Rehabilitation of Hydromechanical equipments in PH1 tunnel entry in Sholayar dam in Valparai taluk of Coimbatore District

Amount

Repair & Renewal of the existing damaged embedded parts shall be repaired & replaced as per the following specification. On depletion of water in the tunnel upto the min level, a ring bund shall be made around the trash rack in the leading channel to restrict water from accidental flowing into the leading channel. Alternate arrangements shall be deployed to avoid flow of water from dam to the leading channel by the department. The existing embedded parts shall be inspected throughout the depth of 170’of the tunnel by employing a suspended platform operated with a motorised winch. On observation of the grooves, the damaged portions due to the sudden impact shall be repaired.The roller track, side seal track,top seal track and sill seat shall be replaced with SS 304 grade

material as per IS 4622. The patch work in civil structure due to this replacement shall be done good with micro concrete. The cost includes cost of MS materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel & lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including warranty and maintenance for 5 years.

Design , fabrication, transport, supply & erection at site of vertical shutter including skin plate with vertical stiffeners, horizontal girders, end verticals, connecting plates, rib plates etc, suitable of tunnel entry emergency gate of vent size 3050x3650mm as per IS 9349 : 2006. The skin plate, end verticals, vertical stiffeners, horizontal girders, lifting assembly, side seal base plate, side seal cover, bottom seal cover & top seal cover shall be made of structural steel confirming to IS 2062 : 2011. The welding shall be done as per standard procedures and the burr and slag shall be removed by grinding the top of welds. A good weld is as strong as the base metal. A suitable electrode shall be chosen and welded with a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. On fabrication of all components of the shutter, a trial assembly shall be done at the shopfloor to ensure the dimensional accuracy and integration of all sub components. Also, the layout shall be clearly marked & serially numbered by punching. Match drilling in different components and cleats provided wherever necessary to assure minimum tolerance levels. The existing rollers in the damaged shutter shall be salvaged, then modified to the exact size & overhauled. New SS rollers pins made

of 30CR 13 grade confirming to IS 1570 shall be fabricated and then machined to match the rollers to be assembled in the new shutter. New rubber seals ‘P’ type shall be used for the side seals & top seals whereas flat type seal shall be used for the gate bottom as per IS 15466. The surface coating shall be given with a priming coat of 70µ with zinc epoxy primer which would be the sacrificial coat and a protective coat over it with coal tar epoxy to a thickness of 300µ as per IS 14177. The coating shall be done only after a blast cleaning of all metal surfaces to SA 2 ½ standard. The cost includes cost of MS materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel & lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including warranty and maintenance for 5 years.

Design, fabrication, transport & erection at site of support structure to the gantry hoist frame as per the following specification. The structure shall be designed as per IS 800 for the proposed gantry hoists. The raw material used shall confirm to IS 2062. The welding shall be done as per standard procedures and the burr and slag shall be removed by grinding the top of welds. A good weld is as strong as the base metal. A suitable electrode shall be chosen and welded with a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. The surface coating shall be done with a zinc epoxy primer to a thickness of 70µ which serves as a sacrificial coat. An intermediate coat with MIO micaceous iron oxide shall be applied to a thickness of 75µ and a finish coat of polyurethane finish aluminium oxide to a thickness of 60µ in 2 coats of 30µ each. All these surface coating shall only be done after blast cleaning of all metal surfaces as per SA 2 1/2 standard with indentation of 30-40µ to near white metal finish. The foundation bolts for this stanchions shall be made on the existing concrete at the ground level. Holes are drilled in this structure at appropriate points as per design size. Then the MS foundation bolts shall be fixed inthese holes with hybrid epoxy

vinyl mortar. The stanchions shall be erected in these foundation bolts. The cost includes cost of MS materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel & lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including warranty and maintenance for 5 years

Design, fabrication, transport & erection at site of hoist bridge to the gantry hoist frame as per the following specification. The structure shall be designed as per IS 800 for the proposed gantry hoists. The raw material used shall confirm to IS 2062. The welding shall be done as per standard procedures and the burr and slag shall be removed by grinding the top of welds. A good weld is as strong as the base metal. A suitable electrode shall be chosen and welded with a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. The surface coating shall be done with a zinc epoxy primer to a thickness of 70µ which serves as a sacrificial coat. An intermediate coat with MIO micaceous iron oxide shall be applied to a thickness of 75µ and a finish coat of polyurethane finish aluminium oxide to a thickness of 60µ in a 2 coats of 30µ each. All these surface coating shall only be done after a blast cleaning of all metal surfaces as per SA 2 1/2 standard with indentation of 30-40µ to near white metal finish. The foundation bolts for this stanchions shall be made on the existing concrete at the ground level. Holes are drilled in this structure at appropriate points as per design size. Then the MS foundation bolts shall be fixed in these holes with hybrid epoxy vinyl mortar. The stanchions shall be erected in these foundation bolts. The platform all round the hoist bridge shall be provided with composite chequered plate. The cost includes cost of MS materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel &

lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including warranty and maintenance for 5 years

Design, drawing, fabrication, transport & erection of hoist equipments as per IS 6938. The components in the hoist like rope drum, gearwheel, pinion wheel, rope, etc are designed and pattern shall be made as per requirement. Then mould shall be cast with IS 1030-28-54 gr material. To verify the soundness of material the raw mould shall be cleaned and NDT test shall be conducted. Then on ensuring the soundness, stress relieving shall be done with annealing process to normalise the molecular structure in the mould components. Machining to dimensional accuracy is done as per design & drawing to match the components with appropriate tolerance. The drum & gear shafts shall be of appropriate dia & length with material confirming to EN8 standard. Bearings, plummer blocks & pin bush coupling shall be sourced from a standard manufacturer. Motor shall be 3 phase S3 duty with double end shafts confirming to IS 325 . Worm reducers & gear box shall be provided as per IS 3734, EM brake, a safety device. The rope shall be steel core, the length & dia shall be provided as per IS 2266 Hoist enclosures shall be provided with composite materials as per site measurements. The electrical cables from power room to gantry shall be provided. Starters shall be enclosed in composite double door boxes to avoid rain & Shine. The starter box enclosure made of hybrid composite super structure panels. This process ensures freedom from all defects and this increases the strength of the

composite box. UV resistant polyester polymer, fire retardant and high grade reinforcement shall be used for manufacture of composite enclosures. Excellent corrosion resistant gel coat shall be applied during the process. The composite material has high strength to weight ratio, durable, excellent corrosion resistant and very good insulator. The cost includes cost of materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel & lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including warranty and maintenance for 5 years.

Modification of lifting arrangements of the existing service shutter as per following specification. The existing lifting plate in the service shutter is cut and ground to a smooth finish. Appropriate bracket shall be fabricated and welded to the shutter at top . Then the exiting pulley with pin in the scrapped spreader beam shall be welded to the new bracket of the service shutter. The welding shall be done as per standard procedures and the burr and slag shall be removed by grinding the top of welds. A good weld is as strong as the base metal. A suitable electrode shall be chosen and welded with a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. Then the assembly is tested with the new rope & hoist assembly. The surface coating shall be given with a priming coat of 70µ with zinc epoxy primer which would be the sacrificial coat and a protective coat over it with coal tar epoxy to a thickness of 300µ as per IS 14177. The coating shall be done only after a blast cleaning of all metal surfaces to SA 2 ½ standard. The cost includes cost of MS materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel & lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including warranty and maintenance for 5 years.

Sub Total

GST @ 18% of SubTotal

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