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IS 10096-2 (1983): Recommendations for inspection, testing

and maintenance or radial gates and rope drum hoists, Part
2: Inspection, testing and assembly at the time of erection
[WRD 12: Hydraulic Gates and Valves]

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IS : 10096 ( ParI 2 ) - 1983

(Reaffirmed 2005)

Indian Standard
RECOMMENDATIONS FOR
INSPECTION, TESTING AND MAINTENANCE
OF RADIAL GATES AND THEIR HOISTS
PART 2

INSPECTION, TESTING AND ASSEMBLY

AT THE TIME OF ERECTION
FIrst Repnnt OCTOBER 2007
( Including Amendment No I )

UDC 626 422 23 620 I

Copyright 1984

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

Gr3

March 1984

IS I 10096 ( Part 2 ) 1983

Indian Standard
RECOMMENDATIONS FOR
INSPECTION, TESTING AND MAINTENANCE
OF RADIAL GATES AND THEIR HOISTS
PART 2 INSPECTION. TESTING AND ASSEMBLY
AT THE TIME OF ERECTION

Hydraulic Gates and Valves Sectional Committee, BDC 56

RLpHsen/mg

Cha"man

SHIll Y.

Tungabhadra Steel Product. Limited, Tunaabhadra Dam ( Kamataka )

AOINARAYAMA SASTIU

Membe"
SURI G S ANNIGIlRI ( Alternate to
Sh" Y. AdiDarayana Sastn )
CHIEFENOINIlBR ( TDD )
Irrigation Works, Government of Punjab,
Chandtgarh
DIRECTOR ( M{E) (Allernale )
Suar R. C CHOPRA
TEXMACO Ltd, Calcutta
SURI R. BHATTACHARYA ( Alternate )
Sual H C DBINORA
Haryana Stale Mmor Irriganon (Tubewellt)
Corporauon Ltd, Chandigarh
SHRI R C CHAUHAN ( Alternate)
DIRECTOR
Central Water & Power Research Station, PUDO
SHRI A. V GOP....LA KR.ISHNA RAO
( Alternate)
DIRECTOR( GATES DESIGN I )
Central Water Commission, New Deihl
SHRI C. L VERMA ( Alternate )
Nanga! Workshops, Nanga! Township
SKRI R. N GUPTA
SURI N S CHAWLA ( Altemate v
SHRI K. K JULKA
Beas Project, Bhakra Beas Management Beard,
Nangal Township
SHRI V. P KAUSUAL ( Attemase )

Tarml Nadu Public

Works
Corporation Ltd. Madras

MANAOINO DIRECIOa

Engmeermg

WORKS MANAGeR ( A/fernare )

SMal K V S. MURTHY

Trrveru Structwals Ltd, Nairn

SURI M. K. V. SAlUdA (Alternale )

( Continued o. page 2 )

@ Copynghl 1984
BIJRE-\U OF II'.OIA'" "T.-\NOARD~
This publication i. protected under the Indian CopYlI,hl Acl (XIV 01 1957) and
reproduction in whole or m part by any means except WIth written permissson of the
publisher shall be deemed to be an mlnngement of copynght under the SBId Act.

IS I 101196 ( Part 2 ) 1911:J

(Conlittued/rom page 1 )
Members

Representing
Irrtgenon Department, Government
Pradesh, Lucknow
Bharat Heavy Electncals Lid, Bhopal

SKR[ NARI!N'DRA S,NOH

SIQU Ilu

KUMAR

of UHar

SHJU N. Y N .uAo.sJMHAN ( AlfernQIt! )

SHRJ S K SADUU
SHRl S. NAG (

Jessop & Co Ltd, Calcutta

Allernale)

SUPElUNTENDINO ENGINlER (

PH )

(COO)
SHRl R

SWAaUP

Irrrgauon & Power Department, Government of

Maharashtra, N asik
Central India Machmery Manufacturing Co Ltd.
Bharatpur

SUR' K C BAKETY ( Allerna'e )

SHRJ M C TewARI
Himachal Pradesh State Electricity Board, Simla
SItIU N VISVANA1HAN
Nauooal Hydroelectric Power Corporauou, New
DelhI

Director General, lSI (Ex-officla Member)

SUR' O. RAMAN,
Director ( Civ EogS )

Secretary
SHkI HEMANT KUMAR

Assistant Director ( CIV Engg ). lSI

Panel for Inspection, Testing and Maintenance of Radial Gates.

