INSPECTION & MAINTENANCE

OF

RADIAL GATES, VERTICAL LIFT GATES

&

ELECTRICALLY OPERATED FIXED HOISTS

&

GANTRY CRANES

Page 1 of 1
 GENERAL INSTRUCTIONS FOR INSPECTION AND MAINTENANCE OF
GATES & HOISTS.

(A) RADIAL GATE:

(I) Inspection of gate shall include all the components of the gate including
its leaf assembly, vertical/Horizontal stiffeners, Horizontal girders,
inclined arms, Yoke/Trunnion girders, trunnion assemblies, side guides,
sill beams, wall plates etc.
(II) A cursory inspection of the gate along with the hoist shall be carried out
daily to ensure that there is no unusual happening.

( B) Monthly Inspection:

(1) Seals shall be inspected for leakages. Locations of excessive leakages shall be
recorded for taking remedial measures. Weeping or slight flow in localized area
will not require immediate remedial measures.
(2) The excessive or widespread leakages, if any shall be repaired to engineer-in-charge
and remedial measures like tightening of bolts are carried out. Further adjustment
is carried out during annual maintenance.
(3) If leakage is so mush excessive that immediate repair is considered necessary, the
stop log gates shall be dropped and seals are repaired or replaced.

NOTE: - During monsoon period, stop log gates shall NEVER be lowered in spite of
heavy leakage through seals.

(4) Remove all dirt, grit etc. from trunnion assembly and lubricate trunnion bearings of
the gate with suitable water resisting grease as recommended by bearing
manufacturers.

(C ) Quarterly Maintenance

The inspection of following components and their maintenance shall preferably be

carried out once in three months but not less than thrice in a year including permission and
post monsoon maintenance.

(1) Inspection of Trunnion blocks assembly and its anchorages:

(i) All the nuts and bolts of Trunnion block assembly and its anchorages shall be
checked for tightness.
(ii) Check all the welds for soundness and rectify defects.
(iii) Check whether the Yoke girder and thrust block is covered on nor. If not, cover
it with mild steel plates.
(iv) Cover the trunnion pin with anti corrosive jelly.

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(2) Inspection of Gate Structures:

(i) Check all the welding for soundness and rectify defects.
(ii) Check welding between arms and horizontal girders as well as between latching
bracket and skin plate with the help of magnifying flass for cracks/defects and
rectify the defects.
(iii) Clean all drain holes including those in end arms and horizontal girders.
(iv) Check all the nuts and bolts and tighten them.
(v) Check upstream face of skin plate for pitting, scalling and corrosion. Scaling be
filled with weld and grinded. Corroded surface shall be cleaned and painted. In
case of gates which cannot be raised every quarter, these can be carried out in
annual maintenance.
(3) Annual Inspection and Maintenance:

The annual Inspection shall be combined with one of the quarterly inspections and in
addition to those required in quarterly inspection, the following shall also be carried out:

(i) All the sill beams and wall plates shall be inspected for crack, pitting etc. and
defects shall be rectified.
(ii) The guide roller pins shall be lubricated.
(iii) Check the condition of wire rope and if poor replace.
(iv) Adjust the rope tension of wire rope if unequal.
(v) Check the condition of rubber seal, adjust at locations of leakages. If damaged,
replace the seals.
(vi) Grease the wire rope.
(vii) Check the condition of rubber seals. All bolts and nuts holding rubber seals shall
be tightened. If rubber seal is damaged, replace the seal.

MAINTENANCE:
As per IS: 10096 (part3)

