TECHNICAL SPECIFICATIONS OF VERTICAL LIFT GATE, EMBEDDED PARTS

AND HOISTS FOR RIVER BARRAGE

1. SCOPE OF WORK:

This section covers technical specifications for design, fabrication, supply, erection, painting, testing and commissioning of the following equipments.

i) Embedded parts for barrage gate ii) Gate leaf iii) Chain pulley block hoisting system with all necessary with all

accessories, controls and supporting structures.

2. GENERAL DESCRIPTION:

Two hundred and ten numbers of gates are proposed in the over flow section of barrage. Simple self closing slide gates are proposed. The function of gates is mainly to augment the storage. It is proposed to provide hand operated mechanical hoist system like chain pulley block or similar system for rope drum hoist for operating these gate. The gates could be in a single ..eat or in multiple elements.

3. APPLICABLE PUBLICATIONS:

All the materials, designs, fabrication and erection of embedded parts, gates and hoists will conform to the latest edition of the relevant Indian Standard Specifications or other Internationally recognised standard specifications unless otherwise specified.

4. DESIGN CONSIDERATION AND DATA FOR DESIGN:

5. Barrage gate and embedded parts :

The barrage gates will be self closing slide type designed on a semi-flexible basis The gate leaf will consist of up stream skin plate supported on horizontal girders which in turn be mounted on end boxes so that the total water load is transmitted through the wheels to the track plates embedded in concrete. Teflon cladded rubber seals will be provided on upstream face of the gate leaf. The thickness of skin plate will not be less than 10 mm.

Clear vent opening : 2.00 x 4.50 m

Full reservoir level (FRL) : RL 344.00 m Maximum flood level (MWL) : RL 346.50 m Sill level : RL 339.50 m Location of skin plate : Downstream Location of seals : Downstream Operation of gate : By chain pulley block or similar simple

system Number of gates : 210 The gate and embedded parts will be: i) Designed for FRL condition with permissible stresses not

exceeding the values specified in IS: 5620 for wet and inaccessible condition for embedded parts and gate leaf.

ii) Checked for MWL plus earth quake condition with permissible stresses indicated in (i) above increased by 33.33 percent subject to a maximum of 0.85 yield point stress (YPS).

The coefficient of horizontal acceleration for earthquake condition will be taken as 0.12 g applied uniformly. The bearing pressure for concrete will be taken as 50 kg/sqcm. The maximum deflection of the gate leaf will be less than 1/800 of the distance between centre to centre of the seals. The embedded parts will be designed to withstand the load transmitted by the gate and to transfer the load effectively to

the concrete.

6. Chain pulley block and Accessories :

The capacity of the chain pulley block or similar simple system shall be designed for operation of barrage gate under MWL condition with 20% reserve capacity . The operating speed shall be 0.3 metre per minute.

7. DESIGNS AND DRAWINGS :

The drawings showing the general arrangement of gates and hoists are included in the Bid documents. These drawings are illustrative and can be modified with the concurrence of the Engineer to suit the design of the equipment to be supplied. It is binding on the part of the Contractor to adhere to these drawings as far as clear vent openings and levels are concerned. The Contractor will prepare detailed designs and drawings and get the same approved by the Engineer. The equipment will be modified at the convenience of the Engineer if required for operational and maintenance facilities.

The design and drawings will be scrutinised by the KBJNL and approval will be communicated. Any changes, additions, alterations in the designs and drawings considered necessary in the opinion of the Engineer will be incorporated by the Contractor in the final designs and drawings. The Contractor will submit revised drawings duly incorporating all such changes, additions, alterations etc., proposed by the Engineer for final approval.

The Contractor will fabricate and supply the gates/embedded parts/hoists/controls etc., as per his designs supported with detailed drawings and calculations and as approved by the KBJNL from time to time. Contractor will prepare all necessary shop drawings, covering the equipment to be furnished under these specifications and will be

responsible for the correct fitting of all parts. Unless otherwise specifically provided for in the schedule or in the specifications or on the drawings, the Contractor will furnish all the materials, accessories and appurtenant parts called for in the specifications or shown in the drawings and anything shown on the drawings and not mentioned in the specification or required by the specifications and not shown on the drawings as if required or shown in both. The Contractor will furnish such other parts and accessories not explicitly shown on the drawings or mentioned in the specifications if such parts are essential in the Contractor's opinion for satisfactory performance of the equipment.

8. MATERIALS: 9. General:

i) Materials used in the fabrication of the gates, embedded parts,

hoists etc., to be furnished under these specifications will be of high grade, free from defects and imperfections, of recent manufacture, unused and of the classifications and grades designated in the specifications and approved drawings. Where any material has not been specified, it will be the best available for the purpose for which it is proposed to be used considering strength, ductility and best engineering practice and conform to the latest applicable Indian standards or other equivalent standards in the country of manufacture, to the satisfaction of the Engineer.

ii) The name of the contractor of the complete equipment which are

contemplated in the work will be furnished for approval together with performance capacities and other pertinent information pertaining to the equipment. Samples of materials will be submitted for approval when so directed.

