ERECTION OF THE GATES AND HOISTS AND MAINTENANCE

• Classification of Gates
• Vertical Lift Gates
• Stoney Type Gates
• Hoisting Equipment
• Hydraulic Hoists
• Manual Operation
• Selection of Suitable Hoist
• Erection of Gates
• Radial Gates
• Hoist Bridge
• Hoisting Equipment
• Rubber Seals
• Testing of Gates After Erection
• Maintenance of Gate

1. Introduction:

Gates are sometimes termed as hydraulic control equipments and their purpose is to control
the flow of water. Gates are nothing but valves to regulate the flow of water. Where the water pressures
are low, gates are used to control the flow of water. Where it is desired to regulate the flow of water
at very high pressures, valves are generally used. The main difference is water will be on one side
only for the gate where as valve will be in contact with water on both the sides.

1.1 CLASSIFICATION OF GATES:-

Gates can be classified according to

1) Waterhead

2) Purpose

3) Method of Movement

4) Materials
Design & Construction – Erection of the Gates and Hoists and Maintenance 2

According to water head:

1) low head gates - upto 15 M

2) Medium head gates - 15M to 30M

3) High head gates - above 30 M

According to Location:

1) Barrage gates 2) Spillway gates

3) Draft Tube gates 4) Intake gates

5) Penstock gates 6) Sluice gates

7) Outlet gates 8) Bulk head gates

9) Emergency gates.

According to shape:

1) Stop logs

2) Vertical lift gates

3) Radial gates

4) Flap gates

5) Fish Belly gates

6) Sector gates/Drum Gates

7) Tilting gates

According to Movement:

1) Sliding gates 2) Fixed wheel gates

3) Stoney or roller gates 4) Caterpillar gates

According to Material:

1) Timber or wooden 2) Steel 3) R.C.C.

The sequence of erection mainly depends on the construction of the type of the gates and
there by the other connected components.
 3 Design & Construction – Erection of the Gates and Hoists and Maintenance

Similarly the life of a gate and its hoisting equipment mainly depends on the effective and
frequent periodical maintenance of the moving parts.

In view of the above let us study in brief, the description of the various types of gates and
their hoisting arrangements.

The essential features of a gate are:

1) The closing members of the gate

2) Groove

3) Hoisting arrangement.

The gate should be strong enough to withstand the hydraulic pressure and it should be
water tight. It consists of skinplate and other supporting structural members.

The groove in which the gate moves should be supported by members strong enough to
withstand the water pressure transmitted by the gate. These arc called embedded metal parts.

The hoisting arrangement should be capable of lifting the gate leaf up and down in order to
close or open the water passage.

VERTICAL LIFT GATES

The closing member of the gate consists of a frame work, to which the skin plate is attached.
The skin plate will be placed normally on
the upstream side in order to avoid
accumulation of trash. The general
arrangement of the gate in the groove is
shown below :

Sometimes the large sized gates

are divided into two leaves moving
independently. The main advantage of
this is the reduction in weight of the gate
and thereby in the hoisting arrangement
as well as reduction in height of the pier.
Small floods, floating debris or ice can
pass over the upper gate in its lowered
position and in this position the raising
of the lower heavier leaf would not be
required. The two leaves of the gate will
be cither in two grooves or in the same
groove.
Design & Construction – Erection of the Gates and Hoists and Maintenance 4

Sliding type gates:

In sliding gates the frame of the gates is directly in contact with the down stream guide
members, thereby reducing separate scaling arrangement. As the co-efficient of friction, varies
from 0.5 to 8.9, the hoisting capacity required will be large not only for raising as well as for lowering.
Hence these are used only in small spillways and also where there will be sealing problems due to
high heads.

Fixed Wheel gates:

In these gates, wheels are mounted on the gate thereby transmitting the water thrust on the
upstream of the gate to the downstream through the rolling wheels. As there will be only rolling
friction plus axle friction the gates will be self closing on account of its weight.

STONEY TYPE GATES:

In these gates, moving train of rollers are substituted in place of fixed wheels. These rollers
will be in a cage and arc suspended independently in between the gate and the E.M.part. Since the
rollers transmit the entire load of the gate onto the E.M. part there will be no axle friction and there
will be only rolling friction. Since the

gate moves on the roller diameter, while ihc roller moves on its radius, lie roller cage moves only
one half of the distance of the gate movement.

