Coal Authority
Downbrook MWTS Specification
Coal Authority
Downbrook MWTS
Specification
Coal Authority
Downbrook MWTS Specification
PART C
WORKS INFORMATION
Date: 21/11/2011
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Coal Authority
Downbrook MWTS Specification
SECTION 1 – DESCRIPTION OF THE WORKS
1.1
Introduction
Covered in CA Documentation
1.2
Description of the project
Covered in CA Documentation
1.3
Site Location
Covered in CA Documentation
1.4
Extent of Works
1.4.1
Work under this Contract
The works at Downbrook Minewater Treatment Scheme shall include but not be limited to the
following:
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Factory Acceptance Testing (FAT).
Delivery to site, off loading and handling on site.
Construction of a headworks surround, hardstanding area, Motor Control Centre Slab
and false flooring and installation of interconnecting duct work.
Supply and installation of all headworks steel work.
Supply and Installation of Motor Control Centre, including supply and programming of site
controller (PLC).
Supply and installation of Steel Kiosk.
Supply and installation of borehole pump, riser pipes, headplate, above ground pipework,
valves and instrumentation.
Supply and installation of discharge range, intermediate chambers, valves and other
defined fittings.
Cabling and installation work associated with all pumping plant and services as above.
Instrumentation as required to control and monitor the plant.
Commissioning and putting into service.
Record drawings in paper and electronic (CAD) form.
Operating and Maintenance manuals in paper and electronic format.
Training of Purchaser’s staff.
Installation of ‘free-issue’ telemetry equipment.
The Works shall include all items necessary for the complete execution of the Contract whether
expressly listed or not.
In respect of the site installation and modification works in the Contractor’s scope the Contractor
shall survey the site to determine the exact requirements.
All equipment shall be installed and connected in accordance with the manufacturer’s
recommendations. The Contractor shall not degrade the performance, reliability or robustness of
the systems to be modified in any way.
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1.4.2
Work by Others
The work to be undertaken by others shall include the following:
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1.4.3
Provision of power supply to the site (client to manage)
Provision of telecommunication to the site (client to manage)
Telemetry configuration
Variations and Deviations from Specification
Where the Contractor identifies an alternative means of delivering the works, the Contractor will
submit for approval the details and any associated cost increase or saving to the Coal Authority
for review.
Any deviations from the specification will not be implemented without written acceptance or
approval from the Coal Authority or their nominated representative.
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Downbrook MWTS Specification
SECTION 2 – PARTICULAR SPECIFICATION
2.1
Introduction
2.2
Construction (Design & Management) Regulations 2007
The Contractor shall be appointed Principal Contractor, following assessment for competence,
and shall carry out the duties of Principal Contractor as defined in the Construction (Design and
Management) Regulations 2007. In addition, the Contractor shall carry out the duties of Designer
as defined in the Construction (Design and Management) Regulations 2007 for all aspects of
design the Contractor carries out. The Contractor shall ensure a Designer’s Risk Assessment is
produced for the design work he is responsible for and submit it to the CDM Co-ordinator for
acceptance at least 14 days before construction starts.
2.3
Programme of Works
The Contractor shall submit a detailed Programme of Works for review by the Client.
The programme shall be detailed sufficiently to allow the Project manager to assess its validity.
The Programme shall as a minimum include the following work:
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Design and submission of drawings
Procurement
Works Testing and Factory Acceptance Testing (FAT)
Construction
Site installation
Commissioning
Site Acceptance Testing (SAT)
Submission of manuals
Training
The contractor will include a 2 week review period of any proposed plant and equipment, prior to
placing orders for any such plant or equipment. Similarly any plant which requires further design
development, e.g. the MCC, drawings and Functional Design Specification will be submitted for
review prior to progressing the manufacture of any such items.
2.4
General Technical
The Contractor shall adopt the initial design and develop it to construct a fully equipped and
operational pumping station. The installed pumping installation shall be automatically controlled
by a PLC system, the software for which will be developed by the Contractor or appointed sub
contractor.
2.5
Design
Within this specification, Appendix A, the Contractor is provided with drawings and information.
The Contractor shall recognise that such drawings and/or information shall in no way diminish or
negate the Contractors design responsibility to provide a fully functional pumping station. The
content of all drawings / information provided shall be verified by the Contractor as correct.
Where not explicitly stated within this specification, standards for plant; equipment and installation
will be in accordance with the standards referred to in Appendix C.
The details of all plant being supplied by the Contractor, will be submitted to The Coal Authority,
or nominated representative, for review and approval, prior to orders being placed by the
Contractor.
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2.6
Plant Performance
The Contractor shall guarantee the BH pump performance as declared in his submission. This
will include the submission of at least 3 options for the borehole pump, which meet the operating
criteria specified in section 2.10.1, including full performance curves, guaranteed work test values
and comparative costs. This will enable the Coal Authority to choose the optimum pump
performance, following a Capital and Operating expenditure analysis.
