B -1 TENDERwrd.maharashtra.etenders.in/tnduploads/wrd/tnd...Item No. 26 : Design, Supply and...

For Authorised Use Only

(Government of Maharashtra Undertaking)

Construction and Conversion of Patharwala K.T.Weir

into Barrage

VOLUME

CHIEF ENGINEER (WR), WATER RESOURCES DEPARTMENT,

Aurangabad Irrigation Circle

Jalna

AURANGABAD (Government of Maharashtra Undertaking)

B -1 TENDER

Name of Work


into Barrage Tq. Ambad Dist. Jalna

VOLUME - II (B) Mech. Work

SPECIFICATIONS

HIEF ENGINEER (WR), WATER RESOURCES DEPARTMENT,

AURANGABAD

Superintending Engineer

Aurangabad Irrigation Circle

Aurangabad

Executive Engineer

Jalna Minor Irrigation Division

Jalna


HIEF ENGINEER (WR), WATER RESOURCES DEPARTMENT,

GODAVARI MARATHWADA IRRIGATION DEVELOPMENT CORPORATION, AURANGABAD.

Contractor Nos. of Corrections Executive Engineer

SP 2

INDEX Sr.No Particulars Page No.

Form To

1 2 3 4

1 SECTION NO. 1

Item wise specification

3 26

2 SECTION NO. 2

General technical specifications

27 93

3 APPENDIX – A 94 98

4 APPENDIX - B 99 108



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SECTION - I

ITEMWISE SPECIFICATIOS

SECTION – 1

ITMEWISE SPECIFICATIONS



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NAME OF WORK :

CONSTRUCTION AND CONVERSION OF PATHARWALA K.T.WEIR INTO

BARRAGE INCLUDING VERTICAL LIFT TYPE GATES . TQ AMBAD,

DIST. JALNA

Item No. 25: Design, Supply and erection and testing of Vertical gates, lift

type, Steel pylons including fixing of embedment with all fixtures as per

detail design, cleaning the every part with sand blasting & painting with two

coats of zinc primer & two coats of Coal Tar Epoxy paint etc complete as

directed including fixing or rubber seals, seal seat & S.S. sill beam top

plate, Track plate CRS BHN 250 including cost of special electrodes for

welding of CRS with M.S. & S.K.F. bearings in rollers of vertical leaf

gates pylons including preparing detail design & drawing vetting from

C.D.O. and as directed by Engineer-in- charge with all leads and lifts.

i) Scope of Work : The item includes Design, Manufacturing and Supply,

Transportation and Erection of 27 Barrage Gates as per specifications of the

project. The item includes cost of steel and other materials (i.e. cutting gases,

welding electrodes, sundry materials, Bought out items sand Blasting and

painting workshop charges, Labour charges, Completing the work as per

drawings and specifications. This item also includes construction of coffer

dams, level platform, internal site roads & dewatering as required in all respect

in view of completion of this item.

ii) Mode of Measurements : The Payments will be made on the basis of Physical

weight of the Item after fabrication and welding completed as per drawings

and site requirements etc. the quantity will be measured as actually placed at

required place and shall be finally calculated to the two decimal of M.T. by

weight. The Contractor should make all necessary arrangements for weighing

the fabricated parts.



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iii) Mode of Payment : The Payment shall be made as under :

a) Design and Drawings gates, Embedment, Pylons :2 %

Vetted from C.D.O

b) Fabrication Material received at site :33 %

c) Manufacturing and assembling :35 %

d) After Erection (Fabrication) of Gates, Pylons, embedment parts :20 %

e) After test and trial during Maintenance :1) First year – 5%

2) Second year – 3%

3) Third year – 2%

Item No. 26 : Design, Supply and Erection of Hoist bridge for vertical lift

types gates of various size in all respect including cleaning every part with

sand blasting & painting with two coats of approved paint fixing electrometric

/ Rocker bearings below plate girders as per design & preparing detail design

& vetting from C.D.O. and as directed by Engineer-in-charge with all leads

and lifts, including construction of cofferdams, level platform, internal site

roads fro movement of heavy machinery & dewatering as and when required

during erection & testing etc. complete as per specifications.

i) Scope of work : The item includes design, Manufacturing (Fabrication) and

supply, Transportation and Erection of 27 bays of hoist bridge as per

specifications of the project. The item includes cost of steel and other

Materials (i.e. cutting gases, welding electrodes, sundry materials, Bought

out items sand Blasting and painting workshop charges, Labour charges,

Completing the work as per drawings and specifications. The item also

includes construction of coffer dams, level platform, internal site roads &

dewatering as required in all respect in view of completion of this item.

ii) Mode of Measurements : The Payments will be made on the basis of

Physical weight of the Item after fabrication and welding completed as per

drawings and site requirements etc. the quantity will be measured as

actually placed at required place and shall be finally calculated to the two

decimal of M.T. by weight. The Contractor should make all necessary

arrangements for weighing the Fabricated parts.




SP 6

a) Design and Drawings of hoist –Bridges : 2%

Vetted from C.D.O

b) Construction Material received at site : 33%

c) (Fabrication)Manufacturing and assembling : 35%

d) After Erection of Hoist Bridge : 20%

e) After test and trial during Maintenance :1) First year -5%

2) Second year -3%

3) Third year – 2%

Item No. 27 : Design, Supply & Erection of and testing hoist Machinery of

designed capacity and hoisting mechanism for vertical lift gates of various

sizes including cleaning every para with sand blasting & painting with two

coats of zinc primer & two coasts of approved paint, all electric cables,

electric panels & wire ropes, gear assembly, rope drums central drive unit with

two way power supply arrangement i.e. from MSEB & Generator as per detail

design including preparing detail design & vetting from C.D.O. in all

respect as directed by Engineer in charge with all leads and lifts,

including construction of coffer dams, level platform, internal, site roads for

movement of heavy machinery & dewatering as and when required during

erection & testing etc. complete as per specifications.

i) Scope of work : The item includes design, Manufacturing and supply,

Transportion and Erection of Hoist mechanism and all components as per

specifications of the project. The item includes cost of steel and other Materials

(i.e. cutting gases, welding electrodes, sundry materials, Bought out items

sand Blasting and painting workshop charges, Labour charges, Completing

the work as per drawings and specifications. This item also includes

construction of coffer dams, level platform, internal site roads & dewatering

as required in all respect in view of completion of this item.

ii) Mode of Measurements : The payments will be made on the basis of

Physical weight of the Item after fabrication and welding completed as per

drawings and site requirements etc. the quantity will be measurement as

actually placed at required place and shall be finally calculated to the two



SP 7

decimal of M.T. by weight. The Contractor should make all necessary

arrangements for weighing the Fabricated parts.


a) Design of Hoist Assembly vetted from COD : 2%

b) Construction Material received at site : 33%

c) (Fabrication) Manufacturing and Assembling at site : 35%

d) After Erection of hoist Assembly : 20%

e) After test and trial during Maintenance :1) First Year - 5%

2) Second Year – 3%

3) Third Year - 2%

Item No 28 : Operation & maintenance of vertical lift type gates, pylons, hoist

bridge hoisting arrangements after satisfactory completion of Erection and

testing including all test & trial every year for three years including

maintenance of all gate components before mansoon and after monsoon as

required and operation of the gates while monsoon for stroing water in

barrage including replacement of any part if necessary and rectification of

any component if required in view of smooth operation of gates as directed by

Engineer in charge, including cost of all consumables & maintenance of

approach road etc. complete.

I) Scope of work : After successful testing trials and commissioning of vertical

lift type service gates of various sizes the contractor is required to operate and

maintain these gates for further period of three years.

1) Period of operation and maintenance :

a) The work of fabrication, erection, testing trials, operation and

commissioning of vertical lift type service gates is included in the initial

contact period i.e. upto first filling of lake.

b) The operative year for operation and maintenance will be reckoned from Ist

June of the year after giving successful test and trial and the gates are ready

for storing water against them. For example if the work is completed in

January of the year and after giving successful test and trial and after

inspection if the gates are ready for storing water against them, the



SP 8

operation and maintenance period will be started from Ist June of that year

and the operation and maintenance year shall be counted from Ist June to

31st May of next year. The operation and maintenance period will be

countered as above and this period will last for further three years.

2) Personnel equipment and consumable required for operations and

maintenance:

a) Personnel : The Contractor should engage the sufficient number of

skilled and unskilled workmen as per requirement for the maintenance

work as per direction & to the satisfaction of Engineer in charge.

b) Equipments :

i) Movable Welding Machine.

ii) Welding Equipment.

iii) Tools required for operation and maintenance

iv) Gas cutting equipment.

c) Consumables shall be arranged for operation and maintenance work as

per the requirements of Dam Safety Organization, Government of

Maharashtra.

3) Mode of Operation and Maintenance :

a) Pre monsoon and post monsoon inspection will be carried out by

Departments. According to instructions given during these inspections

will be communicated to contractor in wirting for implementation.

b) Gate operation schedule shall be got prepared fro MERI Nashik by the

contractor and gate operations shall be made accordingly.

c) Mostly the gate will be kept open during heavy monsoon period.

Instrucitons to these effect will be issued to contractor from time to

time. It should be ensured that the Barrage will be filled to the required

level and as such gate operation will have to be planned.

d) General operation schedule will comprise of

i) Prior to monsoon, every gate shall be tested for its free and fair

movement.

ii) Hosting arrangement and gearing arrangement should be tested for

smooth operation.



SP 9

iii) Rollers and slide channel should be well lubricated to avoid friction

iv) Rubber seals tested for leak proof ness. These should be water tight

against full reservoir level.

v) The operation of gate should be done by the electric supply supplied by

M.S.E.B and also electric supply supplied by generator i.e. standby

arrangement.

e) Standby arrangement in lieu of power failure will be provided by

Department free of cost. Charges for energy supply will be borne by

Department.

4) Mode of Payment : The operation and maintenance charges will be paid to

the contractor on quarterly basis. Period of the first quarter will be counted

from June to August every the payment of first quarter will be made in

September as detailed below.

Sr.No Quarter Month of Payment No.

1 June to August September

2 September of November December

3 December of February March

4 March to May June

Annual charges for operation and maintenance have been mentioned is

schedule of payment. These charges will be equally distributed over four

quarter of operation and maintenance year and the same will be paid

accordingly.

The bills for operations and maintenance charges will have to be presented by

contractor quarterly as mentioned above for releasing payments.

GENERAL TECHNICAL SPECIFICATIONS

1.1 GENERAL



SP 10

1.1.1 This sections covers general technical specifications pursuant to the contract

and will form an integral part of the contract. The following provision shall be

applicable to all the detailed technical specifications except otherwise

modification.

1.1.2 SCOPE OF WORK.

The scope of work shall comprise of design, manufacturing and erection of

various sizes vertical lift type gate, embedded parts, Hoists, Crane,

Accessories, ancillary equipment etc. Complete. The contractor shall be fully

responsible for the supply of components of various specified gates i.e. for

their manufacture, testing, commissioning packing and transport and transport

to the project site including all leading unloading, stacking, obtaining all

customs and other clearances, payment of taxes, duties and providing

incidental services etc. complete.

The contractor should prepare layouts and design for vertical lift type gate,

Hoists, Cranes, stop logs, embedded parts and pier etc. as per the requirements

and recommendations in BIS-IS4622 and get the these approved from the

CD0- Nashik before manufacture. The minimum design criteria are as per table

No. 1.

1.2 LIMIT CONTRACT

1.2. Equipment furnished shall be complete in every respect in all mounting,

fittings, fixtures and standard accessories normally provided with such

equipment and/or needed for erection, completion and safe operation of the

equipment as required by the applicable codes through they may not have been

specifically detailed in respective specifications, unless included in the list of

exclusions. All similar standard equipment provided shall be interchangeable

with one another.

Structural part Description of Goods

1) Vertical lift type gate 1) Service gate leaves

2)Hoist



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3)Embedded parts

4)Ancillary equipments

1.3 ENGINEERING DATA

1.3.1 All engineering data submitted by the contractor after final process including

review and approval by the CDO- Nashik shall from part of the contract

documents and entire works covered under these specifications shall be

performed in strict conformity to the final data, unless other wise expressly by

the Govt. in writing.

1.4 DRAWINGS

1.4.1 All the tentative drawings relevant to this contract are attached at the end. The

details shown therein are as per the departments design.

1.4.2 Further work by the contractor shall be in strict accordance with these

drawings and no deviation shall be permitted without the approval of the Govt.

if so required.

1.4.3 All manufacturing and fabrication work in connection with equipment prior

and commissioning shall be done according to the technical specifications

given in BIS No. 15/46221/92 and as per the provisions given.

1.5 FIRST FILL OF CONSUMABLE, OIL LUBRICANTS:

1.5.1 All the first fill of consumables such as oils, lubricants etc., which will be

required to put in use the equipment covered under the scope of the

specifications, for successful trails, operations shall be furnished by the

supplier unless specially excluded under the exclusions in these specification

and documents. Any consumable, which is needed for successful erection of

plant available in India shall be supplied by contractor. Consumable needed for

future operation and maintenance shall strictly be equivalent to one available in

India. Contractor shall ascertain and certify the same.

1.5.2 The specifications and quantity of the lubricating and insulating oils required

for each equipment shall be furnished. The price of the oils shall also be born



SP 12

by the suppliers. The detail of company and trade name of oil, lubricants etc. of

equivalent grade redial available in India shall also be indicated.

1.5.3 If so desired by the Engineer-in-charge shall be prepared to place order for

lubricating and insulating oil required for the equipment on a contractor to be

indicated at later date. He shall arrange for shipment of this oil simultaneously

with the equipment.

1.7 MANUFACTURING SCHEDULE :

1.7.1 The contractor shall submit to the Engineer in charge his date wise

manufacture and delivery schedule for all equipments within thirty (30) days

from the date of order letter, and in no case delivery shall be delayed

beyond contracted date. Progress of manufacture shall be submitted to the

Engineering in charge once every month there after, by the contractor.

Progress report shall also include the materials and equipments purchased

from other contractor.

1.8 DESIGN IMPROVEMENT :

1.8.1 The Engineer in charge or the supplier may propose changes in the

specifications of the equipment or quality there of and if the parties agree

upon any such changes the specification shall be modified accordingly.

1.8.2 All the technical data, descriptive literature, drawings and

supplementary description and current specifications are in English

language only. Where required, additional information and data

may be furnished by the contractor to supplement, amplify or

clarify the information required in the specifications. They may

also point out any special features and advantages if any of the goods and

services offered by them.

1.9 SUGGESTIONS/MODIFICATIONS IN SPECIFICATIONS :



SP 13

1.9.1 While the Govt. does not bind himself to accept the lowest or any other tender,

due consideration shall be given to any special device or equipment put

forward by the tender with a view to increase the efficiency of the equipments

and to minimize the initial or maintenance cost of the equipment as a whole.

1.10 STANDARDS

1.10.1 All materials and equipments shall comply in all respects with the of the latest

edition of the relevant Indian International Electro-Technical Commission

(ITC) and internally accepted standard which ensure equal or higher quality

than the standard mentioned in the specification.

1.10.2 Where a certain equipments is stated not to comply with the India IIEC or any

other equivalent standard, the salient point or comparison between the standard

adopted and those mentioned above shall clearly brought out in the tender

making at the same necessary corrections for operations under the conditions

specified therein. Wherever a standard is specifically mentioned in these

specifications, it is understood that the corresponding standard from amongst

the sources mentioned above shall also apply. It is however, understood the

plant and equipment offered shall comply with one consistence set of

standard except so far as they are modified by the requirement of these

specifications.

1.10.3 In case of a conflict between such codes and / or standard and the specifications

the latter shall govern. Such codes and / or standard referred to shall mean the

latest revision, amendments / changes adopted and published by the relevant

agencies. In case of any further conflict in this matter the same shall be

referred to the Engineer in charge whose decision shall be final and binding.

1.10.4 All codes or standards used for the contractor's own designs including those

listed in the equipment specification must be listed in the schedules. Two (2)

English language copies of all national and international codes and / or

standards used in the design of the plant and equipment and listed in the tender

and approved by the Engineer in charge shall be provided by the contractor to



SP 14

the Engineer in charge within two calendar months from the date of order

letter.

1.11 FOUNDATION AND FIXTURES :

1.31.1 All fixtures necessary for the proper erection of embedded parts shall be

supplied by the contractor and the contractor shall assist the Engineer in charge

in fixing necessary fixtures.

1.12 MATERIAL AND WORKMANSHIP : 1.12.1 GENERAL

All parts shall be manufactured true to the approved drawings and dimensions.

All tolerances shall be defined on the drawings for both manufacturing and

installation purposes. These shall conform to tolerances in Appendix A of

Section IX of Technical specifications. The material used in the manufacturing

of the gates, equipment shall be new and of high quality and selected

particularly to meet the duties required by them. The use of materials liable to

attack by termites or other insects shall not be allowed. All workmanship shall

be of the highest quality throughout to ensure smooth and vibration free and

noise free operation under all possible operation conditions and the designs,

dimensions and materials of all parts, shall be so chosen that the stresses to

which they may be subjected shall not render them liable to distortion or

damage under the most severe conditions encountered in actual service.

Material and workmanship shall confirm to the latest editions of the relevant

standards and B.I.S. -IS-4622.

1.13 METAL WORK FABRICATION AND MACHINE WORK:

1.13.1 All equipments, materials and supplies shall be of the most suitable quality for

work. The contractor shall without extra cost provide samples and co-operate

in the testing of materials and inspection of the works. The Govt. shall have

access at all times to the places of storage and to the places where material are

being fabricated or processed to determine whether their fabrication and

process proceeding in accordance with the specifications and contractor's

drawing approved by the Engineer in charge.



SP 15

1.13.2 The Engineer in charge may reject at any stage any work which he considers to

be defective in quality and he shall not be debarred from rejecting the wrought

materials by reason of his having previously passed them in an unworked

condition. Any portion of the materials rejected shall be removed from the

work site by the contractor at his expense, upon written instructions to that

effect by the Govt. Replacement of such materials shall be made by the

contractor at his expense.

1.13.3 No work shall be covered up or put out of view without the approval of the

Govt. and the contractor shall afford full opportunity for examination and

measurement of the materials. The contractor shall give due notice to the

Engineer in charge whenever such material is ready for examination and

measuring the materials, unless he considers it unnecessary and advice the

contractor accordingly.

1.13.4 SCREW THREADS:

The threads for bolts and nuts shall have metric threads of international

standards organization and conforming to Indian standard ISO Metric Screw

Threads Diameter Pitch Combination (First Revision with Amendment No.l)

IS : 4218 (Part-II)-1976.

1.13.5 FITS AND TOLERANCES:

Fits used for different components shall be accordingly to the best modem

shop practice. Due considerations shall be given to the special nature of

function of the parts and to the corresponding accuracy required to secure

proper operation The Fits shall be in accordance with Indian Standard : "Guide

for the selection of Fits (First Revision)" 15:2709-1982. These shall be

subjected to the approval of the Engineer in charge.

The tolerance for embedded parts and components of gates shall be as given in

Annexure TS 'A' of technical specifications.

1.13.6 MACHINE FINISH:



SP 16

The type of finished surfaces shall be in accordance with the approved

drawings. Where a smooth finish corresponding to roughness value ranging

between 0.2 and 0.8 / cum is specified or required the machine work shall be

performed in such a manner as to produce smooth surface free from tool

marks. This grade finish shall be required for highly loaded bearing surface

and / or for surface to be polished for appearance. Where an average ranging

between 1.6 and 6.3 microns is specified or required, smooth surface shall be

produced by ordinary machining methods, but slight tool mark shall be

allowed, This grade of finish shall be required for ordinary work. Where a

rough finish corresponding to roughness value ranging between 12.5 and 25.0

microns is specified or required, rough machining sufficient only ‘o uniform

surface shall be allowed. This grade of finish shall be used primarily for

surfaces which are not in contact, but which require finish for dimensional

accuracy.

1.13.7 FABRICATION OF STRUCTURAL STEEL:

The structural steel work for the equipment covered by the specification shall

conform to the requirement of "Reamed work" and shall conform to the

following requirements unless otherwise called for in these specifications. All

completed members shall be free from twist, bends and open joints. Attention

is called to the special nature of the work involved in the manufacture or

equipment which require close adherence to the dimensions, tolerances and

finish called for:

1.13.8 STRAIGHTENING:

Before being laid off or worked in any manner, structural material shall be

straight without twist, bends or links and shall be cleared or all rust and dirt. If

straightening is necessary, it shall be done be method that will not injure or

mar the the materials.

1.13.9 SHEARING, CHIPPING AND GAS CUTTING :



SP 17

Shearing, chipping and gas cutting shall be done carefully by torch or by

electric arc and all portions of the work which shall be exposed to view shall

present a neat appearance. Gas cutting shall be mechanically controlled. Re-

entrant cuts and copes in beams and channels shall be filleted before cutting.

1.13.10 PLANNING OR FINISHING EDGES :

Planning or finishing the sheared or cut edges or plates or rolled shapes shall

not be < accepted except as otherwise specified for welded edges or as shown

on the approved drawings.