Above figure shows the general arrangement of a stoncy type of gate or free roller gale in
the groove on one side. On account of low Co-efficient of rolling friction, the stoncy type of gates
have been extensively used in the past for large self closing gates in spillway regulators. However
from experience it is found that stoney type gates are not suited for operation of rivers carrying
 5 Design & Construction – Erection of the Gates and Hoists and Maintenance

large quantity of silt and debris, since the rollers require careful maintenance for smooth operation.
Another disadvantage noticed in these gates, is the lack of accessibility for the structural portion of
the gate in the groove.

Radial gate:

Radial gates are often considered the cheapest type of gates as per the comparative studies
made its merit lies in its mechanical simplicity

The basic idea of the design is to put the main struts supporting the gate frame into
compression. The hydrostatic forces acting on the gate skin plate has a radial resultant which
passes through the gate trunion or pivot. These gates arc self closing by weight.

The following are the advantages of these gates :

1. Simplicity of construction

2. Easy accessibly for maintenance

3. Absence of grooves in the piers which are unfavourable for smooth hydraulic flow
condition.

4. Absence ol” wheels and wheel assemblies.

5. Reduction in hoist capacities compared to fixed wheel gales.

6. Risk of jamming of the gale is very much reduced.

7. Hoists can be arranged at the deck level and no huge hoist bridge is required as in the
vertical li ft gates.

8. The gate adopts itself to automatic control.

Recommendations for the design of these gates are indicated in I..S. - 4023 - 1984. (Later
amendments if any). Generally the trunions will be located within the elevation of the lowerhalf of the
gate but when necessary to provide flood clearance, the centre line of the trunions may be located
upto a maximum of 0.75H above the sill where ‘H’ is the vertical distance between the top of the
gate and the horizontal through the sill or 1.5 M clear off the water profile, the radius of the gate (ie)
the distance from the centre of the trunion pin to the inside face of the skin plate shall as far as
possible be from H to 1.25 H.

The location of the gate, thereby the sill beam preferably be located slightly downstream of
the crest to avoid cavitation of the downstream glacis.

The arms may be straight or parallel or inclined. The arms if inclined may be fixed to the
horizontal girder at about 1/5 of the width of the gate span.
Design & Construction – Erection of the Gates and Hoists and Maintenance 6

The arms of the gate shall be rigidly connected to the hubs to ensure full transfer of loads.

The load on the gate will be transferred to the piers either in bond as bond stress between
anchors and concrete or in bearing as a bearing stress between the concrete and the embedded
girders at the upstream side of the piers and the anchors will be in this case are insulated from the
concrete.

The bonded type of anchors may be hooked at the end or alternatively provided with anchor
plates. These anchors should be insulated to a minimum of 500mm length from the trunion.

All the load carrying anchors either bonded or bearing should be pretensioned on the trunions
to ensure proportionate load sharing by the anchor rods.

In case of load carrying anchors and trunion tie if used, the trunion bracket shall be so fixed
as to be able to slide on the anchor girders. Bronze or stainless steel pads shall be used for the
purpose both on the rest beam and at the bottom of trunion bracket.

Guide rollers should be provided on the sides of the gate to limit lateral movement of the
gate on sideways to not more than 5mm in either direction.

HOISTING EQUIPMENT:

The hoists, which arc meant for lifting the gate irrespective of the type of gate; can be broadly
classified into two types

1. Positive driven

2. Loose driven

In the positive driven hoists, the screw rod and the link connected to the gates should
withstand both compression and tension during closing and opening. In the second type of the
hoist connecting link can not transmit or withstand compression. Therefore the gate weight should
be more than the friction and buoyancy effect.

1. Positive driven -

a) Screw rod hoist

b) Hydraulic hoist

c) Rack & Pinion type hoist

2. Loose driven

a) Rope hoist
b) Chain hoist
 7 Design & Construction – Erection of the Gates and Hoists and Maintenance

Capacity of the hoist:

This depends on the weight of the gate leaf, weight of the moving parts, wheel and track
friction, seal friction, hydraulic down pull etc.