2.7
Plant Access
2.7.1
General
As far as practicable within this design, the Contractor shall ensure all plant, valves and
equipment are fully accessible for maintenance and removal in a safe manner.
2.7.2
Craneage
The Contractor shall make his own arrangements in regard to any offloading and lifting during the
works.
2.7.3
Free Issue Items
For this site the following items will be “free issued”:
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2.8
Radio Telemetry Unit (Opus)
GSM Modem and SIM Card.
Commissioning
FAT & SAT documents shall be provided at least 2 weeks prior to the commencement of
commissioning.
The MCC shall undergo tests at the factory, including but not limited to: high voltage “flash” tests,
visual inspections and checks, and functional tests including PLC I/O signals, instrument
transmitters and control equipment. The Employer shall be given opportunity to witness the tests
at the factory. A test procedure shall be submitted for approval at least two weeks before the
tests are due to take place. A record of the tests shall be submitted immediately after the tests
are concluded.
The Contractor shall undertake such pre-commissioning tests as are necessary to ensure that the
plant is ready for commissioning with the Client’s representative.
2.9
Training
The Contractor shall include 2 training sessions, duration not exceeding 4 hours each.
The training sessions shall be designed to complement the Operating & Maintenance manuals
and shall prepare the Coal Authority’s appointed Operations and Maintenance Contract staff for
routine operations and detailed maintenance of the plant supplied. A process overview will be
required with detailed training on equipment maintenance procedures, including the type and
frequency of maintenance.
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Downbrook MWTS Specification
2.10
Mechanical Works
2.10.1 Borehole
2.10.1.1 Borehole Pump Specification
The Contractor shall supply and install within the Borehole, a single submersible pump-set
operating at variable speed from an AC inverter drive mounted in a remote MCC, generally in
accordance with WIMES 1.05.
Borehole Details:
Top of Borehole Level Bottom of Casing Level Proposed Minimum Pump Level Bottom of Borehole Level ID of Casing ID of Open Hole Casing Note:
~90.5mAOD
70.5mAOD
71.0mAOD
67.0mAOD
380mm
250mm
Actual Pump installation depth will ensure that NPSH requirements of the pump are met
at the proposed Pumping Level of 71.0mAOD. This will be determined following a review
of the pump performance curves provided under Section 2.6.
Pumping Borehole Water Levels:
At Rest Level –
Discharge Control Level –
Proposed Pumping Level –
~84.9mAOD
82.4mAOD
79.4mAOD
Pump Duties:
Normal duty (At target level)
Flow –
Head -
15 l/s
18.5 m
Maximum flow (Initial drawdown)
Flow –
Head -
30 l/s
15 m
The borehole pump, including all internal and external components, will be suitable for the long
term operation whilst pumping water of the quality contained within the borehole. A detailed water
analysis is provided in Appendix B.
The Contractor shall provide full characteristic curves, including pump/motor combined overall
efficiency and NPSH requirements at maximum (duty) speed and at the minimum speed
recommended by the motor manufacturer. Pump curves will offer guarantee points to BS EN ISO
9906 Class 1 tolerances, with no negatives on pump efficiency.
Pumps will be works tested and curves provided for review prior to despatch. The Client or
nominated representative, will be given the opportunity to witness any such performance tests.
Each pump motor is to be appropriately rated for operation with a frequency inverter to provide
variable speed control. The motor shall be suitably rated to deliver the maximum absorbed power
across the complete available operating range specified by the pump manufacturer, plus a margin
of 10%. Where there is a non overloading power curve characteristic, the motor will be rated to
the maximum possible power plus a margin of 10%. This will be verified by the Coal Authority’s
nominated representative prior to an order being placed.
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Downbrook MWTS Specification
Pump motors will be wound with high temperature windings and include temperature monitoring
sensors (PT100s). The temperature monitoring sensors will be provided with sufficient cable to
enable the signals to be presented to a temperature monitoring unit housed within the new MCC,
this does not preclude the use of a local junction box at the head works.
The Contractor shall ensure that all electric cables are suitable for the operating conditions under
which they will operate. The length of cable attached to the motor will be sufficient to reach the
headwork’s junction box, plus 5m, to enable the cable to be cut and re-used on subsequent pump
changes.
2.10.1.2 Borehole Rising Main
The Contractor shall supply a 150mm diameter rising main of total length to suit the pump
position when the intake level is set as specified in clause 2.10.1.1. Each pipe section shall be a
maximum of 3m in length and connected with flange joints.
The contractor will provide a starter pipe, 500mm long, to provide a means of clamping the pumpset for installation; this pipe will also be used, where necessary, to make the transition from the
pump discharge flange to the rising main flange.
The pressure rating of the column pipe shall safely withstand the closed valve delivery pressure
of the pump, plus the combined weight of the pump set and column pipe.
