1

SECTION - 1 GATES, STOPLOGS AND TRASHRACKS 1.1 GENERAL The equipment included in the scope of work shall be as per the general description given hereunder and as shown in appended drawings, suitable for operating functions as defined. 1.2 1.2.1 SPILLWAY GATES The spillway structure consists of eight bays each having a width of 14.25 metres. ates have been provided in all the bays. The gates shall normally be kept at fully closed position and shall be raised !i.e. opened" during flood season to maintain the #eservoir $evel on upstream side. The lowering%raising of gates shall be under unbalanced head conditions and therefore these shall be capable of gravity closing !i.e. due to weight of gate" under these conditions. The gate of spill way are radial type with hydraulic hoist arrangement including construction of head sluice with gates and hoist arrangement, stop logs, gantry crane with all accessories complete will be provided and constructed as per &.'.&. guidelines and approved specification. &ontractors have to design and will submit drawing, design to (ngineer)in)&harge for approval and fabrication%erection will be done as per approved drawing and design. 1.2.2 The gates operate within fabricated steel gate frames embedded in concrete. The gate frame consists of wheel tracks !base of structural steel and track of corrosion resisting steel"* side seal and bottom seal seats !base of structural steel and faces of corrosion resisting steel" and structural steel guides. 1.2.3 (ach gate is operated by independent electrically operated rope drum hoist consisting of central drive unit !electric motor", reduction unit, shafts, reduction

units, rope drums etc. +rovision in the hoist mechanism shall also be made to operate it manually in the event of power failure. The hoists shall be installed on a platform supported on steel columns above top of piers. ,pproach ladder from pier top to hoist platform shall also be provided. &ontrols for all the hoists shall be housed in a control room. 1.3 1.3.1 SPILLWAY GATE HOISTS -or each spillway gate, one electrically operated mechanical hoist is proposed. The capacity of the hoist to meet the operation requirements as outlined in para 1..2 shall be worked out by the supplier of the gate and hoist, which shall be 25/ more than all the forces opposing the raising of gate. The hoist capacity shall, however, be not less than 25 tonnes with the provision of counter weight. The hoist shall raise or lower the gate at a speed of 5. cms%minute. The hoist shall be designed to conform to 0ndian 1tandards 1pecification 0123456 and other relevant 012 specification or their approved equals. The hoist shall be installed on the operating platform%hoist bridge as shown in the appended drawings. The hoist shall be capable to perform the operation of crack opening of the gate under ma7imum unbalanced head conditions and shall also take care of down pull in this operation. 1.3.2 , clear walkway for the operating%maintenance personnel of 1.. m width shall be provided on either side of hoist bridge. ,ny item which is essential for the efficient performance of the equipment but not specifically mentioned in these 1pecifications shall be considered included in the scope of supply of the &ontractor. 1.3.3 8ormal operation of the hoist shall be by electric motors. 9anual operation shall be provided for operation of the hoist in the event of electric supply failure. 9anual operation system shall conform to &lause 3.: of 01 2 3456)1464. 1.3.4 The hoist and its components shall be simple in design and rugged in construction so as to give trouble free operation with minimum maintenance. These shall be suitable for out)door service. The driving unit shall comprise of

an electric motor, electro magnetic brake, reduction unit, limit switches, electric control elements, necessary shafts, bearings and fle7ible couplings. The driven unit shall comprise of two rope drums, reduction units, shafts, couplings and bearings. The electric motor, brakes, reduction units and rope drums shall be provided with removable weather proof metal covers. 1.4 1.4.1 SPILLWAY STOPLOGS +rovision to close any two bays out of the bays at a time by stoplogs has been made to facilitate repair and maintenance of the spillway gates. -or this purpose, stoplog grooves have been provided upstream of the spillway gates in all the bays. The stoplogs shall be lowered when water level in the reservoir is at 9;;$ 0nspection, maintenance and repairs of spillway gate shall be planned to be started and completed in lean flow period. Thus water level in the reservoir shall remain at -#$ or below it, as long as the stoplogs are in position and these shall be removed before water level in the reservoir rises above -#$. The stoplog shall be lowered%raised under balanced head conditions i.e. under no flow conditions. (ach stoplog unit shall be capable of self closing i.e. by gravity under its own weight. The stoplogs shall be handled by a mono)rail hoist of suitable capacity. (ach set of stoplog shall consist of not more than three units of almost equal height. (mbedded metals for stoplogs shall be provided in all the bays. ;ogging%latching devices shall be provided in the stoplog grooves to enable storage of stoplog units. , lifting beam has also been provided to handle the stoplog units. The lifting beam shall be designed to automatically grapple and ungrapple the stoplog units under water. 1.4.2 (ach stoplog unit is vertical lift, slide type of fabricated steel construction and shall be formed by two vertical end girders between which hori<ontal girders are spaced according to design loads and the d%s face is covered with a skin plate. The top of each unit is provided with two lifting lugs. (ach unit shall be provided with seals on downstream side. =n vertical sides, seals shall be of rubber music note type and bottom seal of rubber wedge type. >ori<ontal bottom seal of rubber wedge type shall also be provided between intermediate units. The seals shall be fastened to the stoplogs using galvani<ed steel bolts and

nuts. (ach unit shall be provided with two guide shoes on each side. =ne unit of each set shall be provided with two filling valves each of not less than 15. mm diameter operated manually for filling the space between spillway gate and stoplog to create balanced head conditions before lifting operation of stoplog units. The stoplog unit shall be handled by a monorail using a lifting beam capable of grappling and ungrappling of stoplog units under water. The lifting beam shall be attached to the monorail hoist at two points. ,lignment pins shall be provided between consecutive units of stoplogs for their proper alignment during placement. 1.4.3 -abricated steel frames shall be provided in each bay to receive the stoplog units. The frames shall consist of side and bottom seal seats, tracks i.e. load carrying faces to bear the thrust pads fi7ed on the stoplog units and guides on both sides. -aces of seal seats and tracks shall be of corrosion resisting steel.

1.5 1.5.1

MONORAIL HOIST FOR SPILLWAY STOPLOGS (lectrically operated monorail hoist is proposed which shall raise%lower stoplog. The hoist shall traverse all the bays of the gates. $owering%raising and traverse speed shall be as specified in para 1.4.4. The hoist capacity shall be worked out by the supplier which shall be adequate to meet the operational requirements outlined in para 1.4 and shall be 25/ more than all the forces opposing the raising of gate. The hoist capacity shall, however, not be less than 2. tonnes.

1.5.2

The hoist shall be designed%manufactured to conform to 0ndian 1tandards 1pecifications 0125456 or their approved equivalents. The hoist shall be installed on the mono)rails supported on >oist ?ridge structure as shown in the appended drawings.

