inspection of mechanical gates


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  • i want to know more on inspection of gates underwater by remotely operated (ROV)
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  • 'Inspection of Gates' in plates 1-35,does not serve the purpose of a format for Pre- and post-monsoon inspection of Dam Gates. It is too vague.A sample check-list giving specific component to be inspected,what to check what %,what action was taken or required to be taken etc.It would not be feasible or necessary to carry out all checks listed in the note.Highlighting those essentials , Rand em-sampling in other cases,Defects noticed and their extent and urgency for planning rectification have to be brought out.
    Item14 mentions of Diesel Hoisting Unit. If this is meant as a stand-by for electric motor of CDU, I feel it does not serve the purpose.
    A more detailed proforma check list with specific component ,what to look for, ,a column to' tick' if found ok, action taken/to be taken etc is desirable My E-book ,Guidelines for operating and maintenance of Spillway Gates on Dams' available free at on internet could help in evolving such a checklist for each project.I am accessible on e-mail M.V.S.MURTHY
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  • very concise
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inspection of mechanical gates

  2. 2. <ul><ul><li>Crest gates ( Radial or Vertical) are provided in the dams for release of flood water to restrict the submerged area due to back water effect during high flood . </li></ul></ul><ul><ul><li>Proper Operation and Maintenance of these gates is necessary for their smooth functioning, improved performance and increased life. </li></ul></ul><ul><ul><li>Therefore periodical inspection and trial testing, atleast twice a year (pre-monsoon & post-monsoon), of these gates is necessary. </li></ul></ul><ul><ul><li>Looking to different pattern of storm / flood in different region of the Gujarat state, the size of Radial gates are standardized as </li></ul></ul><ul><li> (a) 30’ x 20’ </li></ul><ul><li>(b) 41’ x 27’ </li></ul><ul><li>(c) 49’ x 35’ </li></ul><ul><li>(d) 51’ x 46’ </li></ul>INTRODUCTION
  3. 3. <ul><li>Inspection of Radial Gates. </li></ul><ul><li>Anchor Girder </li></ul><ul><ul><li>Check all the nuts, studs, bolts of anchor rod assembly for their proper tightness / torque. </li></ul></ul><ul><ul><li>Check all welding for cracking and rectify if necessary. </li></ul></ul><ul><ul><li>Check whether drain holes in anchor girder are clean so that water does not accumulate in the slots. </li></ul></ul>
  4. 4. <ul><li>Trunnion Bracket & Anchorages </li></ul><ul><ul><li>Check all the nuts and bolts of Anchor girder to trunnion bracket for proper functioning </li></ul></ul><ul><ul><li>Check the bolts of Trunnion pin lock plates for proper tightness. </li></ul></ul><ul><ul><li>Check whether trunnion pin ends are covered with anti- corrosive jelly for smooth movement. </li></ul></ul><ul><ul><li>Check whether flexible sheath cover is provided to prevent entry of debris in the trunnion assembly. </li></ul></ul>
  5. 5. <ul><li>End Arms </li></ul><ul><ul><li>Check welding joints throughout the length with magnifying glass for cracks. </li></ul></ul><ul><ul><li>Check whether drain holes drilled in the end arm are clear so that water does not accumulate to prevent rusting. </li></ul></ul><ul><ul><li>Check the straightness of arm, If found bent, take immediate action for repair. </li></ul></ul><ul><ul><li>Check all the nuts and bolts for proper tightness and all welds for soundness. </li></ul></ul>
  6. 6. <ul><li>Horizontal Girder </li></ul><ul><ul><li>Check all the welding joints of horizontal girder assembly for proper soundness. </li></ul></ul><ul><ul><li>Check whether the drain holes of horizontal girder are clear to prevent accumulation of water and rusting. </li></ul></ul><ul><ul><li>Check for any deformation of girders particularly at ends. Take immediate action for repair if any deformity found. </li></ul></ul>
