Replacement of corroded steel wire rope and wornout Rubber seals in Pambar dam at Uthangarai Taluk of Krishnagiri District.

Amount

Replacement of corroded steel wirerope of the following specification. The existing wornout 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 ungalvanized 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.

Providing socketing to the wirerope on one end as per the following specification. Seizing is done using soft annealed iron wire. Brooming of wire rope is done by unlaying the strands of the wirerope as far as the seizing. The broom is cleaned in ultrasonic cleaner or trichloroethane with brush & dip method. Position the socket over broom until the wires are level with the top of the socket basket or to a minimum embedded length. Rope & socket shall be clamped vertically ensuring alignment of their axis. Oversized socket should not be used. Zinc or white metal. (lead, Tin and Zinc) shall be used & heated to a molten mixture at 2250 C in case of zinc molten and 1200c in case of white metal molten. Proper heating should be given in metal container giving appropriate temperature, when mixture liquates it is carefully poured into the socket cone & the mixture shall be left to cool down for 45 minutes or more. Putty from socket base shall be removed and wire rope shall be lubricated as required. The rope would be supplied by the department free of cost. The cost includes cost of socketing, labour charges, etc., complete.

Replacement of Z type seal as per IS 11855:2004 at sides of the Radial 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 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

Repairs and Replacement of bottom rubber seal of the Radial shutter 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 100x10mm 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.

Repair & Replacing the existing electromagnetic brake of 200mm Ø 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 transported to the factory for overhaul, varnishing & painting the outer surface area of motor. The motor shall be transported back 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, ending in 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 materials, consummables, assembly of EM brake and synchronising it to the existing system, cost of flexible couplings, rent charges for welding machine, cutting, drilling & grinding machine, generator, hoist & pulley etc, complete as directed by the departmental officers.

Realignment of trunnion girder as per the following specification. The existing trunnion girder is of length 2400mm made of ISMB 600. The trunnion beam is not aligned to the existing wall and has to be adjusted and seated appropriately. The nut M50 in the anchor rods shall be removed and trunnion beam shall be loosened. A 50t jockey may be employed to move the trunnion beam to butt on the wall properly without any gap inbetween. So, the shutter now would be in made in proper alignment using chain block and shall be seated on the sill beam and alignment verified with the jockey in place, the nuts in the anchor rod shall be again tightened under this pressure. Now, the shutter shall be operated & trial operation conducted as directed by the departmental officers. 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.

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, corecut, 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

Replacement of old damaged starter box for the following specification. The starter to motor old cable shall be replaced with 4 core x 6 sqmm copper flexible unarmoured cable for cable leading from starter to motor. Necessary gland & lugs shall be used as required. Starter to motor cable shall be protected with 1” Ms pipe. A new DOL starter with forward & reverse shall be provided inside the old panel box after removing the old existing damaged starter. The starter box enclosure made of hybrid composite super structure panels. This process ensures freedom from all defects and this increases the strength of the composite box. UV resistant polyester polymer, fire retardant and high grade reinforcement shall be used for manufacture of composite enclosures. Excellent corrosion resistant gel coat shall be applied during the process. The composite material has high strength to weight ratio, durable, excellent corrosion resistant and very good insulator. The starter shall be housed in 20A contactor – 2nos, 12 to 18 amps relay – 2nos, single phase preventer – 1 no, pushbutton for forward, reverse & off, indicators lamps -3 nos, 32A 4 pole MCB -1 no & terminal -1 no shall be welded after removing the existing cover. The cost includes cost of composite enclosure box & accessories cable from starter to motor, labour charges, painting , transport charges, erection at site etc., complete.

Repair & Replacement of the suspension guide channel as per the following specification. The suspension guide channel is inside the sluice well to guide the suspension channel connecting the 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 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, necessary scaffolding arrangements 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, complete.

Repair & replacement of suspension channel in canal 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. 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.

Overhauling of worm gear box to the canal 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 worm nut 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.

Special Repairs to the canal sluice shutters as per the following specification. The existing platform shall be opened and the existing shutter of size 910x1530mm at a depth of 12m 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 wire rope 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. A appropriate bearing for a wheel of size 355mm dia shall be provided instead of the broken bearings. The wheel shall be cleaned of all dirt, dust, corrosion and then the bushes shall be fixed inside the wheels. The wheels shall be transported back to site & then wheels shall be fixed to the shutter at appropriate place. The wornout rubber seal shall be replaced with new rubber seal confirming to IS specifications. The bottom shall be provided with flat rubber seal of size 100x12mm & top & sides with ‘P’ type rubber seal of bulb dia 44mm & 14mm thick. The shutter shall then be cleaned of corrosive particles and then a coat of coal tar epoxy shall be applied over a coat of zinc rich primer as directed by the departmental officers.

Super Fabricators