Presentation on O & M of gates by Shri N Kannaiah Naydu,during
One Day Seminar on Safety Inspection and O & M of gates for dams, canals etc
conducted by Gujarat State Center of The Institution of Engineers (India) at Ahmedabad on July 3, 2015.
Video can be seen on facebook as well as Youtube page of IEIGSC.
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 manufacturer’s 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
DO’s Don’t’s
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 2½ Swedish standard SIS 05 5900 with a surface profile not
exceeding 65 microns.
The fig. B Sa 2½ is given.
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
150±5 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
40±5 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 25±5 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 manufacturer’s 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 manufacturer’s 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:-
200Ø 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:-
36Ø ,6/36 CONSTN.,R H LAY UNGALVANIZED, MAIN FIBER
CORE UTS 200KG/MM² 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:-
200Ø 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:-
36Ø ,6/36 CONSTN.,R H LAY UNGALVANIZED, MAIN FIBER
CORE UTS 200KG/MM² 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
Ø1500
944
3500
3700
10.943°
VENT=185004750
9502850950
10.943°
4900100008000
370011100
1949
950950 2850
4750
450
2900
4000
3500 3500
450
LH RH
13°13°
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
13°13°
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)
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:- 400Ø ELECTRO HYDRAULIC THURSTOR
BRAKE,HAVING BREAKING CAPACITY
90 KGM - 1NO.MAKE:-EMC / STERLING CONTROLS
b)BRAKE:- 450Ø 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:- 300Ø 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:- 200Ø 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 40Ø
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 MMØ 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:
200Ø 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
* * * * *