fabrication,erection and repairing oF Dam's Gate

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fabrication,erection and repairing oF Dam's Gate- walmi

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fabrication,erection and repairing oF Dam's Gate

  1. 1. ONE DAY WORKSHOP ON DAM’S GATES ORGANIZED BY NARMADA,WATER RESOURCES, WATER SUPPLY & KALPSAR DEPARTMENT GANDHINAGAR SUPPORTED BY WALMI - ANAND 02/28/11
  2. 2. Sub:- Fabrication, Erection, Operation Repairing & Maintenance of Gate Structure PAPER BY:- ER. M.K.BHAVSAR Retd. Executive Engineer (Mech.) 02/28/11
  3. 3. FABRICATION PROCESS <ul><li>A. Fabrication process. </li></ul><ul><li>Estimation of steel and material from the given drawing. </li></ul><ul><li>Marking of angles, beam, plates as per drawing. </li></ul><ul><li>Cut to size as per finished product. </li></ul><ul><li>Cutting material wastage & machining allowance 5% to 10% of dimension & size and for casting 20% by weigh of finished products. </li></ul><ul><li>Additional allowances of extra fasteners required for manufacturing process e.g. prevention of bending during welding. </li></ul>02/28/11
  4. 4. HORIZONTAL GIRDER HORIZONTAL GIRDER SKIN PLATE BRACING T-VERTICALS STIFFNERS
  5. 6. FABRICATION PROCESS <ul><li>Fabrication involves manufacturing process like </li></ul><ul><li>Gas cutting , </li></ul><ul><li>Welding, </li></ul><ul><li>Casting, </li></ul><ul><li>Machining </li></ul><ul><li>Threading . </li></ul><ul><li>Additional process of straightening of parts before welding by jigs & fixture etc. </li></ul><ul><li>Handling & stacking of finished and unfinished products. </li></ul>02/28/11
  6. 7. GAS CUTTING
  7. 8. JIGS & FIXTURES FOR GATE
  8. 9. GAS CUTTING
  9. 10. WELDING OF ARM ASSEMBLY
  10. 11. WELDING OF GATE LEAF
  11. 12. JOINT WELDING OF TOP & BOTTAM HOPRIZONTAL GIRDER
  12. 13. JOINT WELDING OF TOP & BOTTAM HOPRIZONTAL GIRDER
  13. 14. BENDING MACHINE 02/28/11
  14. 15. ERECTION OF ANCHOR GIRDER
  15. 16. FABRICATION OF HORIZONTAL GIRDER
  16. 17. FABRICATION PROCESS <ul><li>B. Embedded parts. </li></ul><ul><li>Anchor rods- J-type threaded with double nut & washer. </li></ul><ul><li>Sill beam- S.S. plates on I section by welding. Special care during welding should be taken not to allow air gap between surfaces of M.S. & S.S. & welding spots to avoid cutting of rubber seal. </li></ul><ul><li>Wall plate- In case of Radial Gates curvature is to be maintained in forms of radius. </li></ul><ul><li>Guide Roller Assembly- Proper dimensions in terms of diameter, so smooth & free running of guide roller. </li></ul>02/28/11
  17. 18. FABRICATION PROCESS <ul><li>C. Gate Leaf. </li></ul><ul><li>For radial gate jig-fixtures platform is essential for manufacturing of gate leaf in proper radius and curvature of gate. </li></ul><ul><li>After fabrication cut the gate leaf in suitable number of pieces for safe transportation to the site. </li></ul>02/28/11
  18. 19. FABRICATION PROCESS <ul><li>Trunion hub & assembly. </li></ul><ul><li>It involves dissimilar metal joints welding such as C.S. to M.S. For the assembly if the section is not available as per drawing & design, used nearest section & calculate centre of gravity & accordingly lifting bracket is to be welded. </li></ul>02/28/11
  19. 20. <ul><li>ERECTION OF RADIAL ARM & TRUNION </li></ul>
  20. 21. <ul><li>ERECTION OF RADIAL ARM & TRUNION </li></ul>
  21. 22. FABRICATION PROCESS <ul><li>D. Hoist platform & hoist mechanism. </li></ul><ul><li> It includes:- </li></ul><ul><li>Main beam, </li></ul><ul><li>Cross member, </li></ul><ul><li>Chequred plate, </li></ul><ul><li>Railing etc. </li></ul>02/28/11
  22. 23. FABRICATION PROCESS <ul><li>Hoist lifting mechanisms- </li></ul><ul><li>Wire rope, </li></ul><ul><li>Turn-buckle, </li></ul><ul><li>Wire rope drum, </li></ul><ul><li>Gear box(ERU), </li></ul><ul><li>Floating shaft, </li></ul><ul><li>Plummer blocks, </li></ul><ul><li>Bearing, Worm reduction gear, Motor/Diesel engine, </li></ul><ul><li>Clutch, </li></ul><ul><li>Magnetic brake & Dial-indication & Hand lifting mechanism. </li></ul>02/28/11
