1. GENERAL

Proper Maintenance of hydraulic gates and hoists is very important for

satisfactory operation of the project and to achieve the envisaged benefits from

the project. For systematic operation and maintenance of the gates and their

operating equipments, It is very necessary that a Comprehensive Operation &

Maintenance Manual which shall include the design features of various

components, particulars of bought-out items, Operating Instructions, Type of

Lubrication oil and grease to be used, Maintenance and repairs, is prepared for

Hydraulic gates and the operating staff shall be made well conversant with

them and trained for the job.

2. BRIEF DESCRIPTION OF FIXED WHEEL GATE PARTS:

AA. EMBEDDED PARTS:

STILL BEAM:

It is fabricated out of IS: 2062 Quality Rolled Steel Joist with stainless

steel flat of quality: IS: 1570 on the top. The sealing surface of the beam is

smooth and flush with concrete.

ROLLER TRACK:

It is fabricated ‘I ‘section made out of IS: 2062 Quality Plates or Rolled

Steel Joists with stainless steel of Quality IS: 1570 part V on the top of

Roller Track.

SIDE SEAL SEAT:

It is fabricated out of M.S.Angles / M.S.Plates of quality IS: 2062 with

stainless steel plates of Quality IS: 1570 part V on the top. The surfaces of

these parts are so finished, which will provide smooth surface and better

sealing effect.

TOP SEAL SEAT:

It is fabricated out of M.S.Angles / M.S.Plates of quality IS: 2062 with

stainless steel plates of Quality IS: 1570 part V on the top. The surfaces of

these parts are so finished, which will provide smooth surface and better

sealing effect.

SIDE GUIDE:

It is fabricated out of M.S.Plates of quality IS: 2062 so that it guides the

movement of gate in groove and embedded with anchorage in the concrete.

BB. GATE PARTS:

SKIN PLATES:

It is fabricated out of M.S.Angles / M.S.Plates of quality IS: 2062. It will

be straight / vertical in shape.

HORIZONTAL GIRDERS:

It is fabricated ‘I ‘section / ‘T ‘section out of M.S. Plates of IS: 2062

Quality (or) Rolled Steel Joists of IS: 2062 Quality. These will be suitably

spaced and fixed on the skin plate so that stresses are same in all girders.

ROLLERS ASSEMBLIES:

Rollers are made out of Cast Steel conforming to IS: 1030 and Roller Pins

are made out of IS: 1570 (part V) Quality rounds. Rollers are fixed on Pins

with spherical bearings along with Cover Plates and ‘o ‘rings to avoid

entry of dust particles. The Rollers will have less hardness than Track.

LIFTING ARRANGEMENTS:

Suitable hooks are provided on gate top at its C.G. Line so that lifting

beam hook will lock with pin and lift the gates.

SIDE GUIDES:

Side Guides are made out of M.S.Angles / M.S.Plates of IS: 2062 Quality

Plate to suit to shape of guide provided in the embedded parts. These

guides are provided at two ends of the gate to end boxes to avoid side

movement.

CC. HOIST:

DRIVE UNIT:

It consists of suitable capacity worm reducer for reduction in speed, pawl

and ratchet arrangement for holding the gates, chains and sprockets, handle

for manual operation.

GEAR BOX:

It consists of rope drum, set of pinion and gear wheels of Quality Cast

Steel conforming to IS: 1030 to further reduce speed and are provided at

both ends.

LINE SHAFT:

It connects both the gear boxes to the drive unit with Plummer blocks

supports at suitable spacing. This is made out of IS: 2062.

HOISTING STRUCTURES:

Hoist Structures are of Quality IS: 2062 with hand rails for easy movement

of operator and facilitate maintenance works.

3 DESIGN DATA

sl DESCRIPTION VALUESno.1 Type of Gate Fixed wheel type vertical gate

u/s skin plate and u/s sealing

2 Size of vent 3060mmx6100mm3 NO.vents 164 Clear width of opening 3.06 M5 Clear height of opening 6.10 M6 No. of gates 16 SET7 No. of Units in one set 3 UNITS8 No. of embedded parts 169 Side seal c/c 3160 mm10 Track c/c 3630 mm11 Sill to top seal c/c 6200 mm12 SILL Level EL 738.84 M (2424') 80.0013 Top of opening EL 744.94 M14 FRL EL 752.50 M (2468.8') 124.80

HWL EL 127.0015 DESIGN HEAD FRL 13.655 M 44.80

HWL 14.326 M 47.0016 Top of pier (top 0f dam) EL 754.08 M (2474') 130.0017 Permissible stresses

Gate Wet and Inaccessible conditionEmbedded Parts Wet and Inaccessible condition

18 Operation of gate By Rope drum hoist of 20MT Capacity under Un- balanced head condition

19 Dogging level EL 754.08 M 130.00

4 MATERIAL SPECIFICATION

SL.COMPONENT

PART RECOMMENDED IS CODENo MATERIAL

1 Structural parts of gate including IS:2062 skin plate, stiffeners, horizontal girders, diaphragms, track base, seal base, end box plates, Structural steel seal clamp, guide shoes, Structural parts of sealseat base guide/roller track, sill beam, anchor boltsanchors, etc.

