Replacement Repairand Upgradation Works including 1.8 MLD Ultrafiltration System Ozone System Pumps Pipelines and Online Analysers at 4 MLD Sewage Treatment Plant STPIIT Madras Chennai36

Civil Works

Supplying, installation, testing and commissioning of Ultrafiltration (UF) system of 1.8 MLD capacity in Sewage Treatment Plant (STP) at IIT Madras, including dismantling and replacement of existing UF system, complete, all as specified and as directed by the Engineer-in-Charge. The UF system shall comprise SS-304 fabricated UF skid of approximate size 5.20 m × 2.70 m × 1.80 m, complete with 22 Nos. UF membrane modules of 280 mm diameter and 2081 mm (±5 mm) height, including SS double acting pneumatic actuated valves (1 No. 10" dia and 4 Nos. 6" dia), ½" dia SS air piping up to 10 m, SS-304 interconnecting pipelines, fittings, supports, pressure gauges and SS fasteners, etc., complete. The item includes dismantling, removal and disposal of existing UF skid and membranes as per prevailing statutory provisions, integration with existing SCADA system, testing, commissioning, trial run and handing over, complete in all respects as per Annexure-I specifications, approved drawings and instructions of the Engineer-in-Charge.

Service Flow Rate : 100 m3/hr % Recovery : >90% Permeate Flow Rate : 90 m3/hr Permeate capacity : 1800 m3/day Reject Flow Rate : 10 m3/hr Operating Hours/ day : 20 hrs

Supply, Installation, Testing & Commissioning of air compressor of following Specification. Air compressor: Motor Power: 7.5 HP Air Tank Capacity : 300 L Cooling System : Air Cooled Maximum Flow Rate (CFM) : 24.18 CFM Maximum Pressure : 175 PSI Number of Compression Stages: Single Stage Air Refrigrent dryer: Air Flow-rate (3°C): 1.20 m³/min Absorbed nominal power: 0.17 kW Power Supply: 230/1/50 V/Ph/Hz Dew Point (ISO Class): 4 Max Pressure: 16 bar g Air Connection: ½″ BSP Refrigerant: R513A

Pre-Filter to Air Refrigrent dryer Connection size: ¾″ Max Pressure: ~17 bar g Flow rate (at reference condition): ~1.3 m³/min Removes particles down to ~1 µm including water & oil aerosols Housing / material / design: Die-cast aluminium body Temperature / operating limits: Typically rated for compressed air up to ~80 °C (for standard filters)

Post-Filter to Air Refrigrent dryer: Connection Size: ¾″ BSP Maximum Pressure: 17 bar g Flow Rate (at reference conditions): 1.3 m³/min Filtration Efficiency: Removes particles down to 0.01 µm, including oil aerosols and fine contaminants Housing / Material / Design: Die-cast aluminium body Operating Temperature: Suitable for compressed air up to 80 °C (standard version) Auto drain valve operatable with the above air compressor with brass housing material, Environmental protection : IP65 (NEMA4), Timer PCB: SMD technology, ensuring consistency in production, Timer cycle indication: Bright LED illumination.

This cost includes all works upto replacement of existing air compressor, mounting, installation and synchronizing with SCADA of existing line at STP in IIT Madras and disposal of the existing air compressor from IIT Madras.

Upgradation of the Oxygen Generation System by replacing suitable new PSA tower media, providing a new real-time oxygen analyzer, servicing the air compressor and air dryer, and refrigerant refilling in the existing STP at IIT Madras. The scope of work includes replacement of molecular sieve media (zeolite and alumina) in the Pressure Swing Adsorption (PSA) towers, servicing and calibration of pressure gauges and valves, servicing of the air compressor and air dryer including refrigerant refilling, and integration, testing, and proper synchronization of the newly installed real-time oxygen analyzer and the oxygen generator with the existing SCADA system in the STP at IIT Madras.

Supply, Installation, Testing, and Commissioning of Sewage Submersible Pump Set of the following specifications: Power rating: 5.5 kW / 7.5 HP Speed: 2900 rpm Pipe size: 80 mm Maximum solid size: 35 mm Power supply: Three-phase Rated voltage: 415 V Degree of protection: IP68 Minimum discharge: 83 m³/hour Minimum head: 15 m Consistency of medium: < 1.2 × 10³ kg/m³ Maximum ambient temperature: 40°C Frequency: 50 Hz Insulation class: B Impeller material: Cast iron Delivery casing material: Cast iron Motor body material: Cast iron Pump shaft material: Carbon steel The scope of work includes replacement of the existing pump in the balancing tank of the existing STP at IIT Madras, along with all works necessary for complete installation, testing, and commissioning, including connection to the discharge and suction headers, welding works if any, and integration of pump operation and status with the existing SCADA system, all as per the instructions of the Engineer-in-Charge.

