Rehabilitation and Improvements of Kelavarapalli dam and park under DRIP - II in Hosur Taluk of Krishnagiri District. (Hydro Mechanical works) - IBRD loan No. 9181 IN

Amount

Dismantling of existing old corroded spillway crest radial gates from its respective portion by the following process. The gates shall be made to rest on the sill portion. The rope shall be released from the shutter by removing the pin from the rope socket. The shutter shall be cut out into pieces with gas cutting apparatus at the dam site as directed by the departmental officers.

Design, fabrication & supply of skin plate with vertical stiffeners, horizontal girders, etc., suitable for radial gate of vent size 12200x6100mm as per IS 4623 : 2000. The skin plate, vertical stiffeners, horizontal girders,arm and arm bracings lifting assembly, side seal base plate, side seal cover, bottom seal cover, rear angles shall be made of structural steel confirming to IS 2062 : 2011. The fasteners shall be made of stainless steel confirming to IS 1570 : 1985. 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 cost includes cost of materials, cost of consumables like welding rods, grinding wheels, drill bits, oxygen & acetylene gas, oil & diesel for generator, process charges like gas cutting & welding, drilling, hire charges for machinery like gas cutting plant, welding equipment, magnetic drilling machine, generator, equipments like chain pulley block, derrick post, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers. including warranty for 5 years.

Design, manufacture, supply and erection of bottom seal, side seal with fasteners for the spillway crest radial gate of vent size 12200x6100mm as per the following specification. The seals shall be made of a basic polymer that shall be natural rubber. Rubber seals shall be moulded to ensure homogeneous section. Natural rubber seal shall be used as it is elastic, deforms readily and regains its original shape on the removal of loads. The bottom seal shall be a flat seal of size 100x12mm. The side seals shall be of Z type seals of size 74x79x16mm. M 13 holes shall be punched in the rubber seals with seal punchers to match with the holes in the skin plate and cover plate. SS 304 gr fasteners of size M12 shall be used to fasten the rubber seal to the skin plate and cover plate as directed by the departmental officers. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, diesel & oil for generator, process charges like gas cutting, welding, labour charges for loading, lifting, unloading, hire charges for equipments, power charges for generator, etc., complete as directed by the departmental officers.

Conducting the following minimum quality tests as per approved QAP at various stages of work to ensure the raw materials and its fabrication are free from defects as per industry standards and maintenance of records at all stages for assurance of quality. Raw materials such as hot rolled plates and sectional structures are tested for physical & chemical properties - one random sample for minimum of 40 tonnes of plate/structural weight. Stainless steel seal seat, wheel track plate shall be tested for physical & chemical properties – one sample (Random) for entire lot of any size. Steel casting materials shall be checked with ultrasonic testing and magnetic particle inspection on finished surfaces on trunnion hub as per ASME section VIII. Rubber seals are tested in house for physical properties such as Hardness, Elongation, Tensile strength, Tensile test after ageing, water absorption test as per IS 11855 : 2004. All raw materials are 100% dimensional checked and verified in accordance with manufacturer test certificate. In shop welding process, quality of fillet welds are checked visually and using 100% magnetic particle inspection. In site welding, quality of fillet weld is inspected either by 100% dye penetrant or magnetic particle inspection. For butt welds, 100% ultrasonic inspection is done for skin plate joints. Root weld is inspected by 100% dye penetrant test in butt welds. Radiography test shall be carried out for 10% of length in butt weld while fabrication itself. Internal inspection report shall be furnished at all stages of fabrication. Surface protective treatment such as blast cleaning, zinc primer and coal tar epoxy coating shall be done as per standard norms. Quality of blast cleaning is ensured by cleanliness to SA 2 ½ finish and profile measured using calibrated surface profile gauge. Before commencement of blast cleaning & coatings, dew point meter is used to check environmental condition suitable for application as per standard procedure. Adhesion of coating is done with cross hatch / X cut test as per ASTM D 3359. Thickness of primer and coal tar epoxy coatings are ensured by coating thickness gauge at random points. Finally to ensure the quality of coating system to be free from pinholes and cracks through holiday detector at random points. All reports and tests shall be furnished to the appropriate authority as directed by the departmental officers.

Erection, testing & commissioning of spillway crest radial gate for a clear opening size of 12200x6100mm with structural steel skin plate, horizontal girders, vertical stiffeners, etc., complete in all respects as per the technical specification and drawings as directed by the departmental officers. This also includes connection/assembly of hoists with gate for safe, proper and smooth functioning of gates, including warranty for 5 years.

