Is 13349
Is 13349
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Indian Standard
CASTIRONSINGLEFACEDTHIMBLE MOUNTEDSLUICEGATES-SPECIFICATION
UDC 6216465 [ 66913 ] : 628146.5
@ BIS 1992
INDIAN
STANDARDS
ZAFAR
CED 3
FOREWORD This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the Sanitary Appliances and Water Fittings Sectional Committee had been approved by the CiviI Engineering Division Council. Single faced cast ircn controlling the flow. mounted on the wall type is covered by IS ( under revision ). sluice gates are extensivly used in water supply and drainage works for These are of two types one where the gate with spigot back frame is directly The first and the other where mounting on the wall is through wall thimble. 3042 : 1965 Specification for single faced sluice gates ( 200 to 12 mm njxe )
This standard covers sluice gates of second type meant for mounting on the face of wall through a cast iron wall thimble an accessory which is first embedded in the wall and its front flange b&g flush with the face of wall. The gate frame having machined back flange is mounted on thimble flange, with a gasket in between the flanges, and is fastened to it with the help of studs. Thimble mounted sluice gates have following advantages: a) Tt remains clear off the wall even after its installation and hence it can be easilv removed from the face of wall whenever required either for repairs, maintenance or relocation. b) Mounting of flange back gate frame gate on wall thimble eliminates anchor bolts, and providing recesses in the wall. the necessity of using
c) The construction makes the gate rigid and suitable for unseating head applications. d) Flange back construction makes it possible to test the gate at manufacturers works for ita leakage performance making it possible to specify permissible leakage limits. These gates are primarily meant for use in water supply and waste water applications such as water filtration and purification works, intake wells, pumping stations, drainage and irrigation canals, water and sewage treatment plants, flood control, thermal power stations and water cooling plants, etc, requiring flow control or shut off. These gates may also be use for industrial waste faces, wedge water and with other fluids provided the suitability of materials used for the seating facing, stem guide lining, stem nut, guide bush, resilient seat, etc, is first ascertained for their compatability with the end use. The information to be supplied with enquiry and order by the purchaser is given in Annex A.
As sluice gate is a custom eqUipment it iS not practical to specify single type of materjal, or method of construction of fabrication. Various possible alternatives vary with the site conditions and requirements of the users. Such alternatives are dealt with separately at appropriate places in this standard. While formulating this standard an attempt has been made of making this standard in line with other internationally accepted standard available on the subject. Guidance has been taken from ANSI AWWA C-501-87 AWWA Standard for Cast Iron for Sluice Gates, issued by the American Water Works Association. At the same time relating to the practices in this field in the country have been kept in view. of deciding the final value, observed accordance with IS 2 : 1960 of significant places retained value in this standard.
For the purpose
whether a particular requirement of or calculated expressing the result Rules for rounding off numerical in the rounded off value should be
this standard is complied with of a test, shall be rounded offin values ( revised ). The number the same as that of the specified
IS 13349 : 1992
Indian Standard
CASTIRONSINGLEFACEDTHIMBLE MOUNTEDSLUICEGATES-SPECIFICATION
1 SCOPE 1.1 This standard covers single faced vertically sliding type cast iron sluice gates of nominal sizes from 300 to 2 500 mm, suitable for mounting on the flange of cast iron wall thimble. These sluice gates are meant for use for water supply and waste water application. 1.1.1 These sluice gates are designed for either seating head or unseating head, or both.
head shall NOTE - Gates designed for unseating quality in all respects the requirements speciEed for seating head. NOTE - In case of circular obenings, a gate with square opening may be adopted provided that wall thimble has a circular opening to suit the water way opening and a square Range to suit the square flange of the gate frame.
4.2 Types 4.2-l Sluice gates may be manufactured either with rising stem or non-rising stem ( see Annex C ).
NOTE - Non-rising stem generally not recommended. type sluice gates are _,
1.2 Sluice Gates as per this standard in addition to manual may be adapted to electric hydraulic or pneumatic power operation. Requirements for actuating gear except in case of manual operation is left to the mutual agreement between the purchaser and the manufacturer. 1.3 Sluice gates as per this standard may be of the conventional-closure or of flush-bottom closure type. 2 REFERENCES 2.1 Indian Standards listed in Annex B are the necessary adjuncts to this standard. 3 CLASSIFICATION 3.1 Based on maximum unbalanced (seating or unseating ) water heads, sluice gates shall be classified as: a) Class 1 sluice gates Suitable for maximum unbalanced head up to and including 5 metres of water, Suitable for maximum unbalanced head above 5 metres and up to and including 10 metres of water, and Suitable for maximum unbalanced head above 10 metres and up to and including 15 metres of water.
4.2.2 Sluice gates may be either of conventional bottom closure or flush bottom cIosure ( see T Annex D ). 4.2.3 Sluice gates may be for opening or downward opening. either upward
4.2.4 Sluice gates may have operating headstock either mounted on platform or directly mounted on yoke.
NOTE - SIuice gates with hsadstock mxmted on the yoke of frame are called self-contained type. 5
NOMINAL
SIZES
5.1 Nominal sizes of square ( or round ) and rectangular sluice gates shall be as given in Table 1 and Table 2 respectively.
NOTES 1 Nominal size of a sluice gate shall be reckoned by the clear opening of gate frame. In case of rectangular opening, the size shall be specified as Width x Height of opening. The first of the two dimensions shall mean the width of opening. 2 Sizes indicated in Table 1 and Table 2 are preferred sizes. Other sizes as agreed to between the manufacturers and purchasers are permissible.