1.13.11 BENT PLATES AND SHAPES :

Where bending of plates or forming shapes is required, these shall be bent to

the proper curvature by cold forming. Bends in frill plates shall be made across

the grain of the plates with the axis of radii of bends. Normal to the direction in

which the plates were rolled. Afterwards, bent plates shall be tested by any

approved method to ensure that all surfaces at the bends are free from cracks

and incipient fractures. Heating and hammering to correct curvature shall not

be permitted.

1.13.12 REAMED WORK:

Holes in material 20 mm less in thickness shall be sub-punched or sub-drilled

before assembly and reamed to full size after assembly. Holes in material more

than 20 mm in thickness shall be sub-drilled before assembly and reamed to

full size after assembly.

Counter boring shall be done carefully to meet requirement for clearance and

fit of welded studs Anchor bolt holes shall be punched or flamed out to full

size. All other holes shall be made b the following made by the following

methods.

1) Punching:



SP 18

Punching of holes to full size shall not be permitted. For sub-punching, the

diameter of the punch shall be 5 mm smaller than the nominal diameter of the

bolt used and the diameter of the die shall not be more than 2.50 mm larger

than the diameter of punch. All holes shall be cu clean without any burrs.

2) Drilling and Reaming :

For sub-drilling, the diameter of the drill shall be 3 mm smaller Than nominal

diameter of bolt used. Except where tapping is required or where tight fit bolts,

ribbed boy or dowels are to be used full size drilled or reamed holes shall not

be less than 1.5 mm not more than 2.5 mm larger than nominal diameter of the

bolts used. Holes for ribbed bolts shall be drilled or reamed to 1.5 mm less than

the diameter of the ribbed shrunk of the bolts to ensure a tight fit. Reaming of

the sub-punched or sub drilled holes shall be done with machines after

assembly. The templates shall be used when assembled reaming is

impracticable. Tapped holes shall be drilled to the proper diameter for the tap

used and shall be tapped carefully so that the threads will be continuous,

smoothly cut and free from imperfections.

1.13.13 ACCURACY OF PUNCHING, DRILLING AND REAMING :

1) Before assembly :- The accuracy of all holes shall be such that during

assembly, a cylindrical pin 3 mm less in diameter than the normal size of the

holes shall be entered perpendicular to the face of the member, without drifting

in not less than 75 percent of any group of continuous holes in the same plane.

All holes small pass a pin 5 mm smaller in diameter than the nominal diameter

of the hole.

2) After Assembly :- The accuracy of reaming and drilling after assembly shall

be such that not less than 85 percent of any group of continuous holes in the

same plane shall show no offset grater than 0.5 mm between adjacent thickness

of material, unless a greater degree of accuracy is called for on the contractor's

drawings approved by the Govt. or in these specifications.

3) WELDED STUDS :- Welded studs wherever used shall be welded in place

with automatic end welding guns. Templates of sufficient thickness to afford

good alignment shall be used to accurately locate the studs during the welding



SP 19

cycle and to locate matching holes in other material. Bushing shall be used for

template holes, if necessary to ensure alignment of the studs and location

accuracy required for proper fit of parts to be assembled.

1.13.14 PATTERNS :

The rates quoted shall include the cost of all necessary patterns. Patterns shall

remain the property of the contractor. Care shall be taken to avoid sharp corner

or abrupt changes in cross section and amp fillets shall be used. The contractor

shall provide pattern thickness as will conform to his standard foundry practice

and as may be necessary to ensure that all metal thickness of the finished

castings shall be in accordance with the dimensions shown on the contractor's

drawings approved by the Engineer in charge.

1.14 WELDING:

1.14.1 PREPARATION FOR WELDING :

Members to be joined by the welding shall be cut accurate to size and where

required shall be rolled or pressed to the proper curvature in accordance with

the dimensions shown on the approved drawings. The edges of the members to

be joined by welding shall be sheared, flameout or machined to suit the

required type of the welding and to allow through penetration. The cut surfaces

shall expose sound metal free from laminations, surface defects caused by

shearing or flame cutting operation and other injurious defects. The surface of

plates to be welded shall be free from rust, grease and other foreign mater for a

distance of at least 50 mm back from the edge of the weld. In assembling and

during welding the components parts of built up members shall be held in

place with sufficient and proper clamps or other adequate means to keep with

all parts in proper position. Before commencement of welding the supplier

shall submit complete Programme of-welding sequence to minimize stresses

and distortion<of the finished members of the equipment for the approval of

the Engineer in charge.

1.14.2 WELDING TECHNIQUE :



SP 20

All welding shall be performed by electric arc process using coated electrodes

or other means whereby the atmosphere is excluded from the molten metal and

where applicable, automatic machines with correct precision control shall be

used. After being deposited, the weld shall be cleaned of slag or flux and shall

show uniform section, smoothness of weld metal, feather edges without

overlap and free from porosity and clinkers, Visual inspection at the edges and

ends of welding shall indicate good fusion with the base metal. When weld

metal is deposited in successive layers. Each layer except the last shall be

pined moderately with a tool before the next layer is applied.

Particular care shall be taken in aligning and separating the edges of members

to be joined by butt welding, so that complete penetration and fusion at the

bottom of the joint shall be ensured. All pin holes, cracks and other defects

shall be. repaired by chapping or grading the defects to sound metal and re-

welding. Where fillet welds are used the member shall fit closely and shall be

held together during welding. The welding rods used for manual welding shall

be of heavily coated type and shall be suitable for all position welding where

required. In welding, precautions shall be taken to minimize stresses due to

expansion and contraction and distraction due to heat by using the proper

sequence in welding i.e. by pining the welds while hot or by other satisfactory

methods. Reflection of distortion by blows after welding shall not be

permitted. Welds shall not be primer coated until they have been inspected and

approved by the Engineer in charge. The welding shall conform to Indian

Standard "Code of Practice for use of Metal Arc welding for General

construction in Mild Steel (First Revision with Amendments No.l and 2)" IS :

816:1969. All skin plate welds shall be continuous and water tight and shall

develop the full strength of plate. The electrodes shall conform to the Indian

Standard of structural steel for welding products other than sheet and for

welding sheets (Part I and II)" IS : 814 - 1974).

The contractor shall prepare shop and field welding procedure including stress

relieving and preheat requirements and shall submit this procedure to the

Engineer in charge for approval. The procedure shall be in accordance with the

best modern welding practice and shall be such as to minimize residual stress



SP 21

and distortion of the finished members of the structure. Approval of any

procedure however, shall not relieve the contractor of the sole responsibility

for producing a finished product meeting all requirements of these

specifications. Welds in contact with rubber seals shall be ground flush, all

corners and corners welds in contact with rubber seals shall be rounded.

1.14.3 APPROVAL TEST OF WELDING PROCESS :

Specifications of the welding procedure that are proposed to be used shall be

established and recorded and a copy of such procedure specifications together

with certified copies of report of results of tests made in accordance with the

procedure specifications shall be furnished by the contractor. The procedure

specifications shall conform to the Indian Standard "Approved Tests for

welding procedure Part I Fusion Welding of Steel" IS:7307 (Part I) - 1974.

1.14.4 QUALIFICATIONS OF WELDERS :

The contractor shall be responsible for the quality of the work performed by

his welding staff. All welders assigned to the work shall have passed

qualification test for welders. If at any time the work of any welder appears to

be questionable, such welder shall be required to pass additional qualification

test conforming to Indian Standard "Code of Practice for Training and Testing

of Metal Arc Welders" IS : 817.- 196E and Indian Standard " Approval Tests

for Welding procedures Part-I Fusion welding of Steel" IS : 7307 (Part-I) -

1974 to determine his ability to work on which he is engaged.

1.15 CASTING:

All castings shall be true to pattern and the thickness of the metal shall not vary

at any point by more than 1.5 mm from that sown on the drawings approved by

the Engineer in charge. Care should be taken on the foundry to cool the

castings property so that they shall not wrap or twist No casting will be

accepted if it is warped and / or twisted to such extent that machined surfaces

cannot be property finished to the dimensions shown in the drawings approved

by the Engineer in charge by more than 1.5 mm. All' casting shall be free from



SP 22

cracks, large or injurious blow holes or sand holes and other blemishes, they

shall have workmanship like finish inside angles having proper fillets and

unfinished edges of bases, ribs and similar parts being neatly cast with rounded

comer.

All casting shall be suitable heat treated. The method of head treatment and the

relevant records of heat treatment shall be furnished by the contractor to the

Engineer in charge Subsequently all casting shall be subject to radiographic

method of inspection.

Repairs of major defects in castings shall not be allowed, but if the strength

and mach inability of the casting can be ensured, the casting shall be rectified

by welding with the prior approval of the Engineer in charge. All casting shall

be welded in accordance with the procedure laid down in Indian Standard 66

code of procedure for repair and welding process "15:5530-1987, All such

castings in the areas of repairs shall be re-examined as directed by and to the

satisfaction of the Engineer in charge.

1.16 FORCINGS:

1.16.1 All forgings shall be sound and free from scales, cracks, crevices or any other

flaws, that can be detrimental to their use.

All forgings shall be suitably heat-treated. The method of heat-treatment to be

adopted shall be as suggested by the contractor and approved by the Engineer

in charge. Finished surfaces of all forgings shall be smooth and free from

marks.

The sample shall be tested for each cast and heat treatment batch. The

chemical composition and mechanical properties obtained from the sample

shall comply with the specified requirements, the material represented shall be

liable to rejection. The contractor with prior approval of the Engineer in charge

shall be allowed to reheat-treat (Not more than twice) the forgings represented

and resubmit for testing.



SP 23

All forgings shall be subject to bend test to be carried out in accordance with

Indian Standard "Method for Bend Test for steel products other that sheet,

strip, wire and tube (First Revision) (with Amendment No.l) (Reaffirmed

1980) "IS : ' 1599-1985. Where the dimensions permit test piece, 230 mm long

and 32 mm square with edges rounded off, mail be machined lengthwise from

each test sample and bend cold by direct pressure round a former of diameter,

appropriate to the class of steel as shown in Fig.l on page 9 of Indian Standards

: Specification for carbon steel forgings for General. Engineering Purposes

(Second Revision) "15:2004-1991, until the sides of the test piece shall be

brought together by direct pressure and the test piece shall not fracture. One

forging from each delivery run batch shall also be examined for grain flow by

sectioning and macro-etching.

1.17 ERECTION, BOLTS, NUTS, WASHERS AND OTHER

FASTENERS:

Erection bolts, nuts, washers and other fasteners shall be furnished in the

amount of 15 percent or ten bolts, nuts washers and other fasteners whichever

is greater, in excess of the nominal number of each size and length required for

complete installation of equipment.

Bolts in tension shall have a net section at root of thread 15 percent in excess

of the net section required in tension.

1.18 CLEANING AND PRIMER COATING:

1.18.1 GENERAL:

The contractor shall furnish, prepare and supply all materials for cleaning and

coating of metal work as hereinafter specified. All method surfaces for

equipments materials and supplies shall be cleaned and primer coated with

coats of cleaned and primer coated with two coats of cleaned and primer

coated with two coat of applicable primer conforming to the specifications

given herein. The cost of furnishing, preparing and applying all materials

which are required for - cleaning and primer coating operations, including



SP 24

supply of all labour, tools and equipments shall be included in the rate tendered

for fabrication and supply of metal work and machinery.

1.18.2 CLEANING SURFACE: Surfaces shall be cleaned and prepared in

accordance with Indian Standards "Code of Practice for painting of Ferrous

Metal in Building Part I Pretreatment (First Revision) "IS: 1477 (Part I) -1971

for pretreatment and by the method to be used for each item of installation of

metal work and machinery which is indicated in the primer coating schedule

weld spatter or any other objectionable surface irregularities shall be removed

by any suitable means be for cleaning. The following methods shall be applied.

METHOD A : All oil, grease and dirt shall be removed from the surfaces by

using clean mineral spirits, xylol or white gasoline and clean wiping material

METHOD B : All oil, grease and dirt shall be removed from the surfaces to be

primer coated by use of clean mineral spirit, petroleum naphtha or xylol or

white gasoline.

1.18.3 Final cleaning shall be done by using clean wiping material and clean

solvent. Following the solvent cleaning, the surfaces of metalwork and

machinery shall be cleaned off all rust mill scale or other tightly adhering

foreign material by sand blasting or grit blasting as directed by Engineer in

charge to uniform bright base metal. After dry blast cleaning, the surfaces shall

be dusted off or blown off with compressed air free of oil and water cleaned by

mixing air with clean fresh water to which sufficient corrosion inhibitor has

been added to prevent rusting. Corrosion inhibitor compounds are the

materials.

1.19 FASTENING

Nuts, bolts, studs & washers for incorporation in the equipment shall confirm

to the requirements of the appropriate standards where the contract includes

nuts & Bolts of different standards, the tools shall be provided in compliance

with the specifications & shall include spanners, tabs & dies for these nuts &

Bolts. Nuts & Bolts for pressure parts shall be of the best quality bright steel,

machined on the shank under the head & nut. All washers shall be included



SP 25

under the contract including locking devices and ant vibration arrangements.

Paper washers shall be fitted wherever necessary. Where there is a risk of

corrosion, bolts & studs shall be finished flush with the surface of nuts. Bolts

except for high strength friction grip bolts shall be designed so that with the

nuts fully tightened the stress intensity at the bottom of the thread shall not

exceed half the yield point of the material under all conditions. On bolts, nuts

& screws which shall be subject to frequent adjustment or frequent removal in

the course of operation shall be made of corrosion resistant steel or bronze.

Spring type washers will not be permitted where they may damage any

protective coatings. Special tools, wrenches and devices found to be necessary

for the completion of work shall also be provided under this contract.

1.20 ELECTRICAL EQUIPMENT'S

1.20.1 GENERAL

All the electrical equipments required such as electrical motors, starters &

conductors, control relays, pilot devices, terminal block etc. shall be as per

detailed design & drawings & shall confirm to the relevant standards and

specifications

1.20.2 EQUIPMENT WIRING :

Insulated wire for equipment wiring shall be of standard copper conductor

suitable for 650 V service voltage maximum conductor temperatures of 90

degrees C for continuous operation and shall have a minimum cross sectional

area of 2.5 Sq.mm. with the exception of electronic instrumentation circuits

which shall have a minimum cross sectional area of 1.0 Sq.mm. Each

conductor shall be individual individually identified at both ends through a

system providing ready and permanent identification, utilizing slip as per rules

approved by the Engineer in charge. Markers may be typed individually or

made up from set of numbers and letters firmly held in dace. Open (0 type)

markers will not be accepted. Markers must withstand a tropical environment

and high humidity and only fungus proof material will be accepted. Ferrules of

adhesive type are not acceptable. All trip circuits shall employ markers having

a red background. Sensitive control circuit shall be effectively shielded against

extraneous signals and interference. A separate terminal shall be provided for



SP 26

termination of individual cable shields which will be grounded at source end

only except where stated otherwise.

SECTION – II

ADDITIONAL TECHNICAL SPECIFICATIONS

ADDOTIONAL TECHNICAL SPECIFICATIONS



SP 27

2.1 GENERAL:

2.1.1. The description of the item given is a general one to indicate broadly the scope of

work involved . The detailed description with break-up in the items to be supplied

is given in the schedule ‘B’ enclosed with the tender and also in the detailed

specifications. The contractor shall be required to follow all these provisions and

specifications while manufacturing, supplying. Installing, testing and commissioning

of the various gates

2.1.2 Not with standing whatever has been mentioned either in the schedule of quantities

or description of the item or the technical specifications, the contractor shall be

responsible for the supply of all the required parts installation and items of work in

under to make the final installation of gates fully operative and functional. In order to

fulfill such obligation the contractor shall, if necessary, supplement the Drawings and

mention such modifications while tendering in order to ensure thoroughly

satisfactory performance of these gates the cost of such variation shall be deemed to

have been included in the rates.

2.1.3 TOLERANCE:

Various tolerances of embedded parts and component of gates, stop logs, embedded

parts has been given in Appendix ‘A’ attached to these technical specifications. These

will have to be adhered at the time of fabrication and should assembly as well as

during the supervisions installation, commissioning and test ion of the gates, stop

logs etc. With all accessories.

2.1.4 APPLICABLE STANDARDS/PUBLICATIONS ETC:

The fabrication as well as the material of construction shall conform to the respective

latest edition of the Indian standard specifications and other publications listed in

Appendix ‘B’ of the Technical Sections.

2.2 VERTICAL LIFT TYPE SERVICE GATES:

Item: Supply and erection of vertical lift type gates of various sizes with embedded

parts and ancillary equipments including design, fabrications and erection of pylon

along with providing, erecting of suitable capacity for erection hoisting of gate along

with adequate power supply arrangements from M.S.E.B. and auto-generator system

etc. Complete.

2.2.1 GENERAL REQUIREMENTS:

The supply of the these items and embedded parts required for these shall be as per

drawings and specifications.



SP 28

The vertical lift type service gate has been designed for a maximum head of 4.50 m

meters and is a fixed wheel vertical lift thpe gate with U/s skin plate and U/s

sealing arrangement. 27 service gates are required to be provided for clear openings

of various size {height}. The gates shall be designed as per recommendations given in

IS 4622-1992

The salient details of the gate area as under:

1. Clear opening size As per detail design vetted from CDO

2. Gate leaf size

3. Design head 4.50

4. Sill level 412.00

5. No. Of openings 27

6. No. Of gates 27

7. Hoisting arrangement Mechanical Hoists 27 Nos.

8. Hoist capacity approx 25 M.T.

9. A. Closing time 10 Minutes

b. Openings time 10 Minutes

2.2.2 The gate is rather large and may pose transport problems. Therefore the gate leaf

proposed to be manufactured in pieces and assembled at site. The contractor shall

review the split up ot the gate leaf into pieces and reassembling at site or may suggest

alternative methods. Side seal and top seal shall be of double stem type fluorocarbon

laded reinforce rubber seals and the bottom seal shall be wedge type or rectangular

type rubber seal.

2.2.3 The Gate has a structure of U/s skin plate supported by a framework of horizontal

girders and end vertical channel of structure steel. The wheels are to be attached to

the end vertical with a roller pins of chrome Nickel and spherical, roller bearing. The

gates shall be operated by wire rope of high alloy steel.

2.2.5 WHEELS:

2.2.2.1 The wheels have been designed as provided as per provisions of Is-4622-1992 and are

without flanges. The treads of the wheel shall be crowned to accommodate gate

defection under the heaviest load which shall not be greater than.1/800 of the span

(i.e. center to center distance between wheels). The wheels shall be machined true and

shall operate smoothly without vibrations and without under going any drifts. The

radius of crowing of wheel shall be such that the central rise shall not be greater than

1.6 mm

2.2.5.2 The wheel pins shall be of corrosion resistant steel and shall be supported at two pints

at the web of the end vertical girder and to the stiffener plate. Grease fitting shall be



SP 29

provided to permit greasing of the bearing at an easily accessible location and suitable

shall be suitable stiffened against bearing and tearing. The pins shall be given 5mm

eccentricity to permit alignment of wheels.

2.2.5.3 The wheel bearing shall comprise of a single self aligning spherical roller bearing of

SKF make (size 160*400 No. 23032) or equivalent. The bearing shall be suitable for

underwater use and shall be suitably sealed to prevent ingress of silt. A suitable

arrangement for greasing the bearing shall be provided. The outside diameter of the

bearing. Mild steel retains shall be provided to retain wheel bearings in position. Oil

seals and ‘0’ rings etc. Shall be provided to ensure that the assembly is leak proof.

Other fixtures like licking plate, Vermeer plat. Cover plate etc. Of mild steel shall be

provided as shown.

2.2.6. GUIDE ROLLING AND GUIDE RAILS

2.2.6.1 For limiting lateral motion of the service Gate. Guide Rolling shall be

provided as shown n the drawings. The rollers shall be adjustable and shall travel on

guide rails securely welded to the slot-liners. The faces of the rollers shall be slightly

crowned. The guide rollers shall be provided with bronze bush rotating on fixed steel

pins. Suitable arrangement is for the lubrication of the rollers shall also be provided.

The guide rollers and the pins shall be of corrosion resisting steel (BHN-170

conforming to IS-1570, Part-V-1985) and the guide- rail shall be standard crane rail of

structural steel weighing 45 Kg/M. The rollers shall be machined true to the specified

shape and shall operate smoothly without vibrations or jerks.

2.2.6.2 The guide bracket shall be of structural steel conforming to IS-2062-1984 and the

wheel pins shall be greasing arrangement shall be provided to permit greasing the

bearings easily and suitable reuse-nipples shall be provided in the pin for this

purpose . The guide- rollers shall be provided with roller bearings, as shown totting

on a fixes steel pin

2.2.7 SEALS AND ACCESSORIES

The specifications for the side seals, top seals and bottom seals for the Service Gates

shall be applicable.

