Operation Manual1 1
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Transcript of Operation Manual1 1
1. GENERAL
Proper Maintenance of hydraulic gates and hoists is very important for
satisfactory operation of the project 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 &
Maintenance Manual which shall include the design features of various
components, particulars of bought-out items, Operating Instructions, Type of
Lubrication oil and grease to be used, Maintenance and repairs, is prepared for
Hydraulic gates and the operating staff shall be made well conversant with
them and trained for the job.
2. BRIEF DESCRIPTION OF FIXED WHEEL GATE PARTS:
AA. EMBEDDED PARTS:
STILL BEAM:
It is fabricated out of IS: 2062 Quality Rolled Steel Joist with stainless
steel flat of quality: IS: 1570 on the top. The sealing surface of the beam is
smooth and flush with concrete.
ROLLER TRACK:
It is fabricated ‘I ‘section made out of IS: 2062 Quality Plates or Rolled
Steel Joists with stainless steel of Quality IS: 1570 part V on the top of
Roller Track.
SIDE SEAL SEAT:
It is fabricated out of M.S.Angles / M.S.Plates of quality IS: 2062 with
stainless steel plates of Quality IS: 1570 part V on the top. The surfaces of
these parts are so finished, which will provide smooth surface and better
sealing effect.
TOP SEAL SEAT:
It is fabricated out of M.S.Angles / M.S.Plates of quality IS: 2062 with
stainless steel plates of Quality IS: 1570 part V on the top. The surfaces of
these parts are so finished, which will provide smooth surface and better
sealing effect.
SIDE GUIDE:
It is fabricated out of M.S.Plates of quality IS: 2062 so that it guides the
movement of gate in groove and embedded with anchorage in the concrete.
BB. GATE PARTS:
SKIN PLATES:
It is fabricated out of M.S.Angles / M.S.Plates of quality IS: 2062. It will
be straight / vertical in shape.
HORIZONTAL GIRDERS:
It is fabricated ‘I ‘section / ‘T ‘section out of M.S. Plates of IS: 2062
Quality (or) Rolled Steel Joists of IS: 2062 Quality. These will be suitably
spaced and fixed on the skin plate so that stresses are same in all girders.
ROLLERS ASSEMBLIES:
Rollers are made out of Cast Steel conforming to IS: 1030 and Roller Pins
are made out of IS: 1570 (part V) Quality rounds. Rollers are fixed on Pins
with spherical bearings along with Cover Plates and ‘o ‘rings to avoid
entry of dust particles. The Rollers will have less hardness than Track.
LIFTING ARRANGEMENTS:
Suitable hooks are provided on gate top at its C.G. Line so that lifting
beam hook will lock with pin and lift the gates.
SIDE GUIDES:
Side Guides are made out of M.S.Angles / M.S.Plates of IS: 2062 Quality
Plate to suit to shape of guide provided in the embedded parts. These
guides are provided at two ends of the gate to end boxes to avoid side
movement.
CC. HOIST:
DRIVE UNIT:
It consists of suitable capacity worm reducer for reduction in speed, pawl
and ratchet arrangement for holding the gates, chains and sprockets, handle
for manual operation.
GEAR BOX:
It consists of rope drum, set of pinion and gear wheels of Quality Cast
Steel conforming to IS: 1030 to further reduce speed and are provided at
both ends.
LINE SHAFT:
It connects both the gear boxes to the drive unit with Plummer blocks
supports at suitable spacing. This is made out of IS: 2062.
HOISTING STRUCTURES:
Hoist Structures are of Quality IS: 2062 with hand rails for easy movement
of operator and facilitate maintenance works.
3 DESIGN DATA
sl DESCRIPTION VALUESno.1 Type of Gate Fixed wheel type vertical gate
u/s skin plate and u/s sealing
2 Size of vent 3060mmx6100mm3 NO.vents 164 Clear width of opening 3.06 M5 Clear height of opening 6.10 M6 No. of gates 16 SET7 No. of Units in one set 3 UNITS8 No. of embedded parts 169 Side seal c/c 3160 mm10 Track c/c 3630 mm11 Sill to top seal c/c 6200 mm12 SILL Level EL 738.84 M (2424') 80.0013 Top of opening EL 744.94 M14 FRL EL 752.50 M (2468.8') 124.80
HWL EL 127.0015 DESIGN HEAD FRL 13.655 M 44.80
HWL 14.326 M 47.0016 Top of pier (top 0f dam) EL 754.08 M (2474') 130.0017 Permissible stresses
Gate Wet and Inaccessible conditionEmbedded Parts Wet and Inaccessible condition
18 Operation of gate By Rope drum hoist of 20MT Capacity under Un- balanced head condition
19 Dogging level EL 754.08 M 130.00
4 MATERIAL SPECIFICATION
SL.COMPONENT
PART RECOMMENDED IS CODENo MATERIAL
1 Structural parts of gate including IS:2062 skin plate, stiffeners, horizontal girders, diaphragms, track base, seal base, end box plates, Structural steel seal clamp, guide shoes, Structural parts of sealseat base guide/roller track, sill beam, anchor boltsanchors, etc.
