TENDER SCHEDULE 5 METHOD STATEMENTS

Title: Installation of Canal Gates:

Location: Upstream Control Radial Gate Head and Cross Regulator on
the Conveyor Canal:
1.0 Introduction:
The purpose of this document is to outline all the work that Trashracks, stoplogs
and radial gates will be doing during the Roseires project stage 1, this will
include all the work procedures and instruction that are made by attached
specifications.
1.1 Scope:
This method statement will apply to the installation of the Trashracks, stoplogs
and radial gates as per drawing attached.
1.2 Electromechanical plants:
The canal has three water structures that regulate the flow and to create the
suitable head for off-takes (branch canals) along it. These regulators can be
construct new at the locations that explained on Annex along the canal. The
regulators will provided with radial gates to provide automatic downstream
water level control under continuous flow process. The gate type is AVIO at the
canal head, AVIS.
There are also 00 branch canals, of fourth order, take from the main canal.
Branch canal length varies from 00 to 00 km. Two branch canals, of fifth order,
take from nn canal as shown in Annex).
1.2.1Downstream water level control:
The self-regulating gates (float operated radial) are provided to branch canals
to respond to water level fluctuations in the downstream. These gates open to
bypass more flow when farmers abstraction increases in the downstream and
close when water withdrawal is stopped. The gates close completely when water
levels rise to approximately 10 cm above the crest level of the tail escape. Two
types of downstream control gates were suggested; AVIO and AVIS as shown
in attached drawings. The first was recommended for relatively higher upstream
water levels while AVIS is for smaller upstream levels.
Automating a canal system is by implementing a control system that
includes automatic monitoring or the control equipment.
. Automation creates a need for technical expertise to maintain computer
software and electronic equipment. Technical skills are required to apply
general principles of control system development and implementation and to
repair problems. Development and implementation work would probably be

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accomplished as part of the initial specifications contract and be considered as a

capital.
1.2.1.1 Equipment and Instrumentation:
Transducer sensors were positioned to record/measure the upstream and
downstream water levels of the gate. The gate can be operated manually or
remotely with the use of a built in gate position sensor in the actuator.
A doppler flow meter will install downstream of the radial gate and will be
mounted on the bottom of the canal.
The radial gate acts as: Pressure is transferred from the curved face through the
horizontal support beams to the radial arms at the sides of the opening. The
arms act as columns and transfer thrust to a common bearing located on either
side of the gate opening. Flow is underneath the curved face as the gate is
opened. This design results in a lightweight, gate that can be opened and closed
with minimum effort and with comparatively small number of turns of the hand
wheel on the hoist.
1.2.1.2 Methods of general construction statement and instructions:
During construction of a electromechanical plant, Electromechanical Resident
Engineer manages all the stages of the project, and performs a complex of the
facility building operations: design, construction and installation works
including deliveries of the process and engineering equipments, and
commissioning of the facilities. The corporate project management system
allows Electromechanical Resident Engineer specialists to monitor all the
processes fully, construction and installation works, and also to make sure that
the construction schedule is observed. The complex of services offered by
Electromechanical Resident Engineer during construction of electromechanical
plants includes:
Carrying out surveys, feasibility studies and design reviews;
Delivery of complete power generating equipment;
Building, installation, adjustment, and commissioning of facilities;
Complex servicing of the constructed power engineering facilities including
delivery of spare parts;
Modernization and reconstruction of the power engineering facilities;
Sharing experience, dispatching specialists and training of the local operating
personnel both in the country of the Customer and in manufacturing country.
Safety:
1- Personal Protective Equipment:
We shall wear the Personal protective equipment clothing listed at all
times when on site. No workers shall be permitted on site without the
full PPE as specified
Hard hat
Goggles
Overalls with high visibility reflector vest
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 Steel toe boots / gumboots in wet areas

