Rehabilitation and repairs to the shuttering and hoisting arrangements in North branch, south branch including sand vents of Lower anicut system across coleroon river in Anaikarai village in Thiruvidaimaruthur taluk of Thanjavur District.(hydro mecha

Design, fabrication, supply, erection, testing and commissioning of fixed wheel vertical shutter including skin plate with vertical stiffeners, horizontal girders, end verticals, rear angle, connecting plates, rib plates, etc, suitable for spillway gate of vent size 10160x2750mm as per IS 4622. The skin plate, end verticals, vertical stiffeners, horizontal 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. This also includes connection/assembly of hoists with gate for safe, proper and smooth functioning of gates. All steels 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 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 existing rollers shall be dismantled, overhauled with suitable new bearings/ bushes and erected the new gate. 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 side rubber seal shall be provided with Z type seal of size 74x79x16mm and bottom seal shall be provided with 75x12mm flat type seal. The shutter shall be blast cleaned to SA 2 1/2 standard and the surface shall be applied one coat of epoxy zinc primer with 50 µ. The finish coat of coaltar epoxy for 250µ in two coat shall be applied. The cost includes cost of MS materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel & lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including warranty for 5 years.

Fabrication, supply, erection, testing and commissioning of stoney type wheel vertical shutter including skin plate with vertical stiffeners, horizontal girders, end verticals, rear angle, connecting plates, rib plates, etc, suitable for spillway gate of vent size 10160x2750mm. The skin plate, end verticals, vertical stiffeners, horizontal 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. This also includes connection/assembly of hoists with gate for safe, proper and smooth functioning of gates. All steels 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 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 existing stoney type rollers shall be repair & renewal as following, the rollers shall be dismantled with existing corroded frame. The pivot shall be removed and the roller outer surface shall be machined with out undues. The new pivot shall be provided with 15 cr 30 grade material. The rollers shall be assembled with new fabricated frame and erected in groove. The new 5/8” robe shall be connected with stoney roller frame and another end fitted with counterweight hook. 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 side rubber seal shall be provided with Z type seal of size 74x79x16mm and bottom seal shall be provided with 75x12mm flat type seal. The shutter shall be blast cleaned to SA 2 1/2 standard and the surface shall be applied one coat of epoxy zinc primer with 50 µ. The finish coat of coaltar epoxy for 250µ in two coat shall be applied. The cost includes cost of MS materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel & lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including warranty for 5 years.

Fabrication, supply, erection, testing and commissioning of vertical shutter including skin plate with vertical stiffeners, horizontal girders, end verticals, rear angle, connecting plates, rib plates, etc, suitable for spillway gate of vent size 6100x3350mm. The skin plate, end verticals, vertical stiffeners, horizontal 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. This also includes connection/assembly of hoists with gate for safe, proper and smooth functioning of gates. All steels structures shall be welded appropriately with skilled workmen. The existing rollers shall be dismantled, overhauled with suitable new bearings/ bushes and erected the new gate. The welding shall be done as per standard procedures and the burr and slag shall be removed by grinding the top of welds. A good weld is as strong as the base metal. A suitable electrode shall be chosen and welded with a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. On fabrication of all components of the shutter, a trial assembly shall be done at the shopfloor to ensure the dimensional accuracy and integration of all sub components. Also, the layout shall be clearly marked & serially numbered by punching. Match drilling in different components and cleats provided wherever necessary to assure minimum tolerance levels. The side and top rubber seal shall be provided with musical note rubber seal of size 100x44x14mm and bottom seal shall be provided with 75x12mm flat type seal. The shutter shall be blast cleaned to SA 2 1/2 standard and the surface shall be applied one coat of epoxy zinc primer with 50 µ. The finish coat of coaltar epoxy for 250µ in two coat shall be applied. The cost includes cost of MS materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel & lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including warranty for 5 years

Fabrication, supply, erection, testing and commissioning of vertical shutter including skin plate with vertical stiffeners, horizontal girders, end verticals, rear angle, connecting plates, rib plates, etc, suitable for spillway gate of vent size 5180x3350mm. The skin plate, end verticals, vertical stiffeners, horizontal 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. This also includes connection/assembly of hoists with gate for safe, proper and smooth functioning of gates. All steels structures shall be welded appropriately with skilled workmen. The existing rollers shall be dismantled, overhauled with suitable new bearings/ bushes and erected the new gate. The welding shall be done as per standard procedures and the burr and slag shall be removed by grinding the top of welds. A good weld is as strong as the base metal. A suitable electrode shall be chosen and welded with a good welding equipment and a trained welder. All non – metallic substances shall be removed in the weld joints before commencement of welding. On fabrication of all components of the shutter, a trial assembly shall be done at the shopfloor to ensure the dimensional accuracy and integration of all sub components. Also, the layout shall be clearly marked & serially numbered by punching. Match drilling in different components and cleats provided wherever necessary to assure minimum tolerance levels. The side and top rubber seal shall be provided with musical note rubber seal of size 100x44x14mm and bottom seal shall be provided with 75x12mm flat type seal. The shutter shall be blast cleaned to SA 2 1/2 standard and the surface shall be applied one coat of epoxy zinc primer with 50 µ. The finish coat of coaltar epoxy for 250µ in two coat shall be applied. The cost includes cost of MS materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel & lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including warranty for 5 years.