6 MATERIALS 6.1 Materials used in the manufacture of various components of sluice gates shall conform to the Indian Standards given in Table 3. 6.1.1 Components other than mentioned in Table 3 shall conform to the appropriate Indian standard, where one exists. 1
AND TYPES
4.1.1 The opening of the sluice gates and the wall thimble may be either circular, square or rectangular.
Is 13349 : 1992 Table 2 Nominal size of Rectangular Sluics Gates, in mm ( Clause 5.1 )
Width x Height 400 300 x 300 400 x 500 x 400, 750 500 x 400 600 x 750 600 x 750 750 750 750 900 900 500 x 600 x 900 x x 1 100 600 x x 1 200 Width x Height 1000 x 750 1 000 x 1 200 1 000 x 1 500 1 100 x 900 1 100 X 1 500 1 200 x 900 1 200 1 200 1 400 1 400 1 500 1 500 x x x x x x 1 500 1 800 1 000 1 800 1 000 1 200 Width x Height 1 500 x 1 800 1 500 1 600 1 600 1 800 1 800 1 2 2 2 2 2 2 800 000 000 250 250 500 500 x x x x x x x x x x x x 2 000 1 200 2 000 1200 1 500 2 500 1 500 2 500 1 500 2 500 1 600 2 000
7 GENERAL DESIGN AND CONSTRUCTION REQUIREMENTS 7.1 Frames 7.1.1 Design The frame shall be designed for maximum head indicated in 3.1 for the appropriate class with a minimum safety factor of five with regard to tensile, compressive and shear strengths. 7.1.2 Construction The frame shall surround the periphery of waterway opening and shall be of unit construction without any joint, cast in one piece. The frame shall be machined on the rear face for bolting directly to the machined face of wall Materials
Material (3)
Table 3
Sl No.
Item
( Clause 6.1 )
Conforming
(1)
1.
(2)
Thimble, frame, guide, cxtensicn guide slide ( shutter ), gear box pedestal, stem guide, bracket, wedges, flushbottom seal support bar Yoke ( Bridge ) Wedges, Wedge facings Cast Iron
2. 3.
4. 5.
6.
Seating faces
7. 8. 9. 10. 11.
seal retainer
bar
Cast Iron Structural Steel Naval Brass Phosphor Bronze Leaded Tin Bronze Stainless Steel Leaded Tin Bronze Cast Iron Tin Bronze Leaded Tin Bronze Naval Brass Phosphor Bronze Tin Bronze Leaded Tin Bronze Stainless Steel Mild Steel Stainless Steel Natural or Synthetic Cast Iron Mild Steel Stainless Steel Cast Iron Phosphor Bronze Stainless Steel Mild Steel Stainless Steel
210 : 1978 226 : 1975 291 : 1989 7814 t 1985 318 : 1981 6911 : 1972 318 : 1981 210 : 1978 306 : 1983 318 : 1981
291
: 1989
Rubber
7814 : 1985 306 : 1983 318 : 1981 6911 : 1972 226 : 1975 6603 : 1972 11855 : 1986 210 : 1978 226 : 1975 6603 : 1972 210 : 1978 7814 : 1985 6603 : 1972 226 : 1975 6603 : 1972
NOTES 1 Minimum grade of cast iron used shall not be lower than FG 200. 2 In the case of brass, bronze or stainless steel used for various components, as specified in the relevant Indian Standard shall be complied with. only the chemical composition,
3 When copper zinc alloy comes in contact with water containing acid or alkali, zinc from the alloy dissolves leaving the alloy metal porous and weak. This loss of zinc from the copper zinc alloy results in a type of corrosion called dezincification. Low zinc content may resist dezincification. Bronze having less than 2 percent The use of brass should be avoided where dezincification can occur. If dezincification aluminium and 5 percent zinc should be used where dezincification of bronze can occur. of the bronze is a problem, sluice gate seat facings and bronze castings should be phosphor or silicon bronze both of which meet the low zinc requirement. 4 Use of stainless steel for the seating faces and wedges should be avoided wherever possible, less steel machined surfaces rubbing against each other under high pressure have a tendency may result in severe damage to the sliding surfaces. because stainto gall which ;
$1
IS 13349 : 1992 thimble. All other surface bearings shall be machined. 7.2 Slide ( Shutter ) 7.2.1 Design The slide made of cast iron with strengthening ribs where required and a reinforced section at the edges to receive the seating faces shall be designed for the maximum head indicated in 3.1 for the appropriate class with a minimum safety factor of five with regard to tensile, compressive and shear strengths. -7.2.2 Construction The slide shall have tongues on each side extending the full length. The tongues shall be machined accurately on contact surfaces. .Surfaces of the slid? that come into contact with the seat facings and wedges shall be machined accurately. The maximum allowable clearance between th? slide and the slide guides shall be 15 mm. ^7.2.3 Provision for Connecting Slide with Stem The slide shall be provided with an integrally -cast pocket above the horizontal centre line of the slide, reinforced by ribs, to house the con:necting block in case of rising stem or an operating nut in case of non-rising stem. The ,operating nut pocket shall be drained. 7.3 Seating Faces 7.3.1 Design -The seating faces made of strips of either naval brass or bronze or stainless steel depending upon the quality of fluid to be handled shall be :secured firmly in machined grooves of either :rectangular or dovetail cross section in the frame .and slide faces in such a way that they will remain in place, free from distortion and loosening during the life of sluice gate. ,In case of class 1 duty gates the seating faces -may be attached to the machined flat faces of frame and slide with the help of either brass rivet pins or counter sunk head machine screws of the same material. 703.2 Clearance The face shall be so finished that the maximum clearance between the seating surfaces, with the -slide in the closed position, shall be 010 mm. 7.4 Seals for Flush Bottom Gates 7.4.1 General Resilient seals for flush bottom gates shall be Reclaimed .of natural or synthetic rubber. rubber shall not be used. Rubber seals shall be copper -resistant to microbiological attack. 3 forming joints or poisoning and ozone attack. Rubber compounds shall contain no more than 1.5 plrts of wax per 100 parts of rubber hydrocarbon and shalt be free of vegetable oils, vegetable oil derivatives, animal fats and animal oils. 7.4.2 Design Th: desiga of the senl shall be such as to provide for the minimum leakage requirtmentr specified in 11.4 and 13.3. 7.4.3 Construction The rubber seal shall be mounted on the slide or the frame and shall be held securely in place with a retainer bar bolted to the frame or slide leaving an unobstructed flush invert. 7.5 Guides 7.5.1 Design Guides made of cast iron shall be d-signed for the maximum head indicated ( see 3.1) with a safety factor of 5 for shear, compression and They shall be capable of taking the tension. entire thrust produced by water pressure and wedging action with a safety factor of 5. The guides shall be of such length that they extend above waterway opening atleast by ( 0.5 X H + 250 ) mm, where H is the height of waterway opening in millimetres. 7.5.2 Construction Guides may be either integrally cast with the frame or may be formed by bolting suitable guide strips or guide bars with grooves to the Provision shall be made to prevent frame. lateral movement of bolted on guides. Wedges or wedge facings shall be attached securely to the guides at points where, in the closed position, they will make full contact with wedging surfaces on the slide. d 7.5.2.1 Guide extensions, that is portion of guides extending vertically upwards of the frame may either b: integral with the frams casting or integral with the guide bars. Alternatively, guide extensions may b: in split construction and may be bolted either to the top of fram: or to the top of guide bars. 7.5.2.2 secured pins or proper Split guide extensions shall be firmly at their joints with the help of dowel slot and tennon arrangement to ensure alignment of guide grooves.