1.5.3

>oist will consist of two electric motors @one for hoisting and the other for traversing mechanism", two independent electro)magnetic%thruster brakes, gear reduction units for both the motors !working independently", rope)drum, ropes, pendant switch, limit switches, main hoisting controls, +A& insulated cable for

power supply and its mounting structure, other accessories etc. (lectric interlocking shall also be provided to ensure that either hoisting%lowering operation or traverse motion is operative at a time. 1.5.4 ,ny item which is essential for the efficient performance of the equipment but not specifically mentioned in these specifications shall be considered included in the scope of supply of &ontractor. 1.5.5 The equipment shall be simple in design and rugged in construction so as to give long trouble free operation with minimum of maintenance. 0t shall be suitable for outdoor service. The hoist shall be manufactured by a reputed manufacturer of such equipment and approved by ?ureau of 0ndian 1tandards and shall have 010 mark. 1.6 TECHNICAL REQUIREMENTS The >ydromechanical equipment included in the scope of work shall conform to the following basic requirements and specifications2 1.6.1 !a" S !""#$% G$&'( Aarious components of the gate and embedded parts shall be designed in accordance with the provisions of 0124322. The hori<ontal girders and wheels shall be so spaced that they carry equal load !appro7imately". !b" !i" $oads to be considered for design2 The gate shall be designed for the hydrostatic head corresponding to 9'$ in the reservoir. !ii" The gate design shall be checked for the combination of above design head and earthquake effect in accordance with 1521645)1464 B0ndian 1tandard &riteria for (arthquake #esistant ;esign of 1tructuresB. ,llowable stresses in this case shall be increased by 55.5/ subCect to an upper limit of 65/ of

yield point !D.+.". The gate design shall also be checked for hydrostatic head corresponding to 9'$ plus 2.. m head for vacuum resulting from operation under unbalanced head conditions with allowable stresses increased by 55.5/ subCect to an upper limit of 65/ of D.+. 1.6.2 S !""#$% G$&' H)!(&( Aarious components of hoist such as wire rope, drums, sheaves%pulleys, gears and pinions, worm gear reducer, shafts, keys, bearings and coupling etc. and their design shall meet the requirements of 01 2 3456. The worm gear reducer shall be a standard superior quality product of established%reputed manufacturer of such equipments. The openings in the housing of the reducer etc. shall be provided, with dust proof seals%packing. ,ll gears%pinions shall be enclosed in fabricated steel cases having air tight covers with windows at the top for inspection. The openings in the gear cases for shafts shall be provided with dust proof seals. The wire rope shall be ungalvani<ed of suitable construction having adequate diameter and shall conform to 0122233. ?olts, nuts and screws used shall conform to relevant 0ndian 1tandards. ?olts and screws in rotating parts shall be locked. ?olts in tension shall be avoided as far as possible. 'herever necessary net section of such bolts at the root shall be increased by 15/. -le7ible coupling between the motor, worm, gear reducer shall permit both angular and off)set misalignment between the coupled shafts. These shall be of the si<e rated for the shafts to which these are connected and shall have torque rating suitable for the loads transmitted. These shall be of flanged type fully enclosed and dust proof and shall conform to relevant clause of 012 3456.

*.6.3 (a)

S !""#$% S&) ")+( $,- S".!/' S&) ")+( Aarious components of stoplogs and embedded parts shall be designed in accordance with the provisions of 012532..

(b)

The stoplogs shall be designed for the hydrostatic head corresponding to -#$ plus ..5 m head for wave effect as these will be in position when water level in reservoir is at or below -#$ and will be removed before water level in reservoir rises above -#$.

(c)

The design of stoplogs shall Bbe checked for the combination of above hydrostatic head and earthquake effect in accordance with 012 1645. ,llowable stresses in this case shall be increased by 55.5/ subCect to an upper limit of 65/ of D.+.

(d)

The ;ogging%$aching devices shall be designed for weight of stoplog section and impact load as applicable.

1.6.4

M),)-0$!" H)!(&( Aarious components of these equipment shall be designed in accordance with provisions of 0125456, 0123456 and 0126.:. &apacities of these shall be 1 25 percent of all the forces opposing the hoisting with loads intended to be handled. These equipment shall be of class 2 classification as per 0126.:.

1.6.5

The lifting beams for stoplogs and trashracks shall be designed in accordance with provisions of 15215541.

1.6.6

1).+2&-).& I&'3( ,ll bought out items shall be of the best available make and shall be the product of manufacturers of repute, bearing standardi<ation marks.

1.6.4

PERMISSI1LE STRESSES

1.6.4.1 S !""#$% G$&'( The gate shall normally remain in contact with water and is of regulating type. The permissible stresses shall be taken those corresponding to wet in)accessible conditions as per ,ppendi7 ? of 1524322)1442 and are given as under2 M$&'0!$" $,- &% ' )5 (&0'(( A. !i" !ii" !iii" !iv" !v" 1. !i" !ii" S&0./&.0$" S&''" ;irect &ompression%tension &ompression%tension in bending 1hear &ombined ?earing C),/0'&' M-25 ?earing 1hear 5... kg%1q.cm 4.. kg%sq.cm ..4 D.+. ..4 D.+. ..5 D +. ..5 D.+. ..45 D.+. P'03!((!6"' S&0'((

1.6.4.2 S&) ")+( ,s the stoplogs are stored above water level and are only occasionally used, permissible stresses have been taken those corresponding to ;ry)accessible conditions as given in ,ppendi7 ? of 012 532.)1465 and are given as under 2) M$&'0!$" $,- T% ' )5 S&0'(( A. S&0./&.0$" (&''" !i" !ii" !iii" !iv" !v" 1. C. ;irect compression%tension &ompression%tension in bending 1hear &ombined ?earing ..55 D.+. ..55 D.+. ..4 D.+. ..:5 D.+. ..4 E.T.1. ...4 E.T.1. P'03!((!6"' S&0'((

1'$0!,+ S&0'(( !, 10),7' ), S&''" C),/0'&' M-25 !i" ?earing !ii" 1hear

5... Fg%sq.cm. 4.. Fg%sq.cm.

1.6.4.3 !i" !ii" !iii" 1.4

T0$(20$/8( -or trashbars =ther sections of trashracks !&ompression%Tension", &oncrete 9)25 type DESIGN CODES The gates, stoplogs and hoisting equipments shall be designed in accordance with the following standards e7cept as otherwise detailed. The latest editions at the time of design shall be used in each case. (quivalent standards of biddersG county may be followed. 0n this event copies of the relevant standards shall be submitted along with design calculations 2 -ailure point stress ..4 D.+.