Dismantling of existing old corroded trunnion girder, trunnion hub, and trunnion bracket of spillway radial gate by removing the existing bolts & nuts using suitable tools and then pulling & lifting from anchor rod using chain pulley/winch. The dismantled materials shall be stocked at dam site as directed by the departmental officers.

End pier

Intermediate pier

River Sluice pier

Design, Drawing, fabrication & supply of Trunnion girder suitable for spillway crest radial gate of vent size 12200x6100mm as per IS 4623 : 2000. The trunnion girder shall be made of IS 2062 : 2011 – E 250 grade mild steel. 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 cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for loading, lifting, unloading, hire charges for equipments like chainpulley block, power charges for generator, including warranty for 5 years, etc., complete as directed by the departmental officers.

End pier

Intermediate pier

River Sluice pier

Erection / installation of Trunnion girder for spillway crest radial gate as per IS 4623 : 2000. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, charges for scaffolding, diesel & oil for generator, process charges like gas cutting, welding, labour charges for loading, lifting, unloading, erection, hire charges for equipments like chainpulley block, crane, power charges for generator, including warranty for 5 years, etc., complete as directed by the departmental officers.

End pier

Intermediate pier

River Sluice pier

Design, drawing, Fabrication and erection of trunnion hub with bracket for the radial gate of shutter size 12200x6100mm as per the following specification. The hub assembly shall be made of cast steel material grade 28-52 as per IS 1030 : 1998. The two hub girders shall be of I sections with appropriate flange & web thickness. The I section shall be the integral part of the hub casted to form a combined single structure. Necessary machining allowance shall be provided. Appropriate slotted holes shall be provided in the web portion and machined to good surface finish. The cost includes cost of all materials, process charges like casting, machining, scaffolding charges, labour charges for loading, lifting, unloading, transport, erection, labour charges for equipments like crane, chain pulley block, power charges from generator, risk allowance for working at a height of more than 3m, conveyance to site and clearing them after completion of work including cost of trial operation warranty for 5 years etc., complete and as directed by the departmental officers.

Overhauling of existing hoisting arrangements for the shutter as per the following specification. The existing hoist covers shall be opened up and stacked for disposal in the stores at dam site. The top cover of plummer blocks connecting the existing transmission shafts shall be opened and old grease shall be removed. Then, the existing bearings shall be cleaned with liquid cleaner and inspected for mis-alignment and breakage. Fresh grease shall be applied to the plummer block and top cover closed with requisite fasteners. The shaft shall be checked for its alignment and redone to ensure straightness of shaft. The existing gear wheels shall be cleaned of dried grease and dust manually. The reduction gearbox shall now be drained of old used lubricant through the drain hole at the bottom. Now, the liquid cleaner shall be poured in the gearbox and the inside surface and gears are thoroughly cleaned and then the contaminated liquid cleaner shall be drained. The drain hole shall be plugged and fresh lubricant of appropriate grade shall be filled to the level as indicated by the department officers. The rope drum mechanism in the hoisting system shall be manually cleaned of dried grease and dirt and appropriate lubricant shall be applied. The existing motor & gearbox outer surface shall be manually cleaned and a coat of metallic paint applied. The whole arrangements shall be tested & passed after a set of trial operation. The cost includes cost of inspection, spares, lubricants, transport charges, charges for dismantling & erection, etc, complete.

Overhauling existing worm gear hoist of the river sluice shutters, canal shutters in LMC & RMC as per the following specification. The worm gear hoist comprising of worm nut and worm screw shall be opened up and cleaned & matched properly. Then requisite oil & grease shall be applied for efficient operation. The thrust bearing & oil seal shall be checked and then reused after cleaning & oiling. The phosphor bronze bush shall also be checked & then used. The cost includes cost of materials, labour charges, cost of servicing, tools & plants, cost of consumables like grease & oil, transport, etc, complete.

