START UP AND PERFORMANCE RUN

I. TEST ON COMPLETION :-

I a. General:-

Prior to the commencement of tests on completion the contractor shall

submit for approval the following:

 Site acceptance test Documents

 As- Built Drawings
 Operation & Maintenance manuals

Tests on completion shall not be commenced until the aforementioned

documents are approved. The initial charges necessary for tests on
completion shall be provided by the contractor. Electricity required for
tests on completion will be provided by the TTD on free of charges for a
period not exceeding 30 days. In case the tests on completion period
exceeds 30 days. The cost of power till start of performance run shall be
borne by contractor.

The cost of any consumables and chemicals required for the tests on
completion shall be borne by the contractor.

I. b Dry test requirements:-

1. General :-

As a minimum requirement the following dry tests shall be carried out as

a general requirement.

 A general inspection to check for correct assembly and quality of

workmanship.
 A check on adequacy and security of plant fixing arrangements.
 A general check to ensure that all covers, access ladders, water –
proofing, guard railings etc., are in place.
 A check on damp proofing, rust proofing and vermin proofing and
particularly the sealing of aperture between building structure,
chambers etc., and the outside.

2. Civil and building works:

As a minimum requirement the following dry tests shall be carried out on

the civil engineering and building works.

Check for the presence of foreign bodies in pipe work and structures.

3. Mechanical works :

As a minimum requirement the following dry tests shall be carried out on

the mechanical systems.

Carry out preliminary running checks as far is permitted by circumstances

in order to ensure smooth operation of plant.

4. Electrical works :-

As a minimum requirement the following dry tests shall be carried out on

the electrical systems:

 Check phasing and polarity.

 Check out point to point check on all cables.
 Check on security of cable termination.
 Check on completeness and adequacy of earthing systems.
  Check setting on protection relays, sizes of fuses and motor
overload setting.
 Carry out checks on cabling system in accordance with the
requirement of the relevant standards.
 Check operation of main circuit breakers by secondary injection
method.
 Check rotational direction of plant.
 Check operation of stand by generator installation and mains /
generator changeover procedures: a 4 hrs load test (using the
normal load of the works) shall be carried out on the generator
when the load is available.
 Check plant functionality.
 Check functionality of the central MMI and its power supply.

1.c. Process plant item / equipment :

As process plant items / equipment shall be tested to ensure they meet

the employer’s requirement for quality of workmanship, construction and
performance.

1.d. Hydraulic wet test requirement:

Hydraulic wet tests shall be carried out on completion of dry tests.

Potable water shall be used for hydraulic wet tests. The purpose of the
tests is to prove as far as is practical the hydraulic performance of the
works. In order to demonstrate the contractor shall ensure that each part
of the works is hydraulically loaded to its maximum rated load thought for
a period of at least seven days at twenty – four hours intervals.

In order to ensure a sufficient supply of potable water to carry out these

tests the contractor shall provide facilities for the disposal off site in an
approved manner.

 In order to remove doubt the following tests inter alia shall be

carried out.
 Pressure testing of all piped systems laid direct in ground in
accordance with the relevant standards.
 Fill all structures and check for leaks as per IS: 3370.
 Running of all pumped systems in order to check for
 Correct functionality.
 Absence of leaks.
 Correct running temperatures.
 Smoothness of running and the absence of undue vibration or
stress.
 Checks drive running currents.
 Carry out valving, diversion etc., to fully hydraulically load each
process element (or where there is a requirement to withstand an
over load), overload each process element.
 Demonstrate correct functionality of electrical, control and
instrumentation system.

The contractor shall simulate where practical the conditions that will
prevail when operating as a process in order to demonstrate the correct
functionality of process control loop etc.,

During these tests a check on the performance of plant shall be made, as

far as site facilities will allow, to compare its site performance with the
factory test data and to identify and constraints on performance due to
site condition.

I.e. Process wet test:

On approval by the TTD the contractor shall carry out process wet tests.
 Raw water shall be used as the primary feed stock for process wet tests.
These tests shall be carried out to demonstrate the process performance
of the works. In order to demonstrate this, the contractor shall ensure that
each part of the works is located to its rated throughput (including a
period of overload if required in order to demonstrate compliance with the
employer’s requirement) for continuous stable operating period of not less
than 48 hours.

The contractor shall provide facilities for the disposal off site in an
approved manner.

