1. 1 OPERATION AND MAINTENANCE OF RADIAL GATES & FIXED WHEEL GATES By ER. N. Kannaiah Naidu Technical Advisor (Hydraulic gates and Handling arrangements) General: Proper maintenance of Hydraulic gates and hoists is very important for satisfactory operation of Gates and to achieve the envisaged benefits from the project. For systematic operation and maintenance of the gates and their operating equipments, it is very necessary that a comprehensive operation and maintenance manual which shall include The design features of various components. Particulars of bought-out items and source of availability with addresses and phone Nos. Operating instructions. Type of lubrication oil and grease to be used and its availability. Schedule of maintenance and repairs are prepared for each hydraulic gate installation and the operation staff shall be made well conversant with them and trained for the job. The list of parts involved in maintenance and operation of gates and hoists generally are as follows: 1. Vertical Lift Gates: i. Embedded parts: Sill beam assembly Roller track Seal seat / Upstream Guide Top seal seat and side guide Dogging arrangement ii. Gate Parts: Skin plate Assembly End Verticals Horizontal girders Vertical Stiffeners Roller assembly Seal Assembly Side guide assembly Lifting Arrangement 2. 2 2. Radial Gates : i. Embedded parts : Common anchorages (Bonded Anchorages) Independent anchorages (Un-bonded anchorages) Sill beam Assembly Wall plate Assembly Horizontal Anchor Rods Trunnion Girder Trunnion girder chairs Vertical rods Thrust block (If tie between trunnion is not used) Sill beam assembly Wall plate assembly Anchor girders Load Anchors / Tie flats Yoke girders Rest plate Vertical rods etc., Thrust block (If tie between trunnion is not used) ii. Gate Leaf : Common anchorages (Bonded Anchorages) Independent anchorages (Un-bonded anchorages) Skin plate Side guide and seal assembly Vertical stiffeners Horizontal Girders Horizontal Girder Bracings Arm Assembly Trunnion Trunnion pin Trunnion Bush Trunnion Bracket Tie between trunnion or Thrust block Lifting Bracket Skin plate Side guide and seal assembly Vertical stiffeners Horizontal Girders Horizontal Girder Bracings Arm Assembly Trunnion Trunnion pin Trunnion Bush Trunnion Bracket Tie between trunnion or Thrust block Lifting Bracket 3. 3 3. Rope drum Hoists: A. For Vertical Lift Gates : Drive Unit Assembly Gear Box Assembly Hoist Supporting structures etc., B. For Radial Gates : Upstream Suspension Down Stream Suspension Drive Unit Assembly Gear box assembly Hoist bridge Lifting arrangement Drive unit assembly Gear box assembly Fixed end support Hoist chasis Line shaft support girder Dial and Dial Assembly etc., Operation and Maintenance: Operating personnel shall be properly trained and experienced so that they can use their initiative and judgment based on their past experience for situations which may arise during operation. Day to-day experience on operation and difficulties if any, encountered should be faithfully recorded in the log book of gates so as to be available for studying the behavior of various structures and equipment. Detailed instructions for inspection and normal maintenance and repairs of gate installation should be given in operation and maintenance manual. However, for carrying out special repairs to gates if any, it is advisable to refer to Experts to execute. Inspection and maintenance experience are compiled in the form of History register of any installation so as to be useful for future designs, investigation of any failure, improper and unusual operation of gates. All such observations shall be recorded in the gates History register maintained for this purpose. 4. 4 The following precautions are to be taken before dry testing of Gates : Checking of all critical dimensions and proper seating of gate over embedded parts is to be ensured. Record of readings may be maintained for future reference. Worm reducer, plumber blocks, trunnion pin, gate wheels and gear wheels should be lubricated. Removal of temporary supports if any. Checking of weld between horizontal girders, arms and trunnions, tees and horizontal girders, cross girders and hoist bridge girders, final welding of lifting bracket etc., and are to be welded if left over. A comprehensive check list is to be maintained . Checking tightness of bolts between trunnion with arms and trunnion with horizontal girders, lock plate bolts of trunnion pin, wire rope clamp bolts and other bolts if used are to be tightened properly if loose. Increase of unbounded anchorage one has to ensure the expansion of tie flats and yoke girder under load. The gates are to be inspected thoroughly for projections, temporary supports coming in the way of gate movement and excess concrete are to be removed if any. All the rubber seals are to be made wet before lowering the gate preferably with water to reduce heat generated between seal and seal seat and ensure fixing of all bolts and mouldings of site joints. Light test may be conducted for checking gap between seal and seal seat. All weld tests are to be conducted. 5. 5 5.0 Maintenance schedules for Radial gates, Vertical lift fixed wheeled gates, electrically operated fixed hoists should be attended preferably prior to monsoon : 5.1 Radial Gates : 5.1 (a): Monthly maintenance : Seals and seal seating shall be inspected for leakages. Locations of excessive leakages shall be recorded for taking remedial measures. Exccessive or wide spread leakages if any shall be reported to Engineer in charge and remedial measures like tightening of bolts is to be carried out. Further adjustment is carried out during annual maintenance or necessary plan for replacement of parts shall be initiated and carried out before floods. If leakage is so much immediate repair is to be considered and seals are to be repaired or to be replaced by using stoplog gates. Remove all dirt, girt, etc., from trunnion assembly and lubricate trunnion bearings of the gate with suitable water resisting grease. More concentration is to be given for checking of welds : Between yoke girder web and tie flats. Between trunnion and tie between turnnion. Lifting bracket and gate. 5.1 (b): Quarterly Maintenance : The maintenance shall preferably be carried out once in three months but not less than thrice in a year including pre- monsoon and post monsoon maintenance. All the nuts and bolts of trunnion assembly and its anchorages shall be checked for tightness. Check all the welds for soundness and rectify defects if any. Check welding between latching bracket and skin plate with help of magnifying glass for cracks / defects and rectify the defects. Clean all drain holes including those in end arms, horizontal girders trunnion and pulley blocks. Check all nuts and bolts for tightness and tighten them if loose. Check upstream face of skin plate for pitting, sealing and corrosion. Sealing formation shall be removed, pitting shall be filled with weld and ground, and Corroded surface shall be cleaned and painted. In case of gate not being raised every quarter, these can be carried out in annual maintenance. 6. 