10. Quality of materials :

i) All materials, parts and assemblies thereof, being used in the work

to be done under these specifications will be of tested quality and all works performed will be subject to rigid inspection and no

articles or materials will be despatched until all tests, analysis and shop inspection have been completed or certified copies of reports of results and analysis will have been accepted.

ii) Certified copies in triplicate of the tests made and of the results

thereof, will be furnished as soon as possible after the tests are completed. The results of the test will be in such forms as to provide means of determining compliance with the applicable specifications for the materials tested.

11. Materials for the components of barrage gate and hoist :

Sl.No.

Component Parts Material Specification

1 Skin plate, girders, stiffeners, seal, track base, sill beams, embedded parts, guide track, anchor bolts etc

Structural steel IS:2062

2 Seal seats (minimum 100 x 8 mm)

Stainless steel IS: 1570 04 Cr 8 Ni10

3 Seals Teflon cladded rubber seals

4 Seal fixing bolts Stainless steel IS: 1570 5 Wire rope 6 x 37

construction IS: 2266

6 Rope shaves Cast steel IS: 1030 7 Hook pins Carbon steel

With Nicrome plating

IS: 1570 C-30 / C-40

8 Chain pulley block or similar system

Of reputed manufacture

12. Conduits:

All electrical conduits will be of heavy gauge and will be hot dip galvanised.

13. FABRICATION: 14. General:

All fabrication work will be done in accordance with the specifications. All works will be performed and completed in a thorough workman like manner as per latest practice in the manufacture and fabrication of equipments of the type covered by these specifications. The work will in all cases be of the highest quality and carefully performed to the satisfaction of the Corporation . The Contractor will ensure satisfactory operation of all the equipments in the tropics under humid and dusty conditions. The Contractor will guarantee all materials and workmanship in fabrication to be free from defects. The Contractor will replace free of cost any defective material or fabricated equipment noticed during erection and will also bear all cost of any modifications or rectification of any defects. The workmanship will conform to the latest standards laid down in Indian Standard Specifications. All structural members will be free of twists, bends or other deformations and all surfaces that will be in contact will be thoroughly cleaned before assembling. Parts will be adjusted to line and fit and will be firmly bolted or otherwise held securely together such that the surfaces are in close contact before drilling, reaming or welding is commenced. Plates with laminations discovered during cutting, welding or at any other time will be rejected.

If the weight limitations and transport clearances do not permit, the gates, embedded parts, hoist, control system and other miscellaneous parts will be fabricated into sub-assemblies. All parts or sub assemblies will be fabricated in accordance with the approved specifications and drawings. The contractor will take special care in fabrication of all parts in respect of their strength, rigidity, water tightness and smooth operation. The contractor will also comply with the following requirements in fabrication :

i) Straightening of members :

Before being laid off or worked in any manner, structural steel will be straight, without twist, bends or kinks and if straightening is necessary it will be done in a method which will not injure the metal. Heating or hammering will not be permitted.

ii) Shearing, chipping and gas cutting : Shearing or chipping will be performed carefully and all portions of the works which, will be exposed to view will present a neat appearance. Planing or finishing of sheared or cut edges of plates or sections will not be required except as shown in the drawings or as per specifications. Gas cutting will be permitted subject to approval by the Engineer.

iii) Edges to be welded :

The edges of plates and sections to be joined by welding will be properly formed to suit the type of welding selected. Where plates and sections have been sheared, the edges to be joined by welding will be machined or chipped to sound metal.

iv) Bent plates and sections :

Where bending or forming of plates or sections is required, the plate or section will be bent by cold forming. Heating and hammering to correct bends will not be resorted

v) Reamed work :

Open holes in material 20mm or less in thickness will be sub-drilled or sub-punched before assembly, and reamed during assembly. Holes in structural steel more than 20mm in thickness will be drilled to full size during assembly or will be drilled 3mm less in diameter than the

nominal diameter of the rivet or bolt before assembly and reamed to full size during assembly. All members will be shops assembled before reaming or drilling holes for field connections.

vi) Punching:

For sub-punching, the diameter of the punch will be 4.5mm smaller than the nominal diameter of the rivet or bolt, and the diameter of the die will not be more than 2.5mm larger than the diameter of the punch. Also holes will be cleaned of torn or ragged edges. vii) Drilling and Reaming:

Except where reaming to size of tapping is required or where tight fit bolts or dowels are to be used, full sized drilled or reamed holes will not be less than 1.5mm nor more than 2.5mm larger than the nominal diameter of the rivet or bolt used. Holes will be accurately located, drilled, and reamed perpendicular to the face of the member and if necessary will be drilled to a template. Counter sunk where required, will be done carefully and to full depth of head. Drilling or reaming during assembly will be done after the pieces forming a built up member are assembled and firmly bolted together with surface in close contact. All reaming will be done with machine and all outside burns will be removed.

viii) Accuracy of punching, reaming and drilling:

a) Before assembly :

The accuracy of all holes will be such that after assembly a cylindrical pin 3mm less in diameter than the nominal size of the holes may be passed through, perpendicular to the face of the member without drifting in not less than 75 percent of group of continuous holes in the same plane. All holes will pass a pin 5mm smaller in diameter than the nominal diameter of the holes.

b) During assembly :

Accuracy of reaming and drilling during assembly will be such that not less than 85 percent of any group of continuous holes in the same plane will show no offset greater than 1 mm between adjacent thickness of materials.

i) Welded studs:

Welded studs wherever used will be welded in place with automatic end welding guns. Templates of sufficient thickness to afford good alignment will be used to accurately locate the studs during the welding cycle and to locate matching holes in other material. Bushings will be used for template holes, if necessary to ensure angular alignment of the studs and location accuracy required for proper fit of parts to be assembled.

ii) Patterns:

The rates quoted in the Schedule of Quantities will include the cost of all necessary patterns. Patterns will remain the property of the Contractor. Care will be taken to avoid sharp corners for abrupt changes in cross section.

iii) Tolerances and Fits: Tolerances and fits used for different components will be according to the modern shop practice. Due consideration will be given to the special nature of function of the parts and to corresponding accuracy required to secure proper operation. The fits and tolerances will generally be in accordance with IS:2709. iv) Screw threads :

Unless otherwise specified on the drawings the threads for bolts and nuts will have metric threads as per latest Indian Standards.

v) Machine finish :

The type of finish, unless otherwise specified will be that most suitable for the part to which it applies and will be smooth, average or rough as defined under IS:3073. In general a very smooth finish (three delta 0.025 to 1.6 microns) will be required for all surfaces in sliding contact, average or commercial finish (two delta 1.6 to 6.3 microns) for surfaces in permanent contact where a tight joint is required and a rough finish (single delta 6.3 microns) for all other machined surfaces.

vi) Castings :

All castings will be true to patterns and the thickness of the metal will not vary at any point by more than 1.5mm from that shown on the drawings. Care will be taken in the foundry to cool the casting properly so that it will not warp or twist. All castings will be free from crack, large or injurious blowholes and other blemishes. They will have a workman like finish, inside angles having proper fillets and unfinished edges of bases, ribs and similar parts being neatly cast with rounded corners.

No welding will be done after the castings are finally annealed. The castings will be tested ultrasonically for their soundness.

vii) Welding :

a) Preparation for welding :

Member to be joined by welding will be cut accurate to size, and where required will be rolled or pressed to the proper curvature in accordance with the dimensions shown on the drawings. The edges of the members to be joined by welding will be sheared, flame cut or machined to suit the required type of welding and to

allow thorough penetration. The cut surfaces will expose sound metal free from laminations, surface defects caused by shearing or flame cutting operations and injurious defects. The surface of plates to be welded will be free from rust, grease and other foreign matter for a distance of at least 500 mm from the edge of the weld. In assembling and during welding, the component parts of built up members will be held in place with sufficient proper clamps or other adequate means to keep all parts in proper position.

b) Welding technique :

All welding will 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 will be used. After being deposited, the weld will be cleaned of slag or flux and will 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 will indicate good fusion with the base metal. When weld metal is deposited in successive layers, each layer except the last will be peeled moderately with tool before the next layer is applied. Particular care will 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 will be ensured. All pinholes, cracks and other defects will be repaired by chipping or grinding the defects to sound metal and re-welding. Where fillet welds are used, the member will be held together during welding. The welding rods used for manual welding will be of heavily coated type and will be suitable for all position welding where required. In welding, precautions will be taken to minimise stresses due to expansion and contraction and distortion due to heat by using the proper sequence in welding, i.e., by peeling the welds while hot or by other satisfactory methods. Rectification of distortions by blows after welding will not be permitted. Welds will not be painted until they have been inspected and approved. The welding will conform to IS:816. All skin plate welds will be

continuous and water tight and will develop the full strength of the plate. Joint welding electrodes and rods will be of the low hydrogen type. The electrodes will conform to the applicable provisions of IS specifications.