a) Defective welding should be chipped out and it should be rewelded duly following
the relevant codal provisions.
Damaged nuts, bolts, revets, screws etc. should be replaced.
Any pitting should be filled up by welding and finished by grinding if necessary.
b) The gate leaf, exposed embedded metal parts, hoists and hoist supporting structure
etc., should be thoroughly cleaned and repainted when required keeping in view the
original painting system adopted and as per the guidelines contained in IS: 14177.
c) Trunnion bearing should be greased wherever required. Keeping trunnion bearings
in perfect working condition is very important. All other bolted connections should
also be checked up for proper tightness.
d) Bolts and trunnion bearing housing should be tightened wherever required.
e) The seals of the gate should be checked for wear and tear and deterioration. These
should be adjusted/replaced as and when necessary.
f) The wall plates, sill beams shall be checked and repaired if necessary.
g) Wire ropes should be properly lubricated.
h) Oil level in the worm reduction unit should be maintained by suitable replenishment.
Oil seals should also be replaced if required. Lubrication of other parts of hoists
such as chains, position indicators and limit switches should also be done.
i) The stroke of the brake should be reset to compensate for lining wear. Worn out
brake linings should be replaced in time.
j) Flexible couplings should be adjusted if required.

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 k) Repairs and replacements of all electrical relays and controls should be attended to.
l) Maintenance of alternative sources of Power such as Diesel Generating sets and
alternative drives wherever provided should be carried out.
m) The list of essential spare parts to be kept available should be reviewed and updated
periodically. The condition of spares should be checked periodically and protective
coating given for use.

VERTICAL LIFT FIXED WHEEL AND SLIDE GATES:

INSPECTIONS

GENERAL:
These gates are provided for controlling water discharges for flood control, water
supply, irrigation and power generation etc. The gates shall be thoroughly inspected for
cracks, defects or damages periodically. A schedule of maintenance is proposed in the
following sub sections which may be adopted with modifications, if required, due to site
conditions and use of gate.

1) QUARTERLY INSPECTION

A) All welds shall be checked for cracks/ damages and defects rectified.
B) All drain holes shall be cleaned.
a) If pitting is observed on surface, it shall be repaired and grounded.
b) The rusted parts, if observed, shall be thoroughly cleaned and repainted as per
approved painting schedule.
c) The Wheels shall be rotated to check their free movement.
d) The wheel bearings and guide rollers shall be lubricated.
e) The seal shall be checked for damages, if needed, shall be replaced.]
f) All nuts and bolts shall be tightened.
g) The guide-assemblies, wheel-assemblies and sealing-assemblies shall be cleared off
grit, sand or any other foreign material.
h) The wheel pin shall be coated with corrosion resistant compound.

2) ANNUAL MAINTENANCE

During annual maintenance following additional checks or maintenance shall be

carried out.
a) All the embedded parts shall be checked for defects/ damages and rectified whenever
noticed.
b) The sill beam and guides shall be cleared for all grit, sand etc.
c) The wire rope shall be checked for equal tension. If broken strands are noticed, the
wire rope shall be replaced.
d) The wire ropes shall be greased.

2. SPECIAL MAINTENANCE:
(I) The repainting of the gates shall be carried at intervals to be decided on
the basis of painting schedule of the gates.
(II) The inspection, testing and maintenance of the hoist shall also be carried
out periodically as suggested by the hoist manufacturer. The salient
procedure has been described in a separate section.

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MAINTENANCE [ as per IS: 7718]

a) Any weld that might have become defective should be chipped out and remade
following the relevant codal provisions.
Damaged nuts, bolts, revet screws etc should be replaced without delay.
b) The gate slot and platform should be cleaned periodically. Scales formed over the
embedded parts should be removed. All bottom corners should be cleaned and
accumulations removed. Anchorages and concrete around anchorages should be
checked for any development of cracks or slackness etc and repairs should be
attended immediately.
c) The gate leaf should be thoroughly cleaned and repainted as and when necessary
according to the procedure or guidelines- indicated in IS: 14177 or as per the
recommendations of the paint manufacturer.
d) Rubber seals should be ground if necessary to keep it in one alignment. All nuts and
bolts fixing the seal to the gate should be tightened uniformly. Seals, if found
damaged or found leaking excessively should be adjusted, repaired or replaced as
considered necessary.
e) Gate roller bearings and guide roller bushes should be properly lubricated.
Whenever necessary these should be opened for rectifications of defects and after
cleaning and lubrication should be refitted. These may be replaced if repairs are not
possible.
f) Hoisting connection of the gate leaf should be lubricated where necessary and
defects if any should be rectified.
g) All nuts, bolts, check nuts and cotter pins of the lifting devices should be checked
periodically.
h) All components should be greased and lubricated. Recommended and approved oils
and grease only should be used.
i) Appropriate remedial measures should be taken so that the salient dimensions
mentioned in clauses 9.2.1.2 and 9.2.2.6 and alignment of components mentioned in
clause 9.2.1 of IS 7718 are set right. Appropriate repairs should also be carried out
where excessive pitting and other surfaces are damaged are noted.
j) Roller assembly should be adjusted by the eccentricity arrangement to ensure all
rollers rest uniformly on the track plates particularly in the closed position of the
gate.
k) Where filling valves are provided as part of the gate structure, all the nuts, bolts,
check nuts etc should be checked periodically. It shall also be ensured that the
filling valves completely shut off the passage of water when the load is removed.
The springs and other components shall be checked periodically and replaced if
necessary.

