Design,fabrication suply errection of spillway vertical gates in vent No.1 to 9Repairand Rehab of radial gates in vent 1 to 3, emergency shutterand Gantry hoist and replacmnt of river sluice shuters modify canal sluice oper systm of vidur dam

Amount

Dismantling of second stage embedded parts and anchors as per the following specification. On removal of existing corroded gates, the corroded guide plate shall be removed from the groove portion by gas cutting. Male rocker beam shall also be removed from the roller track by disconnecting the fasteners from the female rocker. It shall be shifted from its position by using a winch for welding it with carbon steel wheel track base and SS wheel track as directed by the departmental officers.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Fabrication of second stage embedded parts and anchors as per the following Specification. The guide base of size 200x100x20mm shall be fabricated and the edges shall be finished by grinding. 22mm dia holes shall be drilled at a pitch of 110mm in the guide base. Guide plate shall be fabricated and the edges finished by grinding. The male rocker shall be clamped appropriately and welded to carbon steel track base plate. The SS plate of 304 grade and of size shall be welded over the track base plate with suitable electrodes. The roller track assembly is ensured to be free from bend and other welding defects as instructed by the departmental officers. Stainless steel seal seats ( Side and bottom) as necessary shall be provided by the contractor, including maintenance & warranty for 5 years.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Erection/ installation of second stage embedded parts for the following specification. The groove guide shall be fixed in position by making a centre mark in vertical position on the existing guide portion. The holes shall be marked for a pitch of 110mm in vertical intervals of 500mm centre to centre. The groove guide portion in masonary shall be drilled for 24mm dia and depth of 250mm to accommodate the guide base. Anchor rod of 20mm Ø and 300mm length shall be fixed using vinyl ester hybrid mortar chemical. The guide base plate shall be connected to the anchor bolt at vertical intervals of 500mm. Guide plate shall be welded to the centre of base plate in vertical position. The straightness shall be ensured using a plumb level. After fabrication of roller track assembly, male rocker in the roller track shall be fastened to the female rocker using bolt & nuts. New SS 304 grade sill plate of size 80x12000x12mm shall be welded to the existing sill beam with suitable electrodes. The side seal seat shall be of stainless steel material of 304 grade and of size 80x5000x8mm shall be welded to the existing embedded structural in the groove portion. New SS plate of 304 grade of size 80x100x8mm shall be welded to the side seal flat along with sill seat flat. This ensures the seating of side seal at the bottom as directed by the departmental officers, including maintenance & warranty for 5 years.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Fabrication & supply, erection/ installation of dogging/latch beam including embeddment if any along with construction of niche of adequate size in existing masonry/concrete structure for holding the gate above the MWL for gate maintenance & also to facilitate maintenance /repair or replacement of gate wheels/wheel assembly, including maintenance & warranty for 5 years. The includes scaffolding and incidental petty civil works as directed by the departmental officers.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Dismantling of existing old corroded spillway crest 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 apparatus at the dam site 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, hire charges for crane, machinery like cutting equipment, grinding machine & generator etc., complete.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Transportation and storage of dismantled materials in the department yard as per the following specification. The old corroded cut out pieces of embedded parts and shutter cut pieces shall be taken out from the site and carried to the vehicle, loaded into it through manual or mechanical means and then transported from the dam site to the departmental yard and stored as directed by the departmental officers.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

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 10970x4700mm 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. 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 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 and maintenance for 5 years. (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

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 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.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Supply and erection of bottom seal & side seal with fasteners for a vent size 10970x4700mm 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 . 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.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Conducting the following minimum quality tests as per approved QAP at various stages of work to ensure 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% inhouse as per acceptable standard ASME section VIII witnessed by authorized third party agency and NABL approved inspection agencies for lab testing. Rubber seals are tested inhouse for physical properties such as Hardness, Elongation, Tensile strength, Tensile test after ageing, water absorption test as per IS 11885 : 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. In site welding, RT shall be carried out for 10% of length in butt weld. Internal inspection report shall be furnished at all stages of fabrication. Surface protective treatment such as blast cleaning, metalizing, zinc phosphate primer and coal tar epoxy coating shall be done as per standard norms. Quality of blast cleaning is ensured by cleanliness to SA 2 ½ finish and profile measured using calibrated surface profile gauge before commencement of blast cleaning & coatings. Dew point meter is used to check environmental condition suitable for application as per standard procedure. Adhesion of coating is done with cross hatch & X cut test as per ASTM D 3359. Thickness of metalizing, primer and coal tar epoxy coatings are ensured by coating thickness gauge at random points. Finally to ensure the quality of coating system to be free from pinholes and cracks through holiday detector at random points. All reports and tests shall be furnished to the appropriate authority as directed by the departmental officers.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Erection, testing & commissioning of vertical lift gate for a vent size 10970x4700mm 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 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. 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. (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

