1.

GENERAL Proper Maintenance of hydraulic gates and hoists is very important for satisfactory operation of the project 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 & Maintenance Manual which shall include the design features of various components, particulars of bought-out items, Operating Instructions, Type of Lubrication oil and grease to be used, Maintenance and repairs, is prepared for Hydraulic gates and the operating staff shall be made well conversant with them and trained for the job. 2. BRIEF DESCRIPTION OF FIXED WHEEL GATE PARTS: AA. EMBEDDED PARTS: STILL BEAM: It is fabricated out of IS: 2062 Quality Rolled Steel Joist with stainless steel flat of quality: IS: 1570 on the top. The sealing surface of the beam is smooth and flush with concrete. ROLLER TRACK: It is fabricated I section made out of IS: 2062 Quality Plates or Rolled Steel Joists with stainless steel of Quality IS: 1570 part V on the top of Roller Track. SIDE SEAL SEAT: It is fabricated out of M.S.Angles / M.S.Plates of quality IS: 2062 with stainless steel plates of Quality IS: 1570 part V on the top. The surfaces of these parts are so finished, which will provide smooth surface and better sealing effect.

 TOP SEAL SEAT: It is fabricated out of M.S.Angles / M.S.Plates of quality IS: 2062 with stainless steel plates of Quality IS: 1570 part V on the top. The surfaces of these parts are so finished, which will provide smooth surface and better sealing effect. SIDE GUIDE: It is fabricated out of M.S.Plates of quality IS: 2062 so that it guides the movement of gate in groove and embedded with anchorage in the concrete.

BB. GATE PARTS: SKIN PLATES: It is fabricated out of M.S.Angles / M.S.Plates of quality IS: 2062. It will be straight / vertical in shape. HORIZONTAL GIRDERS: It is fabricated I section / T section out of M.S. Plates of IS: 2062 Quality (or) Rolled Steel Joists of IS: 2062 Quality. These will be suitably spaced and fixed on the skin plate so that stresses are same in all girders. ROLLERS ASSEMBLIES: Rollers are made out of Cast Steel conforming to IS: 1030 and Roller Pins are made out of IS: 1570 (part V) Quality rounds. Rollers are fixed on Pins with spherical bearings along with Cover Plates and o rings to avoid entry of dust particles. The Rollers will have less hardness than Track.

LIFTING ARRANGEMENTS: Suitable hooks are provided on gate top at its C.G. Line so that lifting beam hook will lock with pin and lift the gates.

 SIDE GUIDES: Side Guides are made out of M.S.Angles / M.S.Plates of IS: 2062 Quality Plate to suit to shape of guide provided in the embedded parts. These guides are provided at two ends of the gate to end boxes to avoid side movement. CC. HOIST: DRIVE UNIT: It consists of suitable capacity worm reducer for reduction in speed, pawl and ratchet arrangement for holding the gates, chains and sprockets, handle for manual operation. GEAR BOX: It consists of rope drum, set of pinion and gear wheels of Quality Cast Steel conforming to IS: 1030 to further reduce speed and are provided at both ends. LINE SHAFT: It connects both the gear boxes to the drive unit with Plummer blocks supports at suitable spacing. This is made out of IS: 2062. HOISTING STRUCTURES: Hoist Structures are of Quality IS: 2062 with hand rails for easy movement of operator and facilitate maintenance works.

3 sl no. 1

DESIGN DATA DESCRIPTION Type of Gate VALUES Fixed wheel type vertical gate u/s skin plate and u/s sealing 3060mmx6100mm 16 3.06 M 6.10 M 16 SET 3 UNITS 16 3160 mm 3630 mm 6200 mm EL 738.84 M (2424') EL 744.94 M EL 752.50 M (2468.8') EL FRL 13.655 M HWL 14.326 M EL 754.08 M (2474')

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Size of vent NO.vents Clear width of opening Clear height of opening No. of gates No. of Units in one set No. of embedded parts Side seal c/c Track c/c Sill to top seal c/c SILL Level Top of opening FRL HWL DESIGN HEAD Top of pier (top 0f dam) Permissible stresses Gate Embedded Parts

80.00 124.80 127.00 44.80 47.00 130.00

18

Operation of gate

Wet and Inaccessible condition Wet and Inaccessible condition By Rope drum hoist of 20MT Capacity under Un- balanced head condition EL 754.08 M 130.00