Rope drum type Hoist :

In this arrangement cither one or two drums arc used depending on the number of suspension
points which in turn depends upon the width of the gate. The gale will be connected to the drum
through wire ropes. According to the load carrying capacity of the ropes, iwo or more number of
falls may be provided. The ropes may be clamped at the centre or at the ends of the drums. Turn
buckles or equiliscr bars may be provided to cquilisc the tension in the ropes.

Screw hoists:

Screw hoists may be of two types (Viz) 1) Non raising type stem 2) raising stem. For non-
raising stem type, the stem rotates and the engaging nut which is fixed to the gate moves linearly in
the direction of the gate travel. This arrangement may be preferred where there is no head room
but it requires dismantling ol the whole assembly for maintenance. This lypc is generally provided
for small gates with low head acting on it.

In the raising stem type, the nut engaging with the stem which in turn is connected to the gate
is kept in position by sleeve and is rotated through a gear transmission system. The nut gives the
stem a linear movement in ihc direction of the gale travel. The advaniagc of this lypc is that this
mechanism is easily accessible for maintenance.

Generally screw hoists are provided for the hoist capacities upto 30 M.T.

HYDRAULIC HOISTS:

Hydraulic hoists of higher capacities arc economical and operationally better suited. These
arc also best suited where the space may be a problem.

Where the speed of operation is critical particularly closing speed for which gates, Hydraulic
hoist arc preferred. Speeds can also be adjusted within the limits of the system.

Since the parts of this system arc self lubricated units and also totally enclosed these require
minimum maintenance.

A centralised cabinet can be used for the operations of a number of hoists.

This disadvantage lying in the system is that good honed cylinder of sufficient length
depending on the lift of the gate is a problem.
Design & Construction – Erection of the Gates and Hoists and Maintenance 8

MANUAL OPERATION:
The manual operation should invariably be provided for emergency operation in the event
of electric power failure. Electric inter-locks shall be provided to prevent operation by electric power
when the manual drive is engaged.
SELECTION OF SUITABLE HOIST:
The choice or selection of the hoist will be quite obvious in some cases. In other cases
more than one feasible hoisting arrangement may be envisaged from the technical point of view
but the ultimate selection is to be made on the basis of economy, simplicity of the arrangement
orease of maintenance. The following table gives an idea of the hoist to be selected for various
type of gates.

S. No. Type of Gate 1st Choice Hoist II Choice

1. Stop logs Gantry crane/ –
Mono Rail crane/
travelling crane
2. Draft Tube gate:
1. Sliding type -do-
2. Flap type Screw hoist/
Hydraulic hoist
3. Emergency gates Gantry crane/
Rope drum hoist/
Screw hoist/
Hydraulic hoist

4. Penstock gates Hydraulic hoist Rope drum hoist

5. Spillway gates Rope drum hoist
6. Canal regulator Rope drum hoist /
gates screw hoist
7. Construction sluice WincheslR.D.hoist
8. Sluice gates Screw hoist Hydraulic hoisl/
operating at Rope drum hoist
medium heads
9. Sluice gates Rope drum/
operating at high hydraulic hoist
head gates
10. Sluice gate Hydraulic hoists
operating at
very high head
11. Radial gates Screw hoist/
located in sluices Hydraulic hoist
Note:- Medium Head : 15 M to 30 M
Higher head: 30M 50 M
Very High Head : Above 50 M
 9 Design & Construction – Erection of the Gates and Hoists and Maintenance

ERECTION OF GATES:

Apart from the usual men. material & equipment, coordination required in any other construction
activity, erection of hydraulic gates demands precise time scheduling. Especially as it has to cater
for the seasonal conditions of the rivers. Meticulous planning is required particularly in view of the
seasonal nature of work. A close coordination in the delivery of the matching fabricated steel work
to site, arrangement and installation of erection equipment sufficiently in advance to fit into the
erection scheme and lastly, proper man power planning are required for the work to proceed
smoothly.

A preliminary site survey is necessary for the assessment of the material handling facilities,
storage yards required, availability of power supply etc. and in general acquaints one self with the
layout of the site.

The availability of proper plant & equipment will definitely have an effect on the completion of the
project in time and the erection scheme adopted.

