bioscrubber towers
over a biomass support bed. Hydrogen sulphide, dimethyl sulphide, mercaptans and
other odorous compounds are absorbed into the liquid phase, and oxidised by the
biomass. The biomass within each tower is split into two or three beds, each
operating at different pH. The operating pH defines the biomass present, and thus the
type of odour compound removed by each bed. Hydrogen sulphide and ammonia is
removed by the 1st and 2nd beds (the most acidic), followed by DMS, mercaptans and
VOCs in the 2nd and 3rd beds (neutral pH).

The highly acidic waste liquor from the bio trickling filter / bioscrubbing towers is
drained and neutralized before it is discharged to the sewer.

Gas leaving the biotrickling filter / bioscrubber enters the base of the caustic-peroxide
scrubber. The odorous gas enters the packed tower and is contacted counter-
currently with the scrubbing liquor (a solution of sodium hydroxide and hydrogen
peroxide) over the mass transfer media. The remaining hydrogen sulphide, dimethyl
sulphide, mercaptans and other odorous compounds are absorbed into the liquid
phase. Liquor saturated with odour compounds collects in the column sump. The
liquor leaving the sump is dosed with 50% sodium hydroxide solution and 30%
hydrogen peroxide solution to replenish liquor concentrations after the required
neutralisation and oxidation reactions have occurred and prior to the liquor re-
entering the packed column.

A percentage of the re-circulating liquor is wasted to keep oxidation products and

carbonate levels below that in which precipitation occurs.

The caustic-peroxide scrubber shall be designed to treat the full incoming odour load
in case of complete failure of the bio trickling filter / bioscrubber.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 71 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

The ductwork shall be configured so that each of the towers within the bio trickling
filter / bioscrubbing plant and packed towers can be independently bypassed to allow
maintenance without complete plant shutdown.

The treated air shall be discharged to atmosphere via a self supporting stack at a
velocity of 15 to 20 m/s to ensure good dispersion while maintaining the noise at
acceptable level.

19.13.9.3 Treatment Units

a) The number of treatment stages within each treatment unit shall be as stated
on the Technical Schedule.
b) Each treatment stage shall comprise a random or structured porous bed of
inert media and its associated support structure. The volume and
arrangement of the inert media shall be such that the rates of mass transfer
of odorants from the gas to the liquid phase within each treatment stage are
optimised to achieve the specified performance.
c) The configuration of the inert media bed(s) shall be as stated on the
Technical Schedule.
d) The type and composition of the inert media shall be as stated on the
Technical Schedule.
e) The inert media shall be compatible with and/or resistant to the scrubbing
liquid and have sufficient compressive strength to resist all operational loads
without excessive deformation.
f) The type of scrubbing liquid (i.e. chemical reagent) and target operating
parameters (i.e. pH, Redox potential etc.) shall be as stated on the Technical
Schedule.
19.13.9.4 Scrubbing Liquid Make-Up System

a) Full details of the scrubbing liquid make-up system shall be provided with the
Tender.
b) Chemical dosing systems shall comply with WIMES 8.02.
19.13.9.5 Scrubbing Liquid Recirculating System

a) Full details of the scrubbing liquid re-circulating system shall be provided with
the Tender.
b) If possible, liquid distributors shall be of the pipe manifold or weir trough type
(i.e. spray nozzles shall not be used).
19.13.9.6 Scrubbing Liquid Discharge System

a) Full details of the scrubbing liquid discharge system shall be provided with
the Tender.
b) Excess/waste scrubbing liquid shall discharge to the point specified/stated on
the Technical Schedule.
c) The scrubbing liquid discharge system shall incorporate a sampling point and
tundish to enable verification of the scrubbing liquid composition and correct

DM/DNID Section 19 Mechanical Works Rev 00 June Page 72 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

operation of the make-up system.

19.13.9.7 Media Disposal

a) The method of disposal and the waste classification of the spent media shall
be as stated on the Technical Schedule.
b) The time required to completely remove all the spent media from each unit
and replenish it with fresh media shall be as stated on the Technical
Schedule.
19.13.9.8 Caustic-Peroxide Scrubber (Wet Scrubber)

Section 19.13.8 shall be followed.

19.13.10 Hoses
a) In each area where chemicals are dosed or stored and there is the possibility
of chemical spillage, hose reels shall be provided as a minimum standard.
b) They shall comply with BS 5274, BSEN 671-3 and BS 5306 part 1.
c) Each hose end shall be fitted with an adjustable jet spray shut-off of high
impact nylon, and a separate isolating valve.
d) They shall comprise the swinging open type of reels.
e) The Contractor shall supply low pressure low velocity systems.
19.13.11 Drench Showers
a) Drench showers shall be swinging chain operated type with a stainless steel
valve that locks on.
b) Each shower shall have a light to indicate its position.
c) Drench showers shall not be fed directly from the mains, unless a heater is
incorporated to reduce any thermal shock to the user.
d) They shall be fed from surface-mounted water tanks.
e) An emergency eye/face wash fountain with a flexible hose shall also be
incorporated into the drench shower.
f) Operation of the shower/emergency eye wash shall transmit an alarm to the
main MCC/SCADA system/Regional control system.
g) Safety signs shall be attached securely by each shower.
19.13.12 General requirements for odour control units for main sewage pumping
stations
a) All external pipe work and fittings shall be UV stabilized.
b) All anchor bolts shall be resin anchors in SS 316.
c) All chemical storage tanks shall have proper filling points, with fool proof
and colour coded hose couplings. All chemical filling points shall have an
approved wall mounted coupling cubicle with lockable door and a proper
drain pipe for the base of the cubicle.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 73 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

d) For towers more than 4.0 m high, access platforms, ladders and stairways
shall be provided to facilitate the operation monitoring and maintenance of the
equipment.
e) All Droplet separators / Mist eliminators shall be highly reliable and
maintenance-free and drops of scrubber liquid shall not be carried forward to
final air treatment unit, or to the atmosphere.
f) Approved Biological scrubbers to be incorporated in the first stage and
chemical scrubbers to be connected in series with first stage to reduce
chemical consumption and operating cost of the plant.
g) Sampling points shall have proper process piping and mist eliminator /dryer to
avoid air with droplets of scrubber fluid entering the H2S monitor
h) All dampers and isolation valves for all sampling points shall be easily
accessible.
i) All scrubbers shall have suitable manholes with bolted clear blank flanges at
appropriate location for regular observation scrubber fluid.
19.14 VENTILATION
19.14.1 Wall Mounted Air Conditioning Units
Air cooled 'window type' air conditioning units, as supplied by an approved and
accepted manufacturer, shall be installed in positions approved by the Engineer.
They shall be provided complete with slide out chassis and frame, suitable for clear
openings set not higher than 1.5m above floor level. They shall be suitable for
continuous efficient operation in the climatic conditions prevailing and the materials of
construction (particularly concerning the fins or extended surfaces of the refrigerant
to air heat exchangers) shall be subject to the Engineer's approval.

Both fresh air and re-circulated air shall be filtered and the filter shall be arranged for
ease of removal from the main unit for cleaning and replacement.

Depending on the size of the room space and the heat load therein, the air
conditioning units shall be of 1 ton, 1.5 tons or 2 tons refrigeration capacity
(equivalent to an air cooling capacity of 13,250; 19,880 or 26,500 B.T.U.’s per hour)
or multiples thereof.