2 wheels/rollers cast steel IS1030 gr. 340-570

3 Wheel axle/ pin corrosion resistant steelIS 1570-v 30-CR-13

4 Wheel bearing spherical rollers bearingSKF OR Eqt.

5 Spacres for pin Structural steel IS:2062

6 Guide shoe Structural steel IS:2062

7 Lifting pin Stainless steel IS: 1570, part -5, 20Cr13

8 Bushing Bronze IS: 305

9 Track base, sill beam, Structural steel IS:2062 side seal seat base

10 Seals side/top Rubber IS: 11855PTFE Cladded -music note type

Bottom Plain rubber wedge type11 Roller Track corrosion resistant IS: 1570, part -5,

steel 20Cr1312 Seal seat Stainless steel IS:1570,part-5

04 Cr 19 Ni 913 Seal fasteners Stainless steel IS:1570,part-5

04 Cr 19 Ni 9

RECOMMENDED MATERIALS FOR FIXED WHEELS GATES

AND HOISTS:

SL NO DESCRIPTION MATERIAL IS Specification

1 Wheel Cast Steel Surface hardened to

BHN : 130

IS : 1030

2 Wheel axel Corrosion Resitant Steel IS:1570 part V

3 Skin plate & Structural steel IS: 2062

Stiffener

4 Wheel Track Stainless Steel IS:1570 part V

5 Guide Block Structural Steel IS:2062

6 Bearings SKF (or) Equipment

7 Seal blots Stainless Steel Plate, Stainless

steel clad plate

IS:1570 part V

8 Anchor bolts Structural steel IS:2062

9 Seals Rubber IS:11855

10 Embedded parts Structural steel IS:2062

11 Supporting

structures

Structural steel IS:2062

12 Gears & Pinions Cast Steel IS: 1030

Gr: 27 – 54

Gr: 30 – 57

3 DESIGN DATA FOR ROPEDRUM HOIST

1 Vent Size 3.06 MX6.1 M2 Capacity of hoist 20 MT3 Type of suspension on C.G. of gate4 Speed of hoist 0.5to 0.75 M/MIN.5 Max. lift of gate 15.5 M6 Location of hoist Mounted on steel bridge over

Trestles7 No. of drums Two

8 Rope drum Hoist levelEL 754.08+ hoist bridge+trestle =754.08+0.62+7.6=EL 762.3M

Hoist is mounted on steel towers on eachpier of Sluice gate structure.

4MATERIAL SPECIFICATION

SL. COMPONENT PART RECOMMENDED IS CODENo MATERIAL1 Structural parts including IS:2062

main girder, trestles, cross girders Structural steelchq. Plates, hand rails ,covers

2 Drum wheels/pulleys/gearsbrake drum cast steel IS1030 gr. 280-520

3 shafts/pinions carbon steel IS 1570 part-IIGr. 45c8

4 Pins corrosion resistant steel IS 1570 part-V30cr13

5 Bearing /housing std. Make SKF OR Eqt.

6 Motor std. Make KEC, GEC etc.

7 Flange coupling std. Make GEB, HI-CLIFFWMI ETC.

8 Wire rope std. Make Usha martin /Southern wire rope

9 Brake D.C. Electro-magnetic BCH

OPERATION AND MAINTENANCE

The following precautions are to be taken before Dry Testing the gates:

Gate wheels, Gear wheels, Plummer block and worm reducer be

lubricated.

Removal of Temporary Supports if any.

Checking of left over welding if any.

Checking of tightness of the bolts and are to be tightened properly if they

are in loose condition.

The gates are to be inspected thoroughly for nay projections, temporary

supports coming in the way of gate movement and are to be removed if

any.

All the rubber seals are to be made wet before lowering the gate preferably

with water to reduce friction, heat generated between seal and seal seat.

Light ray pass test may be conducted for checking gap in between seal and

seal seat.

Operating personnel shall be properly trained and experienced so that they

can use their initiative and judgement based on their past experience for

situation which may arise during operation.