The shop and field welding procedure will be in accordance with the best modern welding practice and will be such as to minimise residual stresses and distortion of the finished members of the structure. Welds in contact with rubber seals will be ground flush, all corners and corner welds in contact with rubber seals will be rounded. Radiographic tests will be carried out for all important welded joints.

c) Specifications of welding process :

The specifications of the welding process that is proposed to be used will be established and recorded, and if required, a copy of such process and specifications together with certified copies of report of result of tests made in accordance with process, will be furnished. The specifications of the welding process will be atleast equal to that required by the "Standard Specification Procedure" of the Indian Standards.

d) Qualification of Welders :

All welders assigned to the work will have passed a qualification test for welders. If at any time, the work of any welder appears to be questionable, such welder will be required to pass additional qualification test as per relevant Indian Standards to determine his ability to perform the type of work on which he is engaged.

i) Stress relieving :

Stress relieving of parts where required will be carried out after all welding is complete but before that part is machined or assembled into structure.

The stress relieving of parts will be accomplished as follows :

The temperature of furnace will be first raised to 300 degree centigrade and then checked to see that the temperature is uniform throughout. The part is then placed into the furnace. It will then be heated from 300 degree C to 650 degree C in an hour and a half. The temperature of furnace will then be maintained at 650 degree C for 75 minutes and during that time the variation in temperature will be restricted to 50 degree C. The part will then be cooled to 300 degree C in a closed furnace restricting the time of such cooling to 180 minutes. From 300 degree C downwards the part may be cooled at the inside or outside of furnace but the air surrounding the work will be still. Stress relieving of the plates will be carried out as per the provisions of IS: 9349 and for welded girders as per IS: 4623. The stress relieving will be done as per IS: 2825.

ii) Erection bolts and anchors:

The number of erection bolts/anchors to be supplied will be 5% (minimum 10 numbers) in excess of the nominal number of each size required for complete installation of the equipment. Bolts in tension will have a net section at the root of the thread 15 percent in excess of the net section required in tension.

iii) Lubrication :

Lubrication arrangement will be provided for all the working parts and the parts, which are in contact with other parts except for those where the lubrication will hamper the function of the part.

15. Gate Leaf :

The gate leaf will be of structural steel fabricated as per the

specifications and drawings. Templates or lay out plates will be used to ensure correct machining of holes in connecting parts. The gate will be stress relieved, first after welding but before initial or rough machining and secondly after initial machining but before final machining. The C.L of pin holes will be perpendicular to the vertical C.L of the gate and will be in a common plane which will be parallel to the finished surfaces of the seal bases with the tolerance of 1.5 mm.

16. Seals :

The Teflon cladded seals will be of solid bulb music note type or Z type and will be attached to the downstream side of the skin plate. The seals will be in contact with seal seat surface of the embedded parts. Seals will be fixed to the gate leaf by means of clamps/bolts/screws so as to ensure a positive water tightness between the seal and the gate, and to bear tightly on the seal seat to prevent leakage. The rubber for seal will conform to IS:11855.

17. Guide rollers :

Gate guide rollers will be provided on the sides of the gates to limit the lateral motion of the gate to not more than 6mm in either direction. The rollers will be adjustable and will travel on the guide track embedded in concrete. The faces of the rollers will be slightly crowned. The rollers will be provided with bronze bushings turning on fixed steel pins. Suitable arrangement for lubrication of these rollers will also be provided. Where necessary, counter guide rollers will be provided to limit the transverse movement of gate. A minimum of two guide rollers will be provided on each side of the gate to resist the counter and lateral movements of the gate and at the same time to prevent the gate from jamming. A minimum clearance of 3 to 6mm will be provided between the guide rollers and guide track. The guide rollers will be structurally adequate to withstand the load they are likely to be subjected to during operation of the gate. Suitable spring

assembly will be provided beneath the guide roller assembly to restore the gate to normal position after any deflection. The guide rollers will be designed to the maximum loads to which they will be subjected to during operation. A minimum load of 5 percent and maximum load of 10 percent of the total dead weight of the gate is recommended for the design of each guide roller.

18. Embedded parts and liners :

The embedded parts for gate groove will consist of seal seats, sill beam, guide tracks, stiffeners, anchor bolts and complete set of anchorages. The anchor bolts for embedded parts will be with double nuts and washers. Suitable anchor plates will be provided for embedment.

i) Bottom, side seal, seal base and seal seat:

The bottom, side seal base will be of structural steel and will be embedded in concrete. The seal seat base will be stiffened suitably on the back. The seal seat base will be true to line on erection. The seal seat will be of stainless steel plate. The width of the seal seat will not be less than 100 mm and the thickness of plate will not be less than 8mm. The stainless steel seal seat will be welded to the structural steel seat base so as to be water tight and rigid. The seal seats will be finished smooth to present a smooth surface for gate seal. The edges of the seal seat will be rounded/ chamfered to prevent damage to the seals during gate operation. The face of the bottom, sides and top seal seats will be in common plane within a tolerance of 0.4mm in 3 metre length. There will not be any offset or gap at the joints/ junctions of seal seats. The vertical seal seats will be plumb within 1.5mm in over all length will be provided up to top of groove.

