Design Fabrication supply and erection of spillway shutter Deck bridge counter weight and hoisting arrangements for spillway vent No.1,2 and 3 in Sholayar Dam Valparai Taluk of Coimbatore District

Dismantling of existing old corroded vertical gates from its respective groove portion including counterweight, chain, hoisting arrangements, deck bridge with all cross girder and main girder by the following process . The gates shall be made to rest on the sill portion. The counter weight shall be locked to the deck bridge through pin connecting both sides. Lifting chains shall be released from the shutter by removing the pin from the chains. The shutter shall be cut out into pieces with gas cutting equipment. Then the cut pieces shall be carried from vent portion using a crane and then transported to the department store through trucks and stacked as directed by the departmental officers. The counter weight also shall be removed from the vent portion using a suitable lifting mechanism. The damaged concrete counter weight shall be suspended through a winch after releasing the lock from the deck bridge. The counter weight shall then be lowered to the rest portion. After that both ends of the counter weight in groove portion shall be broken using a heavy duty breaker, the balance centre piece of the counter weight shall be lowered to the sill using a winch . Finally the RCC counter weight portion shall be disposed away from the water spread area of dam site. The steel items such as hoisting arrangements, chain, motors, gear boxes, cross and main girders of deck bridge sections, etc shall be stacked as directed by the Engineer - in - charge. The rate is inclusive of consumables like oxygen gas & LPG, grinding wheels, oil, diesel & lubricants for generator, labour charges for dismantling, lifting, loading, unloading & stacking, hire charges for crane, lorry, machinery like cutting equipment, grinding machine & generator, etc., complete and as directed by the departmental officers.

Repair and replacement of second stage embedded parts like roller track plate, side seal track and sill seat as per the following specification. The existing corroded MS roller track plate is in two layers. The bottom layer is made of 100x15mm MS flat securely welded to the roller track embedded in concrete. The top layer is made of 100x15mm MS flat and is welded to the bottom layer. This top layer shall be removed by grinding and gas cutting operations from the bottom layer. Then a SS track plate of size 100x12mm shall be welded to the existing bottom MS track plate appropriately to enable the rollers move vertically on the SS track plate. This would reduce friction to a large extent. The side seal track plate shall be of size 80x8mm made of SS 304 grade. It shall be appropriately welded to the existing angle ISA 120 welded in the upstream side upto 7800mm from sill level. This would facilitate the smooth movement of side seal without friction, while the gate moves up & down. The sill seat shall be made of 80x8mm SS flat of 304 grade. This shall be provided on top of the existing Ms sill beam which is embedded in concrete. This provides an even surface for the bottom seal to land, preventing water from leakage. The groove of the shutters shall be grouted with special cement grout by following standard specification such that the leak on the downstream side wall of groove shall be arrested. The existing corroded guide angle shall be removed. The guide base of size 200x100x32 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 of size 25mm thick plate shall be provided in appropriate size. The groove guide shall be fixed in position by marking a center mark in vertical position on the existing guide portion. The holes shall be marked for a pitch of 110mm in vertical intervals of 500mm c/c. The groove guide portion in masonry shall be drilled for 24mm dia and 250mm depth to accommodate the guide base. Anchor rod 20mm dia 300mm length shall be fixed using vinyal ester hybrid mortar chemical. The guide base plate shall be connected to the anchor bolt at the vertical intervals of 500mm. The guide plate of 25mm shall be welded to the center of base plate in vertical position. The straightness shall be ensured using plumb level. The cost includes cost of materials, labour charges for dismantling and erection at site, hire charges for machinery like grinding machine, gas cutting equipment, drilling machine, welding plant & generator, rental charges for erection equipments like chain block & crane, cost of consumables such as oil, diesel & lubricants for generator, welding rod, grinding wheel, core cutter bits, oxygen & LPG, incidental charges like conveyance to & fro from site of work, loading & unloading, allowance, etc., complete, including warranty and maintenance for 5 years.

