OPERATION AND MAINTENANCE OF RADIAL GATES

& FIXED WHEEL GATES

By ER. N. Kannaiah Naidu
Technical Advisor
(Hydraulic gates and Handling arrangements)

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

ii. Gate Parts:

 Skin plate Assembly
 End Verticals
 Horizontal girders
 Vertical Stiffeners
 Roller assembly
 Seal Assembly
 Side guide assembly
 Lifting 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)

ii. Gate Leaf :

Common anchorages Independent anchorages

(Bonded Anchorages) (Un-bonded anchorages)
 Skin plate  Skin plate
 Side guide and seal assembly  Side guide and seal assembly
 Vertical stiffeners  Vertical stiffeners
 Horizontal Girders  Horizontal Girders
 Horizontal Girder Bracings  Horizontal Girder Bracings
 Arm Assembly  Arm Assembly
 Trunnion  Trunnion
 Trunnion pin  Trunnion pin
 Trunnion Bush  Trunnion Bush
 Trunnion Bracket  Trunnion Bracket
 Tie between trunnion or Thrust block  Tie between trunnion or Thrust block
 Lifting Bracket  Lifting Bracket

2
 3. Rope drum Hoists:
A. For Vertical Lift Gates :
 Drive Unit Assembly
 Gear Box Assembly
 Hoist Supporting structures etc.,

B. For Radial Gates :

Upstream Suspension Down Stream Suspension

 Drive Unit Assembly
 Gear box assembly
 Hoist bridge
 Lifting arrangement
 Drive unit assembly
 Gear box assembly
 Fixed end support
 Hoist chasis
 Line shaft support girder
 Dial and Dial Assembly etc.,

Operation and Maintenance:

 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.

 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
behavior of various structures and equipment.

 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.

 Removal of temporary supports if any.

 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.

 All weld tests are to be conducted.

4
5.0 Maintenance schedules for Radial gates, Vertical lift fixed wheeled gates,
electrically operated fixed hoists should be attended preferably prior to monsoon :

5.1 Radial Gates :

5.1 (a): Monthly maintenance :
 Seals and seal seating shall be inspected for leakages. Locations of excessive
leakages shall be recorded for taking remedial measures.
 Exccessive or wide spread leakages if any shall be reported to Engineer – in – charge
and remedial measures like tightening of bolts is to be carried out. Further adjustment
is carried out during annual maintenance or necessary plan for replacement of parts
shall be initiated and carried out before floods.
 If leakage is so much immediate repair is to be considered and seals are to be
repaired or to be replaced by using stoplog gates.
 Remove all dirt, girt, etc., from trunnion assembly and lubricate trunnion bearings of
the gate with suitable water resisting grease.
 More concentration is to be given for checking of welds :
 Between yoke girder web and tie flats.
 Between trunnion and tie between turnnion.
 Lifting bracket and gate.

5.1 (b): Quarterly Maintenance :

 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.
 All the nuts and bolts of trunnion assembly and its anchorages shall be checked for
tightness.
 Check all the welds for soundness and rectify defects if any.
 Check welding between latching bracket and skin plate with help of magnifying glass
for cracks / defects and rectify the defects.
 Clean all drain holes including those in end arms, horizontal girders trunnion and
pulley blocks.
 Check all nuts and bolts for tightness and tighten them if loose.
 Check upstream face of skin plate for pitting, sealing and corrosion. Sealing formation
shall be removed, pitting shall be filled with weld and ground, and Corroded surface
shall be cleaned and painted. In case of gate not being raised every quarter, these
can be carried out in annual maintenance.

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.

5.1 (C): Annual maintenance:

The following additional checks or maintenance shall be carried out in addition to
checks mentioned under quarterly maintenance.
 All the embedded parts shall be checked for defects / damages and shall be rectified
where ever noticed and exposed parts shall be painted for longer life.
 The sill beam and guides shall be cleared for all girt, sand etc.,
 The wire ropes shall be checked for equal tension. If broken strands are noticed, the
wire rope shall be replaced. Fixing of rope sockets also shall be checked.
 The wire rope shall be greased.
 The guide roller pins shall be lubricated and ensure for its rotation.
 Check the condition of rubber seal. If damaged, replace the seals.
 All bolts and nuts holding rubber seals shall be tightened. Adjust seal if leakages are
found at local points.

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.

5.2(a) : Monthly maintenance :

 Wheels are to be greased properly.

 Check wheel rotation by hand for free rotation.

 Balance points same as Radial Gates – Maintenance may please be carried out.

5.2(b): Quarterly Maintenance:

Same as Radial Gates – Maintenance may please be carried out.

5.2(c): Annual Maintenance:

 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.