2 wheels/rollers cast steel IS1030 gr. 340-570
3 Wheel axle/ pin corrosion resistant steelIS 1570-v 30-CR-13
4 Wheel bearing spherical rollers bearingSKF OR Eqt.
5 Spacres for pin Structural steel IS:2062
6 Guide shoe Structural steel IS:2062
7 Lifting pin Stainless steel IS: 1570, part -5, 20Cr13
8 Bushing Bronze IS: 305
9 Track base, sill beam, Structural steel IS:2062 side seal seat base
10 Seals side/top Rubber IS: 11855PTFE Cladded -music note type
Bottom Plain rubber wedge type11 Roller Track corrosion resistant IS: 1570, part -5,
steel 20Cr1312 Seal seat Stainless steel IS:1570,part-5
04 Cr 19 Ni 913 Seal fasteners Stainless steel IS:1570,part-5
04 Cr 19 Ni 9
RECOMMENDED MATERIALS FOR FIXED WHEELS GATES
AND HOISTS:
SL NO DESCRIPTION MATERIAL IS Specification
1 Wheel Cast Steel Surface hardened to
BHN : 130
IS : 1030
2 Wheel axel Corrosion Resitant Steel IS:1570 part V
3 Skin plate & Structural steel IS: 2062
Stiffener
4 Wheel Track Stainless Steel IS:1570 part V
5 Guide Block Structural Steel IS:2062
6 Bearings SKF (or) Equipment
7 Seal blots Stainless Steel Plate, Stainless
steel clad plate
IS:1570 part V
8 Anchor bolts Structural steel IS:2062
9 Seals Rubber IS:11855
10 Embedded parts Structural steel IS:2062
11 Supporting
structures
Structural steel IS:2062
12 Gears & Pinions Cast Steel IS: 1030
Gr: 27 – 54
Gr: 30 – 57
3 DESIGN DATA FOR ROPEDRUM HOIST
1 Vent Size 3.06 MX6.1 M2 Capacity of hoist 20 MT3 Type of suspension on C.G. of gate4 Speed of hoist 0.5to 0.75 M/MIN.5 Max. lift of gate 15.5 M6 Location of hoist Mounted on steel bridge over
Trestles7 No. of drums Two
8 Rope drum Hoist levelEL 754.08+ hoist bridge+trestle =754.08+0.62+7.6=EL 762.3M
Hoist is mounted on steel towers on eachpier of Sluice gate structure.
4MATERIAL SPECIFICATION
SL. COMPONENT PART RECOMMENDED IS CODENo MATERIAL1 Structural parts including IS:2062
main girder, trestles, cross girders Structural steelchq. Plates, hand rails ,covers
2 Drum wheels/pulleys/gearsbrake drum cast steel IS1030 gr. 280-520
3 shafts/pinions carbon steel IS 1570 part-IIGr. 45c8
4 Pins corrosion resistant steel IS 1570 part-V30cr13
5 Bearing /housing std. Make SKF OR Eqt.
6 Motor std. Make KEC, GEC etc.
7 Flange coupling std. Make GEB, HI-CLIFFWMI ETC.
8 Wire rope std. Make Usha martin /Southern wire rope
9 Brake D.C. Electro-magnetic BCH
OPERATION AND MAINTENANCE
The following precautions are to be taken before Dry Testing the gates:
Gate wheels, Gear wheels, Plummer block and worm reducer be
lubricated.
Removal of Temporary Supports if any.
Checking of left over welding if any.
Checking of tightness of the bolts and are to be tightened properly if they
are in loose condition.
The gates are to be inspected thoroughly for nay projections, temporary
supports coming in the way of gate movement and are to be removed if
any.