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. (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Main spillway vertical gate

Vertical gate Deck bridge

Additional spillway radial gate

Trunnion girder

Radial gate deck bridge

Gantry crane

Providing metallising on gate/ exposed parts using electric arc thermal spraying equipment as per the following specification. The metalizing should be applied within four hours of surface preparation of the component structure. Thermal spraying is a cold process and have proven that they provide long term corrosion protection and outperform all other methods. These thermal spray coating provide corrosion protection by excluding the environment and acting as a barrier coating and they also provide sacrificial anodic protection. The temperatures during the process reach around 95°c. These coating are typically mechanically bonded to a grit blasted surface. Aluminium wire composition as per ASTM standard B833-09 shall be continuously melted in an electric arc spray or gas flame spray gun. Droplets of molten metal from the wire shall be deposited onto the steel forming the protective coating and this avoid corrosion for a long term. The cost includes cost of materials, labour charges, hire charges for machinery, incidental charges like conveyance to & fro from site risk allowance etc., complete. (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Main spillway vertical gate

Additional spillway radial gate

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 /metallising 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. (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Main spillway vertical gate

Vertical gate Deck bridge

Additional spillway radial gate

Trunnion girder

Radial gate deck bridge

Gantry crane

Application of coaltar epoxy over the primer shall be through airless spray method. The colour shall be black and the mixing ratio of base to accelerator should be by manufacturer standards. The dry film thickness should be 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.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Main spillway vertical gate

Vertical gate Deck bridge

Additional spillway radial gate

Trunnion girder

Radial gate deck bridge

Gantry crane

Realignment of existing hoisting arrangements as per the following procedure. The existing hoisting arrangements are checked for proper alignment. Then with the manual operating arrangements, the shutter shall slowly be lifted from its landed position on sill beam. The operation shall be conducted with skilled labour & maintenance engineer for trouble shooting the cause of the hindrance in smooth movement of the shutter during lifting. This shall be repeated a few more times, moving up & down manually to assess the right cause of breakdown. Then the shutter shall be properly aligned after settling the issue Now, the shutter shall be operated using the coupled motor a couple of times and again checked for any misalignment, until smooth movement of shutter is ensured. 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.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Overhauling of existing hoisting arrangements for the shutter as per the following specification. The existing hoist covers shall be opened up and stored separately for reuse after neatly scrapping the surface and painting with a coat of aluminium paint. The top cover of plummer blocks connecting the existing transmission shafts shall be opened and old grease shall be removed. Then, the existing bearings shall be cleaned with liquid cleaner and inspected for mis-alignment and breakage. Fresh grease shall be applied to the plummer block and top cover closed with requisite fasteners. The shaft shall be checked for its alignment and redone to ensure straightness of shaft. The existing gear wheels shall be cleaned of dried grease and dust manually. The reduction gearbox shall now be drained of old used lubricant thro the drain hole at the bottom. Now, the liquid cleaner shall be poured in the gearbox and the inside surface and gears are thoroughly cleaned and then the contaminated liquid cleaner shall be drained. The drain hole shall be plugged and fresh lubricant of appropriate grade shall be filled to the level as indicated by the department officers. The available rope drum 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 inspection, spares, lubricants, transport charges, charges for dismantling & erection, etc, complete.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