Day – to – day experience on operation and difficulties if any, encountered

should be faithfully recorded in the Log Book of gates so as to be available

for studying the behaviour of various structure and equipments.

Detailed instructions for inspection and normal maintenance and repairs of

gate installation should be given in the Operation & Maintenance Manual.

However, for carrying out special repairs to gates if any, it is advisable to

refer to manufacturer.

Inspection and Maintenance experience are complied in the form of

History Register of any installations so as to be useful for further designs,

investigations of any failure, improper and unusual operation in the gates

History Register maintained for the purpose.

4. MAINTENANCE SCHEDULE FOR VERTICAL LIFT FIXED WHEEL

GATE:

These gates are provided for controlling water discharge for flood control,

water supply, irrigation and power generation etc. The gate shall be

thoroughly inspected for cracks, defects or damages periodically. A Schedule

of Maintenance is proposed which may be adopted with Modifications, if

required, to suit site conditions and use of gate.

MONTHLY MAINTENANCE:

1. Rollers are to be greased through grease nipples provided to rollers

shaft by using grease gun.

2. Check Rollers rotation by hand for free rotation.

3. Seals and seal seating shall be inspected for leakage when the water

level is full. Location of leakage points for taking remedial measures.

4. Excessive or wide spread leakages if any shall be reported to

Engineer – in – Charge and remedial measures like adjustment of

eccentricity in the roller axel or providing of rubber packing in

between Rubber seal and seal base. Further adjustment may be

carried out during Annual Maintenance.

5. If leakages is so much excessive that immediate repair is considered

and rubber seals are repaired or replaced.

QUARTERLY MAINTENANCE:

1. The Maintenance shall preferably be carried out once in three months

but not less than thrice in a year including pre-monsoon and post

monsoon maintenance.

2. All the Nuts & Bolts shall be checked for tightness.

3. Check all the welds for soundness and rectify defects if any,

4. Clean all drain holes wherever provided.

5. Check upstream face of skin plate for pitting, sealing and corrosion.

Scale formation shall be removed by using wire brush, pitting shall be

filled with weld and flush grind. Corroded surface shall be cleaned and

painted. In case of gate not being raised every Quarter, these can be

carried out in Annual Maintenance.

6. The Roller bearings / guide rollers shall be lubricated for the rotation.

7. The seal shall be checked for damages, wear and tear, if damaged,

shall be replaced.

8. The guide assemblies, wheel assemblies and sealing assemblies shall

be cleared of grit, sand or any other foreign material.

9. General cleaning is to be done for – Hoist Components

10. Lubrication is to be attended for – Bearings ate gate Rollers, Hoist

pulley and pins provided in Hoist and Gates.

11. Rope drum shaft, Plumber blocks, Line shaft plumber blocks.

12. Check tightness of all coupling bolts of Motor to worm reducer and

line shaft. If required they may be tightened.

ANNUAL MAINTENANCE:

The following additional checks or maintenance shall be carried out

in addition to the checks mentioned under Quarterly Maintenance.

1. All the Embedded parts are checked for defects / damages and shall be

rectified wherever noticed.

2. The sill beam and guides shall be cleared for all grit, sand etc.

3. The wire ropes shall be checked for wear and tear and if broken wires

more than permissible or marked corrosion is noticed, the rope shall be

replaced. The Table ‘A’ shows up to which broken wires are allowed.

4. The wire rope shall be greased.

5. The guide roller pins shall be lubricated.

6. Check the condition of rubber seal. If damaged, replace the seals.

7. All bolts and nuts holding rubber seals shall be tightened. Adjust seal if

leakages are found at local points.

8. Re – painting of the gates shall be carried out at intervals to be decided

on the basis of painting schedule of the gates.

9. The inspection, testing and maintenance of the hoist shall be carried

out periodically.

10. Check oil level in Gear box / worm reducer and replace wherever

required with oil of proper grade.

AT EVERY THREE YEARS:

In addition to checks mentioned under Annual, following will be carried:

1. Check seals for damage and alignment.

2. Check seal bolts for damage.

3. Check for any damage to pulley and pin.

4. Check bearings for damages.

5. Check gears and pinions for damages.

6. Check plumber blocks for damages.

7. Check for any painting damages.

AT EVERY SIX YEARS

In addition to checks mentioned under Annual, following will be carried out:

1. Check damaged / cracked welds at

Skin plate joints

Splice joints

Hoist bridges

Bracings

2. Check Wheel Assemblies for

Any breakages

Frozing

Corrosion

Mis – alignment

3. Check seal seats, seal tracks side guides for

For any welding cracks

Bents or loose bolts and nuts

Cracks in the beddings of worm reducers, Rope drum etc.