7.5.2.3 Guides including their extensions upwards of the frame shall be machined on all bearing and contact faces. Faces of extension guide coming in contact with the seating faces of the slide while opening the gate shall be fitted with seating faces of the same material as that on the slide. The maximum allowable clearance between the slide and the slide guide shall be 15 mm.
IS 13349: 1992
752.4 Seating surfaces of the guide extensions coming in contact with the sealing faces of the slkle shall be provided with contacting faces of the same material as that of the sealing faces of slide. 7.5.3 Pads The guides of self-contained gates shall have extended tops provided with pads for mounting of the yoke. The pads shall be machined to a plane perpendicular to the movement of the gate slide. 7.6 Yoke Self contained gates shall be provided with a cast iron or structural steel yoke designed for the thrust of the headstock or hoist with a safety factor of 5. The top of the yoke shall be machined to receive the operating mechanism. The pads on the yoke contacting those on the top of the guides shall be machined on contact faces and bolted to the guides to withstand the thrust developed under maximum operating conditions. 7.7 Operating Nut and Connecting Block Operating nut or connecting block employed for connecting the stem with the slide shall be designed to withstand the thrust developed during gate operation under the maximum operating head condition with a safety factor of 5. On rising stem gates, the connecting block shall be threaded and keyed or threaded and pinned to the stem. On non-rising stem gates, the operating nut shall be threaded but not keyed or pinned to the stem SO that the nut and slide can move up and down the stem as the stem rotates. 7.8 Wedging Devices 7.8.1 General All sluice gates shall be equipped with adjustable side wedging devices to provide contact between the slide and frame facings when the On all gates having gate is jn closed position. width of opening exceeding 600 mm that ~111 be subjected to unseating heads, adjustable top and bottom wedging devices shall also be provided. If the gates are flush-bottom closure gates, they wi]] be provided with adjustable to top wedges only. 7.8.2 Materials upon the quality of fluid to be handled the wedges may have cast iron to cast iron contact or may be lined with brass, bronze or stainless steel contacting strips.
Depending
be provided with suitable arrangement to hold in position after adjustment, without any tendency to loosen, shift or rotate when the gate is opened or closed under load. 7.9 Assembly Bolts, Studs, Nuts Bolts and Anchor
7.9.1 A]1 assembly bolts, studs, nuts and anchor bolts shall be of such size, spacing and numbers as required to provide for the design forces corresponding to the appropriate class of gate ( see 3.1 ) with a safety factor of 5. Corresponding number of holes shall be provided in the flange on the back of the gate in order to prevent leakage and to resist the shearing action caused by closing and opening forces. 7.9.2 All the fasteners on wall thimble and the adjustable wedge blocks shall be essentially of either stainless steel or bronze. Other fasteners coming in contact with fluids shall be either of stainless steel or bronze or mild steel depending upon the quality of fluid to be handled or requirement of the purchaser. Fasteners not coming in contact with the fluid may be of mild steel unless specified otherwise by the purchaser. 7.10 Wall Thimbles 7.10.1 Design A wall thimble is a separate piece and is required to be embedded in the mass concrete wall before the installation of the gate. It shall be sufficiently strong and rigid and shall be designed to withstand all forces including maximum operating load of a gate corresponding to its class of duty. 7.10.2 Construction The cross section of the thimble shall have the shape of the letter F or E, or of a flange and suitable and for attaching to the connecting pipe. E shaped thimbles are recommended for gates meant for very high unseating heads provided these thimbles are not to be attached to any connecting pipe. The front, or mounting flange shall be machined and shall be drilled and tapped to the same template used for its particular gate frame. A ring shall be cast on the periphery of the wall thimble to form a water stop and anchor ring in the concrete. The gate shall be attached to the wall thimble with studs. 7.10.2.1 The depth of the thimble is usually kept equal to the thickness of the wall. If the thickness of the wall is excessive then the depth of the thimble may be restricted to 300 mm unless otherwise agreed to between the purchaser and the manufacturer. 7.10.3 Provision for Release of Air To permit entrapped air to escape as the thimble is being encased in concrete, holes shall bezcast 4
7.8.3 Construction AlI the wedges mounted on slide +a]] be making It posprovided with an arrangement sible to adjust the degree of wedging. They shall
IS 13349 : 1992 or drilled in each entranment zone formed by the reinforcing ribs or the flange and the water
7.12 Stem Guides 7.12.1 Bracket and floor-mounted stem guides ( including both the guide housing and the bracket ) shall be constructed so that when properly spaced they will held the stem in alignment and yet allow it enough play to permit easy operation. The inside diameter of the guide shall not exceed the outside diameter of stem f3 mm. 7.12.2 The guides shall be spaced in accordance with the manufacturers recommendations for each stem size. The slenderness ratio l/r shall not b: greater than 200. The guides shall be adjustable with regard to the bracket to provide proper concentric alignment with the stem and shall be designed so that alignment will be maintained after adjustment. The guides shall be lined with leaded tin bronze and provision shall be made to hold the lining in place. Brackets shall be attached to the wall be sufficient anchor bolts to prevent twisting or sagging under load. 8 SURFACE PREPARATION PAINTING AND
.stop and anchor ring. The holes shall be 40 mm in diameter and no more than 600 mm apart.