ii) Sill Beam :

The sill beam will be of structural steel and will be resting over suitable bearing plates. The bearing plates will be provided below the sill beam and will be welded to the sill beam. To facilitate adjustment of

the level of sill beam, suitable adjustment bolts or anchor bolts will be provided. These anchor bolts will be connected to the bearing plates by nuts. The designed mild steel section of the sill beam will be welded with 8 mm thick (100 mm width minimum) stainless steel plates for proper sealing purpose and machined smooth. The surface will be flush with the surrounding concrete. iii) Guide track base and guide track :

The guide track base will be of structural steel section and the guide track will be of structural steel or rail section rigidly welded to the guide track base. The guide track will be suitable for the type of guide rollers provided on the gate. The guide track base will be anchored/ embedded in concrete firmly. The guide track will be of adequate thickness and will be vertical within a tolerance of 0.5mm in every 3m height with an overall tolerance of not more than 1.5mm. A clearance of 6mm will be provided on all sides between the guide track and the guide roller of gate for easy movement of gate during operation. The guide track will be provided up to the top of gate groove.

Chain pulley Block:

The chain pulley block or similar equipment are proposed for operating the gate shall be of required capacity as per design and shall be of reputed manufacture. Approval of the Engineer is essential before the supply of the hoisting system from any manufacturer.

The operating system shall be such that the gate is connected to hoist using suitable wire rope. The ropes will have sufficient strength.

Design arrangement:

The gates could be in a single element or in more than one element as per the designs and other details to be furnished by the successful bidder. In case of single element, it is desirable to provide suitable arrangement for dogging of gate above the MWL / Road level during

monsoon when the gate vents are kept oven. The agency shall provide suitable arrangement for dogging of gates.

Incase of multiple element gate, arrangements / provisions for lifting and storage of the gate elements shall be provided.

The system / arrangement as required above shall be of most economical type.

19. SHOP ASSEMBLY: 20. 3.08.1 Embedded Parts:

All embedded parts will be checked for accuracy of fabrication and machining in the shop before shop painting.

21. Barrage Gate :

The gates will be completely assembled in the shop to ensure that all parts to be connected fit properly and that all the dimensions, clearances and tolerances called for in these specifications or shown in the drawings have been obtained. The gates will be assembled to ensure proper alignment and holes for field connections will be carefully drilled or reamed while the gates are being assembled. The gates will be assembled as considered necessary to check fabrication and all parts will be carefully match marked to facilitate re-erection at site. The holes to be provided for field connections, if any, will be reamed to such a degree of accuracy that will ensure that the finished faces of abutting sections are held flush.

22. Hoist and its components:

The equipment will be completely assembled and tested in the shop to ensure that all parts fit and operate properly and that all tolerances are within the limits required for the service intended.

All parts will be clearly identified by the Contractor to agree with the working and erection drawings to be prepared by him. Records of all inspection work by the Contractor will be kept complete and made available to the Nigam during the performance and for such longer period as desired by corporation.

All the components of the hoists will be dissembled after the test.

23. SHOP PAINTING :

24. General:

All paints and painting materials required for the field and shop painting will be got approved by Corporation. All paints will be applied by skilled workers in a workman like manner and each coat of paint will be permitted to dry properly before the succeeding coat is applied. Paint will not be applied during damp weather or on surfaces that are not entirely free from moisture. Equipments used for applying paint by spraying will be of the best quality and will include an agitator and means of removing all free oil and moisture from the air supply line. Any warming of paint will be performed by means of hot water bath. Coal tar enamel and coal tar pitch will not be heated to a temperature higher than 40 degree C. All paints will be in thoroughly mixed conditions at the time of application.

25. Preparation of surface:

All the surfaces to be painted or to be protected from rusting and salinity effect, will be cleaned in accordance with the following procedures:

i) All welds spatters or any other surface irregularities will be removed

by suitable means before cleaning. ii) All oil, grease, dirt and contaminations will be removed from the

surface by use of clean mineral spirits, xylol or white gasoline and clean wiping materials except that for surfaces which require coal tar coating, the cleaning solvent will be xylol. Final cleaning will be accompanied by using clean wiping materials and clean solvent.

iii) Following the solvent cleaning, all surfaces to be painted will be

cleaned of all rust, mill scale and other tightly adhering objectionable substances by sand blasting or grit blasting to expose uniform bright base metal as per Indian Standards. Any grit or dust remaining after the cleaning operation will be completely removed from the surface by brushing, air blowing, suction or other effective means.

iv) In case rust formations or other contaminations of the cleaned

surfaces occur in the interval between cleaning and painting, re-cleaning will be carried out. Surfaces of stainless steel, nickel, bronze and machined

v) surfaces adjacent to metal work being cleaned will be protected by

masking tape or by other suitable means.