An erectors job is basically divided into three parts (ie) those parts which are to be embedded,
the gate and the lifting mechanism. Though the E.M. parts may look insignificant either in size/
weight or in money value in relation to the more visible portion of the gate, real success in the gates
performance will depend on the accuracy with which E.M. parts are erected. Hence a good erector
pays special attention and more meticulous with erection of E.M. parts. Further the erection of the
E.M. parts needs close liaison with civil construction.

After completing the work of mobilisation of the men, material and equipment required, the
officer deputed for the erection work, must verify the block outs.left over from fixing the E.M. parts.
The block outs left over must be within the reasonable limits of verticality and must accommodate
the E.M. parts as manufactured according to design. It is advisable to take up the erection of
E.M.parts after the entire civil structure is constructed leaving the block outs required. This enables
to erect the E.M. parts in perfect verticality within the tolerances specified.

The E.M.parts should be erected using the primary anchorages already fixed. This allows early
alignment and for leveling materials prior to the secondary concreting.

Proper care has to be taken during secondary concreting so that alignment of the E.M. parts
already done will not get disturbed.

The following tolerances are recommended for erection ofE.M. parts. (I.S. 4622 - 1978).
Design & Construction – Erection of the Gates and Hoists and Maintenance 10

S.No. Component Low/Medium High Head

Head
1. Tract plates
Plane parallel to flow ± 1.00 + 0.5
2. Distance between ± 1.50 ±1.00
CIL of opening
and track.

3. Coplanarmess ± 1.0 +0.50

4. Guides:-
Alignment in ± 1.0 ± 1.0
plane parallel
to flow

Distance bet ween ± 1.0 ± 1.0

C/L of opening
5. Side seal seats:-
Alignment in plane ± 2.0 ± 1.0
parallel to flow
Distance between ± 1.5 ± 1.0
CIL of opening and
side seal seat
Coplanramess ± 1.0 ±0.5
4) Top seal seat:-
Alignment height ± 1.0 ± 1.0
height above sill ± 3.0 ± 2.0
Coplanramess with ± 1.5 ± 1.0
side seal seat
All the dimensions of the E.M. parts and gates are to be given with reference to the axis of the dam.

The close tolerances as specified above can be obtained by keeping the tension of the steel tape
and the same throughout during the measurement of the various dimensions especially in spillway
gates.

The good erector will initially acquaint himself with all the relevant drawings and also study the
accuracy of the critical dimensions of the E.M.parts to be maintained in relation those indicated in
the gate components.
 11 Design & Construction – Erection of the Gates and Hoists and Maintenance

Further the radial gates most important reference line is the trunion centre line and this is the first
dimension to be set out while carrying out the lay out work and with its reference the C/L of the
anchorages, sill beams and side guides are marked on piers and crests of the spillway. As the axis
of the dam will not be accessible due to construction activities. the gate erector sets out his own
reference line on the downstream of the piers which will be accessible at all stages of erection of
E.M. parts, gates and hoists.

The anchorages steel work which consists of yoke girder. tie girder. anchor girder and trunion
bearing, supporting girder are erected on piers as a whole and aligned and fixed before the
concreting work is taken up.

Then the sill beams side guides and wall plates are to be erected in the block outs as already
indicated.

There are two types of anchorages for the radial gates.

I. Combined anchorages

2. Independent anchorages

Any error in the construction in between two successive piers by civil authorities will have an adverse
effect on the erection of anchorages. in the case of combined anchorages system. This error reflects
in positioning of the anchorages and thereby the gates. In view of this, proper care has to be taken
both by the civil authorities and the erection crew.

Any errors in the civil construction can be taken care by adjustment of anchorages of that particular
gate in the case of independent anchorages.

Recommendations for the tolerances to be followed for the E.M.parts of a radial gatcs:- (I.S. 46233
- 1984).

I) Wall plate and sill beam.-

a) Distance between the C/L, of + 0.00 mm

opening and face of wall plate - 2.00 mm
at sill end.
b) Distance between the C/L of + 2.00 mm
opening and face of wall - 0.00 mm
plate at top end
c) Straightness of face of wall Joint to be grounded
plates and sill plates smooth
d) Normality of the face of the + 0.01 mm
wall plate to gate sill and - 0.00 mm
C/L of trunion bearings
e) Alignment of sill plate to + 0.25 mm
horizontal plate.
Design & Construction – Erection of the Gates and Hoists and Maintenance 12

The inspection of the pier anchorages shall be carried out at the following stages.