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 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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Repair & Replacement of existing punctured incoming cable from busbar panel box 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 25 sqmm armoured aluminium cable shall be provided up to terminal box and 4x6sqmm 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 has 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, pushbutton 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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Repairs and Replacement of bottom rubber seal of the spillway 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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Repair, overhauling & refixing of the Double axis movement double grider crane in veedur dam as per the following specification. The crane has two parallel girders rigidly connected to the end carriages at a distance of 5000mm c/c and spanning the gantry of span 9700mm. The lifting unit is built on to a traversing crab overslung from the beams. The crab is of size 3600x2600mm. 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 unusable. Therefore, all the existing system shall be totally overhauled & repaired wherever necessary & refixed as directed by the departmental officers. The hoisting machinery consists of motor, gearbox, rope drum, rope guide. The gearing is of hardened helical type and motors are of squirrel cage motors. The rope drum is 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 shall be drained & cleaned & re topped. The cost includes cost of all required necessary spares, lubricants, labour charges, charges for dismantling & erection, hire charges for machinery & equipment used during repair, provision of pendant control switches, etc., (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Design, drawing, fabrication, transport & installation of an inspection platform for the Radial shutters at the following size & specification. The total length of the platform shall be 15000 mm and necessary to inspect the shutter trunnion and arms 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 platform shall be of width 900mm and shall be supported by the main girder ISMB 400 on either ends of the platform. 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 over the primer coal tar epoxy with 250µ in two coats over the primer. 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 for 5 years, etc., (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Design, drawing, 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 height & width. A gusset plate made of 8mm thick MS plate and size 160x200mm shall be perpendicularly welded to the cuter side of the main girder on either side to weld the vertical posts of height 1200mm 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 given an excellent finish.

The platform shall be blast cleaned with SA 2 ½ standard and the surface shall be applied epoxy primer with 50µ, The finish coat shall be applied over the primer coal tar epoxy with 250µ 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 for 5 years etc., (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Providing new safety ladder arrangements for accessing from spillway vertical gate D/S sill as per the following specification. The main stiles at both ends shall be 450mm apart and made up of 50x8mm MS Flat. They shall be connected in between with treads of size 16mm dia MS rod. This tread shall be welded to the stiles on either side. The treads shall be spaced onebelow the other at a distance 300mm equidistant from each other. The bottom of the ladder shall be buried in concrete. The top of the ladder shall be embedded to the piers. All members shall be given a coat of redoxide and then two coats of aluminium oxide is given. The old unusable ladder shall be removed and stacked at stores for disposal as directed by the departmental officers. The cost includes cost of materials, labour, erection, transport, warranty for 5 years except protective coatings, etc,(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Design, supply & erection of hydraulic hoist for lifting of vertical gates. The hydraulic hoists consists of a cylinder with upper and lower cylinder head, piston and stem passing through a packing in the lower cylinder head. The hoists are operated by a motor and oil pump arrangement with the directional control by valves which are actuated by electric contacts from any desired position. The cost includes cost of materials, labour charges transport, scaffolding, installation & warranty for 5 years.