  23. 24. FABRICATION PROCESS <ul><li>Alignment & thoroughness of shaft is an important criteria to avoid breaking of Plummer block during lifting. </li></ul><ul><li>Precision of drum grooving for LH & RH drum is an important to avoid gate lifting in slant position. </li></ul><ul><li>Gear cutting profile should be precise , otherwise it will makes noisy operation & leading to more power requirement. </li></ul>02/28/11
  24. 25. ERECTION <ul><li>E. Erection- </li></ul><ul><li>The presence of DEE/SO is require to omit fault / deviation & misalignment of parts during erection. </li></ul><ul><li>Prior planning is carried out before erection . </li></ul><ul><li>Any misalignment of the parts will lead to mal functioning of the gates during operation & leading abnormal wear & tear. </li></ul><ul><li>Site clearance, chipping of extra concrete is carried out before erection. </li></ul>02/28/11
  25. 26. ERECTION <ul><li>E. Erection- </li></ul><ul><li>Embedded parts :- </li></ul><ul><li>1 st stage concreting for anchor bolts should be carried out. </li></ul><ul><li>After placing sill beam in the groove, for proper alignment 2 nd stage concreting is done for wall plate of radial gate. </li></ul><ul><li>Radius of curvature & continuity of groove for radial gate should be observed so as gate do not to go beyond the radius during lifting-operation hence rubber seal may not be cut. </li></ul>02/28/11
  26. 27. PARTS OF EMBEDED BLOCK
  27. 28. <ul><li>ERECTION OF RADIAL ARM & TRUNION </li></ul>
  28. 29. ERECTION OF ANCHOR GIRDER
  29. 30. ERECTION <ul><li>Anchor bolts & trunion should be checked for its centre of radius before fixing the anchor girder. </li></ul><ul><li>The distance between two wall plates of the bay should be checked thoroughly for the entire height before second stage concreting. </li></ul>02/28/11
  30. 31. ERECTION <ul><li>Gate leaf :- </li></ul><ul><li>Joining the suitable no. of pieces of gate leaf in space with proper curvature & radius in case of radial gate is required, fixing of rubber seal, flat & ‘Z’ type, its projection beyond gate leaf observed through the surface. </li></ul>02/28/11
  31. 32. ERECTION OF ANCHOR GIRDER
  32. 33. ERECTION OF ANCHOR GIRDER
  33. 34. ERACTION OF ANCHOR GIRDER
  34. 35. <ul><li>ERECTION OF EMBEDED PARTS </li></ul>
  35. 36. ERECTION OF ANCHOR GIRDER
  36. 37. ERECTION OF SILL BEAM
  37. 38. ERECTION OF SILL BEAM
  38. 39. ERECTION OF SILL BEAM
  39. 40. ERECTION <ul><li>Hoist platform & hoist mechanism :- </li></ul><ul><li>When hoist platform in 3 pieces is to be carried out, the middle portion is to be purposefully kept 3mm raised so the C.D.U. leading proper & alignment of floating shaft should be perfect. </li></ul><ul><li>There should not be any twisting of wire rope to the drum, turn buckle & socket. </li></ul>02/28/11
  40. 41. ERECTION <ul><li>Hoist platform & hoist mechanism :- </li></ul><ul><li>Any blow-holes of air & impurity should be maintained & proper Zinc fill with care. </li></ul><ul><li>Fixing of magnetic break, hand break & manual handling mechanism should be carried out looking to the safety of structure. </li></ul><ul><li>Electrification & wiring should be carried out properly looking to the switching operation & safety. </li></ul>02/28/11
  41. 42. ERECTION OF WALL PLATE
  42. 43. CONCRETE WORK
  43. 44. CHEQUERED PLATES
  44. 45. ARRANGEMENT OF HOIST & PLATEFORM
  45. 46. ERECTION OF HOIST & PLATEFORM
  46. 47. ARRANGEMENT OF HOIST
  47. 48. MECHANISM OF C.D.U. & D.H.U.
  48. 49. ERECTION OF C.D.U. & D.H.U.
  49. 50. <ul><li>ERECTION OF C.D.U. & D.H.U. </li></ul>
  50. 52. MECHANISM OF C.D.U.
  51. 53. <ul><li>MECHANISM OF C.D.U.& D.H.U. </li></ul>
  52. 54. ERECTION OF C.D.U.
  53. 55. <ul><li>MECHANISM OF C.D.U.& D.H.U. </li></ul>
  54. 56. END REDUCTION GEAR UNIT MECHANISM
  55. 57. ERECTION OF E.D.U.
  56. 58. ERECTION OF E.D.U.