1. Trunion Bracket and support girder

2. Load carrying anchors or ties embedded girder

3. Anchor girder or yoke girder

4. Trunion tie.

The yoke girder/anchor girder shall be checked for its alignment and slope in both directions.

The inspection of the E.M. parts and anchorages shall be carried out as per the recommendations
of I.S. - 10096 (Part-2)/I983.

Gates:

A good erector insists that all the components manufactured at shop floor level are matched for
their complete assembly. Work with required tolerances and precision during manufacture will pay
much dividends during erection. Further the shop assembly of all the components will solve the
various problems during erection and also cut down the time of completion of erection work and
thereby the completion of the entire work.

The erecter should first of all prepare a list of sequence of the various operations to be carried
out during erection work and also the various aspects where special attention is to be paid during
erection. The. various tests to be carried for the joints where the load transmission will be done,
should be indicated to the lowermost executive in the field.

As soon as various components are received at site, it should be ensured that welding is carried
as per specifications and all the parts are match marked.

For erection of radial gate or a vertical lift gate, dry sill is an essentiality.

Before lowering the vertical lift gates if it is in single piece it should be ensured that the thickness
of the gate (ie) the critical dimension from the top of rollers to the top of the seal seat is as per that
specified in the drawings and also tallying with the dimension fixed for the erection of E.M. parts. In
case the vertical lift gate is made out of a number of elements and the roller box is one piece or in
different pieces, it should be ensured that all the roller tops are in one line and also in one plane on
both sides of the gate. If not, these are to be adjusted (by adjusting the eccentricity provided to the
roller pins).

As the radial gates are not provided with the gate grooves and load transmitting rollers the
above aspects will not be there in case of radial gates.
 13 Design & Construction – Erection of the Gates and Hoists and Maintenance

Increase of radial gates the only important dimension to be chccked up is the dimension from
the trunion pin centre to the centre of the sill and also with reference to the axis of the dam.

The important critical dimensions to be checked and the tolerances to be followed in the case of
vertical lift gates arc as follows:- (IS - 4622 - 1978).

Low & Med Head High Head

1) C/C distance between seal bases + 2.00 + 1.0

2) C/C distances between centre line + 2.00 + 1.0

of wheel treads

3) Face to face distance between + 3.00 + 2.0

faces of guide shoes or rollers

4) Face to face distance between +2 + 1.0

wheel tread to side seal box base - 0.0 - 0.0

5) Distance between faces of wheel + 2.5 +1.50

tread and C/L of guide shoe/rolls

II. Alignment of gates roller + 1.5 + 1.5

treads in zero eccentricity

RADIAL GATES: (I.S. 4623 -1984)

I. Colinearity of centre lines of + 0.25

both the trunion bearings

2. Horizontality of centre lines of + 0.25

both the trunion bearings.

3. Parallel distance of centerline of + 3.00

both the trunion bearings from

upstream bottom edge of the skin plate

4. Tolerance in diameter of pin, bush To suit required

hub and bracket of trunion assembly. diameter and fit.

As seen from the above, the tolerances specified for fixing the trunion hubs indicate that the
amount of precision and care required to be taken by the erector for the successful operation of
the gate.
Design & Construction – Erection of the Gates and Hoists and Maintenance 14

The important weld joints which require testing by ultrasonic/ X-ray equipment are:-

1. Trunion girders/Yoke girder joints

2. a) Trunion girder/Yoke girder to the tie flats in case of bearing anchors.

b) Trunion girders to the trunion anchor (bearing anchors).

3. Anchor girder joints.

4. Anchor girder joint to the tie flats or bearing anchors.

5. Radial arm joints to the horizontal girder

6. Horizontal girder joint with the skin plate clement

7. Bearing anchor joint/bonded anchor rod joints -,

HOIST BRIDGE:

Erection of the hoist bridge follows immediately after the completion of the gate steel work.
Reference for the placement of the hoist bridge on the piers is again taken from the trunion CIL. In
this case also it is economical and time saving if the same is first assembled at site I or at shop
itself.

In case of vertical lift gates the reference is the axis of the drum and also the hoist bridge should
be installed properly with reference to the centre of gravity of the gate or according to the E.M.
parts already fixed.

