ONE DAY WORKSHOP ON DAM’S GATES

ORGANIZED BY NARMADA, WATER RESOURCES, WATER SUPPLY & KALPSAR DEPARTMENT

GANDHINAGAR

SUPPORTED BY

WALMI -ANANAD

Sub:- MAINTENANCE OF GATES

PAPER BY:- ER. S.K.SUTHARRetd. Deputy Executive Engineer (Mech.)

04/10/23 2

MAINTENANCE OF GATES

The gates might have been well designed and sturdy and timely inspected but if the follow up action is not taken, the gate will not run smoothly. Hence periodical maintenance should be done with in prescribed timing..

STEPS FOR MAINTENANCE

LUBRICATION WIRE ROPES PAINTING

HORIZONTAL GIRDER

HORIZONTAL GIRDERSK

IN P

LATE

BRACING

T-VERTICALS

STIFFNERS

HORIZONTAL GIRDER

HORIZO

NTAL G

IRDER

BRACING

T- VERTICAL

LUBRICATION

• Various parts of Gate are required to be lubricated by using proper Grade of lubrication.

• Lubrication schedule has been given in the Table .

• Approximate quantity of lubricant shall be kept ready which may vary as the number of gates. However the required quantity can be ascertained by experience.

LUBRICATION

• In the Table, the lubricants grade mentioned are of INDIAN OIL CORPORATION. However equivalent grade of any Reputed make may be utilised.

TABLESr No Parts to be

LubricatedLubrication Recommended

APPROXIMATE QUNTITY

SCHEDULE REMARKS

1 Trunnionpin

Servo Coat 120

As requiredQuarterly 1Kg.

May, AugustNov

Pin should be lubricated till grease squeezes out from sides.

2 Wire Ropes CardiumCompound

35 Kg May When ropes are dry

3 Guide rollers Servo coat-140

1 Kg •Six Monthly•May, Nov.

4 Turn buckle Servo Coat-120

As required Prior to MonsoonMay

TABLE 5 Bushing in rope

drum &all Bearings

Servogum-2 5 Kgs Prior to Monsoon

6 Drum gear,Intermediate gearPinions,

Servogum-140 5 Kgs Quarterly(May,Aug,Nov,Feb)

7 Reduction unit Servogum-2 25 ml Yearly (May)

8 Electrical Motor Bearing

Servogum-2 Small Quantity

Change after every 2000 Hrs

9 Electro Magnetic brake rings &Pins

Servogum-2 Small Quantity

Quarterly(May,Aug,Nov,Feb)

10 Sprocket Wheel &chain

Servogum-2 Small Quantity

Quarterly(May,Aug,Nov,Feb)

APPLICATION OF LUBRICANTS

• The wire ropes should be cleaned and dried and a jet of air or wire brush is used prior to application of lubricants

• The brush is dipped into the Lubricants to be applied.

• It may also be applied by hand with leather gloves especially when a heavy, on flowing lubricants is applied.

• Lubricants should be slightly heated to get a smoother and better application.

04/10/23 12

HOIST MECHANISM

04/10/23 13

FLOATING / LINE SHAFT

04/10/23 14

FLOATING / LINE SHAFT

WIRE ROPES

• 1. Shifting the wire ropes at point of clamping position on Drums and cutting its end.

• 2. Lubrication of wire ropes.

• 3. Maintenance of wire ropes can be carried out As per I.S.3973-1967.However some of details given in next slide.

WIRE ROPES• Lubrication shall be free from harmful substances

such as acids &alkalis.

• It should be light grade that may penetrate between the wires &strands of the ropes before being wiped off or absorbed by surface dirt.

• Cardium Compound is used as during manufacturing of wire ropes are fully lubricated including fibre core &layers to reduce internal abrasion to exclude moisture and delay corrosion.

• In service the initial lubricant will tend to dry out and therefore it is desirable to lubricate all ropes at regular interval

SILL BEAM

WALL PLATE

END VERTICAL

MAIN ROLLER

ROLER PIN

END VERTICAL

MAIN ROLLER

ROLER PIN

WALL PLATE

Z TYPE RUBBER SEAL

TOP PLATE

SKIN PLATE

WIRE ROPE

PAINTING

NEED FOR PAINTING• A. Iron and steel structure exposed to

sun, rains and air are deteriorated due to corrosion effect.

• Once corrosion set in, it goes on continuously eating metal.

• Only 1.6 to2.0 mm corrosion allowance is provided in design of gates. Therefore it should be regularly painted on Upstream and Downstream sides as indicated in Table

TABLESR NO

MANE OF GATES PART TO BE PAINTED

PAINTS REOMMENDED FREQUENCY

1 Gate leaf-UPSTEAM SIDE Anticorrosive black H.D. of renowned make

Two coats/three coats once in a year or as required.

2 Gate leaf-Downstream side &all Other parts except Hoist covers and the bars

Anticorrosive black L.D. of renowned make

Single coat /two coats once in a year or once in two years depending upon the condition.

3 Hoist covers Primary coat-Red OxideFinal coat-Blue enamel or dowel deep orange.

Once in a year.

4 Railing pipes Primary coat-Red oxideFinal coat- Aluminum oxide

Once in a year

5 Railing pipes Primary coat-Red oxideFinal coat- Aluminum oxide

Once in a year

NOTE

• Painting should be done by adopting proper painting procedure prior to which scraping, chipping etc.should be done and vegetation developed should be removed.

• Brass plates and rubber seal should not be paint

• The paints to be used depend on site situation i.e. whether water is to acidic or basic, Dams located near to sea.etc.

• Painting should be carried out after drying of first coat and before applying paint, it should be perfectly cleaned &free from moisture,dust.etc,

HUB

BRACKET

TRUNION PIN

LOCK PLATE

ANCHOR GIRDER

GUSSETPLATE

04/10/23 26

FLOATING / LINE SHAFT

HORIZONTAL GIRDER

HORIZO

NTAL G

IRDER

BRACING

T- VERTICAL

ELECTRICAL PARTS

• Electrical cables should be checked for puncture.

• Cable clamps and lugs should be checked, tightened or replaced, if found faulty.

• Contacts of main switch should be checked.

• Overload relay may be checked and tested and put in operational condition.

• Check wiring, contacts of starter and tighten as required. Burnt or worn out may be replaced.

04/10/23 32

HOIST MECHANISM

ELECTRICAL PARTS

• Check the operation of Electromagnetic brake and clean periodically the plunger and barrel as deposition of dust or dirt will make chattering noise and hammering.

• Adjust brake shoes depending upon wear and tear of shoes.

• If magnetic coil is found burnt then it should be replaced.

04/10/23 34

• Check the digital indicators are in working condition, if it is not in working condition, gate could not be operated /seen from the control room.

CONTROL ROOM

04/10/23 36

CONTROL ROOM

04/10/23 37

DIESEL GENERATOR ROOM

ELECTRICAL PARTS

• Check the operation of Limit switches and if, not in working condition, it should be checked for proper contact with dial or wiring.

• T.P.I.C. should be checked for proper contact of all three phase otherwise single phasing will result in burning of motors.

THANKS

POWER POINT PRESENTATION PREPARED BY

ER.J.R.RATHOD,ER. K.B.TRIVEDIER. R.C.RANAD.E.E.(MECH.)

N.W.R.W.S.& Kalpsar Department, Gandhingar