All pipework shall be fabricated in carbon steel using tubes conforming to BS3601, API 5L Grade
B, HFS or equivalent, rated for 16 bar working pressure, with a minimum wall thickness of 9mm.
All flanges shall be raised face steel plate type to BS EN 1092-1:2002, PN16 with continuous
internal and external fillet welds. Welding shall comply with BS 2971:1001. Flange fixing holes
shall be sized so that the correct diameter bolts can be fitted without damaging the protective
coating.
Flange fixings shall be in grade A2 stainless steel with a flat washer located under each bolt head
and each nut. The nut will be manufactured in grade A4 stainless steel, to prevent ‘pick-up’, whilst
assembling and removing the bolts during installation and future removal.
Flange gaskets shall be full faced, to BS 2494, manufactured in EPDM rubber. If required, a
double flanged or similar adaptor shall be supplied to connect the pump set to the column pipe.
On completion of fabrication the column pipe sections shall be grit blasted to SA 2.5 and coated
internally and externally with a fusion bonded epoxy resin. The coating material shall be 100%
solid thermosetting fusion bonded epoxy resin as ‘ScotchKote 206 N’; Rilsan; or an approved
equivalent. The thickness of the finished coating shall be not less than 0.3mm.
During installation the motor cables and temperature monitoring cables, shall be securely
supported at the pump flanges using non-corrodible clamps as detailed in the drawings held in
the appendices of this specification.
The contractor shall supply a set of certified lifting clamps for the purpose of installing the rising
main and pump-set, they shall be left on site for future use by the Coal Authority. The lifting
clamps will be manufactured in mild steel, before being hot dip galvanised. They shall be load
tested to 150% of the maximum possible load in service. Test certificates shall be provided.
2.10.1.3 Borehole Headworks
The contractor shall provide a borehole extension piece, with integral dip tube mounting plates,
cable way and cable cover with access plate. This will enable the motor and instrument cables to
be directed into the cable trench adjacent to the headworks, for connection into remote junction
boxes. The configuration of the borehole extension will generally be in accordance with the
drawings provided in the appendices.
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The headworks will include a headplate, which will be bolted to the borehole extension and act as
the support for the rising mains, and the transition point to the headworks discharge pipework.
The headplate will generally be in accordance with the drawings provided in the appendices and
include a ½” bsp tapping below the headplate for the connection of a pressure transducer, which
will be accessible from above.
2.10.1.4 Borehole Headworks Pipework and Valves
The Contractor shall supply and install a range of 200mm NB pump delivery pipework from head
plate to below ground, where the transition will be made to a 225 SDR17 MDPE (PE80)
discharge range.
Each delivery pipe shall be fitted with all necessary isolation valves and branches to comply with
the proposed layout drawing held in the appendices.
The scope of borehole pump pipework shall include but not be limited to; all pipe, fittings, valves,
flange jointing, pipe supports/straps, cleaning access points & small bore tappings for
instrumentation etc.
The Contractor shall include the following within the scope of delivery pipework:
1 No. connection for automatic air valve located on crown of pipe, at least 2 diameters
downstream of the headplate bend. Supply with isolating valve.
Butterfly valves shall be the double flanged type, manually operated by a hand wheel and a
gearbox, the hand wheel will be removable. Face to face dimensions will be in accordance with
EN 558, Series 14.
Gate valves will be double flanged and manually operated by a hand wheel, which will be
removable. The gates will be resilient seated to provide a full bore aperture within the valve and
will conform to BS 5163.
The first 90o bend bolted to the head plate/clamp shall have sufficient horizontal straight length,
such that disconnection at the first joint allows unrestricted lift of the borehole pump or head
plate/clamp.
All pipework shall be fabricated in carbon steel using tubes conforming to BS3601, API 5L Grade
B, HFS or equivalent, rated for 16 bar working pressure.
All bends will have a long radius to allow cleaning pigs to pass through easily.
Upon completion of fabrication the pipework shall be grit blasted to SA 2.5 and coated externally
and internally with fusion bonded epoxy resin, as 'Skotchkote 206 N'; or Rilsan; or an approved
equivalent. The thickness of the finished coating shall be checked with a calibrated thickness
tester and shall not be less than 0.3mm.
Flange adaptors shall be nylon coated or fusion bonded epoxy coated. All flange adaptors shall
be tied to the pipework to resist thrust. Flange fixings shall be to BS 4190 grade 8.8 or
equivalent, hot dip galvanised to BS EN ISO 1461 with a washer located under both bolt head
and nut. Flange gaskets shall be full faced to BS 2454 manufactured in EPDM.
Where pipework is damaged or modified on site, the affected areas will be repairs in accordance
with the coating suppliers recommendations using materials, supplied or approved by the coating
manufacturer/applier.
2.10.2 Borehole Instrumentation
The Contractor shall supply and install the following instrumentation at the borehole:
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(a)
(b)
(b)
A Borehole level transducer terminated at a local junction box, housed beneath the
headworks steel work.
