Rehabilitation of shutters and hoisting arrangements in vent No. 8 to 14 of barrage across Cauvery at Upper Anicut in Srirangam Taluk of Trichy District

Amount

Repair and restoration of end vertical channel and skin plate for the vertical geared shutters of size 12200x3050mm. The old corroded end vertical guide channel and Skin plate size of 1500x3000mm shall be cut both end. Necessary scaffolding should be provided for safe working. The new ISMC 400 and 12mm plate shall be is marked & cut to exact size and lifted & positioned along with the cutting portion of the skin plate and horizontal girders with a chain pulley block and aligned carefully. Diaphragm plate of 10mm thick of size 400x280mm is provided at appropriate places. New wheel locking plate of size 240mmx230mm is provided to accommodate the wheel shaft in all the 3 wheels of the shutter. 100x100x10MS angle of length 300mm is provided at the joints connecting the end vertical channel and horizontal girder at both ends of the shutter. The new channel with skin plate shall be welded to the skin plate and horizontal girders of the shutters to enable smooth movement of rollers and the shutter. The channel should be welded strictly to the plump bob. The joints are butt joints & hence done very carefully as directed by the departmental officers. The cost included cost of materials, deducting the cost of old scrab materials and charges for transport, erection including scaffolding, hire charges for machinery, fuel charges for generator, warranty for 5 years etc., complete and as directed by departmental officers.

Repair, overhaul and refixing of the rusted cast iron wheels of the existing shutters with gas cutting equipment and reconditioning with bushes or bearings and refixing to the original condition as per the site requirements. The wheel is of 350mm diameter & moves in the recessed groove of the vertical guide channel. The shutter shall be lifted to a workable height and the locking plate shall be removed by cutting the corroded bolts & nut with gas cutting equipments. The wheel pin shall also be removed. Then the wheel shall be transported to the workshop where the wheel shall be opened up and the old broken bearing & sleeves shall be removed after cleaning the wheel. Then the outer wheel surface shall be machined true to required size and so that it shall operate smoothly without vibration and without undergoing undue drift. The inside of the wheel shall also be machined to have a uniform surface. The existing bearing shall be cleaned and inspected for misalignment and breakage. Then shall be replaced as the case may be. The existing pin shall be machined and fitted snugly. Then the wheel shall be closed and fitted to the end vertical channel. Trial operation shall be conducted to ensure free movement & rotation of wheels. The cost includes cost of all materials, deducting the cost of old scrab materials and process charges like gas cutting, welding, machining, scaffolding charges, labour charges for dismantling, loading, lifting, unloading, transport, erection, labour charges for equipments like crane, chain pulley block, power charges for generator, risk allowance for working at a height of more than 3m, conveyance to site and clearing them after completion of work including cost of trial operation etc., complete and as directed by the departmental officers.

Repairing the eroded portion of the grooves including dismantling the eroded portion of the groove channel ISMC 400 at the bottom portion on both sides by gas cutting equipments and with concrete brakers without damaging the sill beam and conveying the dismantled parts to the section stores by lorries and stacking them at the places shown by the departmental officers. Cutting the new ISMC 400 for required length with gas cutting equipments and grinding the edges to form V shape for welded with the cutting portion of the groove channels at the top portion . Providing anchorage arrangement made up of 65x65x8mm mild steel angle fixed at the center portion of the grooves at an interval of 0.50m Fixing the new groove channel with the top portion of the grooves and with sill beam at bottom by means of welding to the plumb position and to the correct alignment. The joints are butt joints and hence done very carefully as directed by the departmental officers. After welding grinding the welded portion for smooth finish and painting with two coat of coaltar epoxy paint primer over one coat of epoxy primer . 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, warranty for 5 years etc., complete as directed by the departmental officers.

Replacement of bottom rubber seal of the regulator shutter as per the following specification. The old rubber seal shall be removed from the akin 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 cover flat surface shall be neatly cleaned on either side by grinding. Now, the existing seal cover flat made of 100 x 10mm MS flat ft. 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 cover flat to align with that in the skin plate, if necessary. 18mm holes shall he punched accordingly in the rubber seal of size 100x12mm. The inside surface of the seal cover flat shall be 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 scat cover shall be placed and fastened with SS bolts ft nuts of size M 16x60. The cost includes cost all of materials, deducting the cost of old scrab materials and labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site, etc., complete and as directed by departmental officers.