ELECTRICALLY OPERATED FIXED HOISTS.

1. General Instructions;

a) Operation of fixed hoist without lifting the gate is not possible and need not
therefore be attempted. It will be possible to operate the unit and observe operation
of load carrying hoist component when gate is being lifted or lowered.
b) Never open any bolt or nut on motor, gear boxes, rope drums and other load carrying
hoist components when the gate is in raised position. The gate should be fully
closed or rested on the gate latches before carrying out any work on hoist
components including motor and trusts brake and other electrical equipment.

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c) The periodic maintenance of commercial equipment like motors, brakes, thrusts etc.
shall be carried out as per manufacturers operation and maintenance manual.
However, general maintenance schedule of motors and brakes has been described
under Maintenance of Commercial Equipment.

Daily Inspection

1. Entrance to all hoist platforms shall be kept locked. All keys shall remain with the
shift supervisor.
2. A cursory daily inspection shall be made of hoist and gate to ensure that there is no
unusual happening.

Monthly Maintenance:

1. Clean all hoisting equipment and hoist platform.

2. Check oil level in gearboxes and replenish wherever required with oil of proper
grade.
3. Apply grease of suitable grade by grease gun through all the greasing nipples.
4. Lubricate all bearings, bushings, pins, linkages etc.
5. Check all the fuses on the power lines.
6. All bolts and nuts on gear boxes, hoist drum and shaft couplings should be checked
for tightness.
7. Check the supply voltage.

Electrical Maintenance:

a) Starters should be cleaned free of moisture and dust.

b) Each individual contactor should be tried by hand to make sure that it operates
freely.
c) All wearing parts should be examined in order to take note of any wear which may
have occurred during operation.
d) If the contactor hums, the magnet faces should be cleaned (Blackening of contacts
caused by deposition of silver due to arching is of no importance).
e) Examine all connections to see that no wires are broken and no connections are
loose.
f) Clean the surface of the moving armature and magnet core which comes together
when the contactor closes, free of dust or grease of any kind.
g) Examine the mechanical interlocks between the reversing contactor and see when
the contact tips of one of the contactor units are touching, it is impossible to get the
contact tips of the other unit to touch.
h) The contact tips should be kept free from burns or pits by smoothening with fine
sand paper or emery paper.
i) Replace the contact tips which have worn away half-way.
j) Do not lubricate the contacts.

Quarterly maintenance

1. Carryout all those listed for monthly maintenance.

2. Drain sample gear oil from each of the gear boxes. If excessive foreign particles or
sludge is found, the gear box shall be drained, flushed and filled with new oil.
3. All the geared couplings shall be greased.

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4. Raise and lower the gate by hoist motor and check for smooth, and trouble free
operation of gate without excessive vibration.
5. Observe current drawn by motor at the time of lifting and check if it is more than
normal. If so, stop the hoist and investigate the cause and rectify.
6. Check the condition of painting of various components and remove rust wherever
noticed and repaint the portion after proper cleaning as per painting schedule.

