Renewal of low level sluice shutter in the vent no.2 3 4 5 and repairs to the shutter in vent no 1 in Stanley Reservoir at Mettur Taluk in Salem District.

Amount

Design, Drawing, Fabrication, erection, testing & Commissioning of Low Level Sluice shutter of size 5170 x 2945mm.. Raw material testing needs to be done for chemical and mechanical properties and mill TC should be verified. Deviations in the raw material chemical properties will lead to weldment with defects. The existing shutter arrangement is removed by safely dismantling and shifting the hoisting arrangements and then dismantling the shutter gate from the dam without any damages to the guide ways and guide rollers.The main Vertical Beams of the shutter are NPB 500 beams. Utmost priority is given to ensure the straightness of the beam or else the shutter will not be able to slide through the guideways freely. Straightness of beam is ensured by using musical string. 11 numbers of horizontal support beams of NPB 400 are to be placed in between vertical beams. Straightness of horizontal beams are also to be ensured using musical string to ensure proper seating of skin plate. The NPB 500 and NPB 400 beams shall be properly welded to each other using 16mm thick pad plates. The welding will be done only using E 7018 welding electrodes for proper weldment and strength. The electrodes are to be preheated to at least 350°C to remove moisture from the welding electrodes, if any Dye Penetrant (DP) test will be done on all welds to detect and resolve all welding errors/ defects, if any. The Skin Plate for the shutter of size 2285*4415mm are to be made from 16mm thick ASTM A 240 SS316 plates. This plate is to be welded with the previously welded horizontal beams (NPB 400 and NPB 500) The skin plate material is also tested for mechanical and chemical properties to ensure strength and performance of the shutter. The skin plate is to be welded to the beams using electrode grade E 309L. The electrodes are to be heated to rid it of any moisture. Seals and seal adjustment plates have to placed and welded on both horizontal and vertical sides of the skin plate using 45mm thick SS 316 plate. Brass flat of size 15mm x 45mm has to fastened on both sliding ends of SS 316 45 mm thick vertical sealing plate. On the top sealing plates adjustment plate has to provided. Milling is to be done for the length of 1735mm for the seating of shutter gate on top. Machining has to be done on all surfaces of the seals to ensure they are perfectly flat. Shutter deflection dampening mechanism has to be fixed on the vertical main beams on back side of shutter. 4 numbers of 75 mm x 190mm 2285mm plates made of IS 2062 E 250 have to be milled to the required profile and 6 numbers mounting blocks of size 180mm x 60mm height made of IS 2062 E 250 are to be used for mounting of the profile milled plates. 4 numbers of guide rollers have to be placed on the vertical main beam. Roller made of EN 24 has to be machined on outside and inside with utmost care and concentricity is to be maintained. Connecting pin should be made of ASTM A276 SS420. Phosphor Bronze bush has to be placed in between the pin and roller which should contain oil grooves for the lubrication. After fabrication transportation of shutter gate assembly to the Mettur dam low level sluice. Erection of shutter arrangements using cranes. Fixing of hoisting arrangements and guide roller assemblies. Transportation of dismantled shutter to the PWD yard and disposal as per the instruction of PWD Engineers.

Repair & Renewal of stoney type cast iron rollers of size180mm dia and190mmin length behind the shutter as per the following specification. The emergency shutter shall be used in the vent and then the service shutter shall be takenup for maintenance. The service gate shall be lifted upto service deck and rested. The stoney type roller connected with a rope to the shutter shall be delinked. Now, the roller frame shall be retrieved from its position with a rope drawn fromthe winch overhead. The roller frame is of size 245mm x160mm x4630mm. The outer member is made of solid MS plate of thickness 25mm and size 160x4630mm. This solid plate has a groove throughout itslength of size 25x5mm at the bottom of the plate at one side.Two plates are connected by 8mm plate of size 195x160mm neatly placed equidistant from each other at 265mm equal intervals. 18 rollers are placed in between these partitions and roll on a pin as the pivot One roller for tying the connecting rope is provided at the top end.Theold corrodedpinsshallbe replacedwith new30 CR13 steel and the old ones shall be stacked in the stores as directed by the departmentalofficers.All componentsofthe rollerframes shall be neatly cleaned with rust remover compounds and reassembled. Also, the old corroded 58” rope connecting the shutter & the roller frame shall be replaced with a new rope of same size. Each vent has two sets of rollers on either end of the 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 chain pulley block welding machine,cutting set,grinding machine,power charges for generator,conveyance to site and clearing them after completion of work,including cost of trial operation,etc., complete as directed by the departmental officers.

