inspection of gates of Dam


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Inspection of Gates of Dam

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inspection of gates of Dam

  2. 2. SUB:- INSPECTION OF GATES PAPER BY:- ER. P.K.PANCHAL Executive Engineer (Mech.) 02/27/11
  3. 3. INTRODUCTION <ul><li>Crest gates (Radial or Vertical) are provided in dams for release of flood water to restrict the submerged area due to back water effect during high flood. </li></ul><ul><li>Proper Operation and Maintenance of these gates is necessary for their smooth functioning, improved performance and increased life. </li></ul>02/27/11
  4. 4. INTRODUCTION 02/27/11
  5. 5. <ul><li>ANCHOR GIRDER </li></ul><ul><li>Check the Anchor nut, check nut on horizontal Anchor girder for proper tightening otherwise gates will come out or heavy load will be imposed on Anchor girder. </li></ul><ul><li>Checks the vertical Anchor nuts for proper tightening. </li></ul><ul><li>Check the studs for pedestal plates otherwise Anchor girder bent. </li></ul>02/27/11 INSPECTION OF RADIAL GATES ONLY ANCHOR NUT PROVIDED
  6. 6. <ul><li>4 Check the drain holes in anchor girders are provided & it should be cleaned for proper function otherwise water will be accumulated inside Anchor girder & rusting will take place. </li></ul>02/27/11 Anchor Girder DRAIN HOLES
  7. 7. <ul><li>Check all bolts & nuts for proper tightening between Anchor girder of Trunion bracket. </li></ul><ul><li>If not properly tightened, it will dismantle or twist damaging the gate operation. </li></ul>02/27/11 TRUNNION BRACKET & ANCHORAGES TRUNION BOLTS/NUTS
  8. 8. <ul><li>Check the bolts of Trunion lock plates for proper tightness, otherwise lock plate will be dismantled and pin will rotate inside hub. </li></ul>02/27/11 TRUNION LOCK PLATE/BOLTS TRUNION PIN
  9. 9. <ul><li>Check whether pin ends are covered with Anticorrosive jelly, otherwise the friction will occur between Pin & HUB and affect the operation of gates. </li></ul><ul><li>Check the flexible sheath cover is provided on top of trunnion bracket, otherwise debris will enter inside Trunnion Pin & HUB and damages Trunnion assembly. </li></ul>02/27/11
  10. 10. <ul><li>Check the drain holes are provided in END arms and are clean otherwise water will be accumulated and rusting will take place which affects the strength of M. S. parts . </li></ul>02/27/11 END ARMS
  11. 11. <ul><li>Checks the welding joints between Trunion HUB and end arms for any crack with magnifying glass otherwise it will affects the strength of end arms. </li></ul><ul><li>Check the straightness of end arms otherwise it will affect the movement of gates and also touches the piers surfaces which obstruct the gate operation. </li></ul>02/27/11 END ARMS WELDING JOINTS
  12. 12. <ul><li>Check the bolts/nuts provided at the joints between horizontal girder and end arms for proper tighting otherwise the joints will be opened and affects the strength of end arms. </li></ul>02/27/11 END ARMS BOLTS /NUTS
  13. 13. <ul><li>Check the drain holes are provided in horizontal girders and are clean otherwise water will be accumulated and rusting of M. S. parts will take place which will reduce the strength of Horizontal girder. </li></ul>02/27/11 HORIZONTAL GIRDER
  14. 14. <ul><li>Check the welding carried out in Horizontal girder for any crack, otherwise it will affects the strength of horizontal girder. </li></ul>02/27/11 HORIZONTAL GIRDER WELDING JOINTS
  15. 15. <ul><li>Check the deformation of girders particularly at ends, Due to horizontal girders touching the pier surfaces. this will affect the movement of gates. </li></ul>02/27/11 HORIZONTAL GIRDER DEFORMATION OF GIRDERS
  16. 16. <ul><li>SKIN PLATE </li></ul><ul><li>As upstream side of skin plate remains in touch with water, the pitting, scaling and corrosion will take places which reduces the strength of skin plate. So every year, Painting should be carried out. </li></ul>02/27/11 GATE LEAF T-GURDER SKIN PLATE
  17. 17. <ul><li>Check the downstream of skin plate, welding joints between skin plates and T-girders. T-girders and Horizontal girders for any pitting rusting, corrosion or crack otherwise it will damage the skin plate assembly and reduce the strength. </li></ul><ul><li>Check any deformation of bottom corners of gate leaf which is taken place due to touching of corner of skin plate with pier concrete otherwise the skin plate corner will be jammed and gate will not be operated. </li></ul>02/27/11 GATE LEAF