10

LIST OF CODES OF 1UREAU OF INDIAN STANDARDS AND DESCRIPTION IS 9 4622 0ndian 1tandard ) -i7ed wheel gates 1tructural ;esign

#ecommendations. IS 9 562: #ecommendations for 1tructural ;esign &riteria for $ow >ead 1lide ates. IS 9 ;:: &ode of +ractice for use of 1tructural 1teel in &onstruction. IS 9 456 IS 9 ;45 IS 9 ;45 IS 9 1;*3 &ode of +ractice for +lain and #.&.&. &ode of +ractice for 1tructural 1afety of ?uildings H $oading 1tandards &riteria for (arthquakes #esistant ;esign of 1tructures. &ode of +ractice for ;esign, 9anufacture, (rection and Testing !1tructural +ortion" of &ranes and >oists. IS 9 2:62 IS 9 ;5:: IS 9 ;13 IS 9 ;14 IS 9 ;16 1tructural 1teel fushion welding quality. 1tructural 1teel !>igh Tensile" fusion welding Iuality. 1cheme of symbols for welding. &overed electrodes for metal arc welding of 9ild 1teel &ode of +ractice for use of metal are welding for general construction in 9ild steel. IS 9 ;22 &ode of +rocedure for 0nspection of 'elds. eneral ?uilding

11

IS 9 ;23 IS 9 154:

&ode of +rocedure for manual metal welding of 9ild 1teel. 1chedules for 'rought 1teel for &orrosion resistant steel". eneral (ngineering +urposes !w.r.t.

IS 9 113;; IS 9 6*3; IS93*3; IS9135*1

#ecommendations for design of Trashracks for 0ntakes. ;esign of #ope ;rum and chain >oists for >ydraulic +ractice. ;esign of 9onorail >oist !0ndustrial (lectric wire rope hoists". &riteria for ;esign of $ifting ?eams. ates )&ode of

1.;

MATERIALS ,ll materials incorporated in the equipment shall be new, unused and of first class qualify, free from defects and in accordance with relevant 0ndian 1tandard !$atest revisions" or equivalent standards in the country of manufacture. 9aterials and +roprietary items shall be selected taking into consideration customary use for type and class of equipment having regard to strength, the durability and best engineering practice. ,s a general guidance materials used for various items of gates and hoists are given as under2

12

1.;.1 S !""#$% G$&'(

1.8o

&omponent +art

9aterial 1tructural 1teel

9aterial 1pecs 012 2.32 01265..

!i". 1tructural +arts of gate i.e. skin plate, stiffeners, hori<ontal girders, vertical girders, seal bases, seal clamps, guide shoes etc. !ii" 'heel track bases, seal seat bases, sill beam base, auides, anchor !iii" 'heels !iv" 'heel ,7le%pin !v" 'heel ?earing !vi" 1eals !a" 1ide

1tructural 1teel -orged 1teel &ast 1teel &orrosion #esistant 1teel 1pherical roller ?earing #ubber)music note type 44 mm dia !>ollow"

0122.32 012 65.. 012 16:5 0121.5. 01215:. 1F- 9ake or equivalent 01211655

!b" ?ottom !vii" 'heel tracks and 1eal 1eats

#ubber wedge type &orrosion resistant steel

01211655 01215:.

13

1.;.2 S&) ")+(

1.8o.

&omponent +art

9aterial

9aterial 1pecs !$atest"

!i" 1tructural +arts of stoplogs i.e. skin +late, hori<ontal griders, end vertical girders, vertical stiffeners, seal bases, seal clamps, guide shoes etc. !ii" Track bases, seal bases, sill beam base, guides, anchor bolts etc !iii" Tracks, seal seats !iv" 1eals !a" 1ide

1tructural 1teel

0122.32 01265..

1tructural 1teel &orrosion #esistant 1teel #ubber music note type 44 mm dia !>ollow"

012 2.32 012 15:. 012 11655

!b" ?ottom !v" Thrust pad

#ubber 'edge Type 1tructural 1teel &ladded 'ith ?ron<e !9in. 1. mm" Thick"

012 11655 012 2.32 012 5.5

,ll corners shall be premoulded and have a suitable radius on the inside edge. ,ll Coints both shop and field shall meet the following requirements 2 ) ) ,ll shop Coints shall be vulcaansied. -ield Coints shall be kept to a minimum and shall be carefully machine cut and butte during assembly. The Coints shall be held with double fasteners or each side of the Coint. ) ) Aulcanised Coints shall not break or tear when bent 16.. The longitudinal strength in tension of vulacnised Coints shall be not less than :1.4 kg%cm2 as tested in accordance with ,1T9 ;412.

14

'hen Teflon cladded or fluorocarbon faced seals are used a 1.5 mm thick cladding, snail be bonded to the rubber on sealing surface of the bulb. The coating%cladding shall have following physical properties. 1.* Tensile strength (longation FRICTIONAL RESISTANCES The following friction coefficients shall be used in calculation of various loads acting on the gates2 M$&'0!$" C)'55!/!',& )5 F0!/&!), S&$&!/ #ubber seal on steel -luoro carbon%Teflon cladded seals on steel ?ron<e or stainless steel on steel ..5. . 5. 1.5. ..2. M)<!,+ 1.2. ..15 145 kg%cm2 min. 25./ min.

1.1:

SPILLWAY GATE HOIST CONTROLS

1.1:.1 The controls of the hoist shall be so arranged that the cycle for either closing or opening shall be completed and the hoist shall stop automatically at the fully closed or fully open position by the limit witches. =ver travel limit switches shall also be provided in both directions of travel which shall trip the motor control circuit when the normal limit switches fail to operate. 0t shall also be possible to stop the hoist in any intermediate position during any cycle and restart or reserve as desired during normal operation.

15

1.1:.2 There shall be arrangement for local operation of gate. The local control shall be from the control cabinet installed in control room near the pump house. The local panel shall have three push buttons marked GopenG, GcloseG and GstopG. G=penG push button will initiate the raising of the gate. The GcloseG push button will start closing cycle of the gate. ?y pressing GstopG push button the gate can be stopped in any intermediate position during either opening cycle or closing cycle. 0ndicating lamps shall be mounted on the &ontrol panel for the operator to know the position of ate. ?lue and green indicating lamps will show that the gate is being lowered and raised respectively and these lamps will be switched off automatically with the stoppage of gate movements. The red lamp, will indicate that the gate is in open position. The &ontrol shall also fulfill the following requirements2 , solenoid brake shall be provided to hold the hoisting mechanism in any position. 0t will come into action automatically as soon as it is de)energised on cutting or failure of the ,.&. supply to the motor. The e7treme position of the gate shall be restricted by limit switches when the gate reaches the e7treme positions, blue%green lamp is switched off and the solenoid brake applied automatically. 1.1:.3 The design of the hoisting mechanism shall be based on a gate opening%lowering time corresponding to speeds given in para 1..2.5. The gate shall fall under its own weight so as to effect closer of the bay, the only operation involved shall be to release the brakes. 0t shall be possible to accomplish this operation in any one of the following two ways2 ?y pressing the push button on the local panel to G&loseG position, ?y hand lever provided on the brake in case of failure of power.