6 The wheel bearings and guide rollers shall be lubricated. The seal shall be checked for damages, if damaged, shall be replaced. All nuts and bolts shall be tightened. The guide assemblies, wheel assemblies and sealing assemblies shall be cleared of girt, sand or any other foreign material. General cleaning is to be done for the following : Hoist Bridge Components. Trunnion girders / Yoke girders. Trunnion brackets, trunnions, arms and horizontal girders. Lubrication is to be attended for : Bearings at Gate wheels, trunnion bushes, hoist pulleys and pins provide in Hoist Bridge at hoist level and gate. Rope drum shaft Plummer blocks. Line shaft Plummer blocks. Check tightness of all coupling bolts of motor to work reducer and line shaft. If required they may be tightened. Care shall be taken to check the condition of holding rope with rope socket and balancing of gate is to be observed and if necessary adjusted. 5.1 (C): Annual maintenance: The following additional checks or maintenance shall be carried out in addition to checks mentioned under quarterly maintenance. All the embedded parts shall be checked for defects / damages and shall be rectified where ever noticed and exposed parts shall be painted for longer life. The sill beam and guides shall be cleared for all girt, sand etc., The wire ropes shall be checked for equal tension. If broken strands are noticed, the wire rope shall be replaced. Fixing of rope sockets also shall be checked. The wire rope shall be greased. The guide roller pins shall be lubricated and ensure for its rotation. Check the condition of rubber seal. If damaged, replace the seals. All bolts and nuts holding rubber seals shall be tightened. Adjust seal if leakages are found at local points. 7. 7 5.2 Vertical Lift fixed wheeled Gates: These gates are provided for controlling water discharge for flood control, water supply, irrigation and power generation etc., The gates shall be thoroughly inspected for cracks, defects or damages periodically. A schedule of maintenance is proposed which may be adopted with modifications, if required, to suit site conditions and use of gate. 5.2(a) : Monthly maintenance : Wheels are to be greased properly. Check wheel rotation by hand for free rotation. Balance points same as Radial Gates Maintenance may please be carried out. 5.2(b): Quarterly Maintenance: Same as Radial Gates Maintenance may please be carried out. 5.2(c): Annual Maintenance: Same as Radial Gates Maintenance may please be carried out. The re-painting of the gates shall be carried out at intervals to be decided on the basis of painting schedule of the gates. The inspection, testing and maintenance of the hoist shall also be carried out periodically as per the maintenance manual. For larger No. of gates ie., more than 10Nos. is very difficult for through maintenance in lean period available. Hence the No. of gates divided into 3 groups and through maintenance of welding, painting shall be carried out at least one in three to five years depends on requirement. 8. 8 5.3 Electrically Operated Fixed Hoists for Radial Gates and Vertical Gates: The periodical maintenance of brought out items like motor, brakes, radicons, etc., shall be carried out as per the manufacturers advice / maintenance schedule. 5.3(a) Daily Inspection : Entrance to all hoist platforms shall be kept locked. All keys shall remain with the shift supervisor. A cursory daily inspection shall be made of hoist and gate to ensure that there is no unusual happenings and ensure operation when called for. 5.3(b) Monthly Maintenance: Clean the dust of all hoisting machinery and hoist platform. Check oil level in gear boxes and replenish wherever required with oil of proper grade. Apply grease of suitable grade by grease gun through all the greasing nipples and replace grease nipple if missing. Lubricate all bearings, bushings, pins, linkages, etc., Check all the fuses on power lines and ensure closing of panel board covers not to entry of dust and moist. All bolts and nuts on gear boxed, hoist drum and shaft couplings should be checked for tightness. Check the supply voltage. Check the expansion provision in case of independent anchorages. Starters should be cleaned free of moisture and dust. Each individual contactor should be examined to make sure that it operated freely. All wearing parts should be examined and take remedial action to avoid reoccurrence. The magnet faces should be cleaned if the contacted Hum. Examine all connections to see that no wires are broken and no connections are loose. Clean the surface of the moving armature and magnet cone which comes together when the contractor closes, free of dust or grease of any kind. The contact tips should be kept free from burns or pits by smoothening with fine sand paper or emery paper. Replace the contact tips which have worn half way. Do not lubricate the contacts. 9. 9 5.3(c) Quarterly Maintenance: Carry out all those listed for monthly maintenance. Drain sample gear oil from each of the gear boxes. If excessive foreign particles or sludge is found, the oil shall be drained, flushed and filled with new oil. All the geared couplings shall be greased. Raise and lower the gate by hoist motor and check for smooth and trouble free operation of gate without excessive vibration. Observe current drawn by motor at the time of lifting and check if it is more than normal. If so, stop the hoist and investigate the cause and rectify. Check for condition of painting of various components and remove rust wherever noticed and repaint the portion after proper cleaning as per painting schedule. Check Electrical connection and wiring: 1. From supply point to main switch. 2. Main switch to starter. 3. Starter to motor. 4. Contact points of starter. 5. From starter to all lighting points, availability of bulbs and its glowing. 5.3(d) Annual Maintenance: The annual maintenance shall be combined with one of the quarterly maintenance; the following shall be carried out in addition to those mentioned under Quarterly Maintenance. All trash, sediments and any foreign material shall be cleared off the lifting rope and lifting attachment. All ropes shall be checked for wear and tear and if broken wires more than permissible or marked corrosion is noticed, the rope shall be replaced. Refer IS code for maintenance of wire ropes. All wire ropes shall be checked and all visible oxidation shall be removed. All wire ropes shall be greased with cordium compound or equivalent brand. Adjust the rope tension of wire if unequal. 10. 10 Check the overload relays and limit switches for proper functioning. Check tightens of all nuts & bolts, soundness of welds. All bolts shall be tightened and defective welding must be rectified. Check the pulleys, sheaves and turn buckles for soundness. Check the limit switches and adjust for design limits duly operating. The effectiveness of the brakes shall be checked by stopping the gate in intermediate operation duly raising and lowering operations. The brakes shall be adjusted if needed. When the gate is operated, there should not be any noise or chatter in the gears. Check for all gears and pinions for proper mesh, uneven wear and adjust for proper contact and grease the gears. Repaint the hoist components, hoisting platform and its supporting structures after a time interval depending upon the painting schedule. 5.4 General maintenance on Radial Gate / Vertical Gate : 5.4(a) For every three years: Ref: IS7718, IS: 10096 (part 3) latest In addition to check mentioned under annual, following will be carried. Check seals for damage and alignment; Check seal bolts for damage; Check for damage to wire rope; Check for any damage to pulleys and pins; Check bearings for damages; Check gears and pinions for damage; Check Plummer blocks for damage; Check for any painting damage. 11. 