Annual Maintenance

The annual maintenance shall be combined with one of the quarterly maintenance and in
addition to those required in quarterly maintenance, the following shall also be carried
out.
1. All trash, sediments and any other foreign material shall be cleared off the lifting
rope and lifting attachment.
2. All ropes shall be checked for wear and tear and if broken wires are noticed, the
rope shall be replaced.
3. All the wire ropes shall be checked and all visible oxidation shall be removed.
4. All wire ropes shall be greased with shell cardium compound or equivalent brand.
5. Check the overload relays for proper functioning.
6. Check all the nuts, bolts, rivets, welds and structural components for hoisting
platform and its supporting structure for wear, tear and damage. All damages shall
be rectified. All bolts shall be tightened. The portion with damaged painting shall
be touched up.
7. Check the pulleys, sheaves and turb-buckles.
8. Raise and lower the gate for its full lift several time ( at least three to four) and
observe the following:
a. Check the limit switches and adjust for design limits.
b. The effectiveness and slip of the breaks shall be checked by stopping the gate
in raising and lowering operations. The brakes shall be adjusted if needed.
c. When the gate is operated, there should not be any noise or chatter in the
gears.
9. Adjust the rope tension of wires if unequal.
10. Check for all gears and pinions for uneven wear and adjust for proper contact.
Grease the gears.

PAINTING

Repaint the hoist components, hoisting platform and its supporting structures after a
time interval depending upon the painting schedule.

MAINTENANCE OF COMMERCIAL EQUIPMENT

Moisture, oil, dirt, grease and carbon and metallic dust are the principal causes of
break down. The motors shall, therefore, be kept dry down. The motors shall,
therefore, be kept dry and clean. The frequency of inspection, serving and
maintenance largely depends upon the nature and periodicity of its usage and its
operating conditions. The following its operating conditions. The following
maintenance schedule may be adopted in general.

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Quarterly Maintenance

1. Blow out windings thoroughly by clean and dry air to clear air passage in the
stator and the rotor of any accumulated dirt. The air pressure shall not be too
high to damage the insulation.
2. Examine earth connections and motor leads.
3. Examine motor windings for overheating
4. Examine control equipments
5. Examine starting equipment for burnt contacts
6. Check and tighten all nuts and bolts
7. Clean and tighten all terminals and screw connections all contact surfaces
shall be made clean and smooth.

Half yearly maintenance

1. Lubricate the bearings

2. overhaul the controllers
3. Inspect and clean circuit breakers.
4. Wipe brush holders and check bedding of brushes.

Annual maintenance

1. Blow out windings thoroughly by clean and dry air. The pressure shall not
be so high that insulation may get damaged.
2. Check the insulation resistance of the motor between any terminal and the
frame which should not be less than (1000+rated H.P.) megohms. If the
measured resistance is less than this value, then steps shall be taken to dry-
out the motors either by passing a low voltage current through the windings
or by placing the stator and rotor only in a warm dry place for a day or so.
Important The complete motor shall never be put in an oven for drying as
theat may melt the grease out of bearings.
(3) Coat the windings with an approved high temperature resisting insulation
enamel or varnish.
(4) Over haul the motor, if required.
(5) Check the switch fuse units and renew, if required.
(6) Check resistance or earth connections.
(7) Check air gap.

Solenoids Operated Brakes

a) Quarterly maintenance
1) All fixing bolts shall be checked and tightened at least once in three months.
2) The magnet stroke should be reset to compensate for war.
3) Read just the brake when the magnet stroke reaches the value given on the
instruction plate.
4) Brake lining should be checked and replaced when required.
5) Examine all electrical leads and connections.
6) Rubber bushes or couplings should be checked and replaced if defective.
7) The pins should be tightened.
8) Brake drum shall be cleaned to remove any dust or grease.

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LUBRICATION AND GREASING:

A chart showing the lubricants normally used frequency of use for spillway
radial gates and vertical lift gates, hoists is appended in Annexure-II

OPERATION AND MAINTENANCE OF GANTRY CRANE

Following aspects need to be attended before crane driving operations:

Lubrication of each part of crane
Removal of any loose/foreign material along the rail track
Actuating tests of limit switches
Actuating tests of brakes.
All fuses in the control panel should be checked and if necessary it should be
replaced.
Necessary terminal connections of motors, brakes, thrust or etc is to be checked.
Overload relay should be checked.
Visual inspection of wire ropes for any snapped loose wire and its proper
lubrication.
Checking of rope clamps on the drum and tighting of bolts if required.
Gearbox assembly should not have any leakage of oil.
Unusual noise/vibration if any should be checked and rectified before operation.