A discharge pressure transducer.
A 200 NB electro magnetic flow meter.
See Section 2.11 for details.
The contractor shall supply and install 3 off dip tubes suspended from the dip tube support plate
detailed on the enclosed drawings, the dip tubes will be of a trapezoidal thread design to provide
a smooth external and internal wall, include an end cap to prevent instruments from dropping into
the well area and a screened casing at the top and bottom to allow water in and air to vent within
the dip tube, the dip tubes will finish with a bsp adapter, suitable for screwing into the support
plate and a suitable cap for glanding and supporting any instruments installed within the dip
tubes.
2.10.3 Discharge Range
2.10.3.1 Pipework
The contractor shall be responsible for the supply and installation of a 225OD SDR 17 MDPE
PE80 discharge range from the headworks, below ground to each of the cascades; this will
include all intermediate inspection chambers, cross connection and valve chambers as detailed
on the supplied drawings.
The nominal depth of lay will be 900mm to crown, with imported backfill in accordance with Coal
Authority Standards Specifications and CESWI specifications/guidelines.
The pipework will be installed using butt fusion techniques with electro-fusion couplers
acceptable at transitions in materials in conjunction with stub flanges.
The line of the discharge range is to be a straight as possible, where bends need to be used, they
will have a long radius to ensure cleaning ‘pigs’ can pass unobstructed through the full length of
the discharge range.
Pipework entering and exiting chambers will be mild steel and include puddle flanges as detailed
on the drawings provided.
All pipework shall be fabricated in carbon steel using tubes conforming to BS3601, API 5L Grade
B, HFS or equivalent, rated for 16 bar working pressure.
Upon completion of fabrication the pipework shall be grit blasted to SA 2.5 and coated externally
and internally with fusion bonded epoxy resin, as 'Skotchkote 206 N' or an approved equivalent.
The thickness of the finished coating shall be checked with a calibrated thickness tester and shall
not be less than 0.3mm.
Flange adaptors shall be nylon coated or fusion bonded epoxy coated. All flange adaptors shall
be tied to the pipework to resist thrust. Flange fixings shall be to BS 4190 grade 8.8 or
equivalent, hot dip galvanised to BS EN ISO 1461 with a washer located under both bolt head
and nut. Flange gaskets shall be full faced to BS 2454 manufactured in EPDM.
All bolting exposed to ground conditions on flanges and couplings shall be suitably protected by
wrapping with an appropriate proprietary tape protection system. Details of the proposed system
shall be submitted to the Project Manager for approval before use.
Pipework shall be designed and installed to allow removal of any valve requiring replacement or
maintenance without the need to dismantle large sections of pipework, i.e. with the use of tied
flange adaptors.
Upon completion the pipework will be tested in accordance with the Water Research Council test
method Type 2 or Type 1, to a pressure of 1.5 x the rated pressure of the lowest rated
component on the system.
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Detailed Method Statements and Risk Assessments will be issued at least 2 weeks prior to any
testing for review by the Coal Authority or nominated representative.
2.10.3.2 Valves
The Contractor shall provide all valves necessary to provide a complete installation and to enable
operation and maintenance to be carried out on pumps rising, main and the discharge range,
without the need for a complete system shutdown and drain.
Gate valves installed below ground will be double flanged, c/w a cap top for operation with a bar
and key, the gates will be resilient seated to provide a full bore aperture within the valve, to
enable any cleaning pigs to pass through easily.
2.10.3.3 Inspection chambers
Due to the relative short length of the rising main/range, it is not envisaged that any intermediate
inspection or hatch box chambers will be required.
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2.11
EICA Works
2.11.1 Introduction
The EICA Works shall include but not be limited to design, manufacture, supply, witnessed tests
at the factory, installation, tests at site, training for the Employer’s operatives, operating and
maintenance instructions, record drawings, diagrams and other documentation, commissioning
and setting to work.
2.11.2 Electrical installation design
The Contractor shall provide a complete electrical installation design, in accordance with IEE 17th
Edition Wiring Regulations, including calculations, diagrams, schedules, drawings and all other
documentation required to demonstrate a satisfactory design.
2.11.3 Electrical single line diagram
The Contractor shall prepare a detailed single line diagram for the new pumping station.
2.11.4 Main electricity supply
The Client will arrange for a new electricity supply to be provided to the proposed Scheme by the
energy provider.
The contractor shall ensure that a suitable meterbox is included in the booster kiosk design
complete with locking arrangement to allow access for both energy provider and the Employer.
The meterbox requirements are provided by the Energy provider and these will be forwarded
once the provider’s quotation is received.
2.11.5 Motor Control Centre
Whilst the pump-set duty is likely to require an 18.5kW drive, there may be a requirement to
increase the output from the borehole to achieve the required drawdown, therefore the inverter
drive rating is to be increased to 30kW and the incomers oversized accordingly.