All the rubber seals are to be made wet before lowering the gate preferably
with water to reduce friction, heat generated between seal and seal seat.
Light ray pass test may be conducted for checking gap in between seal and
seal seat.
Operating personnel shall be properly trained and experienced so that they
can use their initiative and judgement based on their past experience for
situation 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 behaviour of various structure and equipments.
Detailed instructions for inspection and normal maintenance and repairs of
gate installation should be given in the Operation & Maintenance Manual.
However, for carrying out special repairs to gates if any, it is advisable to
refer to manufacturer.
Inspection and Maintenance experience are complied in the form of
History Register of any installations so as to be useful for further designs,
investigations of any failure, improper and unusual operation in the gates
History Register maintained for the purpose.
4. MAINTENANCE SCHEDULE FOR VERTICAL LIFT FIXED WHEEL
GATE:
These gates are provided for controlling water discharge for flood control,
water supply, irrigation and power generation etc. The gate 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.
MONTHLY MAINTENANCE:
1. Rollers are to be greased through grease nipples provided to rollers
shaft by using grease gun.
2. Check Rollers rotation by hand for free rotation.
3. Seals and seal seating shall be inspected for leakage when the water
level is full. Location of leakage points for taking remedial measures.
4. Excessive or wide spread leakages if any shall be reported to
Engineer – in – Charge and remedial measures like adjustment of
eccentricity in the roller axel or providing of rubber packing in
between Rubber seal and seal base. Further adjustment may be
carried out during Annual Maintenance.
5. If leakages is so much excessive that immediate repair is considered
and rubber seals are repaired or replaced.
QUARTERLY MAINTENANCE:
1. 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.
2. All the Nuts & Bolts shall be checked for tightness.
3. Check all the welds for soundness and rectify defects if any,
4. Clean all drain holes wherever provided.
5. Check upstream face of skin plate for pitting, sealing and corrosion.
Scale formation shall be removed by using wire brush, pitting shall be
filled with weld and flush grind. 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. The Roller bearings / guide rollers shall be lubricated for the rotation.
7. The seal shall be checked for damages, wear and tear, if damaged,
shall be replaced.
8. The guide assemblies, wheel assemblies and sealing assemblies shall
be cleared of grit, sand or any other foreign material.
9. General cleaning is to be done for – Hoist Components
10. Lubrication is to be attended for – Bearings ate gate Rollers, Hoist
pulley and pins provided in Hoist and Gates.
11. Rope drum shaft, Plumber blocks, Line shaft plumber blocks.
12. Check tightness of all coupling bolts of Motor to worm reducer and
line shaft. If required they may be tightened.
ANNUAL MAINTENANCE:
The following additional checks or maintenance shall be carried out
in addition to the checks mentioned under Quarterly Maintenance.
1. All the Embedded parts are checked for defects / damages and shall be
rectified wherever noticed.
2. The sill beam and guides shall be cleared for all grit, sand etc.
3. The wire 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. The Table ‘A’ shows up to which broken wires are allowed.
4. The wire rope shall be greased.
5. The guide roller pins shall be lubricated.
6. Check the condition of rubber seal. If damaged, replace the seals.
7. All bolts and nuts holding rubber seals shall be tightened. Adjust seal if
leakages are found at local points.
8. Re – painting of the gates shall be carried out at intervals to be decided
on the basis of painting schedule of the gates.
9. The inspection, testing and maintenance of the hoist shall be carried
out periodically.
10. Check oil level in Gear box / worm reducer and replace wherever
required with oil of proper grade.
AT EVERY THREE YEARS:
In addition to checks mentioned under Annual, following will be carried:
1. Check seals for damage and alignment.
2. Check seal bolts for damage.
3. Check for any damage to pulley and pin.
4. Check bearings for damages.
5. Check gears and pinions for damages.
6. Check plumber blocks for damages.
7. Check for any painting damages.
AT EVERY SIX YEARS
In addition to checks mentioned under Annual, following will be carried out:
1. Check damaged / cracked welds at
Skin plate joints
Splice joints
Hoist bridges
Bracings
2. Check Wheel Assemblies for
Any breakages
Frozing
Corrosion
Mis – alignment
3. Check seal seats, seal tracks side guides for
For any welding cracks
Bents or loose bolts and nuts
Cracks in the beddings of worm reducers, Rope drum etc.