5.3(a) Daily Inspection :

 Entrance to all hoist platforms shall be kept locked. All keys shall remain with the
shift supervisor.
 A cursory daily inspection shall be made of hoist and gate to ensure that there is
no unusual happenings and ensure operation when called for.

5.3(b) Monthly Maintenance:

 Clean the dust of all hoisting machinery and hoist platform.
 Check oil level in gear boxes and replenish wherever required with oil of proper grade.
 Apply grease of suitable grade by grease gun through all the greasing nipples and
replace grease nipple if missing.
 Lubricate all bearings, bushings, pins, linkages, etc.,
 Check all the fuses on power lines and ensure closing of panel board covers not to
entry of dust and moist.
 All bolts and nuts on gear boxed, hoist drum and shaft couplings should be
checked for tightness.
 Check the supply voltage.
 Check the expansion provision in case of independent anchorages.
 Starters should be cleaned free of moisture and dust.
 Each individual contactor should be examined to make sure that it operated freely.
 All wearing parts should be examined and take remedial action to avoid
reoccurrence.
 The magnet faces should be cleaned if the contacted Hum.
 Examine all connections to see that no wires are broken and no connections are
loose.
 Clean the surface of the moving armature and magnet cone which comes together
when the contractor closes, free of dust or grease of any kind.
 The contact tips should be kept free from burns or pits by smoothening with fine
sand paper or emery paper.
 Replace the contact tips which have worn half – way.
 Do not lubricate the contacts.

8
5.3(c) Quarterly Maintenance:

 Carry out all those listed for monthly maintenance.

 Drain sample gear oil from each of the gear boxes. If excessive foreign particles
or sludge is found, the oil shall be drained, flushed and filled with new oil.
 All the geared couplings shall be greased.
 Raise and lower the gate by hoist motor and check for smooth and trouble free
operation of gate without excessive vibration.
 Observe current drawn by motor at the time of lifting and check if it is more than
normal. If so, stop the hoist and investigate the cause and rectify.
 Check for condition of painting of various components and remove rust wherever
noticed and repaint the portion after proper cleaning as per painting schedule.
 Check Electrical connection and wiring:
1. From supply point to main switch.
2. Main switch to starter.
3. Starter to motor.
4. Contact points of starter.
5. From starter to all lighting points, availability of bulbs and its glowing.

5.3(d) Annual Maintenance:

 The annual maintenance shall be combined with one of the quarterly

maintenance; the following shall be carried out in addition to those mentioned
under Quarterly Maintenance.
 All trash, sediments and any foreign material shall be cleared off the lifting rope
and lifting attachment.
 All 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. Refer IS
code for maintenance of wire ropes.
 All wire ropes shall be checked and all visible oxidation shall be removed.
 All wire ropes shall be greased with cordium compound or equivalent brand.
 Adjust the rope tension of wire if unequal.

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.

5.4 General maintenance on Radial Gate / Vertical Gate :

5.4(a) For every three years:
Ref: IS7718, IS: 10096 (part 3) latest
 In addition to check mentioned under annual, following will be carried.
 Check seals for damage and alignment;
 Check seal bolts for damage;
 Check for damage to wire rope;
 Check for any damage to pulleys and pins;
 Check bearings for damages;
 Check gears and pinions for damage;
 Check Plummer blocks for damage;
 Check for any painting damage.

10
5.4(b) For every Six years:

In addition to check mentioned under annual, following will be carried out.

 Check damaged / cracked welds at the following:

I. Skin plate joints
II. Splice joints
III. Hoist bridges
IV. Arms, Horizontal girders and bracings
V. Tie flats
VI. Trunnion girders / Yoke girders
VII. Trunnion brackets
VIII. Tie between trunnion

 Check Wheel assemblies for the following:

I. Any breakage
II. Frozing
III. Corrision
IV. Misalignment

 Check seal seats, seal tracks, side guides for the following:
I. Any damages
II. Corrosion
III. Pitting
IV. Misalignment

 Check Hoist Bridge and Platforms

I. For any welding cracks
II. Bent or loose bolts and nuts
III. Cracks in the bending or motors
IV. Radicons, ropedrum etc.,

