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Whereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public.

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“Step Out From the Old to the New”

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है”ह”ह

IS 10096-2 (1983): Recommendations for inspection, testingand maintenance or radial gates and rope drum hoists, Part2: Inspection, testing and assembly at the time of erection[WRD 12: Hydraulic Gates and Valves]

IS : 10096 ( ParI 2 ) - 1983(Reaffirmed 2005)

Indian StandardRECOMMENDATIONS FOR

INSPECTION, TESTING AND MAINTENANCEOF RADIAL GATES AND THEIR HOISTS

PART 2 INSPECTION, TESTING AND ASSEMBLYAT THE TIME OF ERECTION

FIrst Repnnt OCTOBER 2007( Including Amendment No I )

UDC 626 422 23 620 I

c Copyright 1984

BUREAU OF INDIAN STANDARDSMANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002

Gr3 March 1984

IS I 10096 ( Part 2 ) • 1983

Indian Standard

RECOMMENDATIONS FORINSPECTION, TESTING AND MAINTENANCE

OF RADIAL GATES AND THEIR HOISTS

PART 2 INSPECTION. TESTING AND ASSEMBLYAT THE TIME OF ERECTION

Hydraulic Gates and Valves Sectional Committee, BDC 56

Cha"man

SHIll Y. AOINARAYAMA SASTIU

RLpHsen/mg

Tungabhadra Steel Product. Limited, Tunaabha­dra Dam ( Kamataka )

Membe"

SURI G S ANNIGIlRI ( Alternate toSh" Y. AdiDarayana Sastn )

CHIEFENOINIlBR ( TDD ) Irrigation Works, Government of Punjab,Chandtgarh

Central Water Commission, New Deihl

EngmeermgSHRI V. P KAUSUAL ( Attemase )

MANAOINO DIRECIOa Tarml Nadu Public WorksCorporation Ltd. Madras

DIRECTOR ( M{E) (Allernale )Suar R. C CHOPRA TEXMACO Ltd, Calcutta

SURI R. BHATTACHARYA ( Alternate )Sual H C DBINORA Haryana Stale Mmor Irriganon (Tubewellt)

Corporauon Ltd, ChandigarhSHRI R C CHAUHAN ( Alternate)

DIRECTOR Central Water & Power Research Station, PUDOSHRI A. V GOP....LA KR.ISHNA RAO

( Alternate)DIRECTOR( GATES DESIGN I )

SHRI C. L VERMA ( Alternate )SKRI R. N GUPTA Nanga! Workshops, Nanga! Township

SURI N S CHAWLA ( Altemate vSHRI K. K JULKA Beas Project, Bhakra Beas Management Beard,

Nangal Township

WORKS MANAGeR ( A/fernare )SMal K V S. MURTHY Trrveru Structwals Ltd, Nairn

SURI M. K. V. SAlUdA (Alternale )

( Continued o. page 2 )

@ Copynghl 1984

BIJRE-\U OF II'.OIA'" "T.-\NOARD~

This publication i. protected under the Indian CopYlI,hl Acl (XIV 01 1957) andreproduction in whole or m part by any means except WIth written permissson of thepublisher shall be deemed to bean mlnngement of copynght under the SBId Act.

IS I 101196 ( Part 2 ) • 1911:J

(Conlittued/rom page 1 )

Members Representing

Irrrgauon & Power Department, Government ofMaharashtra, N asik

Central India Machmery Manufacturing Co Ltd.Bharatpur

SKR[ NARI!N'DRA S,NOH Irrtgenon Department, GovernmentPradesh, Lucknow

SIQU Ilu KUMAR Bharat Heavy Electncals Lid, BhopalSHJU N. Y N .uAo.sJMHAN ( AlfernQIt! )

SHRJ S K SADUU Jessop & Co Ltd, CalcuttaSHRl S. NAG ( Allernale)

SUPElUNTENDINO ENGINlER ( PH )(COO)

SHRl R SWAaUP

of UHar

SUR' K C BAKETY ( Allerna'e )SHRJ M C TewARI Himachal Pradesh State Electricity Board, SimlaSItIU N VISVANA1HAN Nauooal Hydroelectric Power Corporauou, New

DelhISUR' O. RAMAN, Director General, lSI (Ex-officla Member)

Director ( Civ EogS )