The Contractor shall provide a Form 4 motor control centre (MCC) with front only access and
bottom cable entry, it shall be constructed, generally in accordance with WIMES 3.01, and shall
have the following compartments:
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Main incoming supply, with door mounted multi-function digital power meter (reading V,
A, kW, kVA, PF, kWh, etc.) and a phase failure relay with front panel indication and voltfree contact for PLC
Generator incoming supply, with a phase failure relay with front panel indication and voltfree contact for PLC, with Castell key interlock with the main incoming supply circuit
breaker to prevent simultaneous closure, generator connection facilities and access for
generator cables
Borehole Pump Variable speed drive
Small power distribution section.
PLC control system, including UPS and telemetry system
All terminals will be of a disconnect type, e.g. knife.
A full-length electrical insulation rubber mat will be supplied for in front of the MCC 9.5mm thick,
compliant with BS921 Electrical Safety Matting.
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Main Incoming Supply
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100 Amp four pole ‘Mains Supply’ moulded case circuit breaker, with adjustable overload
and short circuit protection module fitted with door interlocked handle and Castell key
switch.
An earth leakage detection module, with adjustable trip setting, nominally 100mA.
Set of mains monitoring unit current transformers and H.R.C. fuse protection, as required.
Phase failure relay.
Set of engraved designation labels to complete.
Multi Function Kwhr meter with pulsed contact output for remote monitoring.
Generator Supply (Temporary):
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100 Amp four pole generator moulded case circuit breaker with adjustable overload and
short circuit protection module fitted with door interlocked handle and Castell key switch.
Set of mains monitoring unit current transformers and H.R.C. fuse protection, as required.
Phase failure relay.
Set of engraved designation labels to complete.
30kW Borehole Pump Drive – Variable Speed
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Triple pole door interlocked moulded case circuit breaker with door interlocked handle.
Triple pole 30kW. Motor rated 'Line' contactor.
30K.w. ACS 550 VSD complete with Keypad.
Set of Instrument protection fuses.
Anti-condensation heater.
Current transformers.
Set of control circuit relays to give the required sequence of operation.
Set of electronic timers to give the required sequence of operation.
415/110V A.C. Control transformer.
Temperature monitoring unit, recording motor winding temperature and generating a 420mA signal to the PLC.
Set of Klippon polyamide control circuit terminals for all incoming and outgoing
connections.
Set of main motor terminals.
Mounted on the Front of the Panel door:
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Multi-function digital power meter (reading V, A, kW, kVA, PF, kWh, etc.)
Temperature display for Motor Winding Temperature
Hours Run indicator.
'Hand/Off/Auto' selector switch.
'Start/Stop' pushbuttons for use in the 'Hand' position.
Pilot lamps to indicate pump status.
Lamp Test pushbutton.
Mushroom headed stay put pattern 'Emergency Stop' pushbutton unit.
Ventilation fan and filter unit.
Set of engraved designation labels.
PLC and Control and Instrumentation
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Date: 21/11/2011
Internal isolator.
Allen Bradley P.L.C. system type Compact Logix and comprising:o CPU
o RS232 connection to telemetry.
o Additional Ethernet connection to telemetry.
o Power supply.
o Set of digital input cards (16 Inputs).
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o Set of digital output cards (8 Outputs).
o Set of Analogue input cards (16 Inputs).
o Set of Analogue output cards (4 Outputs).
Door mounted HMI.
5A 24V D.C. Power supply.
PT100 to analogue converter.
UPS unit with capacity of supporting the above P.L.C. and telemetry unit for 20 minutes.
Set of MCB’s.
240V Socket outlet.
Internal light fitting with door operated switch.
Indicator lamps.
Fault Reset pushbutton.
Free Issue Telemetry Unit and Modem
Distribution
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Internal mounted 63A moulded case circuit breaker
3 Phase Merlin Gerin Pan Assembly fitted with a selection of miniature circuit breakers.
230V Socket outlet.
110V Tool socket transformer.
110V Tool socket.
24V Tool socket transformer.
24V Tool socket.
2.11.6 Control, HMI & Telemetry
Control
A new Allen Bradley CompactLogix PLC system shall be supplied and installed in the MCC to
control the borehole pump and monitor site parameters.
A Functional Design Specification (FDS) for the control of the pumping plant will be developed by
the contractor for review by the Client. The software will be capable of automatically starting and
stopping the pump to maintain a water level within the borehole, which can be input through the
HMI, this will be combined with an ability to enter a set point flow rate, to ensure the pump-set
operates at or near it’s best efficiency point.
An internal time clock, will enable certain periods of operation to be inhibited, when the electricity
tariffs are particularly high, this inhibit function will be overridden if the water level rises to an
unacceptably high level, irrespective of the time of day or tariff.