Heat load calculation shall be approved by the engineer and air conditioners for MCC
rooms shall have additional 25% of calculated heat load added to decide the capacity
of the unit. Sufficient number of units shall be provided and they shall work on duty-
standby principle and there shall be provision for timed automatic duty changeover.
This requirement is general and applicable for all types of air conditioners.

Each unit shall be provided with a manually adjustable thermostatic air temperature
control and such other controls necessary to allow the following modes of operation:

1) Off.
2) Fan only with two speeds.
3) Cooling at two possible fan speeds.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 74 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

4) Re-circulation of air from room, through unit and back to room.

5) Part re-circulation of air with some exhaust air flow.
6) Part re-circulation of air with some fresh air inlet flow.

Each unit shall also be fitted with an automatic delay timer in the compressor control
circuitry to prevent the compressor having to start against gas pressure in the event
of an interruption in the power supply or the cooling mode being switched off and on
rapidly.

19.14.2 Centralised Air Conditioning Systems

Centralised air conditioning systems shall comply with the requirements of the
Particular Specification.

The system shall be complete with all necessary ductwork, diffusers, air grilles etc.
Where required, two single package units shall be provided and installed. Each unit
shall be capable of providing 60% of the total cooling load.

Machinery shall be from an approved manufacturer, of types readily available in

Dubai and suitable for installation in direct sunlight. Filters, re-heaters and/or
humidifiers shall be provided as necessary to maintain the condition of the
equipment.

Supply and return air ducting shall be run in the void above the suspended ceiling
where applicable. Air vents to conditioned areas shall be via slot diffusers integral
with the suspended ceiling. The whole system shall be designed to give an even
temperature distribution throughout the air conditioned areas.

Single package units shall be of the type with two compressors and split coils
arranged so that the failure of a compressor shall not lead to total failure of the air
conditioning to any area. The two units shall be identical to limit the quantity of
spares.

Work on installation of air conditioning systems is only to be undertaken by an

approved local air conditioning Tenderer or by an international air conditioning
Tenderer who is associated with an approved local air conditioning Tenderer.

It is recommended that the Tenderer engages the services of an air conditioning

specialist who is familiar with local requirements and conditions to design and specify
the system and liaise with Dubai Electricity and Water Authority, regarding approvals
and inspections.

Copies of the design calculations, unit specifications and system descriptions and
drawings are to be submitted to the Engineer for approval by Dubai Municipality who
will finally be responsible for the air conditioning system. Dubai Municipality will
require two additional copies of the operating manuals for the air conditioning system.
Representatives of the Dubai Municipality will require to be in attendance during
commissioning.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 75 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

A five year guarantee shall be provided against all malfunctions of the compressor by
the Dubai Electricity and Water Authority approved local air conditioning Tenderer
appointed.

19.14.3 Split Unit Air Conditioners

All materials used in the manufacturing of the units shall be produced to approved
International Standards. The cooling tubes shall be manufactured from solid drawn
copper and shall be tested to 20 bars. Fins shall be of Aluminium and shall be
permanently bonded to the tube. Cabinets shall be manufactured from pre-galvanised
sheet steel and the outer panels electrostatically powder coated with epoxy and
stoved. Panels shall be removable for access.

Condensate trays shall be fitted and the outlets piped to a suitable drain point.

Fans shall have corrosion resistant steel impellers. Motors shall comply with the
relevant parts of the Specification. Anti-vibration mountings shall be provided.

Air filters shall be fitted having 90% efficiency. If they are of the throw-away type a
five year supply of spare elements shall be provided.

The condenser unit shall be suitable for outdoor installation and condenser coils shall
have special anticorrosive coating suitable for installation in sewage pumping stations

The coils shall be pressure tested to 20 bars and fins shall be permanently bonded to
them.

Motors shall be weatherproof and shall comply with the relevant parts of the
Specification.

Compressors shall be hermetically sealed. Crank-case heaters and anti-vibration

mountings shall be provided.

High and low pressure switches and overload protection shall be provided and also
an anti-recycling timer.

The units shall be sized to maintain a dry bulb temperature of 26°C and a relative
humidity of between 40% and 60% when the external shade temperature is 52°C and
the external relative humidity is 50%.

19.15 CENTRIFUGAL FANS (AIR BLOWERS)

Centrifugal Fans to be used as air blowers shall be of heavy duty, single inlet direct
drive type. They shall be suitable for handling temperature up to 80°C, dust free air,
and aggressive gases and moisture normal to the sewage environment. The fan
shall be low-noise, corrosion resistant and explosion proof when handling aggressive
gases in sewage.

The blower shall be designed to handle, as a minimum, the rated air volume against
the stated head, as indicated in the Contract Documentation.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 76 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.15.1 General Construction

Mating flanges and/or flexible connection, as appropriate, shall be provided for the
inlet and outlet. Fan inlet shall be provided with sand traps and filter.

The fan shall be mounted together with motor support pedestal on a common base
frame. Fan blades, casing and other parts normally in contact with gases shall be of
stainless steel or plastic construction.

The fan shall have a backward curved centrifugal impeller which shall be overhung on
the motor shaft.

Driving motors shall be of well-known manufacture and shall be supplied with anti-
condensation heater and thermistor. Motor shall be in accordance with Section 18 -
General Specifications for Electrical & Instrumentation Works

Blower Enclosure panels shall be of GRP modular construction materials consisting

of chopped strand mats, roving and unsaturated polyester resin to approved
international standards.

The GRP material shall be composed of 0.5 mm minimum thickness gelcoat to

provide chemical resistance, layers of chopped strand mat reinforcing in resin content
60-70% by weight. Woven roving glass fabric layers to provide strength and rigidity
with resin content 45-55%, surface layers shall consist of “C” glass surface mat (45-
50 gm per square metre) with resin content of 90% by weight.

All cut edges shall be made smooth using a resin top coat and are to be gel coat
sealed. Rigidity of the enclosure can be increased by adding sufficient stiffeners.

The enclosure shall be U.V. resistant, have high impact resistance, high abrasion
resistance, low sound absorption dB 10-15 in the 100 - 500 Hz range, low thermal
conductivity of 1.4 W/m² 0C and be non-combustible.

19.16 LIFTING EQUIPMENT

19.16.1 Electrically Operated Traversing Cranes
Cranes shall be electrically operated traversing type and be complete with gantry rails
and all accessories including a set of slings.

The gantry joists and rails shall be provided with provision for jointing and fixing to the
structure. The lifting capacity of the equipment shall be sufficient for the heaviest
load which will be obtained when erecting or dismantling the plant or other parts of
the installation. The capacity of the cranes proposed shall be stated in the equipment
supply schedule.

The crane shall be tested at the maker’s works at 25% above the rated load, and test
certificates shall be provided.

Load tests shall be conducted at site in the presence of Engineer to witness the load
test. The load test shall be carried out on site by an approved independent body. The
proof load applied for certification shall be 50% in excess of the Safe Working Load
(SWL) which shall be clearly marked on the lifting block and on the runway beam.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 77 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

The test date is to be displayed on the runway beam. Load test by the approved
independent testing authority at 1.5 SWL to be repeated at the end of Defects Liability
Period.

Local authority inspection and approval is to be obtained prior to its operation and
handover.

The crane shall be of the double girder travelling type. The traveller carriage shall run
on bridge rails which shall be securely fixed to the gantry.

The crane shall be provided with a maintenance platform over the full span. The
maintenance platform shall be provided with double handrails throughout and a fixed
ladder access.