SecretarySHkI HEMANT KUMAR

Assistant Director ( CIV Engg ). lSI

Panel for Inspection, Testing and Maintenance of Radial Gates.BDC 56; P8

CO"J1~ner

S..... M N SHARMA Irrigation Works, Government ofCnandigarh

Punjab,

Members

SUR] G S ANNJGERI Tungabhadra Steel Products Ltd, TungabhadraDam ( Karnataka )

DIRECTOR ( GATES DESIGN I ) Central Water Commtvsron, New DeihlSm. R N GUPTA Nanga! Workshops, Nanga! Township

SUR' N S CHAWLA ( Allernare)SURI Y R KALRA BSL Project. Bhakta Beas Management Board,

Sundernagar ( HP )SHRI R. N AGGARWAL ( Alurnote )

SBRI A K MUKHERJEE Jessop & Co I td CalcuttaSUPERINTENDING ENGJNEER Jrrrg.ruon and Power Department, Government

(GAT" ) ( COO) of Maharashcre. NasrkSHRI R. SWARUP Central India Machmery Manufacturing Co Ltd,

Bh .ratpurSHRI M C. TEWAJU Himachal Pradesh Stale Electrrcny Board.

Government of Himachal Pradesh, Srmla

2

AMENDMENT NO. 1 NOVEMBER 1992TO

IS 10096(Part 2) : 1983 RECOMMENDATIONS FORINSPECfION, TESTING AND MAINTENANCE OF

RADIAL GATES AND THEIR HOISTS

PART 2 INSPECTION, TESTING AND ASSEMBLV AT THETIME OF ERECTION

[ Cover page, page 1 and page 3 ( 1111£ and clause 1.1 ) 1- Substitute'Rope Drum' for 'Their',

(RVD12)

Pnnted at Simco Pnntmg Press, Deihl

AMENDMENT NO. 2 JANUARY 2011 TO

IS 10096 (PART 2) : 1983 RECOMMENDATIONS FOR INSPECTION, TESTING AND MAINTENANCE OF RADIAL GATES AND ROPE DRUM HOISTS

PART 2 INSPECTION, TESTING AND ASSEMBLY AT THE

TIME OF ERECTION

(Page 7, clause 2.7.7, line 1) –– Substitute ‘correct’ for ‘corrcet’. (WRD 12)

Reprography Unit, BIS, New Delhi, India

IS: lOO96( Part:1) - 1983

Indian Standard

RECOMMEND-\TIONS FORINSPECTION, TESTING AND MAINTENANCE

OF RALJIAL GATES AND THEIR HOISTS

PART 2 INSPECTION, TESTING AND ASSEMBLYATTHE TIME OF ERECTION

O. FOR EWOR D

0.1 This Indian Standard ( Part J ) was adopted by the Indian StandardsInst.tutton on 28 November 1983. after the draft finalized by the HydraulicGates and Valves Sectional Committee had been approved by the 0,,1Engineering DIvision Council.

0.2 Almost every river valley project has 3 reservoir or diversion work forthe control of floods or to store water for Irrigation and power generationor for both. and a spillway with spillway gates for release of flood watersdunng monsoons. Controlled releases of water are also affected by control­led gate, provided in conduits m the body of the dam and tunnels. Onemethod of providing such control in spillways and conduits IS by radialgates.

0.3 This standard is being published in three parts. Part I deals With ins­pection, testing and assembly at the manufacturing stage. Part 2 dealsWIth inspection. testing and assembly at the time of erection and Part 3deals with mspecuon, testmg and mamtenance after erection.

0.4 For the purpose of deciding whether a particular requirement of thisstandard is complied With, the final value, observed or calculated, expres­sing the result of a test or analysis, shall be rounded off in accordanceWIth IS : 2-1960'. The number of sigruficant places retained In the roundedoff value should be the same as that of the specified value m this standard.

1. SCOPE

1.1 This standard ( Part 2) lays down the recommendations for mspection,tesung and assembly of radial gates and their hoists at the time of erecuon.

*Rqles for rOQn(fjng off numerical values ( revised).

3

IS I 10096 ( Part 2) . 1983

2. INSPECTION

1.1 In order to detect damage and defects, If anv, inspection duringerection work shall be carried out at thc followmg stages

a) General mspecuon;b) Inspection of block outs,c) Inspection of pier anchorages,d) Inspection of SIll beam;e) Inspection of wall plates;f) Inspection of gate; andg) Inspection of complete gate mstallation, horsts including

electrical items.

