Design Fabrication supply and erection of spillway shutter No 1 3 hoist lifting arrangement for spillway vent No1 to 3 in Parambikulam Dam Repair and realignment at Parambikulam Tunnel entry shutters in Chittur Taluk of Palghat District

Amount

Repair and replacement of second stage embedded parts like roller track plate, side seal track and sill seat as per the following specification. The existing corroded MS roller track plate is in two layers. The bottom layer is made of 100x25mm MS flat securely welded to the roller track embedded in concrete. The top layer is made of 100x20mm MS flat and is welded to the bottom layer. This layer shall be removed by grinding and gas cutting operations from the bottom layer. Then a SS track plate of size 120x20mm shall be welded to the existing bottom MS track plate appropriately to enable the rollers move vertically on the SS track plate. This should reduce friction to a larger extent. The side seal track plate shall be of size 80x8mm made of SS 304 grade. It shall be appropriately welded to the existing angle ISA 100 welded in the upstream side upto 8.50m from sill level. This should facilitate the smooth movement of side seal without friction, while the gate moves up & down. The sill seat shall be made of 80x8mm SS flat of 304 grade. This shall be provided on top of the existing sill beam which is embedded in concrete. This should provide an even surface for the bottom seal to land on preventing water from leakage. The cost includes cost of materials, labour charges for dismantling and erection at site, hire charges for machinery like grinding machine, gas cutting equipment, drilling machine, welding plant & generator, rental charges for erection equipments like chain block & crane, cost of consumables such as oil, diesel & lubricants for generator, welding rod, grinding wheel, core cutter bits, oxygen & LPG, incidental charges like conveyance to & fro from site of work, loading & unloading, risk allowance, etc., complete, including warranty and maintenance for 5 years. The works shall be executed as per the standard specifications and as directed by departmental officers.

Spillway vertical gate vent no.1 & 3

Dismantling of existing old corroded vertical gates from its respective groove portion by the following process. The gates shall be made to rest on the sill portion. The counter weight shall be locked to the deck bridge through pin connecting both sides. Lifting chains shall be released from the shutter by removing the pin from the chains. The shutter shall be cut out into pieces with gas cutting equipment. Then the cut pieces shall be carried from vent portion using a crane and then transported to the department store through trucks and stacked as directed by the departmental officers. The cost includes cost of consumables like oxygen gas & LPG, grinding wheels, oil, diesel & lubricants for generator, labour charges for dismantling, lifting, loading, unloading & stacking, hire charges for crane, lorry, machinery like cutting equipment, grinding machine & generator, etc., complete.

Spillway vertical gate vent no.1 & 3

Design, fabrication & supply of vertical shutter including skin plate with vertical stiffeners, horizontal fabricated girders, end verticals, rear angle, connecting plates, rib plates, etc, suitable for spillway gate of vent size 12800x8300mm as per IS 4622. The skin plate, end verticals, vertical stiffeners, horizontal fabricated girders, 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 connecting fasteners shall be made of MS confirming 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 need to be 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 inaccessible areas such us the inside of the end vertical and diaphragm plate shall be applied with metallising to a thickness of 150µ. 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 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, conveyance, unloading, etc., complete and as directed by the departmental officers including warranty and maintenance for 5 years. The works shall be executed as per the standard specifications and as directed by departmental officers.

