Repair and renewal of side seal wall plate, replacement of rubber seals and EM brake and over hauling of hoist arrangements of spillway gate in Vaniar dam at Pappireddypatty Taluk of Dharmapuri District

Amount

Repair & renewal of side seal seat and alignment of shutter as per the following specification. The existing side seal seat is made of MS material and hence it is corroded and the smooth movement of shutter is hindered by the abrasive corroded surface causing frequent replacement of rubber seals and therefore leakage through the sides of the shutter. To enable a smooth movement of the shutter, SS 304 grade stainless steel seals shall be used. The existing MS seals seat shall be stripped down using gas cutting equipments. Then the alignment of the side wall plate shall be verified and necessary packing shim sheet shall be provided and welded is wherever necessary. Then, SS 304 grade 100x4700x10mm plate shall be cut to the appropriate radius and welded to the wall plate. Suitable electrode, welding method and skilled labour shall be employed while welding the SS seal seat to the MS wall plate. 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 chainpulley block, welding machine, cutting set, grinding machine, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation, complete as directed by the departmental officers.

Replacement of bottom rubber seal of the Spillway shutter of size 7570x6400mm as per the following specification. The old rubber seal shall be removed from the skin plate after removal of the rusted bolts & nuts by gascutting equipments. The seal seat cover shall be removed along with the rubber seal. The skin plate & seal seat cover surface shall be neatly cleaned on either side by grinding. Now, the existing seal seat cover made of 100 x 10mm MS flat & the new rubber seal shall be now matched with the existing holes in the skin plate and then holes shall be drilled in the seal seat cover to align with that in the skin plate, if necessary. 18mm holes shall be punched accordingly in the rubber seal of size 100x12mm. The inside surface of the seal seat cover is given a coat of anticorrosive zinc rich primer over which two coats of coal tar epoxy shall be applied at an interval of 24 hours between each coat. Now the rubber seal shall be placed on the skin plate over which the seal seat cover shall be placed and fastened with SS bolts & nuts of size M16x75. The cost includes cost all of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site, etc., complete and as directed by departmental officers.

Replacement of Musical note rubber seal/ Z type seal as per IS 11855:2004 at top, bottom & sides of the shutters 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 100mmx44mmx14mmØ /74x79x16mmshall be placed on the skin plate over which the seal seat cover shall be placed and fastened with CSK SS bolts/hex bolt. The cost includes cost of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site etc., complete.

Overhauling of existing hoisting arrangements for the shutter as per the following specification. The existing hoist covers shall be opened up and stored separately for reuse after neatly scrapping the surface and painting with a coat of aluminium paint. 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 thro 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 available rope drum sprocket 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.

Providing electromagnetic brake of 150mm Ø in the 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 metallic paint shall be applied 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 material like EM brake, Brake drum, flexible coupling shaft and support structural materials, fasteners, hire charges for machinery like welding machine, grinding machine, gas cutting plant, core cut machine, process charges for machinery, milling, welding, charges for transport to & fro labour charges for dismantling, erection, loading, unloading etc., complete.

Special Repairs to the River sluice shutter as per the following specification. The existing platform shall be opened and the existing shutter of size 2200x1980mm shall be lifted with chain pulley block. The shutter shall be rendered immovable with the chain pulley block and the pin shall be removed from the lifting plate. The released suspension channel shall be lifted and kept separately for reuse. The shutter shall then again lifted and rested in the resting platform. The wheels in the shutter shall be now removed and brought to factory for service. The wheels shall be openedup and existing bearings shall be removed and cleaned. The wheel surface shall be machined true to required size so that it shall operate smoothly without vibration and without undergoing undue drift. The wheel shall be cleaned of all dirt, dust, corrosion and then the bushes shall be fixed inside the wheels. Then the wheels shall be fixed to the shutter at appropriate place. The shutter shall then be cleaned of corrosive particles and then a coat of coal tar epoxy is applied over a coat of primer as directed by the departmental officers. Then the shutter is lowered to the sill level and the suspension channel is refixed to the lifting plate with the pin. The suspension channel shall also be cleaned of corrosive particles and a coat of coal tar epoxy shall be applied over a coat of primer. The screw rod shall then be connected to the suspension channel and trial operation is conducted. The cost includes cost of all materials, process charges like gas cutting, welding, machining, scaffolding charges, labour charges for dismantling, loading, lifting, unloading, transport, erection, labour charges for equipments like crane, chain pulley block, power charges from generator, risk allowance for working at a depth of more than 3m, conveyance to site and clearing them after completion of work including cost of trial operation, etc., complete and as directed by the departmental officers.

Repair & replacement of suspension channel in LMC & RMC sluice as per the following specification. New suspension channel shall be made of 125x65mm twin channels facing each other at a distance of 65mm with ISMC 125x65 welded between them as spacers. The spacers shall be provided at a vertical distance of 500mm c/c from each other. These twin channels shall withstand the designed loads. The existing screw rod of size 100mmØ & 3000mm length shall be connected to the new suspension channel with a system of bolt & nuts of size 6"x5/8". The suspension channel shall be of appropriate height as per site condition but should be fabricated in cut lengths of 3m since beyond that the suspension channel for screw rod cannot be removed from its position for maintenance. The suspension channels shall be connected to each other with a system of 10mm plate of size 200x250mm using bolts & nuts. The bottom of the suspension channel extends upto the top horizontal member of the shutter. Then it shall be assembled for efficient operation, as directed by the departmental officers. All members shall be given a coat of epoxy primer overwhich two coats of anticorrosive coaltar epoxy paint shall be applied. The cost includes cost of materials, labour charges, hirecharges for machinery like derrick, chainpulley block, gas cutting equipment, welding plant, erection, etc, cost of conveyance to & fro from site of work, risk allowance, trial operation, etc, complete.

Repair & Replacement of the suspension guide channel as per the following specification. The suspension guide channel is inside the RMC sluice well to guide the suspension channel connecting the RMC sluice shutter to the hoisting arrangements. The old corroded suspension guide channel shall be cut and removed from the masonary with concrete breaker machine & stacked at PWD stores as directed by the departmental officers. The new suspension guide channel shall be cut to the required size and given a coat of zinc rich primer over which two coats of coal tar epoxy shall be applied. The masonary on either ends of the channel shall be broken at appropriate places and then the channel shall be embedded with concrete at the appropriate place. The cost includes cost of materials, labour charges, hire charges for machinery like derrick, chain pulley block, gas cutting equipment, welding plant, erection, etc, cost of conveyance to & fro from site of work, risk allowance, trial operation, etc, complete.

Renewal & refixing of wirerope of the following specification. The existing broken wirerope is unwound from the rope drum and removed from the rope locking plate & stacked as directed by the departmental officers. A new rope as per IS 2266 is provided in place of the old damaged rope. The rope is 6 strand with steel core bright or ungalvanised C flattened strand winding rope 6 x 36 with nominal diameter 22mm and wire strength 1770 N/mm2. The sheave groove is ensured that is is supporting the rope for 33% of its circumference as greater contact area between the rope & the pulley reduces abrasion & enhances service life. The spooling/anchorage of rope on drum should be proper as improper spooling induces torque in rope, reducing the rope life. The end of rope is fixed to the locking plate provided in the drum. The cost includes cost of rope, Labour charges, transport, erection, etc, complete.

Overhauling of worm gear box to the LMC & RMC sluice shutters as per the following specification. The worm gear box comprising of worm nut and worm screw which 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 if its wornout & then used. The cost includes cost of materials, labour charges, cost of servicing, tools & plants, cost of consumables like grease & oil, transport, etc, complete.

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