Design, fabrication, supply, erection, testing and commissioning 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 12800x7620mm as per IS 4622 and current seismic parameters.. The skin plate, end verticals, vertical stiffeners, horizontal fabricated girders, lifting assembly, side seal base plate, side seal cover, bottom seal cover, rear angles shall be made of structural steel confirming to IS 2062 : 2011. The connecting fasteners shall be made of MS confirming to IS 2062. 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 inaccessible areas such us the inside of the end vertical and diaphragm plate shall be applied with metallising to a thickness of 150µ. On fabrication of all components of the shutter, a trial assembly shall be done at the shopfloor to ensure the dimensional accuracy and integration of all sub components. Also, the layout shall be clearly marked & serially numbered by punching. Match drilling in different components and cleats provided wherever necessary to assure minimum tolerance levels. The cost includes cost of MS materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel & lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including warranty and maintenance 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 of size 350mm dia with bearing and retainers shall be machined as per approved drawing. The required tolerance shall be provided for wheel to fix the bearing & retainers. Spherical roller bearing of appropriate size and quality manufactured by a 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 corrosion resistant 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.

Manufacture, supply and erection of bottom seal intermediate joint seals & side seal with fasteners for a vent size 12800x7620mm as per the following specification. The seals shall be made of a basic polymer that shall be natural rubber. Rubber seals shall be moulded to ensure homogeneous section. Natural rubber seal shall be used as it is elastic, deforms readily and regains its original shape on the removal of loads. The bottom seal shall be a flat seal of size 75x12mm. The side seal shall be a Z type rubber seal of size 74x79x16mm . The intermediate element joint seal between the two element connecting shall be provided 170x10mm flat type seal. M 13 holes shall be punched in the rubber seals with seal punchers to match with the holes in the skin plate and cover plate. SS 304 gr fasteners of size M12 shall be used to fasten the rubber seal to the skin plate and cover plate as directed by the departmental officers. The cost includes cost of materials like rubber seal & fasteners, labour charges punching of rubber seal & erection in the shutter, oil, diesel & lubricants for generator, loading & unloading, conveyance charges, etc, complete

Design, drawing, fabrication , supply and erection of hoist bridge for spillway vertical gate of size 12800 x 7700mm as per IS 800 : 2007. The hoist bridge frame made of IS 2062 : 2011- E250 grade. 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 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 loading, lifting, unloading, hire charges for equipments like chainpulley block, power charges for generator, including warranty for 5 years, etc., complete as directed by the departmental officers.

Replacement of hoisting arrangements for the vertical gates in the spillway of the Sholayar dam as per the following specification. The spillway vertical gate in vent of size 12800x7620mm shall be parked in the rest position on the sill beam. The counterweight shall be locked with the dogging beam. The lock pin in the hoist chain shall be disconnected. The chain shall be removed from the chain sprocket. The complete hoist assembly with all gearwheels & pinion wheels shall be removed. They shall be safely stored at the departmental stores. New pattern shall be made for the gearwheels and cast with material adhering to grade 28-54 as per IS 1030. The cast blocks shall be annealed appropriately and machined to requisite sizes. The teeth shall be cut by hobbing as per requirement. Shaft shall be made with EN8 materials. Keyway shall be done appropriately in the shaft. New pinbush couplings shall be provided to match that of the new shafts. The motor of 7.5HP capacity with S3 duty & 1440 RPM shall be provided along with a U600 worm reducer gearbox. New Plummer blocks, bearings & sleeves shall be provided. These components shall be assembled and trial operation conducted. Once the operation is smooth, the newly sourced chain shall be connected with the chain sprocket. The counterweight & shutter shall be connected by the chain. The locked counterweight shall be released. The moving components such as hoist gear, chain, plumber block etc shall be lubricated as per standards. The sprocket shall be made of C45 material with 10 teeth and tip diameter of 450mm. The teeth profile should adhere to ISO 606. The pitch shall be 130mm. Heat treatment shall be done to a case depth of 1.00mm. The minimum breaking strength of strap shall be 500 N/mm2. The straps shall be connected with medium carbon heat treated steel pins. The breaking strength of pin shall be 600 N/mm2. The new chain assembly shall suit existing chain sprocket. The upstream end of chain shall be fastened to shutter lifting assembly. The downstream end of chain shall be connected to counter weight lifting assembly. The hardness shall be 30-40 HRC. The tolerance shall be followed as per IS 2102. The teeth profile edges shall be chamfered. A phosphor bronze bush shall be provided in the bore of 170mmØ. The upstream end of chain shall be fastened to shutter lifting assembly. The downstream end of chain shall be connected to counter weight lifting assembly. Necessary lubrication shall be applied to the chain link components. Trial operation shall now be conducted and the components shall be ensured that they sink with eachother. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheels, oxygen & acetylene gas, diesel & oil for generator, process charges like gas cutting, welding, labour charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like chainpulley block, welding machine, cutting set, grinding machine, power charges for generator, conveyance to site and clearing them after completion of work, warranty and maintenance for 5 years, complete as directed by the departmental officers.