II.GENERAL PRECAUTIONS TO BE TAKEN FOR OPERATION OF CRANE

Crane should have interlocking system so that on one single operation namely
hoisting, lowering forward or backward can only be affected at a time through the
push button controller.
Hoisting and lowering motion should be carried out only after the crane is securely
clamped to the rails.
Load on the crane at no time should exceed the safe working load.
Operator should be well conversant for operating the crane for various motions of
the crane and under various loading conditions. The operator should check long
travel, cross travel, hoist motion etc. The operator should never use limit switches as
a normal means of stopping the hoist motion. Limit switches are only emergency
devices.
No load should be left suspending from the crane.
Crane should not have excessive side play while in motion on the gantry rail.
Excessive sparking from any electrical devices, smoke from motors or brake drums
if any should be rectified immediately.

III. PRE CAUTIONERY MEASURES:

I) Ensure that the gates are operated by fully trained operators and that they are
familiar with the operating instructions.
II) No other person should be allowed to go near the operating mechanism without
operator or his superior officer.
III) Any unusual phenomenon such as excessive vibrations, noises, faults and
damages are recorded and immediately reported to the competent authority.
IV) Ensure limit switch arrangement is properly set.
V) That check list on maintenance of gates is periodically signed by the inspecting
authority.

Page 9 of 9
 VI) Safety guards around moving parts must not be removed except during
maintenance operation and with the equipment under static condition. It should
be isolated electrically.
VII) Safe and proper access to the maintenance working areas must be provided.
VIII) When equipment is stationery, working parts may be under load, so due care
must be taken before dismantling any part and when ever necessary, suitable
supports should be provided.
IX) Before equipment is put back to work, all parts should be checked thoroughly
and see that they are properly assembled.

CONCLUSIONS:
1. CHECK - LIST

A check list is a list of items to be checked systematically by Engineers during inspection of

hydro-mechanical equipments. It has also been referred to as an aide-memoir. The
advantage of using checklists lies in the fact that by considering all points contained therein,
the Engineer has not overlooked any standard which ought to be complied with at work
place. Check Lists may be descriptive checklists or corrective check lists. The check lists
are enclosed as Annexure I.
A time Schedule for maintenance of all the hydro-mechanical equipment is to be prepared
for each project individually based on the maintenance personnel available quantum of work
involved (i.e. depending on the number of gates hoists or other hydro-mechanical
equipment, age of the equipment, frequency maintenance etc.) or as per requirement by the
project in charge of maintenance.
The Lubrication schedule is enclosed as Annexure II.
The maintenance schedule is enclosed as Annexure III.
A typical Quality Assurance plan is enclosed as Annexure IV.
NOTE: Check lists can be modified to suit the requirements at site.

REFERENCES:

A) IS: 4622
B) IS: 4623
C) IS : 5620
D) IS : 9349
E) IS: 6938
F) IS: 10096 (PART-I/Sec.1)
G) IS: 10096 (PART -1/Sec.2)
H) IS: 10096 PART 2
I) IS:10096 PART 3
J) IS: 7718
K) IS: 7349
L) IS: 11855
M) IS: 14177
N) IS: 11228

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 ANNEXURE I

CHECK LIST FOR HYDRAULIC GATES

CHECK LIST FOR THE LOW HEAD SLIDE GATES/ FIXED WHEEL GATES:

Sl.No. Item Yes No

A. Hoist

(i) Is the operation of hoist smooth?

(ii) Whether the indicator is provided?
(iii) Is the stop nut provided?
(iv) Check nut and bots of the king post
(v) Check lubrication
(vi) Observe the king post nut while lifting the gate
(vii) Is correct Tommy bar used?

B. Stem Rod

i) Are the stem rods in plumb?

ii) Whether the guide bracket bushing touch the stem rods
iii) Are all the flange bots tight?
iv) Weather the top stem rod portion is well lubricated and fitted with the
indicator.