Dust mask
Ear plugs (when working in a noisy area)
All employees will be equipped with their PPE and no one shall be
on site without the above required PPE
The PPE clothing is applicable to everyone coming on site
2- First Aid, emergency equipment and procedure:
We will ensure that persons at work receive prompt first aid treatment
in case of injuries or emergency
We will provide first aid box or boxes at or near the work place which
shall be available and accessible
No persons is allowed to carry on with their task in case an emergency
siren or alarm sound
Every minor injury shall be treated on site by the competent first aider
as Occupational Health and Safety act
All person working on site will undergo induction, safety awareness training
and environmental training with regarding emergency procedures, fire, or
electrical shut down.
The general statement of construction as:
1- Gate Face:
The standard radial gate face is constructed by using horizontal structural
members and a curved face plate. The curved steel face plate is 1/4 in. minimum
thickness.
The face plate is attached to the horizontal structural members by welding.
Sufficient holes are located around the perimeter of the assembly for attaching
the seals.
2- Horizontal Support Beams:
Horizontal face support beams are made from structural steel canals. These
beams vary in size with the width of the gate and maximum head of water. They
also vary in quantity and spacing with the height of the gate. Welded to the end
of each canal is a heavy steel gusset with holes punched to receive the side
arms. These support beams are normally painted.
3- Seals:
Side Seals
Side seals on both the overflow and breast-wall gates are made from neoprene.
The standard side seal is a J-seal bolted to the edge of the face plate and is held
in place by a steel retainer bar. The side seal is adjusted to compress against the
side rubbing plate to form a watertight seal.
4- Bottom Seal:
The bottom seal is also a J-seal that is attached to the gate by bolting. As the
gate closes, its weight causes a slight deflection in the seal as it contacts the
invert of the opening. This flexibility allows the bottom seal to compensate for
slight irregularities in the concrete floor.
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5- Top Seal:
The top seal on a breastwall-type radial gate is made by attaching a flat section
of rubber to the underneath side of the breastwall. An angle attached along the
top front face of the gate projects toward the breastwall and forms the other
portion of the seal. As the gate is closed, the protruding leg on the angle makes
contact with the rubber projecting from the breastwall and seals the space along
the top of the opening.
6- Radial Arms and Pin Plate:
Radial arms are fabricated from structural steel angles, with larger and thicker
angles being used as the gate height increases. Each angle acts as a column in
transmitting the load from the face support canal to the pin plate. The forward
or upstream end of each angle is punched with holes to match those in the
gusset plate. The back end of each angle terminates at a common pin plate in a
fan-like arrangement.
This steel pin plate is made thicker as the gate height, width, and head increase.
A steel collar is welded to the pin plate to form a hub to receive the pin. The
hub and pin are cross drilled to hold the gate pin in position. The pin is
removable to facilitate installation of the gate. The entire assembly is painted.
7- Bearing and Pin Assembly:
Pin bearings are a heavy cast iron housing and are bored to receive the pin.
Bearings are supplied with fins to firmly anchor them and distribute the total
thrust to the concrete. Pin bearings aligned and supported in the forms and
concrete poured around them, or a recess can be formed at the proper location in
the side walls and the bearings can be grouted in place after the gate is installed.
Removable cold-rolled steel pins of the proper diameter are supplied to transmit
the thrust on the gate to the pin bearings. The pin bearing is located high and
downstream out of the water.
8- Adjustable Sill and Side Rubbing Plates:
During construction, a recess is left at the sides and bottom of the gate opening
where the adjustable rubbing plates and the bottom sill are to be mounted.
Anchor bolts are set in the forms and extend into the recesses. Projection of
these anchors is less than the depth of the recess.
When forms are stripped, the adjustable plates are installed on the projecting
anchors. By use of double nuts on each anchor, the side rubbing plates and
bottom sill can be properly aligned.
Side rubbing plates are adjusted with the gate closed to obtain a good seal fit
and compression. Side seals and side rubbing plates should be adjusted so that a
slight wedge-shaped opening is formed to reduce seal drag and wear as the gate
opens. As an alignment check, the gate should operate to ensure that proper
contact is being made with the rubber seals on the gate.
All plates are then grouted in to complete the gate installation.