BDC 56; P8
CO"J1~ner

S.....

Irrigation Works,
Cnandigarh

SHARMA

Government of

Punjab,

Members
SUR] G S

ANNJGERI

DIRECTOR ( GATES DESIGN I )

Sm. R N GUPTA
SUR' N

S CHAWLA (

SURI Y R KALRA

Tungabhadra Steel Products Ltd, Tungabhadra

Dam ( Karnataka )
Central Water Commtvsron, New Deihl
Nanga! Workshops, Nanga! Township

Allernare)
BSL Project. Bhakta Beas Management Board,
Sundernagar ( HP )

SHRI R. N AGGARWAL ( Alurnote )

SBRI A K MUKHERJEE
SUPERINTENDING ENGJNEER
(GAT" ) ( COO)
SHRI R. SWARUP
SHRI M C. TEWAJU

Jessop & Co I td Calcutta

Jrrrg.ruon and Power Department, Government
of Maharashcre. Nasrk
Central India Machmery Manufacturing Co Ltd,
Bh .ratpur
Himachal
Pradesh Stale Electrrcny Board.
Government of Himachal Pradesh, Srmla

AMENDMENT NO. 1 NOVEMBER 1992

TO
IS 10096 (Part 2) : 1983 RECOMMENDATIONS FOR
INSPECfION, TESTING AND MAINTENANCE OF
RADIAL GATES AND THEIR HOISTS
PART 2 INSPECTION, TESTING AND ASSEMBLV AT THE
TIME OF ERECTION
[ Cover page, page 1 and page 3 ( 1111 and clause 1.1 )
'Rope Drum' for 'Their',

1-

Substitute

(RVD12)
Pnnted at Simco Pnntmg Press, Deihl

AMENDMENT NO. 2 JANUARY 2011

TO
IS 10096 (PART 2) : 1983 RECOMMENDATIONS FOR INSPECTION, TESTING
AND MAINTENANCE OF RADIAL GATES AND ROPE DRUM HOISTS
PART 2 INSPECTION, TESTING AND ASSEMBLY AT THE
TIME OF ERECTION
(Page 7, clause 2.7.7, line 1) Substitute correct for corrcet.

(WRD 12)
Reprography Unit, BIS, New Delhi, India

IS: lOO96( Part:1) - 1983

Indian Standard
RECOMMEND-\TIONS FOR
INSPECTION, TESTING AND MAINTENANCE
OF RALJIAL GATES AND THEIR HOISTS
PART 2

INSPECTION, TESTING AND ASSEMBLY

ATTHE TIME OF ERECTION

O. FOR EWOR D
0.1 This Indian Standard ( Part J ) was adopted by the Indian Standards
Inst.tutton on 28 November 1983. after the draft finalized by the Hydraulic
Gates and Valves Sectional Committee had been approved by the 0,,1
Engineering DIvision Council.
0.2 Almost every river valley project has

reservoir or diversion work for

the control of floods or to store water for Irrigation and power generation
or for both. and a spillway with spillway gates for release of flood waters
dunng monsoons. Controlled releases of water are also affected by controlled gate, provided in conduits m the body of the dam and tunnels. One
method of providing such control in spillways and conduits IS by radial
gates.
0.3 This standard is being published in three parts. Part I deals With inspection, testing and assembly at the manufacturing stage. Part 2 deals
WIth inspection. testing and assembly at the time of erection and Part 3
deals with mspecuon, testmg and mamtenance after erection.
0.4 For the purpose of deciding whether a particular requirement of this
standard is complied With, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance
WIth IS : 2-1960'. The number of sigruficant places retained In the rounded
off value should be the same as that of the specified value m this standard.

1. SCOPE
1.1 This standard ( Part 2) lays down the recommendations for mspection,
tesung and assembly of radial gates and their hoists at the time of erecuon.
*Rqles for rOQn(fjng off numerical values ( revised).

