Replacement, Febrication and Erection of Vertical Shutter in old Existing Spillway vent 1and 2 with hoisting arrangements in Gomukhi Dam near Vadakanandhal Village of Chinnasalem Taluk in Kallakurichi District

Repair and replacement of second stage embedded parts like roller track plate, side seal track and sill seat for spillway gate of vent size 12200x6100mm as per the following specification. The existing corroded MS roller track plate is in two layers. The bottom layer is made of 100x16mm MS flat securely welded to the roller track embedded in concrete. The top layer is made of 100x16mm MS flat and is welded to the bottom layer. This layer shall be removed by grinding and gas cutting operations from the bottom layer. Then a SS track plate of size 90x12mm shall be welded to the existing bottom MS track plate appropriately to enable the rollers move vertically on the SS track plate. This would reduce friction to a large extent. The side seal track plate shall be of size 80x8mm made of SS 304 grade. It shall be appropriately welded to the Existing 100 welded in the upstream side upto 6.50m from sill level. This would facilitate the smooth movement of side seal without friction, while the gate moves up & down. The sill seat shall be made of 80x8mm SS flat of 304 grade. This shall be provided on top of the existing sill beam which is embedded in concrete. This provides an even surface for the bottom seal to land on preventing water from leakage. The existing corroded guide base and guide angle shall be removed. The guide base of size 200x100x32mm shall be fabricated and the edges shall be finished by grinding. 22mm dia holes shall be drilled at a pitch of 110mm in the guide base. Guide plate of size 25x100x8000mm shall be fabricated and the edges finished by grinding. The groove guide shall be fixed in position by marking a center mark in vertical position on the existing guide portion. The holes shall be marked for a pitch of 110mm in vertical intervals of 500mm c/c. The groove guide portion in masontry shall be drilled for 24mm dia and 250mm depth to accommodate the guide base. Anchor rod of 20mm dia and 300mm length shall be fixed using vinyl ester hybrid motor chemical . The guide base plate shall be connected to the anchor bolt at vertical intervals of 500mm. Guide plate of 25mm shall be welded to the center of base plate in vertical position. The straightness shall be ensured using plump level. The cost includes cost of materials, labour charges for dismantling and erection at site, hire charges for machinery like grinding machine, gas cutting equipment, drilling machine, welding plant & generator, rental charges for erection equipments like chain block & crane, cost of consumables such as oil, diesel & lubricants for generator, welding rod, grinding wheel, core cutter bits, oxygen & LPG, incidental charges like conveyance to & fro from site of work, loading & unloading, risk allowance, etc., complete, including maintenance & warranty for 5 years.

Dismantling of existing old corroded vertical gates of vent size 12200x6100mm from its respective groove portion by the following process. The gates shall be made to rest on the sill portion. The counter weight shall be locked to the deck bridge through pin connecting both sides. Lifting chains shall be released from the shutter by removing the pin from the chains. The shutter shall be cut out into pieces with gas cutting equipment. Then the cut pieces shall be carried from vent portion using a crane and then transported to the department store through trucks and stacked as directed by the departmental officers. The cost includes cost of consumables like oxygen gas & LPG, grinding wheels, oil, diesel & lubricants for generator, labour charges for dismantling, lifting, loading, unloading & stacking, hire charges for crane, lorry, machinery like cutting equipment, grinding machine & generator, etc., complete.