Supply, Installation, Testing, and Commissioning of Sewage Submersible Pump Set of the following specifications for RAS (Return Activated Sludge) and SAS (Surplus Activated Sludge) pumps: Power rating: 1.5 kW / 2 HP Speed: 2840 rpm Pipe size: 50 mm Maximum solid size: 22 mm Power supply: Three-phase Rated voltage: 415 V Degree of protection: IP68 Minimum discharge: 11 m³/hour Maximum head: 15 m Consistency of medium: < 1.2 × 10³ kg/m³ Maximum ambient temperature: 40°C Frequency: 50 Hz Insulation class: B Impeller material: Cast iron Delivery casing material: Cast iron Motor body material: Cast iron Pump shaft material: Carbon steel The scope of work includes replacement of the existing pump in the SBR tank of the existing STP at IIT Madras, along with all necessary works up to complete installation, testing, and commissioning, connection to the discharge and suction headers including welding works, if any, and integration of the pump operation and status with the existing SCADA system. All works shall be carried out as per the instructions of the Engineer-in-Charge.

Supply, Installation, Testing, and Commissioning of Sewage Submersible Pump Set of the following specifications: Power rating: 5.5 kW / 7.5 HP Speed: 2900 rpm Pipe size: 80 mm Maximum solid size: 35 mm Power supply: Three-phase Rated voltage: 415 V Degree of protection: IP68 Minimum discharge: 83 m³/hour Minimum head: 15 m Consistency of medium: < 1.2 × 10³ kg/m³ Maximum ambient temperature: 40°C Frequency: 50 Hz Insulation class: B Impeller material: Cast iron Delivery casing material: Cast iron Motor body material: Cast iron Pump shaft material: Carbon steel The scope of work includes replacement of the existing pump in the balancing tank of the existing STP at IIT Madras, along with all works necessary for complete installation, testing, and commissioning, including connection to the discharge and suction headers, welding works if any, and integration of pump operation and status with the existing SCADA system, all as per the instructions of the Engineer-in-Charge.

Supply, Installation, Testing, and Commissioning of Permeate Water Transfer Pumps in the STP at IIT Madras, of the following specifications: Flow rate: 75 m³/hour Differential head: 35 m Maximum head: 38 m Speed: 2920 rpm Frequency: 50 Hz Maximum operating temperature: 50°C Maximum pressure: 10 barg Materials of Construction (MOC): Pump casing material: Cast Iron (MOC: CI260 / IS 210 Gr. FG 260 or equivalent) and Impeller material: Stainless Steel (CF8M / 40C8) conforming to ASTM A351. The scope of work includes removal of the existing pumps and replacement with new pumps, along with all works necessary for complete installation, testing, and commissioning, including connection to the suction and discharge headers, welding works if any, and integration of pump operation and status with the existing SCADA system, all as per the instructions of the Engineer-in-Charge.

Supply, installation, testing, and commissioning of online COD, BOD, TSS, and pH analyzer for permeate water in the existing STP at IIT Madras, based on UV 254 nm absorption with full-spectrum scanning, complete with self-cleaning sensor, IP55 wall/structure-mounted panel, 8” TFT display, 230 VAC power supply, and RS-485 output. The analyzer shall be installed at the influent/effluent pipeline with all necessary fittings and accessories and integrated and synchronized with the existing STP SCADA system. Measuring Ranges: COD – up to 500 mg/L; BOD – up to 100 mg/L; TSS – up to 150 NTU; pH – 0–14. complete in all respects as per the direction of Engineer in-charge.

Supply, installation, testing, and commissioning of online MLSS analyzer (0–50,000 ppm, SS sensor with wiper and 9 m cable, 100–240 VAC, 4–20 mA/Relay/RS485, Japan) for SBR tank in the existing STP at IIT Madras, including all fittings and integration with existing SCADA system, complete in all respects as per the direction of Engineer in-charge.

Supply, installation and commissioning of a coarse bar screen (40 mm spacing), made of SS 316L, by replacing the existing coarse screen in mechanical coarse bar screen at the existing STP, IIT Madras, at all levels. The scope of work includes removal, dismantling, and safe disposal of the existing coarse screen from the mechanical coarse bar screen, and complete fixing of the new screen, complete in all respects as per the direction of Engineer in-charge.