16

The control and hoist drive equipment of (lectrically =perated 9echanical >oist shall consist of an electric motor with reversible contactors, main contactor, electro)magnetic brake, disconnection switch, push buttons, limit switches and other appurtenances etc. ?rief descriptions of the maCor components is given in the succeeding paras. The control cabinet shall be of the frame mounting type having sufficient si<e so as to neatly and methodically accommodate all the electric, power and control equipment, (quipment such as indicating lamps, push buttons etc. shall be installed flush mounted on the door of the control cabinet so as to give a clear view of all the indicating lights and that the gate can be operated with the cabinet door closed. The remaining equipments shall be installed inside the cabinet, being accessible when the door is opened. The cabinet shall have access only at front. &ontrol cabinet shall be suitable for outdoor use in tropical climate and be provided with suitable type of protection against ingress or moisture. , heating element shall also be provided for anti condensation. 0t shall conform to 012 214: B;egree of +rotection provided by enclosures for low voltage switch gear and control gearB. 1.11 CONTROLS FOR MONO-RAIL HOISTS >oist controls shall consist of two electric motors !one for hoisting and the other for traversing mechanism", two independent electro)magnetic%thruster brakes, gear reduction units for both the motors !working independently", rope) drum, ropes, G pendant switch, limit switches, main hoisting controls, +A& insulated cable for, power supply and its mounting structure, other accessories etc. (lectric interlocking shall also be provided to ensure that either hoisting%lowering operation or traverse motion is operative at a time. ,ny item which is essential for the efficient performance of the equipment but not specifically mentioned in these specifications shall be considered included in the scope of supply of &ontractor. ,mber indicating lamp shall be provided in the pendant itself to indicate the electric supply being GonG.

17

1.12

ELECTRICAL EQUIPMENT The electric motors furnished shall be suitable for operation on 41 5 volts, 5 phase, 5. cycles ,.&. supply. The motors shall be squirrel cage, reversing type with high starting torque characteristics and shall conform to 0ndian 1tandard 012525. The motors shall be totally enclosed fan cooled and suitable for outdoor use in tropical climate and highly humid atmosphere. The rated sped of the motor shall not be more than 1... r.p.m. The electric motors shall be designed having starting current kept as low as practicable consistent with good design. The motor shall be suitable for frequent start, stop operation. The winding insulation shall be class Gf and the entire coil, system shall be completely void free and impregnated with an impervious epo7y resin forming a completely solid integrated insulation structure. The entire insulation system shall be moisture free type, mechanically stable, abrasion resistant and sufficiently resilient to withstand effects of thermo cycling without developing defects throughout the life of the electric motor. The ma7imum temperature rise of the winding when the electric motor is delivering rated output continuously at rated voltage and frequency shall not e7ceed 4.J& !1.4J-" above ambient temperature at proCect site. The temperature rise of other parts of the motor shall be in accordance with the 0ndian 1tandards. The electric motors shall be equipped with either ball or roller type self lubricating bearings which shall be properly sealed against loss of lubricant or entrance of dust. To prevent condensation, the electric motors shall be equipped with 24. volt single phase anti)condensation heater mounted in or on the frame. The leads of the electric motor and the heater shall be brought out in a terminal bo7 on the motor having suitable cable entry lugs. .

18

-or isolating the electric motors from the supply system manually operated triple pole disconnecting switch of suitable capacity shall be installed in the cabinet. The disconnecting switch shall conform to 01223.: B,ir break isolator for voltage not e7ceeding 1... voltsG and shall be suitable for operation on 41 5 volts. -or the electric motors, following contactors of suitable capacity shall be provided. Two phase B#aiseB contactors Two phase B$owerB contactors Three phase B9ainB contactors The contactors, shall be direct on the line starting air break type and suitable for operating on 415 volts, 5 phase,5. cycles ,.&. supply. The contactors shall conform to 012 1 622. B,& motor 1tarters of voltage not e7ceeding 1... voltsB and 0122454 B,.&. 9otor contactors of voltage not e7ceeding 1... voltsB. >.#.&. fuses of suitable capacity shall be provided in the main power circuit and control and heater circuit for protection against short circuits. $imit switches, provided for normal stopping of the gate at e7treme position of travel, shall reset automatically on reversing the direction. =ver travel limit switches shall be provided to take care if normal limit switches fail to operate or the raise%lower contactor fails to open. These limit switches shall also be capable of being reset by reversing the direction of travel or pressing the G#esetG push button. The limit switch shall be of totally enclosed type. The cables shall be +A& insulated, +A& sheathed conforming to 012344 B+.A.&. insulated cables for voltage upto 1... AB. &onsideration shall also be given to such factors as ambient temp, grouping and disposition of cables and to the limitation of voltage drop while selecting the cables. The cables from the power and control cabinet to the various equipment shall also be supplied by the contractor. +ower cables shall not be less than 4 sq. mm nominal copper area.

19

The conduits and conduit fittings shall be heavy gauge galvani<ed steel conforming to 0121355 K#igid at 1teel &onduits for (lectrical 'iringL, and 012233: K-itting for rigid steel conduits for electrical wiringL. -le7ible conduit may also be used wherever required. 1.13 SHOP ASSEM1LY AND TESTING ,ll equipment, fabrication and structures covered by the specification shall be fully assembled in 9anufactureMs shop for inspection by (ngineer. ,ll necessary adCustments shall be made in the shop to achieve the specified tolerances. &hecks on dimensions and tolerances shall be recorded by 9anufacturer and three !5" copies furnished to (ngineer within a week of shipment of the material. 'ithout limiting the foregoing, the following shop assemblies shall be carried out. +rior to dismantling. each assembly shall be permanently and clearly match marked in the shop to facilitates sit action. ;ismantling shall be minimum disconnection of electrical wiring. (ngineer will inspect all equipment during fabrication and before shipment and witness the shop tests after final assembly. *.13.1 G$&' F0$3'( The metal work shall be shop assembled to ensure that all parts are properly fitted and that the dimensional and tolerance requirements shown on the drawings have been obtained. ,ll holes for field connections of parts furnished under these specifications shall be drilled or reamed as noted on the drawings, with the embedments so assembled, 9embers to be shop)riveted shall have all parts well pinned up and drawn together with bolts before riveting is commenced.