Replacement of existing corroded mild steel connecting rods at second stage, third stage and top portion of length 4.55m connecting the shutter with the counter weight including close the vent by low down the emergency gate in the emergency gate grooves and after detach the connecting hook from the shutter and remove the first stage SS connecting rod and lifting the rod with wire rope and with hoisting equipment to the top. And detach all the eroded connecting rod at other three stages carefully and lifting them to the top of road.The newly fabricated connecting rods made up of 50mm dia SS 304 rod and 50mm thick SS304 plate of same size and length to the four stages and the bottom most portion connected with existing SS304 connecting rod with pins . After completion of work trial run of shutter and hoisting arrangements to ensure the operation of connecting rods in perfect alignment and position. After completion of trial operation lift the emergency gate from the vent and conveyed to the store. The cost includes cost of all materials, process charges like scaffolding charges, labour charges for dismantling, loading, lifting, unloading, transport, erection, labour charges for equipments like winch arrangements, 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, warranty for 5 years etc, complete and as directed by the departmental officers

Providing abrasive blast cleaning using air blast cleaning with abrasive aluminum 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 The average Surface roughness after blast cleaning shall not exceed 35 to 50 U 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 re cleaning 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, inspection charges, conveyance of machinery to & fro from site of work, transport charges, scaffolding charges, consumables like oil & diesel for generator, risk allowance, etc, complete

Application of a Protecto speciality primer coat to protect the steel structure from highly abrasive, erosive and corrosive environments. This being a speciality coating, enhances the life of the hydraulic structure and reduces the strain of continuous maintenance. The primer provides outstanding performance on blast cleaned steel in immersed service. This special coating imparts cathodic protection to the base metal. The properties of the epoxy resin & high quality zinc makes a perfect primer that provide both barrier & galvanic protection simultaneously. After surface preparation of the structure, a primer coat with epoxy primer shall be applied. The dry film thickness should be 40-60µ for primer coat. The colour is grey and minimum pot time should be 4 to 8 hours. The mixing ratio of base to accelerator by volume should be according to the manufacturers standard. All paint, when applied, shall provide a satisfactory film and a smooth and even surface. Paint shall be thoroughly stirred, 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 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 and international standards as per SSPC/NACE. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) – 1971. The cost includes cost of speciality primer, thinner, etc, labour charges for application of primer, hire charges for compressor, generator, airless spray, etc, cost of oil & diesel for generator, scaffolding charges, transport charges, conveyance of machinery & tools to and fro from site of work, testing & inspection charges, risk allowance, etc, complete.

Application of protecto speciality finish coat over the primer shall be through airless spray method. This speciality coating is a two pack epoxy tar coating having excellent water immersion and alkali resistance. It has outstanding performance under immersed condition. It has the ability to provide excellent barrier protection in multicoat systems. This being a speciality coating, enhances the life of the hydraulic structure and reduces the strain of continuous maintenance. matter. All painting works shall be performed by airless spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Each coat shall be uniform and free from runs, sags and other imperfections. The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer. The paint shall be applied so that the thickness at any point is not less than that stipulated in the approved painting specifications. Surface not required to be coated, but adjacent to surfaces which are to be cleaned and coated, shall be other parts shall be done as per IS specification No.14177-1994 and international standards as per SSPC/NACE. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 The cost includes cost of speciality 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, transport charges, conveyance of machinery & tools to and fro from site of work, testing & inspection charges, risk allowance,etc, complete.