11 5.4(b) For every Six years: In addition to check mentioned under annual, following will be carried out. Check damaged / cracked welds at the following: I. Skin plate joints II. Splice joints III. Hoist bridges IV. Arms, Horizontal girders and bracings V. Tie flats VI. Trunnion girders / Yoke girders VII. Trunnion brackets VIII. Tie between trunnion Check Wheel assemblies for the following: I. Any breakage II. Frozing III. Corrision IV. Misalignment Check seal seats, seal tracks, side guides for the following: I. Any damages II. Corrosion III. Pitting IV. Misalignment Check Hoist Bridge and Platforms I. For any welding cracks II. Bent or loose bolts and nuts III. Cracks in the bending or motors IV. Radicons, ropedrum etc., 12. 12 Lubrication Schedule Sl. No. Parts to be lubricated Mode of Lubrication Lubricant Frequency 1 Trunnion pin bush bearing Pressure grease gun Servo gear 20 or bearing grease Once in three months as per site conditions 2 Gate Wheel bearings Pressure grease gun Servo Gear 20 or Bearing Grease Once in three months as per site conditions 3 Guide rollers Pressure grease gun Bearing Grease Once in three months as per site conditions 4 Hoisting wire rope Hand applied Servo Gear 120 or Cordium Compound Once in a year before monsoon sets in 5 Worm reducer Oil bath Servo HP - 30 Indicator level to be maintained always 6 Spur Gear Bearings Pressure grease gun Bearing Grease Once in three months as per site conditions 7 Line shaft bearings Pressure grease gun Bearing Grease Once in six months as per site conditions 8 Gear Wheels Hand applied Chassis Grease Once in six months as per site conditions 9 Drum shaft Pressure grease gun Chassis Grease Once in three months as per site conditions 10 Lifting Arrangement and buckles Hand applied M. P. Grease Once in six months as per site conditions 11 Hand operation mechanism and other relating parts Hand applied Servolin - 140 Once in three months as per site conditions 13. 13 Chart for maintenance Schedule for Gates IS : 7718 Part III 1975 IS : 10096 part III 1982 Every Quarterly At Ever year At Every three years At Every six years General cleanliness of embedded parts, Gate hoist components In addition of Quarterly maintenance schedule the following are to be checked In addition of yearly maintenance schedule the following are to be checked Check welds for damages at: Check for oil level in radicons. Check the tightness of foundation bolts of Motors, Radicons, Plummer blocks, coupling joints Check the condition of wire rope, pulleys, sheaves, limit switch, brakes, and gear wheels. Skin plate joints Tee girders to Horizontal Girders Horizontal girders to arm Arm Bracings Horizontal girder bracings End boxes Gate stiffeners Greasing of pulleys and pins Check for smooth operation of gate by raising and lowering Check gate seals for damages. Check wheel assemblies for any Breakage Frozing Corrosion Misalignment Trunnion pin, Rope drum hoists, Gear wheels, Hand operation of shaft, guide rollers, Gate wheels Check for condition of painting of all components Check seal bolts for damages. Check for sill beam, side guide, roller tracks for damages, corrosion, pitting Check for operation of Brakes Check Hoist Bridge for foundation bolts for tightening. Check for loose electrical connections (In case of fixed wheel gates) 1. Wheels are to be greased properly 2. Movement of wheels should be smooth and it can be rotated by hand 14. 14 Operation and Maintenance of Gates DOs Donts 1. Authorised Personnel should be allowed near control Pane for operation of gates. 1. Un authorized persons should not be allowed to operate gates 2. Technically qualified or trained operators should be allowed to operate gates. 2. Unqualified persons technically should not be allowed to operate gates. 3. Operate the gates only when there is required power supply as per the design is available. 3. Not to operate gates during low voltage period 4. Adjust the brakes when the gate is lowered fully and rest on sill. 4. Not to adjust the brakes when gate is not dogged 5. Attend maintenance during pre-monsoon season 5. Not to adjust the brakes when gate is not dogged 6. Use proper tools for attending repairs / adjustments 6. Maintenance works should not be attended during rains. 7. Conduct Dry test before putting into operation 7. Do not operate gates without Dry testing 8. Maintain cleanliness of hoist platform, trunnion platforms 8. Not to keep any slippery material on Hoist walkway 9. Insulate damaged electrical wiring, which are exposed to atmosphere 9. Do not allow any persons to operate gate if Bare wires are seen 10. Protect Hoist gear box and motors from rains 10. Not to keep gear box cover open after daily maintenance 11. Ensure wire rope tightness on either side equally before operating gate 11. Not to operate gate when the wire rope is slacked 12. Safety precautions should be taken during maintenance works 12. Not to wear loose dresses during operation of gates 13. Cut off power supply after operation of gates 13. Do not allow power supply to motors when it is not at all required. 14. Check connections and functioning of limit switches before operation 14. Advised not to operate gate if limit switches are not functioning 15. Ensure before operation that no foreign materials fall in the gear teeth 15. Not to switch on Hoist motors if foreign material found in between teeth of gear wheels 16. Check tightness of Plummer block, drive unit, line shaft, coupling bolts 16. Do not operate gate if any bolts of Plummer block and coupling bolts are found loose 17. Ensure no foreign particles stuck up in between roller and roller track/ wall plate and rubber seals etc., 17. Not advised to operate gates if foreign material found in between rollers and roller track and wall plates and rubber seals etc., 18. Maintain oil as per level indicator in the gear box. 18. Not to operate gates with low oil level in gear box 19. Check tightness of wire rope clamps before operation 19. Not to operate gate if wire rope clamps are found loose 20. Operate gate only when grooves are clean without any obstructions 20. Do not operate gate if there is any projection, in the grooves which obstruct movement of gates 21. Provide proper approaches for attending maintenance at grunion bushes and grunion pins, grunion girders etc., 21. Not to use manila rope / wire ropes as approach for attending maintenance works at Trunnions, trunnion girders etc., 15. 15 Painting system for hydraulic gates and hoists Introduction: Hydraulic gates, its embedded parts, gate leaf, hoists and its supporting structures should be protected against corrosion due to climatic condition, biochemical reaction and abrasion due to different forces acting on it. Otherwise these equipments may deteriorate to any extent that the replacement of parts may become necessary and such replacement may become difficult and costly. Therefore it is necessary to do painting to protect the equipment and to increase the life of parts. Therefore application of the paint film has two main purposes. The first one is to protect the steel from corrosion. The second for decorative appearance. Painting for hydro mechanical works shall be carried out as per IS 14177 1971 or latest. The painting system for gates and equipment shall be attended at 2 stages. I. Applying paint as fresh at the time of manufacture. II. Removal of old paint, rust and repainting during maintenance. Surface Preparation: After the equipment has been fabricated, it is essential that before any primer and coat of paint is applied, the surface is properly prepared. Such preparation shall include through cleaning, smoothing, drying and similar operation that may be required to ensure that the primer and or paint is applied on suitable surfaces. The procedure for surface preparation shall be as follows: Weld spatters or any other surface irregularities shall be removed by any suitable means before cleaning. All oil grease and dirt shall be removed from the surface by the use of clean material spirits, Xylol or white gasoline and clean wiping materials. Following the solvent cleaning, the surfaces to be painted shall be cleaned of all rust, mill scale and other lightly adhering objectionable substances by sand blasting. Blast clean to a minimum of Sa 2 Swedish standard SIS 05 5900 with a surface profile not exceeding 65 microns. The fig. B Sa 2 is given. 