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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Overhauling of worm gear box to the river sluice shutters as per the following specification. The worm gear box comprising of worm nut and worm screw which shall be opened up and cleaned & matched properly. Then requisite oil & grease shall be applied for efficient operation. The thrust bearing & oil seal shall be checked and then reused after cleaning & oiling. The phosphor bronze bush shall also be checked if its wornout & then used. The cost includes cost of materials, labour charges, cost of servicing, tools & plants, cost of consumables like grease & oil, transport, etc,(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Fabrication, supply and installation of motor cover for Hoisting arrangements by using composite panels of thickness 2.5mm made as a single unit as per the drawing. A lifting handle in composite material shall also be incorporated. All surfaces shall be applied with two coats of anticorrosive and UV resistant grade polymer coating. The composite material shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties. The cost include cost of materials, labour charges for fabrication, painting, loading & unloading, transport, etc.,(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Replacement of damaged 3.5 core 95sq.mm UG aluminium cable as per the following specification. The old punctured cable shall be removed from its position and new cable from genset room main to New bus bar box @ right side abutment. Necessary clamp & stiffeners shall be provided . Suitable cable lug and glands shall be provided as required at site as directed by the departmental officers. The cost includes cost of materials confirming to IS specifications, labour charges for laying, transport, etc,(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Replacement of damaged 3.5 core 70s.qmm UG aluminium cable as per the following specification. The old punctured cable shall be removed from its position and new cable from Bus bar to DB box @ deck bridge. Necessary clamp & stiffeners shall be provided . Suitable cable lug and glands shall be provided as required at site as directed by the departmental officers. The cost includes cost of materials confirming to IS specifications, labour charges for laying, transport, etc, (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Replacement of damaged 3.5 core 50s.qmm UG aluminium cable as per the following specification. The old punctured cable shall be removed from its position and new cable from Bus bar to Radial gate main. Necessary clamp & stiffeners shall be provided. Suitable cable lug and glands shall be provided as required at site as directed by the departmental officers. The cost includes cost of materials confirming to IS specifications, labour charges for laying, transport, etc, (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Replacement of damaged 3.5 core 35s.qmm UG aluminium cable as per the following specification. The old punctured cable shall be removed from its position and new cable from Bus bar to River sluice starter. Necessary clamp & stiffeners shall be provided . Suitable cable lug and glands shall be provided as required at site as directed by the departmental officers. The cost includes cost of materials confirming to IS specifications, labour charges for laying, transport, etc, (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Replacement of damaged 4 core 25s.qmm UG aluminium cable as per the following specification. The old punctured cable shall be removed from its position and new cable from Bus bar to Gantry starter. Necessary clamp & stiffeners shall be provided . Suitable cable lug and glands shall be provided as required at site as directed by the departmental officers. The cost includes cost of materials confirming to IS specifications, labour charges for laying, transport, etc, (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Replacement of damaged 4 core 16s.qmm UG aluminium cable as per the following specification. The old punctured cable shall be removed from its position and new cable from DB to Gantry starter. Necessary clamp & stiffeners shall be provided . Suitable cable lug and glands shall be provided as required at site as directed by the departmental officers. The cost includes cost of materials confirming to IS specifications, labour charges for laying, transport, etc,(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Replacement of damaged 4 core 10s.qmm UG copper flexible cable as per the following specification. The old punctured cable shall be removed from its position and new cable from DB to Gantry starter. Necessary clamp & stiffeners shall be provided . Suitable cable lug and glands shall be provided as required at site as directed by the departmental officers. The cost includes cost of materials confirming to IS specifications, labour charges for laying, transport, etc,(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Repair & Replacement of old damaged metal DB box to hybrid composite super structure DB box to spillway vertical gate hoist. The DB box 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 DB box shall be housed in Bus bar arrangements with copper flat, 4P -100A MCCB, 32A-4P-MCB and indicator lamp. The cost includes cost of composite enclose box, raw materials, switches, internal wiring wires, labour charges, transport etc.,(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Providing hybrid composite super structure terminal box for cable connections. The Terminal box 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 Terminal box shall be 3 phase 63A cable terminal connectors. The cost includes cost of composite enclose box, raw materials, labour charges, transport etc., (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Repair & Replacing the existing electromagnetic brake in the gantry crane 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, consumables, 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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Modification of existing gantry crane for long travel/cross travel movement in the river sluice emergency shutter hoist. The river sluice in the veedur dam, 2 in number, is laid out, one adjacent to the other. The shutters in the river sluice is appropriate depth 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 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 appropriate length. 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 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 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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Repair & Replacement of the existing river sluice service gate as per the following specification & drawing. The existing service gate is totally corroded and hence leaking & not properly operable. Therefore, the platform around the river sluice service gate shall be dismantled and the suspension channel shall be removed from its position and safely stacked for re erection with new service gate. However care should be taken to paint the existing suspension channel before it is re erected with new service gate. The new river sluice service gate shall be of size 2200x1980mm. The skin plate shall be of 16mm thick and vertical and horizontal stiffeners shall be provided ISMB 300. End verticals shall be provided with ISMC 300. The seal seat and cover shall be 10mm thick. The side & top rubber seal shall be provided with ‘P’ type seal of size 100x44x14. The existing cast steel wheel assembly shall be serviced and reassembled to the new gate. 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 50µ. The finish coat of coaltar epoxy for 250µ in two coats shall be applied. Each coat shall be given be given a drying time of minimum 24 hours. 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 warranty for 5 years except rubber seals, protective coatings, etc.,(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Dismantling, surface cleaning, inspection, nondestructive testing and re-assembly of chain hoist as per the following specification. The shutter shall be rested on the sill and the counterweight shall be locked at dogging portion. The hoist chain shall be removed from counterweight & shutter. The hoist components such as chain link, chain sprocket, gearwheel, pinion wheel and bushes shall be dismantled from the assembly in one vent. Then, the hoist components shall be surface cleaned by water jet equipment at a pressure. Thus the contaminated grease and foreign particles shall be removed from the components. The cracks, dents and damages if any, shall be completely inspected and documented. The dimension of the component shall be checked and drafted using measuring tape, vernier caliper /micrometer . The visual inspection procedure shall be carried out as per ASME section V, article IX. Visual examination shall determine the surface condition of the cracks, dents and damages if any of the hoist components, and damages if any of the surfaces, shape, or evidence of damage and deviations from initial structure. Capabilities include, but are not limited to viewing, magnifying, identifying, measuring, and/or recording observations. Direct visual examination may usually be made when access is sufficient to place the eye within 600 mm of the surface to be examined and at an angle not less than 30 deg to the surface to be examined. Mirrors shall be used to improve the angle of vision, and a magnifying lens may be used to assist examinations.