C. Embedded Parts

i) Are the seal seats intact?

ii) Have you noticed any pitting, corrosion on these parts?
iii) Do seals indicate the normal wear and tear

D. Leaf

a) Inspect the leaf when the water level depletes

b) Check the leaf for the pitting and corrosion.
c) Check the stem rod and leaf connection
d) Check the leaf seals for the wear and tar
e) Check if there are any foreign particles accumulated near the leaf bottom seal which
may obstruct the gate closure.
f) Does the gate seal properly seat on the embedded part seal
g) Check the rollers for wear and tear
h) Check the rollers properly rest & rotate on its track

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 E. General

i) Are there any leakages from seals or the structure?

ii) Check for the noise
iii) Check for the vibrations
iv) Check for the extra effort, if any, during its operation
v) Does the gate close due to water pressure or needs adjustments
vi) Are kaddi shutters provided
vii) Is the ladder provided safely placed
viii) Are there any beehives near the gate
ix) Are there any poisonous snakes in the well or near the structure
x) Are the air vent provided clear
xi) Is the locking arrangement provided on the hoist?
xii) Are the log books properly maintained?
xiii) Is the maintenance properly done?
xiv) Is any emergency plan drawn to meet the unexpected gate or dam failure?

CHECK LIST FOR RADIAL GATES

Sr.No. Item Yes No

(A) Hoist (Mech.)

(i) Electric
(ii) Is the motor working properly?
(iii) Are the foundation bolts tight?
(iv) Does it draw excess current?
(v) Is properly earthed?
(vi) Are all phases working?
(vii) Is the generator set working properly?

(B) Brake

1) Are the brakes properly functioning?

2) Are they tested by lifting the gate load for few CMS?
3) Does it get unlocked while manual cranking?

(C) Gear Train

1. Is adequately lubricated?
2. Are any foreign particles accidentally left in the train?
3. Is a self locking hoist?
4. Is working smoothly?
5. Do bearing /Bushes get heated?

(D) Limit Switches

1. Are the switches well adjusted / maintained?

2. Are these tested?
3. Is the audio indicator fitted in case upper limit switch fails?

(E) Wire Ropes

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 1. Are these properly lubricated?
2. Whether these are properly clamped?
3. Is there any breakage of strand; found during inspection?
4. Have you inspected the lifting bracket?

(F) Trunnions

1. Is the pin properly lubricated?

2. Have you ensured that there are no foreign particles in between the pin end and the
inside bracket face?
3. Are pin locking nuts tight?
4. Does it make any noise while in action?

(G) Anchor Bolts

1. Are all anchor bolts tight?

2. Are these well protected against aging?

(H) Seals

1. Have you checked the rubber seals for cracking / wear/tear?

2. Are the leakages if any within the permissible limit?

(I) Guide Rollers

1. Are the rollers free?

2. Are these well lubricated?
3. Are the nut and bolts tight?

(J) Welding

1. Have you inspected all important welded joints?

2. Do they show signs of distress?

(K) Embedded parts

1. Are all embedded parts checked for the corrosion / pitting?

2. Do they need anti corrosive treatment?

(L) GATE ASSEMBLY

1. Are gate parts free of rusting and corrosion?

2. Are all drain holes clear /
3. Are all nut and bots tight?
4. Does the gate leaf vibrate while opening and closing?
5. Are there any jerks while lifting or closing the gate?

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(M) PAINTING

1. Does the gate need painting?

2. Are any signs of corrosion?
3. Is Ph value of water checked?

(N) INSPECTION

1. Was detailed inspection carried out by the inspection wing?

2. Are points raised in the inspection complied?

(O) General

1. Are stop log gates provided /

2. Are the ladders provided are properly placed and safe?
3. Are there any beehives on or near the gate?
4. Is the structure inhibited by snakes /
5. Is the locking arrangement for the gate provided?
6. Are the log book and other record properly maintained?
7. Are you aware of the emergency plan in the event of the gate/dam failure

REMEMBER DAM SAFETY IS IN YOUR HAND

The check list given below shows the points to be checked by the engineer in charge
at least once a year.