16. 16 17. 17 For more details of cleaning method refer IS 1477 ( part -1 ) 1971 Surface of stainless steel, nickel, bronze and machined surface adjacent to metal work being cleaned or painted shall be protected by making tape or by other suitable means during the cleaning and painting operations. Primers shall be applied as soon as the surface preparation is complete and prior to the development of surface rusting. In case there is considerable time gap, the surface shall be cleaned prior to priming. Shop painting: I. Embedded parts which come into contact of concrete: All embedded parts which come in contact with concrete shall be cleaned as detailed above and given two coats of cement latex to prevent rusting during the shipment while awaiting installation. II. Embedded parts which are not in contact with concrete and gate parts: Two coats of zinc rich primer with epoxy resin shall be applied to all embedded parts surface which are not in contact with concrete and shall remain exposed to atmosphere or submerged in water to obtain a dry film thickness of 75 microns, which shall be followed by two coats at an interval of 24hours of coal tar blend epoxy resin part so as to get a dry film thickness of 80 microns in each coat. Total dry film thickness of paint shall be 300 microns. Surfaces not to be painted: The following surfaces are not to be painted unless or other wise specified a) Machine finished or similar surface b) Surfaces which will be in contact with concrete c) Stainless steel overlay surfaces. d) Surfaces in sliding or rolling contact e) Galvanized surfaces, brass and bronze surfaces. f) Aluminum alloy surfaces All finished surfaces of ferrous metal including bolts, screw threads etc., that will expose during shipment or while awaiting installation shall be cleaned and given heavy uniform coating of gasoline soluble rust preventive compound or equivalent Gates: Primer Coat: over the prepared surface one coat of inorganic zinc silicate primer giving a dry film thickness of 70 5 microns should be applied. Alternatively two coats of zinc rich primer, which should contain not less than 85% zinc on dry film should be applied to give a total dry film thickness of 75 5 microns. 18. 18 Finished paint: Two coats of solvent less coal tar epoxy paints. These shall be applied at an interval of about 24 hours. Each coat shall give a dry film thickness of 1505 microns. The total dry film thickness of all the coats including primer coating shall not be less than 350 microns. III. Hoist and supporting structure: a) Structural components: Primary Primer coats of zinc phosphate primer shall be applied to give a dry film thickness of 405 microns. Final Coats: One coat of alkyd based micaceous iron oxide paint to give a dry film thickness of 65 5 microns followed by two coats of synthetic enamel paint confirming to IS 2932 1974 to give a dry film thickness of 25 5 microns per coat. The interval between each coat shall be 24hours. The total dry thickness of all coats of paint including the primary coat shall not be less than 175 microns. b) Machinery: Except machined surfaces all surfaces of machinery including gearing, housing, shafting, bearing pedestals etc., shall be given. Primary coats: One coat of zinc phosphate priming paint to give minimum film thickness of 50 microns. Motors and other bought out items shall be painted if necessary. Finished coats: The finished paint shall consists of three coats of aluminum paint confirming to IS2339 1963 or synthetic enamel paint confirming to IS 2932 1977 to give a dry film thickness of 255 microns to obtain a minimum dry film thickness of 125 microns. c) Machined surfaces: All machined surfaces of ferrous metal including screw threads which will be exposed during shipment or installation shall be cleaned by suitable solvent and given a heavy uniform coating of gasoline soluble removable rust preventive compound or equivalent. Machined surfaces shall be protected with the adhesive tapes or other suitable means during the cleaning and painting operation of other components. Note: If alternatives are chosen the guaranteed film thickness are to be arrived from the data sheets of leading paint manufacturers and incorporated the total film thickness considering the location and atmospheric conditions of project. 19. 19 Application of paint: Mix the contents thoroughly as directed by pain manufacturer before and during use. a) Brush / roller b) Conventional spray c) Airless spray etc., Painting at shop can be done in any of the three methods so that the paint can be made to suit the convenient direction but once the gate and equipment put in position the general method adopted is only brush / roller. In case of spray lot of precautions are to be taken. For More details: Refer IS1477 Part (II) 1971 Appendix A Brushing of paint Appendix B Spraying of paint Appendix C Spray painting defects: Causes and remedies Removal of old paint / rust and carrying out fresh painting: The carrying of fresh painting is to be considered under the following conditions: The rusting is noticed all over the surface or Rusting is severe or Cracking and blistering has damaged the primer coat exposing the metal and is noticed all over the surface or The paint film has eroded badly, the scrap of entire paint film to the base metal and carry out fresh painting. Note: In case of maintenance and renovation: Refer IS 1477 (Part II) 1971 for checking and repainting. Removal of old paint for repainting: Caution should be exercised while removing the old paint. The surfaces shall be derusted and descaled by either mechanically by one or more of the methods. a) Wire brushing , Scrabing, and chipping. Sand papering or cleaning with steel wool or abrasive paper b) Power tool cleaning c) Flame cleaning d) Sand blasting or shot flasting and e) Chemical rust removal. Note: The method of application shall be decided based on conditions existing. After cleaning painting is to be carried out as originally proposed. Some are painted without removal of old paint and rusting this will amounts to no painting and deteriorate faster than the original one. 20. 20 Inspection and testing of painting The following steps involved in inspection of painting are 1. General inspection before and during painting 2. Viscosity test of paints 3. thickness test using Elcometer 4. Inspection of general appearance of finished work. General: The aim of inspection and testing is to ascertain whether the recommended practice is being employed during every stage of application and whether the final results fulfill the object of painting, inspection therefore means a close supervision while the work is in progress. Any test carried out should be non destructive nature or, if of destructive nature, should be either restricted to areas which can be restored without marring the general appearances, or be such that it is possible to restore easily without necessitating a complete repetition of the work. Inspection of surfaces prior to painting: Inspection methods will depend on whether an article is to be painted for the first time or is to be repainted. New Work ( Not previously painted): The following shall be decided by inspection: a) The method of pre cleaning feasible or recommended; b) The intermediate protective treatments to be applied, if found necessary; c) The painting schedule and the specifications for the paint for ensuring the particular performance required; and d) The method of application, whether by brush, roller or spray. Old Work (Which requires repainting): The following shall be decided by inspection: a) Whether the entire existing paint requires removal; and b) Whether repainting without paint removal would be adequate. 