Illumination for the specific part, component or section thereof being examined shall be required. The minimum light intensity at the examination surface/site shall be 1000 lux. All surfaces where the test points are planned shall be cleaned with emery wheels in grinding machine. All indications of the non destructive tests greater than 20% of the reference level shall be investigated to the extent that they can be evaluated in terms of the acceptance criteria of the referencing Code Section. Rejectable indications shall be recorded. As a minimum, the type of indication such as crack, discontinuities, dent, etc., location, and extent shall be recorded. For all NDT examinations, the surface preparation by grinding or buffing may be necessary where surface irregularities could mask indications due to discontinuities. Prior to examination, the surface to be examined and all adjacent areas within at least 25 mm shall be dry and free of all dirt, grease, lint, scale, welding flux and spatter, oil, or other extraneous matter that could interfere with the examination. All examinations shall be conducted with sufficient field overlap to

ensure 100% coverage at the required sensitivity. The surface defect up to 2mm shall be examined in the accessible area by Liquid penetrant inspection (LPI). This inspection procedure shall be carried out as per ASME section V, article – VI / BIS 3658 - 1999. The liquid penetrant examination shall be effective for detecting discontinuities which are open to the surface of nonporous metals. Typical discontinuities detectable by this method shall be cracks, seams, laps, cold shuts, laminations, and porosity. The liquid penetrant shall be applied to the surface to be examined and allowed to enter discontinuities. All excess penetrant is then removed, the part is dried, and a developer is applied. The developer functions both as a blotter to absorb penetrant that has been trapped in discontinuities, and as a contrasting background to enhance the visibility of penetrant indications. Liquid penetrant examination shall be performed keeping in mind the minimum requirements of dwell time. Rejectable type of indications, location and extent shall be recorded. The hoist components soundness shall be inspected by magnetic particle inspection (MPI) and ultrasonic flaw detection. The spur gear wheels, pinion wheels, chain components and shafts accessible areas shall be inspected and evaluated the defects upto 4mm depth by MPI as per BIS 3703 – 2004 / ASME section V, article – VII. The magnetic particle examination method shall be applied to detect cracks and other discontinuities on the surfaces of ferromagnetic materials.

The sensitivity diminishes rapidly with increasing depth of discontinuities below the surface. Typical types of discontinuities that can be detected by this method are cracks, laps, seams, cold shuts, and laminations up to 4mm depth. The process shall be carried out by magnetizing an area to be examined, and applying ferromagnetic particles to the surface. Prod spacing shall not exceed 200 mm. The hoist components of spur gear wheels, pinion wheels, chain sprocket and chain link pins all accessible critical area defects shall also be analyzed by Ultrasonic examination by ultrasonic flaw detection as per BIS 15452 – 2004 / ASME Section V, article - IV. A pulse-echo-type of ultrasonic instrument shall be used. The instrument shall be capable of operation at frequencies over the range of at least 1 MHz to 5 MHz and shall be equipped with a stepped gain control in units of 2.0 dB or less. The instrument shall have a damping control and it shall not reduce the sensitivity of the examination. The rate of search unit movement / scanning speed shall not exceed 150 mm/s. The flaw identity, maximum amplitude, location, and extent of reflector causing a geometric indication shall be recorded. hardness of the raw material plates and structural shall be inspected with D type pocket hardness tester at 5 random points on all components in accordance to ASTM A956. The alloy composition of all hoist components shall be determined by positive material identification (PMI) as per ASTM IS1476. The XRF principle or spare emission spectrography method shall be adopted for one random testing of hoist components.