11
 Lubrication Schedule

Sl. Parts to be lubricated Mode of Lubricant Frequency

No. Lubrication
1 Trunnion pin bush bearing Pressure Servo gear – 20 Once in three months
grease gun or bearing grease as per site conditions
2 Gate Wheel bearings Pressure Servo Gear – 20 Once in three months
grease gun or Bearing as per site conditions
Grease
3 Guide rollers Pressure Bearing Grease Once in three months
grease gun as per site conditions
4 Hoisting wire rope Hand Servo Gear – 120 Once in a year before
applied or Cordium monsoon sets in
Compound
5 Worm reducer Oil bath Servo HP - 30 Indicator level to be
maintained always
6 Spur Gear Bearings Pressure Bearing Grease Once in three months
grease gun as per site conditions
7 Line shaft bearings Pressure Bearing Grease Once in six months as
grease gun per site conditions
8 Gear Wheels Hand Chassis Grease Once in six months as
applied per site conditions
9 Drum shaft Pressure Chassis Grease Once in three months
grease gun as per site conditions
10 Lifting Arrangement and Hand M. P. Grease Once in six months as
buckles applied per site conditions
11 Hand operation mechanism Hand Servolin - 140 Once in three months
and other relating parts applied as per site conditions

12
 Chart for maintenance Schedule for Gates

IS : 7718 Part III – 1975

IS : 10096 part III – 1982

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.

I. Applying paint as fresh at the time of manufacture.

II. Removal of old paint, rust and repainting during maintenance.

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.

The procedure for surface preparation shall be as follows:

 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.

III. Hoist and supporting structure:

a) Structural components: Primary
Primer coats of zinc phosphate primer shall be applied to give a dry film thickness of
40±5 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.

b) Machinery: Except machined surfaces all surfaces of machinery including gearing,

housing, shafting, bearing pedestals etc., shall be given.
Primary coats: One coat of zinc phosphate priming paint to give minimum film
thickness of 50 microns. Motors and other bought out items shall be painted if
necessary.

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

Removal of old paint / rust and carrying out fresh painting:

The carrying of fresh painting is to be considered under the following conditions:
 The rusting is noticed all over the surface or
 Rusting is severe or
 Cracking and blistering has damaged the primer coat exposing the metal and is noticed
all over the surface or
 The paint film has eroded badly, the scrap of entire paint film to the base metal and
carry out fresh painting.
Note: In case of maintenance and renovation: Refer IS 1477 (Part II) – 1971 for checking
and repainting.

Removal of old paint for repainting:

Caution should be exercised while removing the old paint. The surfaces shall be derusted
and descaled by either mechanically by one or more of the methods.
a) Wire brushing , Scrabing, and chipping. Sand papering or cleaning with steel wool
or abrasive paper
b) Power tool cleaning
c) Flame cleaning
d) Sand blasting or shot flasting and
e) Chemical rust removal.
Note: The method of application shall be decided based on conditions existing. After
cleaning painting is to be carried out as originally proposed.
Some are painted without removal of old paint and rusting this will amounts to no painting
and deteriorate faster than the original one.

19
 Inspection and testing of painting

The following steps involved in inspection of painting are

1. General inspection before and during painting
2. Viscosity test of paints
3. thickness test – using Elcometer
4. Inspection of general appearance of finished work.

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.

Inspection of surfaces prior to painting: Inspection methods will depend on whether an

article is to be painted for the first time or is to be repainted.

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.

Inspection during preparation of surfaces:

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.

2. Derusting and Descaling:

a) Sand blasting: the most satisfactory method of removing rust and scale is by sand
blasting. The criterion of inspection should be that the steel after sandblasting has a
grayish white metallic appearance. The surface should be uniform in color and slightly
rough. Only such a uniform appearance ensures that the surface has been thoroughly
cleaned.

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.

Inspection Before and during intermediate protective treatments:

It is important to inspect the work to make sure that no time is allowed for fresh rust
or other contamination to take place between the precleaning and the intermediate
protective treatment. Inspection of the various suggested intermediate protective
treatments shall be carried out to ensure conformity with the recommended practice as laid
down in this standard and in accordance with manufacturer’s recommendations.

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;

b) That no painting is carried out when there is danger of dew;

c) That tools used are clean and not excessively worn;

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

1.0 Defects in finish :

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.

2.0 Defects in workmanship :

I. Excessive Paint Loss

S.No Possible cause Suggested remedies
Not ‘triggering’ the gun at each It should be a habit to release trigger after
i
stroke. every stroke.
ii Stroking at wrong angle to surface. Gun should be stroked at right angle to surface.
iii Stroking gun too far from the surface. Stroke the gun 150to 250mm from the surface.
iv Wrong air cap or fluid tip. Ascertain and use correct set up.
v Air pressure is too high. Use the least amount of air as necessary.

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.

III. Paint will not come from Spray Gun

S.No Possible cause Suggested remedies
i Out of paint (Gun begins to sputter). Add paint, correctly thinned out and strained.
ii Settled, caked pigment blocking gun tip. Remove obstruction, strip paint thoroughly.
Grit, dirt, paint skins etc., blocking gun Clean spray gun thoroughly and strain the
iii
tip, fluid valve or strainer. paint. Always strain paint before using it.