21. 21 For ascertaining whether the old paint has deteriorated tosuch an extent that its complete removal is necessary, the following test for embrittlement should be employed; A square coin such as a 5 paisa coin shall be pressed with the straight edge on an angle of 45 against the paint film. This will result in a chip of paint breaking loose from the surface if the paint has embrittled, lacks adhersion and requires removal. If the paint is not embrittled, it will curl or shrivel up under such pressure. The square coin test should be combined with an examination of the paint film through a magnifying glass to observe the extent of cracking and a paint film which does not show fine hair cracks under it may be considered as perfectly sound. Inspection during preparation of surfaces: 1. Cleaning and Degreasing- At the work site a visual and physical inspection is adequate. A degreased steel surface is duller in appearance than one which is even slightly oily. Wiping the surface with a piece of white cloth will show if minute traces of grease and dust have been left on the surface. When steel is being degreased by wiping the surface with mineral turpentine ( or any other solvent), it is important to watch the cleaning rags are washed or changed regularly. 2. Derusting and Descaling: a) Sand blasting: the most satisfactory method of removing rust and scale is by sand blasting. The criterion of inspection should be that the steel after sandblasting has a grayish white metallic appearance. The surface should be uniform in color and slightly rough. Only such a uniform appearance ensures that the surface has been thoroughly cleaned. b) Hand Scraping: No defnite method of inspection may be laid down for hand scraping. It is unreasonable to expect hand scraped surfaces to be perfectly clean, and for purposes of inspection, all loose rust or scale ( and all loose paint in case of repainting) shall have been removed. 22. 22 c) Chemical rust removal: In the case of chemical rust removal ( pickling), inspection shall make sure that washing after pickling has removed all traces of acid. All work pieces shall be inspected particularly in inaccessible corners. Inspection Before and during intermediate protective treatments: It is important to inspect the work to make sure that no time is allowed for fresh rust or other contamination to take place between the precleaning and the intermediate protective treatment. Inspection of the various suggested intermediate protective treatments shall be carried out to ensure conformity with the recommended practice as laid down in this standard and in accordance with manufacturers recommendations. General inspection before and during painting: When inspecting general painting work while in progress, it should be ensured: a) That painting follows immediately after pre cleaning or pre treatments; that any contamination which may occur in the interim period is removed, that special precautions are taken when painting after galvanizing; b) That no painting is carried out when there is danger of dew; c) That tools used are clean and not excessively worn; d) That the paint in the drums is thoroughly mixed prior to application; that drums are inspected to make sure that no sediment is left in them; e) That if paint has thickened because of long storage or because of the evaporation of the solvents, its viscosity is adjusted as recommended by the paint manufacturer; f) That each coat is allowed to dry sufficiently but not excessively before applying the following coat; that manufacturers instructions for drying time are adhered to properly; and g) That every individual coat is properly applied, reasonably level and smooth and free from runs and holidays ( minute uncovered areas). 23. 23 The field tests mentioned in 1) and 2) below may be carried out for facility of inspection during and after painting. 1. Viscosity Test of paints: A simple check is to verify the viscosity of the paint with its original value at least once during the course of its use. This may be done by comparing the times of efflux of the paint when filled level in a viscosity cup of standard dimensions and provided with an orifice standard flow characteristics. 2. Thickness test: The thickness of primer paints as well as the total film thickness of all coats applied shall be verified with a suitable instrument. It is important that the setting of the thickness meters is checked prior to the test and for this purpose standardized test bits are supplied with every instrument. It should be noted that instruments like the Elcometer contain a delicate magnet and that the storage and handling of such instruments needs care to ensure that they retain their accuracy. 24. 24 Spray Painting Defects : Causes and Remedies 1.0 Defects in finish : I. Sags S.No Possible cause Suggested remedies i Dirty air cap and fluid tip (distorted spray pattern) Remove air cap and clean tip and air cap carefully. ii Gun stroked too close to the surface. Stroke the gun 150 to 250mm from surface iii Trigger not released at end of stroke (when stroke does not go beyond object) Operator should release the trigger after every stroke. iv Gun stroked at wrong angle to the surface. Gun should be stroked at right angles to the surface. v Paint applied too heavily. Regulate flow of paint iv Paint thinned too much. Add the correct amount of solvent by measure. II. Streaks S.No Possible cause Suggested remedies i Dirty air cap and fluid tip (distorted spray pattern) Remove air cap and clean tip and air cap carefully. ii Insufficient or incorrect overlapping of strokes. Follow the previous stroke accurately to deposit a wet coat. iii Gun stroked too rapidly (dusting of the paint. Avoid whipping and use deliberate slow strokes. iv Gun stroked at wrong angle to the surface. Gun should be stroked at right angles to the surface. v Stroking too far from surface. Stroke 150 to 250mm from surface. iv Too much air pressure. Use less air pressure as necessary. 25. 25 III. Orange peel S.No Possible cause Suggested remedies i Paint not thinned out sufficiently. Add the correct amount and the right type of solvent by measure. ii Not depositing a wet coat. Check solvent. Use correct speed, overlap and stroke. iii Gun stroked too rapidly (dusting of the paint. Avoid whipping and use deliberate slow strokes. iv Insufficient air pressure. Increase air pressure or reduce fluid pressure. v Using wrong air cap or fluid nozzle. Select correct sir cap and nozzle for material and feed. iv Gun stroked too far from the surface. Stroke the gun 150to 250mm from the surface. iiv Over spray striking a previously sprayed surface. Spray detail parts first. End with a wet coat. 2.0 Defects in workmanship : I. Excessive Paint Loss S.No Possible cause Suggested remedies i Not triggering the gun at each stroke. It should be a habit to release trigger after every stroke. ii Stroking at wrong angle to surface. Gun should be stroked at right angle to surface. iii Stroking gun too far from the surface. Stroke the gun 150to 250mm from the surface. iv Wrong air cap or fluid tip. Ascertain and use correct set up. v Air pressure is too high. Use the least amount of air as necessary. 