7.11 Strms and Stem Coupliogs 7.11.1 Design
The operating stem shall be designed for a tensile strength to withstand a force of 900 Newton on the crank or handwheel or a torque of 340 Newton-meter on a wrench nut. It shall also be designed for a critical buckling compressive load of 360 Newton on the crank or handwheel acd 135 Newton-metre torque on a wrench nut. The critical buckling load shall be determined by using the Eulers Column Formula as under: Eulers Column Formula : P = C 7~~E.4 ( r/l) 2 where P = axial load on stem in Newtons. C = defines end restrain taken as 2.
E = modulus
conditions,
to be
r = radius of gyration in mm, and A = area of stem in mm2. 7.11.1.1 Where hydraulic lifts are used, the stem design shall not be less than 12.5 times the output thrust of the hydraulic cylinder under full motive force. 7.11.1.2 Where electric motor-driven lifts are used, the stem design force shall not be less than 125 times the output thrust of the unit in the stalled motor condition. 7.11.1.3 Force required to activate the sluice gate ( slide ) may be determined as per the procedure explained in Annex E. 7.11.1.4 Recommended nominal diameters of mild steel and stainless steel stems for manually operated lift mechanisms are given in Annex F. 7.11.2 Threads The threads of the stem shall be machine cut or rolled and of the square or acme type. The pitch of the threads shall be such as to work most effectively with the lift mechanism used. On rising stem gates with manual hoists the top of the stem shall be provided with a stop collar. 7.11.3 Coupling Where stems are furnishes in more than one -piece, the different sections shall be joined together by solid couplings. The couplings shall be threaded and keyed or threaded and bolted .and shall be of greater strength than the stem. 5
8.1 All surfaces shall be cleaned by commercial sand blasting or by wire brush and grinding to base metal, be dry and free of grease before painting, in conformance with the paint manufacturers instructions. After cleaning, the surfaces shall be primed by application of either one shop coat of zinc chromate or coaltar coating suitab!e for used in potable water and applied in conformance with paint manufacturers instructions. After painted surfaces are dry, the machined or bearing surfaces and the holes, both plain and threaded, shall be
coated with grease to offer temporary protection to the surfaces until the time of installation. 8.1.1 Surfaces of thimble and stem guides which would be in contact with th: concrete shall not
be coated. 8.1.2 Mild steel stems shall accordance with 8.1 above. 9 MANUAL LIFTING
9.1 General
be
painted
in
DEVICES
Manual operating mechan;sm shall be ungeared or geared operatable by handwheel or a crank handle. Geared mechanism may be either single or dual speed, as necessary. Ball or roller thrust bearings shall be provided below the
flange on the lift nut in case of ungeared lift machanism; and above as well as below the flange on the lift nut in case of geared lift mechanism so as to take th:: thrust developed in opening and closing the gltz with a force of 135 Newton-meter on the crank or handwheel. 9.2 Gears Gears shall be m >cl11 :: cut to provide smooth ShafLs mechanism. operation for he lifting shall be provided with bush, with sleeve, ball or
,IS 13349: 1992 roller bearing of appropriate size. All gears and hearing shall be erclosed in a housing. Suitable provisions shall be made for lubrication. 9.3 Lift Mechanism The lift mechanism shall be supplied with a pedestal, machined and drilled to receive the gear housing and drilled for bolting to the The height of the pedestal operating floor. shall be sufficient to provide the horizontal handwheel in case of ungeared lifts cr the horizontal axis of the driving shaft for crank in case of geared lifts at a convenient working height of approximately $00 mm from the base of the pedestal cr the operating floor or which the operator has to stand. The pedestal shall be provided with a suitable covered window to enable easy cleaning and greasing of the stem threads. 9.3.1 Manual lifting mechanism to be mounted directly cn the yoke of self contained gate may be provided with or without pedestal, as required. 9.3.2 The lift mechanism shall be designed in such a marner as to permit the gate operating under the operating head specified, with an effort not mere than 70 Newton-meter on lifting device after the sluice ( that is slide/shutter ) is unseated from its wedges. 9.3.3 Guidance as necessary may be obtained from IS 11228 : 1985 while desgning the lift mechanism of a gate. 9.4 Handwheel/Crank
1
9.8 Surface Preparation All exposed surfaces of the head stock mecha-nism shall have protective coating applied in, accordance with 8. 10 FABRICATION AND WORKMANSHIP 10.1 All parts of the sluice gate and acessories shall be machined accurately on mating and. bearing surfaces. All like parts, except for the seating sea!ing surfaces, shall be interchangeableso that replacement parts can be furnished at any time and attached in the field with a minimum of fitting, chippng or remachining. All parts shall conform to designed dimensions and shall be free from defects of material and workmanship. All attaching bolt holes shall bedrilled accurately to layout indicated on thedrawings. 10.1.1 All castings shall be clean and sound without defects that could impair their function. 10.1.2 The seating faces shall have smooth machined or hand scraped surface finish. All surfaces, such as guides-to-frame and frame-towall thimble shall be machined flat. 11 SHOP TESTING 11.1 All sluice gates shall be subjected to the, tests specified in 11.2, 11.3, 11.4 and 11.5 for their conformity to the specified requirements. 11.2 Seat Clearance Check Before final assembly, all seating and wedging. surfaces shall be cleaned thoroughly of all foreign materials and final adjustments made. With the gate fully closed, the clearance between seating faces shall be checked with a 010 mm thick feeler gauge. If 01 mm thick feeler gaugecan be inserted between seating sealing faces,. then wedging devices must be readjusted or the gate slide or gate frame or both refinished until.1 insertion is no longer possible. 11.3 Smooth Movement Test
The maximum handwheel diameter shall be 8C0 mm and the maximum crank radius shall be 400 mm. The crark shall be removable and fitted with a corrosion resistant sleeve type handle. The wheel or crank shall rotate either in horizontal or vertical plane. 9.5 Opening Direction The direction of wheel or crank rotation to open the gate shall be counter clockwise and shall be indicated on the lift mechanism.