Design, fabrication & supply of vertical shutter including skin plate with vertical stiffeners, horizontal fabricated girders, end verticals, rear angle, connecting plates, rib plates, etc, suitable for spillway gate of vent size 12200x6100mm as per IS 4622. The skin plate, end verticals, vertical stiffeners, horizontal fabricated girders, lifting assembly, side seal base plate, side seal cover, bottom seal cover, rear angles shall be made of structural steel confirming to IS 2062 : 2011. The connecting fasteners shall be made of MS confirming to IS 2062. 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. On fabrication of all components of the shutter, a trial assembly shall be done at the shopfloor to ensure the dimensional accuracy and integration of all sub components. Also, the layout shall be clearly marked & serially numbered by punching. Match drilling in different components and cleats provided wherever necessary to assure minimum tolerance levels. The cost includes cost of MS materials, cost of consumables like welding rods, grinding wheels, drill bits, cut off wheels, oxygen & LPG gas, oil, diesel & lubricant for generator, process charges like gas cutting, welding and drilling, hire charges for machinery like gas cutting plant, welding equipment, corecut machine, generator, electric ovens, grinding machine equipments like chain pulley block, crane, labour charges for loading, lifting, unloading, etc., complete and as directed by the departmental officers including maintenance & warranty for 5 years.

Design, fabrication and supply of cast steel roller assembly for Spillway gates of vent size 12200x6100mm as per the following specification. cast roller wheels with stock allowance for machining shall be manufactured as per IS 2707 : grade 1 material. Roller wheels of appropriate size 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 as directed by the departmental officers. The cost includes cost of materials like steel, fasteners, grease nipple, bearing, retainer plate, roller and pin, process charges like Pattern, Pattern mounting, steel casting, machining, cylindrical grinding, drilling, tapping, case hardening, assembly, cost of oil, diesel & lubricants for generator, conveyance charges, loading & unloading, etc, complete, including maintenance & warranty for 5 years.

Design, manufacture, supply and erection of bottom seal & side seal with fasteners for a vent size 12200x6100mm as per the following specification. The seals shall be made of a basic polymer that shall be natural rubber. Rubber seals shall be moulded to ensure homogeneous section. Natural rubber seal shall be used as it is elastic, deforms readily and regains its original shape on the removal of loads. The bottom seal shall be a flat seal of size 75x12mm. The side seal shall be a Z type rubber seal of size 74x79x16mm . The center joint seal between the two element connecting shall be provided 170x10mm flat type seal. M 13 holes shall be punched in the rubber seals with seal punchers to match with the holes in the skin plate and cover plate. SS 304 gr fasteners of size M12 shall be used to fasten the rubber seal to the skin plate and cover plate as directed by the departmental officers. The cost includes cost of materials like rubber seal & fasteners, labour charges punching of rubber seal & erection in the shutter, oil, diesel & lubricants for generator, loading & unloading, conveyance charges, etc, complete, including maintenance & warranty for 5 years

Erection, testing & commissioning of vertical lift gate for a vent size 12200x6100mm with structural steel skin plate, horizontal girders, vertical stiffeners, wheels, lifting brackets, etc., complete in all respects as per the technical specification and drawings as directed by the departmental officers. This also includes connection/assembly of hoists with gate for safe, proper and smooth functioning of gates. All steel structures shall be welded appropriately with skilled workmen. 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. All heavy erection equipment like cranes, hoists, chain pulley blocks, winches shall be employed appropriately without damaging the existing structure. Scaffolding shall be done with utmost care taking into consideration the safety of human lives. Temporary barricading/platforms shall be provided in risky operational areas like ogee, etc. The cost includes hirecharges of erection equipments like crane, hoists, winches, machinery such as grinding machine, core cutter, gas cutting plant, welding machine & electric ovens, cost of oil, diesel & lubricants for generator, cost of consumables like oxygen & LPG, welding rods & grinding wheels, cost of erection & dismantling of temporary structures, scaffolding, platforms/barricades, etc., complete.