Providing Z type rubber seal on either ends of the shutter with SS side seal seat as per the following specification. The seal scat shall be made of MS flats 50x16mm and seal cover flat made of 50x10mm MS flat of length 1850mm They are tag welded together for matching and 10mm holes shall be drilled with a centre to centre distance of 100mm. Then they shall be parted from each other after matching. The seal seat shall be taped M12 and cover flat shall be drilled free holes of size M14. The seal seat flat shall be welded over the skin plate appropriate position. Now the ‘Z’ type seal of size 74x79x16mm shall be cut to the required size and matched with the seal cover flat and holes are punched in the rubber seal accordingly. Now the Z type seal shall be sandwitched between the skin plate ft seal seat cover. SS bolts 12x35mm shall be used to fasten them to the skin plate. SS flat of size 50x6m and of length 2350mm shall be used as side seal seat. It shall be welded over the MS groove channel to act as side seal flat to reduce the friction during the sliding of rubber seal at the side. The cost includes cost all of materials, deducting the cost of old scrab materials and labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site, etc., complete and as directed by departmental officers

Providing counter weight arrangements of the following size & specification. The steel box is of length 12650mm x 350mm x 630mm height. The bottom plate is made of IS 2062 MS plate 20mm. The sides are made IS 2062 MS plate 16mm. The top cover is made of IS 2062 MS plate 10mm. The joints are firmly welded to withstand rigorous work environment. The box is divided into 6 compartments with IS 2062 MS plate 16mm acting as stiffeners. Concrete blocks of size 300x300x150mm are neatly stacked in these compartments. Locking plates of size 300x870 are welded in the inside of the box from the bottom, on both corners of the box. 40mm dia holes are drilled in the plates for locking of chain & locking of counterweight while carrying out repairs in the shutter. A Groove guideplate made of 20mm MS plate is welded to either sides of the box one at top & one at bottom. This plate serves as guides to the counterweight arrangement while moving up & down. Steel scaffolding is done up to a height of 5m to install the counterweight arrangements. Mobile crane is used to handle the box during installation of the counterweight arrangements. The hoist arrangements for the counterweight is dismantled and inspected for failed components. The main shaft of size 50mmØ, EN 8 rod is dismantled & replaced as it is distorted. The gear shaft of size 80mm dia is replaced ad it is twisted. Also, the Plummer blocks at the end are replaced as they are broken. The hoist arrangements is reassembled with proper alignment & lubricants are applied, wherever necessary. The chain links broken are repaired & replaced wherever necessary. The cost includes cost of materials deducting the cost of old scrab materials and charges for crane , scaffolding, labour charges, hire charges for machinery etc., complete. etc., complete as directed by the departmental officers.

Repair & modification of sill flat of the shutter of size 12200x3040mm as per the following specification. The existing shutter shall be lifted and kept at the height of atleast above 750mm. The old existing sill beam is corroded and the surface is extremely pitted. Hence the sill beam shall be thoroughly cleaned by mechanical means using buffing wheel with steel bristles connected to portable grinding machine. Then, SS flat of size 60x8mm shall be laid centrally on the cleaned sill beam end to end and welded firmly with MS to SS special welding electrodes. The welding shall be done as per standard procedures and the burr and slag shall be removed by grinding the top of welds. A good weld is as strong as the base metal. A suitable electrode shall be chosen and welded with a good welding equipment and a trained welder. All non metallic substances shall be removed in the weld joints before commencement of welding. After welding, a thorough visual inspection shall be done for porosity, blowholes, unfused welds, unfilled craters, under cutting, burning & poor weld appearance, etc. Then the shutter shall be operated to rest on the sill beam and tested. The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, 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, warranty for 5 years etc., complete as directed by the departmental officers.