2.2.10. SEAL SEATS, SEAL-BASES, SILL-BEAMS:

2.2.10.1 Top and side seal seats shall be of stainless plates conforming to IS-1570-part-V—1985.

The width of the seal seats shall be as shown in the enclosed drawings. Seats shall be

welded to the seal-base-plates, Which shall be of structural steel, fusion welding



SP 30

quality. The surface finish of the seal seat shall be machined smooth , within a range

of 1.6 to 6.3 microns. Rounding of edges and other details as per drawing & IS-4622-

1992 shall be followed to prevent damage to the rubber seals during gate operation.

2.2.10.2 The faces of side seals shall be in common plane within 1/2 mm without offsets of

gaps or joints. The seal seats shall be fastened to the structural steel base plates in such

a way that smooth surfaces shall exist over the entire seal area. The base joints

between the seal-seat shall be finished smooth and when assembled the joints shall be

ground flush and shall but closely enough to ensure watertight joints.

2.2.10.3 The bottom seal plates shall also be of stainless steel which shall be welded to the

invert-steel liner of structural steel. The surface finish of the bottom seal plate also

should be same as for the side seal- plates mentioned above and shall be placed flush

with the surrounding steel lining or concrete surface as the case may be.

2.2.11 EMBEDDED PARTS AND SLOT-LINERS:

2.2.11.1 These shall comprise of the slot plates, guide-rails plates, track-grinders, seal-seal

plates (base-plates, sill beams, turn buckles and any such fittings which shall be

necessary to firmly attach the seal plate, track plates, guide-rails etc. To the

surrounding concrete of gate-slot and shall be fabricated and installed as shown in the

respective drawings.

2.2.11.2 The track-plates shall be corrosion resisting steel and shall be welded to the slot-liner

plate, which shall be of structural steel (Fusion welding quality) or fixed to the track-

girder by means of countersunk screw made of high-tensile steel. The holes in the

track plates shall be counter sunk so as to accommodate the conical head of the screws

so that the screw head shall remain.1.00 mm below the surface of the bearing/track

plate. The surface finish of track-p;ate in contact with the wheel of the gate shall be

within the ranges of 1.6 to 6.3 microns conforming to 1-30731967 assessment of surface

roughness (with amendments 1 to 3)

2.2.11.3 The track- plates seal plates, guide rails etc. Shall be fitted to welded to as the case

may be to the slot-linear made of plates of structural steel fusion welding quality

conforming to IS-20621984 (Third revision ,reaffirmed 1992) as per details shown in

the respective drawings by welding process. The slot-liner shall be provided with

anchor blots, anchor bolts. Anchor cleats, and plates and other such fixtures as shown

in the drawings.



SP 31

2.2.11.4 The sill-beam shall be of standard roller I-section of structural-steel or fabricated out

of plates of structural steel. To the top flange of the sill-beam shall be fixed a steel

base-plate on which the stainless steel plate shall be welded as shown in the drawings

. To the bottom flange shall be welded anchor plates and anchor bolts etc. For

property anchoring the sill beam to the invert concrete. The machining finish of the

seal plate shall be within the range of 1.6 to 6.3 microns and it shall be placed flush

with the surrounding steel lining or concrete surface as the case may be.

2.2.11.5 The Contractor is to supply embedded parts for all the items as per drawing. These

embedded parts shall be installed at site and embedded into the surrounding concrete

of gate slot by the respective Civil Contractors. The Contractor shall however help

/Co-operate with them in this task by giving alignments during the erection work , by

giving instructions in writing and by appointing representatives and by providing

allied parts like tom-buckles, additional stays, matching plates ancillary equipments

shall be erected, tested and commissioned by the Contractor. The second stage

concrete behind the steel lined gate grooves shall be tested (though hammering) for

detection of any hollow gaps and shall be appropriately grouted by the Civil

Contractor to fill up the hollows, If any.

2.2.12 FABRICATION OF GATE LEAF AND EMBEDED PARTS:

2.2.12.1 All the components of the gate leaf and the embedded parts shall be manufactured

using the specified materials and the best engineering practices. All tolerances and

allowance shall be as per relevant IS-codes and other codes listed in Appendix-B of

the specification. The gate, gate frames and embedded part shall be fabricated from

the steel plates and rolled steel structural rolled sections or other materials as

specified in the drawings attached and shall be of welded construction. Field joints, if

any, Amy either be welded or bolted as specified (or approved) not shall be

watertight.

2.2.13 ANCHORAGES:

Anchorages in the concrete and rock shall be provided by the respective Civil

Contractor or the Engineering in Charge. The contractor shall however study the

details of these anchors and suggest any changes required for proper anchoring.

2.2.14 HOISTING DEVICE:

It is proposed to provide-twenty seven separate mechanical hoists for twenty seven

gates as shown illustratively in the layout drawings enclosed . The cost of providing .

erecting of hoist arrangement shall be deemed to be deemed to the included in this



SP 32

item. Techincal specification mentioned in paper 2-3 to 2.4.13 shall be applicable

suitable modification of items only if the premium of these items is motioned in

detailed designed barrage work

2.3.1.2 The gate opening is rather large , hence it is proposed to provide 7 pieces of stop

logs(i.e. one set of 7 pieces) size 12.00m (width)* 1.00m (ht) Each piece shall have 4

guide wheels, a pair attached to either side of the gate, Side seals shall be fo rubber

seals and the bottom seal shall be wedge type or rectangular type rubber seal.

2.3.1.3 The gate shall have a structural of D/s skin plate supported by three horizontal

girders and end vertical channels of structural steel, fusion welding quality(IS-2062-

1984) The guide wheels are to be attached to the end vertical channels with brackets

structural steel. The gates will be operated under balanced condition with the help of

a lifting beam. The stop logs shall be self lowering under their own weight.

2.3.2 GUIDE WHEEL AND GUIDE RAIL:

2.3.2.1 The stop-logs will be guided through the gate slot with the stop logs will be guided

through the gate slot with the help of guide wheels, 4 Nos, for each stop-log piece.

The wheels shall be of cost steel conforming to IS-1030-1989 and the guide rail shall be

standard crane rail of structural steel weighing 45 Kg/m . The wheels shall be

machined true to the specified shapes and shall be machined true to the specified

shape and shall operate smoothly without vibratos or jerks.

2.3.2.2 The guide wheel bracket shall be of structural steel. Grease fitting shall be provided to

permit greeting the bearings easily and suitable grease nipples shall be provided in

the pin for this purpose.

2.3.2.3 The bearings for the guide wheel shall be provided with roller bearings rotating or

fixes pins of high alloy steel.

2.3.3 SEALS AND ACCESSORIES:

2.3.3.1 The side seals and the top seal for the top most stop-log gate piece shall be of rubber

seals and the bottom seal of each stop log piece shall be rectangular type rubber seal.

The seal recompression shall be 5 min for the double stem seal.



SP 33

2.3.3.2 The bottom rubber seal shall be molded fro, natural or synthetic rubber containing not

less than 1 % by weight of copper inhibitor and shall have the following physical

properties.

1. Shore A Udometer hardness........... 65+5

2. Minimum elongation 450%

3. Minimum ultimate tensile strength 14.50 N/m

4. The rubber compound shall not absorb water more than 10% by weight in a 7 day

test.

5. The tensile strength of the test specimen after being subjected to an accelerated ageing

rest of 48 hr. In oxygen at 70 degree C and 2.1 N/mm2 pressure, shall not be less than

80% of the strength of the test specimen before ageing.

6. The material should be properly cured in manner to ensure dense homogeneous cross

section free from pitting ,blisters, porosity and other imperfections and the different

elements shall be well bound together

2.3.3.3 The side deals shall be rubber molded from natural or synthetic rubber having the

above mentioned physical properties. Fluorocarbon seal shall be bonded to the rubber

on the rubber on the sealing surface of the bulb. The outside surface of the

fluorocarbon sheath shall be free of adhering or bonded rubber. Fluorocarbon shall

have the following physical properties.

1. Minimum tensile strength.......... 14 N/mm2

2. Minimum elongation....... 250%

3. Minimum thickness of fluorocarbon film 1.50mm

4. Minimum area of cladding- Bulb surface covered in an angle of 120 degree subtended

at the bulb center.

2.3.3.4 Suitable rubber seals shall be provided and tested as per relevant is code.

2.3.3.6 The contractor shall carryout the testes required for measuring the properties of

rubber seals and fluorocarbon films at his cost and shall furnish the result to the

Engineer in charge.

For calculating the frictional force to the overcome. the following ‘friction coefficients

shall be adopted.

Material in sliding

Contract

Coefficient Starting Friction Moving

1] 0.20 0.15

2.3.3.7 The rubber seals shall be fixed to the gate by means of seal clamps plates with counter

sunk screws made from stainless steel. The holes in the seal clamps shall be



SP 34

countersunk to accommodate the conical heads of the screws. The edges of seal

clamps adjacent to seal bulb shall be rounded off.

2.3.3.8 The seal interference / pre-compression shall be 5.00 mm. The projection of the

bottom rectangular seal shall be 3.00 mm. Suitable chamber shall be provided at the

bottom of the skin plate/ clamps plate to accommodate the bottom rectangular seal in

compressed position.

2.3.4 WHEELS:

Suitable wheel arrangement shall be provided as per design requirement-

2.3.5.1 GUIDE WHEELS:

2.3.5.1 For limiting the lateral motion of the stop log gate four Guide wheel shall be provided

for each S.L. pieces as shown in the drawings. The wheels shall be adjustable and

shall travel on girder rails (45 K/gm) securely welded to the slot liners and embedded

in the surrounding concrete. The faces of the wheels shall be slightly crowned. The

guide wheels shall be provided with Bronze bush rotating on fixes steel pins. Suitable

arrangements for lubrication of these rollers shall be provided.

2.3.6 LIFTING LUGS /BRACKETS:

2.3.6.1 A Pair of lifting brackets of structural steel shall be Provided for each stop log Piece as

shown in the drawing and welded to the web of the top horizontal girder , for

handling during transport and operations. The fitting brackets shall be located in a

vertical plane passing through the center of gravity of stop log piece. Suitable slots

shall be provided in the web of the bottom horizontal girder of each stop log piece

(except the bottom most piece) for accommodating the lifting logs of the stop-log

piece below,

2.3.7 SEAL SEATS, SEAL SEST BASES , SEAL BASES:

2.3.7.1 The seal seat plates shall be of high grade stainless steel and of dimensions shown in

the respective the seal seat plates shall be welded to the seal-seat- base. Plates or slot

lining plates as the case may be. The seal-beats shall be finished smooth within a

range of 1.6 to 6.3 microns. The edges of seats shall be suitably rounded /chambered

as indicated in Drawing and is -4622-1922, to prevent damage to rubber seal during

gate operation.



SP 35

2.3.7.2 The faces of side seals, seals and bottom seals shall be in a common plane within “/4

mm without off sets or gaps or gaps or joints. The seal seats shall be festered to the

structural steel base plates in such a way the such smooth surfaces shall exist over the

entire seal area. The but joints between all seals seat sections shall be finished smooth

and when assembled the joints shall be ground and shall but closely enough to ensure

watertight joints.

2.3.8 EMBEDDED PARTS & SLOT-LINERS:

2.3.8.1 These shall comprise of the slot-lining-plate, guide-rails, track plates, track girders,

seal seat plats (base plates), anchor-bars/ bolts, cleat angles anchor-plates, sill-beams,

torn buckles etc. And shall be fabricated and installed as per the details shown in the

respective drawings.

2.3.8.2 The track plates shall be corrosion resisting steel and shall be fixed to the track girder

(of fusion wieldable structural steel ) by means of countersunk screws of stainless

steel. The holes in the in the bearing plates shall be countersunk so to accommodate

the conical head of the screws so that the screw head shall remain 1,00 mm that the

screw head shall remain 1.00 mm below the surface of bearing plate. The surface

finish of the track-plates in contact with the bearing plate shall be within a range of 1.6

to 6.3 microns con forming to Is -3073-1967) Assessment of surface roughness (with

amendments I to 3 ).

2.3.8.3 The seal plates on which the rubber seals beams bear / slide (side, top and bottom)

shall stainless steel and of dimensions given in the drawings.

2.3.8.4 The track- plates, seal-seat-plates, etc. Shall be fitted to or welded to, as the case may

be to the slot – liner made of fusion welding quality, structural steel conforming to Is

20621984 (third revision, reaffirmed 1992) as per details shown in the respective

drawings by welding process. The slot –liner shall be provided with anchor-

bolts/bars, anchor-cleats and plates as shown in the drawings.

2.3.8.5 The sill-beam shall be of standard roller I section of structural steel. To the top flange

of the sill beams shall be fixed a structural-steel plate at top and anchor plate pieces

and anchor bars shall be welded to its bottom flange for proper anchorage in the in

the invert-concrete. The machining finish of the top steel plate shall be within a rage

of 1.6 to 6.3 microns and shall be placed flush with the surrounding steel lining or

concrete surface as the case may be.



SP 36

2.3.8.6 The contractor is to supply embedded parts for all item as per drawing. These

embedded parts will be installed at site by the respective Civil Contractors. The

Contractors, shall however help / co-operate with them in this task by giving

alignments during erection work, by giving instruction in writing and by appointing

representative and by providing allied parts like turnbuckles, additional stays,

matching plates etc. Rest of the components/equipment like gate leaves, E.O.T.

cranes, hoists etc. Shall be erected, tested and commissioned by the Contractor. The

second stage concrete behind the steel lined gate grooves shall be tested (through

hammering) for detection of any hollow gaps and shall be appropriately grouted by

the Civil Contractor to fill up the hallows, if any.

2.3.9 FABRICATION OF STOP-LOG GATES AND EMBEDDED PARTS :

2.3.9.1 All the parts of the gate to be fabricated shall be manufactured using the details and

material specifications given in the drawings and the best Engineering particles. All

tolerances and allowances shall be as per the relevant IS codes and codes listed in

Appendix –B of the specifications and as per Appendix –A of this section.

2.3.9.2 The gates, gate frames and embedded parts shall be fabricated from steel plates and

rolled sections of structural steel or other materials as specified in the drawings

attached and shall be of welded construction. Field joints, if any, may either be

welded or bolted as specified but shall be watertight.

2.3.10 ANCHORAGES :

Anchorages shall be provided in the first stage concrete / rock, with suitable block

out openings, to hold the embedded parts during the second stage concrete. These

will be provided by the respective Civil Contractors or a Govt. The Contractor shll

however study the details of these anchors and suggest any changes required.

2.3.11 LIFTING BEAM :

One lifting beam shall be provided as grappling device for pacing or removing the

stop logs. Lifting beam shall be fabricated as per enclosed drawings and of materials

shown there in and shown herein and shall be in accordance with IS-13951-1922

criteria for design of lifting beams. It shall operate efficiently under water and

arrangements to guide the hooks in grappling position shall be provided. Main rope

and guide with shoes / wheels shall be such as to ensure smooth travel on wheel

track / guide rail of the stop-log gate. The contractor shall supply the main lifting

wire rope and other accessories along with the Goliath crane as per drawings.

2.3.12 HOISTING DEVICE :



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It is proposed to provide one E.O.T. (Gantry (Goliath) Crane for the three stop-log

shafts as shown illustratively in the layout drawings enclosed. The amount of crane is

deemed to be included in the rate quoted for this item.

2.4 GOLIATH CRANE :

2.4.1 SCOPE OF WORK :

2.4.1.1 The scope of work shall comprise of the following :

Manufacture, supply on project site, verification of equipments delivered, handling,

loading, transport, unloading of the goods at / from store sheds at project erection,

testing and purring into use to the following equipment as per detailed specifications

Covered in this document.

i) One number of 20 MT capacity, outdoor type electrically operated traveling

(Goliath) gantry crane of span 5.65 m and a bay length of 200 m. Suitable for

operation from floor through pendent push button control, complete in all respects

including a pair of gantry rails for full bay length, cables down shops leads,

electrical and mechanical equipment, electric wiring, control panels etc. Complete

for the two stop-log gate structure.

2.4.1.2 The scope of work for the above items shall also cover the followings :

i) Providing load for overload test and rated load test at shop and site for each crane.

ii) Supplying and providing proper ear thing for each crane structure, motor frame and

metal cases of all electrical equipment.

iii) Providing the necessary equipment to connect the maintain coming supply cable with

down ship leads / cables of the cranes together with the main switch before the down

ship / leads / cables for each crane.

iv) First filling of the oil, consumables, greases ets. For each crane.

The work pertaining to the cranes and accessories covered shall be undertaken and

completed from the design stage up to and included commissioning and putting to

use the entire equipment.

2.4.2 APPLICABLE STANDARDS :

E.O.T. cranes and associated equipments and accessories shall comply fully with the

provisions stipulates in this section. These provisions are based on Indian standard

specifications (IS) mentioned below. In. Case of non-Indian Contractor, Engineer in

charge may accept other standards provided these ensure equal or higher quality than



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the stipulations mentioned in these specifications. In that event the contractors is

required to furnish copies in English of such Standards along with the tender.

a) IS-807-1976-Code of Practice for design, manufacture, erection and testing,

(Structural portion) or cranes and hoists.(First revision);

b) IS-3177-1977-Code of practice for design of overhead traveling cranes and

gantry cranes other than steel-work cranes (First revision);

c) BS:482-Wrought Iron & mild steel hook or equivalent IS.

d) IS-3443-1980-Crane rail sections (First revision) (Reaffirmed 1987);

e) IS-5749-1970-Forged Ransom Hooks or BS:3017-Ramshom Hooks.

Note : IS – Stands for Indian Standard Specification.

BS – Stands for British Standard Specification.

2.4.2.2 All other associated equipment / material such as steel, castings wire ropes, welding

work, motors cables, conductors and switchgear shall conform to the relevant Indian

Standards equivalent IEC code or internationally accepted Standards.

TYPE AND RATING :

The Goliath cranes covered under these specifications shall be designed and manufactured to

comply with the following particulars.

Sr.No. Particulars 20 MT Crane for stop log

i)

a) Type Class Outdoor type Double girder

Goliath Crane suitable for

Operation from floor level

through pendent push button

control, for occasional duty, class



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II.

b) Number of Cranes One

ii)

Capacity (Safe working load)

a) Main Hook

b) Aux. Hook

20 Tones

Not Required

iii) Span (distance between centre of gantry rails

mm.)

5650 mm

iv)

Desired max. Operating speeds.

a) Hoist, meters / minute

b) Longitudinal Travel

c) Cross Travel, meters/ min

d) D) Micro speed for main hoist, meters /

min.

5.00 or more

10.00 meters / min

About 2.00

About 0.25

v)

Mode of operation

a) For Hoist Motion

b) For Long Travel Motion

c) For Cross-Traverse Motion

Electro-Mechanical

Electro-Mechanical

Electro-Mechanical

vi)

Maximum Clearances :

A. Distance from centre line of gantry rail to

the nearest side obstruction at gantry

beam level.

a. On Left Side

b. On Right Side

450 mm

450 mm

B. Vertical distance from top gantry rail to

The lowest overhead obstruction :mm

Sr.No. Particulars 20 MT Crane for stop log

vi) Maximum Hook approaches :

A. Nearest position of main hook to the

Nearest centre line if gantry rails mm

1500 mm

On right side of flow 1500

mm.On lift side of flow.

B. Max.end clearance of main hook upto

End stopper in the extreme end position

of the crane along the bay length (at

either end)

1500 mm



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C. viii) Hook lifts

Lifts of hook in mm with reference to

floor level (not less than)

A. Main Hoist

a) Above floor level

b) Below floor level

Not less than 20,000 mm

ix) Length of bay 220 mm

x) Type of gantry beams for erection gantry

rails

Steel Type

xi) Power supply 400 volts 10 % volts three phase,

4 wire, 50 Hz 3%, AC

xii) Wheel Details

a) Restrictions on wheel loading (without

impact suggested)

20 Tones

b) No. of wheels on each end carriage of

crane

and wheel base suggested

2 Nos. Not less than 1500

1. The maximum operation speeds which could be achieved shall be stated by the

contactor. These speed shall however be with 90 % to 110 % of hose specified.

2. The equipment to be supplied shall be suitable for satisfactory operation under the

climatic conditions at site mentioned under project description. All parts and surfaces

which are subjected to corrosion, due care shall be taken to project the same from any

injurious effects of excessive humidity.

2.4.4 SERVICE CONDITIONS:

The cranes shall be deemed under service conditions when there are handling (i.e.

Lifting and lowering, holding or traveling and cross traversing at the prescribed

speed. – any load from self weight up to the maximum load for which the cranes are

designed. The cranes are likely to be used for erection, concreting etc.

2.4.5 RATING PLATE :

The bottom block shall bear a permanent inscription on each side, which shall be

readable from the floor level stating the safe working load on the main hook.

2.4.6 STRUCTURE :

The crane structure is designed for the worst conditions of loading care being taken to

allow for the impact factor patria forces including shock and the lateral thrust etc. In

accordance with IS:807-1976. All there structural parts of the cranes shall be fabricated

from tested wieldable quality steel conforming to IS:2062, test certificates for which



SP 41

shall be furnished to the Engineer in charge by the contractor before taking up the

fabrication work, The crane structure shall as per drawing and actual stresses for the

severest combination of loads are not exceed the permissible stresses in accordance

with the above mentioned Para “Factor of Safety”.