Longitudinal and traverse motions shall be provided for the crane and shall be such
that operation is speedy without impairing safety in working. The hook and load
chains shall be such that the hook will reach to the maximum depth.

Ball or roller bearings shall be employed on all motions and the load hook shall
revolve on a ball swivel. All gears shall be machine cut and all runway wheels
machined. A reliable braking and locking arrangement shall be provided.

The crane structure shall be designed in accordance with the requirements of an

approved international standard.

Two hoist speeds shall be provided, not exceeding 3 m/min across the working range
of the crane. Cross travel speeds shall be approximately 15 m/min. All motions shall
be electrically driven. The speeds of all motions shall be confirmed in the appropriate
schedule the speeds on all motions.

The load shall be carried on a flexible steel wire rope coiled onto a cast iron barrel
having right and left hand machine cut spiral grooves to ensure a true vertical lift.
The load rope shall be of sufficient length to reach the maximum depth. The load
hook shall comply with an approved international standard and shall revolve on a ball
swivel. A safety catch shall be fitted to the hook.

The crane shall be remote controlled on all motions from a non-metallic pendant push
button station. Buttons shall be of the hold-to-operate type. The pendant enclosure
shall give protection to IP54 requirements. Operation of the crane shall be possible
from any position across the full span. The pendant legends shall be inscribed in
English and Arabic. The remote control shall be wireless.

The power supply to the hoist shall be of festooned cable type running on a rigid
support system. An earth conductor shall also be provided.

The electrical equipment shall be controlled at 230 volts. The transformer shall be
protected by HRC fuses on both primary and secondary circuits.

A main supply isolator shall be provided and mounted at operating height from
ground level. Three sets of red "conductor alive" warning lamps shall be provided.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 78 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

All motors and electrical equipment shall be rated in accordance with the climatic and
other Specification requirements.

The integrity of the hermetic seal to the box girders is to be maintained. All cables
shall be enclosed in a steel conduit which is to be fastened to the exterior of the
girder.

Crane shall be suitable for humid and highly corrosive atmosphere.

All movements of the crane are electrical and protected by suitable limit switches.
Hoists shall have built-in limit switches for upper and lower limits.
Longitudinal travel of girder and cross travel of trolley shall have limit switches on
both ends. This is in addition to rubber buffers (end stopper) fixed at ends of carriage.

The crane with all ancillaries including bolts and nuts shall be in total compliance to
the specifications in all respects.

Protective coating shall be 300 micron DFT and colour to be agreed. Load hook shall
be Signal Red in colour.

Head room for the crane hoist shall be adequate for lifting the tallest equipment/
Pump in the pumping station and loading it in the truck stationed in the loading bay
inside the station.

19.16.2 Manually Operated Lifting Equipment

A close lift, hand operated gear driven lifting block, on a single runway beam, shall be
provided when specified in the Contract Documentation. The Safe Working Load of
block and beam shall be at least 25% above the weight of the heaviest item which will
require lifting for maintenance purposes. Equipment shall have the following
minimum ratings: 500 kg for the hoist and 1000 kg for the beam.

The whole assembly including beam, gear driven travelling trolley, pulley block and
chains shall be subject to a capacity test carried out on site by an approved
independent body or local authority. The proof load applied for certification shall be
50% in excess of the Safe Working Load (SWL) shall be clearly marked on the lifting
block and on the runway beam. The test date is to be displayed on the runway beam.
Load test by approved independent testing authority at 1.5 SWL shall be repeated at
end of Defects Liability period.

The bottom block shall be of the steel fully swivelling type with a safety catch fitted to
the hook.

A secondary load chain/cable and hook shall be supplied, suspended from the trolley.
The chain/cable shall be fixed length so that the hook is suspended approximately
1000 mm below the bottom flange of the beam. The hook and chain/cable shall be
tested to the same safe working load as the main hoist. The secondary load
chain/cable shall be used to support a lift at intermediate levels whilst the main load
chain is re-slung.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 79 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

All components of the travelling trolley and pulley block shall be suitable for humid
and corrosive atmosphere with traces of hydrogen sulphide

Load chain shall be of special alloy steel or stainless steel suitable for humid and
corrosive atmosphere with traces of hydrogen sulphide

All relevant requirements for motorised lifting equipment shall also be applicable to
manually operated lifting equipment.

19.16.3 Lifting Frames

Lifting Frames shall comprise an "A" frame or portal supporting a composite beam
over the lift centre lines which will carry a hoist block with traverse. The composite
parts of the device shall comply with the relevant specification clauses.

19.16.4 Lifting Davits

Lifting davits shall comprise of a simple single mounting; capable of traversing the
span of the area of lift and be fitted with a chain block as Clause 19.17.2 above. A
socket shall be provided which is to be cast into the reinforced concrete of the
associated structure.

19.17 GAS DETECTORS

19.17.1 Portable Gas Detectors: General
The detector shall be housed in a robust case sealed to comply with an approved
international standard. The case shall be provided with harness-type straps to allow
the equipment to be worn. Alternatively, a purpose-made carrying case, also with
harness straps, shall be supplied. In use, such a carrying-case shall allow the display
to be clearly visible.

The detector shall be explosion proof with an internationally recognised certification

as “intrinsically safe” allowing use in hazardous areas. The detector shall be suitable
for gas groups commonly found at sewage treatment works.

The detector shall be powered by a rechargeable nickel cadmium battery pack which
shall be replaceable. A fully charged battery pack shall operate the detector
continuously for a minimum of 10 hours. In use, low battery power shall initiate an
audible alarm.

The detector shall incorporate sensors to detect gas concentrations and initiate
alarms as follows:

DM/DNID Section 19 Mechanical Works Rev 00 June Page 80 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Mode Display range Alarm initiate

combustible gas or 0 - 100% by volume of air, > 20%

vapour calibrated for methane

hydrogen sulphide 0 - 25 ppm >10 ppm

oxygen 0 - 25% by volume of air >24% <19%

The display may be switchable between the three modes. However, should any one
of the three gas hazards occur, a warning lamp shall light and an audible alarm shall
sound, irrespective of the position of the switch.

Due to the limited life of gas sensor cells, the cells in the detector or any spare cells
provided shall be less than 3 months old at the time of handover to the employer.
Each cell shall have its date of manufacture indicated on its cover.

The detector shall be provided with an extension tube 2 m long and manual pump for
sampling inaccessible places.

Only equipment which is supported by a service workshop in Dubai authorised by the

manufacturer shall be provided.

19.17.2 Portable Gas Detector

One complete set of portable gas detection equipment shall comprise:

1) 1 No. Portable gas detector complete with sensors for combustible gas,
hydrogen sulphide and oxygen, and including rechargeable battery pack,
harness/carrying case and extension tube.
2) 1 No. Single way charger to suit above battery pack
3) 1 No. Stainless steel probe for extension tube

Test gases in 20 litre canisters:

1) 1 No. 2.5% methane in air

2) 1 No. 25 ppm hydrogen sulphide in air
3) 1 No. 17% oxygen in nitrogen
4) 1 No. box to house above equipment, suitable for wall mounting and labelled
“Portable Gas Detector”.