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

V. Gun sputters constantly.

S.No Possible cause Suggested remedies
i Fluid nozzle not tightened to spray gun Tighten securely, using a good gasket.
Leaky connection on fluid tube or
ii Tighten connections. Lubricate packing.
needle packing (suction gun).
Fluid pipe not tightened to the
iii Tighten. Check for defective threads.
pressure tank lid.

VI. Paint leaks from spray gun

S.No Possible cause Suggested remedies
i Fluid needle pacing nut too tight. Loosen nut. Lubricate packing.
ii Packing for fluid needle dry. Lubricate this part daily.
iii Foreign particle blocks fluid tip. Remove the tip and clean.
iv Damaged fluid tip or needle. Replace both tip and needle.
v Wrong size needle. Use correct combination.

27
 TECHANICAL DETAILS
5045 SPILLWAY RADIAL GATES
1650 1350

4400 1 NO OF GATES 7 NOS.

2 VENT WIDTH 12250mm

3000

1000
1650 1350
3 VENT HEIGHT 8800mm
6250 3000 792
1253 4 RADIUS 9000mm

5 SILL LEVEL EL :289.20M

6 TRUNNION LEVEL EL: 292.000M

10500
7 TOP OF GATE EL: 298.300M

8 F R L/MWL EL: 298.00M

9 TYPE OF ANCHORAGES COMMON

F
L
O 45T ROPE DRUM,
W 10 TYPE OF HOIST U/S SUSPENSION

11 PIER THICKNESS 3000/4000mm

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

INSULATION 3 PHASE AC 400 /440 VOLTS 50 CYCLES /

1500

SEC, SHAFT EXTENDED ON BOTH SIDES, WITH TOP

TERMINAL BOX, FRAME SIZE ND-160L.CONFIRMING TO
3000

2150

IS 325-1No.
1500

2. E.M. BRAKE:-
500
425

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:-
RATIO 60:1, TYPE "U", SIZE 8" INPUT H.P10 INPUT SPEED
975RPM OUT PUT TORQUE 394 KGM OUTPUT SHAFT
VENT = 12250

EXTENSION ON EITHER SIDE WITH SELF LOCKING-1No

15250

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

RADIAL GATE WITH

1500

Fig. 1 UPSTREAM HOIST

28
 TECHANICAL DETAILS
SPILLWAY RADIAL GATES
5045 1 NO OF GATES 7 NOS.
1650 1350
4400 2 VENT WIDTH 12250mm

3 VENT HEIGHT 8800mm

3000
4 RADIUS 9000mm
1650 1350

1000
5 SILL LEVEL EL :289.20M
6250 3000 792
1253 6 TRUNNION LEVEL EL: 292.000M

7 TOP OF GATE EL: 298.300M

8 F R L/MWL EL: 298.00M

10500
9 TYPE OF ANCHORAGES COMMON
45T ROPE DRUM,
10 TYPE OF HOIST U/S SUSPENSION

11 PIER THICKNESS 3000/4000mm

F
L DESIGNED AS PER
O 12 IS 4623-2000
W

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

INSULATION 3 PHASE AC 400 /440 VOLTS 50 CYCLES /

SEC, SHAFT EXTENDED ON BOTH SIDES, WITH TOP
3000

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

RADIAL GATE WITH

UPSTREAM HOIST

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)

3 NO. OF STOPLOGS REQUIRED 2 SETS

4 EMBEDDED PARTS 24 SETS
5 SILL LEVEL EL :35.840M
6 F R L/MWL EL: 53.340M
VENT =18500

11100

7 NO. OF ELEMENTS 10 NOS.

8 OPERATION 60T GANTRY CRANE

9 DESIGNED AS PER IS: 5620

10.943°

NOTE:
3700

1. ALL DIMENSIONS ARE IN MM AND

LEVELS ARE IN METERS.
2. ALL WELDS ARE 6MM FILLET CONTINUOUS.
3. THIS DRAWING IS PREPARED BY BASED ON
DRG. NO : SCL/PC/EXE/25
3500