Design, drawing, fabrication, erection at site, commissioning of new river sluice service gate in place of the existing river sluice service gate as per the following specification. The existing service gate is totally corroded and hence leaking & not properly operable. Therefore, the platform around the river sluice service gate shall be dismantled and the suspension channel shall be removed from its position and safely stacked for re erection with new service gate. However care should be taken to paint the existing suspension channel before it is re erected with new service gate. The new river sluice service gate shall be of size 1955x2000mm. The skin plate shall be of 16mm thick and vertical stiffeners shall be of 16mm thick ms plates and assembled as per standards. The seal seat and cover shall be 12mm thick & 10mm thick respectively . The rubber seal shall be of ‘P’ type and of size 100mm x14mmx 44mmØ . The old cast steel wheel assembly shall be overhauled & reassembled. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheels, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like derrick, chain pulley block, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation, warranty for 5 years except rubber seals, etc., complete as directed by the departmental officers.

Design, drawing, fabrication, erection at site and commissioning of new canal sluice gate as replacement of the existing canal sluice gate as per the following specification. The existing service gate shall be totally corroded and hence leaking & not properly operable. Therefore, the platform around the canal sluice service gate shall be dismantled and the suspension channel shall be removed from its position and safely stacked for re erection with new canal gate. However care should be taken to paint the existing suspension channel before it is re erected with new canal gate. The new canal gate shall be of size 1460x1675mm. The skin plate shall be of 12mm thick and end vertical stiffeners shall be of 12mm thick ms plates and assembled as per standards. The seal seat and cover shall be 10mm thick respectively as per drawing. The rubber seal shall be of ‘P’ type and of size 100mmx14mmx44mm dia. The cast steel wheel assembly shall be made of graded EN9 and assembled. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like derrick, chain pulley block, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation, warranty for 5 years, except rubber seals, etc., complete as directed by the departmental officers.

Replacement of Musical note rubber seal as per IS 11855:2004 at top, bottom & sides of the emergency shutter of size 3050x2330mm as per the following specification. The old seal cover plate shall be dismantled from the skin plate after removal of the rusted bolts & nuts by gascutting. The skin plate surface shall be neatly cleaned by grinding. Now, the existing seal seat cover made of 65x10mm MS flat shall be cleaned & painted. The rubber seal shall be now matched with the existing holes in the skin plate and then holes should be punched accordingly to align with that in the skin plate. The rubber seal of size 100mmx14mmx44mmØ shall be placed on the skin plate over which the seal seat cover shall be placed and fastened with CSK SS bolts. The cost includes cost of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site etc., complete.

Providing a dial gauge to read the movement of shutters from the deck bridge as per the following specification. The dial gauge is a safety instrument to read the position of the gate from the deck as well restrict the movement of the gate at predesignated heights. The dial gauge consists of dial with engraved scale, a pointer and a striker. A ultra reduction gearbox 1:20 as per site condition shall be assembled along with of chain & chain sprocket arrangement. The shaft for chain sprocket shall be made 25mm EN8 steel. The sprocket wheel shall be of 25 teeth with pinion of 12 teeth. The chain for sprocket shall be of length 2000mm. Necessary bushes & bearings of best quality shall be used. The whole assembly shall be housed in a composite dial gauge enclosure. The composite material shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties The cost includes design, cost of equipments, assembly, erection at site, etc, complete.

Fabrication, supply and installation of center hoist composite enclosure by using composite panels of thickness 3mm made as a single unit. The composite cover shall be spaced with inherent stiffeners provided to resist deflection. A lifting handle in steel material shall also be incorporated. UV resistant polyester polymer and high grade reinforcement shall be used for fabricating composite centre hoist enclosure. The composite material made of glass fibre reinforced polymer shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties. The cost includes cost of mould, pattern and fixtures, cost of raw material like UV stabilized polymers, multi directional glass fiber reinforcements, hardeners, UV stabilized pigment & fumed silica powders, cost of consumables like rollers, brushes, gloves, sanding sheet, acetone, buffing, grinding & cutting wheels, cost of tools like aluminium paddle rollers, squeegees, fibreglass scissors, measuring beakers, agitators, cost of release agent like, cleaner, sealer, releaser, wax, labour charges for pattern & mould work, hand layup, cutting, grinding, finishing, drilling, loading, unloading, transport, erection, hire charges for equipments like air compressors, pneumatic tools, gelcoat spray gun, warranty for 5 years, etc., complete as directed by the departmental officers.