HOISTING EQUIPMENT:

While erecting the hoisting equipment a good erector always insists for the components which
are preassembled at shop level and match marked.

The erector should ensure that the proper clearances are maintained in the gear train.

Important safety devices like limit switches are tobe provided in the hoist equipment as indicated
below:-

1. Limit switch to engage the manual operating system

2. Limit switches in the dial indicator fixing the lower and upper limits of operation.

The erection Engineer should ensure that all the gears and pinions are truely eccentric to
the shaft and made tight fit.
 15 Design & Construction – Erection of the Gates and Hoists and Maintenance

The following important considerations mentioned below need to be looked into for better alignment.

1. Connection of shaft couplings

2. Connection to the wire rope to the drum and to the gate.

3. The ends of the wire rope should be properly socketed are looped as per the I.S. specifications.

4. The wire ropes should be properly lubricated before commissioning and there should be no
kinks.

It should be ensured that the gate grooves and the sill are perfectly clean and no foreign material
is present in the grooves.

It should be ensured that the operation of the gate is tested on the dry siII condition initially utilising
the manual operation. The hoist provided for the operation of the gate should first be independently
tested without connecting to the gate to ensure its satisfactory working.

RUBBER SEALS:

Rubber seals are the last items to be fitted to the skin plate before painting the steel work is
taken up.

Normally the rubber seals are considered to be the most effective way to make the gates watetight
Sometimes metal cladded seals are also used for the following considerations:

1. To reduce frictional load

2. To prevent the seal from extruding or being jammed into the clearance space available between
the clamp bar and the seal plate due to the venturi action of the water when the gate is being
closed under unbalanced head.

Disadvantages:

1. Comparatively high cost.

2. Rigidity – (Use of quadrant of a metal piece (clad) suggested)

3. Due to improper bonding of themetal clad with the rubber, themetal cladding may peal off
andmay come out and obstruct the movement of the gate.
Design & Construction – Erection of the Gates and Hoists and Maintenance 16

Fully moulded corner seals are always preferable for water tightness.

The first pre-requisite for the seal to become watertight is its positive contact with the seal seat
throughout its length. This depends on following factors:-

1. Trueness in alignment of the seal

2. Relative stiffness of the seal (I.S.4622)

3. Precompression given

4. Seal profile should be smooth and no ripples.

Use of the galvaniscd/S.S. countersunk bolts with washers is recommended for the fixing of
seal for better utility and water tightness.

Coefficient of friction:

1. Rubber seals to Metal seal plate - 1.0

1 Metal clad seal to Metal seal plate - 0.3 to 0.65

General:

In case of rope drum hoist, it is to be tested that the gate is going by its own weight or with ballast
provided.

No additional force is needed.

The winding of the rope on the drum should be uniform.

When the gate is operated under water load, it is to be ensured that there are no vibrations to
the gate, hoist or civil structure at various gate openings.
 17 Design & Construction – Erection of the Gates and Hoists and Maintenance

In case of screw hoists where the hoist bridge and the gate are at a very large distance, the stem
of the screw should be built into parts jointed together by suitable couplings and also supported at
some intermediate points. The intermediate supports should be located in such a way that there
should not be fouling with the stem compiling for the gate full opening. If the width of the gate is
sufficiently large, warranting two point lifting, then provision of a twin hoist with common drive has to
be considered. Special care should be taken to synchronize the movement of the two stems and to
have proper alignment of the two gear boxes.

One of the major problems which face the gate erectors is that transportation of the various
components across the spillway. While sill beams, side guide pieces can be manually handled, it
is absolutely necessary to have a crane for handling of heavier weights of anchorage, gate and
hoist bridge steel work. In embedded parts transportation of steel work by water may be considered
provided water level on the U/S of the dam permits approach of loaded boats. The usual route for
feeding of steel work to the spillway is by way of abutment blocks and cranes are required at these
places for the handling of the various components, for transportation of the
components from pier to pier, a temporary bridge has to be laid over which a crane can run. As
most of the erection activities are on the down stream face of the spillway, this bridge can be
located towards the upstream face of the piers. For erecting the anchorages this bridge is to be
located at a comparatively low level of the piers and the erectors can plan the work bearing in mind
the route and the time for his retreat with all equipment frorn the spill way before the outset or
floods.