19.18 SURGE SUPRESSION & CONTROL

19.18.1 General
a) Where surge suppression equipment is required to be provided under the
Contract, the initial sizing of such equipment will have been carried out by
the DM or his representative. The Contractor shall be responsible for a final

DM/DNID Section 19 Mechanical Works Rev 00 June Page 81 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

assessment of the pressure transients, based on the actual pump selection

and final pipework design.
b) The successful Contractor shall undertake a further more detailed analysis of
the system at the detailed design stage, using a proprietary computer based
hydraulic transient analysis software package modelling the suppressed
hydraulic performance of the system. The software package shall be one that
is approved by DM. The final design of the surge suppression equipment
shall be determined using the modelling capabilities of the software package.
c) A detailed surge analysis report shall be produced for each of the above
simulations. The form of the analysis and the report shall be such that it can
be reviewed by the DM. The cost of analysis shall be deemed to have been
included in the cost of the surge protection equipment.
d) Surge analysis modelling shall be undertaken by suitably qualified and
experienced specialists approved by the DM. The specialist shall be
recognised by a specialist hydraulic Institute.
e) The surge control system shall be designed to:
i. Limit maximum positive pressures in the delivery mains to the maximum
allowable surge rating for the pipe at all parts of the system.
ii. Limit minimum negative pressures in the suction & delivery mains to the
maximum allowable surge rating for the pipe at all parts of the system
(particularly important for GRP pipes).
iii. Prevent liquid column separation occurring where this is detrimental to the
system.
iv. Friction factors selected for the analysis shall be approved by DM.

f) Surge control system performance shall be verified by field site tests at all
duty conditions. The Contractor shall provide a chart recorder and surge
measuring equipment to develop a permanent record for each duty tested.
g) Surge vessels shall be provided where sewerage, potable water or TSE
pumping system pressure transients exceed the operating capabilities of the
associated suction and delivery mains under electricity supply failure
conditions.
h) Surge vessels shall be designed in accordance with PD 5500 or BS EN
13445 "Unfired Fusion Welded Pressure" Vessels.
i) Due allowance shall be made to ensure all materials are compatible with the
medium being pumped and also compressed air.
j) The following options for surge suppression may be considered bladder
vessel, air valves, damped reflux valves, pump flywheel controlled start
stopping of pump set or actuated delivery and suction line isolation valves.
k) Maximum surge pressures shall be controlled within the surge pressure
rating of the rising main pipe material.
19.18.2 Intersection of Welds
Longitudinal seam welds shall not cross at any intersection with circumferential welds
but shall be offset a minimum length corresponding to 90° of shell circumference.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 82 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.18.3 Vessel Geometry

a) Surge vessels shall be fabricated from Carbon Manganese steel, and full
details shall be supplied by the Contractor. The vessel shall comprise two
domed ends with an intermediate cylindrical section. Vertical mounting is
preferred. Not less than two lifting lugs shall be provided for lifting of the
complete vessel.
b) The inlet and outlet pipework shall be designed to the same criteria as the
vessel terminating in flanged connections to BS 4504 or equivalent rated in
association with the pumping plant pipework. A drain line shall be provided
complete with isolating globe valve and flanged hose connection suitable for
direct coupling of a flexible 2" hose.
c) The vessel shall be supplied complete with sight glass(es) and associated
fittings internal inspection port, manhole access, level control switches,
pressure gauges and safety pressure relief valves.
d) Support legs shall be thick section equal angle incorporating drilled feet for
levelling and bolting down of the vessel.
19.18.4 Sight Glasses
a) The Contractor shall supply two flanged entries for 20mm O.D. sight glasses
on the vessel having a minimum viewing length of 600 mm. The liquid level
should be uninterrupted over the length. The maximum operating pressure
of the sight glass shall be higher than the design pressure of the vessel. In
the event of glass failure the vessel shall remain pressurised.
b) The sight glass shall be provided with flanged bronze isolating valves
complete with ball check and displacement device, to prevent loss of liquid
upon gauge breakage, plus drain cock.
c) The sight tube shall be protected with a stainless steel guard and all round
polycarbonate protector. When necessary the sight glass shall be supported
at the centre from the surge vessel side wall.
d) Site glasses shall be sun protected.
19.18.5 Inspection Port
Where applicable, an elliptical inspection port approximately 320 x 220mm oval of the
type that incorporates an internal "pull up" plate with self-sealing joint tightened by
exterior draw bolts on a port bar shall be provided in the cylindrical section of the
surge vessel below top water level.

19.18.6 Main Access Flange

a) A man access hole of not less than 600mm internal diameter shall be
provided in the cylindrical section of the vessel to permit access from ground
level. This shall be covered with a suitable flange which shall be bolted onto
a fabricated flange on the manhole.
b) The man access flange cover shall be provided with a lifting swing davit
which shall incorporate a lifting screw, so that the whole flange cover may be
lifted up and then swung out from the entry port. The davit may be fabricated
onto the cylindrical wall of the vessel.
c) Service points shall be provided, four of these points shall be drilled and

DM/DNID Section 19 Mechanical Works Rev 00 June Page 83 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

tapped entries for level control switches, a further drilled and tapped entry
shall be required for the supply air and pressure gauge line and one other
entry point shall be provided with a flanged entry for the safety relief valves.
All entry points into the main access flange shall be bossed out to suit the
size of the tapping or hole.
19.18.7 Safety Relief Valves & Pressure Gauge
a) A three way plug valve, with no neutral, shall be mounted on the main
access flange, with two in number safety relief valves mounted either side of
the plug valve outlets. The safety valves shall be suitable for air/water and
rated for the pressures likely to be experienced. They shall be adjustable and
incorporate a manual lift device or wedge for testing purposes.
b) A pressure gauge shall be mounted not less than 1m above floor level, have
a 100mm diameter face and be complete with isolating and a drip leg drain.
19.18.8 Bolting & Gaskets
a) All nuts and bolts for all flanges and fittings shall be stainless steel to BSEN
10088.
b) Gaskets shall be rubber insertion of other suitable Elastomer material
approved for use with sewerage or potable water (as applicable). Spiral
wound gaskets are not permitted.

19.18.9 Radiographic Testing

The Contractor shall allow for 100% radiographic testing in accordance with BS EN
12517-1

19.18.10 Welding
a) Welding shall only be carried out by qualified and experienced welders in
accordance with PD 5500 or equivalent, by reference to the following:
i. EN288 or equivalent Approval Testing of Welding Procedures.
ii. EN287 or equivalent Approval of Welders working to Approval Welding
Procedures.
19.18.11 Marking of Vessels
a) The Contractor shall mark clearly with their respective safe working pressure
in lettering not less than 80mm in height in gloss paint.
b) A brass plate shall also be fixed to the vessels which will state:
i. Name of manufacturer with address.
ii. Identification number.
iii. Client's Order number.
iv. Shell Thickness.
v. Corrosion allowance.
vi. Shell diameter.
vii. Head diameter.
viii. Head thickness.
ix. Head corrosion allowance.
x. Degree of X Ray inspection.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 84 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

xi. Tan length.

xii. Design Pressure.
xiii. Hydraulic Test Pressure.
xiv. Weight.
xv. Length.
xvi. Inspection Date.
xvii. Inspector’s initials.
xviii. S.W.P.