20

1.13.2 G$&'( (ach gate and stop log shall be completely assembled in the shop for inspection and that dimensional and tolerance requirements shown on the drawings have been obtained. ,ll holes for field connections of parts furnished under these specifications shall be drilled or reamed as noted on the drawings, with the embedment so assembled. 9embers to be shop)riveted shall have all have all parts well pinned up and drawn together with bolts before riveting is commenced. 1.13.2.1 G$&'( (ach gate and stoplog shall be completely assembled in the shop for inspection and to ensure the all parts fit properly and that dimensions, clearance and tolerances required in the specifications and drawings have been achieved. The gates shall be assembled in a vertical position and holes for field connections carefully drilled or reamed. &onnections which have to be disassembled for shipment shall be made by the use of erections pins, one si<e less in diameter than the designed si<e or temporary shall be checked during shop assembly. 1.13.3 H)!(&( ,ll electrical and mechanical components shall be tested in accordance with the appropriate 0ndian 1tandards at either the 9akerGs or equipment manufacturers works and tests certificate provided. The hoist shall be completely assembled in the shop to ensure that all parts are properly fitted. 1urfaces of metal which will be in contact shall be cleaned before the parts are assembled. The parts shall be adCusted to line and fit and shall be well pinned and bolted so that the surfaces are in close contact before reaming, drilling, rivetting or welding is commenced. ;rifting done during assembly shall be only that is necessary to bring the parts into position and not so much as to enlarge the holes or distort the member, if any, hole must be enlarged to admit fastening, it shall be reamed. The field connections shall be fitted and checked in the shop to assure proper fit during field erection. machine bolts. +roper functioning% operations of filling in valve and lifting beam, automatic engaging% disengaging

21

,fter shop assembly the hoist shall be tested at manufacturerGs works under full load and 25 percent overload on hoisting. The hoist shall be operated under all load to check its operation. The manufacturer shall supply all material equipment and labour required for shop assembly and tests, and cost thereof shall be included in the bid price. ,ll shop tests shall be made in the presence of the (ngineer or his representative. The hoist shall be prepared for shipment in as large units as practicable. =ne print of a diagram of matchmarks shall be enclosed with the shipment and four prints shall be forwarded to the (ngineer. 1.14 SITE TESTING AND COMMISSIONING

1.14.1 P"$/' )5 M$,.5$/&.0' $,- I,( '/&!), The tenderer shall state in his tender the place of manufacturer, testing and inspection of the various portions of the work included in the ?id schedule. ,uthorised representative of the +urchaser may be present at the time of any or all tests and the 9anufacturer shall provide all necessary facilities for the same. #epresentatives of the +urchaser shall also be entitled to access to 9anufacturerGs sub)contractors work at any time during the working hours for the purpose of inspecting the manufacture of equipment and materials. To satisfy himself that the materials and equipment comply with the conditions of contract, the (ngineer)in)&harge of the +urchaser reserves to himself the right of having at his e7pense, any inspection or tests of a reasonable nature carried out in addition to the routine tests specified in the appropriate 0ndian 1tandards. 0f corresponding 0ndian 1tandards is not there, ?ritish 1tandard%,1T9 may be referred. 1.14.2 I,( '/&!), ,ll materials furnished shall be of tested quality and all work performed shall

22

be subCect to rigid inspection and no articles or materials or supplies shall be dispatched until all tests, analysis and shop inspection have been completed or certified copies of reports or results of tests and analysis shall have been accepted. ;uplicate copies of manufacturers test certificate shall be submitted to the (ngineer in &harge of the +urchaser as soon as the tests are completed. 0n case tests certificate are not available for any of the materials, the same may be got tested and only those materials which fulfill the requirements of the specifications shall be used. -rom any part%item, it should be possible to locate its manufacturer ?atch%$ot mark, which shall be achieved by transferring the batch mark before parting the materials. ,ll supplies !which include without limitation raw materials, components, intermediate assemblies and assemblies and end products" shall be subCect to inspection and test by the +urchaser to the e7tent practicable at all times and places. 0f any inspection or test is made by the +urchaser in the premises of the 9anufacturer or sub)contractor, the 9anufacturer without additional charge shall provide all reasonable facilities and assistance and the safety and convenience of inspectors in the performance of their duties. 0f on the request of the +urchaser, inspection or test is made at a point other than the premises of the 9anufacturer or sub)contractor of the 9anufacturer, it shall be at the e7pense of the +urchaser e7cept as otherwise provided in the contract, provided that in case of reCection, the +urchaser shall not be liable for such e7penses. 1.14.3 O '0$&!),$" T'(&( The 9anufacturer shall carry out in the presence of +urchaser such tests on the gate equipment to determine that the gate will fulfill the functions for which they have been designed. The tests shall be carried out in accordance with provisions of 012::16. Tests shall be repeated, if necessary, until successfully carried out to the satisfaction of the +urchaser. $eakage tests and operational tests shall be carried out at the convenience of the +urchaser after completion of other portions of the work and when the reservoir is at full reservoir level.

23

+urchaser shall have the right to carry out such tests also when reservoir is at a level other than full reservoir level. -or hoists the following tests shall be carried at site after erection. =1> I,(."$&!), &'(&(9 ,fter erection but before the hoist is connected to the supply, the insulation of the electrical equipment shall be tested by a suitable instrument and any defects revealed shall be rectified. The voltage required for the insulation resistance test shall be d.c. voltage not less than twice the rated voltage. ,ny reading less than ..5 mega ohm obtained with an insulation resistance tester of the un)regulated type shall be disregarded and the wiring under test shall be sub)divided until a reading higher than ..5 mega ohm is obtained. -ailure to obtain a higher reading shows an unsatisfactory state of insulation. 0f an installation has ben sub)divided for test purpose, each sub)division shall meet the requirements. The insulation resistance of each wiring circuit e7clusive of connected apparatus shall be not less than 2 mega ohms. 0f necessary, it shall be permissible to disconnect individual items of equipment while making this test. =2> T'(& 5)0 ) '0$&!),9 ,fter the supply has been* connected and before the complete hoist installation is put to commercial service, tests shall be carried out to prove the following2 The satisfactory operation of each control switch, contactor, relay and other control devices and in particular the correct operation of all limit switches under the most unfavourable conditions. The correctness of all circuits and interlocks and sequences of operation. 1atisfactory operation of all protective devices. The satisfactory operation of each motion of the hoist.