Fabrication, supply and installation of rope drum enclosure for hoist assembly by using composite panels of thickness 3mm made as a single unit. The composite cover shall be spaced with inherent stiffeners provided to resist deflection. A lifting handle in steel material shall also be incorporated. UV resistant polyester polymer and high grade reinforcement shall be used for fabricating composite rope drum enclosure. The composite material made of glass fibre reinforced polymer shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties. The cost includes cost of mould, pattern and fixtures, cost of raw material like UV stabilized polymers, multi directional glass fiber reinforcements, hardeners, UV stabilized pigment & fumed silica powders, cost of consumables like rollers, brushes, gloves, sanding sheet, acetone, buffing, grinding & cutting wheels, cost of tools like aluminium paddle rollers, squeegees, fibreglass scissors, measuring beakers, agitators, cost of release agent like, cleaner, sealer, releaser, wax, labour charges for pattern & mould work, hand layup, cutting, grinding, finishing, drilling, loading, unloading, transport, erection, hire charges for equipments like air compressors, pneumatic tools, gelcoat spray gun, warranty for 5 years, etc., complete as directed by the departmental officers.

Repair & Replacing the existing electromagnetic brake of 150mm Ø in the spillway radial shutter as per the following specification. The existing electrical wiring shall be disconnected. The motor shall be removed from its bed after dismantling the flexible coupling and installed in the bed channel taking care of the alignment with the EM brake. The flexible coupling in the existing shaft shall be fitted up again. The electrical wiring shall then be connected & energised. Testing shall be done at no load and then shall be gradually loaded to ascertain the capacity & efficiency. The Electromagnetic brake is a mechanical device to keep or stop the gate at the desired position for safety reasons as well for proper operation of gates. The Electromagnetic device has a central shaft which also has a drum with brake lining in the inner side the central shafts extending on either side beyond the brake ends with a flexible coupling on both ends. The other side of the flexible coupling is connected to a worm reducer on one end and to a motor on the other end. The cost includes cost of equipment, assembly of EM brake and synchronising it to the existing system, rent charges for welding machine, cutting, drilling & grinding machine, generator, hoist & pulley etc, complete as directed by the departmental officers.

Providing 6mm thick composite chequered plate in the operating platform with the following specification. The composite chequered plate shall be manufactured in vacuum infusion process. This process ensures freedom from all defects and thus increases the strength of the composite chequered plate. UV resistant polyester polymer and high grade reinforcement shall be used for manufacturing composite chequered plate. Excellent corrosion resistant gel coat shall be applied during the process. The composite material has high strength to weight ratio, durable, light weight and ease in handling. Then it shall be checked for flatness and lifted to the overhead platform and marked and cut to exact size. Care should be taken to provide opening for the drum hoist and centre hoist . Necessary additional stiffeners with ISA 50x50x6mm shall be provided. The measurement shall include the openings provided in the platform . The composite plate has very good anti slippery property and ease in handling. Then the chequered plate shall be laid in the platform screwed to the stiffeners below. Suitable holes shall be provided at appropriate places for drainage of rain water. Then the composite chequered plate shall be loaded, transported to the site, unloaded & erected as directed by the departmental officers. The cost includes cost of mould, pattern and fixtures, cost of raw materials like UV stabilized infusion grade polymers, multi directional & flow media glass fiber reinforcements, core material hardeners, inhibitors, UV stabilized pigment & fumed silica powders, cost of consumables like vacuum film, peel fly, flow mesh, spiral hose, tacky tape, valves, connectors, clamps rollers, brushers, sanding sheets, acetone, buffing, grinding & cutting wheels, cost of tools like aluminium paddle rollers, squeegees, fibreglass scissors, measuring beakers, agitators, cost of release agent like, cleaner, sealer, releaser, wax, labour charges for pattern & mould work, hand layup, cutting, grinding, finishing, drilling, loading, unloading, transport, erection, hire charges for equipments like air compressors, pneumatic tools, gelcoat spray gun, vacuum infusion pump, catch pot, conveyance to site and clearing them after completion of work, warranty for 5 years, etc., complete as directed by the departmental officers.