9.6 Stem Cover
After completion, all seating and wedging. surfaces shall be cleaned thoroughly of all foreign materials and final adjustments made. The sluice gate shall then be shop operated from 1 the fully closed to the fully open position to verify that the assembly is workable. 11.4 Shop Leakage Test by Applying Unseating Hydraulic Pressure A shop leakage test by applying the specified maximum unseating hydraulic head shall be. conducted at the manufacturers workshop. The test shall not show leakage in excess of 25, 3.5 and 45 litres per minute per meter of seating perimeter for class I, class 2 and class 3 sluice, For gates designed for seatgates respectively. ing head only an equivalent unseating head shall) 6
Ezch rising stem unit shall be provided with a suitable stem cover. The cover shall be made of a galvanized pipe. 9.7 Gate Travel Indicator Gate travel indicator shall be indicate the position of the gate.
NOTE -
provided
to
equal
to or greater than two times the height of opening shall be provided with two lifting devices connected by a tandem operation.
IS 13349 : 1992 be used. For this test clamps may be used in place of top and bottom wedges ( see 7.8.2 >. 11.5 Hydrostatic Test 11.5.1 Hydrostatic test shall be carried out on the gate assembly at manufacturers workshop as given in 11.5.2. 11 5.2 Water pressure of 15 times the unbalanced specified maximum operating head shall be applied to the sluice gates in closed position for a period of 5 minutes. Under this test there shall be no leakage through the metal nor shall any part be permanently deformed. 12 WTALLATI~N 12.1 General The purchaser should follow the manufacturers guidelines about the minimum clearance for installation, storing and handling for the gates under supply in addition to those covered in 12.2 to 12.5. It shall be the purchasers responsibility to handle, store and install the wall thimble, gate, operating mechanism, stem, stem guides and accessories in accordance with the manufacturers drawings and recommendations, Care shall be taken to avoid warping the gate frame and to maintain tolerances between seating faces. All gates, thimbles, stems and operators shimmed and aligned shall be plumbed, accurately. 12.2 Hole Protection Tapped holes in thimbles shall be plugged for protection during concrete pouring and setting. 12.3 Surface Protection During erection, the surfaces of the thimble and gate shall be covered or otherwise protected from concrete spillage, paint, oil and debris. Any damage that occurs to the thimble or gate in storage or handling shall be set right prior to installation of the gate or testing and operation of the gate. 12.4 Thimble Thimbles shall be positioned accurately and supported to prevent shifting during the pouring of the surrounding concrete. Thimbles shall be carefully braced both horizontally and vertically to prevent distortion. Concrete shall be poured carefully to provide a good bond to the thimble without voids. Grout shall be forced into the air vent holes. 12.5 Slide After the entire assembly of manually operated gates has been installed, adjusted, and properly 13 INSPECTION, TESTING 13.1 Inspection All work performed under this standard shall be subject to inspection and approval by the purchaser or his agent who shall have access to all places of manufacture where materials are being produced or fabricated, or where tests are being conducted and shall be accorded full facilities for inspection and observation. All sluice gate or part that does not conform to the requirements of this standard shall be made satisfactory or shall be rejected and replaced. 13.2 Shipment Sluice Gates shall be complete when shipped and the manufacturer shall use all due and customary care in preparing them for shipment to avoid damage in handling or in transit. Particular care shall be taken to see that the parts are completely closed and locked in position before shipment. Parts that are to be embedded in concrete may be shipped separately, if requested by the purchaser. Sluice Gates of 600 mm and larger shall be bolted securely or otherwise fastened to skids in such a manner that they may be safely handled. 13.3 Field Leakage Test A field leakage test may be performed by the purchaser after installation of the sluice gate. The manufacturer shall be notified of the test in sufficient time to enable him to have his representative present at the test site. After all adjustments have been made and the mechanism properly lubricated, each gate slide shall be operated through one complete cycle as a fina check on proper operation before starting the leakage test, Seating and unseating heads shall be measured from the top surface of the water to the centre of the gate. 13.3.1 Seating Head Under the maximum specified seating head, the Ieakage shall not exceed I25 lpm ( litres per minute ) per metre of seating perimeter. 13.3.2 Unseating Head Under the maximum specified unseating head, the leakage class 1, class 2 and class 3 sluice gates shall not exceed 25, 35 and 45 lpm ( litres per minute ) per meter of seating perimeter, respectively. 7 SHIPMENT AND FIELD lubricated, each slide shall be operated for one complete cycle, open-close-open or close-openclose.
IS 13349 : 1992
14 MARKING
d) Year of manufacture. 14.2 Any additional marking required may be agreed to between the purchaser and the manufacturer.
14.3 Each sluice gate may also be marked the Standard Mark.
14.1 Following information shall be embossed on the slide of each sluice gate: a) Indication of the source of manufacture, b) Size class and type of sluice gate, c) + for seating and - for unseating head, and
with
ANNEX A ( Foreword )
INFORMATION TO BE SUPPLIED WITH ENQUIRY AND ORDER
A-l When placing orders for sluice gates to be manufactured according to this standard the purchaser should include the following date in his enquiry/order:
1. Number and title of this Indian Standard.
b) in machined grooves. 12. Leakage test, whether required. 13. Type of fluid to be handled: whether fresh or raw water on sewage, etc. 14. Wedges: Whether to be lined with brass, bronze or stainless steel on their mating tapered faces or to have cast iron contacting faces. 1.5. Acceptable materials:
round, square or 2. Shape of waterway; rectangular. 3. Size: If rectangular, width x height. 4. Design head from surface of water to centre line of gate, in metres. a) Seating head, b) Unseating head, c) Both seating head and useating head. 5. Operating head: from surface of water to centre line of gate, in metres. 6. Distance between centre line of waterway to base of operating platform, in metres. 7. Method of operation: Manual/electrial/ hydraulic or pneumatic, if one or the other of the last three particulars of supplies, motive water/air pressures available. 8. Length and shape of wall thimble ( see 7.10.2 ). stem ( see 9. Rising stem or non-rising Annex C ). or Flush 10. Type of closure: Conventional Bottom ( see Annex B ). 11. Type of fitment of sealing faces for class I duty gates: a) On machined flat surface, or
NOTE - In the absence of any specific provision by the purchaser, any listed material shall be acceptable. It is recommended, however, that unless experience has shown that dezincilication or dealuminization has not been a problem, the purchaser should prohibit the use of materials likely to be subject to dezincification or dealuminization.