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9- Hoist:
The hoist consists of a worm gear arrangement with double drums for winding
two cables simultaneously. The individual cables run from each drum to the
bottom corners of the gate face.
The hoist gear box consists of a worm and worm gear totally enclosed in a cast
iron housing. The housing attaches to a bracket, which in turn anchors to the top
of the wall or a support beam. The drum shaft is a fabrication consisting of the
drum tube spanning the opening and flanges for the rope and stub shafts at each
end. One end is supported on a pillow block, the other by the gear box and
bulkhead bearing. The worm is attached to a vertical shaft extending out of the
gear box and is supplied with a hand wheel.
10- Motor Operation:
Hydro Gate hoists motorized using an electric valve actuator attached to the top
of the hoist to drive its vertical input shaft. The unit also includes an electric
motor; reversing controller; push-button stations for raise, stop and lower; two
indicating lights; geared limit switches; torque switches; and Hand wheel for
emergency operation.
11- Automatic Operation:
A hoist with an electrically operated lift mechanism equipped for automatic
operation of the radial gate by use of logic controls to control flow and level, or
to interface with other process controls.
2.0 Methodology for erection of main electromechanical equipments:
2.1 Radial Gates and Stoplogs:
The gate shall be fabricated in various segments such that the weight of each
segment or the heaviest piece does not exceed 25T to suit the capacity of cable
crane.
Following shall be the typical erection sequence of Radial gate components:
Installation of Sluice Liner & Concreting.
Casting of Trunnion Girder.
Installation of Trunnion Assembly.
Placement of Sill Beam.
Placement of Side Seal Supports/Wall Plates.
Placement of Lintel Supports.
Second Stage concreting around Sill Beam, Wall Plates and Lintel Beam.
Erection of Bottom Gate Element.
Erection of Arm-Trunnion Connector.
Erection of Bottom Arms.
Erection of balance gate elements.
Final welding of elements, arms etc..
Erection of Cylinder Support Structure.

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Erection of Cylinder and Connecting with Gate.

Second Stage Concreting of the Cylinder Support Structure.
Placement of Power Packs and Control Panels in the Control Room/Hoist
Gallery.
Installation of Hydraulic Pipings between Power Pack and Cylinders.
Fixing of Limit switches and Electrical cabling.
Filling of Hydraulic Oil in the Cylinders and Powerpack.
Fixing of Rubber Seals on gate and on Lintel Beam.
Fixing of Side Guide Rollers on Gate.
Protective coating and touch up paint.
Trial testing/Dry testing and commissioning of Gate.
2.2Stoplogs:
These Radial Gates shall also be made in various segments. The trunnion
assembly shall be erected with the help of Mobile Cranes moving on bridge at
El &&0m or cable crane used for concreting.
The gate segments shall be lowered by Cable Crane. The gate segments shall
also be lowered by mobile cranes of suitable capacity from upstream road
bridge. Tower cranes travelling on upstream road bridge shall also be provided
for handling the lighter stoplog gate components up to 10T weight.
The erection sequence of the stoplog gate components shall be similar to
erection sequence of radial gates.
2.3 Intake Trash Racks, Intake Stoplogs and Intake Gates:
The second stage trashracks shall be erected using Tower Cranes travelling on
top of pier El &&&m.
The Trashracks, Intake Stoplogs and Intake Gates shall be erected using Mobile
Cranes travelling on road bridge. The tower cranes shall also be used for the
erection of these items.
2.4 Draft Tube Gates:
The erection of second stage Trashracks shall be done from downstream end
using winches and derricks. The gate shall be made in two units, each unit shall
be in one piece. These units will be lowered in the chamber using Draft Tube
Gantry Crane.
2.5 Erection of Sluice Liners:
The rectangular frame of sluice liners shall be fabricated in the needed length of
such that weight of each segment is limited to 25T. These segments shall be
brought by cable crane and will be lowered on the rail track already erected

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&aligned to line and grade over the concrete floor. The erection shall be started
from downstream end progressing towards upstream side.
The segments shall be pulled at desired location using winches & derricks. The
suitable number of hydraulic/mechanical jacks shall be used for final alignment
with the adjoining segment. After ensuring correct line and grade of the
segments, the welding between segments will be completed. After completing
the welding, the concreting shall be completed.
The grouting below the bottom liner shall be completed through various grout
holes.
2.6 Erection of Penstock:
The transport of steel liner from workshop to Cable way shall be done by low
bed trailers.
The unloading of steel liner from trailer shall be done by 30 tone capacity
mobile crane. The 30 tone capacity mobile crane unload the steel liner at the
wide road from where the crab of Cable way will lift it up and place it at the
exact position. The weight of each piece of penstock steel liner will be kept
below 25 tone as the capacity of Cable way is 28 tones.
After erection, concrete back filling and grouting, all temporary
fixtures/appurtenances, debris etc. inside the steel liner shall be carefully
removed.

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