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General:
Proper maintenance of Hydraulic gates and hoists is very important for satisfactory
operation of Gates and to achieve the envisaged benefits from the project. For systematic
operation and maintenance of the gates and their operating equipments, it is very
necessary that a comprehensive operation and maintenance manual which shall include
The design features of various components.
Particulars of bought-out items and source of availability with addresses and phone Nos.
Operating instructions.
Type of lubrication oil and grease to be used and its availability.
Schedule of maintenance and repairs
are prepared for each hydraulic gate installation and the operation staff shall be made well
conversant with them and trained for the job.
The list of parts involved in maintenance and operation of gates and hoists generally are as
follows:
1. Vertical Lift Gates:
i. Embedded parts:
Sill beam assembly
Roller track
Seal seat / Upstream Guide
Top seal seat and side guide
Dogging arrangement
1
2. Radial Gates :
i. Embedded parts :
Common anchorages Independent anchorages
(Bonded Anchorages) (Un-bonded anchorages)
Sill beam Assembly Sill beam assembly
Wall plate Assembly Wall plate assembly
Horizontal Anchor Rods Anchor girders
Trunnion Girder Load Anchors / Tie flats
Trunnion girder chairs Yoke girders
Vertical rods Rest plate
Thrust block (If tie between trunnion Vertical rods etc.,
is not used) Thrust block (If tie between trunnion
is not used)
2
3. Rope drum Hoists:
A. For Vertical Lift Gates :
Drive Unit Assembly
Gear Box Assembly
Hoist Supporting structures etc.,
Operating personnel shall be properly trained and experienced so that they can use
their initiative and judgment based on their past experience for situations which may
arise during operation.
Detailed instructions for inspection and normal maintenance and repairs of gate
installation should be given in operation and maintenance manual. However, for
carrying out special repairs to gates if any, it is advisable to refer to Experts to
execute.
Inspection and maintenance experience are compiled in the form of History register of
any installation so as to be useful for future designs, investigation of any failure,
improper and unusual operation of gates. All such observations shall be recorded in
the gates History register maintained for this purpose.
3
The following precautions are to be taken before dry testing of Gates :
Checking of all critical dimensions and proper seating of gate over embedded parts is
to be ensured. Record of readings may be maintained for future reference.
Worm reducer, plumber blocks, trunnion pin, gate wheels and gear wheels should be
lubricated.
Checking of weld between horizontal girders, arms and trunnions, tees and horizontal
girders, cross girders and hoist bridge girders, final welding of lifting bracket etc., and
are to be welded if left over. A comprehensive check list is to be maintained .
Checking tightness of bolts between trunnion with arms and trunnion with horizontal
girders, lock plate bolts of trunnion pin, wire rope clamp bolts and other bolts if used
are to be tightened properly if loose.
Increase of unbounded anchorage one has to ensure the expansion of tie flats and
yoke girder under load.
The gates are to be inspected thoroughly for projections, temporary supports coming
in the way of gate movement and excess concrete are to be removed if any.
All the rubber seals are to be made wet before lowering the gate preferably with water
to reduce heat generated between seal and seal seat and ensure fixing of all bolts and
mouldings of site joints.
Light test may be conducted for checking gap between seal and seal seat.
4
5.0 Maintenance schedules for Radial gates, Vertical lift fixed wheeled gates,
electrically operated fixed hoists should be attended preferably prior to monsoon :
5
The wheel bearings and guide rollers shall be lubricated.
The seal shall be checked for damages, if damaged, shall be replaced.
All nuts and bolts shall be tightened.
The guide assemblies, wheel assemblies and sealing assemblies shall be cleared of
girt, sand or any other foreign material.
General cleaning is to be done for the following :
Hoist Bridge Components.
Trunnion girders / Yoke girders.
Trunnion brackets, trunnions, arms and horizontal girders.
Lubrication is to be attended for :
Bearings at Gate wheels, trunnion bushes, hoist pulleys and pins provide in Hoist
Bridge at hoist level and gate.
Rope drum shaft Plummer blocks.
Line shaft Plummer blocks.
Check tightness of all coupling bolts of motor to work reducer and line shaft. If
required they may be tightened.
Care shall be taken to check the condition of holding rope with rope socket and
balancing of gate is to be observed and if necessary adjusted.
6
5.2 Vertical Lift fixed wheeled Gates:
These gates are provided for controlling water discharge for flood control, water supply,
irrigation and power generation etc., The gates shall be thoroughly inspected for cracks,
defects or damages periodically. A schedule of maintenance is proposed which may be
adopted with modifications, if required, to suit site conditions and use of gate.
Balance points same as Radial Gates – Maintenance may please be carried out.