Supply and fixing of scientific gauge plates (water level indicators) including supply of 1m length of gauge plate,120mm width is made up of 16 gauge Mild steel sheet painted with two coats of vitreous zinc enamel paint over one coat of epoxy primers including sand blasting process and each time heating the plate in the furnace after applying one coat of vitreous enamel paint and with marking of measurements in centimeters each and every measurements of feet will be marked with figure indication distinctly. All measurements letters and figures will be the engraved style of painting with vitreous enamel finishing in blue and white colours and including supply of meter indication plates for required heights. Necessary holes will be provided in the plates at for screw the plates .Fixing plates in the wall of upstream side of the regulator by drilling the hole with breaker equipments by using travelling winch hanged from the top of regulator. Fixing the gauge plates one by one with required screws from the top level of gate to the top by using travelling winch hanged from the top of the regulator. The cost includes cost of materials, labour charges, cost of consumables like drill bit, diesel & oil for operation of generator, hire charges for generator, breakers, winch, welding machine, grinding machine drilling equipments, etc, transport of men, machinery & material to and fro from site of work, loading, lifting & unloading charges, scaffolding charges, conveyance of tools & equipments, risk allowances for working at height of more than 3m, including all other taxes, etc, complete. and as directed by the departmental officers.

Repairing the damaged limit switch arrangements including dismantling the existing damaged limit switches carefully from the board without damaging the board by using necessary tools and equipments and also remove the old working from the board. Providing new limit switch arrangements of LSP or LSPS type including fixing the switches to the board align with the cut off knobs and wiring the board with new wiring cables. The rate including cost of all materials, wiring, labour charges, charges for equipments , conveyance of equipments and manual labour to and fro from site etc complete and as directed by the departmental officers.

Replacing the brake pad in the electromagnetic brake system of hoisting arrangement of vent size 12200x3050mm. including opening the brake arrangements by necessary tools without cause any damage to the brake system and springs . After removing the system , remove the slipping brake clutch pad from the clutche plates without damage the plate and providing new brake pad of required size to the clutches with required screws. Reassemble the brake system in proper alignment and position by means of equipments and tools. The rate including cost of all materials, wiring, labour charges, charges for equipments , conveyance of equipments and manual labour to and fro from site etc complete and as directed by the departmental officers.

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. 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 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 air free of detrimental oil and water. All surfaces to be shall be completely dry, clean and free from moisture just 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 mose to dissipate static charges should be adopted as directed by the departmental officers. The cost includes cost all materials, abour charges, hire charges for generator, compressor, hopper, , 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, complying with Standard Specifications and as directed by the Departmental Engineers.

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 foreign matter. All painting works shall be performed by airless spraying. When the coating material is applied by spraying, suitable means shall be provided to prevent segregation during the coating operation. Free oil and moisture shall be removed from the air supply lines of all spraying equipment. Primer coat shall be uniform and free from runs, slag and other imperfections. The time between successive coats shall be not less than the minimum nor more than the maximum re-coating time specified by the paint manufacturer. The paint shall be applied so that the thickness at any point is not less than that stipulated in the approved painting specifications. Surface not required to be coated, but adjacent to surfaces which are to be cleaned and coated, shall be adequately protected during cleaning and coating. Repairs to damaged areas of the coating shall be carried out strictly in accordance with the approved painting specifications. Because of the flammable and toxic nature of the coating materials, precautions should be taken to eliminate any health or safety hazard that may arise during the application of the coating. Smoking and welding shall not be allowed within 10 meters of the place when painting is in progress. The painting to the gates, hoists and other parts shall be done as per IS specification No.14177-1994. Guidelines for painting system for Hydraulic Gates and hoists and its Adjuncts Viz., IS: 1477 (Part I) - 1971, IS: 1477 (part II) - 1971, IS: 2339 1963 and IS: 2932-1994. The cost includes cost of primer, thinner, paint, etc, labour charges for application of primer, hire charges for compressor, generator, airless spray, etc, cost of oil & diesel for generator, scaffolding charges, transport charges, conveyance of machinery & tools to and fro from site of work, testing & inspection charges, risk allowance, etc, complete. etc, complete, complying with Standard Specifications and as directed by the Departmental Engineers.

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 complying with Standard Specifications and as directed by the Departmental Engineers.

GST at 18%

POTHIGAI ENTERPRISES