by purchaser,
if any.
special design and construction required for conditions beyond the scope of this standard, should be defined, including intended operation frequency and duration.
18. An
requirement drawing installation should be furnished by the purchaser showing clearances, wall thickness, details of wall pipe and thimble installation, location of lift mechanism, that is, whether on yoke or on platform and whether the gate is to be upwards opening or down-wards opening. Number of un ts required for each similar size and type of gate.
19
IS 13349 1992 :
IS
No.
Title
318 : 1981
291 : 1989
Ezrification for naval brass rods ( suitable for sections machining and forging ) ( second
revision )
Specification for leaded in bronze ingots and castings ( second revision ) Specification for stainless steel bars and flats Specification for stainless steel plate, sheet and strip Specification for phosphor bronze sheet and strip (first revision ) Recommendations for design of screw hoists General requirements for rubber seals for hydraulic gates
306 : 1983
bronze ( third
11855 : 1986
OR NON-RISING
STEM GATES
C-l Rising stem gates have non-rotating stems The lift nut is housed in and rotating lift-nuts. lift mechanism which remains safely above gate well water level.
C-2 Non-rising stem gates have rotating stems The lift nut is and non-rotating lift nuts. housed in a pocket provided at the top of slide. C-3 The big disadvantage of the non-rising stem gates is that the threaded operating life nut and stem remain in the exposed position in the gate well and hence the threads remain exposed to damage and corrosion. Further, since the
threaded part of the stem remains normally submerged it is impossible to regularly clean and lubricate it. Any debris or rubbish jamming in the threads create wear of the stem and the operating nut and make the gate very difficult to operate. Operating problems with such gates increase with the gate size. C-4 Wherever possibIe the use of non-rising stem gates should be avoided. Such gates should be used only in those locations where there is limited head room or where the rising stem is likely to interfere with some other part of the installation over the top of operating headstocks or lift mechanisms.
The conventional closure involves two corrosion resistant seating faces mating against each other, when the gate is fully closed. One such face is provided across the bottom of the slide and the other corresponding horizontal face is provided across the bottom of the frame. The bottom edge of the slide has to travel beyond the invert of the gate to cause this type of closure to be made. Hence gates with conventional bottom closure are recommended for only those installations, where there is an ample
9
vertical clearance between the bottom of the opening, that is, invert of the gate and the invert of the chamber or channel structure. D-1.2 If the gate with conventional closure is installed at a situation, where the bottom of the gate opening is to be at the same elevation as the invert of the chamber or channel structure, then a recess or a cut-out is formed at the invert, where debris, silt and foreign material may collect. These interfere with the proper closing of gate. Gates with flush bottom closure avoid such recess or cut out at the invert and hence
IS 13349 : 1992
such gates are recommendsd for such situations where the bottom of the gate opening, as well as the chamber or channel floor are to b: at the same elevation or level. In case of flush-bottom closure, the bottom corrosion resistant seating face is omitted from the slide as well as the frame. A resilient rubb:r seating face is substituted either along the bottom of slide or along the bottom of the frame. If the rubber seating face is provided along the bottom of slide, it closes against a machined cast iron bar fitted at the bottom of frame with its machined face flush with the gate If the rubber seating face is provided invert. along the bottom of frame, top of the rubber In this case seal is kept flush with gate invert. the slide closes against the resilient rubber seal in the invert. D-l.3 Gates with flush bottom closure are also recommended when complete flushing of the
chlmbzr is needed or when the deE:ction of the bottom edge of the slide under high seating pressure, in case of wider gate, is likely to create problems of interference b:tween the seat facings on the fram: and th- slide at th: tim: of closing the gate. D-l.4 Flush-Bottom Sluice Gntes are installed in the same mlnnet as conventional gates, A recess or cut-out is provided in the floor along the width of waterway op:ning for accommodating the bottom member of frame. After putting the gate in position, the recess can be filled with asphalt surfacing material or concrete containing saw dust. Th: recess should ba filled level with the floor of the chamber and the invert of the gate. Purchasers should consult the manufacturer regarding the dimensions of the reczss or cut out to be provided in the floor.
E-l The maximum force required to activate a sluice gate occurs during the unseating and raising the weight of the slide. In the closing, or normally the downward motion of the gate, the weight of the stem and slide acts in the direction of motion and reduces the force required. E-2 The force required to activate the slide is, in part empirically determined. The weight of the slide and stem, the head of water on the gate at the centre line of the opening, and the friction of the slide against the seats and wedges are required to calculate the force to open the gate. These factors are normally presented in the following manner: F=lO 000xfxAxH+1*5xP,+P* Eq. (1) where
F=lOOOOxfXAxH+P1+Pa
Eq.(2)
The force determined by Eq. 2 will be less than the unseating force and is the force required for sustained effort on the activator.
10
IS 13349 : 1992
F-l Nominal diameters of mild steel or stainless stems recommended for various sizes and three classes of gates calculated on the basis of Eulers Column Formula ( see 7.11.1 ) and assuming maximum slenderness ratio of 200 ( see 7.12.2 ), are given in Table 4. F-2 Threads on the stem are assumed single start square threads with picthes dered as uuder: Stem Dia mm 30 to 45 50 to 75 80 to 90
Pitch
mm
Gate Size in mm S1
@--Y-~----~
Width
x Height (3) 500 600 750 900 1 100 600 900 1 200 750 1 000 1 200 1 500 900 1 100 1500 900 1 200 1 500 1 800 1 000 1400 1 800 1000 1 200
::* 11.