Dismantling , reconditioning & refixing of fabricated intermediate groove channel inbetween counterweight & shutter portion of size 320x230x9400mm for a vertical lift geared shutter of size 10160x2700mm. The existing groove angle embedded in civil structure is damaged and hence, removed with demolition hammer equipment. Then 22mm MS rod shall be anchored to a depth of 350mm in the civil structure at a C/C distance of 500mm on both sides in upstream as well as the downstream side. The new fabricated 320x230x9400mm groove channel shall be erected appropriately and welded to the new anchor rod. 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 shall 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. After welding, a thorough visual inspection shall be done for porosity, blowholes, unfused welds, unfilled craters, under cutting, burning & poor weld appearance, etc. The steel surface shall be blast cleaned to SA 2 1/2 standard and the surface shall be applied zinch epoxy primer with 50µ. The finish coat of coaltar epoxy for 250µ in two coat shall be applied. Trial run shall be conducted to test for smooth operation of cast iron wheels & counterweights and then it shall be commissioned. The cost includes cost of materials, labour charges, cost of consumables like welding rod, grinding wheel, oxygen gas, acetylene, diesel & oil for operation of generator, hire charges for generator, welding plants, grinding machines, drilling equipments, etc, transport of men, machinery & material from factory to site of work & back, loading, lifting & unloading charges, scaffolding charges, conveyance of tools & equipments, cost of trial operation, warranty for 5 years, etc, complete.

Repair, overhaul and refixing of the rusted cast iron wheels of the existing shutters with gas cutting equipment and reconditioning with bushes or bearings and refixing to the original condition as per the site requirements. The wheel is of 350mm diameter and moves in the recessed groove of the vertical guide channel. The shutter shall be lifted to a workable height and the locking plate shall be removed by cutting the corroded bolts and nut with gas cutting equipments. The wheel pin shall also be removed. Then the wheel shall be transported to the workshop where the wheel shall be opened up and the old broken bearing and sleeves shall be removed after cleaning the wheel. Then the outer wheel surface shall be machined true to required size and so that it shall operate smoothly without vibration and without undergoing undue drift. The inside of the wheel shall also be machined to have a uniform surface. The existing bearing shall be cleaned and inspected for misalignment and breakage. Then shall be replaced as the case may be. The existing pin shall be machined and fitted snugly. Then the wheel shall be closed and fitted to the end vertical channel. Trial operation shall be conducted to ensure free movement and rotation of wheels. The cost includes cost of all materials, deducting the cost of old scrab materials and 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 for 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 etc., complete and as directed by the departmental officers.

Overhauling the existing hoisting arrangements of the lift gate of vent size 10.16m x 2.74m as per the following specification. The existing hoist covers shall be opened up and stored separately for reuse after neatly scrapping the surface and repair the covers wherever necessary 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 leaner 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 if 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 lever as indicated by the department offices. The available chain & chain 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 The whole arrangements shall be tested & passed after a set of trial operation. The cost includes cost of all materials pattern making charges machining, milling, teeth cutting and manual labor charges and cost of inspection, spares, lubricants, transport charges, charges for dismantling & erection, etc., complete.

Repair & replacement of broken pinion gear wheels in the transmission line as per the following specification. The shutter shall be rested on the sill & locked without movement. The hoist cover shall be removed and then the existing dog clutch, Plummer blocks with transmission shafts shall be removed and kept aside for reuse after cleaning. The broken pinion wheel with 108 teeth gear wheel shall be disengaged & removed from the assembly along with the support frame. The support frame shall be inspected and welded for firm positioning of gears. New good quality pinion wheel and 108 teeth spur gear wheels shall be assembled replacing the old ones as they are beyond use. The dog clutch, plummer blocks with transmission shaft shall be checked for their usefulness and reerected appropriately. The lubrication shall be done wherever necessary and locked shutter resting on the sill shall be released for testing. The testing shall be done manually lifting & lowering the shutter smoothly a couples of times. Once it’s trouble free, the shutter shall be tested by lifting & lowering the shutter with electrical power 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, etc., complete as directed by the departmental officers.