Spillway vertical gate vent no.1 & 3

Design, fabrication and supply of cast steel roller assembly for Spillway gates as per the following specification. cast roller wheels with stock allowance for machining shall be manufactured as per IS 2707 : grade 1 material. Roller wheels of size 450mm dia with bearing and retainers shall be machined as per approved drawing. The required tolerance shall be provided for wheel to fix the bearing & retainers. Spherical roller bearing of appropriate size and quality manufactured by reputed firm shall be used in the roller assembly. M10.5 drilling & M12 tapping shall be done in the wheel after machining. The retainer shall be drilled to M13.5 size for fastening to the wheel. The roller pin shall be made of a material conforming to IS 1570-30cr13 grade. The roller pin shall be machined as per the approved drawing. The bearing, retainer plates, pin and oil seals shall be assembled together with the roller as directed by the departmental officers. The cost includes cost of materials like steel, fasteners, grease nipple, bearing, retainer plate, roller and pin, process charges like Pattern, Pattern mounting, steel casting, machining, cylindrical grinding, drilling, tapping, case hardening, assembly, cost of oil, diesel & lubricants for generator, conveyance charges, loading & unloading, etc, complete, including warranty and maintenance for 5 years. The works shall be executed as per the standard specifications and as directed by departmental officers.

Spillway vertical gate vent no.1 & 3

Design, manufacture, supply and erection of bottom seal & side seal with fasteners for a vent size 12800x8300mm 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 75x12mm. The side seal shall be a Z type rubber seal of size 74x79x16mm . The center joint seal between the two element connecting shall be provided 170x10mm flat type seal. 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 materials like rubber seal & fasteners, labour charges punching of rubber seal & erection in the shutter, oil, diesel & lubricants for generator, loading & unloading, conveyance charges, etc, complete, including warranty and maintenance for 5 years. The works shall be executed as per the standard specifications and as directed by departmental officers.

Spillway vertical gate vent no.1 & 3

Erection, testing & commissioning of vertical lift gate for a vent size 12800x8300mm with structural steel skin plate, horizontal girders, vertical stiffeners, wheels, lifting brackets, 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. All steel structures shall be welded appropriately with skilled workmen. 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 need to be 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. All heavy erection equipment like cranes, hoists, chain pulley blocks, winches shall be employed appropriately without damaging the existing structure. Scaffolding shall be done with utmost care taking into consideration the safety of human lives. Temporary barricading/platforms shall be provided in risky operational areas like ogee, etc. The cost includes hire charges of erection equipments like crane, hoists, winches, machinery such as grinding machine, core cutter, gas cutting plant, welding machine & electric ovens, cost of oil, diesel & lubricants for generator, cost of consumables like oxygen & LPG, welding rods & grinding wheels, cost of erection & dismantling of temporary structures, scaffolding, platforms/barricades, etc., complete. The works shall be executed as per the standard specifications and as directed by departmental officers.

Spillway vertical gate vent no.1 & 3

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. Blast cleaning shall confirm to Swedish standard SA 2 1/2 (near white metal). Blast cleaned surfaces showing plate surface defects such as scabs 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, recleaning to the same degree shall be required. All safety precautions like wearing helmets, 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 and maintenance for 5 years.

Spillway vertical gate vent no.1 & 3

Counterweight

Operating platform for Parambikulam tunnel entry service shutter for vent No 1 & 2

LS 4000 shutter vent no. 1& 2 at Thunacadavu leading channel

Application of a high performance primary coating to protect the steel structure from highly abrasive, erosive and corrosive environments. This being an industrial coating which 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 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. 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. The cost includes cost of primer & thinner, labour charges for application of primer, hire charges for compressor, generator & airless spray gun with its accessories, cost of oil, diesel & lubricant for generator, scaffolding charges, conveyance of machinery & tools to and fro from site of work, risk allowance, etc, complete, including warranty and maintenance for 5 years. The works shall be executed as per the standard specifications and as directed by departmental officers.

Spillway vertical gate vent no.1 & 3

Counterweight

Operating platform for Parambikulam tunnel entry service shutter for vent No 1 & 2

LS 4000 shutter vent no. 1& 2 at Thunacadavu leading channel

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 between 125-150 µ per coat. 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. 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. The colour of the paint coat when applied is generally black but turns into brown over a period time. However, the properties of the paint remain intact assuring the performance. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) – 1971. The cost includes cost of coaltar epoxy paint, thinner, etc, labour charges for its application, hire charges for compressor, generator, airless spray machine with its accessories , cost of oil, diesel & lubricant for generator, scaffolding charges, conveyance of machinery & tools to and fro from site of work, risk allowance, etc, complete, including warranty and maintenance for 5 years. The works shall be executed as per the standard specifications and as directed by departmental officers.