In erection of gates and hoists a similar bridge is again constructed over high flood level and the
erection crane moves over this bridge. Some times trollies are used on the hoist bridge for
transporting the materials from abutment blocks to the bay where the gate erection is in progress.
The spillway road bridge, if already constructed, comes in very handy to the erectors.

The above is discussed with reference to the erection of radial gates. For erection of barrage
sluice gates (Vertical lift) entirely different problems will be encountered by the erector and different
approach to erection work needs to be considered.

However, it may be appreciated from the above, that precise planning with proper coordination
of various activities is essential for an erector executing work of hydraulic gates.

TESTING OF THE GATES AFTER ERECTION:

The gate should be tested preferably in dry condition with hoist duly connected for its smooth
working. The gate should be move up and down and it should be ensured that there is no obstruction
and no undue effort required for its operation. If the gate is not going down on its own weight or
found tight in some position reasons should be investigated and remedied instead of forcing the
gate down.
Design & Construction – Erection of the Gates and Hoists and Maintenance 18

The testing of the gate seals in dry condition should be done by suitable means such as by
viewing the contact surfaces against a light source.

No grease or lubricant is to be used for rubber seal. Water is a better lubricant.

There should be no noise of friction or any other noise, no signs of excessive friction, no jerking
performance, no twist in the rubber seals and no over pressure on the rubber seals.

The gate is to be kept resting all sill beams (i.e.) in closed condition. The leakage test on the
rubber seals can be done by using a suitable pump with necessary arrangements of jetting water
at 1.5 times the designed pressure on different sealing points trorn bottom to top.

TIle gate should be fully opened and closed to ensure full opening and satisfactory closing.

The arrangements provided for preventing the travel beyond the designed limit are tested and
checked.

In case of rope drum hoist, it is to be ensured that the gate moves down on its own weight. The
winding of the rope over the drum is uniform and according to the design.

The full load current required for movement of the gate shall be measured and checked against
the designed value.

Maintenance of Gates:

The maintenance of gates and hoists of a dam, canal regulators is equally important when
compared with the quality of manufacture and erection. Poor maintenance of the gates and hoist of
a flood control structure may lead to a local or even a national disaster. Negligence of the
maintenance staff for the proper upkeep of the various parts of the gates and hoist will give raise to
several difficulties and even sometimes make the gates in-operative during heavy flood and thereby
causing danger to the entire structure. Sometimes the enaction of the maintenance crew to open
the gates for the passage of flood as per the operational manual will also cause several problems.
In view of this, the maintenance aspect has also assumed greater importance.

The maintenance gang and operating stall must be completely familiar with every part of the
hydraulic equipment and should examine and operate all items of the equipment at regular intervals.
Ofcourse operation of the gates at certain intervals may cause interruption to the regular activities
like generation of power, water regulation to the canals etc., and this inconvenience must be faced
in the interest of the safety and fixed period maintenance should be arranged in each season for
the testing of all the parts of the equipment.

At each test period there should be through examination followed by adjustment, cleaning, oiling,
greasing and painting as necessary and written record should be maintained giving exact details
of the attention given to each item. Standard form of record sheet acts as a valuable reminder to
 19 Design & Construction – Erection of the Gates and Hoists and Maintenance

the men engaged on this work. It is important that correct grade oil and grease should be used as
recommended by the supplies of the machinery.

Gate rollers, seals, sheaves, hoisting wire ropes/chains etc. and in fact the part which are
immersed in water should receive much attention. The painting of the structural parts of the gates,
E.M. parts and hoisting equipment at regular intervals is equally important.

Important hydraulic equipment should be housed in weather proof housings.

Vertical Lift Gates:

The vertical lift gates particularly the fixed wheel gates are of a rugged nature and checking the
leaf once a year when they are required to be operated would be sufficient. The movable parts are
the wheels and it would be necessary to grease the bearings. However before putting the gates
into operation, it would be necessary to see that the wheels arc well greased and they would not
struck up during operation. Thus the vertical lift gates should be checked generally for the following:-

1. Rollers, greasing of pins

2. Seals

3. Hoisting ropes/chains

4. Hoisting equipment.

The hoisting ropes should be lubricated every year by using the specified cardium compound. In
case of stoney type gates the roller case is an important part to be maintained. When the gate is
not under water, the roller cage should be taken out and a check for maintenance is made. It should
be carefully seen that no rollers are broken and the axles of all the rollers arc properly greased.