Providing chain sprocket to suit chain link pins as per the following specification. The sprocket shall be made of C45 material with 10 teeth and tip diameter of 800mm. The teeth profile should adhere to ISO 606. The pitch shall be 235mm. 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 to suit the sprocket bore. The cost includes cost of materials, charges for casting, machining, milling, heat treatment, transport, erection, etc, complete as directed by the departmental officers

Reconditioning the lifting chain of lift gate in the vents of South branch Coleroon regulator including lifting the chain from the vent by detaching the eye bolt connecting the chain to the gate and lifting the chain by using hydra cranes without damage the groove portion and civil structure. Conveying the chain by using hydra crane to the work yard for doing repair. Cleaning the chain with wire brushes and with cleaning liquid for free from rust. Check all the links thoroughly, if found any damages in the links, remove the links by using required tools and replacing with new links made up of EN8 steel. New link made to the shape and size by laser cutting process as the existing damaged link. The new link fixed to the other links with required rivots and pushes in correct alignment and position. Repaired chain conveyed to the vent by hydra crane and lifted over the operating platform and erected to the shutter and counterweight arrangement in proper alignment with required new eye bolt and nuts. After of chain erection the fresh lubricants apply to the chain links.The cost includes cost of all materials, process charges like gas cutting, welding, machining, Milling, Shaping, scaffolding charges, labour charges for dismantling, loading, lifting, unloading, transport, erection, labour charges for equipments like crane, derrick, 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, etc complete and as directed by the departmental officers.

Repair & modification of sill flat of the Vent size 10.16m X 2.74m as per the following specification. The existing shutter shall be lifted and kept at the height of atleast above 750mm. The old existing sill beam is corroded and the surface is extremely pitted. Hence the sill beam shall be thoroughly cleaned by mechanical means using buffing wheel with steel bristles connected to portable grinding machine. Then, SS flat of size 60x8mm shall be laid centrally on the cleaned sill beam end to end and welded firmly with MS to SS special welding electrodes. 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. After welding, a thorough visual inspection shall be done for porosity, blowholes, unfused welds, unfilled craters, under cutting, burning & poor weld appearance, etc. Then the shutter shall be operated to rest on the sill beam and tested. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, diesel & oil for generator, process charges like, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like chain pulley 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, warranty for 5 years etc., complete as directed by the departmental officers.

Repair and renewal of panel board, light posts of the regulator vent as per the following specifications. The existing corroded encloser shall be replace with hybrid composite super structure pannels. The composite material has high strength to weight ratio, durable, excellent corrosion resistant and very good insulator. The existing starter components shall be dismantled, checked the working condition, serviced and re installed the new encloser. The electrical components wherever necessary replaced with new one. The existing lamp post surfaces shall be cleaned by manually and applied a coat of aluminium enamel paint one coat. The new LED street light fittings 1 no shall be fitted in the lamp post with required clamps.The rate including cost of all materials, charges for wiring, welding, drilling, labour charges, charges for equipments to fro conveyance charges etc complete as directed by the departmental officers

Supply of scientific Staff Gauge for 1m or part there of height and width of 120mm. Marking in the staff gauge shall be done in centimeters. Each & every 10cm marking is shown in figures. Also every 50cm is shown in figures, distinctly. Necessary holes are provided in the plate for nailing the plate on to the masonary structure. The scientific staff gauge would be supplied at worksite as directed by the departmental officers. The cost includes cost of materials, transport & delivery at site only.

Strengthening the hoist support beams of the existing deck bridge as per the following specification. The chain hoist assembly level uneven due to the deck bridge main structure beam deflection. The additional support member shall be inserted parallel to the existing hoist bridge upstream side ismc 300. The new ismb/ismc 300 shall be provided and cut to suit of the both ends and fixed parallel to the existing channel in upstream side. 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 good welding equipment and a trained welder. All non - metallic substances shall be removed in the weld joints before commencement of welding. After welding, a thorough visual inspection shall be done for porosity, blowholes, unfused welds, unfilled craters, under cutting, burning & poor weld appearance, etc. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, paint, primer, 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, etc ., complete as directed by the departmental officers.

Repair & Overhauling of dialgauge as per the following specification. The chain & Chain sprocket shall be dismantled and all components shall be cleaned and verified for any defects. They shall be refixed / welded appropriately. Then the alignment shall be checked by conducting a few trial operation the cost includes cost of spares & consumables, hirecharges for tools & machinery, etc.,complete

Renewal of operating platform of sand vent of size 2.16m x 3.75m including dismantling existing corroded platform by using gas cutting equipments and manual labours and remove the cutting pieces from the vent by using necessary hoisting and conveying equipment’s. New operating platform of appropriate size pieces made up of 6mm thick composite chequered plate and provide stiffener with 65x65x 6mm mild steel angle frames not exceeding 500mm in both directions. 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 good welding equipment and a trained welder. All non - metallic substances shall be removed in the weld joints before commencement of welding. After welding, a thorough visual inspection shall be done for porosity, blowholes, unfused welds, unfilled craters, under cutting, burning & poor weld appearance, etc. 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, 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 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 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. 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 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, including cost of trial operation, warranty for 5 years, etc., complete as directed by the departmental officers.