(a) Name of the Project

(b) Name of the Officer
(c) Date of inspection
(d) Water level above the sill
(e) Date of last inspection

INSPECTION CHECK LIST

Yes No

1. Is the gate operator trained?

2. Whether gate is maintained properly?
3. Whether any trouble was noticed in the gate operation on last one year?
4. Is the maintenance programme for the gate chalked out?
5. Is the log book and order book properly maintained?
6. Whether any complaints received from villager due to the faults in gate operation?
7. Are defects if any, reported to the Mechanical Engineer?
8. Are recommended tools, lubricants and spares maintained at the site?

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 ANNEXURE II
LUBRICATION SCHEDULE

Sl. Part to be lubricated Mode of Lubricant Frequency

No. Lubrication
1 Trunnion pin bush Prssure Servo gear- Once in
bearing grease gun 20 or three
bearing months as
grease per site
conditions.
2 Gate wheel bearings Pressure Servo gear- Once in
grease gun 20 or three
bearing months as
grease per site
conditions.
3 Guide rollers Pressure Bearing Once in
grease gun Grease three
months as
per site
conditions.
4 Hoisting wire rope Hand applied Servo gear- Once in a
120 or year before
Cardium monsoon
Compound sets in
5 Worm reducer Oil bath Servo HP-30 Indicator
level to be
maintained
always.

6 Spur Gear Bearings Pressure Bearing Once in

grease gun Grease three
months as
per site
conditions.
7 Line shaft bearings Pressure Bearing Once in six
grease gun Grease months as
per site
conditions
8 Gear Wheels Hand applied Chassis Once in six
Grease months as
per site
conditions
9 Drum shaft Pressure Chassis Once in
grease gun Grease three
months as
per site
conditions.

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 10 Lifting Arrangement Hand applied M.P Grease Once in six
and buckles months as
per side
conditions
11 Hand operation Hand applied Servolin - Once in
mechanism and other 140 three
relating parts months as
per site
condtions.

ANNEXURE III

CHART FOR MAINTENANCE SCHEDULE FOR GATES

(IS: 7718/IS:10096 Part III)
Sl. Quarterly Every Year Every three Every six years
No years
.
1 General In addition to In addition to Check welds for
cleanliness of Quarterly yearly damages at
embedded parts, maintenance maintenance
Gate hoist schedule the schedule, the
components following are following are
to be checked to be checked
2 Check for oil level Check the Check the a)Skin plate joints
in worm reducers tightness of condition of b)Tee girders to
foundation wire rope, horizontal girders
bolts of pulleys, c)Horizontal girder to
Motors, worm sheaves, limit arm
reducers, switch, brakes d)Arm bracings
Plummer and gear e)Horizontal girder
blocks, wheels bracings.
coupling joints f)End boxes
g)Gate stiffeners.

3 Greasing of Check for Check gate Check wheel assemblies

pulleys and pins smooth seals for for any
operation of damages a) Breakage
gate by raising b) Freezing
and lowering c) Corrosion
d) Misalignment

4 Trunnion pin, Check for Check seal Check for sill beam, side
Rope drum condition of bolts for gude, roller tracks for
hoists, Gear painting of all damages damages, corrosion,
wheels, Hand components pitting.
operation of
shaft, guide
rollers, Gate
wheels.
5 Check for Check hoist bridge for
operation of foundation bolts for
brakes tightening

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6 Check for loose
electrical
connections

7 (In case of fixed

wheel gates)
1. Wheels are
to be greased
properly
2. Movement of
wheels
should be
smooth and
it can be
rotated by
hand

Page 17 of 17
 ANNEXURE - IV
(Clause :9.1, IS:7718)
Typical Quality Assurance Plan for Manufacture, erection and periodical Maintenance

Project:_______________________ Type of Gate:______________

Manufacture:___________________
Purchaser:_____________________
Agreement No:__________________

