Renovation of Spillway Shutters in Sathyamoorthy Sagar Dam at Poondi Village of Thiruvallur Taluk and District.

Amount

Repair, overhaul & refixing of the rusted cast iron wheels of the existing shutters with gas cutting equipment and reconditioning with bushes / bearings and refixing to the original condition as per the site requirements. The wheel is of 400mm 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, 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.

Replacement of Musical note rubber seal at side & top 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.

Repair and Replacement of bottom rubber seal of the 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.

Overhauling of existing hoisting arrangements for the shutter as per the following specification. The existing hoist covers shall be opened up and stored separately. The top cover of plummer blocks connecting the existing transmission shafts shall be opened and old grease shall be removed. Then, the existing bearings shall be cleaned with liquid cleaner and inspected for mis-alignment and breakage. Fresh grease shall be applied to the plummer block and top cover closed with requisite fasteners. The shaft shall be checked for its alignment and redone to ensure straightness of shaft. The existing gear wheels shall be cleaned of dried grease and dust manually. The reduction gearbox shall now be drained of old used lubricant thro the drain hole at the bottom. Now, the liquid cleaner shall be poured in the gearbox and the inside surface and gears are thoroughly cleaned and then the contaminated liquid cleaner shall be drained. The drain hole shall be plugged and fresh lubricant of appropriate grade shall be filled to the level as indicated by the department officers. The available chain hoist in the hoisting system shall be manually cleaned of dried grease and dirt and appropriate lubricant shall be applied. The whole arrangements shall be tested & passed after a set of trial operation. The cost includes cost of inspection, spares, lubricants, transport charges, charges for dismantling & erection, etc, complete.

Replacement of old damaged starter box for the following specification. The starter to motor old cable shall be replaced with 4 core x 10 sqmm copper flexible unarmoured cable for cable leading from starter to motor. Necessary gland & lugs shall be used as required. Starter to motor cable shall be protected with 1” Ms pipe. A new DOL starter with forward & reverse shall be provided inside the old panel box after removing the old existing oil starter. The starter shall be housed in a double door box with 32A contactor – 2nos, 12 to 18 amps relay – 2nos, single phase preventer – 1 no, pushbutton for forward, reverse & off, indicators lamps -3 nos, 40A 4 pole MCB -1 no & terminal -1 no shall be welded after removing the existing cover. The cost includes cost of repair to panel box, new DOL starter & accessories cable from changeover to starter & starter to motor, labour charges, painting , transport charges, erection at site etc., complete.

Supply & erection commissioning of electrical motorised operating arrangements for the canal sluice shutter of the following specification. The existing 40mm shaft shall be modified to accommodate a pin bush coupling. The part of the pin bush coupling is coupled to a 3 phase 400v 7.50HP and 960rpm with 40mm single ended shaft. The motor shall be seated appropriately in the motor seat. Hand operation provision shall be provided to operate the shutter in case of electrical motor failure & emergencies. A starter panel box shall be provided. Also electrical connections & wiring from & to the generator & motor shall be provided appropriately as directed by the departmental officers. The cost includes cost of materials, labour charges, transport, erection, testing, commissioning, 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.

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 sandblasting. The average surface roughness after sand blasting 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, scaffolding charges, consumables like oil & diesel for generator, risk allowance,etc, complete.

Providing metallising using thermal spraying equipment as per the following specification. The metalizing should be applied within four hours of surface preparation of the component structure. Thermal spraying is a cold process and most proven that they provide long term corrosion protection and outperform all other methods. These thermal spray coating provide corrosion protection by excluding the environment and acting as a barrier coating and they also provide sacrificial anodic protection. The temperatures during the process reach around 95°c. These coating are typically mechanically bonded to a grit blasted surface. Aluminium wire composition as per ASTM standard B833-09 shall be continuously melted in an electric arc spray or gas flame spray gun. Droplets of molten metal from the wire shall be deposited onto the steel forming the protective coating and this avoid corrosion for a long term. The cost includes cost of materials, labour charges, transport, erection, hire charges for machinery, incidental charges like conveyance to & fro from site risk allowance etc., complete.

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 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. 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 primer & thinner, labour charges for application of primer, hire charges for compressor, generator & airless spray gun with its accessories, cost of oil, diesel & lubricant for generator, scaffolding charges, conveyance of machinery & tools to and fro from site of work, 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 125-150 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. The colour of the paint coat when applied is generally black but turns into brown over a period time. However, the properties of the paint remain intact assuring the performance. 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 coaltar epoxy paint, thinner, etc, labour charges for its application, hire charges for compressor, generator, airless spray machine with its accessories , cost of oil, diesel & lubricant for generator, scaffolding charges, conveyance of machinery & tools to and fro from site of work, risk allowance, etc, complete,

Modification of existing operating platform and shifting the hoisting arrangements from inside the well portion to top of the bund level in the baby canal sluice as per the following specification. The existing operating platform is heavily corroded and beyond use warranting a replacement. The corroded ms chequered plate also shall be dismantled. The existing stiffener frames shall be cut, then the top channel shall be dismantled from the civil structure and stored in the scrap yard as directed by the departmental officers. The existing worm hoist shall be dismantled and safely kept aside for reassembly. The hoist support frame shall be provided with ISMB 300 and fixed to the masonary appropriately with concrete at both ends at top of the vent. Stiffeners shall be made of ISA 50x50x6 placed at an maximum interval of 500x500mm. The existing hoist arrangements shall be over the support frame with suitable fasteners. The new ISMC 100 shall be provided for platform support and welded with hoist support structure.