19

Dogging level

4 SL . No 1

MATERIAL SPECIFICATION COMPONENT PART Structural parts of gate including skin plate, stiffeners, horizontal girders, diaphragms, track base, seal base, end box plates, seal clamp, guide shoes, Structural parts of sealseat base guide/roller track, sill beam, anchor bolts anchors, etc. RECOMMENDED MATERIA L IS:2062 IS CODE

Structural steel

2 wheels/rollers 3 Wheel axle/ pin 4 Wheel bearing 5 6 7 8 9 Spacres for pin Guide shoe Lifting pin Bushing Track base, sill beam, side seal seat base side/top Bottom 11 Roller Track 12 Seal seat 13 Seal fasteners

cast steel corrosion resistant steel

IS1030 gr. 340-570

IS 1570-v spherical rollers bearing Structural steel Structural steel Stainless steel Bronze Structural steel SKF OR Eqt. IS:2062 IS:2062

30-CR-13

IS: 1570, part -5, 20Cr13 IS: 305 IS:2062

10 Seals

Rubber IS: 11855 PTFE Cladded -music note type Plain rubber wedge type corrosion resistant IS: 1570, part -5, steel 20Cr13 Stainless steel IS:1570,part-5 04 Cr 19 Ni 9 Stainless steel IS:1570,part-5 04 Cr 19 Ni 9

RECOMMENDED MATERIALS FOR FIXED WHEELS GATES AND HOISTS: SL NO 1 2 3 4 5 6 7 8 9 10 11 12 DESCRIPTION Wheel Wheel axel Skin plate Stiffener Wheel Track Guide Block Bearings Seal blots Anchor bolts Seals Embedded parts Supporting structures Gears & Pinions MATERIAL IS Specification Cast Steel Surface hardened to IS : 1030 IS:1570 part V IS: 2062

BHN : 130 Corrosion Resitant Steel & Structural steel

Stainless Steel IS:1570 part V Structural Steel IS:2062 SKF (or) Equipment Stainless Steel Plate, Stainless IS:1570 part V steel clad plate Structural steel Rubber Structural steel Structural steel Cast Steel IS:2062 IS:11855 IS:2062 IS:2062 IS: 1030 Gr: 27 54 Gr: 30 57

DESIGN DATA FOR ROPEDRUM HOIST

1 2 3 4 5 6 7 8

Vent Size Capacity of hoist Type of suspension Speed of hoist Max. lift of gate Location of hoist No. of drums Rope drum Hoist level

3.06 MX6.1 M 20 MT on C.G. of gate 0.5to 0.75 M/MIN. 15.5 M Mounted on steel bridge over Trestles Two

EL 754.08+ hoist bridge+trestle =754.08+0.62+7.6=EL 762.3M Hoist is mounted on steel towers on each pier of Sluice gate structure.

4 SL . No 1

MATERIAL SPECIFICATION COMPONENT PART Structural parts including main girder, trestles, cross girders chq. Plates, hand rails ,covers Drum wheels/pulleys/gears brake drum shafts/pinions Pins Bearing /housing Motor Flange coupling Wire rope Brake

RECOMMENDED MATERIAL Structural steel

IS CODE IS:2062

2 3 4 5 6 7 8 9

cast steel

IS1030 gr. 280-520 carbon steel IS 1570 part-II Gr. 45c8 corrosion resistant steel IS 1570 part-V 30cr13 std. Make SKF OR Eqt. std. Make std. Make std. Make D.C. Electro-magnetic KEC, GEC etc. GEB, HI-CLIFF WMI ETC. Usha martin / Southern wire rope BCH

OPERATION AND MAINTENANCE The following precautions are to be taken before Dry Testing the gates: Gate wheels, Gear wheels, Plummer block and worm reducer be lubricated. Removal of Temporary Supports if any. Checking of left over welding if any. Checking of tightness of the bolts and are to be tightened properly if they are in loose condition. The gates are to be inspected thoroughly for nay projections, temporary supports coming in the way of gate movement and are to be removed if any. All the rubber seals are to be made wet before lowering the gate preferably with water to reduce friction, heat generated between seal and seal seat. Light ray pass test may be conducted for checking gap in between seal and seal seat. Operating personnel shall be properly trained and experienced so that they can use their initiative and judgement based on their past experience for situation which may arise during operation. Day to day experience on operation and difficulties if any, encountered should be faithfully recorded in the Log Book of gates so as to be available for studying the behaviour of various structure and equipments. Detailed instructions for inspection and normal maintenance and repairs of gate installation should be given in the Operation &

Maintenance Manual. However, for carrying out special repairs to gates if any, it is advisable to refer to manufacturer. Inspection and Maintenance experience are complied in the form of History Register of any installations so as to be useful for further designs, investigations of any failure, improper and unusual operation in the gates History Register maintained for the purpose.