Design, supply, installation, erection, and commissioning of Oil & Grease Trap system at the grit chamber (T5) in the existing STP at IIT Madras. The system shall include a suitable motor pump for removal of oil and grease from sewage, with movable steel arrangements supported on either sidewall of the chamber. The motor pump shall be mounted on steel rails, painted with epoxy coat (minimum three coats) over the required primer, for smooth movement. The contractor shall obtain approval of the Design Basis Report (DBR) prior to supply, including incorporating any technical inputs from IIT Madras. The work includes complete installation, testing, and commissioning.

Providing and laying S&S Centrifugally Cast Spun) / Ductile Iron Pipes conforming to IS : 8329 : 450 mm dia Ductile Iron Class K-9 pipes, at all level.

Providing and laying D.I. specials of class K-12 suitable for push-on jointing as per IS : 9523 : Up to 600 mm dia, at all level.

Providing and laying D.I. Specials of Class K - 12 suitable for mechanical jointing as per IS : 9523 : Up to 600 mm dia,at all level.

Providing and fixing fully VITRIFIED industrial tiles of M/s Endura grey colour or approved colour of 12mm thick for walls and floors (up to required height and level) of size 300X300X12mm neatly laid over tile fixing or laid in cement mortar 1:3 (1 part cement 3 part sand / M sand) , 20mm thick. The rate inclusive for providing spacer of 5mm thick between the tiles while laying and removing the spacer for laying grout. The cement mortar should admixed with SBR latex of 3kg per bag of cement . Rate inclusive of materials, labour charges at all levels. Rate inclusive of Grouting the tile joints with Laticrete products- Applying Latapoxy SP100 (Grouting of tiles to be done with MYKL Laticrete Latapoxy Sp100 stain free grout as per the methodology specified in the technical data sheet of MYKL. 5mm width grout to be provided between tiles to fill the joints. 1 Unit = 5 Kgs. Coverage: 5.10 Sq.mt.. per Unit ) in the tile joints. The rate inclusive of surface preparation, labour, material, tools and plants etc complete. Rate inclusive of materials, labour charges at all levels. Including cost of spacers.

Demolishing cement concrete manually/ by mechanical means including disposal of material within 50 metres lead as per direction of Engineer - in - charge. Nominal concrete 1:4:8 or leaner mix (i/c equivalent design mix)

Structural Steel work welded in built up sections / tubular sections, trusses and framed work, including cutting, hoisting, fixing in position including surface preparation by shot blasting followed by coat of approved Epoxy Zinc phosphate primer (DFT more coats not less than 40 micron) followed by Epoxy paint with two of approved shade etc . complete as per the instruction of Engineer incharge.

Finishing with Epoxy paint (two or more coats) at all locations prepared and applied as per manufacturer's specifications including appropriate priming coat, preparation of surface, etc. complete. On steel work

Design, fabricating, supplying, installing, testing and commissioning of Cast Iron Flange Back Wall Thimble Mounted Sluice Gates conforming to IS 13349 with Electrically operated actuator, of size 710 mm × 1280 mm, suitable for sewage application with seating head up to 7.50 m, complete with open top frame and flush bottom closure arrangement, including dismantling of existing gate/valve and making good the support arrangements, all complete as per directions of Engineer-in-Charge. The sluice gate shall include CI frame, slide/door, guides, stem guide, hand wheel and headstock of CI conforming to IS:210 Gr. FG-200; spindle and extension spindle of carbon steel EN-8/IS:2062; guide brackets and couplings of M.S. IS:2062; bronze seating and operating nut of LT bronze IS:318 Gr. LTB-2; fasteners of M.S. IS:1367; forged carbon steel anchor bolts, etc., complete. Including electric actuator suitable for automatic operation, headstock for manual operation, accessories, alignment, grouting, testing, commissioning and integration with existing SCADA system, complete in all respects as per approved drawings, specifications and instructions of the Engineer-in-Charge.

Servicing of automatic actuated/ manual sluice valve including shutter. This service includes of repair of electric actuators servicing, replacing of spare parts, frames, electrical connections, switches, all rings, applying lubricants, bushes, including loading, transportation from plant to service centre & back, unloading, fixing in original position, technician / labour charges etc all complete.

Please Enable Macros to View BoQ information