Providing new safety ladder arrangements for accessing from spillway vertical gate D/S sill 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 welded to shutter bottom flange. The top of the ladder shall be welded to the top of shutter flange. 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.

Modification of existing operating platform and shifting the hoisting arrangements from inside the well portion to top of the bund level in the baby canal sluice as per the following specification. The existing operating platform is heavily corroded and beyond use warranting a replacement. The corroded ms chequered plate also shall be dismantled. The existing stiffener frames shall be cut, then the top channel shall be dismantled from the civil structure and stored in the scrap yard as directed by the departmental officers. The existing worm hoist shall be dismantled and safely kept aside for reassembly. The hoist support frame shall be provided with ISMB 300 and fixed to the masonary appropriately with concrete at both ends at top of the vent. Stiffeners shall be made of ISA 50x50x6 placed at an maximum interval of 500x500mm. The existing hoist arrangements shall be over the support frame with suitable fasteners. The new ISMC 100 shall be provided for platform support and welded with hoist support structure. The composite chequered plate shall be manufactured in vacuum infusion process. This process ensures freedom from all defects and thus increases the strength of the composite chequered plate. UV resistant polyester polymer high grade reinforcement shall be used for manufacturing chequered plate. Excellent corrosion resistant gel coat shall be applied during the process. A man hole cover of 500x500mm shall be provided for easy ingress into the sluice well appropriately. All steel members shall be mechanical cleaned and a coat of anticorrosive protomastic primer and two coats of coal tar paint shall be applied. The platform structure shall be covered with composite chequered plate. The cost includes cost of motor and accessories, spares, consumables such as oil, grease, paint, fasteners, etc., process charges like cutting, welding, casting, grooving, machining, etc, labour charges for dismantling loading, lifting, unloading, scaffolding charges, hire charges for equipment like generator, welding & cutting set, etc, conveyance of men & machinery to & fro from site of work & back, risk allowance for working at a height of more than 3m, cost of trial operation, etc., complete.

Providing electrical operating arrangements for the baby canal sluice shutters in Sathiyamoorthi sagar reservoir as per the drawings. The hoisting arrangements includes screw rod with worm gear over the operating platform. A new 5HP geared motor, with appropriate output RPM, Reversible, 3 phase, 400 - 440V, shall be introduced into the existing gear arrangements appropriately, so that the shutter could easily be operated electrically. Necessary wiring from mains and starter for motor are provided as per site requirements. Motor bed shall be suitably provided as per site condition. A dust proof cover shall be provided to safeguard the motor from rain and shine. The surface preparation shall be done manually by wire brush, mechanical tools, etc. All equipment & accessories shall be checked for their correctness and aligned properly for smooth operation as directed by the departmental officers. The cost includes cost of motor and accessories, spares, consumables such as oil, grease, paint, fasteners, etc., process charges like cutting, welding, casting, grooving, machining, etc, labour charges for dismantling loading, lifting, unloading, scaffolding, charges, hire charges for equipment like generator, welding & cutting set, etc, conveyance of men & machinery to & fro from site of work & back, risk allowance for working at a height of more than 3m, cost of trial operation, etc., complete.

Modification of existing spillway shutters as per the following specification. The stored water now leaks thro’ the top seal due undulations in the spillway shutter. Skin plate at the top end. The existing angle shall be cut and new fabricated I beam shall be introduced to reduce the deflection at the top end of the skin plate. Additional stiffeners shall also be provided so as the free end of the skin plate would be strengthened. Welding shall be done appropriately. 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 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, unused welds, unfilled craters, under cutting, burning & poor weld appearance, etc.The cost includes cost of materials, labour charges, consumables, transport, erection, etc., complete.

Dismantling, fabrication, supply and erection of operating platform for the chain hoist vertical shutter of the following size and specification. The total length of the platform is 6400mm and width is 3940mm. The existing old RCC slabs shall be removed carefully and conveyed to a proper place at site. The debris shall be cleared on the existing steel structures. The strengthening of platform shall be done by welding ISA 50x50x6mm in-between the mid span of existing horizontal channel. The cross stiffener of size ISA 35x35x6mm shall be welded as per the engineering drawing. 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 shall be 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, infused welds, unfilled craters, under cutting, burning & poor weld appearance, etc., The platform top shall be finished with composite superstructure panel. The composite superstructure consists of FRP moulded gratings of size 38x38x25mm with 3mm FRP chequered panel. The composite superstructure shall be of high strength to weight ratio, durable, ease in handling and with better anticorrosive properties. All fiber layers shall be applied with UV resistant grade polymer resin. The composite superstructure panel shall be fastened to the steel structure through SS screw/clamp arrangement. All new steel materials shall be given a coat of zinc primer with a overcoat of 2 coats of coal tar epoxy . The cost includes cost of all materials, cost of consumables like welding rods, grinding wheel, oxygen & acetylene gas, diesel & oil for generator , process charge like gas cutting, welding charges for dismantling, loading, lifting, unloading, transport, erection, hire charges for equipments like airless spray machine, chainpully block, power charges for generator, conveyance to site and clearing them after completion of work etc., complete as directed by the departmental officers

GST 18 % in Figures

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