  7. 7. <ul><li>Gate Leaf </li></ul><ul><li>Skin plate : </li></ul><ul><li>- Check all the welding joints of skin plate assembly with magnifying glass for cracks and other defects and rectify immediately, if found. </li></ul><ul><li>- The skin plate should be observed for pitting, scaling and corrosion on upstream. </li></ul><ul><li>- Check for the deformation of bottom corners of gate leaf and if found, take immediate action for repair. </li></ul>
  8. 8. <ul><li>Gate leaf (contd.) </li></ul><ul><li>Seal Assembly: </li></ul><ul><li>- Check the condition/deformation of side and bottom rubber seal and corner joint for proper tightness to prevent water leakage through rubber seal. </li></ul><ul><li>- Check all nuts and bolts fixing the rubber seal to skin plate for wear and tear / tightness . </li></ul>
  9. 9. <ul><li>Gate Leaf (contd.) </li></ul><ul><li>Guide Roller: (contd.) </li></ul><ul><li>- Check the rollers for their free movement on the wall plate. </li></ul><ul><li>- Check all the nuts and bolts of guide roller for their tightness. </li></ul>
  10. 10. <ul><li>Embedded parts : Sill Beam and wall plates. </li></ul><ul><li>- Check all the welding joints of sill beam and wall plates assembly for proper soundness. </li></ul><ul><li>- Check wall plate and sill beam assembly for pitting and rusting. </li></ul><ul><li>- Check for leakage between stage concrete of wall plate and sill beam and grout it if any leakage. </li></ul>
  11. 11. <ul><li>Hoist Mechanism </li></ul><ul><li>Central Drive Unit (C.D.U.) : </li></ul><ul><li>Check the condition of electro-magnetic brake </li></ul><ul><li> - Replace worn out liner </li></ul><ul><li> - Adjust brake shoes carefully. </li></ul><ul><li> - Brake drum and liner should be free from grease / oil. </li></ul><ul><li> - Check the solenoid/magnetic coil for its proper functioning. </li></ul><ul><li>Check worm Reducer for smooth operation and oil level. </li></ul><ul><li>Check all electrical connections of hoist motor, brake, starter and limit switches for proper insulation and tightness. </li></ul>
  12. 12. <ul><li>Hoist Mechanism (contd.) </li></ul><ul><li>Central Drive Unit (C.D.U.) (contd.) </li></ul><ul><li>Check manual operation arrangements and adjust gears / chain etc. if required. </li></ul><ul><li>Check condition of gate position /dial indicator and all its accessories for their proper functioning. </li></ul>
  13. 14. <ul><li>Hoist Mechanism (contd.) </li></ul><ul><li>Diesel Hoisting Unit ( DHU) : </li></ul><ul><li>- Check Diesel Engine and gear box with operating lever for proper working. </li></ul><ul><li>- Check the alignment of DHU with hoist motor unit to prevent vibrations. </li></ul><ul><li>- Check the cover of CDU for rusting and paint it if found rusted </li></ul>
  14. 16. <ul><li>Hoist Mechanism (contd.) </li></ul><ul><li>End Reduction Unit (ERU): </li></ul><ul><li>- Check position of gear and pinion and bring them to correct position if found shifted to either side. </li></ul><ul><li>- Check condition of gears and pinions for uneven wear and contact and adjust properly. </li></ul><ul><li>- Check for breakage of any teeth and rectify it by welding and machining. </li></ul>
  15. 17. <ul><li>Hoist Mechanism (contd.) </li></ul><ul><li>End Reduction Unit (ERU): (contd.) </li></ul><ul><li>- Check for Jamming of bearings and rectify/replace, if not working properly. </li></ul><ul><li>- Check the floating / line shaft and coupling used for connecting C.D.U. and E.R.U. All the nuts & bolts of coupling, alignment of line shaft and its rusting shall also be checked. </li></ul>
  16. 19. <ul><li>Connecting Assembly for Gate Leaf to </li></ul><ul><li>Hoist Mechanism. </li></ul><ul><li>Wire Rope : </li></ul><ul><li>- Check the condition of wire rope for wear and tear and replace it if strength is lost, outer wires becoming loose and displaced, if rope has been kinked, badly distorted or badly damaged. </li></ul><ul><li>- Check the tension in wire ropes. Adjust all wire ropes for equal tension. </li></ul><ul><ul><li>- Check if end of wire rope is properly fastened to drum and properly fixed in the rope socket. </li></ul></ul>