Design, drawing, fabrication, & installation of an inspection platform for the spillway radial shutters at the following size & specification. The length of inspection platform for each vent between the existing piers shall be measured and then appropriately fabricated. The platform is necessary to inspect the shutter trunnion and arms in the downstream side, also it serves for periodical maintenance operations such as oiling, greasing & painting. This easy & quick access enables to monitor any leakage from the shutter and enables carrying out emergency operations. The platform shall be of width 1000mm and shall be supported by the main girder ISMB 400 on either ends of the platform. ISA 50x50x6 mm shall be welded as intermediate stiffeners singularly between the main girders at distance of 500mm c/c from each other. Cross stiffeners at a distance of 500mm c/c from each other shall be provided throughout the length of the inspection platform. A gusset plate made of 8mm thick MS plate and size 160 x 200mm shall be perpendicularly welded to the outer side of the main girder on either side to weld the vertical posts of height 1200 mm made of ISA 75x75x6mm. The handrail pipes of dia 25mm made of GI pipes shall be inserted into the holes drilled in the vertical post shall be equidistant from each other. The platform top shall be finished with 6mm composite chequered plate from end to end throughout the platform for a width of 1000mm. All joints in the frames shall be neatly welded and ground to give an excellent finish. The foundation bolts of size 16mm with base plate of size 250x250x12mm shall be provided to anchor the platform to the existing pier. Necessary petty civil works like concreting & anchoring in existing masonry structure shall be included in the scope of this job. The cost includes cost of materials, labour charges,erection, crane hire charges, power charges from a generator at site, loading & unloading charges, conveyance of machinery to & fro from site of work, hire charges for machinery, scaffolding charges , risk allowance for working at a hazardous location at a height of 10m, warranty for 5 years, etc., complete.

Providing abrasive blast cleaning using air blast cleaning with abrasive aluminium oxide/steel grits/sand as per the following specification. Moisture should not be present on the steel surface during blast cleaning. All, oil, paraffin, grease & dirt shall be removed from the surfaces to be painted primarily before blast cleaning. Then all weld spatter, slag, burrs, loose rust and mill scale and other foreign substances shall be removed by sandblasting. The average surface roughness after sand blasting shall not exceed 35 to 50 µ for primer surfaces and 75 to 100µ for metalising surfaces.Blast cleaning shall confirm to Swedish standard SA 2 1/2 (near white metal) and also with IS 1477:1971. Quality of blast cleaning is ensured with surface compactor and its profile is measured using calibrated surface profile gauge. Dew point meter is used to check the environmental conditions suitable for application prior to blast cleaning. Blast cleaned surfaces showing plate surface defects such as scraps or sharp gouges shall be repaired in an approved manner prior to painting. After blast cleaning, the surface shall be dusted off or blown off with compressed air free of detrimental oil and water. All surfaces to be painted shall be completely dry, clean and free from moisture just prior to and during painting. If rust forms or the surface becomes contaminated in the interval between cleaning and painting, re cleaning to the same degree shall be required. All safety precautions like wearing goggles, respirators & grounding of blast hose to dissipate static charges should be adopted as directed by the departmental officers. The cost includes cost all materials, labour charges, hire charges for generator , compressor, hopper, accessories, conveyance of machinery to & fro from site of work, scaffolding charges, consumables like oil & diesel for generator, risk allowance, etc, complete. including warranty for 5 years

Spillway shutter vent no.1 to 7

Under deck

Emergency shutter

Inspection platfrom

canal shutter

River sluice shutter

Gantry crane

Providing metallising using thermal spraying equipment as per the following specification. The metalizing should be applied within four hours of surface preparation of the component structure. Thermal spraying is a cold process and most proven that they provide long term corrosion protection and outperform all other methods. These thermal spray coating provide corrosion protection by excluding the environment and acting as a barrier coating and they also provide sacrificial anodic protection. The temperatures during the process reach around 95°c. These coating are typically mechanically bonded to a grit blasted surface. Aluminium wire composition as per ASTM standard B833-09 shall be continuously melted in an electric arc spray or gas flame spray gun. Droplets of molten metal from the wire shall be deposited onto the steel forming the protective coating and this avoid corrosion for a long term. The cost includes cost of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site risk allowance etc., complete.