19.18.12 Compressors
a) Compressors shall be the oil-less piston type and shall be mounted adjacent
to the surge vessel. They shall comply with the compressed air Section of
the specification. Duty/standby compressors shall be provided. Each
compressor shall be capable of producing a volume of air at the working
pressure in conjunction with the surge vessel, be controlled by two of the
level probes mounted within the vessel, and have a capacity of not less than
1 litre/second Free Air Delivery at ambient temperatures, humidity and
pressure.
b) The compressors shall be of rugged design to provide a reliable and efficient
operation with a minimum of maintenance. In particular the suction and
discharge valves and pressure regulating system shall be designed to
guarantee a long and trouble free life. The compressor shall be provided with
air filtering, down-loading valve and the non- return valve shall be fitted with
resilient seats and be fitted directly to the surge vessel.
19.18.13 Automatic Air Volume Control System
a) The automatic air-volume control system, in conjunction with solenoid valves,
tank-mounted sensor probe and the air compressor units, shall control the
air/water ratio in the vessel, and maintain the air/water ratio within a range
compatible with the surge control system design. Remote indication of
excessive high or low water level in the tank shall be provided brought out to
electrical contacts for cabling by others.
b) An integral control panel shall be provided complete with all necessary
controls, relays, and time delay circuits, to fully control and actuate the air
add/vent solenoid valves. Solenoid valves shall be energized to open.
c) Solenoid valves for air service shall have forged brass or bronze bodies with
Teflon seats. Internal plungers, core tube, plunger spring, and cage
assembly shall be 316L stainless steel. Valve actuators shall be 240 volt a.c.
Seals shall be Teflon. Valves shall have a maximum operating pressure and
a maximum differential pressure of 2 MPa (290-psi). Solenoid valves shall be
energized to open.
The Contactor shall be responsible for supplying suitable pumping plant and surge
suppression equipment (if any) to ensure that transient pressure surges do not
exceed the following limits:

a) less than 5m below atmospheric pressure at any point along the pumping
main,

DM/DNID Section 19 Mechanical Works Rev 00 June Page 85 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

b) greater than 50% of the pressure rating of the pipes and fittings installed on
the pumping main.
These limits shall not be exceeded under any condition of normal working or power
failure.

The Tenderer shall include for all necessary surge suppression equipment. The
equipment (if any) should be compatible with the characteristics of the pumping plant
proposed. It is therefore recommended that the Tenderer should perform his own
assessment of the pressure transients.

To confirm the results of his initial assessment, the Tenderer shall instruct the pump
manufacturer to carry out a comprehensive pressure surge analysis on the complete
hydraulic pumping system under all operating conditions, and submit three copies of
a report and calculations on the surge in the system within 3 months of contract
commencement to enable surge suppression equipment to be manufactured in time
for delivery and installation if found necessary.

19.19 Supports and Fixings

Unless otherwise specified all supports, fixing bolts, screws, etc., and other fixings
shall be provided, shall be of minimum Grade 316 S16 stainless steel and shall be as
follows;

1) Threaded and fitted with 3mm thick washers beneath bolt and nut. The length
shall be such that when tightened down with a nut & bolt the threaded portion
will not protrude more than half a diameter of the bolt.
2) When fastening galvanised components or aluminium alloy components. PTFE
washers shall be fitted beneath the stainless steel washers for both bolt head and
nut.
3) Stainless steel grade 316S31 shall be used for construction of pumps, fastening
galvanised or aluminium alloy components, holding down and anchor bolts.

Notwithstanding the above, the Contractor shall consider galvanic corrosion between
various metals when selecting materials for proposal.

19.20 Support for Pipework and Valves

All necessary supports, saddles slings, fixing bolts and foundation bolts shall be
supplied to support the pipework and its associated equipment in an approved
manner. Valves, meters, strainers, and other devices mounted in the pipework shall
be supported independently of the pipes to which they connect.

All brackets or other forms of support, which can conveniently be so designed, shall
be rigidly built up of sections.

No point of passage of pipes through floor or walls shall be used as a point of

support, except with the approval of the Engineer.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 86 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.21 SUPPORTS AND ANCHORS

19.21.1 Process Piping
1) Support piping as described hereinafter and as shown by the support details
on the Mechanical Drawings.
2) Unless otherwise specified herein, all standard pipe hanger and support
materials, design, manufacturer, selection and installation shall comply with the
standards of the Manufacturers Standardization Society of the Valves and
Fittings Industry, Inc. (MSS), Vienna, Virginia (001-703-281-6613).
3) See referenced standard specification for MSS pipe support element types.
Element types are presented to aid the Tenderer in identifying and providing
acceptable pipe supports.
4) No attempt has been made to show all required pipe supports in all locations on
the Drawings. The absence of pipe supports and details on any drawings shall
not relieve the Tenderer of the responsibility for providing them throughout the
plant.
5) Where piping connects to equipment, support the piping by a pipe support and
not by the equipment.
6) Size pipe support systems to withstand the loads imposed by the weight of the
pipes filled with water, plus any insulation. Select commercial pipe supports
and hangers for a minimum safety factor of 5.
7) Anchors:
a) Design anchors for the design load specified under paragraph Horizontal
Pipe Supports. The direction of the applied load shall be either parallel to, or
perpendicular to the pipe, whichever produces the greatest stress in the
anchor.
b) Provide anchors for piping smaller than 75 mm as specified in these
specification documents, Expansion Compensation.
8) Support stacked horizontal runs of piping along walls using a metal framing
system.
a) Use standard structural shapes or prefabricated structural members such as
“ Uni-strut” to construct the framing system
b) Pipes cannot be supported from the pipe above or below.
9) Support horizontal piping runs 300mm and smaller along concrete or masonry
walls using welded wall brackets.
10) Single runs of uninstalled pipe smaller than nominal 75 mm may be supported
from masonry walls with steel or stainless steel clips as appropriate. Piping
clamps which resist axial pipe movement through the support shall not be used
for plastic pipe.
11) The minimum design load rating for structural building attachment shall be based
on an allowable stress of 20 percent of the minimum tensile strength of the
material at service temperature. Castings shall include a casting quality factor of
0.80 of the allowable stress specified.
12) Attach hanger support rods to steel beams with beam clamps, to concrete with
inserts or flanges fastened with flush shells. Use only stainless steel insets with
stainless steel rods. Isolate dissimilar metals to prevent galvanic corrosion.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 87 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

13) Do not use point bearing supports (e.g. C-clamps) with PVC piping. If riser
clamps are required, use only the full circumferential type. Provide supports at
manufacturer’s recommended spacing or 1.5m, whichever is less. If operating
temperatures are sufficiently high to lower the strength on PVC pipe, support
continuously using light metallic angles or channels and special hangers.

Pipe support component type shall comply with the following requirements:

1) General Service (0 C to 50C):

Application Type (MSS SP-58) Notes

Horizontal Bare Pipe
Attachments
U-Bolt Hangers 24
Rings 6,11 1
Clevis Hanger 1
Clamps 3
Hanging Rollers 41,43
Supporting Rolls 44,46
Saddles 36,37,38
Horizontal Insulated Pipe
Attachments
Clips 26
Clevis Hanger 1 2
Hanging Rollers 41,43 2,3
Supporting Rollers 44,46 2,3
Protective Shields 39,40
Saddles 36,37,38 2
Vertical Pipe
Riser Clamps 8,42
Hanger Rod Fixtures
Turnbuckles 13,15
Swing Eyes 16,17
Clevises 14
Building Structural Attachments:
Inserts 18 4
C-Clamps 19,23
Beam Clamps 20,21,25,27,28,29,30
Welded Attachments 22,57,58
Brackets

2) Hot Pipe Service (50C to 225C):

Application Type Notes

Horizontal Bare Pipe 5
Attachments
Clevis Hanger 1 1,2
Hanging Rollers 41,43 2,3
Protective Shields 39

DM/DNID Section 19 Mechanical Works Rev 00 June Page 88 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Supporting Rolls 44,46 2,3

Saddles 36,37,38 2
Vertical Pipe
Variable Spring 51 5
Hanger
Hanger Rod
Fixtures -- 5
Building Structural:
Attachment -- 6

Notes:
1. Use for piping 60 mm and smaller.
2. Provide insulated piping with rigid pipe insulation insert
specified under Section 15260.
3. Provide insulated piping with protective shield.
4. See Section 05500 for acceptable anchors or fasteners.
5. Required support components are the same as for general
service.