2.4.7 CRANE BRIDEGE:

2.4.7.1 The crane bridge girder is designed in accordance with IS 807-1976 and also standard

specifications. The girders for the crane bridges shall be of lattice box-type or lattice

type trusses or any other suitable type construction approved by the engineer in

charge and shall be fabricated from tested weld able quality steel confirming to I.S.

2062-1984. Welded girder construction shall be designed to carry safely the load of the

crane without undue vertical or lateral deflection of vibration. The bridge girders and

beams shall be so designed that in addition to complying with the requirements of

allowable working stress etc. As per previously mentioned paragraphs above. The

vertical deflection caused by the safe working load with the crab in the central

position of the bridge shall not exceed 1/900th of span.

2.4.7.2 The crane is of anti-vibration design. The crane girders and beams is designed so as to

limit the natural vibration damping time to less than 15 seconds. The damping of

vibration in the structure shall be submitted to the Engineer in charge.

2.4.7.3 A platform of chequered plating, minimum 1200 mm clear width and property

guarded with double tired tubular hand railings 1200 mm high and toe guards fo a

minimum height of 100 mm shall be provided on both sides of the crane, throughout

the span.

2.4.7.4 Track shall be provided on the top of the crane bridge girders for travel of the crab.

2.4.7.5 All parts in the crane shall be readily accessible for maintenance for easy assembly /

erection at site all parts of the crane structure shall be aligned and match marked at

works before dispatch.

2.4.8 CRAB :

2.4.8.1 The frame work shall be fabricated from rolled structure steel sections conforming to

IS: 2062-1984 fully welded together and shall carry the necessary hoisting and cross

traversing equipment.



SP 42

2.4.8.2 Jacking points for crab should be clearly marked and noted on the crane. Necessary

jacking pads shall be provided for this purpose.

2.4.8.3 The ends of the traversing rails shall be fitted with end stop to prevent over traversing

of the crab. Rubber buffers shall be provided for the crab. Wheel skids shall also be

provided for cross travel motion.

2.4.9 END CARRIAGE :

2.4.9.1 The end carriage shall be fabricated from the rolled steel sections and shall be of rigid

box section of one piece construction provided with suitable diaphragm palter. The

wheel base shall be not less than one faith of the span. The ends of there traveling rails

shall be fitted with end stops to prevent over-running of the crane. Rubber buffers

shall be provided on end carriage. The end carriage shall be fitted with suitable

guards to prevent the crane from derailing. It shall be provided with suitable jack

pads on both the ends. The jacking pants shall be clearly marked and noted on the

crane.

2.4.9.2 The end carriage shall be designed so as to enable the track wheels have been

withdrawn readily. Suitable arrangement for locking of the provided on each of the

end carriages at both the ends. Mechanical jack of suitable capacity and lift shall be

provided for the inspection / replacement of wheels of end carnage and crab.

2.4.10 WHEELS & BEARING HOUSING ASSEMBLY :

2.4.10.1 All the wheels of the crane and the crab shall be double flanged. The shall be of forged

steel and suitably hardened.

2.4.10.2 The hardness at the surface shall be approximately 350 BHN gradually reducing

inwards unto 280 BHN at a depth of 15 to 20 mm. The materials of the wheels shall

be C-55-MN-75. All the wheels of the crane and crane and crab shall be housed in ‘L’

type bearing housing assemblies on either side of the wheels for easy removal and

maintenance. The bearing provided shall be spherical roller bearings.

2.4.11 GANTRY RAILS :

2.4.11.1 The contractor shall supply the gantry rails continuous sole plates, anchors and

necessary fixtures etc. For the total travel of the crane. The gently rails shall be of size

not less than the specified one flat bottom type and shall be suitably clamped to the



SP 43

sole plate thought the length the including and stoppers and anchored suitably. The

detailed drawings for this shall be given by the contractor for the approval of the

Engineer in charge. Except at end portion or machine place the rail shall be supplied

in standard length.

2.4.12 LONG TRAVEL MACHINERY :

2.4.12.1 The long travel motion machinery system shall consist of a totally enclosed il

lubricated horizontal type reduction gear box fitted on the bridge is driven b in

electric motor. The output shift of the gear box shall extend on one side and coupled

to the Tong travel shift which drives one the of each end carriage bridge. The entire

transmission system on the output shift of the long travel gear boxes shall be

designed with use geared flexible coupling.

2.4.12.2 Totally enclosed self resetting two way lever type limit switches shall be provided to

limit over traveling of the bridge in both directions. Electro-hydraulic thruster

operated brake shall be provided on long travel motion which applies automatically

when the current supply of the crane is “Off” and brings the end carriage to a stop

without any shock.

2.4.13 CROSS TRAVERSE MACHINERY:

2.4.13.1 Wherever specified the cross traverse wheels of the crab shall be driven by an electric

motor through totally enclosed oil immersed speed reduction gears having machine

cut teeth entire transmission system on the output shaft of the cross traverse gear box

is designed with use of geared flexible coupling. An electro-hydraulic thruster

operated brake with applies automatically when the supply is off shall be provided

to bring the crab without shock. Totally enclosed self resting two way lever type

limit switches shall be provided to limit over traversing of the crab in both direction.

2.4.14 HOISTION EQUIPMENTS :

2.4.14.1 The hoisting equipment shall consist of fabricated mild steel rope drums conforming

to the relevant Indian Standard or British Standards and driven by an electric motor

through a totally a enclosed oil enclosed oil immersed speed reduction gear.

2.4.14.2 The rope drum shall have machined to split the hoisting rope. The drum will be of

such size that there shall not to be more than one layer of rope on the drum when the

rope is fully wound. Also length of the drum shall be such that each lead of rope has



SP 44

a minimum of two full turn on the drum when the hook is in the lowest position not

taking into account the turns covered by anchorage and one spare groove for each

rope lead when the hook is in highest position. The coupling between the hoist gear

box and rope drum shall be with flexible joint. The machine cut grooves shall be

similar on both sides of the drum so as to ensure equal distribution of the load on the

two main beams of the crane bridge. Grooving shall be free from surface defects

liable to injure the rope. Rope anchorage shall be easily accessible. Rope anchorage

shall be easily accessible. Rope drum shall be duly stress relieved, fabricated from

low carbon content steel.

2.4.14.3 A pulley block with cast steel pulleys with ball bearing shall be provided with

guards to prevent the ropes leaving the sheaves when the hook is lowered to rest on

the ground. The sheaves shall be machine grooved to a depth of not less than 1.5

times the diameter of the rope. The grooves shall be finished smooth and shall be

free from surface defect likely to injure the rope.

2.4.14.4 The hook for the crane shall be “Ram shorn” type and shall be of forged steel and

tested for proof load. The hook shall be carried in a thrust bearing with freedom to

swivel and shall conform in all respect to the B.S.No.3017. Special precaution shall be

taken to achieve an absolutely vertical movement of the hook. A locking device shall

be fitted to prevent rotation of the hook whenever required. It shall be possible to

lock the hook in any position. The hook and block shall be arranged to lift or lower

without twisting or horizontal shifting. The snatch block shall be fitted with guards

to prevent the rope from leaving the pulley. Certificates giving actual chemical

composition and physical properties for the hook material shall be forwarded in

original.

2.4.14.5 The hoisting rope shall be of the best plot steel standard construction having the

breaking strength in accordance with IS:2266-1989. The factor of safety under

working condition shall not be less than six (6). The diameter of outer wires of the

rope and the diameter of sheaves shall be so chosen that the wire rope shall have

sufficient fatigue resistance to withstand the effects of bending and vibrations. The

diameter of out wire, the grate of wire and the distribution of wearing surface shall

be so selected as to have sufficient abrasive resistance. The supplier shall clearly state

the methods adopted for selecting the diameter of outer wires as careful balancing of

above properties is essential in selecting the same.

2.4.14.6 The lay of the rope and the number of stands shall be so selected that the rope shall

have sufficient lateral stability. The electro hydraulic thruster operated brake shall be

provided with adequate margin of safety to hold the load to prevent it form coming



SP 45

down when the current supply to the hosting motor is cut off accidentally or

inadvertently. In addition, a three phase solenoid brake of aim dash dot type for

main hoist shall be fitted on the extension shaft of motor for emergency use. Totally

enclosed self resetting positively acting two way rotary type limit switch shall be

provided to prevent over winding and over lowering of the hook.

2.4.15 MECHANICAL BREAKING:

A mechanical load brake shall be provided in the hoist mechanism of goliath cranes

to hold the load in the load in the event of failure of electricla brake. T brake shall be

capable of preventing over speeding. The design of the mechanical load brake shall

be such that downward sleeping of the load is eliminated and accurate positioning of

load is possible within 23 mm.

2.4.16 MICRO SPEED ARRANGEMENT :

To achieve precision while lowering and hoisting the main hook at the 5% of the

speed of main hoist, the hoisting machinery shall be equipment with a micro speed

arrangement through a separate motor and planetary gear box.

2.4.17 BRAKES :

2.4.17.1 All brakes are designed for continuous service conditions having a brake torque of

not less then 150 % of full load torque. The rubbing surface of the brake drum, small

be accurately machined and shall be free from surface defects. The brake drum

balancing shall be carried out and hardness checked. The rubbing shoes of all brakes

shall be self aligning and lined with renewable as best of or Ferrodo lining. The test

report for this shall be submitted by the supplier. The brakes shall be provided with

simple easy and accessible mews of adjustment of the lining. The terminals of the

brake managements shall be protect from, accidental contact and the winding shall

be effectively shall be effectively protected from mechanical damage from accidental

contact and the winding shall be effectively protected from mechanical damages and

weather exposure wherever necessary.

A) 3 phase solenoid brake for hoist motion comprising :

i) AIR DASH POT TYPE SOLENOID:

He brake shall be applied gently without giving jerks.

ii) ELECTROMAGNET :

A.C. Phase electro magnet shall be totally enclosed with removable side

covers for easy maintenance Magnet lamination shall be high grade low

magnetic steel lamination. Coils shall be wound on thoroughly insulated

bakelite bobbin.

iii) COMPRESSING SPRING :



SP 46

Spring shall be made and properly heat treated to give correct hardness.

When the power to the crane is switched off the compression springs shall

provide working pressure to apply the breaks. When the magnet is energized

the solenoid shall exert force against a spring pressure releasing the brakes.

2.4.18 EMERENCY BRAKING :

2.4.18.1 All the brakes shall, irrespective of Controller’s positions, be applied immediately

on pressing of an emergency stop push button assembly.

2.4.19 LUBRICANT :

2.4.19.1 Provision shall be made for lubrication all the bearings. Ball and roller bearings

shall be suitably lubricated before assembly.

2.4.19.2 The lubrication tubes individual points of each group will be brought to a single

board on crab for ease of maintenance. However, the number of such groups shall

not be more than five.

2.4.19.3 A lubricating chart shall be provided indicating all lubricating points, the type of

lubricant or recommended frequency of lubrication. The lubricating nipples

adopted and tubes shall conform in all respects to the relevant to the relevant Indian

Standard equivalent British Standard. The lubrication tubes shall be dispatched

separately and not minted on the main structure, as they are liable to be damage in

transit.

2.4.19.4 The contractor shall supply sufficient quantity of lubricant for the first filling

together with hand greasing gun free of cost.

2.4.19.5 GEARING & GEAR BOXES

2.4.19.6 All gearing for the crane shall be precision machine cut and shall have involutes too

the with a pressure angel of 20 degrees. The gears and pinions shall be forged from

C-55-Mn-75 material and they shall have minimum hardness of 240 BHN. They

shall have a factor of safety not less than 6 (six) under server working conditions.

2.4.19.7 Gear boxes shall be fabricated from the mild steel and they shall be totally enclosed,

dust proof, oil bath type, and will have un split oil sumps. The gear boxes shall be

provided with inspection converse to enable a visual inspection of the working



SP 47

parts, of level gauges shall be provided wherever necessary. Facilities for oil filling,

adequate breathing and drainage shall be provided. The gear couplings shall be

forged from EN 8 material and shall have minimum hardness of 250 BHN. The

fabricated gear boxes shall be stress relieved before machining.

2.4.20 OPERATION OF CRANE:

2.4.20.1 The various operations of the crane namely hoisting, lowering, cross travel, long

travel and emergency braking etc. Shall be possible to be performed from the

respective floor level for which pendant push button control shall be provided.

Pendant control shall be provided at a convenient position on one side of the bridge

with adequate cable length with supports so as to have a free and unobstructed

motion / operation on the crane from the floor and shall afford full cross traverse

motion to be performed without the operator (with pendant control) requiring to

move along with :’e crab assembly. It shall be provided with adequate guards to

prevent accidental contacts of the pendant ropes or chains with down shop leads.

The electrical circuits of pendant control shall be energized at not more than 110

volt. A.C. All controlling devices shall automatically return to off position

immediately after they are released. One off push button shall be lockable type so

that control power is switched of in positive manner when he crane is not in use.

2.4.20.2 The pendant switch shall be capable of with standing rough handling without being

damaged and cover shall be effectively secured.

2.4.20.3 The mass of the pendant shall be supported independently of the electrical cable by

means of the chain or rope. If the pendant is of metal it shall be effectively earthed.

A chain or hook does not provide an effective earth connection and should not be

relied upon for that purpose. On all pendants controlled cranes means shall be

provided to prevent inadvertent operation fro the floor while maintenance work is

being carried out on the crane. An isolator fitted on the crane bridge shall not be

operative from the floor through the pendant.

2.4.20.4 Pendant control shall also be provided with accessories such as alarm bell and

switching (on/off) of the crane lighting circuit.

2.4.22 WALKWAYS, LADDERS AND HAND RAILINGS :

2.4.22.1 Safe means of access shall be provided to every place where a person is expected to

examine and inspect / and perform maintenance work on the crane. Adequate hand



SP 48

railing and foot holds shall be provided wherever necessary. All walkways shall be

of chequered plates open edges of which shall be provided with to guards of min.

75 mm height All hand rails shall be of tubular pipe and double tiered. Chequred

plate platform of min. 750 mm clear width shall be at same elevation throughout its

length, Similarly chequered plate platform attached to each girder along with

necessary equipment shall also be provided for inspection of down shop leads and

the arrangement shall be got approved from Engineer in charge.

2.4.23 ELECTRIC MOTORS :

2.4.23.1 All electric motors shall be totally enclosed drip proof slip ring induction motor

suitable for the crane duty. All motors provided shall be of the same make. The

motor shall comply with Indian Standards 325-1979 or equivalent British Standards

and shall be suitable for frequent acceleration and braking. All the motors shall be

rated at 125 % of the rated output at 10 tune starts per hour & 10 stops per hour

class of duty at ambient temperature and they shall have class ‘B’ insulation and

shall be one hour rated for hoist motion and one hour rated for all other motions

with temperature ruse not exceeding 50 deg. C. Over ambient temperature of 40 dg.

C. Over ambient temperature of 40 deg.c. rating. Motors shall be so located that the

brush gear and terminals shall be readily accessible for inspection and maintenance

purposes. The pull out torque of any motor supplied at rated voltage shall not be

less than 2.25 times the rated torque.

2.4.23.2 A motor shall be suitable for voltage fluctuating between 10 % or rated value and

for all motions, minimum pole motors shall be provided. All motors shall have

grease-lubricated ball and roller bearing at non drive and drive ends respectively.

Cartridge type bearing housing shall be provided for hoist motor so that motor can

be dismantled without disturbing bearing and also for protection against dirt or

dust entering in bearing. For all other motors, the bearing shall be fitted in the

housing accurately bored and machined on and sealed with dust cap.

2.4.23.3 All motors provided shall be of the same make. All motors shall be suitable for

reversing, frequent acceleration and breaking. All motors shall e provided with

suitable anti condensation devices. Motors with rating permitting overloads ad

having construction and characteristics suitable for the specified crane service shall

be provided. All the motors shall have continuously rated slip amply dimensioned

to give long and trouble-free service.

2.4.24 CONTROLS :



SP 49

2.4.24.1 All motor control shall be fully magnetic reversing with definite time limit on

frequency controlled acceleration devices and instantaneous overload and under

voltage protection. The shall be designed so that it will be possible to limit the

vertical movement of the hooks with full rated load and when starting from

complete standstill of within 1.5 mm for the hoods and to limit the movements of

the bridges and trolley, with full rated load and when starting from complete

standstill, to within 6 mm. The contractors of all protective relays shall be so weird

that the operation of any relay will trip all motors, primary contractors, thus making

it necessary to return all controls to “OFF” position before any motor can be started

again. Instantaneous relays shall be adjustable between 200 to 300 percent of the full

load current of motor. All control switches, push buttons and other operating

mechanism shall be marked plainly and permanently.

2.4.25 CONDUCTORS AND RESISTORS :

The conductors and the resistors shall comply with the provisions of the relevant

clauses of IS-3177-1977. They shall be of the non-breakable, corrosion resisting, w

type with a low temperature co-efficient and shall be air cooled. The resistances

shall e of stainless steel grid type and of five minute rating. The resistances shall be

provided in well ventricles sheet metal boxes. The conductors an resistors shall be

adequately protected to prevent, accidental contact with live parts. Resistors shall

be so arranged that they are easily accessible for adjustment, examination and

replacement. care being taken to sea that its not affected by vibration. All

conductors and resistors shall be suitable for appropriate switching duty so as to

suit stipulated motor duties.

2.4.26 ELECTRICAL PROTECTIVE GEAR :

2.4.26.1 An air brake contactor type main circuit breaker shall be provided. It shall e fitted

with magnetic type invest-time’s elements overload relays and under volt tripping

device acting instantaneously in case the supply voltage drops below 80% of its

normal value. The under volt tripping device shall be capable of being used for

tripping the main circuit breaker in emergency. The main circuit breaker shall be

electrically interlocked with the controller in such a way as to prevent the current

supply being reinstated unless all controllers are in the “OFF” position. All this

protective gear shall be of reputed make to e approved by the Engineer in charge.

2.4.26.2 All crane motors shall be provided with circuit breaker with instants magnetic

relays fitted in two phases for protecting the motors against short circuit and shall



SP 50

be also protected against overload by reliable type thermal relays, fitted in each

phase with setting for adjustments between a range of 90% to 190 % of the rated

current. Single Phasing protection shall be provided.

2.4.26.3 A complete wiring diagram of all electrical connections from the main switch of the

respective appliances shall be fixed at suitable position for ready reference. On this

diagram shall be given the rating of each of the motor the cable sizes and such other

information as well to facilitate inspection and maintenance. Similar diagrams but

showing the inside connection of each of the controllers and the main circuit

breakers etc. Shall be fixed to the inside of the covers of the controllers and the

switches. Suitable transformer for low voltage supply with switch fuse shall be

provided. The protective panel shall be located at convenient position and shall

include but not limited to the following items :

i) Main isolating switch interlocked with panel door;

ii) Main air brake contractor type main circuit breaker;

iii) Overload relays of magnetic type for the main incoming supply and for each

outgoing

feeder of the motors;

iv) Indicating lamp for main contractor;

v) Emergency push button for main circuit breaker;

vi) Separate circuit breakers for individual motors;

vii) Plug and socket connection to hand lamp;

viii) Transformer for low voltage supply;

ix) One voltmeter with selector switch and one ammeter with selector switch for

main incoming supply;

x) Ammeter for each motor; and

xi) Three indicating lamps showing the status of three phase main incoming

supply (live of

dead)

2.4.26.4 An additional 4 pole isolating switch fuse unit ( with arrangement for termination

connection of cables at inlet and outlet ) shall be provided by the Contractor at a

height of 1.5m. from the floor level at a suitable location to be approved by the

Engineer in charge before start of down shop leads. The main supply cable switch

will be provided by the Engineer in charge. Further cable connection from isolating

switch up to down shop leads along with necessary accessories and arrangement

which shall include three indicating the status of the down shop leads (live or dead)

and also one voltmeter with selector switch to indicate the voltage level of the

incoming supply shall be provided by the contractor. The indicating lamps and the



SP 51

voltmeter with selector switch shall be hosed in a separate M.S.box which shall be

installed close to the isolating switch descried earlier.

2.4.26.5 For the control and protective panel’s anti condensation heaters anti vibration

mountings and cubicles lighting (complete with switch ) shall be provided.

2.4.27 LIMIT SWITCHES :

Totally enclosed self-resetting two way rotary type limit switch watch cut off

current and stops the motion when the book have to predetermined level shall be

provided to prevent over-winding and over lowering. Totally enclosed self-

resetting two way level switches shall be provided to prevent over traveling in both

directions.

2.4.28 CABLE AND WIRING :

2.4.28.1 All the motors, controllers, current collectors and resistances shall be factor wired.

All connections among the apparatus shall be executed by means of armored.

Trapdoor PVC cables and shall be suitably clamped in troughs. The cables wherever

likely to get damaged should with PVC guards easily removable for maintenance

and inspection. Control and power cables shall be manufactured from electrolytic

copper and shall be executed as regards the minimum sections and type of

insulation in accordance with provision of IS -31771977. The current ratings of the

cables shall be as per the provisions of the appropriate clause of IS -3177-1917.