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53.
(2)
750 750 750 750 750 900 900 900 1 000 1 000 1 000 1 000 1 100 1 100 1 100 1 200 1 200 1 200 1 200 1 400 1400 1400 1 500 1 500 1503 1 500 1 500 1 600 1 600 1 600 1 800 1800 1 800 1 800 2 000 2000 2000 2 250 2 250 2 250 2 500 2 500 2 500 x x x x x x x x x x x x x x x x x x x x x x x x
to be consi-
6 10 12
F-3 Stem diameters as mentioned in Table 4 are checked for interference-free travel of stem coupling, if any, between the stem guides. F-4 Diameters stated in Table 4 are recommended for guidance. The diameter of stem to be finally decided for a particular gate should be checked for being safe in critical buckling as per 7.11.1 for the output of the operating/lift mechanism ( operating headstock > to be adopted by the manufacturer. Table 4 Recommended Nominal Diameters of Mild Steel or Stainless Steel Stems for Various Classes of Gates
Gate Size in mm p--_*--_y Sl Width x Height No. (1) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. (2) 300 300 400 400 500 500 500 600 600 600 x x x x x x x x x x (3) 300 400 300 400 400 500 750 400 600 750 Stem Diameters, in mm for Gates of ~~_~_~*_~~~~~ Class 1 Class 2 Class 3 (4) 30 30 30 30 30 30 30 30 30 35 (5) 30 30 30 30 30 30 30 30 30 35 (6) 30 30 30 30 30 30 30 30 30 35
Stem Diameters in mm for Gate of *-___-~ v----.CIass 1 Class 2 Class 3 (4) (6) (5) 3 30 30 30 30 30 35 35 35 40 40 40 40 40 40 30 30 35 40 40 40 45 45 45 40 35 35 40 40 45 45 45 45 50 50 50 40 40 45 40 40 45 50 50 50 40 40 45 45 45 45 50 50 50 55 55 55 40 40 45 45 45 50 55 55 55 40 40 45 50 45 45 50 55 60 45 50 60 45 50 55 70 50 60 70 60 65 70 60 65 70 50 55 60 45 50 60 45 50 60 70 50 65 70 65 70 70 65 70 75 55 60 65 50 55 70 55 60 70 80 65 75 85 75 85 85 75 85 90
x 1 500 x 1 800 x 2 000 x x x x x x x x x x x x x x x x 1 200 1 600 2 000 1 200 1500 1 800 2 500 1 500 2000 2500 1 500 2250 2 500 1600 2000 2 500
11
1 Standard Mark The use of the Standard Mark is governed by the provisions of the Bureau of Indian Standards Act, 1986 and the Rules and Regulations made thereunder. The Standard Mark on products covered by an Indian Standard conveys the assurance that they have been produced to comply with the requirements of that standard under a well defined system of inspection, testing and quality control which is devised and supervised by BIS and operated by the proStandard marked products are also continuously checked by BIS for conformity to ducer. that standard as a further safeguard. Details of conditions under which a licence for the use of the Standard Mark may be granted to manufacturers or producers may be obtained from the Bureau of Indian Standards.
Bureau of Indian Standards BIS is a statutory institution established under the Bgrerru of Indian Standards Act, 1986 to promote harmonious development of the activities of standardization, marking and quality certification of goods and attending to connected matters in the country. Copyright No part of these publications may be reproduced in BIS has the copyright of all its publications. any form without the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing the standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to copyrrght be addressed to the Director ( Publications ), BIS. Revision of Indian Standards Indian Standards are issued from possession of the to BIS giving the are reviewed periodically and revised, when necessary and amendments, if any, time to time. Users of Indian Standards should ascertain that they are in latest amendments or edition. Comments on this Indian Standard may be sent following reference :
Dot : No. CED 3 ( 4802 ) Amendments Issued Since Poblication Amend No. Date of Issue Text Affected
BUREAU Headquarters
:
OF INDIAN
STANDARDS
Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 110002 Telephones : 331 01 31, 331 13 75 Regional Offices : Central : Manak Bhavan, 9 Bahadur Shah Zafar Marg NEW DELHI 110002 Eastern : l/14 C.I.T. Scheme VII M, V.I.P. Road, Maniktola CALCUTTA 700054 Northern : SC0 445-446, Sector 35-C, CHANDIGARH 160036
37 86 62 53 38 43 235 0216 6 32 92 95
Southern : C.I.T. Campus, IV Cross Road, MADRAS 600113 Western : Manakalaya, E9 MIDC, Marol, Andheri ( East ) BOMBAY 400093 Branches : AHMADABAD. BANGALORE. BHOPAL. BHUBANESHWAR; COIMBATORE. FARIDABAD. GHAZIABAD. GUWAHATI. HYDERABAD. JAIPUR. KANPUR. LUCKNOW. PATNA. THIRUVANANTHAPURAM.
AMENDMENT
NO. 1
TO
JANUARY 1995
IS 13349 : 1992 CAST IRON SINGLE FACED THIMBLE MOUNTED SLUICE GATES - SPECIFICATION
tute 1 2Oofor 12.
( Second
secondpara,
fourth line ) -
Substi-
[ Second cover page, Foreword, fourth para, (b), first line ] - Delete the word gate between back and frame. ( Second cover page, Foreword, fifth para, fourth line ) - Substitute 'used' for use. ( Second cover page, Foreword, eighth para, fourth line ) - Substitute the words relating to after the words the practices. ( Page 2, Table 3 ) - Substitute the following for the existing: Table 3 Materials ( Clause 6.1 )
SI No. (1)
1.