19.21.1.1 Materials

a. All stainless steel pipe supports and all submerged piping supports, guides,
and fasteners or those installed below channel and wet well cover slabs shall
be type 316 stainless steel.
b. Acceptable piping hanger and support component materials for exposed
piping shall comply with the requirements of MSS SP-58 and these
specifications.
c. Provide hangers, rods, clamps, protective shields, metal framing support
components, and hanger accessories for exposed piping of stainless steel
(for stainless piping system) or hot dipped galvanized steel (for all other
piping systems). Hot dip galvanizing shall be in accordance with ASTMA
153 or A 386 unless noted otherwise on drawings.
d. Copper Piping: Use copper plated hangers or cushioned clamp type system.

1. Hanger Rods: Threaded either ends, threaded one end, or continuous threaded.
2. Inserts: Stainless steel. Malleable Iron case or galvanized steel shell and
expander plug for threaded connection with lateral adjustment, top slot for
reinforcing rods, lugs for attaching to forms; size inserts to suit threaded hanger
rods.
3. Sleeves:
a. Pipes through Non-Fire Rated Beams, Walls, Footings, and Floors: Form
with steel or stainless steel pipe as appropriate.
b. Pipes through Fire Rated and Fire Resistive Floors and walls, and
Fireproofing: Prefabricated fire rated sleeves including seals, UL listed.
c. Round Ductwork: Form with galvanized steel.
d. Rectangular Ductwork: Form with galvanized steel.
e. Fire Stopping: A sealant system to match the fire rating of the barrier.
4. Caulk: As specified within these specification documents.
5. Fasteners: Bolts, nuts, concrete anchors and anchor bolts shall be as specified
within these specification documents.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 89 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.21.2 Building Services Piping

19.21.2.1 Pipe Hangers

a) Ferrous Piping up to 150 mm nom. Diameter: Adjustable galvanized steel

clevis complete with galvanized steel pipe covering shield for insulated
piping.
b) Fire Protection Piping up to 50 mm nominal diameter: use of adjustable
galvanized steel band (FM approved) shall be permitted. Copper plated
hangers shall be used for copper piping.
c) Ferrous Piping over 150 mm nom. Diameter: adjustable, cast iron pipe roll
with steel axle, sockets, lock nuts etc. Pipe covering protection saddle shall
be used for insulated piping.
d) Copper Piping (non-insulated): adjustable galvanized steel band with rigid,
preformed, 6 mm thick felt, pipe isolator.
e) Copper Piping (insulated): Adjustable galvanized steel band with steel pipe
covering shield.
f) Multiple Hangers: Steel channel/angles, suspended or attached to frame
work. Pipe hanger/supports shall be as previously specified (make
appropriate selection). For piping placed above the cross member, the use
of U-bolts shall be permitted.
g) Use stainless steel components as specified above for stainless piping
systems.

19.21.2.2 Floor Supports

a) Ferrous Piping up to 150 mm nominal diameter: Adjustable pipe stanchion

saddle support complete with U-bolt, stand pipe with adjuster and floor
flange, use galvanized steel pipe covering shield for insulated piping.
b) Ferrous Piping over 150 mm nominal diameter: cast iron pipe roll with base
and stand, reinforced concrete or structural steel pedestals shall be provided,
as appropriate, to locate the base. Pipe covering protection saddle shall be
used for insulated piping.
c) Copper Piping (non-insulated): adjustable pipe stanchion saddle support
complete with U-Bolt, stand pipe with adjuster and floor flange and rigid
preformed felt, 6 mm thick, pipe isolator.
d) Copper Piping (insulated): Adjustable pipe stanchion saddle support
complete with U-Bolt, stand pipe with adjuster and floor flange and
galvanized steel pipe covering shield.
e) Use stainless steel components as specified above for stainless steel piping
systems.

19.21.2.3 Vertical Piping Supports

a) Ferrous Piping up to 150 mm nominal diameter: Galvanized steel riser

DM/DNID Section 19 Mechanical Works Rev 00 June Page 90 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

clamps and /or offset pipe clamp. Solid wood inserts shall be used at the
supports for insulated piping.
b) Ferrous Piping over 150 mm diameter: Gusset plates with integral bearing
plates (minimum thickness equal to that of the pipe) welded to pipe and
resting on cross channels over heavy duty vibration isolation pads (50
durometer). The cross channels shall be offset to accommodate the piping
insulation and the vapour barrier sealed around the gusset plate with mastic
sealants. ‘Z’ cleats shall be welded on the cross channels at the ends of the
bearing plates to restrict movement.
c) Copper Piping up to 50 mm nominal diameter (non-insulated): Galvanized
malleable iron wall clamps with rigid, preformed felt, pipe isolator.
d) Copper Piping over 50 mm nominal diameter (non-isolated): Galvanized
steel offset riser clamp with isolator.
e) Copper Piping (insulated): Galvanized steel offset clamps over insulation.
f) Use stainless steel components as specified above for stainless steel piping
systems.

19.21.2.4 Distribution Piping In Shafts And Chases

a) Copper Piping: Semi-circular copper straps with ears for attaching to walls.

19.21.2.5 Pipe Anchors

a) Horizontal Ferrous Piping (non-insulated): Galvanized steel anchor chair and

U-bolt attached to structural steel framework.
b) Horizontal ferrous Piping (insulated): Steel plate (minimum thickness as that
of the pipe and length equal to the diameter) welded to pipe, projecting
beyond the insulation; attached to structural steel framing by bolting or
welding. The vapour barrier shall be sealed around the plate with mastic
sealants.
c) Vertical Ferrous Piping (non-insulated): Steel hold down anchor clamp and
base plate attached to reinforced concrete or structural steel supports. The
clamp shall be back welded to the pipe after installation.
d) Vertical Ferrous Piping (non-insulate): same as the support of vertical
insulated ferrous piping over 150 mm nominal diameter; excluding the
vibration isolation pad. The bearing plate shall be welded or bolted down to
the cross channel.
e) Horizontal Copper Piping: Galvanized steel anchor and U-Bolt over 150 mm
long wood inserts all round, attached to structural frame work.
f) Vertical Copper Piping: Galvanized steel offset riser clamps, over 150 mm
long wood inserts all round.
g) Use stainless steel components as specified above for stainless steel piping

DM/DNID Section 19 Mechanical Works Rev 00 June Page 91 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

systems.

19.21.2.6 Hanger Rods

a) Steel Hanger Rods: use stainless steel or galvanized mild steel rods with
continuous male thread as appropriate.