The dismantled components of the vent shall be reassembled and readied for operation.Then, appropriate lubricants shall be applied as directed by the departmental officers. All reports generated shall be authenticated by the accredited consulting agency and shall be furnished to the appropriate authority as directed by the departmental officers. The costs includes hire charges of non-destruction testing equipment such as, ultrasonic flaw detector, magnetic particle inspection / yoke type, Penetrant, cleaner and developer, D type pocket hardness tester, PMI equipment, water jet equipment charges, skilled operation and manpower charges, documentation charges, process charges, spares, consumables, conveyance to site, consultancy charges, etc., (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Spillway shutter

Radial gate

Inspection, surface spot preparation, examination and conducting Nondestructive testing to evaluate the integrity of the shutters as per the following specification. The shutter components in upstream and downstream side shall be visually inspected. The corrosion in each component shall be studied with images and remedial measures shall be suggested. The material defects and weldment/ rivetted joint defects shall also be analyzed by visual inspection. The visual inspection procedure shall be carried out as per ASME section V, article IX. Visual examination shall determine the surface condition of the part, alignment of welded/rivetted surfaces, shape, or evidence of damage and deviations from initial structure. Capabilities include, but are not limited to viewing, magnifying, identifying, measuring, and/or recording observations. Direct visual examination may usually be made when access is sufficient to place the eye within 600 mm of the surface to be examined and at an angle not less than 30 deg to the surface to be examined. Mirrors shall be used to improve the angle of vision, and a magnifying lens may be used to assist examinations. Illumination for the specific part, component or section thereof being examined, shall be required. The minimum light intensity at the examination surface/site shall be 1000 lux. All surfaces where the test points are planned shall be cleaned with emery wheels in grinding machine.

The ultrasonic thickness gauge with through coat / steel substrate feature and other measuring instruments shall be used for thickness measurement of plates and structurals. The overall dimension in the shutter shall be documented. The ultrasonic thickness gauge procedure shall be carried out as per BIS 15435 – 2003. All indications greater than 20% of the reference level shall be investigated to the extent that they can be evaluated in terms of the acceptance criteria of the referencing Code Section. Rejectable indications shall be recorded. As a minimum, the type of indication such as crack, non-fusion, slag, etc., location, and extent shall be recorded. For all NDT examinations, the surface preparation by grinding or buffing may be necessary where surface irregularities could mask indications due to discontinuities. Prior to examination, the surface to be examined and all adjacent areas within at least 25 mm shall be dry and free of all dirt, grease, lint, scale, welding flux and spatter, oil, or other extraneous matter that could interfere with the examination. All examinations shall be conducted with sufficient field overlap to ensure 100% coverage at the required sensitivity.

The vertical fillet welds shall be inspected at 5 random points on bottom, middle and top portion of 100mm length by Liquid penetrant inspection (LPI). This inspection procedure shall be carried out as per ASME section V, article – VI / BIS 3658 - 1999. The liquid penetrant examination shall be effective for detecting discontinuities which are open to the surface of nonporous metals. Typical discontinuities detectable by this method shall be cracks, seams, laps, cold shuts, laminations, and porosity. The liquid penetrant shall be applied to the surface to be examined and allowed to enter discontinuities. All excess penetrant is then removed, the part is dried, and a developer is applied. The developer functions both as a blotter to absorb penetrant that has been trapped in discontinuities, and as a contrasting background to enhance the visibility of penetrant indications. Liquid penetrant examination shall be performed keeping in mind the minimum requirements of dwell time. Rejectable type of indications, location and extent shall be recorded. The welding soundness shall be inspected by magnetic particle inspection (MPI) and ultrasonic flaw detection. The fillet welds shall be inspected at 5 random points on bottom, middle and top portion for 100mm length by MPI as per BIS 3703 – 2004 / ASME section V, article – VII. The magnetic particle examination method shall be applied to detect cracks and other discontinuities on the surfaces of ferromagnetic materials. The sensitivity diminishes rapidly with increasing depth of discontinuities below the surface. Typical types of discontinuities that can be detected by this method are cracks, laps, seams, cold shuts, and laminations up to 4mm depth. The process shall be carried out by magnetizing an area to be examined, and applying ferromagnetic particles to the surface.

Prod spacing shall not exceed 200 mm. The material defects and weldment defects shall also be analyzed by Ultrasonic examination. The butt welds shall be inspected at 5 random points on skin plate joint portion. The overall inspection length shall be inspected for 10% of skin plate butt weld length by ultrasonic flaw detection as per BIS 15452 – 2004 / ASME Section V, article - IV. A pulse-echo-type of ultrasonic instrument shall be used. The instrument shall be capable of operation at frequencies over the range of at least 1 MHz to 5 MHz and shall be equipped with a stepped gain control in units of 2.0 dB or less. The instrument shall have a damping control and it shall not reduce the sensitivity of the examination. The rate of search unit movement / scanning speed shall not exceed 150 mm/s. The flaw identity, maximum amplitude, location, and extent of reflector causing a geometric indication shall be recorded.