Providing counterweight arrangements as per the following specification & size. The counterweight shall be made with MS heavy plates of size 50mm for base plate, 32mm for side walls and 32mm for inside stiffeners. The top cover plate shall be 16mm thick. The plates shall be welded in sequence appropriately with skilled welders. The welding shall be done as per standard procedures and the burr and slag shall be removed by grinding the top of welds. A good weld 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 box is volumetrically divided into 5 compartments with 32mm inside cross stiffeners. The inner surface of the counter weight, which would be inaccessible on erection, shall be applied with metallising to a thickness of 150µ. The space 360x140x1000mm – 4 nos on each side at both ends of the counterweight shall filled up with concrete. To avoid corrosion, concrete blocks of approximate size 280x150x150mm shall be neatly stacked inside the counterweight in the middle portion. The concrete blocks are stacked one over the other in 6 rows. Lifting plates of size 32x300x1310mm are welded in the inside of the box from the bottom, on both corners of the box. 45mm dia holes are drilled in the plates for locking of chain & locking of counterweight while carrying out repairs in the shutter. A Groove guide shall be welded to either sides of the box, one at top & one at bottom. This serves as guides to the counterweight arrangement while moving up & down. Steel scaffolding is done upto a height of 15m to install the counterweight arrangements. Mobile crane shall be used to handle the box during installation of the counterweight arrangements. The cost includes cost of materials, labour charges for fabrication and erection, hire charges for crane, winch, chain block, generator, machinery & tools, consumables such as oil, diesel & lubricants, scaffolding/temporary platforms, risk allowance, transport, etc, complete, with warranty and maintenance for 5 years.

Conducting the following minimum quality tests as per approved QAP for the following components such as the materials used for renewal of Spillway gates, Chain, Counterweight, hoisting arrangements, cross and main girders of deck bridge at various stages of work which includes renewal of Spillway gates, Chain, Counterweight, hoisting arrangements, motors, gear boxes, cross and main girders of deck bridge. 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% in house as per acceptable standard ASME section VIII witnessed by authorized third party agency. Rubber seals are tested in house for physical properties such as Hardness, Elongation, Tensile strength, Tensile test after ageing, water absorption test as per IS 11855 : 2004. All raw materials are 100% dimensional checked and verified in accordance with manufacturer test certificate. In shop welding process, quality of fillet welds are checked visually and using 100% magnetic particle inspection. In site welding , quality of fillet weld is inspected either by 10% 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. Internalinspection report shall be furnished at all stages of fabrication. Surface protective treatment such as blast cleaning, epoxy primer and coal tar epoxy coating shall be done as per standard norms. Quality of blast cleaning is ensured by cleanliness to SA 2 ½ finish and profile measured using calibrated surface profile gauge before commencement of blast cleaning & coatings. Adhesion of coating is done with cross hatch & X cut test as per ASTM D 3359. Thickness of primer and coal tar epoxy coatings are ensured by coating thickness gauge at random points. All Quality assuarance report (QAP) reports and tests shall be furnished to the appropriate authority as directed by the departmental officers.

Replacement of existing chain link assembly in chain hoist as per the following specification. The roller chain for balancing shutter & counter weight assembly shall be made with low/medium carbon steel straps of 5 inch pitch. The minimum breaking strength of strap shall be 500 N/mm2. The straps shall be connected with medium carbon heat treated steel pins. The breaking strength of pin shall be 600 N/mm2. The new chain assembly shall suit existing chain sprocket. The upstream end of chain shall be fastened to shutter lifting assembly. The downstream end of chain shall be connected to counter weight lifting assembly. Necessary lubrication shall be applied to the chain link components. The cost includes cost of all materials, process charges like gas cutting, welding, machining, scaffolding charges, labour charges for dismantling, loading, lifting, unloading, transport, erection, labour charges for equipments like crane, chain pulley block, power charges from generator, risk allowance for working at a height of more than 3m, conveyance to site and clearing them after completion of work including cost of trial operation, warranty for 5 years etc., complete and as directed by the departmental officers.