19.21.2.7 Hanger Rod Attachments

a) Turnbuckles: Provision shall be made for adjusting the heights, where

required.
b) Ball Hangers: Provision shall be made for allowing angular movement of the
hanger rod, where required.
c) Threaded Rod Couplers: stainless or galvanized steel unit, as appropriate,
machined from, bar stock for joining two lengths of threaded hanger rods.
Back nuts shall be provided on both sides of the coupler.

19.21.2.8 Building Attachments

a) Concrete Inserts: Stainless steel malleable iron or galvanized steel concrete

inserts as appropriate for the piping system. Complete with adjustable insert
nut. Suitable for hanger rods of size 22 mm diameter and under. Stainless or
galvanized steel continuous concrete insert may be provided at the
Tenderer’s option.
b) Self Drilling type Concrete Inserts: Stainless or galvanized steel self drilling
expansion type concrete inserts for hanger rods up to 12 mm diameter may
be provided at the Tenderer’s option.
c) Supports Rails (cast-in type): Stainless or electrozinced steel sections with
anchor lugs and filler strip. Complete with hammerhead nut or extension
pieces, as appropriate for the piping system.
d) Support Rails (surface mounted type): Stainless or electrozinced steel
sections with anchor lugs and filler strip. Complete with hammerhead nut or
extension pieces as appropriate for the piping system. The rail shall be
single or double as appropriate.

19.21.2.9 Flashing

a) Metal Flashing: 0.5 mm thick galvanized steel.

b) Lead Flashing: 24.5 kg/sq.m sheet lead for water proofing; 5 kg/sq.m sheet
lead for soundproofing.
c) Flexible Flashing: 1.25 mm thick sheet compatible with roof and wall
waterproofing.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 92 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

d) Caps: Galvanized steel, 0.8 mm minimum; 1.5 mm at fire resistant elements.

19.21.2.10 Sleeves

a) Sleeves (for pipes through fire rated and fire resistive floors and walls):
Schedule 40 stainless or galvanized steel pipe sleeve, as appropriate for the
piping system; packed with 96 kg/cu.m density fibreglass and caulked with
approved fire rated sealant at both ends.
b) Sleeves (for pipes passing through non-fire rated beams, walls, footings and
dry floors): Schedule 40 stainless or galvanized steel pipe sleeve, as
appropriate for the piping system; packed with 96 kg/cu.m density fibreglass
and caulked with approved type sealant at both ends. Sleeve shall be
extended 50 mm (2 inch) above the finish floor level, for vertical piping.
c) Sleeves (for ferrous pipes passing through external retaining walls): Cast iron
or ductile iron with integral puddle; packed with 96kg/cu.m density fibreglass;
caulked at the inside end with approved sealant and at the outside end with
hemp yarn and lead.
d) Sleeves (for cast iron drain, waste and vent piping through wet floors): PVC
pipe sleeve or wooden box to form the opening. After curing of the concrete,
this sleeve shall be removed and on completion of cast iron pipe installation,
the opening shall be filled with non-shrinkable grout and both sides of slab
shall be trowelled smooth and level.

19.21.2.11 Escutcheons

a) Set screw type escutcheons, with size sufficient to completely cover exposed
penetrations shall be provided at all pipe penetrations.
b) This shall be finished with prime coat where adjoining surface is to be field
painted, with baked enamel white finish where adjoining surface is fibre
board and chrome finish where adjoining surface is tiled with ceramic,
marble, etc.

19.21.2.12 Finish

a) All hangers supports inserts, shields and saddles for Building Services Piping
shall be stainless steel or shall have galvanized finish; as appropriate for the
piping system.
b) Hangers and supports for copper piping shall be copper or copper plated,
when used in direct contact with the copper piping.
19.21.3 Execution

19.21.3.1 Inserts

DM/DNID Section 19 Mechanical Works Rev 00 June Page 93 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

a) Provide inserts for placement in concrete formwork for suspending hangers

from reinforced concrete slabs and sides of reinforced concrete beams.
b) Provide hooked rod in concrete for inserts carrying pipes over 150 mm
nominal diameter.
c) Where concrete slabs form finished ceiling, install inserts flush with the slab
soffit.
d) Where inserts are omitted due to error, drill the slab through from below and
provide a through bolt with square steel plate and nut above. Recess items
into slab and grout flush.
e) Where resin type anchors are used, select the type and quality to suit the
concrete into which it is to be installed.

19.21.3.2 Pipe Supports and Hangers (General)

a) Hanger or support assembly shall be capable of taking up the filled weight of

piping for half spans on either side plus 100 kg, with minimum overall factor
of safety of five.
b) Install hangers with minimum 12 mm space between finished covering and
adjacent work.
c) Place hanger within 300 mm of each horizontal elbow. Hanger shall have a
minimum vertical adjustment of 38 mm.
d) Provide multiple or trapeze hangers where several pipes can be installed in
parallel and at same elevation. Provide amply sized structural sections for
multiple trapeze hangers, and braces, supporting frames etc. calculations
shall be provided.
e) Support riser piping independently of connected horizontal piping.
f) Support piping at either side of flexible connections (at the system side only
on connections to equipment).
g) Do not attach supports, hangers or anchors to the building structural
elements wherein their installation, weight or expansion stress will result in
damage to the structure.
h) Apply one coat of zinc rich primer to the weld and surrounding areas, where
pipe support members are welded to building structural framing after
scraping and brushing the area clean.
i) Support piping buried in raft slabs or trenches as detailed on the Contract
drawings. Make the support capable of holding the pipe in position against
buoyant forces exerted during pouring of concrete.
j) Use fender washers and lock nuts with threaded hanger rods.
k) Where special slab construction (like omni slab) is used, install support rails
anchored to concrete portions for installing hangers.
l) Provide riser clamps at mid span for vertical piping up to and including 25
mm nominal diameter.
m) Support Fire Protection piping independently of other piping.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 94 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

n) Provide away bracing on 3000 mm maximum centres unless otherwise

directed by the Engineer.

19.21.3.3 Supports and Hangers for Cast Iron Piping

a) Support horizontal cast iron piping at either side of the joints (at least one on
every piece of pipe) at intervals not exceeding 2.50M.
b) Provide supports for fittings grouped together in horizontal runs, as
appropriate.
c) Anchor piping at horizontal changes in direction, at cleanouts and at start of
horizontal lines.
d) Provide floor clamps at every floor and offset riser clamps below the branch
take off joint in vertical risers.

19.21.3.4 Supports and Hangers for Steel Piping

a) Support horizontal piping as scheduled below.

Pipe size Maximum Spacing Hanger Rod Dia

(mm nominal diameter) (metres) (mm)
Up to 25 mm 2.0 8
32 to 50 mm 3.0 10
65 and 75 3.6 12
100 to 150 4.0 16
200 to 300 4.5 20
350 mm and over 5.0 22

b) Riser clamps /supports shall be provided at every floor, for vertical piping.

19.21.3.5 Supports and Hangers for Copper Piping

a) Horizontal piping shall be supported as scheduled below.

Pipe size Maximum Spacing Hanger Rod Dia

(mm nominal diameter) (metres) (mm)
Up to 25 mm 1.8 8
32 to 50 mm 2.0 10
65 and 75 3.0 10
100 to 150 3.6 12

b) Provide riser clamps with shield at 60 cm above floor level and at branch
take offs for vertical piping.

