Refurbishment and Motorisation of Two No. Penstock Intake Gates at Forebay of CHEP I

Extraction and removal of gates from their installed positions, including disconnection of hoisting arrangements and removal of corroded or damaged components. Cutting and removal of old rusted MS stopper plates, bolts, and nuts, and arranging water diversion or temporary stop-logs as per site requirement. Cleaning and inspection of sill beams, side seal seats, grooves, guide frames, and wheel tracks for wear, corrosion, and deformation. Preparation of a detailed inspection report identifying the extent of refurbishment, parts replacement, and alignment corrections required

Realignment and strengthening of gate leaf assemblies. Replacement/refurbishment of worn-out wheels, wheel pins, bearings, rollers, bushes, and pins with new components of equivalent or higher specification. Complete replacement of flat and bulb rubber seals, stopper plates, nuts and bolts with new materials conforming to relevant IS standards. Repair and renovation of gate guide tracks, grooves, sill beams, and side seal seats including machining, grinding, and surfacing as required. Fabrication and installation of new side guides, wheel tracks, and support structures ensuring proper gate alignment and water tightness

Design, engineering, manufacturing, supply, and installation of electrically operated mechanical rope drum hoist systems suitable for both manual and electrical operation. Each hoist shall include but not be limited to: Structural support columns/frame of adequate capacity (including 30% overload margin) incorporating self-locking features and electromagnetic braking to ensure safe holding of the gate at any position, even during power failure. The Gate system shall consist of precision-machined dual rope drums with 6×37 construction galvanized steel wire ropes, shafts, plummer blocks, and flexible couplings to ensure synchronized and smooth operation on both sides of the gate alongwith Limit switch assemblies (upper and lower).Motor bushes, bearings, brake assemblies ,End reductions and spur gear reducers ,shafts, flexible couplings (gear or bush type), plummer blocks with bearings, worm reducers, and spur gear reductions. Three-phase IP55/IP65-rated motors of suitable power rating with electromagnetic brakes. Heavy-duty worm and spur gear reducers shall be provided for high torque, low-speed operation, with a manual–motor clutch type engaging/disengaging arrangement for emergency manual operation. The entire assembly—including drive train, gear reducers, bearings, and structural frames—shall be fabricated from tested IS 2062-grade steel, duly machined, aligned, and epoxy-coated for corrosion resistance . also including Gate position indicator for accurate indication of gate travel and position

Complete cleaning and surface preparation of all steel components by mechanical or abrasive methods. Application of two coats of zinc-rich epoxy primer followed by two to three coats of smoke grey epoxy finishing paint as per IS 2932/IS 14209 or equivalent. Ensure total dry film thickness (DFT) as per manufacturer’s recommendation for hydro-mechanical equipment. Reinstallation and alignment of refurbished gates in their original positions. Mechanical fit-up, greasing of all moving parts, and application of cadmium compound to wire ropes. Conducting trial runs in both manual and electrical modes .Hydrostatic leak test to confirm proper sealing under pressure. Submission of test reports and commissioning certificates after successful completion. General arrangement (GA) drawings, wiring schematics, and fabrication drawings and Operation & Maintenance manuals and as-built documentation. Conducting hands-on training for operating and maintenance personnel at site on operation, troubleshooting, and periodic maintenance of gates and hoisting systems

Supply of all nuts, bolts, washers, and fasteners of appropriate grade. Transportation, loading/unloading, erection, and handling of all materials and equipment at site. All civil/structural attachments (if required) for proper anchorage, mounting, and safety. Any additional mechanical or electrical attachment necessary for smooth operation and integration of the gates shall be deemed included in the contractor’s scope