IS I 10096 ( Part 2) . 1983

2. INSPECTION

1.1 In order to detect damage and defects, If anv, inspection during

erection work shall be carried out at thc followmg stages
a)
b)
c)
d)
e)
f)
g)

General mspecuon;
Inspection of block outs,
Inspection of pier anchorages,
Inspection of SIll beam;
Inspection of wall plates;
Inspection of gate; and
Inspection of complete gate
electrical items.

mstallation,

horsts including

2.2 General Inspection

2.2.1 It shall be ascertained that the gate parts received at erection site
bave been manufactured according to the design and have necessary
markmgs of shop inspecnon wherever prescribed. It Shall be ensured that
all exposed surfaces of embedded par" have been protected by paintmg,
greasing, etc, as specified, The surlaces of embedded parts in contact with
concrete shall be free from grease, pamt, etc, for better bonding with
concrete. A coatmg of cement wash/cement latex may be apphed, If
necessary.

2.2.2 Dimensional differences, If any, shall be accounted for before

erection and the drawings corrected accordingly. For erecnon the cnncal
dimensions shall be worked out from the drawings.
2.2.3 The reference/centre lmes of piers and bays. and levels having
relation, to completed CIVIl structure shall be established at site so as to
facihtate erection at proper locations
2.2.4 It shall be ensured that the vanous components of the hoisting
arrangement, such as motors, reducnon gear assembly, switches, wire
ropes, etc, are provided according to manufacturer's mstructions and
erected according to hoist supplier's approved drawings.
2.2.5 The permissible tolerances for embedded parts and components of
gate sball be m accordance with Appendix F of IS : 4623-1979',
Re~mrne[]<,Iatlons for

structural design of radial sales (first revlslo,,).

IS 10096 ( Part 2 ) 1983

2.3 Inspection of Block Outs
2.3.1 It should be ensured that correct block outs are kept for accommodating the embedded parts as manufactured according to the design. It
shall also be ensured that the required dowel bars having adequate lengths
are left out In the block outs The entire block out is roughened properly
for further concreting to give necessary bondage to the second stage
concreting.
2.4 Inspection of Pier Anchorages
2.4.1 The inspection of pier anchorages shall be carried out at the
following stages

a) Trunnion bracket and support girder.

b) Load carrying anchors or tres and embedded girder ( if insulated
anchors or ties are used I,

c) Anchor girder or yoke girder, and

d) Thrust block/trunnion ue.
2.4.2 The flier

anchC'lr~~"e"

shalt he <.:heCKE'd wtt.h respect to the centre line

of the pier and the trunnion ,IX" ( Imc parallel to Ihe Cit st ax.s and passmg
through the centre lme of trunnion pins) Control vur vcy marks shall be
given on each pier to check the location 'alignment of pier anchorages.
These shall include the line, parallel to the end at light angle to the
dam/barrage ax" and a bench mark for leI el
2.4.3 Centre to centre distance of adjacent piers shall be checked by a
steel tape It will be preferable to put a steel girder across the span for
taping the distance over the span

[II

case taping

IS

done across. the span

in air, the steel tape shall be given a predetermined pull.

2.4.4 The trunnion bracket/supports shall be placed on top of a stool
and kept in position With the help of strut, and their positron shall be
checked with re-pect to centre hne of pier and trunnion axis A dummy
trunnion assembly may be tiled to cheek the drsrunce be/ween centre Ime
of trunnion and SIll beam centre The slope of the trunnion assembly shall
be checked with the help of an inclination gauge
2.4.5 The two trunnion assemblies for each gate shall be checked with
respect to each other.
2.4.6 The yoke girder/anchor girder shall be checked for its alignment
and slope in both directions For this checking holes may be picked up
from dummy trunnion bearing

IS: 10096 ( Part 2 ) - 1983

2.4.7 Before erection the ue bars/rods shall be checked on a level platform for straightncvs and defects should be rcctrfic d If unv After erection
the slope amI spacmg 01' th, ue bars. rods ,hJI\ be checked. For checking
the spacing. a <p.icer gauge shall be used.
2.4.8 After a"cn'bly the entire pier anchorage shall he checked The two
anchorage... [PI each gate ~hal1 a1"1u be chei.k ed with n-vpect to each other
2.4.9 Before concrcung the pier after erection of pier anchoraee , it l~
ncces . . arv that tl <ccond check of <.III the partv Jf) made to CJlSUTI.: agamvt
any possible drsplaccrncnt dunng welding, nveting, etc For safety of
erected anchorages the grouuug/concrctiug operations shall be commenced
after rmmrnum pos-able interval

2.4.10 For insulated anchorv'nes, the insulation shall be provided and

checker; before siartmg the grnutl11gjl.:nncrctlOg operations

2.5 Inspection of Sill Beam

2.5.1 In ca -,e, trunnion a"...emhly IS not in PO:-,ltl011, the dummy trunnion
assembly shall be rut on adjacent PICh and It, position should be checked.