2.2 General Inspection

2.2.1 It shall be ascertained that the gate parts received at erection sitebave been manufactured according to the design and have necessarymarkmgs of shop inspecnon wherever prescribed. It Shall be ensured thatall exposed surfaces of embedded par" have been protected by paintmg,greasing, etc, as specified, The surlaces of embedded parts in contact withconcrete shall be free from grease, pamt, etc, for better bonding withconcrete. A coatmg of cement wash/cement latex may be apphed, Ifnecessary.

2.2.2 Dimensional differences, If any, shall be accounted for beforeerection and the drawings corrected accordingly. For erecnon the cnncaldimensions shall be worked out from the drawings.

2.2.3 The reference/centre lmes of piers and bays. and levels havingrelation, to completed CIVIl structure shall be established at site so as tofacihtate erection at proper locations

2.2.4 It shall be ensured that the vanous components of the hoistingarrangement, such as motors, reducnon gear assembly, switches, wireropes, etc, are provided according to manufacturer's mstructions anderected according to hoist supplier's approved drawings.

2.2.5 The permissible tolerances for embedded parts and components ofgate sball be m accordance with Appendix F of IS : 4623-1979',

·Re~mrne[]<,Iatlons for structural design of radial sales (first revlslo,,).

4

IS • 10096 ( Part 2 ) • 1983

2.3 Inspection of Block Outs

2.3.1 It should be ensured that correct block outs are kept for accommo­dating the embedded parts as manufactured according to the design. Itshall also be ensured that the required dowel bars having adequate lengthsare left out In the block outs The entire block out is roughened properlyfor further concreting to give necessary bondage to the second stageconcreting.

2.4 Inspection of Pier Anchorages

2.4.1 The inspection of pier anchorages shall be carried out at thefollowing stages

a) Trunnion bracket and support girder.

b) Load carrying anchors or tres and embedded girder ( if insulatedanchors or ties are used I,

c) Anchor girder or yoke girder, andd) Thrust block/trunnion ue.

2.4.2 The flier anchC'lr~~"e" shalt he <.:heCKE'd wtt.h respect to the centre lineof the pier and the trunnion ,IX" ( Imc parallel to Ihe Cit st ax.s and passmgthrough the centre lme of trunnion pins) Control vurvcy marks shall begiven on each pier to check the location 'alignment of pier anchorages.These shall include the line, parallel to the end at light angle to thedam/barrage ax" and a bench mark for leI el

2.4.3 Centre to centre distance of adjacent piers shall be checked by asteel tape It will be preferable to put a steel girder across the span fortaping the distance over the span [II case taping IS done across. the spanin air, the steel tape shall be given a predetermined pull.

2.4.4 The trunnion bracket/supports shall be placed on top of a stooland kept in position With the help of strut, and their positron shall bechecked with re-pect to centre hne of pier and trunnion axis A dummytrunnion assembly may be tiled to cheek the drsrunce be/ween centre Imeof trunnion and SIll beam centre The slope of the trunnion assembly shallbe checked with the help of an inclination gauge

2.4.5 The two trunnion assemblies for each gate shall be checked withrespect to each other.

2.4.6 The yoke girder/anchor girder shall be checked for its alignmentand slope in both directions For this checking holes may be picked upfrom dummy trunnion bearing

5

IS: 10096 ( Part 2 ) - 1983

2.4.7 Before erection the ue bars/rods shall be checked on a level plat­form for straightncvs and defects should be rcctrfic d If unv After erectionthe slope amI spacmg 01' th, ue bars. rods ,hJI\ be checked. For checkingthe spacing. a <p.icer gauge shall be used.

2.4.8 After a"cn'bly the entire pier anchorage shall he checked The twoanchorage ... [PI each gate ~hal1 a1"1u be chei.k ed with n-vpect to each other

2.4.9 Before concrcung the pier after erection of pier anchoraee , it l~

ncces ....arv that tl <ccond check of <.III the partv Jf) made to CJlSUTI.: agamvtany possible drsplaccrncnt dunng welding, nveting, etc For safety oferected anchorages the grouuug/concrctiug operations shall be commencedafter rmmrnum pos-able interval

2.4.10 For insulated anchorv'nes, the insulation shall be provided andchecker; before siartmg the grnutl11gjl.:nncrctlOg operations

2.5 Inspection of Sill Beam

2.5.1 In ca -,e, trunnion a"...emhly IS not in PO:-,ltl011, the dummy trunnionassembly shall be rut on adjacent PICh and It, position should be checked.