The re-painting of the gates shall be carried out at intervals to be decided on the
basis of painting schedule of the gates.
The inspection, testing and maintenance of the hoist shall also be carried out
periodically as per the maintenance manual.
For larger No. of gates ie., more than 10Nos. is very difficult for through
maintenance in lean period available. Hence the No. of gates divided into 3 groups
and through maintenance of welding, painting shall be carried out at least one in
three to five years depends on requirement.
7
5.3 Electrically Operated Fixed Hoists for Radial Gates and Vertical Gates:
The periodical maintenance of brought out items like motor, brakes, radicons, etc.,
shall be carried out as per the manufacturer’s advice / maintenance schedule.
8
5.3(c) Quarterly Maintenance:
9
Check the overload relays and limit switches for proper functioning.
Check tightens of all nuts & bolts, soundness of welds. All bolts shall be
tightened and defective welding must be rectified.
Check the pulleys, sheaves and turn buckles for soundness.
Check the limit switches and adjust for design limits duly operating.
The effectiveness of the brakes shall be checked by stopping the gate in
intermediate operation duly raising and lowering operations. The brakes shall be
adjusted if needed.
When the gate is operated, there should not be any noise or chatter in the gears.
Check for all gears and pinions for proper mesh, uneven wear and adjust for
proper contact and grease the gears.
Repaint the hoist components, hoisting platform and its supporting structures
after a time interval depending upon the painting schedule.
10
5.4(b) For every Six years:
Check seal seats, seal tracks, side guides for the following:
I. Any damages
II. Corrosion
III. Pitting
IV. Misalignment
11
Lubrication Schedule
12
Chart for maintenance Schedule for Gates
Every Quarterly At Ever year At Every three years At Every six years
General cleanliness In addition of Quarterly In addition of yearly
Check welds for damages
of embedded parts, maintenance schedule maintenance schedule
at:
Gate hoist the following are to be the following are to
components checked be checked
Skin plate joints
Tee girders to Horizontal
Check the tightness Check the condition
Girders
of foundation bolts of of wire rope,
Check for oil level in Horizontal girders to arm
Motors, Radicons, pulleys, sheaves,
radicons. Arm Bracings
Plummer blocks, limit switch, brakes,
Horizontal girder bracings
coupling joints and gear wheels.
End boxes
Gate stiffeners
Check wheel assemblies
for any
Check for smooth
Greasing of pulleys Check gate seals Breakage
operation of gate by
and pins for damages. Frozing
raising and lowering
Corrosion
Misalignment
Trunnion pin, Rope
drum hoists, Gear
Check for condition Check for sill beam, side
wheels, Hand Check seal bolts for
of painting of all guide, roller tracks for
operation of shaft, damages.
components damages, corrosion, pitting
guide rollers, Gate
wheels
Check Hoist Bridge
Check for operation
for foundation bolts for
of Brakes
tightening.
Check for loose
electrical connections
(In case of fixed
wheel gates)
1. Wheels are to be
greased properly
2. Movement of
wheels should be
smooth and it can
be rotated by hand
13
Operation and Maintenance of Gates
DO’s Don’t’s
1. Authorised Personnel should be allowed near 1. Un authorized persons should not be
control Pane for operation of gates. allowed to operate gates
2. Technically qualified or trained operators should 2. Unqualified persons technically should not
be allowed to operate gates. be allowed to operate gates.
3. Operate the gates only when there is required 3. Not to operate gates during low voltage
power supply as per the design is available. period
4. Adjust the brakes when the gate is lowered fully 4. Not to adjust the brakes when gate is not
and rest on sill. dogged
5. Attend maintenance during pre-monsoon 5. Not to adjust the brakes when gate is not
season dogged
6. Use proper tools for attending repairs / 6. Maintenance works should not be attended
adjustments during rains.
7. Conduct Dry test before putting into operation 7. Do not operate gates without Dry testing
8. Maintain cleanliness of hoist platform, trunnion 8. Not to keep any slippery material on Hoist
platforms walkway
9. Insulate damaged electrical wiring, which are 9. Do not allow any persons to operate gate if
exposed to atmosphere Bare wires are seen
10. Protect Hoist gear box and motors from rains 10. Not to keep gear box cover open after daily
maintenance
11. Ensure wire rope tightness on either side equally 11. Not to operate gate when the wire rope is
before operating gate slacked
12. Safety precautions should be taken during 12. Not to wear loose dresses during operation
maintenance works of gates
13. Cut off power supply after operation of gates 13. Do not allow power supply to motors when
it is not at all required.