2.4.28.2 The down shop leads shall be of hard drawn copper and shall comply as regards

physical and electrical with the appropriate Indian standards or equivalent British

standards. The down shop leads shall be tightened on ends and supported with out

door insulators and tension adjusting devices. The power to the crab shall be

supplied through flexible cables. These shall be of copper TRS insulated ad shall be

supported in !cops from ball bearing type trolleys running along a track parallel to

the cross traverse.

2.4.28.3 Provision shall be made for the protection of all live bare conductors against

accidental contact. The contractor for the crane shall include in his supply all the

requisite length of down shop leads along with insulators.

2.4.28.4 The protective and control panel wiring shall be provided with formulas with

numbers and shall be terminal on the terminal block inside the panel. Provision of

25% spare terminal shall be made in the terminal block. The relays, timers,



SP 52

contractors etc. Shall be designated by giving type, number which can be located in

wiring diagram.

2.4.29 COLLECTION GEAR :

2.4.29.1 Collector gear for main down shop leads shall be a spring loaded type equipped wit

brass wheels. The collector gear shall be provided by the supplier,. Full

constructional details fo this shall be given to the Bid.

2.4.30 WIRENG DIAGRAM:

A Schematic wiring diagram for the crane, in durable from shall be provided. On

this diagram shall be given the rating of each of the motors, the cable sizes, types of

contractors and resistances and such other information, which will facilitate

inspection and maintenance of the crane. The cable schedule giving the size of cable,

terminal numbers of various equipments, the designation of various electrical

components e supplied by the contractor.

2.4.31 PRECAUTIONS FOR OUTDOOR CRANES:

2.431.1 For all outdoor cranes all electrical and mechanical equipment shall be adequately

protected by the weatherproof covers. All weatherproof covers shall be easily

removable.

2.4.31.2 For all the outdoor cranes except where flexible unarmored cables are essential

cables shall be either armored on enclosed throughout their length in galvanized

trucking or conduits, either flexible or rigid. A flexible metallic tube or duct may not

be used for that purpose. Taped and braided varnished cambric insulated cables

shall not be for outdoor cranes.

2.4.32 LIGHTING:

The cranes shall be provided with permanent A.C lighting system. For illuminating

working area two (20) 500 watts Mercury vapor lamps with indoor type reflectors

shall e provided under each crane bridge of each indoor crane (l.e. Total 4 no. of

lamps per crane) . For all the outdoor type cranes two (2) outdoor types Mercury

vapor lamps of 00 watt capacity shall be fitted underneath each vane-bridge. These

lights shall be of the hinged self- setting type of easy removal. Entire lamp assembly

shall be securely fixed with crane fixtures and protected by wire mesh of good,

thick stainless steel wire. The supplier shall provide lights near the motors and rope

– drums. He shall also provide a hand lamp working on 24-volt supply, with 15m



SP 53

long cable and at least two numbers of three pin plug sockets (15 Amp.) along the

platform at suitable positions. A part from the bridge lights all lights shall be of

tungsten filament type and shall be provided with indoor or outdoor type

reflectors, as the case may be, with shock absorbing sockets.

2.4.32 EARTHING:

The crane and gantry structure, mortar frames and metal cases of all electrical

equipments shall be effectively connected to each by the contact in accordance with

Indian Electricity Rules. For effective earth connections, the ear thing of gantry rails

shall also be done by the contractor.

2.4.34 SPARES:

The contractor shall supply spares necessary for 3 years operation of each

crane/fixed drum hoist, Unit prices of these spares shall be stated in the Tender

Schedule and this shall apply such number of items as may be ordered. Any

additional spares may be recommended by the contractor. All spares furnished

shall be of the same material and workmanship as of the corresponding parts of the

main equipment after completion of work.

2.4.35 TOOLS:

Set of tools, special tools, traces and all other appliances necessary for complete

assembly dismantling and maintenance of each type of Goliath. Crane and fixed

rope drum hoist shall be furnished M.S. box with locking arrangement holding set

of above mentioned tools and tackles etc. Shall be supplied . The list of the erection

tools and tackle, included in the supply be furnished along with the Bid giving their

itemized prices in Schedule V(A) or V(B) of tender Schedules. Which over as

applicable.

2.4.36 PAINTING:

Before leaving the work, the cranes all surface shall be thoroughly cleaned and shall

be treed from scale, rust and grease etc. And painted with one coat at best quality

red oxide paint.

Machinery housing an other mechanical parts shall be painted with finishing earner

of approved color. Bright steel parts shall be treated with anticorrosive compound.

Interior of all gearboxes shall be painted with one coat of oil paint.

After erection at site, every part shall be cleaned and shall then receive two coats of

best quality enamel machine paint of approved color.



SP 54

Cleaning and painting of the crane after erection at site is included in scope of

contractor. The painting scheme shall be got approved from the Engineer in charge

before starting the painting work.

2.4.37 PACKING:

The parts of the crane, which are likely to be damaged during transit shall be

suitably created or packed. Packing material will be the properly of Govt. Open

erection of crane.

Painting shall be accordance with clauses 8.19 and 9.10 of Tech cal specifications.

2.4.38 MATCH MARKING:

2.4.38.1 Before dispatch, all parts of the crane and the crane itself shall be completely

assembled, properly aligned, tested and match marked with distinctive erection

marks etched of them corresponding to those on the drawings so as to ensure

correct assembly and alignment at sit. The weight of the heaviest member of the

structure or part of the crane that has to be handled during erection shall e stated in

the Bid. The contractor shall ensure minimum amount of assembly at site for early

commissioning of the crane after delivery.

2.4.38.2 Site welding for major members of crane will not be allowed . The contractor shall

specifically note that some of the cranes are to be erected on open R.C.C. gantry

structures as shown in the drawings. Thus no hooks will be available for lifting the

crane equipment during erection and the contractor shall arrange for the erector

equipment required, such as derricks, winches, wire rope shackle, pulleys etc. at his

cost.

For the various indoor cranes viz. Goliath cranes for the Take off-gates. Draft tube

gates and Tail surge gate, hooks could be provided if the contractor gives timely

intimation about their capacity, location, numbers etc, while the concerned civil

works are still it progress. The contractor shall verify the position of respective civil

work at the time of submitting the Bid and quote his rate taking into account the

possibility of availability of the hooks etc.

2.4.39 TESTS:

1) AT MANUFACTURE’S WORKS:

A) X-RAY TESTING OF THE WELDED JOINTS OF THE GIRDER:

During the fabrication of the bridge girder, 100% “X” ray testing of the welding on

tension and compression zones of the box girder shall be carries out in presence of



SP 55

the representative of the Engineer in charge and test certificate in this regards shall

be submitted to the Engineer in charge.

B) Six copies test certificates for the chemical composition lamination test, die

penetration test and weld ability of the steel to be used bridge girders and other

important structural items of crane shall be submitted before the fabrication work is

taken by the contractor

C) All forging shall be subjected to ultrasonic tests for internal cracks and forging

defects,. Six copies of the test certificates in this regard shall be submitted by the

contractor.

D) The contractor shall also furnish the test certificates( in six duplicate copies) in

respect of the following for the approval of the Engineer in charge.

a) HOOKS:

The hooks shall be tested as per the relevant BS and IS. The test certificates for the

chemical compositions, yield point, tensile strength, elongation and Brintell ardness

shall also be submitted.

b) WIRE ROPES:

Test certificates for the breaking strength, tensile strength and the elongation of the

wire ropes.

c) Chemical analysis of the material of the track wheel, hardness tests.

d) All electrical and mechanical equipment such as Motors and other auxiliary

equipment shall be tested in accordance with the appropriate Indian Star and also

in accordance with the requirement of the specifications at either crane Maker’s or

equipment manufacture’s works.

Even when the test certificates/test reports are approved by the Engineer in charge

or by his representative, it shall not absolve the contractor of contractual obligations

regarding guaranteeing the performance at site.

2) AT SITE:

Each crane shall be assembled completely including wiring and other fittings and

aligned at works site and the following tested shall be conducted in presence of the

Engineer in charge.

1) DEFLECTION TEST:

The deflection test shall be carried out with the safe working load at rest and with

the crab in a central position. The measurement shall not be taken on the first

applicable of the Test load.

The vertical deflection shall not exceed 1/900 of the span.

2) INSULATION TEST:



SP 56

After erection but before the cranes are connected to the power supply, the

insulation of the electrical equipment shall be tested by a suitable instrument avid

method . as approved by the purchaser, and any defects revealed shall be rectified.

3) MOTION TEST AT RATED LOAD:

All the motions including long travel motion of the crane shall be tested with the

hooks carrying the tatted load to check. Up the compliance with specified

performance requirement such as speed etc. For the long travel portion the idle

running test for the wheel shall be carried out initially.

4) OVERLOAD TEST:

The crane shall be tested to lift and sustain a test load of 125% of the safe working

load keeping the loads at the center or span.

During the over-load test, each motion including along travel shall be in both

direction and the crane shall be capable of safe operation with the overload. The

Contractor shall submit six copies of the complete test reports for above tests to the

Govt. Of approval.

5) Following operational tests shall also be carried out.

a) Satisfactory operation of each controller, switch contractor delay switches;

b) Correction of all circuits and interlocks and sequence of operations,

c) Satisfactory operation of all protective devices;

d) Satisfactory operation of each motion including the long travel motion, and

e) All the gear boxes be run for 6 hours non-stop and checked for noises, vibration

and oil leakages.

2.4.40 GUARANTEE/WARRANTY:

All the equipment must be free from inherent defects in design, workmanship and

material. It must safely handle all required loads and all parts of the equipment

shall remain in satisfactory order till the expiry of performance guarantee period.

Any part of the equipment that will period. Any part of the equipment that will

prove to be defective or inadequate before expiry of guarantee/warranty period,

shall be replaced by the contractor without any charge.

2.4.41 LABLES AND LETTERING:

All apparatus, motors, control gears and all panels shall e clearly labeled indicating

where necessary their purpose and the ‘on ‘ and ‘off’ position. The label shall be

clearly lettered on enameled iron or right aluminum plate. All labels shall be



SP 57

printed in English, Function labels shall be black letters on white background and

danger labels shall be white letters on red background.

2.5 ELECTRICALLY OPERATED MECHANICAL...HOIST:

2.5.1 SCOPE OF WORK:

2.5.1.1 The scope of work shall comprise of the following, Design, manufacture, supply on

project site, verification of equipment delivered, handling, loading, transport,

unloading., of the goods at/from store sheds at project site, erection, testing and

putting into use of the following equipment as per detailed specifications covered in

this document.

Twenty seven of indoor type electrical operated mechanical. Hoist of capacity 25

M.T. for the service gates. The rope drum hoist & its accessories are to be located

above service gate shafts. Hoist equipment shall be covered by suitable covers to

protect it from dust, dirt and direct exposure to moisture.

2.5.1.2 The scope of the work shall also cover the following:

1. Providing load for overload test and rated load at shaft and site for each crane.

2. Preparation and finalization of layout of Hoist with Design.

3. Supplying and providing proper ear thing for hoist structure.

4. Finalizing the arrangements and connecting the main incoming supply to the

electrical equipment of the hoist.

5. The cost for this is deemed to be included in the rate quoted for item.

2.5.2 DESIGN CRITERIA:

The fabrication of the electrically operated fixed drum Hoist shall be done on the

basis of following data.

1. Service gate leaf size 4.50 x 4, 7.50 x 4, 7.50 x 4.50, 4.50 x 4.50, 7.50 x 3.00,

10.50 x 2

As per detailed design vetted from. C.D.O.

2. NO. of gates required 27 ( Twenty seven )

3. Design head Max.4.50

4. Sill level 412.00

5. a) Closing time 10 Minutes

b) Opening time 10 Minutes

6) a) Lifting speed for hoist 1m/Minutes

b) Micro speed for hoist 0.25m/Minute



SP 58

7) Hook lifts

a) above floor level

b) below floor level

2.5.3 MATERIALS:

All material used in the construction of the rope drum hoists shall conform to IS

6938 or other relevant Indian Standard Specification. The contractor shall quote the

reference of IS code for material used. As a general guide to the contractor, Indian

Standards for some important items are given below,

2.5.3.1 STEEL AND CASTINGS:

1. IS 210-1970 Grey iron casting (Revised)

2. IS 2.62-1992 Structural Steel

3. IS 10.30-1989 Steel casting

2.5.3.2 STEEL FORGING:

1. IS 2004 1991

2. IS 1875 1992

2.5.3.3 ALUMINIUM BRONZE:

1. IS 3.5 1981

2.5.3.4 THREADED FASTEMERS:

1. IS 1367-1980 Technical supply of conditions for threaded fasteners.

2. Bolts & nuts Bolts & nuts shall have hexagonal heads & shall be made to

conform to IS 1364-1365 IS 2355 and other relevant Indians standards.

2.5.4 WIRE ROPES:

2.5.4.1 GENERAL:

The wire ropes shall be made fro, improved plough steel, galvanized or normally of

6/36 or 6/37 contention and shall conform to IS-2266-1977.

2.5.4.2 BREAKING STRENGTH:

The breaking strength of wire rope. If not given by the manufacturer of rope shall

be calculated on the basis of IS-2266-1977

2.5.4.3 FACTOR OF SAFETY:



SP 59

The minimum factor of safety for normal operation condition shall be 6 and for

breakdown shall be 3.

2.5.5 HOIST DRUM:

2.5.5.1 The drum shall be strong enough to withstand the crushing as well as bending the

crushing strength of the drum shall be calculated by the following formula

Cr = K x T

P x t

Where,

Cr = Compressive strength in N/mm2

K = Co- efficient which depends on the ni=umber of layers of rope over

the drum

and may be taken as 1.00 for single layer, 1.75 for two layers & 2.00

for three

layers.

P = Pitch of scoring of center to center distance between adjoining

grooves in mm.

T = Tension in the fire rope in N and

T = Thickness of drum at the bottom of groove in mm.

The length of drum shall be such that reach lead of rope has

minimum two full

Turns on the drum when the gate at its lowest position and one spare

groove

for each lead of the drum when the gate is at its highest position.

2.5.5.2 The minimum pitch diameter of the drum shall be 20 times the diameter fo rope

6/36 or 6/37 construction.

2.5.5.3 The drum may be flagged at ends. The flanges shall project to a height of not less

than two rope diameters above the rope . A spur gear secured to the drum may be

regarded as doming one of the flanges.

2.5.5.4 The rope drum shall be machine grooved and contour at the bottom of the grooves

shall be circular over an angel of at least 120. The grooves shall be finished smooth

with round edges. The grooves of the drum shall be so pitched that there shall be a

clearance of not less than the following values between turns of rope.

a) 1.5mm for ropes up to and including 12mm dia.

b) 2.5mm for ropes over 12mm including 30mm dua. &

c) 3.0mm for ropes over 30mm dia,



SP 60

2.5.5.5 The lead angel (feet angle) of the rope shall not exceed 5 degree or in 12 on either

side of helix angle of groove in the drum.

2.5.6 GEARINGS:

2.5.6.1 SPUR GEARS:

Spur gears of 20-degree full depth in volute teeth shall be provided in end reduction

units, The correction factor for general speeds and the efficiency shall also be

considered. Preferably the material of pinions shall be harder than that of gears and

shall be free fro, imperfections such as chatter marks.

2.5.6.2 SPEED REDUCERS:

Standard worm or helical reducers, if used, for the first stage heavy reduction at the

drive unit, shall be high-grade reduction unit suitable for the service intended. The

proportions of all the parts, there in shall be in accordance with the best engineering

practices. Rating and efficiency of the reducers used in calculations shall be as per

manufacturer’s recommendations. The whole assembly shall be housed in a dust

proof casing with suitable lubrication facility. The reducers shall have self-locking

characteristics.

2.5.6.3 GEAR BOXES:

Gear boxes shall be of rigid construction fitted with inspection covers and lifting

handles where necessary . The gear boxes shall be so designed that the gears can be

easily removed or replaced, and shall be such that the gears are suitably lubricated.

Facilities for oil level indications and adequate breathing shall be provided where

necessary . The boxes shall be counted on a level surface.

2.5.7 GATE POSITION INDICATOR:

The indicator dials shall be made from non-rusting metals or enameled plates or

thick plastic sheets. They shall be circular in shape.

The markings of dial in the operating range shall have minimum readability of

0.05m. The meter marking shall be very bold. The words ‘Closed’ ‘open’, or fully

raised shall also be engraved or permanently marked.

The dial shall also be located at conferment place from where it may be easily seen.

The indicator points shall be made of non-rusting metal. Electro-plated indicators

can also be provided

2.5.8 SHAFTS:



SP 61

2.5.8.1 GENERAL:

The shafts shall be designed for appropriate load/torque that is being transmitted

shafts shall have ample strength and rigidity and adequate bearings surfaces. The

shall be finished smoothly and, if shouldered, shall be provided with fillets of large

radius.

2.5.8.2 SIMENSIONS OF SHAFTS:

In dimensioning the shafts the ratio (length/diameter)>50, the angle of twist and

the revolution/minute shall be taken account in addition to simple bending and

torsion. The twist that shall be permitted is Y< degree to 1/3- degree to 1/3- degree

per meter. Linear deflection in the shaft shall not exceed one mm per meter of

length.

2.5.8.3 ALLOWABLE STRESSES:

The allowable stress of solid shaft shall be as follows:

a. Maximum allowable bending stress (6b) either tension or compression on;y. 6b

=0.5 yield point or 20 percent of ultimate strength which ever is less.

b. Maximum allowable torsion shear stress (s)=30 percent of the yields point

c. Combined stress shall be calculated with the following formula and shall not be

greater than as at (a) above.

Where 6c= 6b2+3s2

6c= Combined stress in N/mm2 and shall not exceed 0.24 UTS or 0.6 Yp which

ever is less

6b= Tensile/compressive strength in N/mm2 and

S = Shear stress in N/mm2

The allowable stress for shafts with keys will be 75% of the above value. The shaft

shall also be designed for combined twisting and bending by making use of the

following formula. The equivalent bending or twisting stress shall not secede 1.2

times maximum allowable bending stress at (a) above.

1. Twisting

Te =j2 + m2

Where,

Te = Equivalent twisting moment in N/m2

J = Bending moment in Nm and

M = Twisting moment in Nm

2. Bending

Me = 0.5(M+ M2+T2)

Where,



SP 62

Me = Equivalent bending moment in Nm.

M = Bending moment in N/m and

T = Twisting moment in Nm

2.5.9 SHEAVES OR PULLEYS:

All pulleys shall be in true running balance and shall be provided with pressure

grease arrangement. The ratio between the sheaves pitch diameter and tope

diameter shall not be less than 30.1 for running sheaves and 10.1 for liquidizer

sheaves. The grooves shall be finished. smooth and shall be free from surface

defects likely to injure rope . The contour at bottom, of groove shall be circler over

an angel of approximately 130 degree-degree. The radius of the groove shall be 0.53

times the diameter of the rope. The included angle which is the angel between the

straight slopes at the sides of the groove shall be approximately 52 degree

sheave/pulley shall be provided with guards to retain the ropes in the groove.

2.5.10 SOCKETS FOR WIRE ROPES:

The socket ends shall be slightly stronger than the wire rope. Molten zinc shall be

used to socket the ropes . The sockets may be cast or forged.

2.5.11 TURN BUCKLES AND EQUILISER BARS:

Tom buckets shall be provided to adjust the rope elongation and equalizer bars

shall be provided to ensure equal loading on both sides of equalizer bars.

2.5.12 TYPE IF BEARING:

All the running shafts shall be provided with ball. Roller or brush bearings. Section

of bearings shall be done on consideration of duty losd and speed of the shaft.

Life of ball and bearings shall be calculated in accordance with manufacture

recommendations. Bearings shall be easily accessible for lubrication and/ or

replacement.

2.5.13 COUPLINGS:

1. Solid couplings shall be aligned in such way that they meet accurately. Flexible

Couplings shall be initially aligned with the solid coupling

2. Flexible coupling shall be fit between motors& worm gear reducers and shall be

provided for angular and off set misalignment of the complex shafts.

3. Flexible coupling shall be metallic fully enclosed dust proof, self-oiling types. A

couplings shall fit& accurate on shafts.

2.5.14 ELETRICAL EQUIPMENT:



SP 63

1. EFFICIENCY OF SYSTEM:

The usual values of efficiencies adopted for various elements of hosting mechanism

shall be taken for label given blow. The over all efficiency of the system shall be

then be sorted out . This over all efficiency of the system shall be used in calculating

the electric motor.

Efficiencies of various components of hosting mechanism

Sr.No. Particulars of elements Starting efficiency Running efficiency

1 2 3 4

1 Drum/sheave/pulley

a) bronze bushing 93% 95%

b) Anti friction bushing 95% 98%

2 Each set of spur gear 93% 95%

3 Each set of helical gears 95% 98%

4 Standard device such as

worm reducer, helical gear

reducer etc.