Spillway shutter vent no.1 to 7

inspection platform

canal shutter

River sluice shutter

Application of a high performance primary coating to protect the steel structure from highly abrasive, erosive and corrosive environments. This being a industrial coating, enhances the life of the structure and reduces the strain of continuous maintenance. After surface preparation of the structure, a primer coat with epoxy primer shall be applied. The dry film thickness should be 40-60µ for primer coat. The thickness of the coat is measured by dry film thickness gauge and during application is ensured by wet film thickness gauge. The colour is grey and minimum pot time should be 4 to 8 hours. The mixing ratio of base to accelerator by volume should be according to the manufacturers standard. All paint, when applied, shall provide a satisfactory film and a smooth and even surface. Paint shall be thoroughly stirred, strained, and kept at the uniform consistency during application. Paint shall not be applied when the temperature of the metal or surrounding air is below 10 degree Celsius and that of the metal is above 50 degrees Celsius, or when the humidity is above 90 percent, or when it threatens to rain before the painted coat gets dry and this process is monitored using dew point meter. Primer coat shall be protected during the initial curing period against the possibility of moisture condensation or contamination with foreign matter. All painting works shall be performed by airless spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Primer coat shall be uniform and free from runs, slag and other imperfections. The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer. The paint shall be applied so that the thickness at any point is not less than that stipulated in the approved painting specifications. Surface not required to be coated, but adjacent to surfaces which are to be cleaned and coated, shall be adequately protected during cleaning and coating. Repairs to damaged areas of the coating shall be carried out strictly in accordance with the approved painting specifications. Because of the flammable and toxic nature of the coating materials, precautions should be taken to eliminate any health or safety hazard that may arise during the application of the coating. Smoking and welding shall not be allowed within 10 meters of the place when painting is in progress. The painting to the gates, hoists and other parts shall be done as per IS specification No.14177-1994. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) – 1971, IS : 2339-1963 and IS: 2932-1994. The cost includes cost of primer, thinner, etc, labour charges for application of primer, hire charges for compressor, generator, airless spray, etc, cost of oil & diesel for generator, scaffolding charges, conveyance of machinery & tools to and fro from site of work, risk allowance, etc, complete, including warranty for 5 years

Spillway shutter vent no.1 to 7

Under deck

Emergency shutter

Inspection platfrom

canal shutter

River sluice shutter

Gantry crane

Application of coaltar epoxy over the primer shall be through airless spray method. The colour shall be black and the mixing ratio of base to accelerator should be by manufacturer standards. The dry film thickness should be between125-150 µ per coat. The thickness of the coat is measured by dry film thickness gauge and during application is ensured by wet film thickness gauge. The interval before over coating shall be 24 hours. All paint, when applied, shall provide a satisfactory film and a smooth and even surface. Paint shall be thoroughly stirred, strained, and kept at the uniform consistency during application. Paint shall not be applied when the temperature of the metal or surrounding air is below 10 degree Celsius and that of the metal is above 50 degrees Celsius, or when the humidity is above 90 percent, or when it threatens to rain before the painted coat gets dry and this process is monitored using dew point meter. Each coat shall be protected during the initial curing period against the possibility of moisture condensation or contamination with foreign matter. All painting works shall be performed by airless spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Each coat shall be uniform and free from runs, sags and other imperfections. The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer. The paint shall be applied so that the thickness at any point is not less than that stipulated in the approved painting specifications. Surface not required to be coated, but adjacent to surfaces which are to be cleaned and coated, shall be adequately protected during cleaning and coating. Repairs to damaged areas of the coating shall be carried out strictly in accordance with the approved painting specifications. Because of the flammable and toxic nature of the coating materials, precautions should be taken to eliminate any health or safety hazard that may arise during the application of the coating. Smoking and welding shall not be allowed within 10 meters of the place when painting is in progress. The painting to the gates, hoists and other parts shall be done as per IS specification No.14177-1994. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) – 1971, IS : 2339-1963 and IS: 2932-1994. The cost includes cost of coaltar epoxy paint, thinner, etc, labour charges for application, hire charges for compressor, generator, airless spray, etc, cost of oil & diesel for generator, scaffolding charges, conveyance of machinery & tools to and fro from site of work, risk allowance, etc, complete, including warranty for 5 years

Spillway shutter vent no.1 to 7

Under deck

Emergency shutter

Inspection platfrom

canal shutter

River sluice shutter

Gantry crane

Repair & Extension of second stage embedded parts - wall plate as per the following specification. The existing wall plate is available up to 6500 mm. Now the wall plate entended to upto 12200 mm length. Therefore, scaffolding shall be done to reach the position to a height of above 12m. The existing wall plate of 12mm thick and 300mm width shall be prepared as per existing radius. The new plate made of mild steel wall plate shall be fabricated in lengths of maximum 1000mm and then bent to the profiles. A 20mm rod of length 450mm shall be cut and welded to the rear of the wall plate strip. A hole of dia 22mm is drilled in concrete and then the welded rod is inserted into the hole and refixed into the existing concrete with hybrid vinyl ester. This fixing lug shall be provided required length with minimum of 500mm C/C. The joints shall then be welded as per standards. The slag shall be removed by grinding the joints. Then the shutter shall be moved the uppermost position and parked safely. Then the existing scaffolding shall be removed and redone to takeup the lower of the wall plate. The shutter shall be operated to the full extent to ensure profile in which the rubber seal would travel. MS wall plate matching the profile with bimetal welding rods from the sill level to the top end of the travel of the shutter. The welded joints shall be ground to remove slag and ensure smoothness for the rubber seal to travel smoothly. A trial operation shall be done to verify uniform, trouble free operation of shutter. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like chainpulley block, welding machine, cutting set, grinding machine, scaffolding, power charges for generator, conveyance to site and clearing them after completion of work, etc., complete as directed by the departmental officers.