26. Shop painting schedule: i) General : All stainless steel, bronze, nickel and other machined surfaces adjacent to metal work to be painted will be protected by covering with masking tape or other suitable means. ii) Embedded parts and liners : All surfaces of the embedded parts and liners, which are to come in contact with concrete after erection will be given two coats of cement wash. All unfinished surfaces of the embedded parts which will be exposed to atmosphere or water and tie flats will be given two coats of zinc rich epoxy primer to produce a minimum dry film thickness of 40 microns per coat.

iii) Gates: All the unfinished surfaces of the gates will be given a coat of rust inhibitive wash by brush immediately following the cleaning operations and the surfaces will be thoroughly wetted with the rust inhibitive wash at a rate of approximately 30 ml / sqm and allowed to dry for 24 hours. Rinsing after application is generally not required but un-reacted residue if any will be removed by wiping the inhibited surfaces with damp cloth. Within one hour after the rust inhibitive wash has dried thoroughly and after removing un-reacted residue, two coats of zinc rich epoxy primer will be applied by brushing without thinning to produce a minimum dry film thickness of 40 microns per coat. iv) Hoist and other accessories : All exterior surfaces, which will be accessible for further painting after assembly/erection, will be given one coat of Red oxide Zinc Chromate Primer. All exterior surfaces which will not be accessible after assembly/erection will be given two coats of Red Oxide Zinc Chromate Primer and three coats of synthetic enamel paint of approved make and colour. All machined surfaces in rolling or sliding contact and finished surfaces of ferrous metals including screw/bolt, threads which are likely to rust if not protected during transportation, storage and erection will be given a heavy coat of gasoline soluble rust preventive compound. All parts, which will not be painted, will be coated with rust preventive compound.

27. SHOP INSPECTION AND TESTING:

All supplies (which term through out this clause includes without limitations, raw materials, components, intermediate assemblies and end products) will be subject to inspection and tests by the Engineer or the representative duly authorised by the Engineer to the extent practicable at all times and places including the period of manufacture

and in any event prior to acceptance.

If any inspection or test is made by the Engineer or his representative on the premises of the Contractor, the Contractor without additional charge will provide all reasonable facilities and assistance, for the safety and convenience of the inspection staff to carry out efficiently such tests of the plant.

When the tests have been satisfactorily completed at the Contractor's premises or works or at any other point, the Engineer will issue a certificate to that effect and no plant will be transported before such certificate has been issued. The satisfactory completion of such tests, or the issue of this certificate, will not bind the Corporation to accept the plant so passed for transportation, should on further tests after erection be found not to comply with the specifications.

28. TRANSPORTATION AND STORAGE : 29. General :

After completion of required shop assembly, shop painting, inspection and testing, the equipments will be dis-assembled into minimum number of sub-assemblies convenient for transportation without damage to any part of the equipment.

30. Marking and Labelling :

Each part of the gates, embedded parts, guides, liners, hoists, etc., which is to be transported as a separate piece will be marked to show the unit of which it is a part and match marked to show its relative position in the unit to facilitate correct assembly in the field. Unit marks and match marks will be made with heavy steel stamps and paint.

Each piece, sub-assembly or package to be transported separately will be labelled or tagged with transportation designation consisting of the specifications, number and the mark number of such piece or the number of parts grouped in such sub-assemblies contained in

package for easy identification at site. 31. Weighing and packing :

Each assembly or part will be weighed and net weights exclusive of boxes, crates or skids be painted and tagged on each assembly or part before despatch. All assemblies and parts will be packed in a secure manner in boxes or crates and adequate skids and lifting slings provided where necessary. All protruding pieces or long slender parts will be adequately protected from damage.

All exposed surfaces of the equipment will be adequately protected from abrasion. All packing will allow for easy removal and checking at site. Special precaution will be taken to prevent rusting of component parts during transit Each bale or packing will contain number and date of Contract or order and the name of the office placing the order.

Wooden blocking will be provided to prevent deflection and vibration of all parts of the gates, embedded parts, liners, hoists and hoists components during transportation. All openings will be tightly covered and all parts will be coated with a rust preventive compound as specified. All arrangements will be made for protecting the package so as to avoid loss or damages during transporting by rail or road.

32. Preparation for transportation:

All parts will be prepared for transportation, necessary slings for handling may be attached readily whenever the parts are to be moved. Where it is unsafe to attach slings to the box, boxed parts will be packed with slings attached to the part and the slings will project through the box or crates so that attachments can be made readily. All exposed finished surfaces will be made adequately protected against abrasion during transportation and all long and slender pieces will be adequately supported and blocked. Rubber seals will be dismantled after shop assembly and will be transported separately. They will be wrapped and boxed to protect them from any element, which would

adversely affect their size, shape or physical properties, before they are field assembled.