The hardness of the raw material plates and structural shall be inspected with D type pocket hardness tester at 5 random points on bottom, middle and top portion in accordance to ASTM A956. The alloy composition of plates and structurals shall be determined by positive material identification (PMI) as per ASTM IS1476. The XRF principle or spark emission spectrography method shall be adopted for one random testing of hoist components. The dry film thickness in the available structures shall be inspected with coating thickness measurement gauge at 5 random points on bottom, middle and top portion. The inspection shall be carried out as per BIS 6012: 1992. The hardness of rubber seals shall be inspected by shore “A” durometer, hardness tester at 10 random points on each component. The testing procedure and results evaluation shall be carried out as per BIS 3400: part 23 (2002). Various NDT Inspections shall be carried out on Steel structural for condition assessment, life assessment to avoid failure and for safe and reliable operation of shutters. All reports, mapping of tests generated shall be authenticated by the accredited consulting agency and shall be furnished to the appropriate authority as directed by the departmental officers. The cost includes hire charges of non-destruction testing equipment such as ultrasonic thickness gauge, ultrasonic flaw detector, magnetic particle inspection yoke type, D Type pocket hardness tester, PMI equipment, shore A durometer, coating thickness gauge, measuring tape and plumb bob, skilled operator and manpower charges, documentation charges, process charges, spares, consumables, conveyance to site, consultancy charges, etc., (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Radial gate

Emergency Shutter

Fabrication, supply and installation of Chain hoist enclosure for hoist assembly by using composite panels of thickness 3mm made as a single unit as per the 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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Fabrication, supply and installation for centre hoist cover by using composite panels of thickness 3mm made as a single unit as per the 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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Repair & Replacement of vertical canal shutter as per the following specification. The existing platform shall be dismantled by gascutting the components. The shutter with guide channel & the screw rod shall also be dismantled from its position. The guide channel & platform shall be reused after cleaning it. The old corroded shutter & screw rod should be stacked in the department stores. 12mm ms plate of best quality should be used as skin plate. The end vertical shall be made of 16mm plate. The 4 nos horizontal member shall be provided and welded to the rear of the skin plate at appropriate location. A vertical stiffeners shall be madeup of 12mm plate and welded to the rear of the skin plate. The rubber seal shall be provided on all four sides of the shutter and shall be provided with stainless steel M10 bolts & nuts of higher grade shall be used for fastening the seal seat cover made of 50x10 Ms flat to the shutter sandwitching the rubber seal. The wheel shall be of dia 100mm provided with Polished brass bush of ID 40mm and OD 50mm. The roller pin shall be made of 32mm dia EN9 grade. The dismantled guide channel & platform shall be erected in its place. All steel items should be given a coat of primer over which industrial anticorrosive black paint shall be applied. The cost includes cost of all materials, cost of consumables process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments, conveyance to site and clearing them after completion of work, including cost of trial operation, warranty for 5 years etc., (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Repair & Replacement of hoist bed operating platform in the river sluice as per the following specification. Scaffolding shall be erected in the well for the total depth of 10m to support the existing worm gear. Then the existing corroded ISMB 300 shall be cut & stacked as directed by the departmental officers. The embedded portion of the existing corroded channels in masonary shall also be broken with concrete breaker machine and the embedded channels removed to facilitate fixing of new channels at the same point. The bed platform shall be fabricated with ISMB 300 similar to the existing one assembled at site and then shall be erected in the same position. The embedded portion in masonary shall be laid with concrete. The platform panel shall be provided with 6mm chequered plate after marking & cutting the 6mm chequered plate to required size. The worm gear shall be reerected in the platform and the scaffolding is dismantled from the sluice well. A coat of anticorrosive redoxide & a coat of industrial black paint is applied to the structure. 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, etc., (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Refurbishing of existing emergency shutter as per the following specification. The existing emergency shutter is of size 2740 x 2775 mm. The shutter shall be dismantled from the position from the spreader beam manually and loaded with a crane to a vehicle and shall be transported to factory for repair & service. Repair & overhauling of components of emergency shutter are taken up in the factory as follows. The highly corroded horizontal girder shall be cut wherever required, with gas cutting equipments. Then new plates shall be welded appropriately. The corroded lifting plate rod shall be cut & replaced with new one for extended life. The spring & valves in the lifting assembly shall be overhauled & directed by the departmental officers. The existing rollers shall be removed and then overhauled. The existing pins & bearing inside the rollers shall be removed & operationalised. The whole shutter shall be given a coat of anticorrosive primer overwhich 2 coats of coaltar epoxy. Then the emergency shutter shall be loaded into a vehicle & transported back to the site as directed by the departmental officers. It shall always be stored flat on the platform to avoid stagnation of rain water in the emergency shutter. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like chainpulley block, welding machine, cutting set, grinding machine, power charges for generator, conveyance to site and clearing them after completion of work, including cost of trial operation etc., (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Repair & replacement of suspension channel in veedur dam as per the following specification. New suspension channel shall be made of 125x65mm twin channels facing each other at a distance of 65mm with ISMC 125x65 welded between them as spacers. The spacers shall be provided at a vertical distance of 500mm c/c from each other. These twin channels shall withstand the designed loads. The existing screw rod of size 100mmØ & 3000mm length shall be connected to the new suspension channel with a system of bolt & nuts of size 6"x5/8". The suspension channel shall be of appropriate height as per site condition but should be fabricated in cut lengths of 3m since beyond that the suspension channel for screw rod cannot be removed from its position for maintenance. The suspension channels shall be connected to each other with a system of 10mm plate of size 200x250mm using bolts & nuts. The bottom of the suspension channel extends upto the top horizontal member of the shutter. Then it shall be assembled for efficient operation, as directed by the departmental officers. All members shall be given a coat of epoxy primer overwhich two coats of anticorrosive coaltar epoxy paint shall be applied. The cost includes cost of materials, labour charges, hirecharges for machinery like derrick, chainpulley block, gas cutting equipment, welding plant, erection, etc, cost of conveyance to & fro from site of work, risk allowance, trial operation, warranty for 5 years etc, (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Renewal & refixing of 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 C flattened strand winding rope 6 x 36 with nominal appropriate diameter as per per existing 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, etc, (Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

