Replacement of river sluice and canal sluice shutters and refurbishment of spillway shutters of Aliyar dam in Anaimalai Taluk of Coimbatore District.

Amount

Replacement of the existing river/canal 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 service gate shall be dismantled and the suspension channel shall be removed from its position. Also removing the existing damaged sluice gate from the vent without causing any damage to the other parts and lifting all the cutting parts from the vent by using necessary hoisting equipment and conveying it to the section store and stacking carefully at the section store as directed by the departmental officers . The new river/canal sluice service gate shall be of size 2200x1980mm. The skin plate shall be of 16mm thick and vertical and horizontal stiffeners shall be provided with 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. Fabrication and supply of cast steel roller assembly for service gates as per the following specification. The cast roller wheels with stock allowance for machining shall be manufactured as per IS 2707 : grade 1 material. Roller wheels of size 355mm 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 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 . The shutter shall be blast cleaned to SA 2 1/2 standard and the surface shall be with Aluminium wire metallising as per IS 6586 (1989) with adjuncts to IS 5905 : 1989 and a overcoat of epoxy zinc phosphate primer with 50µ shall be applied. 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 , complete as directed by the departmental officers.

Replacement of suspension channel in Vettikaranpudhur canal, Pollachi canal & River sluice as per the following specification. New suspension channel shall be made of 125x65mm twin channels facing each other at a distance of 65mm with ISMC 125x65 welded between them as spacers. The spacers shall be provided at a vertical distance of 500mm c/c from each other. These twin channels shall withstand the designed loads. The existing screw rod of size 100mmØ & 3000mm length shall be connected to the new suspension channel with a system of bolt & nuts of size 6"x5/8". The suspension channel shall be of appropriate height as per site condition but should be fabricated in cut lengths of 3m since beyond that the suspension channel for screw rod cannot be removed from its position for maintenance. The suspension channels shall be connected to each other with a system of 10mm plate of size 200x250mm using bolts & nuts. 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, etc, complete.

Replacement of the suspension guide channel as per the following specification. The suspension guide channel is inside the sluice well to guide the suspension channel connecting the sluice shutter to the hoisting arrangements. The old corroded suspension guide channel shall be cut and removed from the masonary with concrete breaker machine & stacked at PWD stores as directed by the departmental officers. The new suspension guide channel shall be cut to the required size and given a coat of zinc rich primer over which two coats of coal tar epoxy shall be applied. The masonary on either ends of the channel shall be broken at appropriate places and then the channel shall be embedded with concrete at the appropriate place. The cost includes cost of materials, labour charges, hire charges for machinery like derrick, chain pulley block, gas cutting equipment, welding plant, erection, etc, cost of conveyance to & fro from site of work, risk allowance, trial operation, etc, complete.

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 and as directed by departmental officers.

Replacement of Musical note rubber 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 100mmx44mmx14mmØ shall be placed on the skin plate over which the seal seat cover shall be placed and fastened with CSK SS bolts/hex bolt. The cost includes cost of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site etc., complete.

Overhauling of worm gear box to the 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.

Providing safety limit switches as per the following specification. The safety limit switches shall be used to prevent the accidental impact of shutter to the sill beam. An ‘L’ clamp shall be provided to the gauge plate pipe at the top of the wormgear to fix the limit switch. The limit switch shall be provided appropriately for on/off operation of the shutter at designated heights. The wiring of the switches shall be done with 1.5sqmm x2 core copper flexible cable without joints. The cost includes cost of materials, labour charges, transport, erection, etc,complete.

