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Whereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public.
इंटरनेट मानक
“!ान $ एक न' भारत का +नम-ण”Satyanarayan Gangaram Pitroda
“Invent a New India Using Knowledge”
“प0रा1 को छोड न' 5 तरफ”Jawaharlal Nehru
“Step Out From the Old to the New”
“जान1 का अ+धकार, जी1 का अ+धकार”Mazdoor Kisan Shakti Sangathan
“The Right to Information, The Right to Live”
“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता है”Bhartṛhari—Nītiśatakam
“Knowledge is such a treasure which cannot be stolen”
“Invent a New India Using Knowledge”
है”ह”ह
IS 10096-1-1 (1983): Recommendations for inspection,testing and maintenance of radial gates and rope drumhoists, Part 1: Inspection, testing and assembly at themanufacturing stage, Section 1: Gates [WRD 12: HydraulicGates and Valves]
IS : 141096 ( Part IjSec I ) • 1_(per lUll)
Indian StandardRECOMMENDAnONS FOR
INSPECTION; TESTING AND MAINTENANCE OFRADIAL GATES AND THEIR HOISTS
PART I INSPECTION, TESTING AND ASSEMBLY ATTHE MANUFACTURING STAGE
Section I Gates
( FirstReprinlSEPTEMBER 1993 )
UDC 626.422.23:620.1
© CoPY,i.(ht 1984
BUREAU OF INDIAN STANDARD SMANAK SHAVAN. 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI110002
Grl F,DnuJry 198+
IS : 10096 ( Part 1 Sec 1 ) - 1983
Indian StandardRECOMMENDATIONS FOR
INSPECTION, TESTING AND MAINTENANCE OFRADIAL GATES AND THEIR HOISTS
PART I INSPECTION, TESTING AND ASSEMBLY ATTHE MANUFACTURING STAGE
Section I Gates
Hydraulic Gates and Valves Ser-uona l Co mnutte, HI)C 5(,
Chauman
SliRI Y. ADlNAR"'Y\~'" S .... s-ent
RCj)rrJCntln~
Tunaabhadra Steel Produc rs Lmutcd. TUlll;,ILlj.ttL,~
Dam ( Karnataka )
Memhers
SURr G. S. A~NJnEnI ( Alternatt toShri Y Aclmarayana SaMrI )
CRIEF ENGr ..... Elm ( TDO ) Irrrganon 'V()r"~.
ChandrgarliCOVl rrunc nt of J'IIOJ.d)
Drunca-ou ( Mj E ) ( Alternate )Sam R. C. CHOPRA TEXM.\CO Ltd, Calcutta
SRRC R. BH-\TT\CHAIl.YA (Alternale)SHIn H. C. DHINGHA Haravana State Mmor l rrrganon (Tl1be~\f'lIs,
Corporauon Ltd, ChandrgarhSImI R. C CHAUll-\N ( Alternate)
DIRECTOR Central Water & POWf'J Research Stanon. Punt'SHRI A. V GOPALA KRISHNA
RAG ( Alternate)DIREOTOR ( G~TES DEEHON I ) Central Water Comr.nssion. New D{·1I11
SHRI C L. VERM.l. ( Alternate)SERI R. N. GUPTA Nangal Work~hop~) Nanga! Township
SaRI N. S CUAWL.\ (Alternate)SaRI K. K. jULKA Beas Project, Bhahr.\ nea~ ~LlnJgl ment Brant
Nanga l TownshipSURI V. P KACSHAL (Alternate)
MANAGlNQ Dtuzc'ron Tarru l Nadu Pubhc Worb Engmecrmg CorporationLtd, Madras
WOR'K~ MANAGER ( Alternate)SaRI K V. S MURTHY Trivern Structurals Ltd. N,UOl
SHRI1\-1 K. V. S ..'\RMA (Alternate)
( Co,.lllIlUd on />4c' 2')
IS) O>P)'rlghJ 19BfBUREAU OF INDIAN STANDARDS
This publication is protected under the ["dlAn Copynght Ad (XIV of (957) andreproduction In whole or in part by any means except With written permisston of thepubHshec shall be dumed to ~ an Infriogement of COP} rIght under the tald Act.