93 93
950 503229 1200 229503 950
1450

1450

13° 13°
1300
1220
1050
890

890
1450

1450
1ST STAGE
2800

565 565 565 565

529 529
2ND STAGE

1775 1200 1775 Fig - 3

2375 2375
4750 RADIAL GATE WITH
(END VIEW AT TRN CENTER)
DOWN STREAM HOIST
30
 13° 13°

4000 2700 


6500 3745

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

SPILLWAY RADIAL GATES

2375

1 NO OF GATES 20 NOS.
2850


4750


2 VENT WIDTH 18500mm
2375

VENT HEIGHT ABOVE SILL

950

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

9 TYPE OF ANCHORAGE INDEPENDENT

VENT =18500

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

1775 1200 1775

2375
4750
2375
Fig – 4 RADIAL GATE WITH
(END VIEW AT TRN CENTER) HYDRAULIC HOIST

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

W SKIN PLATE 323

12330
000

12
13424
15

100 100 100

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

ELEVATION 6000R TECHNICAL DATA

RADIAL GATES
1 NO OF GATES 7 NOS
2 VENT WIDTH 8.00 M
3500

3 VENT HEIGHT 12.38M

4 DESIGN OF HEAD 30.880M
INTERMEDIATE PIER
7000

7000

5 TYPE OF GATE GATE WITH INCLINED

TRUST 6 OPERATING BY HYDRAULIC HOIST
2550

BLOCK
3500

7 SILL LEVEL EL 587.120M

8 TUNION CENTER LEVEL EL 599.50 M
2000 950

950
195

9 TOP OF VENT EL 599.50 M

1520480

12.4

? OF ANTIGET SEAL EL 599.675 M

405

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

CLOSED POSTION EL 600.100 M

O
W ? OF HYDRAULIC HOIST
14 EYE END MOUNTING EL 609.500M
1520
950 2000

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



 
   
 




  





 



? SILL ? SILL   

   
  
 
CG CG
OF GATE OF GATE
 
  
    
   







 

    NOTE:-

    1.ALL DIMENSIONS ARE IN MM
 2.ALL LEVELS ARE METERS

TECHNICAL DETAILS TECHNICAL DETAILS

OF RIVER SLUICE SERVICE GATES OF RIVER SLUICE EMERGENCY GATE

 NO OF GATES REQUIRED : 4NOS.  NO OF GATES REQUIRED : 4NOS.

 CLEAR VENT WIDTH : 2100MM  CLEAR VENT WIDTH : 2100MM
 CLEAR VENT HEIGHT : 4000MM  CLEAR VENT HEIGHT : 4000MM
 SILL LEVEL : EL 25.000M  SILL LEVEL : EL 25.000M


TOP OF VENT
FRL / MWL
: EL 29.000M
: EL 53.340M


TOP OF VENT
FRL / MWL
: EL 29.000M
: EL 53.340M
Fig – 6
 LOCATION OF SKIN PLATE : DOWN STREAM SIDE  LOCATION OF SKIN PLATE : UP STREAM SIDE
 

DEPTH OF GROOVE
SILL TO TOP SEAL CENTRE
: 550MM
: 4100MM 
DEPTH OF GROOVE
SILL TO TOP SEAL CENTRE
: 550MM
: 4100MM VERTICAL FOR
 OPERATED BY : 30T ROPE DRUM HOIST  OPERATED BY : 20T ROPE DRUM HOIST.
 DESIGNED : AS PER IS 4622 - 2003.  DESIGNED : AS PER IS 4622 - 2003. RIVER SLUICES

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

3 VENT HEIGHT 4545 MM

6245 4 GATE HEIGHT 4730 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

9 SPEED 1.65 M/MIN

ROPE DRUM HOIST
9 HOIST CAPACITY
200

30T - 1NO PER GATE

COLUMN C/C = 6045 75 10 DESIGNED AS PER IS 6938 - 2005

250 260 600 75 600
250
1950 330
340 270 TECHNICAL DETAILS

1270 930 1550 1200 930 INTAKE STOPLOG GATE

2480 1 NO OF GATES 3 NOS

2 VENT WIDTH 4545 MM

3 VENT HEIGHT 4545 MM

4205 VENT = 4545 4205
4 GATE HEIGHT 4730 MM

5 SILL LEVEL + EL 18.828 M

6 TOP OF PIER + EL 40.00 M

END TO END OF GROOVE =5500
7 FRL + EL38.00 M
WHEEL C/C = 6150 8 MWL + EL 38.00 M

LIFTING C/C3200 9 SPEED 0.50 M/MIN

1610 1100 1610 MOVING HOIST
9 HOIST CAPACITY
25T - 1NO
952

10 DESIGNED AS PER IS 6938 - 1989

477.5
600

340
150

150 1080 1120

930 1270
25

2200

? ? NOTE:
1400 25

1. ALL DIMENSIONS ARE IN MM AND LEVELS ARE

270260
1950

IN METERS.
930 1200 1550
600

2. THE MINIMUM CLEARNESS IS REQUIRED PER

25

500 1450 1800 GATE OPERATION IS INDICATED IN THE

2750

?
600
? DRAWING SAME MAY PLEASE BE ENSURED
1350
25

250 600
75 75
600 250 WHILE CONSTRICTION.
330
1800

1610 1140 1140 1610

3200 82 80
2272.5 2272.5
6535

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

? 915 11583 2089 2330 WITH TRASH RACKS,

STOPLOGS AND SERVICE GATES
1800

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.