Providing abrasive blast cleaning using air blast cleaning with abrasive aluminium oxide/steel grits/sand as per the following specification. Moisture should not be present on the steel surface during blast cleaning. All, oil, paraffin, grease & dirt shall be removed from the surfaces to be painted primarily before blast cleaning. Then all weld spatter, slag, burrs, loose rust and mill scale and other foreign substances shall be removed by blast cleaning . The average surface roughness after blast cleaning 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, 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, strained, and kept at the uniform consistency during application. Paint shall not be applied when the temperature of the metal or surrounding air is below 10 degree Celsius and that of the metal is above 50 degrees Celsius, or when the humidity is above 90 percent, or when it threatens to rain before the painted coat gets dry. Primer coat shall be protected during the initial curing period against the possibility of moisture condensation or contamination with foreign matter. All painting works shall be performed by airless spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Primer coat shall be uniform and free from runs, slag and other imperfections. The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer. The paint shall be applied so that the thickness at any point is not less than that stipulated in the approved painting specifications. Surface not required to be coated, but adjacent to surfaces which are to be cleaned and coated, shall be adequately protected during cleaning and coating. Repairs to damaged areas of the coating shall be carried out strictly in accordance with the approved painting specifications. Because of the flammable and toxic nature of the coating materials, precautions should be taken to eliminate any health or safety hazard that may arise during the application of the coating. Smoking and welding shall not be allowed within 10 meters of the place when painting is in progress. The painting to the gates, hoists and other parts shall be done as per IS specification No.14177-1994 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 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 100-125 µ per coat. The interval before over coating shall be 24 hours. All paint, when applied, shall provide a satisfactory film and a smooth and even surface. Paint shall be thoroughly stirred, strained, and kept at the uniform consistency during application. Paint shall not be applied when the temperature of the metal or surrounding air is below 10 degree Celsius and that of the metal is above 50 degrees Celsius, or when the humidity is above 90 percent, or when it threatens to rain before the painted coat gets dry. Each coat shall be protected during the initial curing period against the possibility of moisture condensation or contamination with foreign matter. All painting works shall be performed by airless spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Each coat shall be uniform and free from runs, sags and other imperfections. The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer. The paint shall be applied so that the thickness at any point is not less than that stipulated in the approved painting specifications. Surface not required to be coated, but adjacent to surfaces which are to be cleaned and coated, shall be adequately protected during cleaning and coating. Repairs to damaged areas of the coating shall be carried out strictly in accordance with the approved painting specifications. Because of the flammable and toxic nature of the coating materials, precautions should be taken to eliminate any health or safety hazard that may arise during the application of the coating. Smoking and welding shall not be allowed within 10 meters of the place when painting is in progress. The painting to the gates, hoists and other parts shall be done as per IS specification No.14177-1994. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) – 1971, IS : 1477 (part II) – 1971, IS : 2339-1963 and IS: 2932-1994. The cost includes cost of colatar 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.

Providing electromagnetic brake of 200mm Ø in the shutter 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 metallic paint shall be applied 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 ends with 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 material like EM brake, Brake drum, flexible coupling shaft and support structural materials, fasteners, hire charges for machinery like welding machine, grinding machine, gas cutting plant, core cut machine, process charges for machinery, milling, welding, charges for transport to & fro labour charges for dismantling, erection, loading, unloading etc., complete.

Repair, overhauling & refixing of the single axis movement double grider crane in Aliyar dam as per the following specification. The crane has two parallel girders rigidly connected to the end carriages at a distance of 8100mm c/c and spanning the gantry of span 3450mm. The lifting unit is built on to a traversing crab overslung from the beams. The crab is of size 3750x2600mm. 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 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. 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.

Repair, overhauling & refixing of the Double axis movement double grider crane in Aliyar dam as per the following specification. The crane has two parallel girders rigidly connected to the end carriages at a distance of 12800/7700mm c/c and spanning the gantry of span 8600/5500mm. The lifting unit is built on to a traversing crab overslung from the beams. The crab is of size 3750x2600mm/4300x2600mm. 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 dismantled & 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.

Dismantling the existing corroded old ladder & replacement with new safety ladder arrangements to the sluice well 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 welded to the operating head platform. 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, etc, complete.

POTHIGAI ENTERPRISES (BID ID -1487680)