Spillway vertical gate vent no.1 & 3

Counterweight

Operating platform for Parambikulam tunnel entry service shutter for vent No 1 & 2

LS 4000 shutter vent no. 1& 2 at Thunacadavu leading channel

Conducting the following minimum quality tests as per approved QAP at various stages of work to ensure that 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. Cast rollers are tested to be free from defects by ultrasonic flaw detector 100% in house as per acceptable standard ASME section VIII witnessed by authorized third party agency. 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. Internal inspection report shall be furnished at all stages of fabrication.

Surface protective treatment such as blast cleaning, epoxy 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. 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 holiday detector shall be employed at random points. All reports and tests shall be furnished to the appropriate authority as directed by the departmental officers.

Spillway vertical gate vent no.1 & 3

Repair & Renewal of the existing deckbridge as per the following specification. The existing deck bridge is heavily rusted and needs strengthening to extend its life and also safe movement of personnel & equipments. MS plates / structurals are needed to be cut to required size and welded to appropriate location which have to be strengthened. 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 beam & channels in the bottom of deckbridge shall be inspected and the joints shall be cleaned with wire brush to eliminate rust & dust and then welded wherever necessary. 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, warranty and maintenance for 5 years, complete and as directed by the departmental officers.

Spillway vent no.1 to 3

Repair and modification of operating platform with composite chequered plate as per the following specification. The existing corroded steel chequered plate shall be removed by using gas cutting. Then the required additional steel stiffeners 40x40x6 angle shall be provided in existing deck bridge. Providing 6mm thick composite chequered plate in the operating platform in 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 shutter. 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.

The composite plate has very good anti slippery property and ease in handling. Then the plate shall be laid in the panel screwed to the stiffeners below. Suitable holes shall be provided at appropriate places for drainage of rain water. Then the shutter, shall be loaded, transported to the site, unloaded & erected as directed by the departmental officers. The cost includes cost of all materials, Cost of raw material like UV stabilized infusion grade polymers, multi directional glass fibre reinforcements, hardners, pigment, cost of pattern and mould process charges for infusion, cost of consumables such as vacuum film, peel ply, flow mesh, spiral hose, tacky tape and equipment charges like vacuum infusion pump, catch pot, pneumatic tools, Air compressor, labour charges for loading, lifting, unloading, transport, erection, power charges for generator, conveyance to site, including cost of trial operation, warranty and maintenance for 5 years, etc., complete and as directed by the departmental officers.

Spillway vertical gate deck bridge vent no.1 to 3

Providing counterweight arrangements as per the following specification & size. The counterweight shall be made with MS heavy plates of size 50mm for base plate, 32mm for side walls and 32mm for inside stiffeners. The top cover plate shall be 16mm thick. The plates shall be welded in sequence appropriately with skilled welders. 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 needs to be 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 box is volumetrically divided into 5 compartments with 32mm inside cross stiffeners. The inner surface of the counter weight, which would be inaccessible on erection, shall be applied with metallising to a thickness of 150µ. The space 360x140x1000mm – 4 nos on each side at both ends of the counterweight shall filled up with concrete, to avoid corrosion concrete blocks of approximate size 280x150x150mm is neatly stacked inside. The concrete blocks are stacked one over the other in 6 rows. Over the concrete blocks, grey cast iron block of size 200x700x60mm shall be stacked in a row.