The following tests inter alias shall be carried out:

 Check and rectify leakage on civil structures, pumps and pipe

work.
 Running of all pumped systems in order to check for:
 Correct functionality.
 Absence of leaks.
 Correct running temperature.
 Smoothness of running and the absence of under vibration or
stress.
 Check drive running currents where the solution pumped is
different from that pumped during hydraulic wet tests.
 Carry out calibration of instruments.
 Carry out valving, diversion etc., to fully hydraulically load each
process element ( or where there is a requirement to withstand an
over load ), overload each process element;
 Demonstrate correct functionality of electrical, control and
instrumentation systems not checked during dry or hydraulic wet
tests or which may have changed as a result of the different
operating condition now prevailing.

On completion of process wet test on the various parts of the works the
contractor shall run the plant as a whole in order to demonstrate the full
functionality and performance of the works at various throughput rates for
a continuous period of not less than 7 days. In this period power utilized
by the contractor shall be compared with the guaranteed power
consumption given by the contractor. This shall be considered as
completion of ‘test on completion’ and shall be certified by TTD.

2. PERFORMANCE RUN AFTER START UP :

2.1. General :

On successful completion of ‘Test on completion ‘i.e. start up and

commissioning, certified by TTD , contractor should start the performance
run of the plant for 3 months.

The contractor is to carryout operation & Maintenance ( O & M ) of the

whole plant including civil works for 3 months under performance run.
TTD shall monitor the operation and maintenance by the contractor.

During the performance run period, the contractor shall provide following
as minimum for round the clock operation.

Staff:

Mechanic / Operator: one on general shift

Electrician: one on general shift
Skilled workman / fitters: one on each shift
Mazdoors( Helpers / gardener cum watch man ) : Two on each shift

Chemicals and consumables: As required.

 Spares: As required for replacement during performance run period. The
spares used from the spare supplied under the contract shall be replaced
by the contractor.

TTD shall supply power and water during performance run period free of
cost. All other materials such as chemicals, consumables, lubricants,
tools & plants, spares etc., shall be provided by the contractor. The
contractor, if required, shall provide activated sludge or any other material
for the stabilization of the plant.

The contractor shall provide operators for various units / plants for three
shifts and other staff / supporting personnel in general shift.

The contractor shall submit a weekly report to the Employer, about the
operation and maintenance indicating the manpower, electric power,
chemicals and other consumables consumed and also problems faced
and rectified.

During the period, the contractor shall ensure that the design treated
sewage quality standards are met in accordance with the specification
within the rate of power and chemicals consumption as committed by the
contractor. The raw and treated sewage analysis pH, SS, BOD and oil &
grease shall be carried out on daily basis from the day of commissioning
at a reputed laboratory as approved by Engineer- in- charge. 90% of the
treated sewage samples should fall within prescribed limits of the treated
sewage. The sampling location for raw sewage shall be at raw sewage
sump and that of treated sewage shall be at outlet of chlorine contact
tank.

The analysis of sewage for the above parameters at different locations

such as outlet of secondary clarifier shall also be carried out on monthly
basis. The contractor shall take immediate steps to correct the operation
of the plant to meet the guaranteed performance. The charges for
analysis at the laboratory are to be borne by the contractor.

The contractor’s responsibility includes the safety and security of the

works / plants during the course of performance run.

The contractor shall provide the key personal for performance run with
the minimum qualification and experience.

3. PERFORMANCE RUN CERTIFICATE :-

The conditions for issuance of a performance run certificate as detailed in

the conditions of contract shall comprise:

1. The completion of three months operation and maintenance under

performance run of the treatment plant to the satisfaction of TTD.

2. 90% of the treated sewage samples fall within the prescribed limits
of the treated sewage as mentioned.

3. The O & M manuals have been updated following three month’s

operational experience and approved by TTD.

4. All defects identified during the three months operation of the works
have been rectified.

TTD shall issue a completion certificate for ‘Performance run of Plant

‘after successful completion of performance run of plant for 90
consecutive days by contractor to the satisfaction of TTD.

OPERATION AND MAINTENANCE

1. Scope of work :-
The contractor is to operate, maintain and monitor the 3.00 MLD Sewage
treatment plant for 36 months after successfully completing performance
run. The scope of work is given below but not limited to the following. This
may include other incidental items of work connected with the regular
operation and maintenance of the treatment plant as decided by Engineer
– in – charge from time to time.

The contractor shall execute separate agreement for O & M with

Executive Engineer – VIII, TTD Tirumala.

1. The contractor shall ensure proper running of the plant to give the
desired effluent standards i.e. BOD less than 20 mg/l, TSS less than
30 mg/l, O & G less than 10 mg/l. The contractor shall also be
responsible for overall maintenance of the plant i.e civil, electrical and
mechanical systems. The contractor shall also be responsible for all
repairs of equipment / machinery.