2 VENT WIDTH 4545mm

3 VENT HEIGHT 4545mm

4 SILL LEVEL EL :-2.873M

5 FRL EL :17.8M

7000
6 MWL EL :19.0M

7 TOP OF PIER EL :20.5M

HOIST CAPACITY HYDRAULICHOIST
8
30T - 1NOPERGATE
9 TYPE SINGLE ACTING
2500 10 STROKE 5300 M

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.

2 VENT WIDTH 4545mm

3 VENT HEIGHT 4545mm

4 SILL LEVEL EL :-2.873M

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

9 TYPE GANTRY CRANE

10 SPAN 2500MM
OPERATION THROUGHPENDENT
11
2

CONTROL
2316

12 DESIGNOF CRANE AS PERIS 3177 &807

5200

600 1125 600

600 250
600 200
250

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

1406 11169 1922 2319

INTAKE STRUCTUREWITH
TRASH RACKS, STOPLOGS
ANDSERVICE GATES
OPERATEDBY HYDRAULIC
HOIST AND GANTRYCRANE.
35
Fig - 7(b)
7000

1250 1250

MAX WHEEL LOADS

LIFTING C/C 4200
1000

8500
2500
2187
320
75
2588 650 867
4500
1000
320 330

WITHOUT IMPACT 18.1T 18.1T

WITH IMPACT 21.5T 21.5T

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

25T GANTRY CRANE -1NOS FOR OPERATION OF DRAFT

CAPACITY TUBE GATES
NEERUKATTE MINI HYDEL SCHEME.

CLASS AND CLASS II OUTDOOR DUTY GANTRY CRANE.

2588 650 1187 DUTY DESGINED AS PER IS 3177-1999 AND IS807-2006
AND IS 6938 - 2005
75 320
Recess HOIST -1.25M/MIN
OPERATION CRAB TRAVEL - 3.0M/MIN ±10%
SPEED GANTRY TRAVEL -6.00M/MIN

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

3 VENT HEIGHT 4270mm

4 SILL LEVEL EL :12.550M

4350

5 MAX. TWL. EL :32.000M

6 TOP OF PIER EL :37.000M

7 HOIST CAPACITY 25T

66 8 TYPE GANTRY CRANE
9 SPAN 2500MM

10 OPERATION LIFTING BEAM

1920 VENT = 6830 1920 11 DESIGN OF CRANE AS PER IS 3177 & 807
75 RECESS
2663

TRACK C/C =7350

4848

2500
650

650

1045

810
1187

320
652

DRAFT TUBE GATE

36 WITH GANTRY CRANE

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

ELEVATION END VIEW

HOIST TROLLY / CROSS LONG TRAVEL

MECHANISM TRAVEL
MOTOR:-
a)37 KW (50.0 HP) 728 RPM. SLIP RING CRANE DUTY MOTOR:- 4.MOTOR :
MOTOR 40% CDF150 STARTS/HOUR CLASS `F` 4.8 KW (6.4 HP) 702 RPM. SLIP RING 4.8 KW(6.4 H.P),702 RPM SLIP RING
INSULATION TEFC, FOOT MOUNTED WORKING CRANE DUTY MOTOR 40% CDF150 CRANE DUTY MOTOR 40% CDF 150
ON 3 PHASE 400 /440 V 50 CYCLES/SEC, STARTS/HOUR CLASS `F` STARTS/HOUR, CLASS 'B/F'
CONFORMING TO IS: 325; FRAME SIZE NDW:250M- INSULATION TEFC, FOOT INSULATION TEFC FOOT
1NOS MOUNTED WORKING ON 3 PHASE MOUNTED WORKING ON 400/400V
MAKE:-CROMPTON GREEVES/ALSTOM/KIRLOSKER 400 /440 V 50 CYCLES/SEC, 3PH AC 50 CYCLES/SEC
MOTOR:- CONFORMING TO IS: 325;FRAME CONFIRMIG TO IS 325-FRAME SIZE:
b)CREEP MOTOR:-
5.4KW (7.0 HP) 705 RPM. SQUIRREL CAGE SIZE NDW160M- 1NOS. SHAFT EXTENDED ON BOTH SIDES.
CRANE DUTY MOTOR 40% CDF150 STARTS/HOUR MAKE:- CROMPTON GREEVES / NDW: 160M - 4NOS.
CLASS `B/F` INSULATION TEFC, FOOT MOUNTED ALSTOM / KIRLOSKER MAKE:- CROMPTON GREEVES,
WORKING ON 3 PHASE 400 /440 V 50 CYCLES/SEC, ALSTOM / KIRLOSKER
9