14. Check connections and functioning of limit 14. Advised not to operate gate if limit
switches before operation switches are not functioning
15. Ensure before operation that no foreign 15. Not to switch on Hoist motors if foreign
materials fall in the gear teeth material found in between teeth of gear
wheels
16. Check tightness of Plummer block, drive unit, 16. Do not operate gate if any bolts of
line shaft, coupling bolts Plummer block and coupling bolts are
found loose
17. Ensure no foreign particles stuck up in between 17. Not advised to operate gates if foreign
roller and roller track/ wall plate and rubber seals material found in between rollers and roller
etc., track and wall plates and rubber seals etc.,
18. Maintain oil as per level indicator in the gear 18. Not to operate gates with low oil level in
box. gear box
19. Check tightness of wire rope clamps before 19. Not to operate gate if wire rope clamps are
operation found loose
20. Operate gate only when grooves are clean 20. Do not operate gate if there is any
without any obstructions projection, in the grooves which obstruct
movement of gates
21. Provide proper approaches for attending 21. Not to use manila rope / wire ropes as
maintenance at grunion bushes and grunion approach for attending maintenance works
pins, grunion girders etc., at Trunnions, trunnion girders etc.,
14
Painting system for hydraulic gates and hoists
Introduction:
Hydraulic gates, its embedded parts, gate leaf, hoists and its supporting structures
should be protected against corrosion due to climatic condition, biochemical reaction and
abrasion due to different forces acting on it. Otherwise these equipments may deteriorate
to any extent that the replacement of parts may become necessary and such replacement
may become difficult and costly. Therefore it is necessary to do painting to protect the
equipment and to increase the life of parts. Therefore application of the paint film has two
main purposes.
The first one is to protect the steel from corrosion.
The second for decorative appearance.
Painting for hydro mechanical works shall be carried out as per IS 14177 – 1971 or latest.
The painting system for gates and equipment shall be attended at 2 stages.
Surface Preparation:
After the equipment has been fabricated, it is essential that before any primer and
coat of paint is applied, the surface is properly prepared. Such preparation shall include
through cleaning, smoothing, drying and similar operation that may be required to ensure
that the primer and or paint is applied on suitable surfaces.
Weld spatters or any other surface irregularities shall be removed by any suitable means
before cleaning.
All oil grease and dirt shall be removed from the surface by the use of clean material
spirits, Xylol or white gasoline and clean wiping materials.
Following the solvent cleaning, the surfaces to be painted shall be cleaned of all rust,
mill scale and other lightly adhering objectionable substances by sand blasting. Blast
clean to a minimum of Sa 2½ Swedish standard SIS 05 5900 with a surface profile not
exceeding 65 microns.
The fig. B Sa 2½ is given.
15
16
For more details of cleaning method refer IS 1477 ( part -1 ) – 1971
Surface of stainless steel, nickel, bronze and machined surface adjacent to metal work
being cleaned or painted shall be protected by making tape or by other suitable means
during the cleaning and painting operations.
Primers shall be applied as soon as the surface preparation is complete and prior to the
development of surface rusting. In case there is considerable time gap, the surface
shall be cleaned prior to priming.
Shop painting:
I. Embedded parts which come into contact of concrete:
All embedded parts which come in contact with concrete shall be cleaned as detailed
above and given two coats of cement latex to prevent rusting during the shipment while
awaiting installation.
II. Embedded parts which are not in contact with concrete and gate parts:
Two coats of zinc rich primer with epoxy resin shall be applied to all embedded parts
surface which are not in contact with concrete and shall remain exposed to
atmosphere or submerged in water to obtain a dry film thickness of 75 microns, which
shall be followed by two coats at an interval of 24hours of coal tar blend epoxy resin
part so as to get a dry film thickness of 80 microns in each coat. Total dry film
thickness of paint shall be 300 microns.
Surfaces not to be painted: The following surfaces are not to be painted unless or
other wise specified
a) Machine finished or similar surface
b) Surfaces which will be in contact with concrete
c) Stainless steel overlay surfaces.
d) Surfaces in sliding or rolling contact
e) Galvanized surfaces, brass and bronze surfaces.
f) Aluminum alloy surfaces
All finished surfaces of ferrous metal including bolts, screw threads etc., that will expose
during shipment or while awaiting installation shall be cleaned and given heavy uniform
coating of gasoline soluble rust preventive compound or equivalent
Gates:
Primer Coat: over the prepared surface one coat of inorganic zinc silicate primer
giving a dry film thickness of 70 ± 5 microns should be applied. Alternatively two coats
of zinc rich primer, which should contain not less than 85% zinc on dry film should be
applied to give a total dry film thickness of 75 ± 5 microns.
17
Finished paint: Two coats of solvent less coal tar epoxy paints. These shall be
applied at an interval of about 24 hours. Each coat shall give a dry film thickness of
150±5 microns. The total dry film thickness of all the coats including primer coating
shall not be less than 350 microns.