24

The compliance of the hoist with the specified performance requirements. Tolerances on specified speed on full load shall be within N 1./. =3> D'5"'/&!), &'(&( The deflection test shall be carried out with the safe working load at rest. The measurement shall not be taken on the first application of the load. =4> O<'0")$- &'(&( ,fter the above tests but before the hoist is put into service, it shall, with overload relays appropriately set, be tested to lift and sustain a minimum test load of 125 percent of the working load. 1.14.4 D0% T'(& =perational tests on gates in dry condition shall be carried out as soon as possible after completion of erection of gates, hoists and all controls and permanent power supply have been connected. The tests shall include atleast two complete traverses from the ma7imum raised position to the full sealing position. ,ll adCustments, clearances, brakes etc. shall be checked for proper and smooth operation. 1.14.5 W'& T'(& These test should simulate the actual operating conditions as closely as possible. ,tleast two complete traverses will be made from the fully closed position to the fully raised position as follows2 'hen gate is closed, raise gate to its fully open position in steps and observe the performance including vibration. $ower the gate to the full closed position in steps and observe the performance of the gate including vibration. &heck up proper operation of limit switches.

25

1.14.6 L'$8$+' T'(&( ,fter filling of reservoir upto -#$, leakage tests shall be carried out with the gate resting on to the sill. ?efore measuring the leakage the gate shall be raised and lowered several times by about 2. to 4. cms or so in order to dislodge any debris that may have lodged in the side seal seat. The leakage shall then be measured and recorded. The ma7imum leakage past the seals shall not be more than 15 litres per min. per metre length of seal under ma7imum head conditions. 1.14.4 F!,$" A//' &$,/' -inal acceptance of the equipment shall be based on the following2 a. Iuality and workmanship of the equipment including dimensional accuracy. b. 1atisfactory operation of the equipment after erection as required under these specifications. . c. ,cceptance of various tests or test certificates by the +urchaser. ,ll tests may be witnessed by the 9anufacturer or his authorised representative. =n successful completion of all tests the equipment shall be accepted but all the responsibilities shall remain with the 9anufacturer within the guarantee period. The labour and material for the field tests shall be provided by the +urchaser. The test load and necessary lifting tackles shall also be provided by the +urchaser. 1.14.; G.$0$,&'' 'ithin one year after operation of the equipment has begun, if any part of the gates, embedded parts, hoists etc. are found defective because of workmanship or material or otherwise, the 9anufacturer shall, at his own e7pense furnish and install new parts Gand materials approved by the +urchaser.

26

1.15

WELDING PROCEDURE

1.15.1 The edges of plates and shapes to be Coined by welding shall be properly formed to suit the type of welding selected. 'here plates and shapes have been sheared, edges to be Coined by welding shall be machined or chipped to sound metal. +lates and shapes to be field welded shall have their edges prepared in the shop for the type of weld selected. 'here bending or forming of plates or shapes is required, the plates or shapes shall be bent by cold forming. >eating and hammering to correct bends will not be permitted. 1.15.2 W'"-!,+ 9embers to be Coined by welding shall be cut accurately to si<e and where required, shall be rolled or pressed to proper curvature in accordance with the approved drawings. The dimensions and shape of edges to be Coined shall be such as to allow thorough fusion and complete penetration and plates shall be planned, if necessary, to accomplish this result. 9embers to be welded together shall be in sufficiently intimate contact at the time of welding so that members will not be forced more closely together with the cooling of the weld, thus setting up additional strains and distortions in the weld and parent metal. The surfaces of plates to be welded shall be free from rust, grease and scale for a distance of 12 mm back from the welding edge at the time of welding -lame cutting may be used in the preparation of the various members provided the operation is performed carefully, and the edges so cut are cleaned thoroughly after being cut so as to e7pose clean metal. ,ny contour irregularities at points of critical stress shall be removed by grinding. W'"-!,+ T'/2,!?.' 9 &are shall be taken in designs that the welds when being made, are well accessible. =verhead welding is to be avoided, if possible and flat position welding is to be strived for. ;rawings should clearly indicate the Coint position, shop or field welding, kind of welding, method of welding si<es

27

and other required information%data. 1ymbols to be shown on the drawing would conform to relevant 0ndian 1tandards. ,ll welding shall be done by the electric arc method by a process which will e7clude the atmosphere from the molten metal, e7cept where otherwise specifically permitted. ,ll welding electrodes required shall be furnished by the contractor. &orrect selection of electrodes shall be done taking due care of welding method and base metals of components to be welded. The welding electrodes shall be of heavily coated type designed for all position welding The make, type and si<e of all welding electrodes shall be subCected to the approval of the purchaser. 0n assembling and during welding the component parts of built up members shall be held in place by sufficient clamps or other adequate means to keep all parts in proper alignment and position. #adiographic tests shall be carried out for all critical full strength butt welds. 1.&& @)!,&( 9 0n principle, butt Coints shall be made with back)run. ?acking strap should be laced and welding should be so made that the molten metal fully penetrates and a full penetration is achieved. ;ye)penetration test shall be carried out after each pass of the weld. #adiographic testing of butt welds shall be carried out to the e7tent required by the +urchaser as specified in ,rticle 1..22. F!""'& A)!,&( 9 ,ll fillet welds shall be continuous. -or the main member, no fillet welding should be made on members whose thickness differs substantially. -illet weld at T.Ooints should be made, as a rule, on each side of the Coint unless it is otherwise agreed due to some practical reasons. #adiographic test is not normally required for fillet welds. ,ll the fillet welds shall be checked by ;ye +enetrant Test by the 9anufacturer in the shop. >owever 2./ to 5./ of fillet welds shall be checked by dye)penetrant test in presence of +urchaser to check soundness of weld.

,t 'elded butt Coints, where the weld material is required to be deposited on Bboth sides of the Coints, the weld shall be chipped or melted to obtain a clean

28

surface prior the application of the first head of the welding on the opposite side of the Coint. 'here fillet welds are used, the lapsed sections shall fit closely and shall be held together during the welding operation. 'hen weld metal is deposited in two or more layers, each layer shall be brushed with a wire brush or otherwise cleaned before subsequent layer is deposited. 0n welding, precautions shall be taken to minimi<e stresses due to e7pansion or contraction either by peening the welds while hot, or by other satisfactory methods and also by using the proper sequence in welding. &orrection of distortion by blows after welding is completed and the place is cold, will not be permitted. Epon completion, the welds shall be brushed with wire brushes and shall show uniform section, smoothness of weld metal, feather edges without e7cessive overlaps and freedom from porosity and clinkers. Aisual inspection at edges and ends of fillets and butt Coints welds shall indicate good fusion and penetration into base metals. W'"-!,+ P0)/'(( 9 , specification of the welding process, that is proposed to be used, shall be established and recorded and if required, a copy of such specification together with a certified copy of report for results of tests made in accordance with the process and specifications shall be furnished. The qualification of the welding process shall be at least equal to that required by G1tandard Iualification +rocedureG of the 0ndian 1tandards and the minimum requirement of the tests shall be atleast as stated in the said G1tandard Iualification +rocedureB2 Q.$"!5!/$&!), )5 W'"-'0( 9 The 9anufacturer shall be responsible for the quality of the work performed by his welding staff. ,ll welders assigned to the work shall have passed qualification tests for welders. 0f at any time the work of any welder appears questionable, welder shall be required to pass additional qualification tests to determine his ability to perform the type of work on which he is engaged.