They shall be manufactured out of graded grey cast iron consists of graphite flakes in metallic matrix. Moulds of appropriate size shall be made and material poured to required size. The casting shall be ground to requisite dimensions. Specific weight of grey cast iron blocks being more than concrete, is used to increase the load of the counterweight with lesser space. Sample block shall be tested for its properties from a NABL approved laboratory the grade being 220. The Hardness should be 270 BHN. Lifting plates of size 32x300x1310mm are welded in the inside of the box from the bottom, on both corners of the box. 45mm dia holes are drilled in the plates for locking of chain & locking of counterweight while carrying out repairs in the shutter. A Groove guide shall be welded to either sides of the box, one at top & one at bottom. This serves as guides to the counterweight arrangement while moving up & down. Steel scaffolding is done upto a height of 15m to install the counterweight arrangements. Mobile crane shall be used to handle the box during installation of the counterweight arrangements. The cost includes cost of materials, labour charges for fabrication and erection, hire charges for crane, winch, chain block, generator, machinery & tools, consumables such as oil, diesel & lubricants, scaffolding/temporary platforms, risk allowance, transport, etc, complete, with warranty and maintenance for 5 years. The works shall be executed as per the standard specifications and as directed by departmental officers.

Spillway vertical gate vent no.1 & 3

Design, fabrication, transport & installation of an inspection platform for the spillway vertical shutters of the following size & specification. The platform shall be provided in between the piers parallel to the skin plate of the shutter as well around the piers in the downstream side for effective inspection of shutters and its components. 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 900mm and shall be supported by the main girder ISMB 400 on either ends of the platform. The platform in between pier shall be supported with “A” frame. The frame shall be anchored to piers with hybrid vinyl ester compound. ISA 50x50x6 shall be welded as intermediate stiffeners singularly between the main girders at distance of 450mm c/c from each other and cross stiffeners at a distance of 500 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 equidistant from each other as in the drawing. The platform top shall be finished with 6mm composite chequered plate from end to end throughout the platform for a width of 900mm. All joints in the frames shall be neatly welded and ground to give an excellent finish. The platform shall be blast cleaned with SA 2 1/2 standard and the surface shall be applied epoxy primer with 50µ, The finish coat shall be applied overthe primer coal tar epoxy with 250 µ in two coats. The foundation bolts of size 16mm with base plate of size 250x250x12mm shall be provided to anchor the platform to the existing pier. Necessary 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, transport, 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, painting, scaffolding charges , risk allowance for working at a hazardous location at a height of 30m, warranty and maintenance for 5 years etc., complete. The works shall be executed as per the standard specifications and as directed by departmental officers.

Spillway vertical gate vent no.1 to 3

Design, fabrication, transport & installation of a approach staircase to the platform of the following size & specification. The staircase shall descend from the road bridge from an appropriate entry point to the inspection platform with adequate steps & hand rails. This is necessary to inspect vertical gate from 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 staircase shall be of width 900mm and shall be supported by the main girder ISMC 200 on either ends of the staircase. The tread & the risers shall be of appropriate width & height. 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 equidistant from each other as marked in the approved drawing. The platform top shall be finished with 6mm composite chequered plate from end to end throughout the platform for a width of 900mm. All joints in the frames shall be neatly welded and ground to give an excellent finish.

The platform shall be blast cleaned with SA 2 1/2 standard and the surface shall be applied epoxy primer with 50µ, The finish coat shall be applied overthe primer coal tar epoxy with 250 µ in two coats. The foundation bolts of size 16mm with base plate of size 250x250x12mm shall be provided to anchor the platform to the existing pier. Necessary 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, transport, 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, painting, scaffolding charges , risk allowance for working at a hazardous location at a height of 30m, warranty and maintenance for 5 years etc., complete. The works shall be executed as per the standard specifications and as directed by departmental officers.