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 complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)

Providing protection arrangements to the hoisting components in the vents of the spillway vent Hoist bridge as per the following specification. The main vertical posts along the periphery of the platform shall be made of ISA 75x75x6 mm to a appropriate height at an upstream & downstream side and at an interval of 2000 mm from each other . The connecting members at the top of the vertical posts shall also be made of ISA 75x75x6 mm. This assembly shall be fitted to the existing deck bridge with bolts and nuts of appropriate size. The horizontal members along the periphery shall be at an interval of 300 mm C/C and made up of 3/4” GI pipe 20 mm Ø holes shall be drilled at 300 mm C/C in the vertical members and the GI pipe shall be inserted in to the vertical members through the holes. The weldmesh production to upstream and downstream side of size 30x60mm with 2.5mm thickness shall be welded in a MS frame between the main vertical posts made with 25x25x5 mm MS angle for the entire height . The cross stiffeners shall be provided to the weldmesh frame made with 25x5 flat. The additional stiffeners shall be provided horizontal and vertical direction at center of the frame. The front & back entrance of the deck bridge of the openable double door frame shall be provided with appropriate size. The outer frame shall be made of 65x65x6 angle and inter mediate stiffeners shall be provided with 25x5 flat. The weldmesh shall be welded over the frame. The purlin shall be provided at an top portion over the connecting members. They shall be provided in max distance of 1200mm. The ends of purlin shall be closed. Cleat angles shall be fabricated and appropriate holes shall be drilled in the cleat angle and matching holes in rafter for bolted joints.

Colour coated corrugate colour profile sheets shall be provided for roofing. All steel members shall be mechanically cleaned and give a coat of Zinc chromate enamel primer. Then, two coats of aluminium shall be applied over the primer. The cost includes cost of all materials, process charges like gas cutting, welding, manual labour charges, loading, lifting, unloading, transport, erection, hire charges for equipment’s, power charges from generator, scaffolding charges, risk allowance for working at height of more than 3m, conveyance to site and clearing them after completion of work.(Complete complying with standard specifications and as directed by the departmental officers. including maintenance & warranty for 5 years.)