Final Coats: One coat of alkyd based micaceous iron oxide paint to give a dry film
thickness of 65 ± 5 microns followed by two coats of synthetic enamel paint confirming
to IS 2932 – 1974 to give a dry film thickness of 25 ± 5 microns per coat. The interval
between each coat shall be 24hours. The total dry thickness of all coats of paint
including the primary coat shall not be less than 175 microns.
Finished coats: The finished paint shall consists of three coats of aluminum paint
confirming to IS2339 – 1963 or synthetic enamel paint confirming to IS 2932 – 1977
to give a dry film thickness of 25±5 microns to obtain a minimum dry film thickness of
125 microns.
c) Machined surfaces:
All machined surfaces of ferrous metal including screw threads which will be
exposed during shipment or installation shall be cleaned by suitable solvent and
given a heavy uniform coating of gasoline soluble removable rust preventive
compound or equivalent. Machined surfaces shall be protected with the adhesive
tapes or other suitable means during the cleaning and painting operation of other
components.
Note: If alternatives are chosen the guaranteed film thickness are to be arrived from
the data sheets of leading paint manufacturers and incorporated the total film
thickness considering the location and atmospheric conditions of project.
18
Application of paint:
Mix the contents thoroughly as directed by pain manufacturer before and during use.
a) Brush / roller
b) Conventional spray
c) Airless spray etc.,
Painting at shop can be done in any of the three methods so that the paint can be
made to suit the convenient direction but once the gate and equipment put in
position the general method adopted is only brush / roller. In case of spray lot of
precautions are to be taken.
For More details: Refer IS1477 Part (II) – 1971
Appendix A – Brushing of paint
Appendix B – Spraying of paint
Appendix C – Spray painting defects: Causes and remedies
19
Inspection and testing of painting
General: The aim of inspection and testing is to ascertain whether the recommended
practice is being employed during every stage of application and whether the final results
fulfill the object of painting, inspection therefore means a close supervision while the work is
in progress. Any test carried out should be non – destructive nature or, if of destructive
nature, should be either restricted to areas which can be restored without marring the
general appearances, or be such that it is possible to restore easily without necessitating a
complete repetition of the work.
New Work ( Not previously painted): The following shall be decided by inspection:
a) The method of pre cleaning feasible or recommended;
b) The intermediate protective treatments to be applied, if found necessary;
c) The painting schedule and the specifications for the paint for ensuring the particular
performance required; and
d) The method of application, whether by brush, roller or spray.
Old Work (Which requires repainting): The following shall be decided by inspection:
a) Whether the entire existing paint requires removal; and
b) Whether repainting without paint removal would be adequate.
20
For ascertaining whether the old paint has deteriorated tosuch an extent that its
complete removal is necessary, the following test for embrittlement should be
employed;
A square coin such as a 5 paisa coin shall be pressed with the straight edge on an
angle of 45 against the paint film. This will result in a chip of paint breaking loose from the
surface if the paint has embrittled, lacks adhersion and requires removal. If the paint is not
embrittled, it will curl or shrivel up under such pressure. The square coin test should be
combined with an examination of the paint film through a magnifying glass to observe the
extent of cracking and a paint film which does not show fine hair cracks under it may be
considered as perfectly sound.
1. Cleaning and Degreasing- At the work – site a visual and physical inspection is
adequate. A degreased steel surface is duller in appearance than one which is even
slightly oily. Wiping the surface with a piece of white cloth will show if minute traces of
grease and dust have been left on the surface. When steel is being degreased by wiping
the surface with mineral turpentine ( or any other solvent), it is important to watch the
cleaning rags are washed or changed regularly.
b) Hand Scraping: No defnite method of inspection may be laid down for hand scraping. It
is unreasonable to expect hand scraped surfaces to be perfectly clean, and for purposes of
inspection, all loose rust or scale ( and all loose paint in case of repainting) shall have been
removed.
21
c) Chemical rust removal: In the case of chemical rust removal ( pickling), inspection
shall make sure that washing after pickling has removed all traces of acid. All work pieces
shall be inspected particularly in inaccessible corners.
General inspection before and during painting: When inspecting general painting work
while in progress, it should be ensured:
a) That painting follows immediately after pre cleaning or pre treatments; that any
contamination which may occur in the interim period is removed, that special
precautions are taken when painting after galvanizing;
d) That the paint in the drums is thoroughly mixed prior to application; that drums are
inspected to make sure that no sediment is left in them;
e) That if paint has thickened because of long storage or because of the evaporation of
the solvents, its viscosity is adjusted as recommended by the paint manufacturer;
f) That each coat is allowed to dry sufficiently but not excessively before applying the
following coat; that manufacturer’s instructions for drying time are adhered to
properly; and
g) That every individual coat is properly applied, reasonably level and smooth and free
from runs and ‘holidays’ ( minute uncovered areas).