: 10096 ( Part IfSec I ) - 1983
( Cvnhnued fllllll !Iflr:~ 1
Uttarof
Irrrgation & PU\'\Ier Department, Government ofMohareshua, Na<sik
Central Indra Machmer y Manufacturing Co Ltd,Bh;,rarpul
";1I111 K C H \ 111"'\Y ( A[lerltlllt )Snm M. C "J, \\' \F' Himachal Pradesh State Elccrnc ity Board, Simla~Hl(':oJ VI...\·A -, A·! J( \:-1' Nauonal Hvdr oek ctrrc Power Corporation,
Nt'w nt·JillDn cct or Genetal , lSI ( E.l.~OffiCiO Member)Smu G. R \),J \S,
Director ( elV Lngg )
R'!ITeSenflllg
Irr iaauon Depar rmout. GovernmentPr adcsh, Lucknow
SHf-1 R \J Kt-:..f .... ll Bhar.u Heavy Elec rrrcals Ltd, BhopalSI.HIN Y N,ll\SlMI1\..,(Alltrnale)
Suur S K S'lIll\! JI'SSOP & Co Ltd, CalcuttaSuru S N \1, ( .1JI,molt)
l..,uPFfllN'rl':'J:'I\ '.::1' l-..... (.INm;1l
( PH I ( CDo )Snur R ~\, vn ur-
.\certfar)1
Snur l-h,\1\NT Ku~rAll
A\sist.\nt Drrecror ~ Crv Engg ), lSI
Panel for Inspecuon, Testing and Maintenance of Radial Gates,BDC 56: P8
CO'lt'rn~r
Suru M. 1\ ~ll Hu.I \ Irrrganon works, GovernmentCharuhgarh
of Punjab,
SHin!l.L C TrW,wI
J[embers
SHnJ G S ANNIl" HI Tungabhadra Steel Products Ltd. TungabhadraD.im < Karn.'i:taka r
Dl1n~( TOil ( GA.'Il'>, DI':... tcxe I ) Central Water Ccmrmssron, New Delhi~11J1! R. N (;.t1I'j \ N.mg..d Workshops, Nangal Township
S'l!'l:,\ S Cn \\\L \ < .1ilernatc)SHUI Y R K \\,It.... BSL Project, Bhakta Bcas Management Board,
'vundc magar ( H P. )"'IWf R "\i AGt:AI.\\ \L (Ahrnat~)
SIH r '\ K Me kHE/t lJ';I: J<"s,op Co Ltd, CalcuttaSt'pnll.:s'r"<JIJ'f: E=.-.C:INl-:EIl, l rrigation Department, Government of Maharashtra,
( G \ I! ... ) ( CDO ) ltombavSUHl R S\\ \ll\ P Ce-ntra! India Machinery Manufacturmg Co Ltd,
Bh..ratpurHImachal Pradesh Srate Electrrcny Board,
Government of Himachal Pradesh, SImla
2
AMENDMENT NO. I JANUARY 1993TO
IS 10096 ( Part l/See 1) : 1983 RECOMMENDATIONSFOR INSPECTION, TESTING AND MAINTENANCE OF
RADIAL GATES AND THEIR HOISTS
PART 1 INSPECTION, TESTING AND ASSEMBLY AT THEMANUFACTURING STAGE
Section 1 Gates
( Cover page, page 1 lind page 3, tule ) - Substuute 'ROPE DRUM' [orTHEIR'
(RVD 12)Reprography URI I, BlS, New DeII1J..lodla
IS : 10096 ( Part I/Sec I ) • 1983
Indian StandardRECOMMENDATIONS FOR
INSPECTION, TESTING AND MAINTENANCE OFRADIAL GATES AND THEIR HOISTS
PART' INSPECTION. TESTING AND ASSEMBLY ATTHE MANUFACTURING STAGE
Section I Gates
O. FOREWORD
0.1 This Indian Standard (Part llSec I ) was adopted by the IndianStandards Instituuon on 25 November 1083, after the draft finahzed bythe Hydraulic Gates and Valves Sectional Committee had been approvedby the Civil Engmeering Division Council.
0.2 The gates are used not only to pass large floods but also to ,egulatethe reservoir level during minor variations in flow. The gate, in generalis a structural steel frame consisting of end vertical girders with properlyspaced horizontal girder between them. The spacing depends on thedesign water pressure and on dimensions of the gate. The frame is heldapiece by secure welding or riveting.