26. 26 II. Excessive Spray Fog, Surface Haze or Bloom S.No Possible cause Suggested remedies i Too high air pressure Use least amount of compressed air as necessary. ii Spraying past surface of the product. Release trigger when gun passes target. iii Wrong air cap or fluid tip. Ascertain and use correct set up. iv Gun stroked too far from the surface. Stroke the gun 150to 250mm from the surface. v Material thinned out too much. Add the correct amount. vi Too humid an atmosphere Spray during dry period. If not use retarders or slow evaporating solvents as advised by the manufacturers. III. Paint will not come from Spray Gun S.No Possible cause Suggested remedies i Out of paint (Gun begins to sputter). Add paint, correctly thinned out and strained. ii Settled, caked pigment blocking gun tip. Remove obstruction, strip paint thoroughly. iii Grit, dirt, paint skins etc., blocking gun tip, fluid valve or strainer. Clean spray gun thoroughly and strain the paint. Always strain paint before using it. IV. Paint will not come due to defects arising from Pressure tank. S.No Possible cause Suggested remedies i Lack of air pressure in pressure tank Check for leaks or lack of air entry. ii Air intake opening, inside of pressure tank lid, clogged by dried up paint. This is a common trouble. Clean the opening periodically. iii Leaking gaskets on tank over. Replace with a new gasket. 27. 27 V. Gun sputters constantly. S.No Possible cause Suggested remedies i Fluid nozzle not tightened to spray gun Tighten securely, using a good gasket. ii Leaky connection on fluid tube or needle packing (suction gun). Tighten connections. Lubricate packing. iii Fluid pipe not tightened to the pressure tank lid. Tighten. Check for defective threads. VI. Paint leaks from spray gun S.No Possible cause Suggested remedies i Fluid needle pacing nut too tight. Loosen nut. Lubricate packing. ii Packing for fluid needle dry. Lubricate this part daily. iii Foreign particle blocks fluid tip. Remove the tip and clean. iv Damaged fluid tip or needle. Replace both tip and needle. v Wrong size needle. Use correct combination. Relief Valve heated 28. 28 5045 6250 3000 1650 1350 1000 855314061215 70 800 1891 730 10500 NO OF GATES 7 NOS. VENT WIDTH 12250mm VENT HEIGHT 8800mm RADIUS 9000mm SILL LEVEL EL :289.20M TRUNNION LEVEL EL: 292.000M F R L/MWL EL: 298.00M TYPE OF ANCHORAGES COMMON TYPE OF HOIST PIER THICKNESS 3000/4000mm SPILLWAY RADIAL GATES 45T ROPE DRUM, U/S SUSPENSION TECHANICAL DETAILS 1 2 3 4 5 6 7 8 9 10 11 TOP OF GATE EL: 298.300M DESIGNED AS PER IS 4623-200012 792 3600 3000 1253 TIE BETWEEN TRUNNION TRUNNION LEVEL PLATFORM F L O W 17395 940 2800 1650 1350 F L O W VENT=122503000 15001500 3000 15001500 500 425 2150 425 500 15250 4400 VENT = 122503000 3000 1.MOTOR:- 10HP(7.5kw) 975 RPM SQ.CAGE INDUCTION MOTOR, SI CONTINUOUS DUTY, TEFC,FOOT MOUNTED CLASS 'B' INSULATION 3 PHASE AC 400 /440 VOLTS 50 CYCLES / SEC, SHAFT EXTENDED ON BOTH SIDES, WITH TOP TERMINAL BOX, FRAME SIZE ND-160L.CONFIRMING TO IS 325-1No. 2. E.M. BRAKE:- 200 AC ELECTRO MAGNETIC SOLINOID OPERATED SINGLE PHASE BRAKE,100% COIL RATING, CLASS "B" INSULATION, WORKING ON 400 / 440V AC, 50 C/S WITH BRAKING TORQUE CAP=15.0KGM. 3. WORM REDUCER:- RATIO 60:1, TYPE "U", SIZE 8" INPUT H.P10 INPUT SPEED 975RPM OUT PUT TORQUE 394 KGM OUTPUT SHAFT EXTENSION ON EITHER SIDE WITH SELF LOCKING-1No 4.WIRE ROPE:- 36 ,6/36 CONSTN.,R H LAY UNGALVANIZED, MAIN FIBER CORE UTS 200KG/MM HAVING BREAKING LOAD=151886 KG CONFARMING TO IS 2266-1989 LENGTH= RADIAL GATE WITH UPSTREAM HOISTFig. 1 29. 29 5045 6250 3000 1650 1350 1000 855314061215 70 800 1891 730 10500 NO OF GATES 7 NOS. VENT WIDTH 12250mm VENT HEIGHT 8800mm RADIUS 9000mm SILL LEVEL EL :289.20M TRUNNION LEVEL EL: 292.000M F R L/MWL EL: 298.00M TYPE OF ANCHORAGES COMMON TYPE OF HOIST PIER THICKNESS 3000/4000mm SPILLWAY RADIAL GATES 45T ROPE DRUM, U/S SUSPENSION TECHANICAL DETAILS 1 2 3 4 5 6 7 8 9 10 11 TOP OF GATE EL: 298.300M DESIGNED AS PER IS 4623-200012 792 3600 3000 1253 TIE BETWEEN TRUNNION TRUNNION LEVEL PLATFORM F L O W 17395 940 2800 1650 1350 F L O W VENT=122503000 15001500 3000 15001500 500 425 2150 425 500 15250 4400 VENT = 122503000 3000 1.MOTOR:- 10HP(7.5kw) 975 RPM SQ.CAGE INDUCTION MOTOR, SI CONTINUOUS DUTY, TEFC,FOOT MOUNTED CLASS 'B' INSULATION 3 PHASE AC 400 /440 VOLTS 50 CYCLES / SEC, SHAFT EXTENDED ON BOTH SIDES, WITH TOP TERMINAL BOX, FRAME SIZE ND-160L.CONFIRMING TO IS 325-1No. 2. E.M. BRAKE:- 200 AC ELECTRO MAGNETIC SOLINOID OPERATED SINGLE PHASE BRAKE,100% COIL RATING, CLASS "B" INSULATION, WORKING ON 400 / 440V AC, 50 C/S WITH BRAKING TORQUE CAP=15.0KGM. 3. WORM REDUCER:- RATIO 60:1, TYPE "U", SIZE 8" INPUT H.P10 INPUT SPEED 975RPM OUT PUT TORQUE 394 KGM OUTPUT SHAFT EXTENSION ON EITHER SIDE WITH SELF LOCKING-1No 4.WIRE ROPE:- 36 ,6/36 CONSTN.,R H LAY UNGALVANIZED, MAIN FIBER CORE UTS 200KG/MM HAVING BREAKING LOAD=151886 KG CONFARMING TO IS 2266-1989 LENGTH= RADIAL GATE WITH UPSTREAM HOIST Fig 2 30. 30 4352 3705 21370 1455 148109590 24400 15002000 4900 21009001352 7073 7073 1352900 2375 4698 3000 10000 490080008027 8450 5600 11850 42777 NO OF GATES 24 NOS. VENT WIDTH 18500mm VENT HEIGHT 17500mm RADIUS 26000mm SILL LEVEL EL :35.840M TRUNNION LEVEL EL: 50.650M F R L/MWL EL: 53.340M TYPE OF ANCHORAGE INDEPENDENT TYPE OF HOIST PIER THICKNESS 4750mm SPILLWAY RADIAL GATES ROPE DRUM HOIST D/S SUSPENSION TECHNICAL DETAILS 1 2 3 4 5 6 7 8 9 10 11 TOP OF GATE EL: 53.640M DESIGNED AS PER IS 4623-200012 37955 3400 14251425 2950 NOTE: 1. ALL DIMENSIONS ARE IN MM AND LEVELS ARE IN METERS. 2. ALL WELDS ARE 6MM FILLET CONTINUOUS. 3. THIS DRAWING IS PREPARED BY BASED ON DRG. NO : SCL/PC/EXE/25 69 1200 2170 1500 944 3500 3700 10.943 VENT=185004750 9502850950 10.943 4900100008000 370011100 1949 950950 2850 4750 450 2900 4000 3500 3500 450 LH RH 1313 26000 R 8200 R 13 13 950 2950 950 LH RH NO OF GATES 24 NOS. SIZE OF STOPLOG 18.500M(W) X 17.350M(H) NO. OF STOPLOGS REQUIRED 2 SETS EMBEDDED PARTS 24 SETS SILL LEVEL EL :35.840M F R L/MWL EL: 53.340M OPERATION 60T GANTRY CRANE STOPLOG GATES TECHNICAL DETAILS 1 2 3 4 5 6 7 8 9 DESIGNED AS PER IS: 5620 NO. OF ELEMENTS 10 NOS. 1.85 X = 225.562 Y 135 135 950 229 1050 1220 890 565 529 1300 2800 1450 1450 503 (END VIEW AT TRN CENTER) 2ND STAGE 1STSTAGE 93 13 890 565 529 1450 1450 13 4750 2375 2375 23752375 12001775 1775 1200 950229503931200 565565 RADIAL GATE WITH DOWN STREAM HOIST Fig - 3 31. 31 NO OF GATES 20 NOS. VENT WIDTH 18500mm VENT HEIGHT ABOVE SILL LEVEL 17000mm RADIUS 23350mm SILL LEVEL EL :58.500M TRUNNION LEVEL EL: 72.000M F R L/MWL EL: 75.500M TYPE OF ANCHORAGE INDEPENDENT TYPE OF HOIST PIER THICKNESS 4750mm SPILLWAY RADIAL GATES HYDRAULIC HOIST CYLINDERS/GATE TECHNICAL DETAILS 1 2 3 4 5 6 7 8 9 10 11 TOP OF GATE EL: 75.800M DESIGNED AS PER IS 4623-200012 NOTE: 1. ALL DIMENSIONS ARE IN MM AND LEVELS ARE IN METERS. 2. ALL WELDS ARE 6MM FILLET CONTINUOUS. 