22
The field tests mentioned in 1) and 2) below may be carried out for facility of inspection
during and after painting.
1. Viscosity Test of paints: A simple check is to verify the viscosity of the paint with its
original value at least once during the course of its use. This may be done by
comparing the times of efflux of the paint when filled level in a viscosity cup of standard
dimensions and provided with an orifice standard flow characteristics.
2. Thickness test: The thickness of primer paints as well as the total film thickness of
all coats applied shall be verified with a suitable instrument. It is important that the
setting of the thickness meters is checked prior to the test and for this purpose
standardized test bits are supplied with every instrument. It should be noted that
instruments like the Elcometer contain a delicate magnet and that the storage and
handling of such instruments needs care to ensure that they retain their accuracy.
23
Spray Painting Defects : Causes and Remedies
I. Sags
S.No Possible cause Suggested remedies
Dirty air cap and fluid tip (distorted Remove air cap and clean tip and air cap
i
spray pattern) carefully.
ii Gun stroked too close to the surface. Stroke the gun 150 to 250mm from surface
Trigger not released at end of stroke
Operator should release the trigger after
iii (when stroke does not go beyond
every stroke.
object)
Gun stroked at wrong angle to the Gun should be stroked at right angles to
iv
surface. the surface.
v Paint applied too heavily. Regulate flow of paint
Add the correct amount of solvent by
iv Paint thinned too much.
measure.
II. Streaks
S.No Possible cause Suggested remedies
Dirty air cap and fluid tip (distorted Remove air cap and clean tip and air cap
i
spray pattern) carefully.
Insufficient or incorrect overlapping of Follow the previous stroke accurately to
ii
strokes. deposit a wet coat.
Gun stroked too rapidly (‘dusting’ of Avoid ‘whipping’ and use deliberate slow
iii
the paint. strokes.
Gun stroked at wrong angle to the Gun should be stroked at right angles to
iv
surface. the surface.
v Stroking too far from surface. Stroke 150 to 250mm from surface.
iv Too much air pressure. Use less air pressure as necessary.
24
III. Orange peel
S.No Possible cause Suggested remedies
Add the correct amount and the right type of
i Paint not thinned out sufficiently.
solvent by measure.
Check solvent. Use correct speed, overlap
ii Not depositing a wet coat.
and stroke.
Gun stroked too rapidly (‘dusting’ of Avoid ‘whipping’ and use deliberate slow
iii
the paint. strokes.
iv Insufficient air pressure. Increase air pressure or reduce fluid pressure.
Select correct sir cap and nozzle for material
v Using wrong air cap or fluid nozzle.
and feed.
iv Gun stroked too far from the surface. Stroke the gun 150to 250mm from the surface.
Over spray striking a previously
iiv Spray detail parts first. End with a wet coat.
sprayed surface.
25
II. Excessive Spray Fog, Surface Haze or Bloom
S.No Possible cause Suggested remedies
Use least amount of compressed air as
i Too high air pressure
necessary.
ii Spraying past surface of the product. Release trigger when gun passes target.
iii Wrong air cap or fluid tip. Ascertain and use correct set up.
iv Gun stroked too far from the surface. Stroke the gun 150to 250mm from the surface.
v Material thinned out too much. Add the correct amount.
Spray during dry period. If not use retarders or
vi Too humid an atmosphere slow evaporating solvents as advised by the
manufacturers.
IV. Paint will not come due to defects arising from Pressure tank.
S.No Possible cause Suggested remedies
i Lack of air pressure in pressure tank Check for leaks or lack of air entry.
Air intake opening, inside of pressure This is a common trouble. Clean the opening
ii
tank lid, clogged by dried up paint. periodically.
iii Leaking gaskets on tank over. Replace with a new gasket.
26
Relief Valve heated
27
TECHANICAL DETAILS
5045 SPILLWAY RADIAL GATES
1650 1350
1000
1650 1350
3 VENT HEIGHT 8800mm
6250 3000 792
1253 4 RADIUS 9000mm
10500
7 TOP OF GATE EL: 298.300M
2800
800
70
940 12 DESIGNED AS PER IS 4623-2000
3000 VENT = 12250 3000
1891 730 1215 1406 8553 3600
17395
1.MOTOR:-
10HP(7.5kw) 975 RPM SQ.CAGE INDUCTION MOTOR, SI
CONTINUOUS DUTY, TEFC,FOOT MOUNTED CLASS 'B'
425
500
2150
IS 325-1No.