Radial Gates:

These gates are superior to the vertical li It gates in so far that they have no movable parts. The
important part is the trunion which should be kept duly greased. It should be ensured that the trunion
is always kept approachable.

All the checking in maintenance should be.definitely made before the onset of monsoon.

Hoists:

Hoists are very important so far as the operation of the gates are concerned but redeeming
feature is that the hoist are always approachable since they are above water. Before the floods,
the hoist should be checked, carefully.
Design & Construction – Erection of the Gates and Hoists and Maintenance 20

Periodical maintenance has to be arranged for the different pans of the gates and hoists
depending upon their wear and tear and accessibility,

Generally period of maintenance is recommend for every three months, six months and one
year for the different parts, A chart has to be prepared for strict adherence,

Periodical Check-up:

a) After every 25 operations or 3 months whichever occurs first

i) Check up complete installation for general cleanliness.

ii) Check up and ensure that all electrical connections are tight and in order,

iii) Check up and adjust the brake shoes for any wear and check up the cleanliness between
the plunger and coil of the electro magnetic brake,

iv) Check up oil level in the worm reducer with the dip stick or the level indicator and replenish
if required.

v) Check up the wire rope lor any cut strands, corrosion, abrasion etc., throughout the
length of wire rope.

vi) Check up the rubber seals lor any damage due to foreign materials.

vii) Checkup tile cleanliness of limit switches.

After every 50 operations or half year whichever occurs first the following are to be done in addition
to those mentioned in (a) above.

i) Check up the main switch contact points for proper contact.

ii) Check up and tighten the base bolts of motor. worm reducer. brake and base frames of
central drive units and gear boxes.

iv) Check up the limit switch levels in the dial indicator system to operate their corresponding
limit switches properly,

v) Check up and lighten the coupling bolts and check up their rubber bushes for wear in couplings
provided in.gear boxes and in central drive units.

e) After every 100 operations or yearly (preferably before the commencement of monsoon
season) whichever occurs first -
 21 Design & Construction – Erection of the Gates and Hoists and Maintenance

The following are to be done in addition to those mentioned in (a) and (b) above.

i) Check and consider replacement of contacts and carriers in the main switch.

ii) Check up the general security and condition of all the cables.

iii) Check up the insulation resistance of the motor both body the different phase and phase after
disconnecting the supply terminals.

iv) Check up and consider replacement of brake shoes and brake coils.

v) Drain out the oil in the worm reducer and fill it up with fresh oil specified grades.

vi) Check up for the tightness of all plumper block holding bolts, wire rope clamps holding the
wire ropes on the drums.

vii) Check up the security of the wire rope socket provided.

viii) Paint the gates and hoists as per the standard procedure. This can be revised depending
on the nature of the painting schedule followed.

ix) After about 300 operation or once the three years whichever occurs first -

The following are to be done in addition to those mentioned in (a) (b) and (C) above.

i) Check up for wear of all the gears and bearings.

ii) Check up carefully the entire length or wire rope for cut strands, rusting, abrasion etc., and
consider replacement.

iii) Check up the entire length of rubber seals on the gate for any visual damage, wear, etc.,
and consider replacement.

iv) Check up the completeness of the spares as per the spares list, the tools and replenish any
drawls or missing from the box.

Spares to be Maintained:

The following parts as per specifications are recommended to be preserved as spare to facilitate
immediate replacement when it is called for. Action must be immediately taken to replenish the
stock when any article is uitilised from the spares.

i) Complete set of rubber seals for one gate.

ii) Bolts/nuts required for fixing one set.

Design & Construction – Erection of the Gates and Hoists and Maintenance 22

iii) Hoisting wire rope for one gate.

iv) One complete set of plumper blocks for one gate, line shaft and gear box assembly.

v) Coupling bolts with bushes for one gate.

vi) Brake liners for E.M. Brake 1 set (pair)

vii) Contacts - a) Fixed contractors - 1 set

- b) Moving contractors - 1 set

viii) HRC Fuse units/Fuse wire - 5A, 10A, 15A - each 3 Pcs.

ix) Motor - 1 No.

x) Limit switches -2 Nos