29

1.16

NON-DESTRUCTIBE TESTSCINSPECTION 0n addition to and notwithstanding any requirements covered in previous clauses. 9anufacturer shall perform adequate inspection and quality control and conform to the inspection procedures outlined below. ,ll material entering into the work shall be subCect to inspection by (ngineer and all purchase orders for materials and supplies shall carry a notation to this effect. &opies of all purchase orders and subcontracts shall be submitted to (ngineer at the time of placing the order. 'aiving)off 0nspection by (ngineer shall not relieve the 9anufacturer from the responsibility of supplying material and workmanship acceptable to (ngineer. 9anufacturer shall be responsible for proving quality of material and workmanship, either by records of inspection or by immediate inspection. 9anufacturer shall perform any non)destructive testing and inspection required by (ngineer on any material or workmanship in which defects are suspect. 'itness tests and inspection of material will be made at the place of manufacture by * (ngineer. (ngineer shall at all times have access to all places of manufacturer where equipment or materials are being made or prepared for use under this &ontract and shall have full facilities, including office space and communication facilities, for unrestricted inspection of such materials and equipment. 'hereas such witnessing and inspection will be conducted so as to interfere as little as possible with the operation of manufacture, 9anufacturer shall conform to the requests made by (ngineer, concerning the method of test or correction of defective workmanship. Enless otherwise specified, any reCection based on witness tests or general inspection will be reported to the 9anufacturer within 1. days. 9aterial which shows inCurious defects subsequent to its acceptance at the 9anufacturerGs works will be reCected and the 9anufacturer shall be notified. Test pieces which represent reCected material shall be preserved for a period of time to be mutually agreed upon between (ngineer and 9anufacturer and 9anufacturer may make claim for a rehearing.

30

9agnetic particle inspection shall be conducted in accordance with relevant codes. #adiography on welds for pressure containing parts, including the standard of acceptability, shall be performed according to relevant ?oiler and +ressure Aessel &ode. #adiographic testing of welds on structural steel, including the standards of acceptability, shall be performed in accordance with relevant &odes. ,ll radiographic e7amination of shop and field welds shall be done by the 9anufacturer. ,ll field labour and access to equipment required for field radiographic e7amination shall be)provided by the 9anufacturer. Eltrasonic e7amination of welds shall also be carried out. ,ll unacceptable defects in welds shall be chipped out to sound metal and such areas shall be checked by magnetic)particle inspection, radiographic or ultrasonic testing by the 9anufacturer, as directed by the (ngineer, to ensure that the defect has been completely removed before re)welding. >undred !1.." percent of the butt welds and T. Ooints in load carrying members shall be radio graphically tested. ,ll testing of weldments shall be performed by 9anufacturer at his e7pense. #adiograph and magnetic particle inspection of weldments shall be performed by 9anufacturer on all high stress carrying members. 9anufacturer shall show the e7tent and location of weldment inspection on his drawings submitted to (ngineer for review. 9anufacturer shall arrange his fabrication program to permit inspection to be carried out in the following manner.

31

T% ' )5 W'"?utt welds 9anual and semi)automatic fillet welds -ully automatic -illet welds

T% ' )5 I,( '/&!), #adiographic 9agnetic particle 9agnetic particle

ED&',& )5 !,( '/&!), 1.. percent 1. percent 5.. mm at start and stop, 1./ throughout the remainder.

!9inimum #equirements for 8on)destructive Testing" 'here welds are subCect to radiographic e7amination, the technique to be used and the standards of acceptability of the welds shall be in accordance with relevant &odes. ,ll defects in welds beyond the limits shall be removed t+ sound metal and such areas shall be magnetic particle inspected to determine that the defect has been completely removed before repair welding will be permitted. #epair welding shall be performed using a qualified procedure and in a manner acceptable to (ngineer. #ewelded Coints, and weld)repaired areas shall be radiographically e7amined. ,ll records of radiography to be maintained by the &ontractor. 1.14 SURFACE PREPARATION AND PAINTING

1.14.1 G','0$" The 9anufacturer shall provide as part of his supply the surface treatment, priming, corrosion protection and painting of the equipment furnished. 1uch work shall include the cleaning by sand blasting, coating and painting work at the workshop and at the site upto and including the finish painting. Enless otherwise specified the coating and painting shall be carried out in accordance with the latest 0ndian 1tandards or equivalent approved standards. ,ll paints, painting material and accessories for painting shall be included in the price bid. ,ll finished and unfinished surfaces of metal work !other than of aluminium brass, bron<e or stainless steel") e7cept screw threads, mating surfaces, sliding surfaces, rolling surfaces shall be cleaned and protective coatings applied as specified herein after.

32

,ll paints and painting material shall satisfactorily fulfill the requirements imposed by the site conditions, as well as the stresses to which the respective equipment is subCected during operation of the works. 1hades of the finishing coatings shall be as approved by the (ngineer)in)charge. The paints and shades of the finished coatings proposed by the 9anufacturer must be got approved by the +urchaser before application of the same. The analysis in respect of paint properties, paint composition and performance requirements of the paints shall be submitted by the 9anufacturer for check and approval. ,ll painting material shall conform to relevant 0ndian 1tandards. (ach coat of primer and paint shall be compatible with the previous and subsequent coats. ,ll pigmented primers and paints which will be used for priming and painting at the site shall be delivered in original and sealed containers packed by the manufacturer. The 9anufacturer shall supply full details regarding the e7tent to which sandblasting, priming and painting will be carried out in his workshops !or his subcontractors, as the case may be" at the site and after erection. , properly equipped paint shop shall be set up at the site using a specialist organisation, e7perienced and skilled in the preparation and application of protective coatings at the conditions prevailing at the site. 1.14.2 S.05$/' P0' $0$&!), ,fter the equipment has been fabricated, it is essential that before any primer and coat of paint is applied, the surface is properly prepared. 1uch 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. &lean cloths and clean fluids shall be used to avoid greasy film or greasy residue on the surfaces being cleaned. The procedure for surface preparation shall be as follows2 'eld spatters or any other surface irregularities shall be removed by any suitable means before cleaning.