33. Manufacturer's Name Plate :

Name plate will be provided indicating manufacturers name, address, etc., on equipment at a suitable location. Cast lettering except pattern numbers will not be permitted on any of the castings. Suitable name plates will be provided in the control cabinets and other locations where necessary. The name plate will be opaque and consist of black lettering over white background or white lettering over black background. The name plates, instruction plates, warning plates and any markings whatever on the equipment and its parts will be in English language.

34. Handling and storage :

The Contractor will be responsible for loss or damage due to defective packing during transit to the indicated destination. The necessary transit insurance for the equipment will be born by the contractor. The Contractor will make his own arrangement for transportation of all materials and their storage at project site. All the packages brought to project site will be checked for their contents and the materials will be stacked/stored neatly and safely until they are removed from the store yard for erection/assembly.

35. FIELD PAINTING :

36. Repair of shop coat :

Metal work, which has been shop painted, will be handled with care so as to preserve the shop coat in the best practicable condition. Before proceeding with any painting operation, all areas of shop paint which are defective or damaged will be repainted after cleaning. Metal work

adjacent to field welds, riveting or bolting where the shop paint coating has been damaged due to handling or due to heat will be cleaned thoroughly to expose the base metal and will be repainted. Paint applied to such areas will be of the same type as used for the original shop coat.

37. Procedure for field painting :

Paint and coating materials will be applied in accordance with this sub-para and painting schedule. When paint is applied by spraying, suitable means will be provided to prevent segregation during the painting operations. Effective means will be provided for removing all free oil and moisture from the air supply lines of all spraying equipment. Each coat of paint will be free from runs, holidays and sags. Except as otherwise specifically provided each coat will be allowed to dry or harden for 24 hours before the succeeding coat is applied. Surfaces to be painted that will be inaccessible after installation which have been shop coated with priming paint will be completely painted as per schedule prior to installation.

38. Painting Schedule :

The following schedule of painting will be adopted for the various portions of the embedded parts, gates and hoists.

i) Embedded Parts : The surfaces of embedded parts, which will come in contact with concrete will not be painted. All unfinished surfaces of embedded parts exposed to atmosphere and water and tie flats will be given four coats of cold applied coal tar epoxy paint by brush or by spray to produce a minimum dry film thickness of 100 micron per coat over a touch up coat of Zinc rich epoxy primer.

ii) Gates :

All the surfaces of the gates except the finished surfaces will be painted with cold applied coal tar epoxy paint. The paint will be free from lumps, which cannot be dispersed readily by hand stirring. Thinning with solvents of any kind will not be permitted. Three coats of coal tar epoxy paint will be applied over a touch up coat of Zinc rich epoxy primer to produce a minimum dry film thickness of 100 microns per coat. The surfaces exposed to sunlight, will have a protective coat of Shaliplastic SL, a cold applied coal tar emulsion. The paint will be applied by brush or special air free spraying equipment to produce a minimum dry film thickness of 100 micron per coat.

Two coats will be applied with 24 hours drying time between each coat. The temperature for painting may range between 13 degree C to 60 degree C.

When so applied, the dried film will be free from pin hole and conspicuous brush mark and will be not more than slightly seedy granular or fibrous in appearance.

iii) Hoists:

The component parts of the hoists which requires field painting or coating of other protective compounds will be painted as per the specifications of the hoist contractor.

iv) Miscellaneous components: Miscellaneous components such as hand rails, gratings and frames, machinery, ladders, piping etc., will be suitably painted.

Any other items which have not been specifically mentioned and which require painting or protective coating will be given painting or protective coating as per standard requirement.

39. Inspection of painting works :

All painting works will be inspected thoroughly for any slackness in uniformity, continuity, soundness and other following details.

i) Runs, sags, holidays, shadowing or pin holing.

ii) Evidence of poor coverage at plate edges, crevices, pockets, corners or re-entrant angles.

iii) Damage due to handling before the paint is sufficiently dry, or to

any other causes.

iv) All defective surfaces will be re-cleaned and painted as specified earlier

40. Specifications Of Paints :

i) Zinc rich Epoxy Primer: 1. Purity of Zinc for Zinc dust : 94% minimum as per IS:

7411

2. Fineness of mesh : 325

3. Zinc content in the paint : 86 + 1%

4. Process : Electrolytic

5. Curing : Polyamide cured

6. Pot life at 45 degree C : Not less than 8 hours

7. Dry film thickness (DFT) : 40 microns/coat

8. 3/2 pack : 2 pack

9. Volume solids corresponding to 86% Zinc content : 38%

10. Covering capacity (in sqm/litre/coat)

I. Theoretical : 9.3

II. Practical : 8.4

1. Percentage of thinner: Max : 10 - 12%

2. Epoxy content in dry film : 12%

3. Mixing Ratio by Volume : 3:1 (Base : Hardener)

ii) Coal Tar Epoxy Paint: 4. DFT with thinner : 100 Microns/coat

5. Volume solids on DFT : Not less than 67%

6. Pot life at 45o C : Not less than 3 hours.

7. Epoxy content : Not less than 35% (total resin content more than 50%) 8. Covering Capacity (in sqm/litre/coat)

3 Theoretical : 6.6

4 Practical : 5.0

1. Percentage of thinner : 5% maximum

2. Mixing ratio by Volume : 2:1 (Base : Hardener)

3. Application : By Brush

41. Erection: 42. General :

The Contractor will prepare erection Schedule which will describe the sequence of operations to be carried out with reference to the construction schedule of civil structure , the methods to be used, the measurements to be taken and the tolerance to be met in the erection and alignment of the above equipment. Scheduling of all works will be done in such a manner as not to interfere with other construction activities.

The gates, hoists, and embedded parts including groove liners will be installed under the supervision of erection personnel with full responsibility. for the erection and satisfactory operation of the gates, hoists and other components.

43. Materials and equipments for Erection :

The Contractor will make his own arrangements with necessary, tools required for erection of all the equipments.

44. Gates, Frames, Guides, Tracks and Groove liners:

Frames, guides, tracks, seal seat and groove liner arrangements will be assembled in the respective blockouts brought to line, grade and plumb within the erection tolerances and secured in place by anchorages as shown in the drawings or otherwise according to the best modern practice and as necessary for successful functioning of these units.

The erection tolerances for the frames and guides will be as indicated in the drawings. Extreme care will be taken to ensure that their surfaces are in a true plane within the tolerances throughout their entire length to ensure trouble free performance of gates. Assembly will be by bolting and welding and connections to embedded anchorages will be adjusted and finally tightened to hold the frames, guides and liners securely in position while concrete is being placed in the blockouts.

Before placing the concrete in any one lift and between placement of successive lifts, alignment tolerances will be checked and remedial action will be taken if any displacement has occurred.

45. Erection and Erection Personnel:

The Contractor will be fully responsible for the correct and accurate erection of equipment offered by him and will furnish all the erection personnel, skilled or unskilled, for the installation of all equipments. The Contractor will also furnish tools, tackles and other special equipments required for the erection.

46. Erection of Hoist and Electrical Equipment :

The Contractor will prepare a detailed procedure for erection of the hoist and other electrical equipments, which will describe the sequence of erection and operation. The erection of the hoist will be done under the supervision of experienced erection personnel. The Contractor will be fully responsible for the erection and satisfactory operation of the hoist. The erection will be done to line, grade and plumb within the erection tolerances and secured in place by proper anchorages as shown in the drawings or according to the best modern practice and as necessary for successful functioning of the hoist.

47. Operational Tests:

After the equipment has been installed in the field it will be operated and tested and when so operated and tested it will meet all the requirements of the specifications and drawings. The gate will be raised and lowered several times for their full length of travel. The primary requirement for acceptance in operational test is to ensure the smooth lowering and raising of each gate. The gates and hoist equipment will be further subjected to performance test before acceptance.

48. Performance Tests:

49. General :

The Contractor will carry out such tests on the gates and hoisting equipments as may be required by the Engineer in order to determine that the gates and hoisting equipments perform all the functions satisfactorily for which they have been designed, fabricated and erected. The Contractor will be responsible for any modifications and adjustments necessary in the systems as a result of such tests.

Tests will include:

i) Performance tests in dry condition.

ii) Performance test with water at FRL. iii) Leakage tests with reservoir at FRL.

Tests will be repeated, if necessary, until these are successfully carried

out to the satisfaction of the Engineer.

Leakage tests and performance tests will be carried out at the convenience of the Engineer after completion of other portions of the works and when the reservoir is at full level/particular level.

50. Performance Tests in Dry Condition :

Performance tests in dry condition will be carried out after completion of erection, when all controls and permanent power supply have been connected and adjusted. The tests will include at least two complete traverses over the entire length of gate groove from the maximum raised position to the fully lowered position. All adjustments, clearances, motors and controls, etc., will be checked for proper operation.

51. Leakage Test:

Leakage test will be carried out with the gates fully lowered. Before the observation for leakage, the gates will be raised and lowered about one metre several times in order to dislodge any debris that might have lodged in the side and bottom seals. The leakage will then be measured, and remedial measures will be taken if it exceeds permissible limits of 5 litres/per minute/ metre length of seal.

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