1500
2. E.M. BRAKE:-
500
425
3. WORM REDUCER:-
RATIO 60:1, TYPE "U", SIZE 8" INPUT H.P10 INPUT SPEED
975RPM OUT PUT TORQUE 394 KGM OUTPUT SHAFT
VENT = 12250
F
L
TRUNNION LEVEL
O
W
PLATFORM
4.WIRE ROPE:-
TIE BETWEEN
TRUNNION 36Ø ,6/36 CONSTN.,R H LAY UNGALVANIZED, MAIN FIBER
CORE UTS 200KG/MM² HAVING BREAKING LOAD=151886 KG
CONFARMING TO IS 2266-1989 LENGTH=
1500
3000
28
TECHANICAL DETAILS
SPILLWAY RADIAL GATES
5045 1 NO OF GATES 7 NOS.
1650 1350
4400 2 VENT WIDTH 12250mm
1000
5 SILL LEVEL EL :289.20M
6250 3000 792
1253 6 TRUNNION LEVEL EL: 292.000M
10500
9 TYPE OF ANCHORAGES COMMON
45T ROPE DRUM,
10 TYPE OF HOIST U/S SUSPENSION
2800
800
70
940
3000 VENT = 12250 3000
1891
1215 730 1406 8553 3600
17395
1.MOTOR:-
500
10HP(7.5kw) 975 RPM SQ.CAGE INDUCTION MOTOR, SI
425
CONTINUOUS DUTY, TEFC,FOOT MOUNTED CLASS 'B'
1500 1500
5002150
TERMINAL BOX, FRAME SIZE ND-160L.CONFIRMING TO
IS 325-1No.
425
2. E.M. BRAKE:-
200Ø AC ELECTRO MAGNETIC SOLINOID OPERATED
SINGLE PHASE BRAKE,100% COIL RATING, CLASS "B"
INSULATION, WORKING ON 400 / 440V AC, 50 C/S WITH
BRAKING TORQUE CAP=15.0KGM.
3. WORM REDUCER:-
VENT = 12250
RATIO 60:1, TYPE "U", SIZE 8" INPUT H.P10 INPUT SPEED
15250
F
975RPM OUT PUT TORQUE 394 KGM OUTPUT SHAFT
L EXTENSION ON EITHER SIDE WITH SELF LOCKING-1No
O TRUNNION LEVEL
PLATFORM
W
TIE BETWEEN
TRUNNION 4.WIRE ROPE:-
36Ø ,6/36 CONSTN.,R H LAY UNGALVANIZED, MAIN FIBER
CORE UTS 200KG/MM² HAVING BREAKING LOAD=151886 KG
CONFARMING TO IS 2266-1989 LENGTH=
1500 1500
3000
Fig – 2
29
2950 42777
11850 8027 8000 10000 4900 13° 13°
Ø15
8450 3400 944
00
1200
950
LH RH
9590
1425
5600 1425 950 2950
7073 900
1352
2375 4698
3000
3500 3500
1500
1200
24400
2000
2900
4000
4900
14810
13° 13°
0R
1949
00
26
LH RH
135 135
450 450
950 2850 950
4750
2170
69 1.85
900 2100
1352 X = 225.562 Y
TECHNICAL DETAILS
7073 4352 3705 21370 1455 SPILLWAY RADIAL GATES
1 NO OF GATES 24 NOS.
37955
2 VENT WIDTH 18500mm
3 VENT HEIGHT 17500mm
4 RADIUS 26000mm
5 SILL LEVEL EL :35.840M
6 TRUNNION LEVEL EL: 50.650M
7 TOP OF GATE EL: 53.640M
8 F R L/MWL EL: 53.340M
9 TYPE OF ANCHORAGE INDEPENDENT
ROPE DRUM HOIST
10 TYPE OF HOIST D/S SUSPENSION
8000 10000 4900
8200 R 11 PIER THICKNESS 4750mm
12 DESIGNED AS PER IS 4623-2000
2375 2375
950
4750
2850
950
TECHNICAL DETAILS
10.943° STOPLOG GATES
3700
1 NO OF GATES 24 NOS.
2 SIZE OF STOPLOG 18.500M(W) X 17.350M(H)
11100
10.943°
NOTE:
