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ONE DAY WORKSHOP ON DAMS GATES ORGANIZED BY NARMADA, WATER RESOURCES, WATER SUPPLY & KALPSAR DEPARTMENT GANDHINAGAR SUPPORTED BY WALMI -ANANAD.

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Presentation on theme: "ONE DAY WORKSHOP ON DAMS GATES ORGANIZED BY NARMADA, WATER RESOURCES, WATER SUPPLY & KALPSAR DEPARTMENT GANDHINAGAR SUPPORTED BY WALMI -ANANAD."— Presentation transcript:

1 ONE DAY WORKSHOP ON DAMS GATES ORGANIZED BY NARMADA, WATER RESOURCES, WATER SUPPLY & KALPSAR DEPARTMENT GANDHINAGAR SUPPORTED BY WALMI -ANANAD

2 Sub :- MAINTENANCE OF GATES PAPER BY:- ER. S.K.SUTHAR Retd. Deputy Executive Engineer (Mech.) 1/8/20142

3 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..

4 STEPS FOR MAINTENANCE LUBRICATION WIRE ROPES PAINTING

5 HORIZONTAL GIRDER SKIN PLATE BRACING T-VERTICALS STIFFNERS

6 HORIZONTAL GIRDER BRACING T- VERTICAL

7 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.

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

9 TABLE Sr NoParts to be Lubricated Lubrication Recommended APPROXIMAT E QUNTITY SCHEDULEREMARKS 1Trunnion pin Servo Coat 120 As required Quarterly 1Kg. May, August Nov Pin should be lubricated till grease squeezes out from sides. 2Wire RopesCardium Compound 35 KgMayWhen ropes are dry 3Guide rollersServo coat KgSix Monthly May, Nov. 4Turn buckleServo Coat- 120 As requiredPrior to Monsoon May

10 TABLE 5Bushing in rope drum &all Bearings Servogum-25 KgsPrior to Monsoon 6Drum gear, Intermediate gear Pinions, Servogum-1405 KgsQuarterly (May,Aug, Nov,Feb) 7Reduction unitServogum-225 mlYearly (May) 8Electrical Motor Bearing Servogum-2Small Quantity Change after every 2000 Hrs 9Electro Magnetic brake rings &Pins Servogum-2Small Quantity Quarterly (May,Aug, Nov,Feb) 10Sprocket Wheel &chain Servogum-2Small Quantity Quarterly (May,Aug, Nov,Feb)

11 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.

12 1/8/ HOIST MECHANISM

13 1/8/ FLOATING / LINE SHAFT

14 1/8/ FLOATING / LINE SHAFT

15 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 However some of details given in next slide.

16 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

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18 SILL BEAM WALL PLATE

19 END VERTICAL MAIN ROLLER ROLER PIN

20 END VERTICAL MAIN ROLLER ROLER PIN

21 WALL PLATE Z TYPE RUBBER SEAL TOP PLATE SKIN PLATE WIRE ROPE

22 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

23 TABLE SR NO MANE OF GATES PART TO BE PAINTED PAINTS REOMMENDEDFREQUENCY 1Gate leaf-UPSTEAM SIDEAnticorrosive black H.D. of renowned make Two coats/three coats once in a year or as required. 2Gate 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. 3Hoist coversPrimary coat-Red Oxide Final coat-Blue enamel or dowel deep orange. Once in a year. 4Railing pipesPrimary coat-Red oxide Final coat- Aluminum oxide Once in a year 5Railing pipesPrimary coat-Red oxide Final coat- Aluminum oxide Once in a year

24 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,

25 HUB BRACKET TRUNION PIN LOCK PLATE ANCHOR GIRDERANCHOR GIRDER GUSSET PLATE

26 1/8/ FLOATING / LINE SHAFT

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30 HORIZONTAL GIRDER BRACING T- VERTICAL

31 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.

32 1/8/ HOIST MECHANISM

33 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.

34 1/8/ 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

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36 1/8/ CONTROL ROOM

37 1/8/ DIESEL GENERATOR ROOM

38 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.

39 THANKS POWER POINT PRESENTATION PREPARED BY ER.J.R.RATHOD, ER. K.B.TRIVEDI ER. R.C.RANA D.E.E.(MECH.) N.W.R.W.S.& Kalpsar Department, Gandhingar


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