Spillway vertical gate vent no.1 & 3

Replacement of hoisting arrangements for the vertical gates in the spillway of the parambikulam dam as per the following specification. The spillway vertical gate in vent of size 12800x8300mm shall be parked in the rest position on the sill beam. The counterweight shall be locked with the dogging beam. The lock pin in the hoist chain shall be disconnected. The chain shall be removed from the chain sprocket and safely stored. The hoist assembly consists of 3 interlocking gearwheels & appropriate pinion wheels which shall be removed. They shall be safely stored. Now, new patterns shall be made for the existing gearwheels and cast with material adhering to grade 28-54 as per IS 1030. The cast blocks shall be annealed appropriately and machined to requisite sizes. Teeth shall be cut by hobbing as per the requirement. Shaft shall be made with EN8 materials. Keyway shall be done appropriately in the shaft. New pin-bush couplings shall be provided to match that of the new shafts. The motor of 7.5HP capacity with S3 duty & 1440 RPM shall be provided along with a U600 worm reducer gearbox.

New plummer blocks, bearings & sleeves shall be provided. These components shall be assembled and trial operation conducted. Once the operation is smooth, the existing chain shall be connected with the existing chain sprocket. The counterweight & shutter shall be connected by the chain. The locked counterweight shall be released. The moving components such as hoist gear, chain, plummer block etc shall be lubricated as per standards. Trial operation shall now be conducted and the components shall be ensured that they sink with each other. 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, warranty and maintenance for 5 years, complete as directed by the departmental officers. The works shall be executed as per the standard specifications and as directed by departmental officers.

Spillway vertical gate vent no.1 to 3

Providing electromagnetic brake of 200mm 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. The works shall be executed as per the standard specifications and as directed by departmental officers.

Spillway vertical gate vent no.1 to 3

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 cost of design cost of materials like ultra reduction gear box, chain, chain sprocket, composite head, hire charges for machinery like welding machine, grinding, consumables like welding rod, grinding wheel, core cut, drill bits, process charges like machinery, milling, mould charges, labour charges, charge for transport to & fro, etc., complete and as directed by departmental officers.

Spillway vertical gate vent no.1 to 3

Fabrication, supply and installation for centre hoist cover by using composite panels of thickness 3mm made as a single unit as per the approved drawing. The composite cover shall be spaced in such a way to resist bending with inherent stiffeners provided. A lifting handle in steel/composite 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, conveyance to site and clearing them after completion of work, including cost of trial operation, including warranty for 5 years, etc., complete and as directed by the departmental officers.

Spillway vertical gate vent no.1 to 3

Fabrication, supply and installation of Chain Sprocket enclosure for hoist assembly by using composite panels of thickness 3mm made as a single unit as per the approved drawing. The composite cover shall be spaced in such a way to resist bending with inherent stiffeners provided. 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, conveyance to site and clearing them after completion of work, including cost of trial operation, including warranty for 5 years, etc., complete and as directed by the departmental officers.

Spillway vertical gate vent no.1 to 3

Providing sprocket to suit rollers of dia 48mm as per the following specification. The sprocket shall be made of C45 material with 10 teeth and tip diameter of 450mm. The teeth profile should adhere to ISO 606. The pitch shall be 130mm. Heat treatment shall be done to a case depth of 1.00mm. The hardness shall be 30-40 HRC. The tolerance shall be followed as per IS 2102. The teeth profile edges shall be chamfered. A phosphor bronze bush shall be provided in the bore of 170mmØ The cost includes cost of materials, charges for casting, machining, milling, heat treatment, transport, erection, warranty for 5 years etc, complete and as directed by the departmental officers.

Spillway vertical gate vent no.1 to 3

Replacement of existing chain link assembly in chain hoist as per the following specification. The either ends of the chain hoist shall be provided with new chain link. The roller chain for balancing shutter & counter weight assembly shall be made with low/medium carbon steel straps of 5 inch pitch. The minimum breaking strength of strap shall be 500 N/mm2. The straps shall be connected with medium carbon heat treated steel pins. The breaking strength of pin shall be 600 N/mm2. The new chain assembly shall suit existing chain sprocket. The upstream end of chain shall be fastened to shutter lifting assembly. The downstream end of chain shall be connected to counter weight lifting assembly. Necessary lubrication shall be applied to the chain link components. 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 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.