4. MAINTENANCE SCHEDULE FOR VERTICAL LIFT FIXED WHEEL GATE: These gates are provided for controlling water discharge for flood control, water supply, irrigation and power generation etc. The gate 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. MONTHLY MAINTENANCE: 1. Rollers are to be greased through grease nipples provided to rollers shaft by using grease gun. 2. Check Rollers rotation by hand for free rotation. 3. Seals and seal seating shall be inspected for leakage when the water level is full. Location of leakage points for taking remedial measures. 4. Excessive or wide spread leakages if any shall be reported to Engineer in Charge and remedial measures like adjustment of eccentricity in the roller axel or providing of rubber packing in between Rubber seal and seal base. Further adjustment may be carried out during Annual Maintenance. 5. If leakages is so much excessive that immediate repair is considered and rubber seals are repaired or replaced. QUARTERLY MAINTENANCE:

1. The Maintenance shall preferably be carried out once in three months but not less than thrice in a year including pre-monsoon and post monsoon maintenance. 2. All the Nuts & Bolts shall be checked for tightness. 3. Check all the welds for soundness and rectify defects if any, 4. Clean all drain holes wherever provided.

5. Check upstream face of skin plate for pitting, sealing and corrosion. Scale formation shall be removed by using wire brush, pitting shall be filled with weld and flush grind. Corroded surface shall be cleaned and painted. In case of gate not being raised every Quarter, these can be carried out in Annual Maintenance. 6. The Roller bearings / guide rollers shall be lubricated for the rotation. 7. The seal shall be checked for damages, wear and tear, if damaged, shall be replaced. 8. The guide assemblies, wheel assemblies and sealing assemblies shall be cleared of grit, sand or any other foreign material. 9. General cleaning is to be done for Hoist Components 10. Lubrication is to be attended for Bearings ate gate Rollers, Hoist pulley and pins provided in Hoist and Gates. 11. Rope drum shaft, Plumber blocks, Line shaft plumber blocks. 12. Check tightness of all coupling bolts of Motor to worm reducer and line shaft. If required they may be tightened. ANNUAL MAINTENANCE: The following additional checks or maintenance shall be carried out in addition to the checks mentioned under Quarterly Maintenance. 1. All the Embedded parts are checked for defects / damages and shall be rectified wherever noticed. 2. The sill beam and guides shall be cleared for all grit, sand etc.

3. The wire ropes shall be checked for wear and tear and if broken wires more than permissible or marked corrosion is noticed, the rope shall be replaced. The Table A shows up to which broken wires are allowed. 4. The wire rope shall be greased. 5. The guide roller pins shall be lubricated. 6. Check the condition of rubber seal. If damaged, replace the seals. 7. All bolts and nuts holding rubber seals shall be tightened. Adjust seal if leakages are found at local points.

8. Re painting of the gates shall be carried out at intervals to be decided on the basis of painting schedule of the gates. 9. The inspection, testing and maintenance of the hoist shall be carried out periodically. 10. Check oil level in Gear box / worm reducer and replace wherever required with oil of proper grade.

AT EVERY THREE YEARS: In addition to checks mentioned under Annual, following will be carried: 1. Check seals for damage and alignment. 2. Check seal bolts for damage. 3. Check for any damage to pulley and pin. 4. Check bearings for damages. 5. Check gears and pinions for damages. 6. Check plumber blocks for damages. 7. Check for any painting damages.

AT EVERY SIX YEARS In addition to checks mentioned under Annual, following will be carried out: 1. Check damaged / cracked welds at Skin plate joints Splice joints Hoist bridges Bracings 2. Check Wheel Assemblies for Any breakages Frozing Corrosion Mis alignment 3. Check seal seats, seal tracks side guides for For any welding cracks Bents or loose bolts and nuts Cracks in the beddings of worm reducers, Rope drum etc.