LUBRICATION SCHEDULE
SL NO PARTS TO BE
LUBRICATED
MODE OF
LUBRICATION
LUBRICANT FREQUENCY
1 Gate Wheel
bearings
Pressure Grease
gun
Servo Gear -20
Or
Bearing grease
Once in three months as per site
condition
2 Guide Shoes Pressure Grease
gun
grease Once in three months as per site
condition
3 Hoisting wire rope Hand applied Servo Coat – 120
Or Cordium
Compound
Once in a year before monsoon
sets in
4 Worm reducer Oil bath Servo HP - 30 Indicator level to be maintained
always
5 Gear wheels Hand applied Chassis grease Once in six months as per site
condition
6 Drum shaft Pressure grease gun Chassis grease Once in three months as per site
condition
7 Lifting arrangement Hand applied M.P. Grease Once in six months as per site
condition before monsoon sets in
8 Hand operation
Mechanism & other
relating parts
Hand applied Servolin - 140 Once in three months as per site
condition before monsoon sets in
CHART FOR MAINTENANCE SCHEDULE FOR GATES
AT EVERY
QUARTERLY
AT EVERY YEAR AT EVERY 3 YEARS AT EVERY 6 YEARS
General cleanness of
embedded parts,gate,
hoist components
In addition to Quarterly
Maintenance schedule
the following are to be
checked
In addition to Yearly
Maintenance schedule
the following are to be
checked
Check welds for damage
at
Check for oil level in
Radicons
Check for tightness of
foundation bolts of
Radicons, Plummer
blocks, Coupling joints
Check the condition of
wire rope, pulleys,
sheaves, gear wheels
Skin plate joints gate
stiffeners
Greasing of pulleys &
pins rope drum hoist,
gear wheels, Hand
operation shaft, guide
rollers, gate wheels
Check for smooth
operation of gate by
raising & lowering
Check gate seals for
damage
Check wheel assemblies
for any Breakage,
Frozing.
Wheels are to be greased
properly
Check sill beam,
sideguide, roller track for
damages, corrosion,
pitting
Movement of wheels
should be smooth & it
can be rotated by hand
Check hoist bridge
foundation bolts for
tightening
OPERATION AND MAINTENANCE OF GATES
SL NO DO’S DON’T’S
1 Authorised / Technically qualified
personnel should be allowed for
operation.
Unauthorised / Unqualified person should
not be allowed to operate gates.
2 Attend Maintenance during pre –
monsoon season.
Maintenance works should not be
attended during rains.
3 Use proper tools for attending repairs /
adjustment.
Improper tools not to be used for any
repairs / adjustments.
4 Conduct DRY TEST before putting into
operation
Do not operate gates without DRY
TESTING.
5 Maintain cleanliness of hoist platform. Not to keep any slippery material on hoist
walkway.
6 Protect hoist gear box and other parts
from rains.
Not to keep gear box covers open after
daily maintenance.
7 Ensure wire rope tightness on either side
equally before operating gate.
Not to operate gate when the wire rope is
slacked.
8 Ensure before operation that no foreign
material fall in the gear teeth.
Not to run the hoist if foreign material
found in between teeth of gear wheels.
9 Check tightness of plumber block, drive
unit line shaft, coupling bolts.
Do not operate gate if any bolts of
plumber blocks and coupling bolts are
found loose.
10 Ensure no foreign particles stuck up in
between roller and roller track and rubber
seal etc.
Not to advise to operate gates if foreign
material found in between rollers and
roller track and rubber seals etc.
11 Maintain oil as per level indicator in the
gear box.
Not to operate gates with low oil level in
gear box.
12 Check tightness of wire rope clamps
before operation.
Not to operate gate if wire rope clamps
are found loose.
13 Operate gate only when grooves are clean
without any obstruction.
Do not operate gate if there is any
projection in the grooves which obstruct
movement of gate
CONCLUSION
Hydraulic Gates and Operating equipments form an integral component of Dam’s
Barrage and other Hydraulic Structures. Gates and Hoists equipments play an
important role for Dam’s to control, regulate, discharge floods etc. It is essential that
Hydro Mechanical equipments are inspected periodically as suggested above and
carries out Maintenance as a routine so that Hydro Mechanical equipment function
smoothly at all times to avoid loss. The Maintenance of gate is very important to have
longer life of gate.
It will be helpful if the gates are operated by technically qualified, trained (by us)
persons and it reduces unnecessary repair and maintenance expenses.