1949 950950 2850 4750 450 2900 4000 3500 3500 450 LH RH 1313 13 13 950 2850 LH RH NO OF GATES 20 NOS. NO. OF STOPLOGS REQUIRED 2 SETS EMBEDDED PARTS 20 SETS OPERATION 70T GANTRY CRANE STOPLOG GATES TECHNICAL DETAILS 1 2 3 4 5 6 DESIGNED AS PER IS: 5620 NO. OF ELEMENTS PER SET 10 NOS. 135 135 950 229 1050 1220 890 565 529 1300 2800 1450 1450 503 (END VIEW AT TRN CENTER) 2ND STAGE 1STSTAGE 93 13 890 565 529 1450 1450 13 4750 2375 2375 12001775 1775 1200 950229 503 93 1200 565 565 2375 VENT=1850035004750 2375 950 7502 4064 4325 19052 2527 37470 21001500 135009000 6500 4000 2700 13600 600011575 19527 4027 3745 2225 1000 9502850950 8200 1835 18547 22200 20.65 8692 63 18.636 23350 R3 95018500950 C/CofTrunnion=20400 2375 2500 29968 X = 21.448Y 1.85 RADIAL GATE WITH HYDRAULIC HOIST Fig 4 32. 32 EL615.00 8000 3000 18000 4000 EL620.00 900 2500 INTERMEDIATE PIER PLAN 9502000 8000 950 480 1520 2000 ?OF SILL SILL EL 587.120 6000 F.R.L/M.W.L EL 618.00 900 1100 TOP OF SLUICE EL 607.50 EL599.50 EL597.50 R=15000 29000900 ELEVATION EL599.675 1520480 195 405 16X425=6800 20 298 25 800800 600 9502550 7000 EL 602.50 EL 587.50 BOTTOM OF GATE WHEN FULLEY LIFTED EL599.935 3528 35003500 7000 12330 STOPLOGGATEGROOVESTOPLOGGROOVE F L O W F L O W 'Y' 'X' 6000R NOTE : 1. ALL DIMENSIONS ARE IN MM AND ALL LEVELS ARE IN METERS. 1 2 3 4 5 6 7 8 10 11 12 VENT WIDTH VENT HEIGHT DESIGN OF HEAD TYPE OF GATE OPERATING BY SILL LEVEL TUNION CENTER LEVEL ? OF ANTIGET SEAL BOTTOM OF GATE WHEN FULLEY LIFTTED TOP OF GATE IN CLOSED POSTION TOP OF VENT TECHNICAL DATA RADIAL GATES 8.00 M 12.38M 30.880M GATE WITH INCLINED HYDRAULIC HOIST EL 587.120M EL 599.50 M NO OF GATES 7 NOS ? OF HYDRAULIC HOIST EYE END MOUNTING F L O W 13 9 EL 599.50 M EL 599.675 M ? OF TOP SEAL EL 599.935 M 14 EL 600.100 M EL 609.500M 100 12 350 10 800 400 400 250100 250 100 100 150 150 14 DETAIL AT 'Z' 'Z' 15000 SKIN PLATE POWER PACK R=6000 5500 10000 9426 10620 11582 11413 20990 36.68 10.78 EL 609.50M EL 611.0M DOGGING OF GATE VIEW AA A A 30.184 15000 5530 8470 7.8656 EL 601.669M EL 588.88M EL 599.935 M 2169 7000 450 450 12.459 EL602.00M 965 AXIS OF DAM TRUST BLOCK DETAIL AT 'Y' TOP OF VENT EL599.50 175260 121 6 16 53 51516 175 175 40 102 500 18 40 TOP SEAL CLAMP SKIN PLATE BOTTOM OF GATE WHEN FULLEY LIFTED EL599.935 EL599.675 15058 TO CTR OF TRUNNION 300465 550 350 SKIN PLATE 600 125 125 SILL BEAM BOTTOM SEAL SEAT (SS STEEL) BOTTOM SEAL (RUBBER) EL 587.120 F L O W VERTICAL STIFFENERS R=1500mm DETAIL AT 'X' 400 350 250 323 13424 RADIAL GATE WITH TOP SEAL Fig 5 33. 33 TECHNICAL DETAILS OF RIVER SLUICE SERVICE GATES NO OF GATES REQUIRED : 4NOS. CLEAR VENT WIDTH : 2100MM CLEAR VENT HEIGHT : 4000MM SILL LEVEL : EL 25.000M TOP OF VENT : EL 29.000M FRL / MWL : EL 53.340M LOCATION OF SKIN PLATE : DOWN STREAM SIDE DEPTH OF GROOVE : 550MM SILL TO TOP SEAL CENTRE : 4100MM OPERATED BY : 30T ROPE DRUM HOIST DESIGNED : AS PER IS 4622 - 2003. TECHNICAL DETAILS OF RIVER SLUICE EMERGENCY GATE NO OF GATES REQUIRED : 4NOS. CLEAR VENT WIDTH : 2100MM CLEAR VENT HEIGHT : 4000MM SILL LEVEL : EL 25.000M TOP OF VENT : EL 29.000M FRL / MWL : EL 53.340M LOCATION OF SKIN PLATE : UP STREAM SIDE DEPTH OF GROOVE : 550MM SILL TO TOP SEAL CENTRE : 4100MM OPERATED BY : 20T ROPE DRUM HOIST. DESIGNED : AS PER IS 4622 - 2003. NOTE:- 1.ALL DIMENSIONS ARE IN MM 2.ALL LEVELS ARE METERS 2170 CG OF GATE CG OF GATE ? SILL? SILL VERTICAL FOR RIVER SLUICES Fig 6 34. 34 2272.5 19501800 270330260340 6535 27502200 WHEEL C/C = 6150 2272.5 1270 930 260 340 75 250 1950 1550 1200 270 330 75 600250 80 1085 200 6000 150 4545 915 11583 2089 2330 82 600 25075600250 75 600 500 1450 1800 930 600 200 4730 520 4730 530 525 150 50020 2480 1193 6000 LIFTING C/C3200 500 20 2004730 COLUMN C/C = 6045 42054205 VENT = 4545 127093015501200930 477.5 600 150 25 13501400 ?? ? 1610 1140 1140 1610 600 150 ? 3200 25 10801120 952 25 LIFTING C/C3200 1610 1100 1610 NOTE: 1. ALL DIMENSIONS ARE IN MM AND LEVELS ARE IN METERS. 2. THE MINIMUM CLEARNESS IS REQUIRED PER GATE OPERATION IS INDICATED IN THE DRAWING SAME MAY PLEASE BE ENSURED WHILE CONSTRICTION. TECHNICAL DETAILS INTAKE SERVICE GATE 1 NO OF GATES 3 NOS 2 VENT WIDTH 4545 MM 3 VENT HEIGHT 4545 MM 4 GATE HEIGHT 4730 MM 5 SILL LEVEL + EL 18.828 M 6 TOP OF PIER + EL 40.00 M 7 FRL + EL 38.00 M 8 MWL + EL 38.00 M 9 SPEED 1.65 M/MIN 9 HOIST CAPACITY ROPE DRUM HOIST 30T - 1NO PER GATE 10 DESIGNED AS PER IS 6938 - 2005 TECHNICAL DETAILS INTAKE STOPLOG GATE 1 NO OF GATES 3 NOS 2 VENT WIDTH 4545 MM 3 VENT HEIGHT 4545 MM 4 GATE HEIGHT 4730 MM 5 SILL LEVEL + EL 18.828 M 6 TOP OF PIER + EL 40.00 M 7 FRL + EL38.00 M 8 MWL + EL 38.00 M 9 SPEED 0.50 M/MIN 9 HOIST CAPACITY MOVING HOIST 25T - 1NO 10 DESIGNED AS PER IS 6938 - 1989 25 VENT = 4545 4205 120015509301270 2480 COLUMN C/C = 6045 COLUMN C/C = 6045 COLUMN C/C = 6045 42052353 2353 19501800 600600 270330 VENT = 4545 VENT = 4545 8750 8750 340260 ? ? END TO END OF GROOVE =5500 6245 6245 567 69 1950 70 INTAKE STRUCTURE FOR MINI HYDELS WITH TRASH RACKS, STOPLOGS AND SERVICE GATES WITH ROPEDRUM HOIST Fig -7(a) 35. 35 5230STROKE52002200 657 135522 220220 75 600 340 550 1114636 1750 250 89 61 52005200 600 250 2500 7000 23162 1922111691406 2319 NOTE: 1. ALLDIMENSIONSAREINMMANDLEVELSAREIN METERS. 2. THEMINIMUMCLEARNESSISREQUIREDPERGATE OPERATIONISINDICATEDINTHEDRAWINGSAME MAY PLEASEBEENSUREDWHILECONSTRICTION. 6001125 90 NOOFGATES 10NOS. VENTWIDTH 4545mm VENTHEIGHT 4545mm SILLLEVEL EL:-2.873M TYPEOFMOUNTING TRUNNION MOUNTING INTAKESERVICEGATE TECHNICALDETAILS 1 2 3 4 5 6 7 8 11 HOISTCAPACITY TYPE STROKE HYDRAULICHOIST 30T- 1NOPERGATE SINGLEACTING 5300M 9 10 FRL EL:17.8M MWL EL:19.0M TOPOFPIER EL:20.5M SPEED 0.5MMIN12 LOWERING NORMAL1MMIN EMERGENCY4MMIN 13 CUSHIONINGSTROKE 250MM 14 DESIGNOFHOIST ASPERIS1021014 NOOFGATES 1NOS. VENTWIDTH 4545mm VENTHEIGHT 4545mm SILLLEVEL EL:-2.873M OPERATION THROUGHPENDENT CONTROL INTAKESTOPLOGGATE TECHNICALDETAILS 1 2 3 4 5 6 7 8 11 HOISTCAPACITY TYPE SPAN 25T GANTRYCRANE9 10 FRL EL:17.8M MWL EL:19.0M TOPOFPIER EL:20.5M DESIGNOFCRANE ASPERIS3177&80712 2500MM 600 200 600 61 INTAKESTRUCTUREWITH TRASHRACKS, STOPLOGS ANDSERVICEGATES OPERATEDBYHYDRAULIC HOISTANDGANTRYCRANE. Fig- 7(b) 36. 36 66 650 75 Recess 2588 NO OF GATES 3 NOS. VENT WIDTH 6830mm VENT HEIGHT 4270mm SILL LEVEL EL :12.550M DRAFT TUBE GATE TECHNICAL DETAILS 1 2 3 4 5 6 7 8 11 HOIST CAPACITY TYPE SPAN 25T GANTRY CRANE 2500MM9 10 MAX. TWL. EL :32.000M TOP OF PIER EL :37.000M OPERATION LIFTING BEAM VENT = 68301920 1920 1000 1000 2500 7000 4350 LIFTING C/C 4200 DESIGN OF CRANE AS PER IS 3177 & 807 4200 65011872663 650 320 75RECESS VENT = 68301920 1920 TRACK C/C =7350 1045 810 2187 1187 320 330 12501250 320 4500 104 4848652 2500 4500 2588 75 650 320 867 24450 BALLAST TO BE PROVIDE 2t ON D/S WHEEL BOGIE 2t ON U/S WHEEL BOGIE WITHOUT IMPACT 18.1T 18.1T WITH IMPACT 21.5T 21.5T MAX WHEEL LOADS 8500 NOTE: 1.ALL DIMENSIONS ARE IN MM 2.ALL LEVELS ARE IN METERS TECHNICAL DETAILS CAPACITY 25T GANTRY CRANE -1NOS FOR OPERATION OF DRAFT TUBE GATES NEERUKATTE MINI HYDEL SCHEME. CLASS AND DUTY CLASS II OUTDOOR DUTY GANTRY CRANE. DESGINED AS PER IS 3177-1999 AND IS807-2006 AND IS 6938 - 2005 OPERATION SPEED HOIST -1.25M/MIN CRAB TRAVEL - 3.0M/MIN GANTRY TRAVEL -6.00M/MIN LIFT 25.0M 3 PHASE 400/400 V AC 50 CYC/SEC. POWER SUPPLY 10% DRAFT TUBE GATE WITH GANTRY CRANE Fig - 8 37. 