CONFORMING TO IS: 325;FRAME SIZE NDW160M

8

BR4
7

REDUCTION UNIT:-
6
BR3

REDUCTION UNIT:- HELICAL GEAR BOX :

a)THREE STAGE HELICAL GEAR BOX RATIO 90:1
5

THREE STAGE VERTICAL HELICAL NEWTECH CRANE DUTY VERTICAL

BR2

INPUT HP 39.5KW,INPUT SPED 750 RPM WITH INPUT

GEAR BOX RATIO 400:1 INPUT HP GEARBOX RATIO 200:1,RATING
AND OUT PUT SHAFT EXTENTION ON BOTH SIDE TO
6000
4

6.4HP,INPUT SPED 750 RPM WITH 4.8KW@720RPM,CENTER DISTANCE

SUIT ASSEMBLY TYPE SIZE HTN- DD-360- 1NOS.
INPUT AND OUT PUT SHAFT 705,WITH HALLOW KEYED SHAFT.
REDUCTION MAKE:-SHANTHI /NU TECH / ELECON
BR1

EXTENTION ON,BOTH SIDE TYPE

3

UNIT b)PLANTERY GEARBOX RH=2 NO, LH=2 NOS.

SIZE : HQN- DD-250-1NOS.
2

CREEP SPEED CRANE DUTY MAKE:- SHANTHI / NU TECH / ELECON

MAKE:-SHANTHI/NU TECH/ELECON
RATIO 10:1 INPUT HP 9,INPUT SPED 703RPM WITH
INPUT AND OUT PUT SHAFT EXTENTION ON BOTH
CHAIR

SIDE MODEL NO X10063 - 1NOS

1

MAKE:-MAGTORQ / ELECON / SHANTHI

a) BRAKE:- 400Ø ELECTRO HYDRAULIC THURSTOR BRKE:- BRAKE:

BRAKE,HAVING BREAKING CAPACITY 200 MMØ SINGLE PHASE 200Ø HYDRAULIC FOOT OPERATED
90 KGM - 1NO.MAKE:-EMC / STERLING CONTROLS E.M.BRAKE,100% COIL RATING BRAKE TORQUE CAPACITY:15 KGM
CLASS `B` INSULATION WORKING -4NOS.
350
20 640 1040 500 b)BRAKE:- 450Ø 3 PHASE E.M.BRAKE,100% COIL ON 400 / 440V AC,50 CYCLE/SEC.
330
RATING CLASS `B` INSULATION WORKING ON HAVING BREAKING CAPACITY 15.0 BRAKE:200 MM DIA E.M BRAKE 100%
400 / 440V AC,50 CYCLE/SEC. HAVING BRAKING KGM -1NO. COIL RATIG CLASS 'B'
CAPACITY 74.0 KGM - 1NO.MAKE:-EMC / STERLING MAKE :- EMC / STRELING INSULATION,BREAKING TORQUE
CAPACITY:15KGM -4 NOS.
PLAN BRAKES
c)BRAKE:- 300Ø SINGLE PHASE E.M.BRAKE,100% COIL PLUMMER BLOCK:- SNA 522 WITH
RATING CLASS `B` INSULATION WORKING ON 400 / 2222K BEARING +H322 SLEEVE MAKE :- EMC / STERLING CONTROLS
440V AC,50 CYCLE/SEC. HAVING BREAKING CAPACITY DYNAMIC CAPACITY:122 KN,
6000 38.8 KGM (TO SUIT PLANYERY GEARBOX-OUTER DIA STATIC CAPACITY:52 KN- 4 NOS.
X10063) MAKE:-EMC / STERLING CONTROLS MAKE :- MASTA / FAG

d) BRAKE:- 200Ø SINGLE PHASE E.M.BRAKE,100% COIL

TECHNICAL DETAILS RATING CLASS `B` INSULATION WORKING ON 400 /
440V AC,50 CYCLE/SEC. HAVING BREAKING CAPACITY
LOCATION / OPERATION:---------------- OUT DOOR, DOUBLE ROPE DRUM,ELECTRICAL OPERATED FROM CABIN. 15.0 KGM. MAKE:-EMC / STERLING CONTROLS
6
POWER / SUPPLY:-------------------------- 400 / 440V.AC.3PHASE 50CYCLES / SEC FROM PLUG POINT AT THE GANTRY RUNWAY. WIRE ROPE 40Ø 36 CONSTRUCTION, RIGHT
HAND LAY UNGALVANIZED IMPROVED
DUTY CLASS / SPECIFICATION:-------- CLASS II OUTDOOR DUTY DESIGNED AS PER IS 3177-1999 & IS:807-1976. WIRE ROPE PLOUGH STEEL MAIN FIBERECORE UTS 180 KG/MM2
------ ------
HAVING MIN- BREAKING LOAD = 95209 KG,
LIFT (M)----------------------------------------- 65.0M LENGHT REQUIRED 580M -1 LENGTH. AS PER IS:2266
MAKE:- BHARAT WIRE ROPE /
WHEEL
CAPACITY (T)---------------------------------- 100T 8 NOS
QUANTITY ------ 4 NOS
THREAD DIA 710DIA
------ 500 DIA
SPEED------------------------------------------- HOIST:-MAIN SPEED 1.5 M/MIN 2 NOS
DRIVE ENDS ------ 2 NOS
CREEP SPEED 0.15 M/MIN RAIL SIZE CR - 120
------ CR - 120
CRAB TRAVEL :-3.0 M/MIN MATERAIL CAST STEEL GR 340-570W IS :1030
------ CAST STEEL GR 340-570W IS :1030
GANTRY TRAVEL:- 8.0 M\MIN THREAD 300 BHN
------ 300 BHN
LENGTH OF TRACK------------------------- 210M HARDNESS