Repair and renewal of electrical arrangements for the spillway and river sluice shutter as per the following specification. Providing a new DOL forward/ reverse starter box with high corrosion resistance composite material. The starter box comprising 32 amp contactor 2 nos, relay 6 to 12amps -2 nos, single phase preventer -1 no, push button forward, reverse & off, indication lamp - 3nos, 32 amps 4 pole MCB -1 no & terminal block - 1 no with suitable internal wiring and double door type starter box shall be provided . All the cables shall be provided with new PVC glands and terminated in the Starter arrangement 4 core x 10sqmm armoured aluminium cable shall be provided from starter to motor with MS/GI pipe casing. The busbar / DB box shall be serviced and the incoming cables shall be checked, if any damages found should be replaced. The cost includes cost of all materials & equipments, cost of consumables like welding rods, grinding wheels, drill bits, oxygen & acetylene gas, oil & diesel for Generator, process charges like gas cutting & welding, drilling hire charges for machinery like gas cutting plant, welding equipment, generator, grinding machine, labour charges for Loading, lifting, unloading, transport, erection, scaffolding & synchronising with existing systems, conveyance to site and clearing them after completion work, including cost of trial operation, etc.. Complete as directed by the departmental officers.

Inspection, testing and maintenance of radial gates, vertical gates, hoist assembly and gantry crane shall be carried out in pre & post monsoon i.e., twice a year for a total period of 5 years as per IS 10096 (Part 3): 2002 and IS7718: 1991.The inspection of components & materials shall be carried out as follows. The drain holes in horizontal girders and arms shall be checked & cleared, visual inspection of exposed surfaces of embedded parts such as sill beam, wall plate, seal seats and gate leaf, vertical stiffeners, horizontal stiffeners, arms, trunnion assembly, trunnion girder, yoke girder, thrust block, rope connections, hoisting equipment – gear train assembly, drive unit, gear boxes, flange coupling, bearing housing & foundation bolts in hoist bridge. All exposed bolt & nut connections shall be checked for tightness. The defects found during visual inspection of rubber seals, painting, weldments in steel structures, wire ropes, gears & gears trains, embedded parts, roller tracks & grooves shall be immediately notified to the engineer in charge. The weldment visual inspection shall be done with magnifying glass. The maintenance of radial gates, vertical gates, hoist assembly and gantry crane shall be executed as follows. The exposed gate leaf & structures, embedded parts, hoists assembly, gantry crane and hoist supporting structure shall be thoroughly cleaned from dust, sharp materials and foreign particles. The trunnion bearing shall be greased. The oil level in the worm reduction shall be maintained. The following after inspection, if necessary, shall be repaired or replaced. The draining & refilling of gear oil, the worn-out EM brake linings in gates, the adjustment of flexible couplings, damaged bolt & nut in gate and hoist assembly, bearings and bearing housing. The rotation of guide roller shall be checked. The lubrication of moving components such as guide rollers, vertical gate rollers, trunnion assembly, pulley sheaves, brackets, rope drums, line shaft bearing, wire ropes, matching teeth of gear box shall be carried out. The inspection and maintenance check list shall be maintained as directed by engineer in charge. Replacement of defective / worn out ropes, electrical relays & controls, motors, generator parts, rubber seals and repainting shall be done departmentally, if and when, indicated / suggested in the periodical inspection. The cost includes cost of inspection, testing & maintenance, industrial grease, bearing grease, gear oil, inspection charges and documentation, process charges for cleaning, checking & adjustment, scaffolding charges, consumables charges for cotton waste & solvents for cleaning, labour charges for checking, cleaning, application of lubrication, tools / tackles, trial operation as directed by departmental officers.

Ist year maintenance

II nd year maintenance

III rd year maintenance

IV th year maintenance

V th year maintenance

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