2. The contractor shall monitor the quality of raw and treated sewage.
The contractor shall intimate and take adequate action to ensure
smooth and satisfactory running of the plant. The raw and treated
sewage analysis for DO, pH, SS, BOD and oil & grease shall be
carried out on Biweekly basis during O & M period at any approved
laboratory. The above analysis shall also be carried out once in a
month for water samples collected from up stream and down stream
side of the site of treated sewage disposal.

3. The contractor shall prepare and implement an effective plant

maintenance programmer in consultation with Engineer – in- charge.
It shall be absolutely contractor’s responsibility to look after all sorts of
maintenance whether preventive or break down. The contractor shall
maintain the operational activity record as prescribed in this volume.

4. The contractor shall be responsible for keeping updated record of

documents including History – Card for equipment and maintaining
every day logbook relating to running of machinery, consumption of
energy, and other consumables etc., and various analyses performed.
In addition to above the contractor shall maintain the operation and
maintenance data for the following.

 Daily status record of STP

 Daily flow record
 Daily analysis record
 Operation records of mechanical screens in STP
 Operation record of grit channel
 Operation record of primary clarifier
 Operation record of Aerators
 Operation record of secondary clarifier
 Operation record of sludge pumps
 Operation record of chlorination system
 Record of quantity of sludge generation and sludge dewatering
system
 Performance data of Aeration tank
 Performance data of chlorination system
 Any other allied works required by TTD during O & M

5. The contractor shall submit a monthly report to TTD, about the

operation and maintenance indicating the manpower, electric power,
chemicals and other consumables consumed, problems faced and
rectified along with various analysis performed for raw and treated
sewage.

6. The contractor shall be responsible to carry out day to day as well as

periodic maintenance necessary to ensure smooth and effective
performance / running of all equipment / instruments installed at the
 sewage treatment plant. The contractor shall hand over machinery &
site to the department after expiry of the contract period in good
running condition.

7. The contractor shall maintain all treatment plant and other civil
structures in the STP premises including boundary wall in sturdy
manner to complete its natural / desired life. He should paint all MS /
CI / GI structures at least once in a year to prevent rusting as and
where required and as directed by TTD.

8. The contractor shall also be responsible for proper upkeep of

administrative block of the sewage treatment plant.

9. He shall be responsible for proper maintenance of all the pumps and

allied items including mechanical screens, gates, diffusers/ aerators,
primary and secondary clarifiers, air blowers, sludge pumps,
centrifuge, chlorinator etc.,

10. He shall be responsible for timely removal and safe disposal of the
dried sludge as directed by the department. He should get approval
for the location of the disposal of the dried sludge from TTD.

11. He shall be responsible for maintenance of streetlight, poles & fixtures

also.

12. The sewage system in the STP premises, roads and pathways
provided at the sewage treatment plant shall be maintained properly.

13. Round the clock watch and ward of the entire premises including plant
/ machinery etc., will also be the responsibility of the contractor.

14. The entire STP premises including will be kept neat and clean.

15. The records maintained by the contractor shall be produced

periodically to the Engineer – in – charge for proper monitoring as
directed by him.

16. Operation & maintenance of boundary wall of STP, landscaping and

forestation done in the sewage treatment plant premises etc., shall be
carried out.

2. GENERAL TERMS AND CONDITIONS

1. TTD shall supply power and water to the contractor free of cost during
O & M period of 24 months.

2. During O & M period the contractor is to keep there staff engaged

continuously without any break for operation, maintenance and
monitoring of STP.

3. The contractor will supply all consumables, reagents and spares. The
contractor will employ its own staff for testing purpose. However the
department will be a liberty to get random sampling & testing done on
its own or from any other agency, to the entire satisfaction of Engineer
– in – charge. In case of testing from other agency charges will be
borne by TTD.

4. Contractor’s laborers and supervisors shall have to normally observe

office timings of general shift.
 5. Plant and equipment covered under this contract shall be totally
attended to by the contractor including any “Trouble Shooting" to
ensure smooth and trouble free operation.

6. The maintenance period shall be twenty four months from the date of
completion of successful performance run of sewage treatment plant.
In this period the contractor shall supply all spares required for
maintenance of the plant at free of cost.

7. For effective maintenance of STP, the contractor shall employ

sufficient staff with proper qualification. For his guidance the pattern
and no. of minimum staff to be engaged is described in this chapter.

8. The contractor shall take operational measures that there shall be no

flooding of STP area.

9. The contractor shall abide by all central / state. Govt / local bodies
rules regulations, pertaining to this contract, without any extra cost.

10. In the event of any damage / loss of life / theft of property, due to
negligence on the part of contractor, the contractor shall be solely
responsible and liable for compensation and damages, regarding
negligence and the decision of Engineer – in – charge shall be final.