As per

manufacturer’s

recommendations

As per

manufacturer’s

recommendations

5 Electrical motors As per

manufacturer’s

recommendations

As per

manufacturer’s

recommendations

The ratio of overall running efficiency to the overall starting efficiency shall be

less than the ratio of starting torque-running torque of motor,

2.5.15 MOTOR:

2.5.15.1 The motor shall be totally enclosed fan cooled, high starting torque, squirrel case

three phase induction motor of adequate capacity conforming to IS 325- 1978 or

equivalent. The motor shall be suitable for reversing frequent acceleration and

mechanical breaking.

2.5.15.2 The breakdown torque shall not be less than 200% of full load torque. The hoist

components such as drums, shafts, gears, wire rope etc. shall be checked for, this

condition.

2.5.15.3 Each motor shall be equipped with heater switch and thermostat to prevent

condensation of moisture drawn into the motor during shut down periods. Motor

shall be so located that the brush gear and terminals are readily accessible for

inspection and maintenance and normal ventilation is not restricted.



SP 64

2.5.15.4 The winding insulation for motor shall be special impregnation suitable for

operation in high humid atmosphere.

2.5.15.5 Motors chosen shall have rated speed not more than 1000 re./minute.

2.5.16.1 ELECTROMAGNETIC BRAKE:

2.5.16.1 The electro-magnetic brake shall be of spring set, shoe type. It shall be solenoid

operated and continuously rated. The brake shall be effective in both directions of

travel and shall be capable of overcoming at least 150 percent of the full load torque

exerted by motor.

2.5.16.2 The brake shall set automatically when the current is cut off from the motor and it

shall be electrically released when the current is applied to the motor. The brake

shall be equipped AM heaters if required, shall be provided to prevent

condensation on moving parts.

2.5.17 LIMIT SWITCHES:

2.5.17.1 GENERAL:

The limit switches after being tripped shall automatically reset them selves within a

reasonable distance traveled in opposites direction. This does not prevent the use of

change over type limit switches. Here resetting is achievement by striker then

moving in opposite direction. They may be mechanically driven from the shaft.

2.5.17.2 HOIST LIMIT SWITCH:

It is a device provided to cut off the current, the motion of hoist mechanism and to

apply the brake when the gate has risen to pre determined level. Limit switches for

intermediate positions of travel, if required shall also be provided.

2.5.18 CONTROL PANEL:

2.5.18.1 Suitable control panels shall be provided near the motor and shall be enclosed in a

property insulated metal cabinet. The supplier submit the arrangement showing

main panels. Distribution panels and control panels including all wiring and other

accessories for approval of the purchaser. All electrical control equipment shall

conform to IS 6938-1989.



SP 65

2.5.18.2 Each control panels shall contain single phase prevent or, thermal overload tripping

relays, starter, heaters if required push buttons, indicating lights with complete

wiring etc. All the controls shall be inter located for proper functioning of the

individual parts.

2.5.19 MATERIAL SPECIFICATION FOR HOIST:

The material to be used in various components of the hoist shall conform strictly to

the following specifications.

Sr.

No.

Item Material Specification

1 Wire Rope 6 x 36 or 6 x 37 Fiber core

improved plough steel

ungalvanised

IS : 2266-1989

2 Shafts Forged Steel IS : 2062/IS-1875 1984

3 Drum Cast steel/mild steel IS : 1030-1989

IS : 2062-1984

4 Sheaves and

pulleys

Cast Steel IS : 1030-1989



SP 66

5 Gears Forged steel/mild steel IS : 1875-1992

IS : 2004 pof 1991

IS : 1030 of 1989 6

6 Pinions ..................”................................... ...............”..................

7 Plummer block Cast iron standard IS : 210 SKF

Equivalent with felt

washers/seals

8 Bushings Bronze IS : 305-1981

IS : 318-1981

9 Base frames Gear

Case covers etc.

Structural Steel IS : 2261

IS : 2062 of 1984

10 Bearing Roller/Ball SKF of equivalent

11 Turn buckles Forged steel IS : 1875-1992

12 Roller socket Drop forged steel IS : 2485

13 Keys Mild steel/forged steel/Cast

steel

IS : 2062 of 1984

IS : 1875-1992

IS : 1030-1989

14 Couplings .................”........................ ...............”..................

15 Clamps Cast Steel IS : 1030-1989

2.5.20 LUBRICATION:

Lubrication of motors, gear reducers and roller and ball bearings shall be as

specified by the manufacture of the respective equipment. The points of lubrication

of the bearings and journal shall be readily accessible & where necessary piped to

convenient points using copper or brass pipe . Grease grooves shall be provided in

the bearing surface for satisfactory distribution of the lubricant. A levered type

hand compressor for forcing the lubricant to the bearing shall be provided duly

equipped with couplings suitable for the industrial button type fittings.

2.5.31 EARTHING:

The specifications as mentioned in relevant Para shall be applicable.

2.5.22 LIGHTING:

The specifications as given in relevant Para shall be adhered as applicable.



SP 67

2.5.23 DRAWINGS & MANUALS:

Schedule of drawings & manuals and other guaranteed data to be furnished by the

supplier. The details as given in relevant Para shall be furnished as applicable and

furnish detailed technical in respect of rope drum hoist to be supplied in the

Proforma included under schedule- A for the applicable items.

2.5.24 SPARES:

The specifications as given in the relevant Para shall be applicable.

2.5.25 TOOLS:

The specification as given in the relevant Para shall be applicable.

2.5.26 PAINTING:


2.5.27 PACKING:

The parts of hoist which are likely to be damaged during transit shall be suitably

created or packed and packing material shall be property of Government only.

2.5.28 TESTS:

The only relevant specifications as mentioned in relevant Para are suitable for tope

drop hoist shall be applicable.

2.5.29 GUARANTEE/WARRANTY:


2.5.30 LABLES AND LETTERING:


2.6 PAINTING:

2.6.1 GENERAL:

All paints and other materials required for painting shall be supplied by the

contactor and shall deemed to be included in the rate quoted for each item. The

paints proposed to be used by the contractor shall be got approved fro, the Engineer

in charge both in respect of quality and shade etc. The analysis and performance

requirements of the paints shall be submitted by the contractor for examination and

approval of the Govt. Painting shall be done in accordance with IS: 1477-1971-part 1



SP 68

& 2 code of practice for painting of ferrous metals in buildings – patt-1

[pretreatment, part-2- painting (first revision).

2.6.2 PREPARATION OF SURFACE:

Surface preparation shall be in accordance with the following procedure.

1. Weld spatters or any other surface irregularity shall be removed by any suitable

means before cleaning.

2. All oil, grease, dirt shall be removed from the surface by use of clean mineral

spirit, xylol or white gasoline (lead free) and clean wiping materials; except that

for surfaces which require coal-tar coating the clearing the clearing solvent shall

be xylol.

3. Following the solvent cleaning the surface to be painted shall be cleaned of all

rust, ill scale and other lightly ‘adhering objectionable substances by sand

blasting or grill blasting to uniform bright base metal. In case rust forms or the

cleaned and Sand blasted surface becomes otherwise contaminated in the

interval between cleaning and painting, reclining shall be carried out. Surface

of stainless steel, nickel, bronze and other machined surfaces adjacent to metal

work being cleaned or painted shall be protected by masking tape or by other

suitable means during the cleaning and painting operation.

2.6.3 PRECAUTIONS:

2.6.3.1 All paints and coating materials shall be in a thoroughly mixed condition at the

time of application.

2.6.3.2 The air temperature at the time of application must not below 10 deg. Celsius

and relative humidity must be below 60% to 70%. Surface to be painted should

be free from moisture at the time of application. Effective means shall be

provided for removing all free oil and moisture from the air supply lines of all

spraying equipments.

2.6.3.3 The first cost shall be applied by brushing immediately after cleaning the

surface.

2.6.4 PAINTING SCHEDULE:

2.6.4.1 The following are the various painting system to be used for the purpose of this

specifications.

SYSTEM-1



SP 69

To be prepared as per IS:290-1961 (reaffirmed 1986) – Coal Tar Black paint

(revised) or relevant (BS) specification.

Prier: Zinc Rich Primer one coat to obtain a dry film at a coverage rate of 2.5 sq.

m/lit for the faces exposed to water or atmosphere shall be primed as above . but

the surface coming in contact with concrete shall be given a cement wash

1st Coat Finishing: Coal Tar Epoxy paint one coat to obtain a dry film at a

coverage rate of 2.5 sq.m per liter.

2nd Coat Finishing: Same as 1st coat finishing. Interval between the coats: 24

hours.

SYSTEM- II

Primer: Red oxide Zinc Chromate- 1st coat to obtain a dry film at a coverage rate

of 10 sq. m/llt and 2nd coat be applied to obtain a dry film at a coverage rate of 10

sq. mAit. For the surfaces exposed to atmosphere.

1st Coat Finishing: Synthetic Enamel paint or one coat to obtain a dry film at a

coverage rate of 10 sq. m/lit.

Land Coat Finishing: Aluminum paint or machinery finish paint one coat to

obtain a dry film at a coverage rate of 10 sq.m/lit

Interval between the coats: 24 hours.

SYSTEM-III:

Heavy uniform coating of Gasoline soluble rust preventive compound.

SYSTEM- IV:

Smooth coating of a thin mixture of white lead oil and grahia.

SYSTEM- V:

Primer: Red oxide Zinc Chromate- 1st coat to obtain a dry film at a coverage rate

of 10 sq. m/lit and 2nd coat be applied to obtain a dry film at a coverage rate of 10

sq. m/lit. For the surfaces exposed to atmosphere.

1st Coat Finishing: Synthetic Enamel paint or one coat to obtain a dry film at a

coverage rate of 10 sq. m/lit.



SP 70

For embedded parts the surfaces coming in contact with concrete shall be given a

cement wash.

1st & 2nd Coat: Superior quality synthetic enamel paint to IS:904-1978 or as

approved by the purchaser.

Interval between coats-24 hours.

2.6.4.2 The following shall be application of the above painting systems.

System Application

System-1 All unmachined ferrous surfaces of gates. Lifting beams and

embedded parts exposed to atmosphere or water. The

surfaces of embedded parts, which are to come in contact

with concrete shall not be required to be given finishing coats

but shall be given cement wash before erection/embedment.

System-2 All surfaces of machinery (except machined surfaces

including motors, hoists, gearing housing , shafting, bearing,

pedestals base plates. Hoist bridge, hoist frames, trestles,

railings etc.

System-3 All finished surface of ferrous metal including screw-threads

that will be exposed during shipment or while awaiting

installations. All machined surface in rolling or sliding

contact.

System-4 Finished surface of bolt joints in sections that are to be

shipped, assembled and the shanks and threads of bolts etc.

System-5 External and internal surface control cubical/plants, crane

girders, cubing ladders, hydraulic piping (external surfaces)

support anchors, brackets shackles, hooks, external surface

and air tanks etc.

2.6.4.3 In case of System-1 and 2 priming coats shall be applied in the field. The first

finishing coat shall be applied in the field after damage of shop coat and 2nd



SP 71

finishing coat shall be applied erection. For System-3 The prier and 1st coat shall be

applied for the shop. The 2nd finishing coat shall be applied in the field as and final

coat shall be applied after erection in case of parts becomes inaccessible after

erection an extra coat is to be the shop and final coat in the field before erection. In

case of System 6 only the primary coat be applied in the shop and both the coasts of

enamel paints shall be applied in the field, prior erection as found convenient.

2.6.5 APPLICATION PROCEDURE;

2.6.5.1 All the paints and coating materials shall be in thoroughly condition at the time of

application and shall not be thinking as herein after specifically provided. Any

warming be performed by means of hot water bath paint shall not when the

temperature of metal or surrounding below 10 deg. F and relative humidity is

above 60% to 70% unless the specified by the paint manufacture inject to the

approval.

2.6.5.2 All surfaces to be painted shall be free from moisture at the time or painting. The

first or priming coat of paint shall be applied immediately after cleaning and except

otherwise specifically provided shall be applied by brushing and subsequent coats

shall be applied by either brushing or spraying. When paint is applied by spraying.

A mechanical agitator tyrpe paint-pot shall be used . If the supplier sues the special

type of equipment designated for spraying heavy bodied materials means shall be

provided for removing all free oil and moisture from the air supply line of all the

spraying equipment. Each coat of paint shall completely cover the surface and shall

be free from the runs, slag’s pinholes, holidays or partly covered areas. Each coat of

paint shall be allowed to dry or preventive compound shall be applied by any

convenient method to ensure complete coverage of heavy coating.

2.7 TESTING:

2.7.1 GENERAL:

All materials and components of the equipments offered under these specifications

shall be tested y the contractor prior to fabrication. After fabricating the equipments

shall be performed by the contractor to ensure accuracy in fabrication and

workmanship. The contractor shall carry out such tests as may be required by the

Engineer in charge in order to determine that the slide gates, hoists and stop log

gates. A fulfill the functions for which they have been designed. The tractor shall be

responsible for all modifications and adjustable required for the work as a result of

such tests. The test shall repeated, if necessary, until they are successfully carried



SP 72

out the satisfaction of Engineer in charge. The contractor shall out all inspections

and Tests.

2.7.1.1 After manufacturing, the acceptance of gates shall be satisfactory testing and

inspection through the reputed and ties/agency approved by the dept/Govt. The

inspection for be paid by the deptt/Govt. And recovered from the contractor.

2.7.2 INSPECTIONS:

Inspection during manufacturing stages is to carried out in respect of the following,

by the contractor.

2.7.2.1 MATERIALS:

(a) All materials, supplied parts and assemblies there of use: in the work to be

done under these specifications shall tested quality and all works performed

shall be subject inspection and no article or material or supply shall be until

all tests, analysis and shop inspection have been by the contractor and

certified copies of reports of analysis have been accepted by the Govt.

(b) All materials and components supplied by the manufacturer/ contractor

shall be tested as per the requirements of the relevant Indian standard. In the

absence of the Indian standard for any material other specifications,

mutually agreed to between the Govt. And the Contractor. May be used. For

important components, manufacturer’s test certificates shall be furnished.

In addition to above, all the plates used for the fabrication work Gates

embedment and hoists shall be tested ultrasonically to detect lamination and

other defects. The ultrasonic test results shall be furnished along with other

test reports . The test shall be conducted as per IS- 42251979- ‘Recommended

practices for straight beam Ultrasonic test of steel plates. Ten (10) percent of

plates of plates shall be shall be rested by X-ray radiographic examination.

Results shall be furnished for the acceptance of the Govt.

(c) Certified copies in six copies of the test made and of the results thereof, shall

be furnished as soon as possible after the tests are completed by the

contractor. The results of the tests shall be in such forms as to provide means

of determine compliance with the applicable specifications for the

equipments materials and supplies tested. Lie required tests or trials shall be

made in the authorized representative who shall be given sufficient notice to

enable him to reach the sit the workshop.

2.7.2.2 CASTING:

(a) All casting shall conform to the relevant standard.



SP 73

(b) If the defects are within acceptable limits as per the relevant Indian

standards, repairing of casting can be allowed with out impairing the

strength of machinability.

(c) Visual examination shall be done to ascertain the general soundness of the

casting and, if required, these may be subjected to nondestructive tests.

2.7.2.3 FORGING:

a) All forgings shall conform to relevant Indian standards.

b) All forgings be suitably heat treated, whenever deed essential.

2.7.2.4 WELDING:

a) All welding shall conform to the relevant Indian standards.

b) Qualified welders, complying with IS 7318 (Paart-1) : 1974 shall be employed

for the welding work.

c) Visual examination shall be carried out of all welded joints to ensure that

wildings is free from the following.

1) Cracks on the surfaces of the joints or parent metals located in the heated

zone of the joint.

2) Undercuts in the parent metals;

3) Sponginess and porosity in the welded metals

4) Non –uniform width of the fillet joints;

5) Misalignment and distortion of the welded member &

6) Irregular reinforcing beads of welds.

d) Defective welds shall be removed and redone.

e) The welds which seen questionable, shall be checked by the manufacturer,

using nondestructive testing methods to ensure the soundness of the weld.

f) Ten (10) percent of butt welds on major stress carrying member like gate

girders, unsupported but joints on skin shall be examined by radiographic

test (x-ray, Gamma ray, etc.) 50 percent of the remaining but joints shall be

examined by any nondestructive tests namely ultrasonic tests magnetic

particle tests etc.

g) If necessary, any component may be stress relived according to the

procedure laid down in IS 2825: 1969.

2.7.2.5 MANUFACTURING TOLERANCES:

The gates and the embedded parts shall be manufactured to such an

accuracy and tolerance as are required for efficient operation of the gates.

Unless otherwise specified, the tolerances given in (a),(b) and (c) below may

be used as a general guide.



SP 74

a) embedded parts:

1. Deviation of any point on the face of the seal seats or wheel track from a 2M.

Machined straight edge held against it shall riot exceed 0.5 mm. However.

Overall deviation for the entire length shall not be more than 1mm.

2. Deviation from straightness of the guide track shall not be more than 2 mm

in 2 m length and 3 mm. For the entire length.

3. The offset or gap at any ad jointing field joints between seal seats, wheel

tracks and guide tracks shall not be ore than 0.5 m. the gap joint shall not be

seat wide and ground smooth.

b) Fixed Wheel Gates:

1) These gates shall be so assembled that when a machined straight edge is

held against all the wheels on either side in neutral position, it shall not be

possible to insert a feeler gauge thicker than 1.5 mm between any of the

wheels and the straight edge.

2) The distance between the side guide, shoe or guide roller on one side of the

gate and the corresponding guide shoe or guide roller on the other side shall

not differ from the dimension shone in the drawing by more than 1.5 mm.

c) Slide Gates:

1. The gate and the components shall be so manufactured that on assembly, the

side and top seal basis coincide on the same plane within the tolerance as

given below:

When a machined straight edge is held against the seal bases shall not be

possible to insert 0.2 m feeler gauge between the seal base and straight edge

anywhere.

2. After fixing metallic seals their faces shall be tested to ensure that these are

in a common plane within the tolerance given below:

When a machined straight edge is held against the metallic seal aces, it shall

not be possible to insert a 0.2 mm feeler gauge between the seal face and

straight edge at any point.



SP 75

3. The distance between the side guide shoes or guide rollers on either side of

the gate shall not exceed the dimension shown in the drawing by more than

1.5 mm.

2.7.3 SHOP ASSEMBLY AND TESTING:

2.7.3.1 GENERAL:

Gate shall be assembled, complete with wheels and guides, either in horizontal

of vertical position for proper alignment and inspection. Side guide shoes or

guide rollers may e shimmed, in necessary, to maintain the required tolerances.

All the wheels of the gate shall be rotated a number of times to ensure their free

movement. If ballast is provided, it should be ensured that is placed incorrect

position and secured to avoid dislodging during operation of the gate. The

marking and match marking on the components shall be made before the final

dispatch of the components.

The slide gates, fixed wheel gates, other gates and hoists and cranes shall be

completely assembled in the shop for inspection and the ensure that all part to be

connected are fitted properly and that all the dimensions clearances and

tolerances called for in these specifications and/ show in the suppliers drawings

approved by the purchaser are obtained. Any templates or layout plates required

ensuring correct matching of holes in connecting parts for erection shall be

furnished by the supplier to the purchaser. The gates, hoists and stop log gates

shall be assembled in vertical/ lined position to ensure proper alignment and

holes for field connections shall be carefully drilled or reamed while the gates ate

being shop assembled. All the gates shall be shop assembled as considered

necessary to check fabrication and all parts shall be carefully match marked to

facilitate erection at site.

2.7.3.2 SLIDE GATES:

Each slide gates shall however be assembled in the suppliers workshop in a

position to ensure proper alignment. The suppliers shall demonstrate and

operate the equipment for the inspection of the purchaser or his authorized

representative before disassembly and preparation for shipment. For ensuring

good hydraulic performance , it is very essential the water passage ways through

the gate frames are true, smoothes and in proper alignment without any

projection or burrs.



SP 76

All slide gates, gate fames and appurtenances shall be assembled at the suppliers

workshop to ensure accurate fitting and proper alignment of all dimensions,

tolerance and clearances as cover by the specifications. All shop connections of

slide gates, which ate required to be watertight shall be tested for water tightness

prior to shop prier coating.

2.7.3.3 FIXED WHEEL GATES:

The seals shall be fixed to the gate leaf by means of conquers sunk screw made of

stainless steel. The holes in seals shall be counter bored to accommodate the

conical head of the screw shall remain 1.0mm below the surface of the seal.

Minimum threaded length equivalent to 1.5 times the diameter of screws shall be

screwed with the gate leaf. The screws shall be adequately tightened to a

constant torque and locked by the punch mark. A compressed asbestos gasket

shall be provided between the scales and the gate leaf to prevent leakage. When

each wheel is carefully located on the wheel –pin a plane passing through any

wheel perpendicular to the lapin axis and intersecting the same side off the gates

and shall be parallel to the corresponding plane through the wheels on the other

side of the gates. These planes. through the midpoint or treads, shall be

perpendicular to the finished surface or the seal bases and shall be rotated 360

deg. To ensure satisfactory adjustment in all positions and to ensure even

distribution of the bearing lubricant.

After completion of required shop assembly, inspection and tests, the

equipments shall be disassembled into minimum number of sub- assemblies

convenient for shipment without damage to any parts of the equipments.