2.5.2 Before erecuon, centre line oisil] beam shall be marked on pierfaces. "Ihe centre Imc of gate shall be inscribed on the crest shilted by300 rnrn or so on upstream "de.

2.5.3 The ,,1I beam centre 11110 shall be checked m relanon to thetrunnion centre hnc

2.5.4 Aftcr erection, the alignment and angular selling of SIll beam shallbe checked For angular ,eHlng of sill beam 3 to 5 frames can be used

2.5.5 Arter ahgmng the SIll beam, all the bolts and nuts shall be put In

posuron The reinforcement bars and dowels be welded with anchor holtsso that the complete assembly IS firmly held m posuron and 13 not distur­bed during grouting.

2.5.6 The aggregate used for grouung shall not he more than ~o mm.The concrete mIX shall be hand-compacted by US1l1~ rods No mechanicalvibrators should be used

2.6 Inspection of Wall Plates ( Side Seal Seats)

2.6.1 The wall plates shall be ,n true alignment with respect to centrehne of trunmon pin. The dummy trunnion assernbiy wuh extension rodsshall be used for checking the alignment of w.rl] plate, 1 he vcrucairty ofthe wall plates should be checked 10 ensure that "all plates are trulyvertical.

6

IS : 10096 ( Part :1 ) • 1983

2.6.2 After setting of wall plates, all the bolts and nuts shall be put inposiuon. The reinforcement bats and dowels In the block out shall be ade­quatcly welded to the side scats m such a manner that wall plates are notdisplaced durmg concreting or otherwise

2.6.3 The shuttering planks for concretmg the wall plates shall be at leastI 5 to 3 mm clear from the metal parts of the wall plate.

2.6.4 Maximum SIze of ag;regate u-ed for concretmg the block. outsshall not be more than 20 rnrn

2.6.5 All concrete nux used shall be hand-compacted and done mconversant stages as the shuttering pi ogresses III upward dircctron,Cornpacuon may be donc by cO mrn rods No mechanical vibrators shouldbe used.

2.7 Inspection of Gale

2.7.1 The subassernbhes of the gate which are received at srte duly ms­peered III workshop should be reinspected at site before lowermg of assem­bly tn the bay

2.7.2 Checking of all the drrnensrons of the gate shall be done afterskeleton assembly of eac h gate 15 made and before final weldmg/rrvetmgIS allowed 1 hrs dunensronai check shall be repeated after welding IS done.

2.7.3 VIsual Inspection of all welds and bolts/rrvets shall he made to theextent 01 1\)0 percent.

2.7.4 The followmg criucal dimcnsrons should be checked'

,I) Centre to centre distance between SIde guide rollers and shoes,b) Centre to centre distance between the '11(,11.: seals and bases. and

~I Distance of bottom seal-base from centre line of trunnion pill.

2.7.5 1 he seal bolts should be tightened adequately and uniformly andthe guide wheels be checked lor .r ec rotauon

2.7.6 10 check the etfc cuveness of the seals, acuve seal mterfeienceshould he compared With that provided In the design, because on thisaspect ".11 depend to a great extent the efficiency of scaling arrangementand ea-y operauon of the gate.

2.7.7 In case of counterweighted gate 1\ shall be ensured that corrcetweight has been provided.

7

IS I 10096 ( PIll1 2 ) _ 1983

2.8 IlISpectlon of Complete Gate Inslallation aod Hoists Ioeludlog ElectricalItems

2.8.1 Visual inspection of all gates and heists shall be carried out aftererection.

2.8.2 Tbe erection tolerance shall be checked for all parts during andafter erection

2.8.3 In case of hoists, the following pomts which are by no meansexhaustive, need be looked mto by engineer-in-charge:

a) Connecuons like sbaft couplings, connections of wire ropes tothe drum and gate. connection of hoist components to the base,etc, have been properly made.

b) Intermediate supports for shafts are provided at the requiredlocations to permit free movement of shaft,

c) In case of double hoists both the hoists are properly synchro­nized;

d) Tbe ends of wire ropes are properly looped and sufficient 'U'clamps have been provided,

e) The rope has been tightly wound over the drum, has no kinksand IS properly !ubncated,

f) The wire ropes or chams at both ends of the gate and counter­weight ( If provided ) have equal initral tension;

g) Electnc installations have been properly earthed; andh) The Iinnt switches have been properly adjusted.