WHEEL LOADS (U/S)

8000 THE DETAILS OF COMPONENTS TO BE LIFTED
COUNTER WEIGHT REQUIRED
A) 7.7m(LENGTH) X 7.765m (HEIGHT) X 1.152m (WIDTH)
FOR STABILITY OF CRANE
(REF DRG NO: CE(D)/D&PH/UF/74(R2)
TOP D/S TIE GIRDER
B) STOPLOG GATE 8.264m(LENGTH) X 1.354m (HEIGHT) X 2.25m (WIDTH)
& END OF RAIL GIRDER ------- 45.0T
A B C D C) LIFTING BEAM:- THE HEIGHT OF LIFTING BEAM FOR PEN STOCK
BOTTOM D/S TIE GIRDER ---- 50.0T
A B WITH IMPACT 71.0 71.0 71.0 71.0 C STOPLOG GATE IS ABOUT 2100m (REF DRG NO: 89-SS-38-204, VOL III OF
D 95.0T
WITH OUT IMPACT 60.0 60.0 60.0 60.0 TENDER DOCUMENTS FOR 100T GANTRY CRANE)
850 850 850 850
D) STEM OF HYDRAULIC HOIST OF ABOUT 9.6m LENGTH
COUNTER WEIGHT IN THE MIX OF
WHEEL LOADS (D/S) CONCRETE + MS SCRAP OR
8000 CONCRETE + IRON CORE + SCRAP

100T GANTRY CRANE FOR OPERATION

WITH A DENSITY OF 3.5T/M3 SHALL BE
PROVIDED.
A B C D NOTE:
1.ALL DIMENSIONS ARE IN MM AND ALL LEVELS ARE METERS
WITH IMPACT 9.0 9.0 9.0 9.0

OF STOPLOGS IN INCLINED POSITION

A B C D 2.LUBRICATION:-INDIVIDUAL POINT LUBRICATION FOR L.T
WITH OUT IMPACT 13.0 13.0 13.0 13.0 WHEELS,TOP PULLEYS,LIFTING PULLEYS&DRUM PEDESTAL
850 850 650 850

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

F.R.L/MWL 890 1500 1000

EL 266.190M
2000
BREST WALL

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

LIFTING C\C 7200

STOPLOG GATE
SERVICE GATE GROOVE

13700
3350
F
L
O
W

SILL
EL 254.300M 67
EL 253.900M 67 733

1283 3484 2633

1500 7400 8050 1500

18450

TECHNICAL DETAILS TECHNICAL DETAILS

VERTICAL LIFT SERVICE GATE STOPLOG GATES
2100 750 3350 800 11450
. NO OF GATES : 1 SET
. NO OF GATES : 6 NOS
. VENT WIDTH : 10000MM . VENT WIDTH : 10000MM
. VENT HEIGHT : 8500MM . VENT HEIGHT : 8500MM
? OF ? OF
3000

STOPLOG SILL SERVICE GATE SILL

. GATE HEIGHT : 8600MM . HEIGHT OF ELEMENT
. PIER THICKNESS : 3000MM IN ASSEMBLED : 8600MM
. CAPACITY OF HOIST : 85T CONDITION
. SPEED : 0.5 M/min ±10% . NO OF EMBEDED PARTS : 10 SETS.
3484
. TYPE : VERTICAL LIFT . NO OF ELEMENTS : 4 NOS.
PIER PLAN ROLLER GATE . HEIGHT OF EACH ELEMENT : 1400 mm
. OPERATED BY : ROPE DRUM HOIST . OPERATED BY : 25T GRANTRY CRANE
. LIFT : 15.0M AUTOMATIC LIFTING BEAM
. DESIGNED : AS PER IS 4622 - 2003. . DESIGNED : AS PER IS 4622 - 2003.

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