  18. 18. <ul><li>B RUBBER SEAL ASSEMBLY </li></ul><ul><li>Check the condition/deformation of side, bottom and corner rubber seal for proper tightness with wall plate and seal beam. Otherwise water leakage will be observed. </li></ul>02/27/11 GATE LEAF
  19. 19. <ul><li>RUBBER SEAL ASSEMBLY </li></ul><ul><li>Check all the bolts/nuts used for fitting of rubber seal with skin plate for proper tightening otherwise water leakage will be observed through the holes whereas bolts/nuts are not provided. If bolts/nuts are found wear & tear, water leakage will be observed </li></ul>02/27/11 GATE LEAF
  20. 20. <ul><li>B. RUBBER SEAL ASSEMBLY </li></ul><ul><li>If there is gap between wall plate and rubber seal due to not proper erection, water leakage will be observed between the gaps and water will fall on horizontal girders ends arms etc. rusting the M. S. parts and affects the strength. </li></ul>02/27/11 GATE LEAF
  21. 21. <ul><li>GUIDE ROLLER </li></ul><ul><li>Check all the guide rollers are provided on skin plate for control of lateral movement of gates. </li></ul><ul><li>Check all the bolts and nuts for proper tightness otherwise guide rollers becomes loose and falls which affects the lateral movement of gates. </li></ul>02/27/11 GATE LEAF
  22. 22. <ul><li>Check the wall plates assembly for proper alignment for bottom to top so that rubber seal assembly will travel on clad plate provided on wall plate assembly and water leakage will not be observed. </li></ul>02/27/11 EMBEDED PARTS SILL BEAM OF WALL PLATES
  23. 23. <ul><li>Check the sill beam assembly and flat rubber seal for proper seating otherwise water leakage will be found between the gap of flat rubber seal and sill beam. </li></ul>02/27/11 EMBEDED PARTS: SILL BEAM OF WALL PLATES
  24. 24. <ul><li>Check any water leakage between stage concrete of will plate and sill beam otherwise water coming from the stage concrete will fall on ends arms, horizontal girder etc. which will corrode the M. S. parts of affects the strength of M. S. Parts. </li></ul>02/27/11 EMBEDED PARTS: SILL BEAM & WALL PLATES
  25. 25. <ul><li>CENTRAL DRIVE UNIT (CDU) </li></ul><ul><li>ELECTROMAGNETIC BRAKE </li></ul><ul><li>Check the wear/tear of brake shoes otherwise drum will be damaged and affect the braking effect so brake shoes should be regularly adjusted/replaced. </li></ul>02/27/11 HOIST MECHANISM
  26. 26. <ul><li>Brake drum of liner should always be free from grease, oil for proper braking of motor torque. </li></ul><ul><li>Check the solenoid coil (magnetic coil) for proper operation of plunger and barrel assembly otherwise burning of solenoid coil, loose wiring, deposition of dust or dirt will make the brake to produce noise of hamming. </li></ul><ul><li>Check all the bolts/nuts for proper setting and operation of brake. If, E. M. brake is not in working condition, the gate will not stop during operation and gate will fall on sill beam assembly, damaging the bottom skin plate of gate. </li></ul>02/27/11 HOIST MECHANISM
  27. 27. <ul><li>WORM REDUCER (REDUCER ASSEMBLY) </li></ul><ul><li>Check the worm reducer for its smooth drive otherwise torque will not be transmitted to line shaft. </li></ul><ul><li>Check periodically the oil level in worm reducer to avoid the wear of worm/worm wheel. </li></ul><ul><li>Check the flange coupling provided for transmission of power from reducer to line shaft for proper alignment otherwise vibrations will be observed. </li></ul><ul><li>Check all the bolts/nuts provided on coupling are properly tightened so that full torque will be transmitted from reducer to line shafts. and vibration will not be produced. </li></ul>02/27/11 HOIST MECHANISM
  28. 28. <ul><li>ELECTRICAL MOTERS </li></ul><ul><li>Check the proper voltage was received on control panel of CDU for operation of electrical motor. Otherwise if sufficient voltage is not received by motor it will be damaged and operation of gates will not be carried out. </li></ul><ul><li>Check the reading of Ammeter provided on control panel during the Up/Down movement of gate. If ammeter does not show correct reading, the gate operation should be checked. it may also indicate that gates parts may touch to pier surface or proper tightening of wire ropes are not carried out. </li></ul>02/27/11 HOIST MECHANISM