D.3 Reference to the following Indiafj Standards ,..;11 be found useful lB
implementation of this standard:
IS: 210-1978 Grey iron castings (third retnsion )
IS : 226-1975 Structural steel ( standard quality) (fifth revision)
IS : 306-1968 Tin bronze ingots and castings ( second revision)
IS: 318-1981 Leaded tin bronze ingots and castings (second revlSlon)
IS: 823-1964 Code of procedure for manual metal arc welding ofmild steel
IS : 1030-1974 Carbon steel castings for general engineering purposes( second revision )
IS : 1570-1961 Schedules for wrought steels for general engineeringpurposes
3
IS : 10096 ( P"rt I/Sec I ) • 1983
IS 2004-1 'l78 Carbon steel forgings for general engineering purposes( second "VlSIon )
IS: 2062-1980 Structural isteel (fusion welding quality) (seconatension )
IS : 25%-1978 Code of practice for radiographic testing (firstrmision )
IS . 3648-l966 Hexagon fit bolts
IS: 3658-1981 Code of practice for liquid penetrant flaw detection(first "visIon)
IS· 3664-1'l81 Code of practice for ultrasonic pulse echo testing bycontact and Immersion methods (jirst remsion)
IS: 3703-1980 Code of practice for magnetic particle flaw detection(first "v'SlOn )
IS 7307 (Part I )-1974 Approval tests for welding procedure"Part I FUSIOn welding of steel
T.~ . 7~1O ( Part I )-1974 Approval testing of welders working topl {11(1(f procedures: Part I Fusion welding of steel
b. iJ18 ( Part I )-1 114 Approval tests for welders when weldingprocedure approval is not required: Part I Fusion welding of steel
0.4 This standard is being pubhshed in three parts. Part I deals withmspec.tion, testing and. assembly at manufacturing stage, Part .2 dealswith inspection and tesnng at the time of erection, and Part 3 deals withinspection, tesung and maintenance after erection.
0.4.1 Part ] i_ being published in two sections. Other section of thispart WIn cover the hoists ( under preparation ).
0.5 For the purpose of deciding whether a particular requirement of thissrandar d IS complied with, the final value, observed or calculated,exprc"sm~ the result of a test, shall be rounded off in accordanceWIth IS : 2-1960'. The number of significant places retained in therounded off value should be the same as that of the specified value inrlus standard.
I. SCOPE
1.1 ThIS standard ( Part IISec I ) lay, down the recommendations formspection, tesnnc and assembly of radial gates at the manufacturingstage. It does not cover hoisting equipment.
"Rules for roundmg off numerical values ("vlSed).
4
IS : 10096 ( Part ItSec 1 ) • 1983
2. GENERAL
2.1 All materials and components used for the work shall be new andfree from defects and subject to the tolerances specified under thisstandard.
2.2 Complete inspection shall be made at the place of manufacture priorto despatch.
3. MATERIALS
3.1 All materials and components supplied by the manufacturer shallconform to the requirements of the latest relevant Indian Standards. Inthe absence of Indian Standard for any particular material or component, other specification mutually agreed to between the purchaser andthe supplier may be used.
3.2 All materials used shall be of tested quality. Original manufacturer', test certificates for bought out Items such as castings, forgings andseals, shall be furnished by the gate manufacturer to the purchaser ondemand.
3.3 Castings
3.3.1 All castings shall conform to the relevant Indian Standards.
3.3.2 Visual examination shall be done to find out the generalsoundness of the castings and if required, non-destructive tests shaIl beconducted on the castings.
3.3.3 Repairs of major defects in castings by welding shall notgenerally be allowed, but if the strength aud machinability of thecasting can be ensured, the repairing may be undertaken with theapproval of the purchaser.
3.3.4 Defective castings as permitted under 3.3.3 shall be heat-treatedafter repairs by welding, where deemed essential.
3.4 Forgings
3.4.1 All forgings shall conform to the latest relevant IndianStandards
3.4.2 All forgings shall be suitably heat-treated according to relevantIndian Standards
3.4.3 VISual inspection of forgings shallsurface shall be smooth and free from defects,rive tests shaIl be conducted on the forgings.
5
be done and the finishedIf required, non-destruc-
IS : 10096 ( Part 1;Sec 1 ) • 1983
4. WELDING
4.1 All weldings shall conform to the relevant Indian Standards andapproved electrodes shall be used.
4.2 Welding procedure for all major welds shall be dr awn-up and cart redout and if required by the purchaser, test pieces may be made to ensurethe soundness of the welding.