Sl.No Component Characteristics Type of Check Quantity of Accecptance

Check norm
1 RAW MATERIALS
Hot rolled plates, Physcial Verification of 1 per batch As per relevant
section and rolled properties material testing Indian standard
1.1 rounds. certificate
Chemical -do- -do- -do-
1.2 properties
Dimensional Measurements Random/full IS 1852
1.3 check
Ultrasonic UT Examination 100% Level III, IS
check for 3664
1.4 Laminations
2 CAST STEEL - Items
Gate rollers, Physcial Mech. Test with 1 per heat As per relevant
Guide roller properties bar Indian standard
Assembly, Gear
2.1 wheels
Chemical Chemical analysis -do- -do-
2.2 properties
2.3 Heat treatment Heat chart -do- -do-
2.4 Dimensions Measurements 100% -do-
2.5 UT testing UT Ex. -do- IS 3664
Hardness Hardness As specifided Tolerance 10
2.6 in App. Drg.
3 FORGINGS
Rollers and pins Physcial Verification of Entire Lot As per relevant
properties material testing Indian standard
3.1 certificate
Chemical -do- -do- -do-
3.2 properties
3.3 Bend test -do- -do- -do-
3.4 Heat treatment Heat chart -do- -do-
Dimensions Measurements 100% No significant
3.5 defect
STAINLESS
4 STEEL
Plates for seal Physcial Verification of test 100% As per relevant
seats, wheel properties certificate Indian standard
4.1 tracks and pins
Chemical -do- -do- -do-
4.2 properties
4.3 Hardness Measurements -do- -do-
4.4 Dimensions -do- -do- -do-
Surface defects Visual inspection -do- Approved
4.5 Drawing

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 U.T. tests for UT test -do- Level III, IS
4.6 internal defects 3664
5 RUBBER
Rubber seals Physcial
5.1 properties
I) Hardness Verification of test Random one IS 11885
after vulcanizing certificate for batch
ii) Elongation -do- -do- -do-
iii) Tensile -do- -do- -do-
strength
iv) Water -do- -do- -do-
absorption test
v) Dimension Measurements 100% Approved
Drawing
BOUGHT OUT
6 ITEMS
Bolts, nuts & Hardware items Verification of test Random Approved
6.1 bearings etc. certificate Drawing
Specification -do- -do- -do-
6.2 and make
Dimensional Measurements -do- -do-
6.3 check
Physcial Verification of test -do- As per
properties certificate approved
drawings and
relevant Indian
6.4 Standard
Chemical -do- -do- -do-
6.5 properties
7 WELDING
Fillet welds and Weld procedure Verification of Random IS 3658, IS
butt welds for fillet and butt document 3664
7.1 welds
Qualification of -do- -do- IS 7318 (Part-
7.2 welders 1) & IS 822
Quality of fillet Visual -do- No significant
7.3 welds defects
Quality of fillet Die penetration 100% No Significant
7.4 welds Defects
Ultrasonic 10% Level III
Test/Radiographic IS3664
Test
FABRICATION
OF GATE PARTS
Dimensional Measurements Each Approved
8 inspection Drawing
Skin Plate Assy. -do- -do- -do- Tolerance as
Horizontal girders, per relevant
Wheels, Pins Indian
8.1 Standard
-do- -do- Tolerance as
per relevant
Indian
8.2 Standard
Surface Finish Visual / 100% Approved
(Machined) Comparison with Drawing
8.3 comparator

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 EMBEDDED
9 PARTS
LH Measurements Each Approved
9.1 Drawing
RH -do- -do- Tolerance as
per relevant
Indian
Standard
9.2 LH-Top -do- -do- Tolerance as
LH-Bottom per relevant
Indian
Standard
9.3 RH-Top -do- Tolerance as
RH-Bottom per relevant
Indian
-do- Standard
Surface Finish Visual / 100% Approved
(Machined) Comparison with Drawing
9.4 comparator
10 PAINTING
Gates Surface Visual Random Approved
preparation Drawing or
technical
specification
10.1
10.2 Primer Coat -do- -do- -do-
Intermediate -do- -do- -do-
10.3 Coat
10.4 Finish Coat -do- -do- -do-
Thickness of Measurement -do- -do-
10.5 paint with comparator
11 ERECTION
Check for Measurements Each Approved
critical Drawing or
dimensions technical
specification
11.1
11.2 Balancing of gate Verification -do- -do-
Visual with light
11.3 Dry test source -do- -do-
As per Clause
11.4 Leakage test Visual -do- 8

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