  57. 59. <ul><li>ERECTION OF FOOT BRIDGE </li></ul>
  58. 60. VIEW OF GATED SCHEME
  59. 61. OPERATION <ul><li>F. Operation :- </li></ul><ul><li>* Before operation of gate, its visual observation should be carried out for any visible obstruction or hindrance on its patch of movement. </li></ul><ul><li>* If the motor is tripped by starter, watch for any blockage or additional friction of the moving parts. </li></ul><ul><li>* Observe the temperature of the cable for any over heating. </li></ul><ul><li>* Additional noise in the gear, pulleys etc., rectify accordingly. </li></ul>02/28/11
  60. 62. OPERATION <ul><li>Manual operation :- </li></ul><ul><li>* In case of power failure or fault in the electrical wiring or instrument, manual lifting of gate is to be carried out. </li></ul><ul><li>* Check free magnetic brakes. </li></ul><ul><li>* Spare handle should be kept ready for emergency. </li></ul><ul><li>* Other source of emergency lighting for visualization. </li></ul>02/28/11
  61. 63. REPARING & MAINTENANCE <ul><li>G. Repairing & Maintenance of Gate structure :- </li></ul><ul><li>* Rusting is a main problem in gate structure. </li></ul><ul><li>* Oiling, greasing & painting should carried out periodically. </li></ul><ul><li>* Check visual obstruction of log, shrubs etc. </li></ul><ul><li>* Pre-monsoon & post-monsoon inspection as per scheduled. </li></ul>02/28/11
  62. 64. REPARING & MAINTENANCE <ul><li>G. Repairing & Maintenance of Gate structure :- </li></ul><ul><li>* Periodically operation of generating set, and visual inspection of cables & wire. </li></ul><ul><li>* Remove any be-hive development in the vicinity of the gate structure. </li></ul><ul><li>* In case of air-bottle started generators like SKODA, check leakage of air and completely filled with full pressure. </li></ul>02/28/11
  63. 65. REPARING & MAINTENANCE <ul><li>In case of repairing works :- </li></ul><ul><li>A- Replacement of Rubber seal :- </li></ul><ul><li>1. Any damage of rubber seal cause leakage of water, it should be replaced. </li></ul><ul><li>2. Proper edging of skin plate should be carried out. </li></ul><ul><li>3. Brass nut & bolts should be fixed to avoid corrosion. </li></ul><ul><li>4. The sill beam & wall plate surface should be checked for any bulging, blur or cut on its surface. </li></ul>02/28/11
  64. 66. REPARING & MAINTENANCE <ul><li>In case of repairing works :- </li></ul><ul><li>B-Replacement of wire rope :- </li></ul><ul><li>For checking of alignment lift the gate slightly, fill Zinc properly on socket & adjust turn buckle for any slackness of wires. </li></ul>02/28/11
  65. 67. REPARING & MAINTENANCE <ul><li>C- Replacement of guide roller :- </li></ul><ul><li>Lift the gate, remove the damaged guide roller. Check wall plate groove for clear & obstruction free & put sufficient nos. of different thickness of support plate below the guide roller for play free movement. </li></ul>02/28/11
  66. 68. END VERTICAL MAIN ROLLER ROLER PIN
  67. 69. VERTICAL GROOVE GUIDE ROLLER TRACK
  68. 70. REPARING & MAINTENANCE <ul><li>D- Repairing of arm assembly etc. :- </li></ul><ul><li>Attempting the repairing of arm assembly, try to analyze the force causing mis-alignment & damage of it. Care should be taken for dissimilar metal joints. </li></ul>02/28/11
  69. 71. 02/28/11 END ARMS
  70. 72. REPARING & MAINTENANCE <ul><li>E- Repairing of Gate leaf :- </li></ul><ul><li>Any damage of gate leaf or its parts, it should be cut proper ’V’ groove for better welding. Single or double groove cut depend on thickness of the plate. </li></ul>02/28/11
  71. 73. REPARING & MAINTENANCE <ul><li>F - Repairing of Floating shaft, Hubs, Gears, Plummer block etc.:- </li></ul><ul><li>1. check for alignment. </li></ul><ul><li>2. Repairing/Replacing electrical cable switches, contacts, magnetic brake etc. </li></ul><ul><li>3. Dust & moisture protection should be observed. </li></ul><ul><li>4. Check joints, make connections with glands etc. </li></ul>02/28/11
  72. 74. SAFETY <ul><li>H. Safety :- </li></ul><ul><li>Safety of man, material, structure is utmost importance in fabrication, erection, operation, maintenance & repairing of gate structure. Hazard from mechanical, electrical or natural i.e. flood water etc. or from public at U/S & D/S side during operation in flood controlling situation. </li></ul>02/28/11
  73. 75. POWER POINT PRESENTATION PREPARED BY ER.J.R.RATHOD ER. K.B.TRIVEDI ER. R.C.RANA D.E.E.(Mech.) N.W.R.W.S. & Kalpsar Department, Gandhinagar 02/28/11

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