The gate shall be completely assembled in the suppliers workshop to ensure that

all parts to be assembled, fir accurately and properly and all dimensions and

tolerances required in the specifications and the drawings approved by the

purchaser have been achieved. The gate shall be assembled as one unit and the

supplier shall demonstrate and operate the gate in assembled positing for the

inspection of the purchaser before disassembly and preparation for shipment.

2.7.3.5 WEIGHING:

Before transportation, the supplier shall determine by the accurate means

available the net weight of each piece assembly that is to be transported as a unit,

and such new weights exclusive of boxes. Crates, or skips shall be the Govt. And



SP 77

shall be printed on the respective pieces assemblies and stated on the tags

attached thereto.

2.7.3.6 PREPARATION FOR TRANSPORTATION:

2.7.3.6.1 All parts shall be prepared for transportation so that slings for handling may be

attached readily whenever the parts are to be moved. Where it is unsafe to attach

a sling to the box, boxed parts shall be packed with slings attached to the part,

and the slings shall project through the box or crater, so that attachment can be

made readily. All exposed finished surfaced surfaces shall be adequately

protected against abrasion during transport, and all long and slender pieces shall

be adequately supported and blocked. Rubber seals shall be dismantled after

shop assembly and shall be transported separately. These shall be wrapped and

boxed to protect them from any elements, which should adversely after their size

shapes or physical on before they are field assemble the gates. The gates shall be

prepared for transport so as to permit min amount of field assembly.

2.7.3.6.2 Each case shall be clearly marked ,superintending Engineer Aurangabad

irrigation circle. Aurangabad - 431001 and the items to which the contents

pertain and shall contain a packing list which will also include similar details.

Copies of the packing list shall also be sent to the purchaser by registered post

along with the transportation documents such as shipping documents or railway

receipts. Packing materials shall be the properly of Govt. Only .

2.7.3.6.3 All projecting plates etc. shall be kept in shape in timber or angels bolted to

them. All straight bats and plates. Except small pieces shall be sent, cut in

convenient bundles, temporarily bolted or bound together. All bolts, nuts,

washers, plates under 0.3 m 2 and generally such small articles as may be

selected shall be packed in strong cases and the whole made secure for

transportation to site. All bolts and nuts of different sizes shall be packed in

separate bags each having & label indicating the contents of the bags.

2.7.4 MISCELLANEOUS:

2.7.4.1 MANUFACTURER’S NAME PLATE:

The contractor shall be permitted to attach a metal plate indicating his name

address etc. on equipment at a suitable location approved by the Engineer in

charge. Cast lettering except pattern numbers will not be permitted on any of the

castings.



SP 78

2.7.5 PAINTING:

2.7.5.1 Painting shall be done according to the requirement of Engineer in charge the

application procedure shall be as recommended by the paint manufacturer.

2.7.5.2 Prior to painting, proper surface preparation should be ensured.

2.7.5.3 The painting work done shall be checked for the required specification regarding

quality of paints, dry dim thickness.

2.7.6 INSPECTION DURING ERECTION WORK IS TO BE CARRIED OUT AT

THE FOLLOWING STAGES:

2.7.6.1 GENERAL INSPECTION:

2.7.6.1.1 It should be ascertained that the gate parts received at site have been

manufactured according to the design and have necessary match markings made

at shop. It shall be ensured that all exposed surfaces of the embedded parts have

been protected by painting, greasing etc. The surface of the embedded parts in

contact with concrete should be free from grease, paint etc. for bonding with the

concrete. A coating of cement wash may be given in necessary.

2.7.6.1.2 The reference axis lines. Centers of openings and levels having relations to

completed civil structure shall be established on the site so as to ensure emotion

at proper locations.

2.7.6.1.3 It shall be ensured that all the components of hoisting assemblies, such as meter,

reduction gear assembly, wire rope, control panels etc. are received without any

damage. Care shall be taken for proper stage and handling of the components.

2.7.6.1.4 Concreting behind the gate groove may be done in one or two stages by the civil

contractors. If done in two stages, it should be ensured that adequate blackouts

are kept for accommodating the gate parts as manufactured both with respected

to dimensions and anchorage provision according to the design. Ensure that the

perquisite dowel bars of adequate length are left out in the block outs. The entire

block out should be left roughened properly for further concreting to give

necessary bunt to the second stage concreting.

2.7.6.3 INSPECTION OF EMBEDDED PARTS:



SP 79

2.7.6.3.1 It should be ensured that the sill beam is correctly positioned both in level and

location. All the nuts and bolts of anchorages of the sill should be tightened so as

to prevent dislocation during and after concreting.

2.7.6.3.2 The embedded parts, namely track beam, guides, seal seats, gate groove lining,

etc. shall be checked when all these parts are in their final position it least up to

double the gate height in one height in one operation. The check should be

carried out both with respect to the location and levels with respect to the sill

beam already established in position. Each part should be checked first

individually and thereafter relatively with the other parts. It should be should be

ensured that manufacturing tolerances, as prescribed, are considered while

erecting these parts and even after accounting for these tolerances the erection

work is carried out according to the provision.

2.7.6.3.3 The track beam and seal seats shall be in true alignment. The alignment can be

checked by means of a fine plumb bob and feeler gauge preferably at 300 mm

intervals from bottom to top-side of the gate opening . Alternatively, diagonal

checking or any other satisfactory method can be adopted for checking the

alignments.

2.7.6.3.4 After checking the track beams and seal seats on both sides it shall be ensured

that they are in terms of their respective planes. It should be checked that top

seat, seat, whatever provided should also be in the required plane.

2.7.6.3.5 Guides the counter guides, if provided should be checked for exact location and

true alignment, first individually and then also relatively.

2.7.6.3.6 Groove liners and corner protection angels, when provided, should be checked

for trace location and true alignment.

2.7.6.3.7 The following salient dimensions shall be checked at intervals of 300 mm from

the bottom to double the gate height.

a) Center to center distance of track beams,

b) Center to center distance of side seal seats,

c) Face to face distance of guides,

d) Face to track beam to face of side seal seat.



SP 80

e) Face to track beam to center line of guide and

f) Vertical distance between sill and the center line of top seal seat.

NOTES:

1. Use of a suitable template for checking (d) and (e) is recommended to

maintain corresponding portions of vertical embedded parts from sill level up

to the to of embedded parts.

2. For the portions falling above the level corresponding to double the gate

height the checking interval may be increased to one meter.

3. In case a tope seal is provided, the dimensions between the face of the track

beam and the face of the top seal should also be checked.

2.7.6.3.8 Eccentricity of some such arrangement, if provided to a gate for its fine

adjustment in the groove, shall not be accented for, while erecting embedded.

2.7.6.3.9 Anchorages, should be fastened or welded rigidly, after adjustment of the

embedded parts, so as to prevent dislocation of the parts while pouring second

stage concrete.

2.7.6.3.10 The gate groove concreting shall be done only after satisfying all the above

requirements, together with generating and securing proper records thereof.

Randomized recheck of alignment of the embedded parts shall be done after

concreting.

2.7.6.3.11 It shall be ensured that there is no step at the joint while extending the

embedded parts.

2.7.6.3.12 Second stage concrete surface must be smooth and properly matched with the

surface of the embedded parts and of the first stage concrete design p file, so as

to avoid any future cavitations. For high head gates, special care shall be taken

for:- latching the concrete surfaces with the embedded parts wherever the free

steam flow velocity is likely to exceed 30 m. per Sec.

2.7.6.4 INSPECTION OF GATE.

2.7.6.4.1 The gate which is received on site. After having it duly inspected in the

workshop, should be re inspected at the site for overall dimensions before



SP 81

lowering it in the gate groove to ensure proper fitting. It should be ensured

before lowering that the gate has been painted according to the specification.

2.7.6.4.2 The following salient dimensions shall be checked at intervals of 300 mm least

wherever applicable.

a) Center to center distance between wheel treads.

b) Center to center distance between side seals/bases.

c) Face to face distance between guide shoes rollers,

d) Face to seal bats to wheel tread.

e) Center line of guide shoes/roller to wheel tread in Zero position, and

f) Vertical distance between sill and the center line of top seal/bases.

2.7.6.4.3 The seals of seal bases should be checked to ensure that they are coplanar. All

the wheels should be adjusted to ensure that all wheel treads are in their proper

alignment. The wheel pipe should be locked after making this adjustment.

2.7.6.4.4 The seal bolts shall be tightened adequately and uniformly.

2.7.6.4.5 The gate wheel should be checked for free rotation to ensurre that they are not

jammed during transport/ handling. To check the effectiveness of the seal, actual

seal interference should be compared with that provided and easy operation of

gate. For the river carrying abnormal logs or solid floats, adequate protection

should be devised to safeguarded the life of the seats. This can he done either by

operational parameters of gates or by providing screening device before the gate.

2.7.6.4.6 In case of counterweighted gates or gates with ballast it should be ensured that

the weights have been added and secured properly at correct place. This is very

important consideration to achieve the correct seating pressure.

2.7.7 INSPECTIION OF COMPLETE GATE INSTALLATION:

2.7.7.1 It should be ensured that the installation of the various parts of the gate and

hoisting arrangement conforms to specify location and alignment, particularly

with respect to correct positioning and attachment of rope /stem of the gate as

well hoist.



SP 82

2.7.7.2 It should be ensured that the groove, sill and the embedded part are thoroughly

cleaned and no foreign material is present in the groove. Before lowering the

gate it is advisable to check the gate passage, either with the help of templates

representing the cross section of the gate in plan or by any other mean, to ensure

that the gate groove is free from any obstruction.

2.7.7.3 During inspection it may be ensured that there is an adequate space to carry out

maintenance, replacement or repairs on gates or parts like wheels, rubber seals

etc.

2.7.8 FIELD TEST:

2.7.8.1 The contractor shall install and commission the gates hoists cranes and their

accessories and supplied as shown on the drawings furnished by engineer in

charge on the drawings of supplier approved by the engineer in charge. the

embedded parts however will be got installed through the contractor for civil

work. The contractor shall assist by supervising the installing and

commissioning in order to determine that the equipments supplied by the

supplier fulfill the functions for which they have been supplied. The engineer in

charge wills carryout required field-tests for gates and their accessories and after

their installation. The contractor shall carry all modifications and adjustments as

required to the equipments, materials and supplies of the work as a result of

such tests.

2.7.8.2 Field tests shall be for the slide gates, hoists and stop-log gates and shall include.

1. Operational tests in dry

2. Leakage tests

3. Operational test with stipulated full reservoir level. The tests shall be

repeated, if necessary, until they are successfully carried out to the satisfaction of

the engineer in charge.

1) OPERATIONAL TESTS IN DRY:

Operational tests in dry will be carried to after of creation. The tests will include

at least two complete traverses fro, the maximum raised position to the fully

seated positional adjustments, clearances etc, shall be checked by the contractor

for proper operation.



SP 83

2) LEAKAGE TESTS:

Leakage tests will be carried out with the slide gate wheel-gate. Before the

observation for leakage the slide gate/wheel gate will be raised and lowered

suitably in order to dislodge any debris that might have lodged in the side and

bottom seals. The tests are successfully carried out to the satisfaction of the Govt.

Leakage test and operation test will be carried out at the convenience of the

Govt. After completion of other portions of the works and when the reservoir is

at full reservoir level. However, the Govt. Will have the right to carry out such

tests when the reservoir is at a level owner than full reservoirs level. The Govt.

will also have the right to carryout the leakage test by jetting water at 5 times the

normal working pressure on sealing positions from bottom to top.

A) The test against leakage shall be carried out as follows. The gate is to first rest on

the sill beam that is the closed position. The leakage test can be taken in this

position by using suitable pump, with necessary arrangements of jetting water at

1.5 times the designed pressure on seal position from bottom to top. Particularly

all corner joints and other joints, if any, are to be tested to ensure perfect working

of the gate. Allowable leakage is from 5-15 liters/m length of the seal per min.

For medium and low head gates such as draft tube gates allowable leakage shall

be less than 5 limiting/m length of the seal. For high head gates such as stop log

gates, in take service gates and take off gates allowable leakage rate shall be less

than 15 lit/min/m length of the seal.

a) The gate should be tested preferably in a dry condition with the hoist duly

connected for its smooth working. The gate should be moved up down in the

groove with no obstruction and no undue efforts required for its operation. If the

gate cannot slide down of its own weight or if it found to be going tight

anywhere reasons should be investigated and remedied instead of forcing the

gate down.

b) The testing of the gate seals in dry conditions should be done by suitable means,

such as by viewing the contact surfaces against a light source. Ensure that the

seal rides smoothly over the seal seat at the time of its approach to the latter

during the gate operation. Seal seat shall be cleaned before the trial operation.

c) In case of rubber seals, water should be initially poured over the seals so that

there is no dry friction of the seals. In case of metal-to metal contract ,oil or

grease is to be used. No grease or lubricant is to be used at rubber seals.



SP 84

d) There should be no noise due to friction of otherwise, not any signs of excessive

friction. There performance shall be free of jerks or any dug in at any position.

There shall be no dangling of the gate of twist in the rubbed seals. The top seals

should not leave their plane and the rubber scales should not be over pressed.

B) All the tests indicated under clause no. 9.11.8.2(1) with suffixes (a) (b) (c) (d) and

clause no. 9.118.2 (2) (a) should be, wherever possible, also performed with water

standing at the site to the design head.

3) OPERATIONAL TESTS WITH FULL RESERVOIR LEVEL:

The tests will simulate the actual operating conditions as closed as possible. At

least one complete traverse shall be made from fully closed position to the

normal raised position as follows:

a) When the slide gates/ wheel-gates are closed, raise the gates to their normally

open position, and,

b) Lower the gates is operate under standing water, it is to be uniformly ensured

that there are no vibrations of the rate or of the civil structure at any of the gate

openings.

By pass arrangement made for the water should be checked to ensure the proper

working of the arrangement. By pass arrangement shall be provided with an

additional emergency blue as a safety measure.

Air vents, when provide, are to be tested for their choke free performances.

2.7.9 PERIODIC INSPECTION AFTER ERECTION:

In order to detect normal wear and tear defects, if any, periodical inspection of

installed gates shall be carried out during warranty period. Dried visual

inspection of these gates shall be done as and when necessary but at least twice a

year corresponding to the period when upstream after may be necessary through

divers. Inspection shall be done for both through the following.

1. Embedded parts, and

2. Gate leaf and components.

1. Inspection of Embedded parts:



SP 85

All parts, either rigidly fixed in the concrete are partly exposed shall be subjected

to the periodical inspection. This covers sill beam seal seats, track path, guide

path, liners etc.

All the debris and blockage at and over these parts shall be cleared. Any peculiar

formation or deposition, over the embedded parts should carefully monitored.

Photographic records may be maintained, if useful.

a) Due to constant use and various known and unknown hydraulic phenomena

seal death, sill beams, track paths etc, get pitted. Eating of the metal of seal seat,

if any, should be compared with the previous rescore, variation damages

excessive scaling, uneven surfaces, stepping and should be carefully checked

preferably by using magnifying glass.

b) Due to wear and tear, surfaces may become uneven and may have

indentations, for example, roller marks over the track paths. The embedded parts

should be in their alignment. Readings of alignments should be taken at intervals

of at least 60 cm. Some fixed point may be used for taking readings at every

inspection to determine comparative war and tear.

c) The following salient dimensions should be periodically checked at

longitudinal

intervals, not less than 300 mm for uniformity as designed.

a) Center to center distance between the track plates,

b) Center to center distance between side scales,

c) Face to face distance between guide,

d) Face of seal seat to face of track path,

e) Center of guide path to face of track path, and

f) Vertical distance between sill and the center line of top seal/seat.

d) The maintenances of conformity in the dimensions mentioned in 9.11.9 (1) (d)

shall be equally obtained for the gate leaves as well.



SP 86

e) All nuts, bolts and screws shall be periodically checked for wear, tear and

tightness. Countersunk screws and bolts shall be checked for holding on to their

proper positions.

All welds shall be shacked for cracks and other defects, if any.

f) The entire gate slots shall be checked thoroughly so as not to have any

obstructions for travel of the gate.

g) In case of sliding gates all sliding metallic surface shall be inspected with utmost

care.

2) Inspection of gate leaf & components:

a) A debris and sealing should be removed from the gate leaf peculiar

formations, if any on the leaf should be carefully stripped off the scales.

Photographic records should be kept, if necessary. The skin plate and other

components should be lapped lightly by hammer to examine soundness.

b) The dry side of the skin plate should be checked for the welds, joints of

horizontal and vertical members and any drain holes for the horizontal

members.

c) Hoisting connection on the gate leaf should be checked for shearing or

punching effect and wear and tear.

d) Alignment of seals should be precision checked by means of a thread and

feeler gauge. All comer joints should be checked for any cracks. In case of

musical not rubber seals, twists, overlapping bulb flatness, deformation etc,

should be checked. There should not be any undesirable material into the

rubber seal and in between the rubber seat and the skin plate. Retractable

seals should be checked for their effectiveness. Use of oil or grease over

rubber seals should be avoided. Gladded rubber seals should be inspected for

proper adhesion between cladding and the-rubber. All the nuts and bolts,

fixing rubber seals to the gate, should be check. In case of metallic seals,

thickness and camber, if any should b: checked. Lubrication system if

provided should be shacked for free flow of lubricant.

e) Alignment of rollers should be checked and deviation of alignment should e

noted. Each roller should be checked for mal adjustment of the pin or any



SP 87

other defect. It should be rotated a number of times to ensure its free rotation.

The bearings should be shacked for conformity as designed.

f) The following salient dimensions should be periodically checked at

longitudinal intervals, not less than 300 mm for conformity as designed.

1) Center to center distance between the rollers of the fixed wheel gate.

2) Center to center distance between the side seals.

3) Face to face distance between the face of guide shoes of guide rollers,

4) Face of the rollers to face of the seal base.

5) Distance between the when fact and the center of guide shoe or guide roller in

case of fixed wheel gate and distance between the face of slide plate ad center

of the guide shoe or guide rollers for slide gates.

g) The maintenance of conformity in the dimensions shall be equally obtained

for the embedded parts.

h) All the nuts, bolts and screws shall be periodically checked for wear, tear and

tightness. Countersunk screw and shall be checked for holding on to their

position. All welds shall be checked for cracks and other defects, if any.

i) Drain holes in the components of tile gates and stop logs shall be so checked

that they do not get clogged with silt causing accumulating of water in the

horizontal girders and arms.

j) Functioning of the limit switches, interlocking devices, indication lamps etc.

shall be checked for proper working.

k) The operating system of the gate shall be checked for their proper

functioning.

l) Inspection of the gate shall be carried out the detect defects, if any, after

erection and when the reservoir is full. The gates shall be operated up and

down several times to make sure that they function well, without vibration.

m) Inspection, after erection shall consist of visual inspection of exposed surfaces

of embedded parts, sill beams, wall plates, seal seats, gate leaves, hoisting



SP 88

equipments, hoists, supporting structures and checking of important

dimensions in case of inaccessible parts, necessary inspection shall be carried

out with the help of divers or remotely operated under water vesicles fitted

with video cameras to be provided free of cost by the contractor. The choice of

method of inspection of the inaccessible parts shall be of the engineer in

charge.

n) Inspection shall be carried out of the connections of gate structures, tightness

of all fittings, soundness of all welds, leak ages through gates. Lubrication of

all bearings, guide rollers machinery and equipment, wear soundness of

metal, electrical checking of all machinery, checking of locations and level of

all parts and proper functioning of all components of gates, machinery and

equipment.

2.7.10 TESTING:

a) The gate shall be tested for its smooth travel trough out in the groove,

both up and down, without appreciable away, anywhere. All rollers

shall always be in contact with the track surface during entire travel.

b) The gate shall not be subjected to undue pressure; nor should any

extra effort be needed to operate the gate, under no load condition.

The operation should trouble free and without rattle. If it is noticed

that extra efforts are needed it should be measured by torque meter

suitable arrangements.

c) On load (i.e. when there is water) there should be no undue

vibrations in the gate and the structure . in case vibrations are noticed

during the operation of the gate, the reason thereof should be

investigated. Until remedial are taken shall not kept in the position

which vibrations are noticed.

d) The gate should be watched against any leakage in its close position

at least one under maximum head condition available in a year.

2.7.11 MAINTENANCE OF GATE:

a) Any weld that might have become defective should be chipped out

and remade damaged nuts, bolts, rivets, screws etc. Should be

replaced without delay.