In addition the PLC will monitor and record the pump performance and power used to generate a
real time pump efficiency, which will be displayed on the HMI.
The following PLC signals for the new booster installation shall include:
Analogue inputs
 Main Input Power
 Borehole Level
 Pump delivery pressure
 Pump delivery flow
 Pump power (prior to inverter)
 Pump speed (from inverter)
 Pump Motor Temperature (PT100)
Analogue outputs
 Pump required speed
Digital inputs
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Kiosk intruder (doors open)
Mains supply healthy
Generator supply healthy
Pump available
Pump running
Pump tripped
kWhr Pulse from Main Incomer
kWhr Pulse from pump starter section
Flow pulse from flow meter
UPS Status (Healthy/by-pass)
Digital outputs
 Pump start
HMI
A HMI Panel will be fitted to the door of the PLC compartment and act as an operator interface to;
display the status and values of all signals being monitored; enable set points such as pump flow
and borehole level to be input.
Telemetry
Telemetry equipment will be free-issued for incorporation within the ICA section of the new MCC,
details of the telemetry equipment is held in the appendices.
2.11.7 Instrumentation
The Contractor shall provide all instrumentation including:
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Borehole Water Level transducer
Pump delivery pressure transducer
Pump delivery flowmeter
Motor temperature PT100s – (Pump manufacturer supply)
Borehole Level Transmitter
The transducers shall be of the two wire type, provide a 4-20mA signal manufactured by Trafag
or equivalent and have the provision to detach the transducer head from the vented cable.
The transmitter will be terminated at a control junction box sited at the borehole headworks below
the galvanised steel framework.
Pressure Transducers
These shall be installed on the delivery pipework of the borehole rising main as described
previously and fitted with an isolation valve. The pressure transducer shall be of the two wire
type and provide a 4-20mA signal, manufactured by Trafag or equivalent.
The transmitter will be terminated at a control junction box sited at the borehole headworks below
the galvanised steel framework.
Flow Meters
The Contractor shall supply and install ABB flow meters to monitor the common borehole flows.
The flow meters shall be manufactured and tested in accordance with EN ISO 9001 QA system
and comply with the following requirements:
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Size:
Medium:
Pressure:
Flanges:
Protection sensor:
Cable:
Transmitter:
Display:
Flowrate range:
Working temp:
Option:
200mm
Minewater
16 bar maximum
BS 4504 PN16
IP68
SWA
Remote (240V ac power supply)
3 line with keypad
Abstraction 0 - 50 l/s
-10deg C to +50deg C
Calmaster card & fingerprint
The Contractor shall install the flowmeter transmitter head, cable and duct as necessary to
complete the installation.
A 4-20mA analogue output and flow pulse signal will be connected from the flow transmitter to
the PLC.
2.11.8 Building Services for Control Kiosk
2.11.8.1 Lighting
Internal fluorescent lighting shall be installed to provide an area illumination of 500lux. Corrosion
resistant luminaires shall be provided. The luminaires shall provide maintained emergency
lighting for a minimum of 3 hours on main electricity supply failure.
2.11.8.2 Heating
The kiosk shall be provided with heaters to maintain an internal temperature of 5ºC with an
external temperature of -10ºC. The heaters shall be controlled by a single room thermostat.
2.11.8.3 Ventilation
Fan assisted ventilation shall be provided to limit the pumping station internal temperature to a
maximum value suitable for the equipment installed within. The ventilation system shall be
controlled by a tamperproof thermostat, set to activate the system at 20ºC. The kiosk shall be
provided with fixed air inlet and outlet louvres.
2.11.8.4 Earthing and Bonding
Compliance with Earthing and Bonding Regulations and Standards shall include bonding across
pipe work joints and couplings, provision of main equipotential bonding of entry and exit points of
pipe work to the local earth bar.
2.11.8.5 Earthing
The Contractor shall provide an independent earthing system designed for full earth fault current
and with a maximum resistance to earth of 1 ohm. The independent earth shall be connected by
a disconnection link to the Booster Kiosk earth bar. Provision will also be made for the connection
of a mobile generator earth point.
Proprietary inspection pits shall be provided for inspection of all terminations.
2.11.8.6 Cabling
The Contractor shall provide a complete electrical and wiring installation design, in accordance
with IEE 17th Edition Wiring Regulations, including calculations, diagrams, schedules, drawings
and all other documentation required to demonstrate a satisfactory design.
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The installation shall comprise all cables, cable containment and supports, wiring accessories
and all other plant required to provide a complete functional installation.
Cabling Power
The Contractor shall include within the price for all necessary power cabling to produce a
complete and operational site.
Preference shall be given to the use of multicore XLPE insulated armoured cables to BS 5467.
Other types of cable may be used with the Client’s approval.