Spillway vertical gate vent no.1 & 3

Overhauling of existing hoisting arrangements for the shutter as per the following specification. The existing hoist covers shall be opened up for inspection of hoisting components. 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 any 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 using a water jet machine. The reduction gearbox shall now be drained off 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 or the chain & chain sprocket mechanism in the hoisting system shall be manually cleaned of dried grease and dirt and appropriate lubricant shall be applied. The whole arrangements shall be tested & passed after a set of trial operation. The cost includes cost of lubricants like gear oil, lithium based grease, servo coats, hire charges for machinery like welding machine, grinding machine, gas cutting plant, corecut machine, hire charges for equipments like chain pulley charges for inspection, labour charges for dismantling erection, overhauling, loading, unloading etc., complete and as directed by the departmental officers.

Tunnel entry service shutter vent no.1 & 2

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 galvanised 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 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, warranty for 5 years etc, complete. The works shall be executed as per the standard specifications and as directed by departmental officers.

Tunnel entry service shutter vent no.1 & 2

Repair, overhauling & refixing of the double axis movement double grider crane in parambikulam tunnel entry as per the following specification. The crane has two parallel girders rigidly connected to the end carriages at a distance of 12000mm and spanning the gantry of span 8000mm. The crane traverses in the second axis on the floor of the dam over rails to a distance of 22000mm for lifiting of emergency shutter. The lifting unit is built on to a traversing crab overslung from the beams. The crab is of size 3800x3200mm. The wheels run directly over the crane grider. Due to ageing prolonged use and minimal maintenance the health of all the systems has deteriorated and become unusable. Therefore, all the existing system shall be overhauled & renewed wherever necessary & refixed as directed by the departmental officers. The hoisting machinery consists of motor, gearbox, rope drum, rope guide and rollers for long travel trolley and crab. The gearing shall be of hardened helical type and motors are of squirrel cage motors. The rope drum shall be large and the rope pulleys ensure that the rope shall be retained in the pulley . All safety features as existing shall be repaired to ensure safety of operations, increased productivity & optimal maintenance planning. This existing machinery as described above shall be tested for best performance & repairs attended, wherever necessary. All lubricants are drained & cleaned & retopped. The cost includes cost of all required necessary spares, lubricants, labour charges, charges for dismantling & erection, hire charges for machinery & equipment used during repair warranty for 5 years etc complete and as directed by departmental officers.

Tunnel entry emergency shutter

Modification of existing gantry crane for lateral movement and cross travel movement in the tunnel entry shutter of size 3770x3840mm. The tunnel entry in the Parambikulam tunnel entry , 2 in number, is laid out, one adjacent to the other. The shutters in the tunnel entry is at a depth of 72’ from ground level. They have to be lifted to ground level in case of repair /maintenance. However, the gantry crane, at present, has to be moved manually to reach different shutters. This strenuous manual effort is not safe during emergency and urgently procuring scarce manpower for lateral movement is difficult. Therefore, the lateral movement and cross travel movement shall be made possible by motorising & modification by introducting a gear system in the existing gantry crane as per the following specification. The drive shaft is of dia 50mm and appropriate length presently. This drive shaft shall be cut into two at the centre to accommodate a pair of spur gears made as per IS 1030. The gears shall be made of cast steel Gr 27-54/EN9 with 35 teeth, 8 module & 20 facedepth & 40mm facewidth. Suitable plummer block S511 with bearing 1211K and sleeve H211 shall be introduced on either side of the spur gear.