LUBRICATION SCHEDULE SL NO 1 PARTS TO BE LUBRICATED Gate Wheel bearings 2 3 Guide Shoes Hoisting wire rope MODE OF LUBRICATION Pressure Grease gun Pressure Grease gun Hand applied LUBRICANT Servo Gear -20 Or Bearing grease grease Servo Coat 120 Or Cordium 4 5 6 7 8 Worm reducer Gear wheels Drum shaft Lifting arrangement Hand operation Mechanism & other relating parts Oil bath Hand applied Pressure grease gun Hand applied Hand applied Compound Servo HP - 30 Chassis grease Chassis grease M.P. Grease Servolin - 140 FREQUENCY Once in three months as per site condition Once in three months as per site condition Once in a year before monsoon sets in Indicator level to be maintained always Once in six months as per site condition Once in three months as per site condition Once in six months as per site condition before monsoon sets in Once in three months as per site condition before monsoon sets in

CHART FOR MAINTENANCE SCHEDULE FOR GATES

AT EVERY QUARTERLY General cleanness of embedded parts,gate, hoist components Check for oil level in Radicons

AT EVERY YEAR In addition to Quarterly Maintenance schedule the following are to be checked Check for tightness of foundation bolts of Radicons, Plummer blocks, Coupling joints Check for smooth operation of gate by raising & lowering

AT EVERY 3 YEARS In addition to Yearly Maintenance schedule the following are to be checked Check the condition of wire rope, pulleys, sheaves, gear wheels Check gate seals for damage

AT EVERY 6 YEARS Check welds for damage at

Skin plate joints gate stiffeners

Greasing of pulleys & pins rope drum hoist, gear wheels, Hand operation shaft, guide rollers, gate wheels Wheels are to be greased properly

Check wheel assemblies for any Breakage, Frozing.

Check sill beam, sideguide, roller track for damages, corrosion, pitting Check hoist bridge foundation bolts for tightening

Movement of wheels should be smooth & it can be rotated by hand

OPERATION AND MAINTENANCE OF GATES SL NO 1 DOS Authorised / Technically qualified DONTS Unauthorised / Unqualified person should

personnel should be allowed for 2 3 4 5 6 7 8 9 operation. Attend Maintenance during pre monsoon season. Use proper tools for attending repairs / adjustment. Conduct DRY TEST before putting into operation Maintain cleanliness of hoist platform. Protect hoist gear box and other parts from rains. Ensure wire rope tightness on either side equally before operating gate. Ensure before operation that no foreign material fall in the gear teeth. Check tightness of plumber block, drive unit line shaft, coupling bolts. 10 Ensure no foreign particles stuck up in between roller and roller track and rubber 11 12 13 seal etc. Maintain oil as per level indicator in the gear box. Check tightness of wire rope clamps

not be allowed to operate gates. Maintenance works should not be attended during rains. Improper tools not to be used for any repairs / adjustments. Do not operate gates without DRY TESTING. Not to keep any slippery material on hoist walkway. Not to keep gear box covers open after daily maintenance. Not to operate gate when the wire rope is slacked. Not to run the hoist if foreign material found in between teeth of gear wheels. Do not operate gate if any bolts of plumber blocks and coupling bolts are found loose. Not to advise to operate gates if foreign material found in between rollers and roller track and rubber seals etc. Not to operate gates with low oil level in gear box. Not to operate gate if wire rope clamps

before operation. are found loose. Operate gate only when grooves are clean Do not operate gate if there is any without any obstruction. projection in the grooves which obstruct movement of gate

CONCLUSION Hydraulic Gates and Operating equipments form an integral component of Dams Barrage and other Hydraulic Structures. Gates and Hoists equipments play an important role for Dams to control, regulate, discharge floods etc. It is essential that Hydro Mechanical equipments are inspected periodically as suggested above and carries out Maintenance as a routine so that Hydro Mechanical equipment function

smoothly at all times to avoid loss. The Maintenance of gate is very important to have longer life of gate. It will be helpful if the gates are operated by technically qualified, trained (by us) persons and it reduces unnecessary repair and maintenance expenses.