2.5.2 Before erecuon, centre line oisil] beam shall be marked on pier
faces. "I he centre Imc of gate shall be inscribed on the crest shilted by
300 rnrn or so on upstream "de.
2.5.3 The ,,1I beam centre
trunnion centre hnc

11110

shall be checked m relanon to the

2.5.4 Aftcr erection, the alignment and angular selling of SIll beam shall
be checked For angular ,eHlng of sill beam 3 to 5 frames can be used
2.5.5 Arter ahgmng the SIll beam, all the bolts and nuts shall be put In
posuron The reinforcement bars and dowels be welded with anchor holts
so that the complete assembly IS firmly held m posuron and 13 not disturbed during grouting.
2.5.6 The aggregate used for grouung shall not he more than ~o mm.
The concrete mIX shall be hand-compacted by US1l1~ rods No mechanical
vibrators should be used
2.6 Inspection of Wall Plates ( Side Seal Seats)
2.6.1 The wall plates shall be ,n true alignment with respect to centre
hne of trunmon pin. The dummy trunnion assernbiy wuh extension rods
shall be used for checking the alignment of w.rl] plate, 1 he vcrucairty of
the wall plates should be checked 10 ensure that "all plates are truly
vertical.

IS : 10096 ( Part :1 ) 1983

2.6.2 After setting of wall plates, all the bolts and nuts shall be put in
posiuon. The reinforcement bats and dowels In the block out shall be adequatcly welded to the side scats m such a manner that wall plates are not
displaced durmg concreting or otherwise
2.6.3 The shuttering planks for concretmg the wall plates shall be at least
I 5 to 3 mm clear from the metal parts of the wall plate.
2.6.4 Maximum SIze of ag;regate u-ed for concretmg the block. outs
shall not be more than 20 rnrn
2.6.5 All concrete nux used shall be hand-compacted and done m
conversant stages as the shuttering pi ogresses III upward dircctron,
Cornpacuon may be donc by cO mrn rods No mechanical vibrators should
be used.

2.7 Inspection of Gale

2.7.1 The subassernbhes of the gate which are received at srte duly mspeered III workshop should be reinspected at site before lowermg of assembly tn the bay
2.7.2 Checking of all the drrnensrons of the gate shall be done after
skeleton assembly of eac h gate 15 made and before final weldmg/rrvetmg
IS allowed 1 hrs dunensronai check shall be repeated after welding IS done.
2.7.3 VIsual Inspection of all welds and bolts/rrvets shall he made to the
extent 01 1\)0 percent.
2.7.4 The followmg criucal dimcnsrons should be checked'
,I) Centre to centre distance between SIde guide rollers and shoes,
b) Centre to centre distance between the '11(,11.: seals and bases. and
~I

Distance of bottom seal-base from centre line of trunnion pill.

2.7.5 1 he seal bolts should be tightened adequately and uniformly and

the guide wheels be checked lor .r ec rotauon
2.7.6 10 check the etfc cuveness of the seals, acuve seal mterfeience
should he compared With that provided In the design, because on this
aspect
depend to a great extent the efficiency of scaling arrangement
and ea-y operauon of the gate.