Item (2) Thimble, frame, guide, extension guide, slide ( shutter J, gear box, pedestal, stem guide, bracket, wedging devices, flush bottom seal support bar Yoke ( Bridge )
Grade/Designation (5) FG
200 or higher
2.
Cast Iron Structural Steel Cast Iron Naval Brass Phosphor Bronze Leaded Tin Bronze
Stainless Steel
Glade
FG 200 or A
higher
3.
a) Wedges
FG 200 or higher Grade 1 or Grade 2 Grade 1 or Grade 2 LTB 1 or LTR 2 Grade 2 Grade 1 or Grade 2 HB, Grade 2 or HB, Grade 3
h) Wedge facings
Price Group 1
Table 3 Materials
SI No.
(1) Item (2)
( Continued
Conforming to IS (4)
)
Grade/Designation
Material
(3)
(5)
LTB I or LTB 2 0401 Ni or 04Crl7Ni12Mo2Ti or 12Cr12 or 15Cr16Ni2 LTB 1 or LTB 2 FG 200 or higher Sand Cast LTB 1 or LTB 2 Grade 1 or Grade 2 HB, Grade 2 or HB, Grade 3 Sand Cast LTB 1 or LTB 1 04Cr1, Nine or 04Crl7Ni12Mo2Ti or 12Cr12 or 15Cr16Ni2 Grade A 04Crl8NilO or 04Cr17Ni12Mo2Ti20 or 12Cr13 or 15Cr16Ni2
4. 5.
Leaded Tin Bronze Cast Iron Tin Bronze Leaded TinBronze Naval Brass Phosphor Bronze
318 : 1981 210 : 1993 306 : 1983 318 :1981 291 : 1989 7814 : 1985
6.
Seating faces
Tin Bronze 306 : 1983 Leaded Tin Bronze 318 : 1981 6911 : 1992 Stainless Steel
7.
Stem extension
road
8. 9.
11855 : 1986 210 : 1993 2062 : 1992 6603 : 1972 FG 200 or higher Grade A 04Cr18NilO or 04CrUNiIZMo2Ti20 or 12Cr1.3 or 15Cr16Ni2 FG 200 or higher HB, Grade 2 or HB, Grade 3 04CrlSNilO or 04Cr17Ni12Mo2Ti20 or 12Cr13 01 15Crl6Ni2
10.
seal
Table 3 Materials
S1 No. (1) 11. Item (2) Anchor bolts Material (3) Mild Steel Stainless Steel
( Concluded )
Conforming to IS (4) 2062 : 1992 6603 : 1972 Grade/Designation (5) Grade A 04Crl8NilO or 04Cr17Ni12Mo2TiZO or 12Cr13 or lSCr16Ni2
13.
Fasteners like assembly bolts, studs, nuts, etc: a) For wall thimbles b) For gate assembly, stem guides and lifting devices Stainless Steel 6603 : 1972 04Cr18NilO or 04CrI7Ni12Mo2Ti20
Mild Steel
1363 (Part 1): 1992 and 1363 (Part 3): 1993 6603 : 1972 040 18NilO or 04Cr17Ni12Mo2Ti20
NOTES 1 In case of brass, bronze or stainless steel used for various components, only the chemical composition as specified in the relevant Indian Standard shall be complied with. 2 When copper zinc alloy comes in contact with water containing acid or alkali, zinc from the alloy dissolves leaving the alloy metal porous and weak. This loss of zinc from the copper zinc alloy results in type of corrosion called dezincification. Low zinc content may resist dezincification. 3 Use of stainless steel for the seating faces and wedges should be avoided wherever possible, because stainless steel machined surfaces rubbing against each other under high pressure have a tendency to gall which may result in severe damage to the sliding surfaces. The use of brass should be avoided where denzincification can occur. Bronze having less than 2 percent aluminium and 5 percent zinc should be used of the bronze is a cohere dezincification of bronze can occur. If dezincification problem, sluide gate seal facings and bronze castings should be prosphor or silicone bronze both of which meeting the low zinc requirement. ( Page 4, clause 7.5.2.4 ( Page 4, clazrse 7.8.1, ( Page 5, clmse for fu&shes.
) -
Delete.
7.11.3Jkst
hold with
eleventh line ) -
Substitute
the word
Substitute Substitute
the word
use for
used. ( Page 5, clause 9.1, seventh line ) nismfor 6machanism. the word mechathe word bearing on which
( Page 5. clause 9.2, jfth line ) - Substitute for hearing and enclosed' for erclosed. ( Page 6, clause 9.3, tenth line ) for or which. Substitute
the words
Substitute
( Page 7, clause 12.1, secondpara, sixth line ) between the words warping and Gthe gate.
( Page 7, clause 13.3.2, second line ) - Add the word for between leakage and class 1. ( Page 8, clause A-l, third line ) - Substitute datafor date. ( Page 8, clause A-l, S1 No. 12 ) - Add the word Field before Leakage. ( Page 8, clause A-l, SZ No. 14 ) - Substitute the following for the existing: 14. Wedges : Whether the wedging devices should have cast iron, bronze or stainless steel wedges. If wedges are of cast iron, whether they should have cast iron contacting faces or should have brass or bronze or stainless steel facings. ( Page 9, Annex B ) Substitute the following for the existing:
life
210 : 1993
291 : 1989
Specification for phosphor bronze ingots and castings ( second revision ) Specification for grey iron castings (fourth revision ) Specification for naval brass rods and sections ( suitable for machining and forging ) ( second revision )
cc
,e for
&vi.~ion)
Snecification
Specification for leaded tin bronze ingots and castings ( second revision ) Specification
( fouth
revision )
purposes
Specification for corrosion resistant high alloy steel and nickle base castings for general applications (second
revision )
6603 : 1972 6911 : 1992 7814 : 1985 11228 : 1985 11855 : 1986
Specification Specification
for stainless steel bars and flats for stainless steel plate, for phosphor bronze sheet and strip sheet and strip
( jirst revision )
Specification
(first revision )
requirements
castings
ision )
(CED3)
--~.._~~
Press. Khuria.
(suitable
India