Cabling Control
The Contractor shall include within the price for all necessary control and instrumentation cabling
to produce a complete and operational site. All analogue signals shall be cabled using screened
twisted-pair cable. All spare cores/pairs in multicore/multipair cables shall be connected to
individual disconnect type terminals. Adequate terminals shall be provided for terminating
individual and overall screens, and connection to signal earth where appropriate.
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2.12
Civil & Building Works (ATKINS TO EXPAND ON CIVILS REQUIREMENTS)
2.12.1 General
Nominal cover to all steel reinforcement including links shall be not less than 40mm.
A blinding layer of minimum thickness 75mm and minimum grade C16/20 concrete, shall be used
under all foundations. The minimum grade of concrete to be used in the building foundation shall
be grade C28/35.
The structural requirements for all structures will be calculated and details of calculations and
results will be sent to the Client for review as part of the detailed design process.
2.12.2 Borehole Headworks Slab
The Contractor shall design and construct a reinforced concrete foundation around the existing
borehole liner flange, generally in accordance with the drawings held in the appendices.
The ground preparation and slab will be designed to support the weight of the pump-set, cable,
rising main full of water and the head works, which will be transmitted onto the slab directly and
through the support beams bolted to the slab.
There will be provisions within the slab for 3 off ducts from the GRP Kiosk foundation, 2 off to the
borehole head works support steel work and one adjacent to the flow meter.
2.12.3 Kiosk Foundation
The Contractor shall design and construct a reinforced concrete foundation to support the new
Control Kiosk and the plant installed within it.
The construction of the foundation will generally be in accordance with the detail provided in the
drawings, the final dimensions will be determined by the size of the proposed Motor Control
Centre and associated equipment offered by the contractor.
The foundation shall include all cable ducts/drawpits as required to accommodate the installed
equipment and will include:
2 No. Ducts to the Borehole Headworks Slab
1 No. Duct to beneath the flow meter
1 No. 150mm Long Radius duct (Black) for the new main incoming supply.
1 No. Duct to the external earthing arrangement.
The profile of the slab will enable the Kiosk to be positioned and bolted down, and the area
flooded with a free flowing concrete mix to fill the void, thus covering holding down bolts and
providing a sealed base.
2.12.4 Kiosk Steel Work
The contractor will supply and install all necessary steel work to support the MCC and open mesh
flooring, as well as the open mesh flooring.
All steel work is to be suitably sized for the anticipated loads and will be hot dip galvanised after
manufacture.
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2.12.5 Kiosk/Control Building
The Contractor shall provide and install a building, manufactured from steel, to house the new
Motor Control Centre and associated equipment for the operation and monitoring of the borehole
pump.
The building will generally be in accordance with the drawings provided, the final dimensions will
be determined by the size of the Motor Control Centre provided, and will have a minimum internal
height of 2500mm.
The kiosk will be supplied with a detachable roof, to enable the MCC to be installed and removed,
without disturbing the building.
The Kiosk will have an access door and a second door for access to the REC incoming fuses and
metering, housed in the segregated section of the Kiosk, within the metering section, a flame
retardant mounting board will be required.
The building shall include an emergency generator cable entry point consisting of a ‘cat flap’ type
access door, which can be locked in both closed and open positions.
The building shall be fully weather proof, finished to provide a matt gloss finish. Colour Green, 14
C 39 to BS 4800.
The kiosk will be manufactured from steel range and meet the requirements of Loss Prevention
Certification Board (LPCB) level 4.
The building will be of an insulated construction giving a U Value of 0.3w/m2/oC.
The Internal finishes will be painted white or any BS4800 colour, fully boarded options are
endless see above photos for some examples.
Doors are also to be certified to LPCB level 4 insulated, preference is for a single point
padlockable system with an internal override. Details of the proposed locking system are to be
submitted to the Coal Authority or nominated representative for approval prior to manufacture.
The kiosk shall be supplied with the following additional facilities and fixtures.
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Doors shall have stainless steel hinges and a restraining open mechanism.
Thermostatically controlled heating to maintain temperature at 10 o C.
High and low level natural ventilation panels with fly / vermin guards.
Thermostatically controlled ventilation.
Internal fluorescent lights to IP55 switched at inside of doorway, one unit with emergency
light facility and test switch, lights will have a means of disconnecting/unplugging to
facilitate the removal of the roof without extensive wiring alterations.
1 double socket (BS4343) RCD protected outlet.
SP and N Distribution board c/w MCBs and isolator for above electrics plus at least 2
spare ways.
Wiring for 230v 50 hertz operation.
Wiring to 17th edition of IEE regulations.
Security – Door Open contacts.
2.12.6 Chambers
It is not envisaged that any additional chambers will be required.
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APPENDICES
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APPENDIX A
DRAWINGS
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Title
Drawing No.