The inner spur gear shaft shall be connected with a shaft of dia 50mm to a worm reducer UD 500 with ratio 100:1. This worm reducer, in turn shall be connected through a flexible coupling to a 3 HP motor squirrel cage induction motor with 960RPM Class E insulation, 400-440V, as per IS 325. The motor shall be of double end type totally enclosed & fan cooled and the other end of the motor shall be connected to a EM brake of 150mm dia with a maximum braking torque 5.6kgm. The EM brake in turn shall be connected to a manual operating chain wheel through a 45mm dia dog clutch & plummer blocks. A pendent switch arrangements shall be provided to operate the crane effortlessly.Necessary dust proof cover arrangements shall be provided for these equipments.The new motor shall be provided with suitable electrical connection and starters. The equipments shall be mounted on the existing frame work and they may be modified as per the load & movement. All these equipments shall be procured from the market, transported to site, necessary modification in the supporting structural framework made and then shall be assembled at site. All new steel support structure shall be painted as directed by the departmental officers. The gantry crane shall be conducted with a trial operation. The cost includes cost of motor and accessories, spares, consumables such as oil, grease, paint, fasteners, etc., process charges like cutting, welding, casting, grooving, machining, etc, labour charges for dismantling loading, lifting, unloading, scaffolding, charges, hire charges for equipment like generator, welding & cutting set, etc, conveyance of men & machinery to & fro from site of work & back, risk allowance for working at a height of more than 3m, cost of trial operation, warranty for 5 years etc., complete. The works shall be executed as per the standard specifications and as directed by departmental officers.

Tunnel entry emergency shutter gantry hoist

Repair & Replacement of existing punctured incoming cable from service shutter and main switch to Gantry starter, providing new DOL starter and pendant switch with required cable. The old punctured cable shall be removed and new 4 core x 35 sqmm armoured aluminium cable shall be provided up to terminal box and 4x10sqmm copper flexible cable shall be provided from terminal box to starter box. The copper flexible cable shall be tagged with real and GI wire. This cable arrangements would enable the cable to move along with gantry crane trolley forward & Reverse movement. The existing damaged starter box shall be removed and replaced with new DOL forward reverse starter. The starter box enclosure shall be 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 should have high strength to weight ratio, durable, excellent corrosion resistance and very good insulator. The starter shall be housed with 32A contactor – 2nos, 18 to 25 amps over load thermal relay – 2nos, single phase preventer – 1 no, push button for forward, reverse & off, indicators lamps -3 nos, 32A 4 pole MCB -1 no & terminal block -1 no . The new pendent switch shall be provided for hoist motor forward & reverse, lateral movement motor forward & reverse and cross travel motor forward & reverse operation. The Pendant switch shall be housed with forward, reverse push button 3 sets & 1 no for stop bush button with “NO” & “NC” switches. The 10 core x 1sqmm cable shall be connected with starters. The cost includes cost of materials like cables, pendant switch, starter box, terminal box and, labour charges for laying, transport, etc., complete and as directed by departmental officers.

Tunnel entry emergency shutter gantry hoist

Repair and strengthening of the existing platform for tunnel entry service shutter as per the following specification. The existing platform is of size of 10000x2150mm at the top and 10000x700mm at the bottom . The stiffeners are heavily corroded and needs strengthening to extend its life and thus ensure safe movement of personnel & equipments. The existing chequered plate shall be opened and stacked safely for reuse. The corroded stiffeners shall be removed by using gas cutting equipments. The new ISA 75x75x8, MS plates & structurals shall be cut to required size and welded/fastened to appropriate location which have to be strengthened. 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 needs to be 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 existing chequered plate shall be lifted and laid appropriately. 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, warranty for 5 years, complete and as directed by the departmental officers

Tunnel entry

Providing additional ballast in the counterweight as per the following specification. The cast grey iron blocks shall be of size 283x153x152mm & 700x200x50mm. They shall be manufactured out of graded gray cast iron consists of graphite flakes in metallic matrix. Moulds of appropriate size shall be made and material poured to required size. The casting shall be ground to requisite dimensions. Specific weight of gray cast iron blocks being more than concrete, this is used to increase the load of the counterweight with lesser space. Sample block shall be tested for its properties from a NABL approved laboratory the grade being 220. The Hardness should be 270 BHN. All materials applied with anticorrosive coating before loading into the counterweight. The cost includes cost of materials, labour charges, transport, handling & erection at site and as directed by the departmental officers.

Spillway vertical gate vent no.2

GST at 18%

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