LUBRICATION SCHEDULE

SL NO PARTS TO BE

LUBRICATED

MODE OF

LUBRICATION

LUBRICANT FREQUENCY

1 Gate Wheel

bearings

Pressure Grease

gun

Servo Gear -20

Or

Bearing grease

Once in three months as per site

condition

2 Guide Shoes Pressure Grease

gun

grease Once in three months as per site

condition

3 Hoisting wire rope Hand applied Servo Coat – 120

Or Cordium

Compound

Once in a year before monsoon

sets in

4 Worm reducer Oil bath Servo HP - 30 Indicator level to be maintained

always

5 Gear wheels Hand applied Chassis grease Once in six months as per site

condition

6 Drum shaft Pressure grease gun Chassis grease Once in three months as per site

condition

7 Lifting arrangement Hand applied M.P. Grease Once in six months as per site

condition before monsoon sets in

8 Hand operation

Mechanism & other

relating parts

Hand applied Servolin - 140 Once in three months as per site

condition before monsoon sets in

CHART FOR MAINTENANCE SCHEDULE FOR GATES

AT EVERY

QUARTERLY

AT EVERY YEAR AT EVERY 3 YEARS AT EVERY 6 YEARS

General cleanness of

embedded parts,gate,

hoist components

In addition to Quarterly

Maintenance schedule

the following are to be

checked

In addition to Yearly

Maintenance schedule

the following are to be

checked

Check welds for damage

at

Check for oil level in

Radicons

Check for tightness of

foundation bolts of

Radicons, Plummer

blocks, Coupling joints

Check the condition of

wire rope, pulleys,

sheaves, gear wheels

Skin plate joints gate

stiffeners

Greasing of pulleys &

pins rope drum hoist,

gear wheels, Hand

operation shaft, guide

rollers, gate wheels

Check for smooth

operation of gate by

raising & lowering

Check gate seals for

damage

Check wheel assemblies

for any Breakage,

Frozing.

Wheels are to be greased

properly

Check sill beam,

sideguide, roller track for

damages, corrosion,

pitting

Movement of wheels

should be smooth & it

can be rotated by hand

Check hoist bridge

foundation bolts for

tightening

OPERATION AND MAINTENANCE OF GATES

SL NO DO’S DON’T’S

1 Authorised / Technically qualified

personnel should be allowed for

operation.

Unauthorised / Unqualified person should

not be allowed to operate gates.

2 Attend Maintenance during pre –

monsoon season.

Maintenance works should not be

attended during rains.

3 Use proper tools for attending repairs /

adjustment.

Improper tools not to be used for any

repairs / adjustments.

4 Conduct DRY TEST before putting into

operation

Do not operate gates without DRY

TESTING.

5 Maintain cleanliness of hoist platform. Not to keep any slippery material on hoist

walkway.

6 Protect hoist gear box and other parts

from rains.

Not to keep gear box covers open after

daily maintenance.

7 Ensure wire rope tightness on either side

equally before operating gate.

Not to operate gate when the wire rope is

slacked.

8 Ensure before operation that no foreign

material fall in the gear teeth.

Not to run the hoist if foreign material

found in between teeth of gear wheels.

9 Check tightness of plumber block, drive

unit line shaft, coupling bolts.

Do not operate gate if any bolts of

plumber blocks and coupling bolts are

found loose.

10 Ensure no foreign particles stuck up in

between roller and roller track and rubber

seal etc.

Not to advise to operate gates if foreign

material found in between rollers and

roller track and rubber seals etc.

11 Maintain oil as per level indicator in the

gear box.

Not to operate gates with low oil level in

gear box.

12 Check tightness of wire rope clamps

before operation.

Not to operate gate if wire rope clamps

are found loose.

13 Operate gate only when grooves are clean

without any obstruction.

Do not operate gate if there is any

projection in the grooves which obstruct

movement of gate

CONCLUSION

Hydraulic Gates and Operating equipments form an integral component of Dam’s

Barrage and other Hydraulic Structures. Gates and Hoists equipments play an

important role for Dam’s to control, regulate, discharge floods etc. It is essential that

Hydro Mechanical equipments are inspected periodically as suggested above and

carries out Maintenance as a routine so that Hydro Mechanical equipment function

smoothly at all times to avoid loss. The Maintenance of gate is very important to have

longer life of gate.

It will be helpful if the gates are operated by technically qualified, trained (by us)

persons and it reduces unnecessary repair and maintenance expenses.