Rev
Site Layout
Proposed Site Layout
IWK278_100 Sht 1 of 1
0
IWK278_110 Sht 1 of 7
IWK278_111 Sht 2 of 7
IWK278_112 Sht 3 of 7
IWK278_113 Sht 4 of 7
IWK278_114 Sht 5 of 7
IWK278_116 Sht 6 of 7
IWK278_117 Sht 7 of 7
0
0
0
0
0
0
0
Headworks Arrangement and Detail Drawings
Headworks Configuration
Headworks Concrete
Borehole Extension
Headplate Detail
Pipework Detail
Proposed kiosk slab
Proposed kiosk layout
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APPENDIX B
WATER QUALITY ANALYSIS
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APPENDIX C
SPECIFICATIONS AND STANDARDS
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WIMES SPECIFICATIONS
1.05
Submersible Borehole Pump Units. 2: 1 May 2010
This Specification defines the requirements for the performance, design and testing of submersible
borehole pump units in the Water Industry in the form of text and DATA SHEETS.
The pump unit shall be of centrifugal, multistage, closed impeller design and be driven by an integral,
direct coupled, squirrel cage, induction motor.
3.01
Low Voltage Switchgear and Controlgear Assemblies. 4: 1 Jan 2011
This Specification defines the requirements for the design, construction, inspection and testing of lowvoltage switchgear and controlgear assemblies for use in the Water Industry in the form of text and DATA
SHEETS.
3.02
Low Voltage Electrical Installations. 3: 1 Jul 2008
This Specification defines the requirements for the design, construction, and initial inspection and testing
of low voltage electrical installations (hereafter termed the 'installation') associated with plant, equipment
and ancillary services in the Water Industry.
3.02(A) Profibus and Optical Fibre Network Design. 1: 1 Jul 2008
This Specification defines the requirements for the design of Profibus DP, Profibus PA and optical fibre
networks in the Water Industry.
The installation of Profibus DP, Profibus PA and optical fibre networks is covered by Section 9.4 of
WIMES 3.02 (Issue 3).
3.04
Low Voltage Electrical Specification for Package Plant. 4: 1 Jan 2011
This Specification defines the requirements for electrical equipment forming part of package plant
(hereafter termed ‘electrical equipment’) for use in the Water Industry in the form of text and DATA
SHEETS (refer to Guidance Notes).
The package plant will typically be designed to deliver a defined functional performance based on a
proven solution. Usually, this solution will not vary significantly from site to site or application to
application, other than by the adjustment of operating levels or set points.
The electrical equipment shall typically comprise a low voltage switchgear and controlgear assembly
(hereafter termed the ‘Assembly’) and a number of local control stations and items of control and
monitoring instrumentation, incorporating electrical components or equipment specific to the package
plant, together with all associated interconnecting cabling and wiring systems.
The total incoming supply to the electrical equipment shall be generally limited to a maximum of 100 A
and be protected by a fuse. If the total incoming supply is greater than 100 A, short circuit withstand tests
are required and the electrical equipment is outside the scope of this Specification. In this case, WIMES
3.01 (Low Voltage Switchgear and Controlgear Assemblies for use in the Water Industry) and WIMES
3.02 (Low Voltage Electrical Installations) shall apply.
3.05
Electrical Components (For Use in LV Assemblies). 3: 1 Jan 2011
This Specification defines the requirements for the performance, construction, design and testing of
electrical components (for use in LV Assemblies) for use in the Water Industry.
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3.07
Uninterruptible Power Supplies. 3: 1 Feb 2011
This Specification defines the requirements for the performance, design and testing of static, on-line
(double conversion) uninterruptible power supplies (UPS) in the form of text and DATA SHEETS.
The UPS shall incorporate a bypass facility that shall automatically transfer the load to the bypass circuit,
by means of a transfer switch, in the event of a UPS fault or overload.
4.01
Paints & Polymeric Coatings for Corrosion Protection. 3: 1 Sep 2005
This Specification defines the requirements for the corrosion protection of mild steel structures and
assemblies, items of machinery and ductile and cast iron pipework (incorporating pipes, valves and
fittings) for use in the Water Industry by paints and polymeric coatings (hereafter termed 'coatings').
Typical application areas shall include:
a) Machinery and package plant support structures (e.g. baseplates, pedestals and/or support frames); b)
Sludge separation equipment (e.g. sludge scraper assemblies); c) Grit separation and removal equipment
(e.g. settlement tanks, grit scraper and separator assemblies, and/or rake classifiers); d) Screens (e.g.
screen curtain support structures); e) Machinery items (e.g. pumps and gearbox casings); f) The exterior
and/or interior surfaces of storage tanks or vessels; and g) The exterior and/or interior surfaces of
pipework (incorporating pipes, valves and fittings).
8.03
Mechanical Installation. 2: 1 Aug 2006
This Specification defines the requirements for the mechanical installation of equipment in the Water
Industry in the form of text and DATA SHEETS.
Additional specification clauses relating to the installation of specific types of equipment (e.g. pumpsets,
screens etc.) may be given in the appropriate WIMES for these items of equipment, where such WIMES
exist.
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