4.3 Only tested welders shall be employed for the welding work.
4.4 Visual exammation shall be carried out of all welded joints to ensurethat welding is free from:
a) cracks on the surfaces of the joints or parent metals located nearthe heat affected zones,
b) undercuts in the parent metals,c) non-uniform width of fillet joints,d) misalignment and distortion or the welded member, and
e) irregular reinforcing beads of welds.
4.4.1 Welds found to be defective shall be subjected to non-destructivetests to ensure soundness of welding.
4.5 Proper sequence of welding shall be followed for welding of heavystructural parts in order to minimize distortion.
4.6 Defective welds after testing shall be removed and rewelded.
4.7 All major stress carrying welded joints shall be subjected to suitablenon-destructive testing, as specified by the purchaser.
4.8 Any item or part may be stress- relieved according to the requirements and procedure laid down in IS : 2825·1969*. Generally followingitems require stress-relieving.
a) Yoke/trunnion girders, anchor girders and trunnion bracketswhere heavy welding is involved; and
b) Trunnion hub if part of the arm ( structural portion) is weldedto the casting.
5. MANUFACTURING TOLERANCES
5.1 The gates and embedded parts shall be manufactured to suchaccuracy and tolerances as are required for the safe and efficient operation of the gates. Unless otherwise specified, the tolerances given in 5.2and 5.3 may be used as a general guide.
• Code for unfired pressure vessels.
6
IS : 10096 ( Part IjSec 1 ) • 1983
5.2 Embedded Parts
5.2.1 Deviation of any point on the face of seal seat from 2 m machinedstraight edge held against it shall not exceed 0'5 rnrn.
5.2.2 Deviation from straightness of the wall plate shall not be morethan 2 mm in 2 metre length.
5.2.3 Offsets and gaps at any adjoining joints between seal :seats,guides, etc, shall not exceed 0'5 mm.
5.3 Gates
5.3.1 The gate leaves with stiffeners shall generally be manufactured On
a jIg and fixture. The tolerance on the radius of gate leaf shall be I r:ooof radius or ± lO mm whichever is less.
5.3.2 The drsta nce between the side guide rollerjguide shoes on oneside of the gate to the corresponding guide roller/guide shoes on the otherside shall not vary from dimension shown in the drawing' by more than+ 0'00 mm to - 2'00 mm.
5.3.3 Parallel distance of centre line of both the trunnion bearingsfrom upstream bottom edge of skin plate shall not vary more than=3'0 mm,
5.3.4 The horizontal distance between the centre to centre of trunnionsshall not vary from the dimension shown in the drawings by more than± 3'0 mm.
5.4 Connections -- At all sphces, the holes shall be match drilled. Iffit bolts are provided, holes shall be reamed at assembly.
6. SHOP ASSEMBLY AND TESTING
6.1 Gates and Embedded Parts - The anchor girder together withthe tre bars of convenient length for testing and yoke girder shall be loadtested equivalent to 1'5 times the design load before erection. The loadshall be applied gl adually by means of hydraulic Jacks and the assemblyshall remain under load to enable all the observations required by thetest procedure to be made.
6.1.1 Assembly of wall plates and sill beams shall be done at shop.
6.1.2 Gates shall be assembled complete WIth guide rollers and trunnions for proper alignrnenr and inspection. AU the dimensions specifiedin 5.2 and 5.3 and other central dimensions shall be checked onassembly.
7
IS • 10096 ( Part l{Sec 1 ) - 1983
6.1.3 Side guide rollers may be shnnrncd , if necessary, to maintain therequired tolerances as specified in 5.3.2.
6.2 Seals - Seals may be assembled either at shop or during erectionaccording to the convenience of the manufacturer. The holes in sea"shall be match drilled with seals base and clamps.
6.3 Ballast - Ballast if required, can be provided either at shop or atsite.
6.4 Marking
6.4.1 All erection marks shall be hard-punched.
6.4.2 All the components shall be match-marked before dismanthng.
7. CLEANING AND PAINTING
7.1 Surface 'hall be cleaned thoroughly, preferably by sand.shot blasting.
7.2 Painting shall be as specified by the purchaser and the applicationprocedure shall be as recommended by the paint manu facturer
8
BUREAU OF INDIAN STANDARDS
82104
62306
52435
5382728705
231083
52 51 71
8347121 8B7855507
554021
2834839 49 66
2184341 2918
8329295
8-71 199833177
NanharnSoulhern
tWeotern
• Eastern
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