2.8.4 It shall be ensured that tbe gate sill, "all plates and other embed­ded parts are thoroughly cleaned and no foreign rnaterial rs present.

2.8.5 The hoist provided for operanon of tbe gale should firsI be indepen­dently tested" ben II IS not connected to the gate to ensure ItS satisfactoryworking. The hoist should be kept runnmg for sufficient period so as tosatisfy its independent working Bushmgs and beanngs shan be checkedfor temperature nse to sausfy that there" no undue fricuon

2.8.6 Before operation of the gate, the following checks shall be made:

a) Electnc supply and fuses,b) Overload relay, If provided, to sec that it tnps otfthe starter;c) All bearmgs and wire ropes for proper greasmg;d) All bolts of gear boxes, h01St drums and shafts, couphngs for

tightness, ande) The 011 level m gear reduction unit.

8

IS : 10096 ( Part2 ) • 1983

3. TESTING

3.1 The gate shall be tested in a dry condition with hoist duly connectedfor its smooth working. The gate should be fully closed and fully openedand it should be ensured that there IS no obstruction and no undue effortsrequired for its operation. [f the gate IS not gomg down of Its own weightor found tight in some position, reasons should be mvesngated andremedied instead of forcing .he gate down

3.2 The testing of gate-seals in dry con.liuon should be done by SUItablemeans, such as by viewmg the contact suuucc against a light source

3.3 In case of rubber seals, water should be poured over the seals so thatthere WIll not be dry friction of the seals, In case of metal to metalcontacts, oil or grease rs to be used. No grease or lubncant is to be usedfor rubber seals.

3.4 There shall be no noise of friction or any other noise, no signs ofexcessive friction, no jerky performance, no dug in any posrtion, nodangling of the gate, no twist in rubber seals and rubber seals are notoverpressed.

3.5 The gate is to be first kept resnng on srll beam, that is in closed posi­tron. The leakage test can be done III this position by using suuable pumpwith necessary arrangements of jetting water at 1'5 trmcs the designedpressure on sealing positions from bottom to top All joints if any, shall betested to ensure perfect working of the gate

3.6 The gate should be fully opened and closed to ensure full opening andsatisfactory closing. The time required for 300 mm open109 or closing ofthe gate IS to be recorded.

3.7 The arrangements provided for preventing the travel of the gate orhoist beyond the designed limit are tested and checked for proper working.

3.8 In case of rope drum hoist, it is ensured that the gate moves down ofits own weight. The gates shall also go up and down without uneven pullto the gate, The winding of rope over the drum is uniform and accordingto the design.

3.9 Tn case of hydraulic hoists, it should be ensured that oil pressures arewithin the designed limits.

3.10 The full load current required for movement of the gate on load shallbe measured and checked against the designed value.

3.11 When the rainy season starts. visual inspection of gates sh311 be madeand they shall be lowered and raised several times to make sure thateverything is in order,

9

IS. 10096 ( Part 2 ) - 1983

3.12 When the water starts overflowing, lower the gates to hold the waterto half the height of gates In this position the seals may be tested and anyleakage shall be attended to The gate. may also be operated up and downwith this water load and operation of hoist shall be observed

3.13 The gates shall also be tested in a similar way against full water load.

3.14 During the testmg of gate ID dry condition ( see 3.1 to 3.9 ) and underwater pressure, the following observations shall be made and a record bekept:

a) Movement of gate and indication of jamming, if any;b) Effective stop is achieved by the gate stops wherever provided;c) Speed of opening and closing, and the current requirement at

specified voltage,d) Operation of brakes and limit switches;e) Manual operauon of gate, if provided;f) Efficiency of guide rollers to check the side sway of the gate;g) Correctness of indrcation by local position indicators;hl Synchromzauon of remote position indicators, if provided; aodj) Vibrauon of gate, hoist, and civrl structure.

10

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