33

,ll oil grease and dirt shall be removed from the surface by the use of clean mineral spirits, 7ylol or white gasoline !lad free" and clean wiping materials. -ollowing the solvent cleaning, the surfaces, to be painted shall be cleaned of all rust, mill scale, and other lightly adhering obCectionable substances by sand blasting or grit blasting to uniform bright base metal. ,verage surface roughness for sand blasted area shall not e7ceed 4. microns. ,ny grit or dust remaining after the cleaning operation shall be completely removed from the surface by wire brushing* air blowing, suction or other effective means before the surface is painted. 1urfaces of stainless steel, nickel, bron<e and machined surface adCacent to metal work being cleaned or painted shall be protected by masking tape or by other suitable means during the cleaning and painting operations. +rimers shall be applied as soon as the surface preparation is complete and prior to the development of surface rusting. 0n case there is considerable time gap, the surface shall be recleaned prior to priming. 1.14.3 S2) P$!,&!,+ 1tainless steel and bron<e surfaces shall only be cleaned but not painted. ,ll surfaces of the embedded parts which are to come in contact with concrete shall be cleaned as mentioned above and given two coats of cement late7 to prevent rusting during shipment and while awaiting installation. Two coats of <inc rich primer with epo7y resin shall be applied to all unfinished surfaces of the embedded parts and gates which shall remain e7posed to atmosphere or submerged in water to obtain a dry film thickness of 3. microns, which shall be followed by three coats at an interval of 24 hours of coal tar blend epo7y resin paint, so as to get a dry film thickness of 6. microns in each coat. Total dry film thickness of paint shall be 5.. microns.

34

,ll finished surfaces of ferrous metal including bolts, sere w threads, etc., that will e7pose during shipment or while awaiting installation shall be cleaned and given a heavy uniform coating of gasoline soluble rust preventive compound or equivalent. ,ll e7posed surfaces for hoists, supporting structures, shall be given two coats of red lead primer at the coverage rate of 14 sq.m%litre to obtain dry film thickness of 55 microns which shall be followed by two coats of aluminium paint at the coverage rate of 3 sq.m%litre to obtain dry film thickness of 15. microns !i.e. :5 microns for each coat". Total thickness of film shall be 225 microns. >oist machineries may be given machinery finish paint. ,ll other surfaces to be painted shall be primed with one coat of an approved synthetic vanish vehicle, rust preventive and lead paint. The surface which will be GBaccessible after assembly shall be given an additional coat !total two coats" of the same paint. 1.14.4 M'$(.0'( D.0!,+ P$!,&!,+ ,ny bare spots or holidays shall be recoated with additional application of primer. ,ll runs, sags, floods, or dips shall be removed by scrapping and cleaning, the cleaned area shall be retouched or all such defects shall be remedied by reblasting or repriming. 1pecial attention shall be given to obtaining good coverage on rivets, welds and sharp edges and corners. 1uitable measures shall be taken to protect applied primer from contact with ram, fog, mist, dust or other foreign matter until completely hardened and ne7t coat applied. The air temperature at the time of application must not be below 1. ;eg. & and relative humidity must not be above 3./. )

35

1.14.5 F!'"- P$!,&!,+ The painted metal work shall be handled with care so as to preserve the coats. The area of the shop paint which has been damaged during transport be cleaned to bass metal and repainted. +aint applied to such areas shall be same type as used originally in shop painting. ,ll unfinished surfaces of embed parts and gates that are e7posed to atmosphere or submerged in water shall given a finishing paint of aluminum)(po7y paint to as to obtain shining surface +leasing colour. This finishing coat should be able to reflect light and limit the he absorption when e7posed to sun.

36

1.1;

ERECTION TOLERANCES

1.1;.1 S !""#$% G$&'( C)3 ),',&( =A> E36'--'- P$0&( 1. 1.1 1.2 1.5 2. 2.1 2.2 3. T0$/8 P"$&'( ,lignment in plane parallel to flow ;istance between centre line of opening and track &oplanerness G.!-'( ,lignment in plane parallel to flow ;istance between centre line of opening and face of guide S!-' S'$" S'$&( N 2..mm N1.5 mm N1..mm N 1.. mm N 1.. m m N1.. mm N1.5 mm N1.. mm T)"'0$,/'(

,lignment in plane parallel to flor ;istance between centre line of opening and side seal seat &oplanerness 4. C0!&!/$" D!3',(!),( &entre to centre distance between track plates &entre to centre distance between side seal seats -ace to face distance between guides -ace of track to face of side seal seat -ace of track to centre line of guide =1> G$&'

N5..mm N5.. mm N2..mm N... mm N2.5 mm

37

1. 1.1 2.

W2''"( ,lignment of treads in <ero eccentricity position S!-' S'$" 1$(' N1.. mm N1.. mm N1.5 mm

2.1 ,lignment 2.2 &oplanerness 3. C0!&!/$" D!3',(!),(

&entre to centre distance between seal bases &entre to centre distance between centerline of wheel treads -ace to face distance between faces of guide shoes or guide rollers -ace to face distance between wheel tread to side seal base ;istance between faces of wheel tread and centre line of guide shoe%roller 1.1;.2 S&) ")+( !," (mbedded parts 1. 1ide 1eal 1eat ,lignment in plane parallel to flow ;istance between centreline of opening and seal seat &oplanerness 2. 5 3 S!-' G.!-' T0$/8

N2.. mm N2.. mm N 5.. mm P 2.. mm )... mm N2.5mm

N ..5 mm N 1.5 mm N1.5 mm

2.1 ,lignment in plane normal to flow ;istance between centreline of opening and guide track ,lignment in plane parallel to flow

N 1.5. mm N 1... mm N 1... mm

1)&&)3 S'$" S'$&

38

5.1 ,lignment in hori<ontal plane C0!&!/$" D!3',(!),( &entre to centre distance between side seal seat -ace to face distance between side guide tracks &entre to centre distance between tracks !1> S&) ")+ C)3 ),',& 1. S!-' $,- T) S'$" S'$& 1.1 ,lignment parallel to flow 1.2 &oplanerness 2. S!-' G.!-' 2.1 ,lignment parallel to flow 3.G$&' L'$5 1)&&)3 E-+' 5.1,lignment in hori<ontal plane 1. C0!&!/$" D!3',(!),( &entre to centre distance between side seal plates -ace to face distance between side guides &entre to centre distance between tracks

N ..25 mm

N 5... mm N 2... mm N 5... mm

N ..5 mm N ..5 mm

N 1.5 mm

N..25 mm

N 1.5 mm N 1.5 mm N 1.. mm