37 750 CABLE REELING DRUM 97459001600 6000 1000 1600 8000 1700 1700 6000 6000 35020 640 1040 500 330 MECHANISM HOIST TROLLY / CROSS TRAVEL LONG TRAVEL MOTOR:- a)37 KW (50.0 HP) 728 RPM. SLIP RING CRANE DUTY MOTOR 40% CDF150 STARTS/HOUR CLASS `F` INSULATION TEFC, FOOT MOUNTED WORKING ON 3 PHASE 400 /440 V 50 CYCLES/SEC, CONFORMING TO IS: 325; FRAME SIZE NDW:250M- 1NOS MAKE:-CROMPTON GREEVES/ALSTOM/KIRLOSKER b)CREEP MOTOR:- 5.4KW (7.0 HP) 705 RPM. SQUIRREL CAGE CRANE DUTY MOTOR 40% CDF150 STARTS/HOUR CLASS `B/F` INSULATION TEFC, FOOT MOUNTED WORKING ON 3 PHASE 400 /440 V 50 CYCLES/SEC, CONFORMING TO IS: 325;FRAME SIZE NDW160M REDUCTION UNIT:- a)THREE STAGE HELICAL GEAR BOX RATIO 90:1 INPUT HP 39.5KW,INPUT SPED 750 RPM WITH INPUT AND OUT PUT SHAFT EXTENTION ON BOTH SIDE TO SUIT ASSEMBLY TYPE SIZE HTN- DD-360- 1NOS. MAKE:-SHANTHI /NU TECH / ELECON b)PLANTERY GEARBOX CREEP SPEED CRANE DUTY RATIO 10:1 INPUT HP 9,INPUT SPED 703RPM WITH INPUT AND OUT PUT SHAFT EXTENTION ON BOTH SIDE MODEL NO X10063 - 1NOS MAKE:-MAGTORQ / ELECON / SHANTHI TECHNICAL DETAILS CLASS II OUTDOOR DUTY DESIGNED AS PER IS 3177-1999 & IS:807-1976. LOCATION / OPERATION:---------------- POWER / SUPPLY:-------------------------- 400 / 440V.AC.3PHASE 50CYCLES / SEC FROM PLUG POINT AT THE GANTRY RUNWAY. DUTY CLASS / SPECIFICATION:-------- OUT DOOR, DOUBLE ROPE DRUM,ELECTRICAL OPERATED FROM CABIN. MOTOR:- REDUCTION UNIT BRAKES a) BRAKE:- 400 ELECTRO HYDRAULIC THURSTOR BRAKE,HAVING BREAKING CAPACITY 90 KGM - 1NO.MAKE:-EMC / STERLING CONTROLS b)BRAKE:- 450 3 PHASE E.M.BRAKE,100% COIL RATING CLASS `B` INSULATION WORKING ON 400 / 440V AC,50 CYCLE/SEC. HAVING BRAKING CAPACITY 74.0 KGM - 1NO.MAKE:-EMC / STERLING c)BRAKE:- 300 SINGLE PHASE E.M.BRAKE,100% COIL RATING CLASS `B` INSULATION WORKING ON 400 / 440V AC,50 CYCLE/SEC. HAVING BREAKING CAPACITY 38.8 KGM (TO SUIT PLANYERY GEARBOX-OUTER DIA X10063) MAKE:-EMC / STERLING CONTROLS d) BRAKE:- 200 SINGLE PHASE E.M.BRAKE,100% COIL RATING CLASS `B` INSULATION WORKING ON 400 / 440V AC,50 CYCLE/SEC. HAVING BREAKING CAPACITY 15.0 KGM. MAKE:-EMC / STERLING CONTROLS WIRE ROPE WIRE ROPE 40 6 36 CONSTRUCTION, RIGHT HAND LAY UNGALVANIZED IMPROVED PLOUGH STEEL MAIN FIBERECORE UTS 180 KG/MM2 HAVING MIN- BREAKING LOAD = 95209 KG, LENGHT REQUIRED 580M -1 LENGTH. AS PER IS:2266 MAKE:- BHARAT WIRE ROPE / QUANTITY THREAD DIA DRIVE ENDS RAIL SIZE MATERAIL THREAD WHEEL ------ ------ ------ ------ ------ ------ 4 NOS 500 DIA 2 NOS CR - 120 CAST STEEL GR 340-570W IS :1030 300 BHN MOTOR:- 4.8 KW (6.4 HP) 702 RPM. SLIP RING CRANE DUTY MOTOR 40% CDF150 STARTS/HOUR CLASS `F` INSULATION TEFC, FOOT MOUNTED WORKING ON 3 PHASE 400 /440 V 50 CYCLES/SEC, CONFORMING TO IS: 325;FRAME SIZE NDW160M- 1NOS. MAKE:- CROMPTON GREEVES / ALSTOM / KIRLOSKER BRKE:- 200 MM SINGLE PHASE E.M.BRAKE,100% COIL RATING CLASS `B` INSULATION WORKING ON 400 / 440V AC,50 CYCLE/SEC. HAVING BREAKING CAPACITY 15.0 KGM -1NO. MAKE :- EMC / STRELING REDUCTION UNIT:- THREE STAGE VERTICAL HELICAL GEAR BOX RATIO 400:1 INPUT HP 6.4HP,INPUT SPED 750 RPM WITH INPUT AND OUT PUT SHAFT EXTENTION ON,BOTH SIDE TYPE SIZE : HQN- DD-250-1NOS. MAKE:-SHANTHI/NU TECH/ELECON PLUMMER BLOCK:- SNA 522 WITH 2222K BEARING +H322 SLEEVE DYNAMIC CAPACITY:122 KN, STATIC CAPACITY:52 KN- 4 NOS. MAKE :- MASTA / FAG 4.MOTOR : 4.8 KW(6.4 H.P),702 RPM SLIP RING CRANE DUTY MOTOR 40% CDF 150 STARTS/HOUR, CLASS 'B/F' INSULATION TEFC FOOT MOUNTED WORKING ON 400/400V 3PH AC 50 CYCLES/SEC CONFIRMIG TO IS 325-FRAME SIZE: SHAFT EXTENDED ON BOTH SIDES. NDW: 160M - 4NOS. MAKE:- CROMPTON GREEVES, ALSTOM / KIRLOSKER HELICAL GEAR BOX : NEWTECH CRANE DUTY VERTICAL GEARBOX RATIO 200:1,RATING 4.8KW@720RPM,CENTER DISTANCE 705,WITH HALLOW KEYED SHAFT. RH=2 NO, LH=2 NOS. MAKE:- SHANTHI / NU TECH / ELECON BRAKE: 200 HYDRAULIC FOOT OPERATED BRAKE TORQUE CAPACITY:15 KGM -4NOS. BRAKE:200 MM DIA E.M BRAKE 100% COIL RATIG CLASS 'B' INSULATION,BREAKING TORQUE CAPACITY:15KGM -4 NOS. MAKE :- EMC / STERLING CONTROLS ------------ 8 NOS 710DIA 2 NOS CR - 120 300 BHN CAPACITY (T)---------------------------------- 100T LIFT (M)----------------------------------------- SPEED------------------------------------------- HOIST:-MAIN SPEED 1.5 M/MIN LENGTH OF TRACK------------------------- 65.0M CREEP SPEED 0.15 M/MIN CRAB TRAVEL :-3.0 M/MIN GANTRY TRAVEL:- 8.0 MMIN 210M 8000 8000 850 850 850 850 650 850 850850 WITH IMPACT WITH OUT IMPACT 9.0 13.0 A B C D WITH IMPACT WITH OUT IMPACT 71.0 60.0 A B C D WHEEL LOADS (U/S) 71.0 71.0 71.0 WHEEL LOADS (D/S) 13.0 13.0 13.0 A B C D A B C D 60.0 60.0 60.0 9.0 9.0 9.0 COUNTER WEIGHT REQUIRED FOR STABILITY OF CRANE TOP D/S TIE GIRDER & END OF RAIL GIRDER ------- 45.0T BOTTOM D/S TIE GIRDER ---- 50.0T 95.0T COUNTER WEIGHT IN THE MIX OF CONCRETE + MS SCRAP OR CONCRETE + IRON CORE + SCRAP WITH A DENSITY OF 3.5T/M3 SHALL BE PROVIDED. NOTE: 1.ALL DIMENSIONS ARE IN MM AND ALL LEVELS ARE METERS 2.LUBRICATION:-INDIVIDUAL POINT LUBRICATION FOR L.T WHEELS,TOP PULLEYS,LIFTING PULLEYS&DRUM PEDESTAL CABLE REELING DRUM PARKING BRAKE EL:146.500 M 5250 CAST STEEL GR 340-570W IS :1030 570 ELEVATION U/STREAM D/STREAM F L O W PLAN END VIEW THE DETAILS OF COMPONENTS TO BE LIFTED A) 7.7m(LENGTH) X 7.765m (HEIGHT) X 1.152m (WIDTH) (REF DRG NO: CE(D)/D&PH/UF/74(R2) B) STOPLOG GATE 8.264m(LENGTH) X 1.354m (HEIGHT) X 2.25m (WIDTH) C) LIFTING BEAM:- THE HEIGHT OF LIFTING BEAM FOR PEN STOCK STOPLOG GATE IS ABOUT 2100m (REF DRG NO: 89-SS-38-204, VOL III OF TENDER DOCUMENTS FOR 100T GANTRY CRANE) D) STEM OF HYDRAULIC HOIST OF ABOUT 9.6m LENGTH 355 11000 CHAIR HARDNESS 415 540 980510 2030 PCD1250 735 2030735 6000 980400 1 2 3 4 5 6 7 8 450 50 2000 1260 1 2 4 6 7 83 5 9 BR1BR2 BR3 BR4 100T GANTRY CRANE FOR OPERATION OF STOPLOGS IN INCLINED POSITION FIG -9 38. 38 SERVICEGATEGROOVE STOPLOGGROOVE F L O W EL 254.300M SILL EL 266.190M F.R.L/MWL EL 253.900M EL 262.800M TOP OF VENT EL 268.000M EL 270.500M 1500 7400 67 733 2633 67 34841283 8050 1500 1500 9950 1500 8450100 EL 277.500M 3600 3600 137009500 1800 1400 6000600 600 VENT 10000 1500 15001500500 13000 STOPLOG GATE SERVICE GATE PIER LIFTING BEAM HOIST BRIDGE GOLIATH CRANE GATE WHEN LIFTED POSITION BRESTWALL LIFTING CC 7200 ABUTMENTPIER INTERMEDIATEPIER 550 950 550950550950500 8550 1900 1750 8050 18450 1825 2500 2500 1225 1840 75 1510 75 7506001500 5500 3350 800 890 1500 1000 2500 4540 EL 269.000M VENT 10000 3000 2000 1750 540500 VERTICAL LIFT GATES, ROPE DRUM HOIST STOPLOGS AND GANTRY CRANE FOR CANAL REGULATOR GATES 2100 750 3350 800 11450 3484 ? OF STOPLOG SILL ? OF SERVICE GATE SILL 3000 PIER PLAN NOTE:- 1. ALL DIMENSIONS ARE IN MM AND ALL LEVELS ARE IN METERS TECHNICAL DETAILS VERTICAL LIFT SERVICE GATE . NO OF GATES : 6 NOS . VENT WIDTH : 10000MM . VENT HEIGHT : 8500MM . GATE HEIGHT : 8600MM . PIER THICKNESS : 3000MM . CAPACITY OF HOIST : 85T . SPEED : 0.5 M/min 10% . TYPE : VERTICAL LIFT ROLLER GATE . OPERATED BY : ROPE DRUM HOIST . LIFT : 15.0M . DESIGNED : AS PER IS 4622 - 2003. TECHNICAL DETAILS STOPLOG GATES . NO OF GATES : 1 SET . VENT WIDTH : 10000MM . VENT HEIGHT : 8500MM . HEIGHT OF ELEMENT IN ASSEMBLED : 8600MM CONDITION . NO OF EMBEDED PARTS : 10 SETS. . NO OF ELEMENTS : 4 NOS. . HEIGHT OF EACH ELEMENT : 1400 mm . OPERATED BY : 25T GRANTRY CRANE AUTOMATIC LIFTING BEAM . DESIGNED : AS PER IS 4622 - 2003. 409 391 Fig - 10 39. 39 Conclusion : The author visited/inspected more than 400 projects in the country/ abroad when troubles started on functioning of the gates and solutions offered for rectification and most of the cause of trouble observed are covered here which are humanly possible for control to give better service to society. The points were enlisted for future guidance and maintenance. Most of our projects failed are improper maintenance and hence few tips were given as readymade list for maintenance people to keep the fit of equipment for control and effective utilization of water to give better service to society and become a part and parcel of country building. Add your experience and if necessary made comprehensive check list and pass it to your future generation for improve of living conditions in Bharat. For Contact : Er N.K.Naidu M/S Balaji Hydro Mech. Experts Plot No.: 384, Sector 1 Matrushri nagar, Miyapur, Hyderabad 500 049 Phone : 9441143272 * * * * *