SP 89

b) The gate slot and platform should be cleaned periodically. Scales

formed over the embedded parts should be removed. All bottom

comers should be cleaned and accumulations, removed. Anchorages

and concrete around anchorage’s) should be checked for any

developing cracks of slackness, etc, and repair should be attended to

immediately.

c) The gate should be thoroughly cleaned and repainted, as and when

necessary, according to the procedure recommended by the paint

manufacturer

d) Rubber seals should be thoroughly cleaned and repainted to keep it

in one alignment. All nuts and bolts fixing the seal to the gate should

be tightened uniformly. Seals, when damaged on found leaking

excessively, should be adjusted, repaired or replaced as considered

necessary.

e) Gate roller bearing and guide roller bushes should be properly

lubricated.

f) Whenever necessary these should be opened for rectifications of

defects; and after cleaning and lubrication should be refitted. These

may be replaced if repairs are not possible.

g) Hoisting connection on the gate leaf should be lubricated where

necessary and defects if nay should be rectified.

h) All nuts, bolts, check nuts and cotter pins of the lifting devices should

be checked periodically.

i) Where filling values are provided as part of the gate structure, all the

nuts. Bolts, check nuts etc should be checked periodically. It shall also

b ensure that the filling values completely shut off the passage of

water when the load is removed. To ensure the springs and other

components shall be periodically checked and replaced if necessary.

j) All components should be greased and lubricated according to coal

provisions. Recommended and approved oils and grease only should

be used.



SP 90

k) Appropriate remedial measures should be taken so that the salient

dimensions and alignment of components are set right. Appropriate

repairs should also be carried out wherever excessive pitting and

other surface damages are noted.

l) The roller assembly should be adjusted by the eccentricity

arrangement to ensure that all the rollers rest uniformly on the track

plates, particularly in the closed position of the gate.

m) Maintenance charts showing the components of gates and hoist and

their periodically undertaken checking maintenance measure should

be displayed in the control room set up with respect to the gates for

timely implementation. A register showing the time and the date of

operation, the amount of opening, discharge, etc, should be

maintained.

2.7.12 COMPOSITION OF SUPPLIERS TEAM FOR SUPERVISION:

The contractor shall install and commission the gates and their

accessories supplier by the contractor as shown on the drawings

furnished by the contractor, and approved by the Govt. Expect the

embedded parts which will be got installed through the contractor for

civil works. The contractor shall provide to the engineer in charge

service of a supervision learn for supervising unloading and stacking

operations of components of gates and hoisting arrangements and

accessories in the stockyard allotted to the contractor by the Govt.

Transport of the components of gates and hoisting arrangements and

accessories from the stockyard of the contractor to the respective

work sites and installation, commissioning and testing of gates, hoist

and their accessories in accordance with the provisions in the

contract.

The supervision team should be thoroughly experienced, competent

and well-versed in supervising the storage, transportation,

installation, commissioning and testing of gates, hoists and

accessories in accordance with the provisions of contact.

The rate quoted shall cover all coasts including transport, lodging

and boarding charges of supervision team. If possible, the Govt. Will

provide on lease unfurnished single room on a rent of Rs. 500/-



SP 91

(Rupees five hundred only) per room per month to the contractor

during period of livery and supervision on installation

commissioning and testing.

Guidelines for supervision of installation and commissioning:

Supervision for installation of the gates, hoist, cranes and their

ancillaries shall be carried out in accordance with Indian Standard

“Recommendations of Inspection, Testing and Maintenance of Fixed

wheel and slide gates IS:7718-1991 unless otherwise specified.

2.7.13 MAINTENANCE AND OPERATION MANUALS:

One set of the following in English shall be furnished by the

contractor along with the equipments at the time of transport.

1) General description of main components,

2) Operating instructions

a) General and

b) Specific (dealing with any unusual features of safety precautions)

3) Maintenance and repair instructions,

4) Lubrication,

5) Material and parts identification list,

6) Adjustments,

7) Reference drawings ,and

8) List all special tools required to follow correctly the servicing procedure.

After the final approval, the contractor shall submit ten complete sets of

Maintenance and operation manuals. All these instructions shall be

written in English.

2.7.14 REPLACEMENT OF DEFECTIVE PARTS AND MATERIALS:

2.7.14.1 If during the progress of the works and/with warranty/guarantee period

after commissioning, the engineer in charge shall decide and inform in

writing to the contractor that the contractor has manufactured or installed any

plant or part of the plant unsound or imperfect or has furnished any plant

inferior that the quality specified, be contractor on receiving details of such

defects or deficiencies shall at his own expense within 7 days of his receiving



SP 92

the notice or other wise. Within such time as may be reasonably necessary for

making it good, proceed to alter or reconstruct or re-install or remove such

work and furnish and install fresh equipment upon the standards of the

specifications. In case the contractor fails to do so the engineer in charge my

on giving the contractor seven(7) days notice in writing of his intention to do

so. Proceed to remove the portion of the works so complained of and at the

cost of contractor perform all such work or furnish all equipment preceded

that nothing in this clause shall be deemed to deprive the Govt. Of or affect

any rights under the contract which the purchase may otherwise have in

respect of such defects and deficiencies.

The contactor’s full and extra liabilities under this clause shall be satisfied by

the payment to the Govt. of the extra cost of such replacement procured

including are fiction as provided for in the contract, such extra cost being the

ascertained difference between the prince paid by the Govt. for such

replacement and the contractors price paid by the Govt. for such replacement

and the contractors price portion for such replacement and the contractors

price portion for such defective plants and repayment of any sum paid by the

Govt. to the contractor in respect of such defective plant. Should the Govt.

not so replace the defective plant the contractors extra liability under this

clause shall be limited to repayment of all sums paid by the Govt. under the

contract for such defective plant/goods.



SP 93

APPENDIX-A

TOLERANCE FOR EMBEDDED PARTS & COMPONENTNS OF GATES

Sr. Parts of Components Tolerances in mm .

A) High Head Slide Gates

EMBEDDED PARTS FOR SLIDE-GATE

1.0 Slide seals seat.

1.1 Alignment in plane parallel to flow +0.25

1.2 Distance between centerline of opening an seal seat. +1.00

1.3 Coplanerness. +0.25

2.0 Top Seal Seat.

2.1 Alignment parallel to flow +0.25

2.2 Height above sill +1.00

2.3 Coplanerness with wide seal seat. +0.25

3.0 Upstream Guide Track

3.1 Alignment in place parallel to flow



SP 94

3.2 Distance between centering of opening & guide. +1.00

3.3 Track Coplanerness +0.25

4.0 Side Guide Track

4.1 Alignment in place normal to flow +0.50

4.2 Distance between cnterline of opening & guide track. +0.50

4.3 Alignment in place normal to flow +0.50

5.0 Bottom Seal Seat.

5.1 Alignment in horizontal plane. +0.25

6.0 Critical Dimensions

6.1 Center-to center distance between side-seal-seats. +2.00

6.2 Face to face distance between side guide tracks. +1.00

6.3 Distance between face fo upstream guide track +0.50

and side seal seat.

6.4 Center to center distance between upstream, guide tracks +2.00

B) SLIDE GATES

1.0 Side and top seal seat.


1.2 Coplanerness +0.25

2.0 Side Guide


3.0 upstream Guide



SP 95


4.0 Leaf bottom Edge

4.1 Alignment in horizontal plane +0.25

5.0 Critical Dimensions +0.25

5.1 Center to center distance between side seal plates +0.50

5.2 Center to center distance between upstream guides. +0.50

5.3 Face to face distance between side guides +1.00

5.4 Face to face distance between side seal plate and upstream guide +0.50

C) EMBEDDED PARTS FOR FIXED WHEEL TYPE GATES

1.0 Track plates.

1.1 Alignment in place paralleled to flow +0.50

1.2 Distance between centering of opening and track +1.00

1.3 Complanarness +0.50

2.0 Guides

2.1 Alignment in plane normal to flow +1.00


2.3 Distance between center line of opening and face of guide +0.50

3.0 Side Deal seat


3.2 Distance between center line of opening and side seal seat +1.00

3.3 Coplanerness +0.50



SP 96

4.0 Top Seal Seat.

4.1 Alignment +1.00


4.3 Complanerness with side seal seat +1.00

5.0 Bottom seal seat

5.1 Alignment in horizontal plane +0.50


6.1 Center to center distance between track plates +2.00

6.2 Center to center distance between side seal seats +2.00

6.3 Face to face distance between guides +2.00

6.4 Face to track to face of side seal seat +1.00

6.5 Face of track to center line of guide +2.00

D) FIXED WHEEL TYPE GATES

1.0 Wheels.

1.1 Alignment of trends in zero eccentricity position +1.50

2.0 Side and Top Seal Base

2.1 Alignment +0.50

2.2 Coplanarness +0.50


3.1 Center to center distance between seal bases +1.00

3.2 Center to cater distance between center line of wheel trades +1.00



SP 97

3.3 Face to face distance between faces of guide shoes or guide rollers +2.00

3.4 Face to face distance between wheel trend to side seal base +0.00

3.5 Distance between faces of wheel tread and center line of guide +1.50

Shoe / roller.

II) FOR LOW HEAD SLIDE GATES

A) EMBEDDED PARTS

1.0 Slide Seal Seat.

1.1 Alignment in place paralleled to flow. +0.50

1.2 Distance between center line of opening and seal seat +1.50

2.0 Top Seal Seat

2.1 Alignment in plane parallel to flown. +0.50


3.0 Side Guide Track

3.1 Alignment in plane normal to flow +1.50

3.2 Distance between center line opening and guide track +1.00

3.3 Alignment in place parallel to flow +1.00


4.1 Center to center distance between side seal seat +3.00

4.2 Face to Face to distance between side guide tracks +2.00

B) GATE

1.0 Side and Top Seal Seat


1.2 Complaneress +0.50

2.0 Side Guide





SP 98

3.1 Center to center between side seal plates +1.50

3.2 Face to Face distance between side guides +1.50

APPENDIX – B

APPLICABLE STANDARDS / PUBLICATIONS ETC

1. IS : 289-1963 Aluminum paste for paints (revised)

(Amendment 1989)

2. IS : 290-1961 Coal tar bar paint (revised)

(Re-affirmed 1991)

3. IS : 291-1989 Naval brass rods and sections (suitable for marching

and forging) (Second Third revision)

4. IS : 305-1981 Specification for Aluminum Bronze ingots and

Castings (second revision) (Reaffirmed 1991)

5. IS : 318-1981 Specification for Leaded Tin Bronze ingots and

Castings (Second revision)

6. IS : 325-1978 Specification for Three phase induction Motors

(Fourth Revision) (with Amendments No.3)

(reaffirmed 1991)

7. IS : 456-1978 Code of practice for plain and Reinforced Concrete

(Third Revision)

(With Amendments No.1)

8. IS : 780-1984 Specifications for sluice valves for water works

purposes-50 to

300 mm size.



SP 99

9. IS : 800-1984 Code of practice for General Construction in steel

(Second Revision)

(Amendments 2 Reaffirmed 1991)

10. IS : 807-1976 Code of practice for design, manufacture, erection

and testing structural portion of cranes and hoists

(First Revision)

(Reaffirmed 1990)

11. IS : 808-1989 Dimensions for hot rolled steel beam, column

channel and angle sections (Third Revision)

12. IS : 814-1991 Specification for carbon Electrodes for manual metal

are welding of carbon and manganese steel.

13. IS : 815-1974 Classification and coding of covered Electrodes for

Metal Arc welding of structural steels (Second

Revision) (With Amendments 2)

14. IS : 816-1969 Code of practice for use of Metal Arc welding for

General Construction in mild steel (First Revision)

(with Amendments No. 1 & 2)

15. IS : 817-1966 Code of practice for Training and Testing of Metal

Arc welders (Revision)

16. IS : 1024-1979 Code of practice for use of welding in Bridges and

Structures Subject to Dynamic Loading. (First

Revision)

17. IS : 1030-1989 Specification for carbon steel castings for general

Engineering purposes (Fourth Revision) (With

Amendments 1)

18. IS : 1068-1988 Specification for Electroplated coatings of Nickel and

Chromium or iron and Steel (Second Revision)

reaffirmed 1987



SP 100

19. IS : 1231-1974 Dimensions of three phase mounted induction

motors (Third Division) (with Amendments 4)

20. IS : 1271-1985 Thermal evaluation and classification of electrical

insulation (First Revision)

21. IS : 1363-1984 Hexagon Head Bolts, Screws and nuts of product

Grade C Part-1

(Part – 1) Hexagon Head Bolts.

22. IS : 1363-1984 (Size Range M5 to M36)

(Part – 2) (Second Revision) (with I Amendment)

(Reaffirmed 1986)


Grade C Part-2

(Part – 3) Hexagon Head Bolts.

(Size Range M5 to M36)

(Second Revision) (With I Amendment)

(Reaffirmed 1986)


Grade C Part-3

(Part – 1) Hexagon Head E,) Its


(Second Revision) (With I Amenc rient)

(Reaffirmed 1986)

25. IS : 1363-1984 Specification for Hexagon Head Bolts, Screws and

nuts of

(Part – 2 ) product Grade A Part – I Hexagon Head Bolts


(Second Revision) (With I Amendment)

(Reaffirmed 1986)



SP 101

26. IS : 1367-1979 Technical Supply conditions for Threaded Steel

Fasteners

(Part – X VIII) Part-I introduction – id General information (Second

Revision)

(Read Irmed 1991)

27. IS : 1367-1979 Technical Supply conditions for Threaded Steel

Fasteners

(Part – II) Part – II product Graces and Tolerances (Second

Revision)

(Reaffirmed 1987)

28. IS : 1367-1979 Technical supply conditions for Threaded steel

Fasteners Part –

(Part – III) III Mechanical properties and test methods for Bolts,

Screw and

studs with full load ability (Second Revision) (With

Amendement

No-1) (Reaffirmed 1989)


Fasteners Part –

(Part – V) V Mechanical properties and test methods for Serew

and similar

three added fasteners not under tensile stresses.

(Second



SP 102

Revision) (With Amendment No.1) (Reaffirmed 1987)


Fasteners Part –

(Part – VI) VI Mechanical properties and test methods for nuts

with

specified proof loads. (Second Revision) (With

Amendment No.1) (Reaffirmed 1987)


Fasteners Part –

(Part – VII) VII Mechanical properties and test methods for nuts

with specified proof loads. (Second Revision) (With

Amendment No.1) (Reaffirmed 1987)


Fasteners Part –

(Part – IX) IX surface Discontinuities on Bolts, Screws and studs.

(Second Revision) (Reaffirmed 1987)


Fasteners Part –

(Part – X) X surface Discontinuities on Nuts (Second Revision)

(Reaffirmed 1987)


Fasteners Part –

(Part – XII) XII Phosphate coating on Threaded Fasteners.

(Second Revision)

(Reaffirmed 1987)


Fasteners Part –



SP 103

(Part – XIII) XIII. Hot Dip Galvanised Coating on Threaded

Fasteners. (Second Revision) (Reaffirmed 1987)


Fasteners Part –

(Part – XIV) XIV stainless steel Threaded Fasteners (Second

Revision)

(Reaffirmed 1990)


Fasteners Part –

(Part – XVI) XVI Designation System and symbols. (Second

Revision)

(Reaffirmed 1991)


Fasteners Part –

(Part – XVIII) XVIII. Marking and Mode of Delivery (Second

Revision)

(Reaffirmed 1x87)

39. IS : 1367-1971 Code pf practice for painting of Ferrous Meals in

buildings. Part-

(Part – I) I-Pretreatment ( First Revision) (Reaffirmed 1990)

40. IS : 1477-1971 Code pf practice for painting of Ferrous Meals in

buildings. Part-

(Part – II) I-Painting ( First Revision) (Reaffirmed 1990)

41. IS : 1570-1979 Schedules for wrought steels Part-II carbon steels

(Unalloyed Steels) (First Revision) sec-2 wrought

(Part – II / Sec.I) products other than wire with specified chemical

composition and related properties (First Revision)

(Reaffirmed 1991)



SP 104

42 IS: 1570-1985 Schedules for wrought steels part-5 stainless and

Heat- (part-5) Resisting Steels (Second Revision)

Reaffirmed 1991.

43 IS: 1599-1979 Method for Bend Test (Second Revision) Reaffirmed

1991

44 IS: 1786-1985 Specification for high strength deformed steel bars

and wires.

For concrete reinforcement (Third Revision)

Reaffirmed 1990

45 IS: 1975-1992 Specification for carbon steel Billets, Booms. Stabs

Bars for

Forgings (Fifth Revision) (with Amendments No. 1 to 4)

46 IS: 1893-1984 Criteria for Earthquake Resistant Design of

Structures (Fourth Reaffirmed 1991.

47 IS: 2002-1982 Specification for steel plates for pressure vessels for

Intermediate and high temp service including boilers

(First Revision) Reaffirmed 1991.

48 IS: 2004-1991 Specification carbon steel forgings for general

revision

(Third Revision) (Amendment No. 3) Reaffirmed

1992.

49 IS: 2062-1984 Specification for weld able structural steel (Third

Revision) (Amendment No.3 ) Reaffirmed 1992.

50 IS: 2243-1974 Designation for types of construction mounting

arrangement For rotating/electrical machines(First

Revision) Reaffirmed 1986

51 IS: 2266-1989 Specifications for steel wire ropes for general

engineering Purpose (Third Revision)



SP 105

52 IS: 2246-1985 Circuit breakers Part-1 requirements and testes

section 1

(part-1 & Sec. 1 : voltages not exceeding 1000v AC or 1200 v DC

(Second Revision) (Revision) (Reaffirmed 1991.

53 IS: 2266-1989 Code for unfired pressure vessels (Reaffirmed 1984).

54 IS: 3073-1967 Assessment of surface roughness (Amendment

3)Reaffirmed 1987

55 IS: 3177-1977 Code of practice for design of cierhead traveling

cranes and Gantry cranes (First Revision) Reaffirmed

1987.

56 IS: 3443-1980 Crane rail sections (First Revision) Reaffirmed 1987

57 IS: 4218-1976 ISO metric screw threads part-3 Basic Dimensions

for

(part-3) Design profiles (First Revision) Reaffirmed 1990

58 IS: 4218-1976 ISO metric screw threads part-4 Tolerances (First

Revision) (part-4) Reaffirmed 1990

59 IS: 4218-1979 ISO metric threads part=5 Tolerances (First Revision)

Reaffirmed (part- 5) 1990

60 IS:4218-1978 ISO metric screw threads part-6-limits of bolts and

(part-6) nuts(Diameter Range 1 to 52 mm) (First Revision)

Reaffirmed 1990

61 IS: 4622-1992 Recommendations for structural Design of Fixed

wheel Gates(First Revision)

62 (a) IS: 4255-1979 Recommended for practice for straight beam

Ultrasonic testing of steel plates.

63 IS: 5530-1987 Recommendation for production Rectification and

repair of steel castings by Metal Arc Welding process

(First Revision)



SP 106

64 IS: 5620-1985 Recommendations for structural design Criteria for

low head slide gates (second Revision) Reaffirmed

1990

65 IS: 4218-5749-1970 Forged Ramshorm hooks Reaffirmed 1988

66 IS: 5897-1985 Specification for Aluminum and Aluminum Alloy

welding rods and wires and magnetic.

67 IS: 5897-1985 Alloy welding Rods (First Revision) Reaffirmed 1991

68 IS: 6938-1989 Specification for High Strength structural nuts (First

Revision) (With I Amendment)

69 IS: 6639-1972 Code of practice for design of rope drum and chain

hoists for hydraulic gate.

70 IS: 6649-1985 Specification for Hexagonal bolts for still structures

(with 4 Amendment) Specification for hardened and

tempered washers for high strength structural bolts

nuts (first revision) with I Amendment- Reaffirmed

1988.

71 IS: 7307-(part-I) Approval test for welding procedures fusion

Reaffirmed 1991.

72 IS: Approval test of working welding procedure.

Welding of Reaffirmed 1987

73 IS: Re communications for inspection and Maintenance

of Fixed steel and Slide Gate.

74 IS: 7814-1985 Prosper Sheet, strip (First Revision and foil

75 IS: 9034-1978 Enamel, synthetic, exterior, air drying for use. On

primed surface of motor vehicles & other equipment

(Reaffirmed 1991.)

76 IS: 9349-1986 Recommendation for structural design of medium

and high head slide gates (First Revision) Reaffirmed

1991.



SP 107

77 IS: 9537-1981 Conduits for electrical installations part 2 Rigid Steel

conducts

(part-II) (With Amendment No. 2)

78 IS: 9537-1983 Conduits for electrical installations part 3 Rigid plain

(part-III) conduits of Insulation materials Reaffirmed 1990.

79 IS: 9595-1980 Recommendations for Metal- Arc Welding of carbon

and carbon manganese steels (Amendment No. 1)

(Reaffirmed 1987)

80 IS: 9917-1981 Specification for calcium base heat resistant Grease

(Reaffirmed 1991)

81 IS: 10210-1982 Design criteria of Hydraulic Hoists for intakes

(Reaffirmed 1991)

82 IS: 11388-1985 Recommendation for design of trash-rack for intakes

(Reaffirmed 1991.

83 IS: 11855-1986 Fluorocarbon / Teflon coated rubber general

requirements rubber seals for Hydraulic Gates

(Reaffirmed 1991)

84 IS: 13951-1992 Criterion for design of lifting beam.

Other Publications

American Society for Testing Materials (ASTM)

(ASTM) Designation : Standard Methods of Test E or Adhesion of D41339

Vulcanized Rubber (Eriction Test) (Re-approved in

195 without change.



SP 108

Note: Use of equivalent applicable international specifications shall be also permissible in

place of Indian

Standard specifications subject to prior approval of the Govt.

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