  17. 20. Connecting Assembly for Gate Leaf to Hoist Mechanism. (contd.) <ul><li> Wire Rope : (contd.) </li></ul><ul><li>- Check equaliser plate assembly and sockets for their proper functioning. </li></ul><ul><li>- Check the conditions of pins. Every pin should be removed for cleaning and lubrication and refitted. </li></ul><ul><li>- Check the rusting, Jamming of lifting bracket pin in the turn buckles. </li></ul>
  18. 21. <ul><li>Hoist Platform </li></ul><ul><li>Check Anchor bolts of base plates, bearing plates for their tightness. </li></ul><ul><li>Check the welding joints of hoist bridge girders, cross members etc. for their soundness. </li></ul><ul><li>Check the chequered plate of platform for rusting and pitting. </li></ul>
  19. 22. <ul><li>Foot Bridge </li></ul><ul><li>Check the condition of nuts and bolts for tightness and all weld joints for soundness. </li></ul><ul><li>Check the condition of chequered plate of foot bridge for rusting and pitting. </li></ul><ul><li>Alluminum oxide painting shall be done timely. </li></ul>
  20. 23. <ul><li>Gantry Crane </li></ul><ul><li>Check the operation of gantry crane by moving it to & fro and also by lowering and lifting stoplog unit. </li></ul><ul><li>Stoplog </li></ul><ul><li>Check the condition of rubber seal. </li></ul><ul><li>Check the movement of main rollers and guide rollers. </li></ul><ul><li>Check the skin plate for corrosion, rusting & pitting . </li></ul>
  21. 24. <ul><li>Communication System </li></ul><ul><li>Check the communication system from control room to each gate of spillway for its proper functioning. </li></ul>
  22. 25. <ul><li>Passenger Lift </li></ul><ul><li>Check the operation of passenger lift for its smooth working. </li></ul><ul><li>Check for timely renewal of its license. </li></ul><ul><li>Check for timely renewal of Annual Maintenance Contract. </li></ul>
  23. 26. <ul><li>Diesel Generator (D.G.) Room. </li></ul><ul><li>Check the Battery for its charged condition. </li></ul><ul><li>Check the sufficiency of diesel in the tank of D.G. set. </li></ul><ul><li>Check the control panel of generator & change over switch for their proper working. </li></ul><ul><li>Instruction chart for operation of Diesel generator set to be provided in Gujarati. </li></ul>
  24. 27. <ul><li>Control Room </li></ul><ul><li>Remote control panel should be in working condition. </li></ul><ul><li>Digital indicator system should show correct position of gate opening / closing. </li></ul><ul><li>Instruction chart for operation of gate to be provided in Gujarati. </li></ul><ul><li>Check the Siren for its working condition. </li></ul>
  25. 28. Electrical Equipment <ul><li>Check the availability of GEB power supply </li></ul><ul><li>Check Ammeter,Voltmeter,KWHmeter,3 phase indicating lamps in working condition </li></ul><ul><li>Cable wiring on railing of hoist platform should be provided in Galvanized tray. </li></ul><ul><li>Stand by cable should be provided between D.G.Room to controlroom </li></ul><ul><li>All MCB Switch should be in workingcondition </li></ul><ul><li>All meters,selector switch,indicating lamps on panel of CDU should be in working condition </li></ul>
  26. 31. Lighting Arrangement <ul><li>Check all the lighting arrangement for their sufficiency and proper working </li></ul><ul><li>Check the flood lights provided on upstream and downstream of spillway </li></ul>
  27. 32. PAINTS . Name of Gate part to be painted. Paint recommended Frequency 1.Gate leaf upstream side. Shalimar anti-corrosive black H.D. Two coats once in a year or as required. 2. Gate leaf downstream side and all other parts except hoist covers and tie bars. Shalimar anti-corrosive black L.C. Single coat once in a year or once in two years depending upon the condition. 3. Hoist covers (of M.S.) Primary coat-Red oxide, Final Coat-Blue enamel or dowel deep orange. Once in a year. 4. Railing pipes Red oxide-primary coat Aluminum oxide-final coat. Once in a year