".11

2.7.7 In case of counterweighted gate

weight has been provided.
7

1\

shall be ensured that corrcet

IS

10096 ( PIll1 2 ) _ 1983

2.8 IlISpectlon of Complete Gate Inslallation aod Hoists Ioeludlog Electrical

Items
2.8.1 Visual inspection of all gates and heists shall be carried out after
erection.
2.8.2 Tbe erection tolerance shall be checked for all parts during and
after erection
2.8.3 In case of hoists, the following pomts which are by no means
exhaustive, need be looked mto by engineer-in-charge:
a) Connecuons like sbaft couplings, connections of wire ropes to
the drum and gate. connection of hoist components to the base,
etc, have been properly made.
b) Intermediate supports for shafts are provided at the required
locations to permit free movement of shaft,
c) In case of double hoists both the hoists are properly synchronized;
d) Tbe ends of wire ropes are properly looped and sufficient 'U'
clamps have been provided,
e) The rope has been tightly wound over the drum, has no kinks
and IS properly !ubncated,
f) The wire ropes or chams at both ends of the gate and counterweight ( If provided ) have equal initral tension;
g) Electnc installations have been properly earthed; and
h) The Iinnt switches have been properly adjusted.
2.8.4 It shall be ensured that tbe gate sill, "all plates and other embedded parts are thoroughly cleaned and no foreign rnaterial rs present.
2.8.5 The hoist provided for operanon of tbe gale should firsI be independently tested" ben II IS not connected to the gate to ensure ItS satisfactory
working. The hoist should be kept runnmg for sufficient period so as to
satisfy its independent working Bushmgs and beanngs shan be checked
for temperature nse to sausfy that there" no undue fricuon
2.8.6 Before operation of the gate, the following checks shall be made:
Electnc supply and fuses,
Overload relay, If provided, to sec that it tnps otfthe starter;
All bearmgs and wire ropes for proper greasmg;
All bolts of gear boxes, h01St drums and shafts, couphngs for
tightness, and
e) The 011 level m gear reduction unit.

a)
b)
c)
d)

IS : 10096 ( Part2 ) 1983

3. TESTING
3.1 The gate shall be tested in a dry condition with hoist duly connected
for its smooth working. The gate should be fully closed and fully opened
and it should be ensured that there IS no obstruction and no undue efforts
required for its operation. [f the gate IS not gomg down of Its own weight
or found tight in some position, reasons should be mvesngated and
remedied instead of forcing .he gate down

3.2 The testing of gate-seals in dry con.liuon should be done by SUItable

means, such as by viewmg the contact suuucc against a light source
3.3 In case of rubber seals, water should be poured over the seals so that
there WIll not be dry friction of the seals, In case of metal to metal
contacts, oil or grease rs to be used. No grease or lubncant is to be used
for rubber seals.
3.4 There shall be no noise of friction or any other noise, no signs of
excessive friction, no jerky performance, no dug in any posrtion, no
dangling of the gate, no twist in rubber seals and rubber seals are not
overpressed.
3.5 The gate is to be first kept resnng on srll beam, that is in closed positron. The leakage test can be done III this position by using suuable pump
with necessary arrangements of jetting water at 1'5 trmcs the designed
pressure on sealing positions from bottom to top All joints if any, shall be
tested to ensure perfect working of the gate

3.6 The gate should be fully opened and closed to ensure full opening and
satisfactory closing. The time required for 300 mm open 109 or closing of
the gate IS to be recorded.

3.7 The arrangements provided for preventing the travel of the gate or
hoist beyond the designed limit are tested and checked for proper working.
3.8 In case of rope drum hoist, it is ensured that the gate moves down of
its own weight. The gates shall also go up and down without uneven pull
to the gate, The winding of rope over the drum is uniform and according
to the design.
3.9 Tn case of hydraulic hoists, it should be ensured that oil pressures are
within the designed limits.
3.10 The full load current required for movement of the gate on load shall
be measured and checked against the designed value.

3.11 When the rainy season starts. visual inspection of gates sh311 be made
and they shall be lowered and raised several times to make sure that
everything is in order,
9

IS. 10096 ( Part 2 ) - 1983

3.12 When the water starts overflowing, lower the gates to hold the water
to half the height of gates In this position the seals may be tested and any
leakage shall be attended to The gate. may also be operated up and down
with this water load and operation of hoist shall be observed
3.13 The gates shall also be tested in a similar way against full water load.
3.14 During the testmg of gate ID dry condition ( see 3.1 to 3.9 ) and under
water pressure, the following observations shall be made and a record be
kept:
a) Movement of gate and indication of jamming, if any;
b) Effective stop is achieved by the gate stops wherever provided;
c) Speed of opening and closing, and the current requirement at
specified voltage,
d) Operation of brakes and limit switches;
e) Manual operauon of gate, if provided;
f) Efficiency of guide rollers to check the side sway of the gate;
g) Correctness of indrcation by local position indicators;
hl Synchromzauon of remote position indicators, if provided; aod
j) Vibrauon of gate, hoist, and civrl structure.

10

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