Fabrication, supply & erection of scour vent of size 2140x3750mm as per IS 4622:2003. The skinplate shall be made of 12mm thick MS plate, horizontal girder with ISMB 200, top channel with ISMC 200, diaphram & cover plate with 12mm thick. The wheels shall be made of cast steel of 200mm Ø and wheel pin with 60mm Ø. Side rubber seal shall be of 'z' type with side seal cover plate of 55x10mm thick. The bottom rubber seal shall be 75x12mm thick and of flat type. Lifting plate shall be 16mm thick. 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. After welding, a thorough visual inspection shall be done for porosity, unused welds, unfilled craters, under cutting, burning & poor weld appearance, etc. Blast cleaning to SA 2 1/2 standard over which epoxy primer to a thickness of 50 µ and final coat of coal tar epoxy of 250µ shall be applied as per IS 14177-1994. The cost includes cost of materials, cost of consumables like welding rods, grinding wheels, 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, grinding machine, compressor, airless spray machine, hoisting equipments like chain pulley block, derrick post, labour charges for loading, lifting, unloading, transport erection, scaffolding, conveyance to site and clearing them after completion of work, warranty for 5 years except protective coatings, rubber seal, etc., complete and as directed by the departmental officers.

Modification of CI headset with wormnut hoist comprising of a screw rod made of 75mm Ø MS Rod of length 3500mm. The threaded portion shall be 3000mm with 12mm pitch. The screw rod shall be connected to the shutter. Wormnut hoist to suit 75mm screw rod shall be provided. The worm wheel shall be made of phosphor bronze with 175mm OD with 25 teeth x 25mm circular pitch. Thrust ball bearings should be provided on either side of the worm wheel. Oil seal of size 110x135x13 shall be provided on either side of the worm wheel. A cast iron cover shall be provided over the whole arrangement. MS Worm 75mm ID & 25mm, pitch double thread shall be provided. Thrust ball bearing O 12 shall be provided on either side of worm. A wormnut stand of height 740mm & 380mm at the top & 590mm at the bottom shall be provided with 10mm MS 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, etc., warranty for 5 years, complete as directed by the departmental officers.

Modification of electrification arrangements in vertical shutter in Kummikkimanniyar. The hoisting arrangements includes screw rod with worm gear over the operating platform. A geared motor, 3 HP, with output RPM 280, Reversible, 3 phase, 400 - 440V, is introduced into the existing worm & worm gear arrangements appropriately, so that the shutter could easily be operated electrically. Necessary wiring from mains and starter for motor are provided as per site requirements. Motor bed is suitably provided as per site condition. A dust proof cover is provided to safeguard the motor from rain and shine. The dust proof cover shall be made of hybrid composite super structure panels. This process ensures freedom from all defects and this increase the strength of composite cover. UV resistant polyester polymer high grade reinforcement shall be used for manufactures of composite cover. Excellent corrosion resistant gel coat shall be applied during the process. All equipment & accessories are checked for their correctness and aligned properly for smooth operation as directed by the departmental officers. The cost includes cost of materials confirming to IS standards like, 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,etc, complete.

Supply, Erection, Testing, Commissioning and hand over of Genset model of 40 KVA (28kw) 3 Phase,415V, 1500 RPM alternator, Std. Control Panel, Base Frame, Fuel Tank (65 liters), Battery with leads (charged) and other accessories with type approved integral KG Canopy as a complete set including First fill of lube oil and Engine Safeties – Transporting the generating set to the site, unloading the set and move to the existing foundation, Erection of generator set with proper alignment over the existing foundation. Providing ISI ear thing ‘ with earth electrode of 2.1 meter length, 1- ½” diameter class “B” GI pipe for alternator and control panel including masonry work with cover slabs for earth pits. Providing earth connection by 1” X 1/8” copper And inter connection of earth pit 1” x 1/8” copper Flat . Supply and laying annunciation cable of suitable capacity between engine and the control panel of the generator .The rate including cost of First charging of lubricating oil and fuel for trial operation and transport, commissioning charges and labour charges etc., complete and as directed by the departmental officers.

Repairs and Replacement of bottom rubber seal of the regulator 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 75x10mm 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 75x12mm. 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 Z type seal as per IS 11855:2004 at 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 74x79x16mmshall be placed on the skin plate over which the seal seat cover shall be placed and fastened with 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.

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.

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 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, IS : 2339-1963 and IS: 2932-1994. The cost includes cost of primer, thinner, paint, 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,

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. 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,

GST 18 % in Figures

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