  29. 29. <ul><li>ELECTRICAL MOTERS </li></ul><ul><li>Check the sectional pillar for switch, meters, push button etc </li></ul><ul><li>If the separate switch &starter are provided, it should be replaced by control panel having MCB switch, contactors relay etc </li></ul><ul><li>Check the limit switches for its proper setting,, if it is not working properly, gates will not stop during operation. </li></ul>02/27/11 HOIST MECHANISM
  30. 30. <ul><li>Check manual operation arrangement i.e. sprockets gears, chain, pedstals, Hand operating lever, shaft and handle to be operated by persons. </li></ul><ul><li>Check whether greasing is carried out regularly for smooth operation of Hand operating Mechanism . </li></ul>02/27/11 MANUAL OPERATION ARRANGEMENT
  31. 31. <ul><li>Check the dial indicator and its assembly for proper functioning. </li></ul><ul><li>If it is not in working condition, check the assembly for setting /repairing /replacement of damaged parts. </li></ul>02/27/11 DIAL INDICATOR
  32. 32. <ul><li>Check Diesel engine and gear box with operating lever for proper working. </li></ul>02/27/11 DIESEL-HOISTING UNIT (DHU)
  33. 33. <ul><li>Check engine oil level before operation of gates and it should be regularly top up. check oil ,air & diesel filter for any choke up condition. All filters should be regularly replaced as per maintenance manual. </li></ul><ul><li>Check the Dog clutch for full engagement. </li></ul>02/27/11 DIESEL-HOISTING UNIT (DHU)
  34. 34. <ul><li>Check the cover of CDU for any corrosion, rusting, painting should be carried out . </li></ul>02/27/11 DIESEL-HOISTING UNIT (DHU)
  35. 35. <ul><li>Check position of gears and pinion of the E.R.U. and bring them to correct position if it is found misalignment the teeth will be broken and power will not be transmitted. </li></ul>02/27/11 END REDUCTION UNIT
  36. 36. <ul><li>Check condition of gear and pinion for wear & tear, if excessive wear occurs it should be repaired/replaced. </li></ul><ul><li>Check the breakage of any teeth found in ERU, it should be repaired/replaced and rectify it by welding and machining. </li></ul><ul><li>Check the pedestal for smooth operation of ERU, if it is in broken condition, it should be replaced. </li></ul>02/27/11 END REDUCTION UNIT (ERU)
  37. 37. <ul><li>Check the floating/line shaft & coupling used for connecting CDU & ERU otherwise during running of line shaft, vibration will be observed. </li></ul>02/27/11 FLOATING / LINE SHAFT
  38. 38. <ul><li>Line shaft should be painted regularly to avoid corrosion, rusting pitting etc. </li></ul><ul><li>All the bolts/nut should be properly tightened to avoid the opening of muff coupling, flange coupling, pedestal etc. </li></ul>02/27/11 FLOATING / LINE SHAFT
  39. 39. <ul><li>Pedestal should be regularly greased to avoid friction. </li></ul><ul><li>Check the alignment of line shaft, otherwise during running vibration will be observed. </li></ul>02/27/11 FLOATING / LINE SHAFT
  40. 40. <ul><li>Check the proper tightening of all wire ropes, otherwise gates will not run smoothly during up/down movements and strength of wire ropes will be affected. </li></ul>02/27/11 CONNECTING ASSEMBLY FOR GATE LEAF TO HOIST MECHANISM (WIRE ROPES)
  41. 41. <ul><li>Wire ropes should be regularly greased to avoid friction between rope drums and wire ropes. </li></ul><ul><li>Check the condition of wire ropes for wear & tear, otherwise it strengths is lost, outer wires becoming loose and displaced of ropes has been kinked, badly distorted or damaged. </li></ul><ul><li>Check the tension in wire ropes and adjust all wire ropes for equal tension, otherwise all the wire ropes will not share equal load and strength will be lost and wire ropes will be broken. </li></ul>02/27/11 CONNECTING ASSEMBLY FOR GATE LEAF TO HOIST MECHANISM (WIRE ROPES)
  42. 42. <ul><li>Check the eye bolt and fork of turn buckle for the free movement of pins inside them, other wise turn buckle will be jammed and there will not be smooth lifting/lowering of gates. All the pins should be regularly cleaned, lubricated and refitted for smooth functioning. </li></ul>02/27/11 CONNECTING ASSEMBLY FOR GATE LEAF TO HOIST MECHANISM (WIRE ROPES)
  43. 43. <ul><li>Check the wire ropes socket for proper fitting of ends of wire ropes every year. Zinc will be filled inside the rope socket for proper fitting of ends of wire ropes inside the rope socket. </li></ul>02/27/11 CONNECTING ASSEMBLY FOR GATE LEAF TO HOIST MECHANISM (WIRE ROPES) (contd.)