DM/DNID Section 19 Mechanical Works Rev 00 June Page 95 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

19.21.3.6 Sleeves

a) Set sleeves in position in form work and provide additional reinforcement

around sleeves.
b) Where sleeves in concrete structural elements are omitted due to error, the
required openings shall be cored only after obtaining written permission of
the Engineer. Sleeves with puddle flanges resting on the concrete surface
shall be placed and the sleeves fixed in position by non-shrink grout. Cutting
of holes by chiselling shall not be permitted.
c) All sleeves in wet areas shall be projected by at least 50 mm above the finish
floor level.
d) Erect sleeves in the formwork perpendicular to the wall face. Fix rigidly to
resist displacement during pouring of concrete.
e) Verticality of flange faces and alignment of bolt holes with connected
equipment (valves etc.) shall be checked and ensured after the pouring of
concrete. Make adjustment where required.

19.21.3.7 Flashing and Sealing

a) Pipes passing through external retaining walls: Clamp a layer of

waterproofing membrane to the pipe and flash over the wall waterproofing
membrane.
b) Pipes passing through roof slab: Provide flashing sleeve with integral
flashing flange. Clamp roof waterproofing membrane in the flashing flange
and fill around with approved type grout.
c) Roof Drains: Coordinate construction details. Develop actual dimensions for
elements like the extension filter etc. so that the required size can be cut at
the factory.
d) Area Drains and Planter Drains: Coordinate construction details. Provide
900 mm diameter lead flashing at the drain to direct the seepage into the
drain.
e) Water Storage Tank Drains: Provide flashing, 900 mm diameter at the drain
with non-toxic synthetic membrane and integrate the same with the tanking,
where provided.
f) Sanitary Fixtures: Seal the joints of all sanitary fixtures at walls and floors
with transparent, hard setting, age proof, sealant.
g) HVAC Piping and Ducting passing through Weather or Water proofed Walls,
Floors and Roofs: Provide flexible flashing and metal counter flashing as
appropriate.
h) Sound Control: Provide acoustic lead flashing around ducts and pipes,
penetrating equipment rooms; in accordance with manufacturer’s instructions
for sound control.
i) Roof Curbs: provide curbs for mechanical roof installations, with a minimum
height of 400 mm above roofing surface. Provide flexible sheet flashing and

DM/DNID Section 19 Mechanical Works Rev 00 June Page 96 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

counter flashing with galvanized sheet metal to make the assembly

watertight.

19.21.3.8 Adjusting and Cleaning

a) Hanger Adjustment: adjust hangers so as to distribute loads equally on all

attachments.
b) Support Adjustment: Piping and equipment shall be brought to the proper
level by providing grout under the supports.
c) Cleaning: all factory finished surfaces shall be cleaned and any marred or
scratched surfaces shall be repaired with manufacture’s touch-up paint; to
the approval of the Engineer.

19.22 VENDOR LIST

Tenderer to select the equipment from the list of recommended vendor list given in
Table 19-5 below and they shall select only one manufacturer or supplier from the list
below and mention in the tender proposal.

It is Tenderer’s responsibility to ensure that the offered make / supplier fully comply
with the tender specifications & functional aspects, delivery, construction requirement
as required by specifications, drawings.

Tenderer to confirm the technical details of the product offered by filling the relevant
technical schedules (including country of origin) as per the format provided in the
tender specification and shall submit in the tender proposal. Technical schedules with
incomplete information will be considered as incomplete proposal.

Tenderer may propose for any equipment item(s) where vendor name are not
specified or not included in the recommended vendor list in the table below. Such
proposal will be subject to Engineer clarifications during tender clarifications and
tender evaluation. All the necessary information required by Engineer will be
requested and it shall be submitted by Tenderer immediately to the Engineer for
tender assessment.

Table 19-5 Vendor List

Sr. Item Manufacturer
1 Submersible pumps for KSB / ABS / ITT Flygt Ltd. /Grundfos
sewage & Axial flow pumps
for drainage
Centrifugal Pumps in CORNELL / KSB
Drywell.

2 Valves AVK, Denmark / Econosto / Erhard, Germany /

Biwater / Saint-Gobain Pipelines plc / Dezurik /
VAG / Noreva / MIV Croatia / CSG UK /
HAWLE South Africa
3 Air valves Vent O Mat / ERHARD / ARI South Africa /

DM/DNID Section 19 Mechanical Works Rev 00 June Page 97 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Sr. Item Manufacturer

HAWLE/ VAG/ AVK
4 Penstocks Ham baker / VAG / Erhard / Adam Hydraulics /
Simon-Hartley / Biwater /KWT Neatherland/
Industrial Penstock
5 Bar Screen / Screening OVIVO / Huber, Germany / Passavant,
equipment Germany.
6 Washpactor & Screw Huber / Passavant / Jones Attwood
conveyor
7 Sump Pumps / Drain Grundfos / Ebara / ABS / ITT Flygt Ltd / KSB /
pumps KAPRARI
8 Positive Displacement Dresser Roots / Ingersol Rand
Blowers
9 Centrifugal Blowers Universal / Howden / Dresser Roots / Ingersol
Rand
10 Submersible Mixer ABS / Flygt / KSB
11 Supports and Anchors B-Line Systems Inc., Highland, IL / Unistrut
Corporation, Wayne, MI / Grinnel Supply Sales
Company, Exeter, NH. / ZSI, Livonia, MI.
12 Split System Air Airtemp / Climatrol / BDP Co./ Carrier NC
Conditioning units Group, Carrier Corp./ General Electric Co./
Mistubishi Electric Corp. / Trane Co. / National
13 Duct Hardware Ventfabrics, Inc / Young Regulator Co.
or similar equivalent
14 Duct Access Doors Air Balance Inc. / Duro Dyne Corp. / Register
& Grille Mfg.Co.Inc / Ruskin Mfg.Co /
Ventfabrics, Inc / Zum Industries, Inc., Air
Systems Div
15 Flexible Connections American / Elgen Co. Energy Div / Duro Dyne
Corp./ Ventfabrics, Inc.
15 Chemical Metering Pumps Diaphragm metering pumps: Wallace &
Tiernan / Pulsafeeder / Aldos, Germany /
Prominent / LMI / Milton Roy

Calibration Chambers: Charles Crowley Co. /

Milton Roy

Pulsation Dampeners : Zemarc Corp / Milton

Roy
16 Single Stage Centrifugal Ingersoll Rand / Atlas Capco / Kaeser
Compressor
17 Safety Showers Haws / Hughes Safety Showers Ltd. /
Speakman
18 Shaftless Screw Conveyor Huber / Passavant
19 Belt Conveyor Sevar , Germany / Taunton Engineering, USA
20 Vibration Isolation Metraflex of Chicago, IIinois (USA) / Mason
Industries, Smithtown, New York (USA) /
Vibration Mountings and Controls Inc.,

DM/DNID Section 19 Mechanical Works Rev 00 June Page 98 of 99

2016
 General Specifications for Mechanical Works
Dubai Municipality
Drainage and Irrigation Department

Sr. Item Manufacturer

Blomingdale, New Jersey (USA)
21 Lifting device Demag / Morris
22 Genset Caterpillar / Perkins / FG Wilson / MTU
23 Odour control System Envicon / Corodex /IPEC Belgium /Amtrad /
Amairair International
24 Flange Adaptors and DMJ MIV Croatia/ Viking Johnson UK/ HELDEN UK
25 Ductile Iron Pipes and MIV Croatia
Fittings

DM/DNID Section 19 Mechanical Works Rev 00 June Page 99 of 99

2016