3700
93 93
950 503229 1200 229503 950
1450
1450
13° 13°
1300
1220
1050
890
890
1450
1450
1ST STAGE
2800
2225
22200
13600
8692 1200
RH
LH
9000
63
950 2850 950
6000
18.636°
20.65°
3500 3500
2100
47
1000
1500
185
2375
4027
11575
2900
4000
13500
0
35 R3
23
2500 13° 13°
1949
19527 LH RH
135 450 135
450
950 2850 950
4750
1835 1.85
X = 21.448Y
7502 4064 4325 19052 2527
29968
37470
8200
TECHNICAL DETAILS
950
1 NO OF GATES 20 NOS.
2850
4750
2 VENT WIDTH 18500mm
2375
950
3 17000mm
LEVEL
4 RADIUS 23350mm
5 SILL LEVEL EL :58.500M
6 TRUNNION LEVEL EL: 72.000M
7 TOP OF GATE EL: 75.800M
8 F R L/MWL EL: 75.500M
C/C of Trunnion = 20400
18500
HYDRAULIC HOIST
10 TYPE OF HOIST
CYLINDERS/GATE
11 PIER THICKNESS 4750mm
12 DESIGNED AS PER IS 4623-2000
TECHNICAL DETAILS
STOPLOG GATES
950
1 NO OF GATES 20 NOS.
NO. OF STOPLOGS
3500
2 2 SETS
REQUIRED
3 EMBEDDED PARTS 20 SETS
4 NO. OF ELEMENTS PER SET 10 NOS.
5 OPERATION 70T GANTRY CRANE
6 DESIGNED AS PER IS: 5620
NOTE:
93 93 1. ALL DIMENSIONS ARE IN MM AND
950 503 229 1200 229 503 950
LEVELS ARE IN METERS.
2. ALL WELDS ARE 6MM FILLET
CONTINUOUS.
14 50
1450
13° 13°
1300
1220
1050
890
890
14 50
1450
1ST STAGE
2800
565 565
529 565 565
529
2ND STAGE
31
350
550
TOP SEAL CLAMP
F
175
7000 L BOTTOM OF GATE WHEN
16
450 450 SKIN PLATE FULLEY LIFTED
O
465
175 EL599.935
W
40
515
260
EL599.675
10
300
EL620.00 2500 2° TOP OF VENT
18
175
EL599.50
16
6°
F.R.L/M.W.L 40
500
15058 TO CT
53
EL 618.00 R OF
121 TRUNNION
900
900 6000 1100 DETAIL AT 'Y'
VIEW AA
8000 3000 18000 4000
EL615.00
m
00m
15
DOGGING OF GATE VERTICAL STIFFENERS
R=
POWER
PACK EL 611.0M SKIN PLATE
BOTTOM SEAL
5500
(RUBBER)
GROOVE
A EL 609.50M
EL 587.120 BOTTOM SEAL SEAT
TOP OF SLUICE (SS STEEL)
°
10.78
EL 607.50 36. SILL BEAM
68°
114
STOPLOG GATE
2
58
400
13
11
A
10000
F
BOTTOM OF GATE WHEN L
FULLEY LIFTED EL602.00M 125 125
EL 602.50 O
EL599.935 EL 601.669M W 350 250
20990
965 600
2169
EL599.675 EL599.50
30.184° EL597.50
'Y' DETAIL AT 'X'
F
L
0
600
O
R=
15000
10620
12
13424
15
250 100
R=
14
AXIS OF DAM
250
EL 588.88M
150 150
10
EL 587.50 9426
SILL
EL 587.120
350
56°
? OF SILL
'X' 400 400
7.86
800
15000 5530 8470
DETAIL AT 'Z'
900 29000
7000
BLOCK
3500
950
195
12.4
10
59
600
? OF TOP SEAL
STOPLOG GROOVE
11 EL 599.935 M
16X425 = 6800
12 BOTTOM OF GATE
F 800 800 WHEN FULLEY LIFTTED EL 599.935 M
8000
L 13
TOP OF GATE IN
20 298 25
NOTE :
1. ALL DIMENSIONS ARE IN MM AND
ALL LEVELS ARE IN METERS.
480
'Z'
3528
Fig – 5
PLAN
32
RADIAL GATE WITH TOP SEAL
2170
33
LIFTING C/C3200
500
TECHNICAL DETAILS
525
500
INTAKE SERVICE GATE
1193
150
1085
20
150
20
1 NO OF GATES 3 NOS
567 520
530
2 VENT WIDTH 4545 MM
6000
6245
6000
4730
5 SILL LEVEL + EL 18.828 M
4730
4730
6 TOP OF PIER + EL 40.00 M
7 FRL + EL 38.00 M
200
200
8 MWL + EL 38.00 M
340
150
930 1270
25
2200
? ? NOTE:
1400 25
IN METERS.
930 1200 1550
600
?
600
? DRAWING SAME MAY PLEASE BE ENSURED
1350
25
250 600
75 75
600 250 WHILE CONSTRICTION.