  44. 44. <ul><li>Check all the pins for corrosions rusting, jamming etc. and movement of pins, otherwise the turn buckle of rope socket will not works smoothly during operation of gates. </li></ul>02/27/11 CONNECTING ASSEMBLY FOR GATE LEAF TO HOIST MECHANISM (WIRE ROPES)
  45. 45. <ul><li>Check the Anchor bolts/nuts of base and bearing plates for proper tightness, otherwise the hoist platform will not be properly seated on base plate . </li></ul>02/27/11 HOIST PLATFORM
  46. 46. <ul><li>Check all the welding carried out in hoist platform assembly for any crack otherwise the member of hoist platform will be dismantled and strength of Hoist Platform will be lost. </li></ul><ul><li>Check the chequerred plate for any corrosion, rusting and pitting, otherwise the strength of chequrred plate will be reduced. </li></ul><ul><li>Check whether inspection windows are provided or not for inspection from top of hoist platform. </li></ul>02/27/11 HOIST PLATFORM
  47. 47. <ul><li>Foot bridge is provided for inspection of down stream gate parts.. </li></ul><ul><li>Check the nuts/bolts are properly tightened between the parts of foot bridges, otherwise foot bridge will be loosed. </li></ul>02/27/11 FOOT BRIDGE
  48. 48. <ul><li>Check all the welding carried out in foot bridge for any crack otherwise parts of foot bridge will be dismantled. </li></ul><ul><li>Check the chequerred plate for any corrosion rusting, pitting etc., otherwise the strength of chequerred plate will be lost. </li></ul>02/27/11 FOOT BRIDGE
  49. 49. <ul><li>In major dams, gantry crane is provided for lifting/lowering of stop logs in the groove provided on upstream side of gate leaf for repairing of the gates when water is on upstream side. </li></ul>02/27/11 GANTRY CRANE
  50. 50. <ul><li>Gantry crane should be checked for to and fro movement on railing provided on bridge for smooth operation . </li></ul><ul><li>Hooks provided on gantry crane should be lowered and lifted several times to check the easy movement of hooks as hooks are used for locking the lifting boom attached to stop logs. </li></ul><ul><li>Check all the electrical appliance provided in gantry crane for proper functioning, otherwise gantry crane will not work at the time of operation of gantry crane. </li></ul>02/27/11 GANTRY CRANE
  51. 51. <ul><li>Stop logs are provided on major dam for repairing of gates when water is on upstream side. </li></ul><ul><li>Check the rubber seal provided on stop logs for its condition, leakage, breakage etc. otherwise the water will leak from upstream side. </li></ul>02/27/11 STOP LOGS
  52. 52. <ul><li>Check the easy movement of main rollers and guide roller in the groove of stop logs for easy lowering/lifting of stop logs. Otherwise stop logs will not travel smoothly on track plates and guide channel provided in the groove and stop logs will be jammed. </li></ul><ul><li>Check the M. S. parts used for fabrication of stop logs for any corrosion, rusting, pitting etc. otherwise the strength of M. S. parts will be lost. </li></ul>02/27/11 STOP LOGS
  53. 53. <ul><li>Hence stop logs should be regularly painted, main rollers and guide rollers regularly serviced for smooth operation of rollers and check the stop logs movement inside the groove provided in piers of dams. </li></ul>02/27/11 STOP LOGS
  54. 54. <ul><li>Check the battery provided D. G. Room are completely in charged condition otherwise engine will not be started due to discharged battery. </li></ul>02/27/11 DIESEL GENERATOR ROOM
  55. 55. <ul><li>Check the engine oil pressure gauge, Ammeter, water temp. gauge speedometer provided on engine in working condition, otherwise engine condition could not be observed. </li></ul>02/27/11 DIESEL GENERATOR ROOM
  56. 56. <ul><li>Check the generator panel provided in D. G. Room for the voltage and frequency . If sufficient voltage / frequency is not generated by generator, the motor operation can not be carried out. </li></ul>02/27/11 DIESEL GENERATOR ROOM
  57. 57. <ul><li>Whether sufficient size of cables is provided between D. G. Room & Control Room, otherwise cable will be heated due to lower capacity of carrying current and insulation will be damaged. </li></ul><ul><li>Powers will not be available at control panel provided in control room. </li></ul><ul><li>To avoid this, one spare cable should be provided from D. G. Room to control room. </li></ul>02/27/11 CONNECTING LINK BETWEEN D. G. ROOM & CONTROL ROOM
  58. 58. <ul><li>Check incoming power from D. G. Room to Control panel provided in control room for properly voltage, if sufficient voltage will not be received, motor will not be started and gates will not be operated. </li></ul>02/27/11 CONTROL ROOM
  59. 59. <ul><li>Check all the switches provided for gate operation in working condition otherwise gate will not be operated. </li></ul><ul><li>Check to siren provided on top of control room for properly working otherwise during the release of floods from the dams necessary information can not be given on down stream side. </li></ul><ul><li>Check the electrical wiring carried out inside the control room for continuity otherwise power will not be available. </li></ul>02/27/11 CONTROL ROOM
  60. 60. <ul><li>Check the digital indicators are in working condition, if it is not in working condition, gate could not be operated /seen from the control room. </li></ul>02/27/11 CONTROL ROOM