Rehabilitation, Replacement and repairs to the shuttering and hoisting arrangements in Surplus Regulators L1, L2, L3, VNSS Regulator and Infall Regulator of Veeranam Reservoir in Lalpet Village in Kattumannarkoil Taluk of Cuddalore District.

Repair and restoration of roller box arrangement with skinplate for 1.50m width and total height of the lift gate of vent size 6.12m x 2.52m. The old corroded skinplate of size 1500mm x 2550mm at the end portion and erroded roller box arrangements cut by gas cutting equipments without cause any damage to the other portion of the skin plate rollers and roller tracks. The cutting portion of the skin plate and roller box arrangements lifted from the vent by using necessary hoisting arrangements, like crane chainpully etc and conveyed to the working yard. The new roller arrangements with skin plate, fabricated with 12mm thick mild steel skin plate for 2.55m height and the roller box arrangement made up of 12mm thick mild steel plates two numbers of 300mm width of 2550mm height provided with holes for fixing roller pins 80mm dia and both the plates connected with diaphragm plate made up of 12mm thick MS plate 6No of size 0.235m x 0.30m at proper intervals. The collar plates of 12mm thick MS plates of size 0.2m x 0.2m on both outer sides of the roller holes in the roller box places. The fabricated roller box conveyed to the side by heavy good vehicle and unloaded at site by moving cranes and leading to the vent portion for erection. Then lifting the roller box over the shutter cutting portion at the end by using crane and positioned along with the existing cutting portion of the skin plate and horizontal girders with the help of chain pullies and manual labors and provided stritch welding at required places for holding the roller box initially. The inner side roller box plate connected with the horizontal girders with connecting angle on top and bottom with 100 x 100x10mm thick mild steel angle of 0.25m length with required welding equipments.

Providing new roller to the roller box arrangements for the lift gate of size 6.12m x 2.52m made up of cast steel of 300mm dia meter and 230mm thickness at the centre of the face width of 100mm including pattern making for casting the rough cast blocks and the casted wheel block machined to required shape and diameter by milling machine lathe and providing holes the centre for fixing gun metal bush and pin for rotating the wheel. The gun metal bush of OD100mm and ID70mm of 240mm length including machining and milling process and snuggly fixed to the centre portion of the roller by using hydraulic pressing machine. And the roller pin of 80mm dia made up of CR steel IS1570 for length of 340mm machined to smooth finish to suit the gunmetal bush and provided with grease nipples and grooves for fixing the lock plate. The fabricated roller painted with two coat of AC black paint over one coat of zincrich primer. After completion of painting, the rollers, conveyed to the work site using goods vehicle. The rollers fixed to the roller box arrangements by using chain pully blocks and other hoisting equipments by smoothly fixing the roller pin in the roller box pin holes and with roller bush in proper alignment and position to ensure the smooth rotation of the wheels. The rollers pin locked with lock plate in the grooves provided in the pin. Then the grease cup to be fastened to the centre of the pin and packed with high quality grease. Trial operation shall be conducted to ensure free movement and rotation of wheels.

Repairing and overhauling the of existing hoisting arrangements of the lift shutter of vent size 6.12x 2.52 m as per the following specification. The existing hoist covers shall be opened up and stored separately for reuse after neatly scrapping the surface and painting with a coat of aluminium paint. 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 leaner and inspected for mis-alignment and breakage. If found any damage replace the plummer blocks with new plummer blocks of same size of standard product. 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 if shaft. The existing gear wheels shall be cleaned of dried grease and dust manually. Thoroughly inspect the gear wheels , if found any damage, necessary replace the pinion wheels , drive wheels with steel casting wheels including charges of pattern making , casting machining and milling as true replica of the existing gear wheels and fixing the wheels in correct alignment and position of the drive system. 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 lever as indicated by the departmental officer. The available rope drum or the chain & chain sprocket mechanism in the hoisting system shall be manually cleaned of dried grease and dirt and appropriate lubricant shall be applied.Provide dial gauge position

Repairing the hoist platform of size 7.25 x 1.82 m including renewal of chequered plate covered the platform is to be done by dismantling the eroded chequered plate and support channels in the platform by using gas cutting equipments without cause any damage to the support girders and support channel and conveying the cutting pieces to the section stores by using required vehicles and heavy manual labours and stacking carefully at the places shown by the departmental officers. Cleaning the support beams and channel by using hand grinder, puffing wheels and wire brushes for free from dirts and rusts. Providing cross support channels of deck bridge portion with ISMC 150 for a length of1.82m at an interval of 0.50mm and cross stiffners with 100 x 50 mm MS channel at required plains by using welding equipments operated with power generators. After welding the channels, painting all portion of the beams, channel except on top with two coat of AC black paint over one coat of red oxide primer. Then Cutting the new 6mm thick chequered plate for required sizes by using cutting equipments and conveying them to the deck bridge by using heavy manual labors and hoisting equipments. Placing the chequered plates over the support beams and channel in correct alignment and position with required gap for welding. After placing the plates welding the joints and welding the plates with support channel at the ends with welding machines operated with power generator. After doing welding providing drain holes at required places by using magnetic drilling equipments operated with power generators. After completion of work painting the chequered plate with two coat of anti corrosive black paint over one coat of red oxide primer. The cost includes cost of all materials, deducting the cost of old scrab materials,process charges like gas cutting, welding, machining, scaffolding charges, labour charges for dismantling, loading,

Renewal of lift gate in VadavarInfall regulator in Kattumannarkoil of vent size 6000x3280m including dismantling the eroded shutter by using gas cutting equipment without cause any damage to the embedded parts and structure and lifting the cutting parts from the vent by using cranes and conveying them by lorries to the section Stores and stacking carefully at the places shown by the departmental officers. Cleaning the embedded Parts by to using hand grinders and puffing machine free from rust. Providing side seal track with stainless steel flat 75x6mm for 3.50m height in the upstream and downstream flanges of the groove channel on both sides by using welding equipments and removing the eroded sill beam from the bed and replacing with new sill beam made up of ISMB 150 for the total width of the gate . After completion of work painting the sill beam and grooves with two coat of coaltar epoxy paint over two coat of zinc rich primer by using spraying equipments. A New shutter shall be designed for a size 6000x3280mm and then shall be fabricated with material confirming to IS 2062 and with following member specifications. The Skin plate of the shutter shall be made up of 12mm thick Steel Plate and 4 nos of horizontal Girders made up of ISMB 350 at the centre to centre distances of 400mm and 750mm from bottom to top respectively. The top of the shutter covered with and top channel with ISMC 300 to the total width of the Gate. The bottom most girder is 250mm above the bottom of the shutter where bottom seal flat shall be fitted. All the Vertical Stiffeners in between horizontal girders shall be made of 12mm thick and 100mm wide steel Plate welded to the webs of the horizontal girder and in four columns at 500mm centre to centre distance. The vertical stiffeners at the bottom of the lowest horizontal girder shall be made of 12mm thick and 350mm wide at Skin plate side and 55mm at Outer Edge for 250mm