Conducting the following minimum quality tests as per approved QAP at various stages of work to ensure raw materials and its fabrication are free from defects as per industry standards and maintenance of records at all stages for assurance of quality. Raw materials such as hot rolled plates and sectional structures are tested for physical & chemical properties - one random sample for minimum of 40 tonnes of plate/structural weight. Stainless steel seal seat, wheel track plate shall be tested for physical & chemical properties – one sample (Random) for entire lot of any size. Cast rollers are tested to be free from defects by ultrasonic flaw detector 100% in house as per acceptable standard ASME section VIII witnessed by authorized third party agency. Rubber seals are tested in house for physical properties such as Hardness, Elongation, Tensile strength, Tensile test after ageing, water absorption test as per IS 11855 : 2004. All raw materials are 100% dimensional checked and verified in accordance with manufacturer test certificate. In shop welding process, quality of fillet welds are checked visually and using 100% magnetic particle inspection. In site welding , quality of fillet weld is inspected either by 10% dye penetrant or magnetic particle inspection. For butt welds, 100% ultrasonic inspection is done for skin plate joints. Root weld is inspected by 100% dye penetrant test in butt welds. Internal inspection report shall be furnished at all stages of fabrication. Surface protective treatment such as blast cleaning, epoxy primer and coal tar epoxy coating shall be done as per standard norms. Quality of blast cleaning is ensured by cleanliness to SA 2 ½ finish and profile measured using calibrated surface profile gauge before commencement of blast cleaning & coatings. Adhesion of coating is done with cross hatch & X cut test as per ASTM D 3359. Thickness of primer and coal tar epoxy coatings are ensured by coating thickness gauge at random points. All reports and tests shall be furnished to the appropriate authority as directed by the departmental officers.

Design, procurement, fabrication & supply, erection/ installation of dogging/latch beam including embeddment if any along with construction of niche of adequate size in existing masonry/concrete structure for holding the gate above the MWL for gate maintenance & also to facilitate maintenance /repair or replacement of gate wheels/wheel assembly, including maintenance & warranty for 5 years. This includes scaffolding and incidental petty civil works as directed by the departmental officers.

Design, supply & erection of hydraulic hoist for lifting of vertical gates. The hydraulic hoists consists of a cylinder with upper and lower cylinder head, piston and stem passing through a packing in the lower cylinder head. The hoists are operated by a motor and oil pump arrangement with the directional control by valves which are actuated by electric contacts from any desired position. Manual operating arrangements shall also be provided along with the hydraulic system. The cost includes cost of materials, labour charges transport, scaffolding, installation and maintenance & warranty for 5 years.

Design, drawing, fabrication, transport & installation of an inspection platform for the gomukhi dam additional spillway radial shutters at the following size & specification. The total length of the platform shall be 12000mm and necessary to inspect the shutter trunnion and arms from the downstream side, Also it serves for periodical maintenance operations such as oiling, greasing & painting. This easy & quick access enables to monitor any leakage from the shutter and enables carrying out emergency operations. The platform shall be of width 900mm and shall be supported by the main girder ISMB 400 on either ends of the platform. ISA 50x50x6 shall be welded as intermediate stiffeners singularly between the main girders at distance of 450mm c/c from each other and cross stiffeners at a distance of 500 c/c from each other shall be provided throughout the length of the inspection platform. A gusset plate made of 8mm thick MS plate and size 160 x 200mm shall be perpendicularly welded to the outer side of the main girder on either side to weld the vertical posts of height 1200 mm made of ISA 75x75x6mm. The handrail pipes of dia 25mm made of GI pipes shall be inserted into the holes drilled in the vertical post equidistant from each other as in the drawing. The platform top shall be finished with 6mm composite chequered plate from end to end throughout the platform for a width of 900mm. All joints in the frames shall be neatly welded and ground to give an excellent finish. The foundation bolts of size 16mm with base plate of size 250x250x12mm shall be provided to anchor the platform to the existing pier. Necessary civil works like concreting & anchoring in existing masonry structure shall be included in the scope of this job. The Cost includes cost of materials, labour charges, transport, erection, crane hire charges, power charges from a generator at site, loading & unloading charges, conveyance of machinery to & fro from site of work, hire charges for machinery, scaffolding charges , risk allowance for working at a hazardous location at a height of 15m, maintenance & warranty for 5 years, etc., complete.