11. The contractor should maintain all kinds of securities in the premises
round the clock for that he should arrange manpower to prevent theft,
robberies and malpractice. No unknown person shall be allowed to
enter the STP premises except TTD staff, officials and other related
persons. Educational study visits of the students are permissible only
on permission from TTD.

12. The site will be open for inspection by the designated officers / official
of TTD at all times during the contract period.

13. The contractor should observe all safety rules and regulations
corresponding to electricity, factory act, and bio – chem. Process fire
and as per building codes. Any accident causing by over sighting the
rules, the contractor at his own cost and risk shall handle the related
cases. Insurance of the entire staff at site is compulsory under
insurance policy drawn from Govt. The copy of the cover note should
be submitted to TTD.

3. FINANCIAL TERMS AND CONDITIONS

During the operation and maintenance period electricity charges will be

borne by the department. The reimbursement rate will be as per market
rate during the day of delivery. However the department will be at liberty
to arrange supply of chlorine to the contractor for consumption at STP. All
other consumable materials and required staff for operation &
maintenance will be provided by the contractor.

The operation & maintenance cost approved by the department shall be

payable on monthly basis on completion of every month on submission of
details by the contractor. The contractor shall maintain the attendance
record of the staff employed by him. This can be checked by the
deparment any time. The contractor will also submit copy of all the data
sheets every month for evaluation.

The spares required shall not be payable to the contractor as the

machinery is within his guarantee period.

The sludge and treated water available from sewage treatment plant shall
be property of TTD. The sludge and waste water will not be sold by the
contractor.

All sort of tools & plant, required for proper operation & maintenance of
the plant shall be arranged by the contractor at his own cost.
 4. DESCRIPTION OF STAFFING

Details of minimum staff required to be employed for the operation and

maintenance of the sewage treatment plant for 24 months is given below.
However, additional staff, if required for proper operation and
maintenance of STP & TTP will be provided by the contractor without any
additional charged.

S.NO Personal Nos Total Main task of the personnel

Experience
1 Mechanics / 1 3 Years Responsible for overall operation for
operators (general STP. And co-ordination of activities
( Diploma or ITI shift ) for satisfactory performance of the
qualified ) STP and reporting to the Engineer –
in –charge and responsible for the
proper functioning & maintenance,
data collection of STP.

2 Electrician 1 3 Years Responsible for maintenance of

( Diploma or ITI (general electrical equipment.
qualified ) shift)

3 Skilled 3 ( One 2 Years Responsible for maintenance of

workman / Fitters on each mechanical equipments.
( ITI qualified ) shift )
4 Mazdoors 6 ( Two 1 Year Responsible for keeping the STP
( Helpers / on each premises clean and neat. Also they
gardener cum shift ) will assist operation in day to day
watch man ) activities. And also to maintain the
garden / landscaping/ watch and
ward of the plant.

5. DEPLOYMENT OF STAFF DURING OPERATION AND MAINTENANCE

PERIOD.

The contractor shall arrange at his cost the staff required during the
operation and maintenance period of 36 months. The lump sum tender
cost shall also include all expenditure likely to incurred for repairs /
replacement of any items executed in the tender during this period.

The department shall provide electric power free of cost. The contractor
should submit detailed information regarding the staff likely to be
deployed by him during o & m period of 36 months.

6. TAKING OVER

The plant will be taken over on satisfactory completion of the operation

and maintenance of the contract for 24 months provided that,

1. The plant / equipment are in running condition.

2. The result of the treated sewage quality during o & m of the plant is
within the limit specified in the tender document.

3. All treatment plant units including interconnecting piping, hand

railings, ladders, staircases, buildings, various tanks, machines,
panels etc., are neatly painted.

4. All records of operation and maintenance during the 24 months period

are handed over to TTD in proper condition.

5. The o & m manuals have been updated following 24 months

operational experience and approved by the TTD.
 In case taking over is delayed on account of contractor’s failure, the o &
m period will be extended further till it meets the above requirements
without any extra cost to TTD.

N.W Construction of 3 MLD sewage treatment plant at

Balaji Nagar area at Tirumala(Balance work)

OUTLET PARAMETERS

The outlet parameters of the proposed construction of 3.0 MLD sewage

treatment plant at Balaji Nagar area, Tirumala, to use the treated water to land
scape irrigation.

Parameters Minimum Maximum

PH 7.0
6.5
COD 150 mg / l
85 mg / l
BOD ( 5 days, 50 mg / l
25deg C )
30 mg / l
Suspended solids 150 mg / l
100 mg / l
Oil and grease 10
8
MBAS 5 mg / l
3 mg / l
Odour 20
10