330
1800
4545
8750 8750
COLUMN C/C = 6045 COLUMN C/C = 6045 COLUMN C/C = 6045
INTAKE STRUCTURE
600
340
1200 1550 930 1270
69 70
? 1950 FOR MINI HYDELS
2480
1950
270
260
600
330
2353 VENT = 4545 4205 VENT = 4545 4205 VENT = 4545 2353
WITH ROPEDRUM HOIST
34 Fig -7(a)
TECHNICAL DETAILS
INTAKE SERVICEGATE
1 NOOFGATES 10 NOS.
5 FRL EL :17.8M
7000
6 MWL EL :19.0M
135
TYPE OF MOUNTING TRUNNION
11
MOUNTING
12 SPEED 0.5M\MIN
2200
522
657
600 LOWERING NORMAL 1M\MIN
13
EMERGENCY 4M\MIN
220 220
14 CUSHIONING STROKE 250MM
340 550
14 DESIGNOF HOIST AS PERIS 10210
STROKE 5200
TECHNICAL DETAILS
INTAKE STOPLOGGATE
1 NOOFGATES 1NOS.
75 5 FRL EL :17.8M
6 MWL EL :19.0M
636 1114
7 TOP OF PIER EL :20.5M
1750
8 HOIST CAPACITY 25T
5200
10 SPAN 2500MM
OPERATION THROUGHPENDENT
11
2
CONTROL
2316
90
89
5230
NOTE:
1. ALL DIMENSIONS ARE INMMANDLEVELS ARE IN
METERS.
2. THE MINIMUMCLEARNESS IS REQUIREDPERGATE
OPERATIONIS INDICATEDINTHE DRAWINGSAME
MAY PLEASE BE ENSUREDWHILE CONSTRICTION.
61 61
1250 1250
8500
2500
2187
320
75
2588 650 867
4500
1000
320 330
BALLAST TO BE PROVIDE
2t ON D/S WHEEL BOGIE
2t ON U/S WHEEL BOGIE
NOTE:
1.ALL DIMENSIONS ARE IN MM
2.ALL LEVELS ARE IN METERS
TECHNICAL DETAILS
4500
24450
LIFT 25.0M
1920 VENT = 6830 1920
POWER
3 PHASE 400/400 V AC 50 CYC/SEC.
SUPPLY
TECHNICAL DETAILS
4200
DRAFT TUBE GATE
1 NO OF GATES 3 NOS.
104
2 VENT WIDTH 6830mm
2500
650
650
1045
810
1187
320
652
Fig - 8
2030 735 735 2030
PCD 1250
980
980
540
415
400
450
510
50
750
1000
1 2 3 4 5 7
6000 6 8
1600
1600
1260
5250
9745
2000
11000
CABLE REELING
DRUM
CABLE REELING
DRUM
570
F
PARKING BRAKE
L
900
O
W EL:146.500 M
355
1700 1700
U/STREAM 6000 D/STREAM 8000
BR4
7
REDUCTION UNIT:-
6
BR3
37
FIG -9
3600 3600
HOIST
BRIDGE
EL 277.500M
1750 1750
500 540
GATE WHEN
GOLIATH 4540
LIFTED POSITION
CRANE
LIFTING
BEAM
9500
8550
100 8450
EL 270.500M
2500 1400
EL 269.000M
1800
EL 268.000M 1825 2500 2500 1225
1500 600 750 1510 1840 800 1900 8050 500 950 550 550 950 950 550
VENT 10000
500 1500 VENT 10000 1500 1500
ABUTMENT PIER
75 75
3000
391 13000 SERVICE GATE
409
INTERMEDIATE PIER
TOP OF VENT 1500 5500 9950 1500 600 6000 600
EL 262.800M
PIER
STOPLOG GROOVE
13700
3350
F
L
O
W
SILL
EL 254.300M 67
EL 253.900M 67 733
NOTE:-
1. ALL DIMENSIONS ARE IN MM
AND ALL LEVELS ARE IN METERS
VERTICAL LIFT GATES, ROPE DRUM HOIST
STOPLOGS AND GANTRY CRANE FOR CANAL
REGULATOR GATES
38
Fig - 10
Conclusion :
The author visited/inspected more than 400 projects in the country/ abroad when
troubles started on functioning of the gates and solutions offered for rectification and
most of the cause of trouble observed are covered here which are humanly possible
for control to give better service to society. The points were enlisted for future
guidance and maintenance. Most of our projects failed are improper maintenance
and hence few tips were given as readymade list for maintenance people to keep the
fit of equipment for control and effective utilization of water to give better service to
society and become a part and parcel of country building. Add your experience and if
necessary made comprehensive check list and pass it to your future generation for
improve of living conditions in Bharat.
For Contact :
Er N.K.Naidu
M/S Balaji Hydro Mech. Experts
Plot No.: 384, Sector – 1
Matrushri nagar,
Miyapur, Hyderabad – 500 049
Phone : 9441143272
*****
39