Scope of Hydro Mechanical Works - 330 MW SHEP

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SCOPE OF
HYDRO MECHANICAL WORKS
Prepared By:Sachin Jain
Certified Energy Manager
Shift In charge, DAM
PROJECT-General Description
BACKGROUND
PROJECT PARTICIPANTS




Conceived by UPPCL in 1980.
Started under PPP by Duncans in 1996.
Taken over by Tata in 2003 as AHPCL.
Taken over by GVK group in 2005



Land acquisition
Construction Start
Commissioned
2006
2007
2015
MAJOR COMPONENTS




Diversion Dam
Water Conductor
Power House
Machine




Civil Works
Electro Mechanical
Hydro Mechanical
Penstocks
L&T (Major)
BHEL
Precision
P&R
SALIENT FEATURES
90m high
6 Km long
4 x 82.5 MW
Vertical Francis








Design Capacity
Energy Generation
Project ownership
Concessionaire
Concession Period
Project Cost
Power Purchase
Free Power
330MW
1397 MU
UPPCL
AHPCL (GVK)
30 Years
5,182 Crs
UPPCL(88%)
UK (12%)
PROJECT LAYOUT
De-siliting Basin
HRT/ Intake
Power Channel
Power House
Dam
Forebay / Intake
HYDRO MECHANICAL -OVERVIEW
Sl.No.
Location
Item Description
Unit
Quantity
1
SPILLWAY STOPLOG GATE
Set
2
2
SPILLWAY STOPLOG GANTRY CRANE
No.
1
3
SPILLWAY RADIAL GATE
Nos.
8
4
Power Pack
Nos.
8
5
Hydraulic Cylinder
Nos.
16
6
Local Control Panel
Nos.
8
Trash Rack Panels
Nos.
60
TRC Machine
No.
1
HRT INTAKE STOPLOG GATES
Set
3
HRT GANTRY CRANE
No.
1
HRT INTAKE SERVICE GATES
Nos.
6
Dam
7
8
INTAKETRASH RACK
9
10
11
HRT INTAKE
Remark
HYDRO MECHANICAL -OVERVIEW
Sl.No.
Location
Item Description
Unit
Quantity
Power Pack
Nos.
6
Hydraulic Cylinder
Nos.
6
14
Local Control Panel
Nos.
6
15
UNDER SLUICE EMERGENCY GATES
Nos.
4
16
UNDER SLUICE SERVICE GATES
Nos.
4
17
Bulck Head Gate
No
1
EOT Crane
Nos.
1
19
Power Pack
Nos.
4
20
Hydraulic Cylinder
Nos.
8
21
Local Control Panel
Nos.
4
DRAFT TUBE GATE
Nos.
12
12
13
18
22
HRT INTAKE
Dam- Under
Sluice
Power House
Remark
HYDRO MECHANICAL -OVERVIEW
Sl.No.
Location
Item Description
Unit
Quantity
23
Power House
DRAFT TUBE GANTRY CRANE
No.
1
24
FOREBAY INTAKE STOPLOG GATE
Set
1
25
FOREBAY INTAKE GANTRY CRANE
No.
1
26
FOREBAY INTAKE GATE
Nos.
4
27
Power Pack
Nos.
4
28
Hydraulic Cylinder
Nos.
4
29
Local Control Panel
Nos.
4
30
DESILING BASIN ISOLATING STOPLOG GATE
Set
1
DESILITING BASIN STOPLOG GANTRY CRANE
No.
1
32
DESILING BASIN FLUSHING GATE
Nos.
2
33
Power Pack
Nos.
2
Power House
31
DSB
Remark
HYDRO MECHANICAL -OVERVIEW
Sl.No.
Item Description
Unit
Quantity
34
Hydraulic Cylinder
Nos.
2
35
Local Control Panel
Nos.
2
36
BYPASS STOPLOG GATE
No.
1
37
BYPASS STOPLOG GANTRY CRANE
No.
1
BYPASS AUTOMATIC REGULATING GATE
Nos.
3
39
Power Pack
No.
1
40
Hydraulic Cylinder
Nos.
3
A
Remote Control Panel
No.
1
LT Panel
No.
1
DC Battery Charging Panel
Nos.
2
Relay Panel
Nos.
4
38
B
D
E
Location
POWER
HOUSE- BY
PASS
Common
Control Room
Dam
Remark
HYDRO MECHANICAL -EQUIPMENTS
The main hydro-mechanical equipments required to manage and control the flow of water are:-
 Radial gates of size 14.5m x 22.067 m provided on the spillway for controlling flood discharge
- 08 Nos.
 Spillway Stoplogs of size 14.5m x 22m consisting of 11 nos. of units each of 2.0m height on the
spillway for inspection and maintenance of the spillway radial gates- 02 Nos.
 Service & Emergency slide type under sluice gates of size 3m x 4m- 4 & 4 Nos.
 Fixed wheel type bulkhead gate of size 5.0m x 5.32m provided for maintenance of Service &
Emergency under sluice gates- 01 No.
 Slide type silt flushing gates of size 2.15m x 2.6m provided for extraction of Silt/sand/gravels from
the desilting basin- 02 Nos.
 Slide type desilting basin stoplog provided for vent size opening of 12m x 10m to isolate the
desilting basin- 01 No.
HYDRO MECHANICAL -EQUIPMENTS
The main hydro-mechanical equipments required to manage and control the flow of water are:-
 HRT Intake slide type stoplog are provided for opening of 5m x 6.2m to isolate the HRT tunnel for
carrying out repairs/maintenance- 03 Nos.
 Fixed wheel type HRT Intake Service Gates of size: 5m x 6.2m- 06 Nos.
 Slide type Forebay Intake stoplog provided for opening of vent size of 4.7 x 5.6m to isolate
Forebay intake to permit maintenance of structure/equipment d/s of the stoplog- 01 No.
 Fixed Wheel type Forbay vertical gates of size: 4.4m x 5.6m- 04 Nos.
 Draft tube gates of size 4.772m x 5.08m are provided to enable the isolation of the draft tube from
the tail water for inspection and maintenance work on the draft tube and turbine runner- 12 Nos.
 Trash racks of size 4.20m x 4.05 m (height 19.7m) in front of HRT intake structure to prevent debris
entering the HRT- (5 x 12) 60 Nos.
HYDRO MECHANICAL -EQUIPMENTS
The main hydro-mechanical equipments required to manage and control the flow of water are:-
 Trash racks of size 4.40m x 4.16 m (height 16.10m) in front of Forebay intake structure to prevent
debris entering the Forebay- (8 x 4) 32 Nos.
 50T capacity Gantry Crane travelling on rails at Dam Top with the respective detachable type semi
automatic lifting beams for operation of Spillway Stoplog Gates and Fixed Wheel Under sluice Bulk
Head Gates- 01 No.
 25T capacity Gantry Crane with requisite lifting beam is provided on deck on out let side of two
desilting basin chambers for operation of desiliting basin isolating stoplogs- 01 No.
 20T capacity gantry crane with requisite lifting beam is provided at deck level of HRT Intake
structure to operate its stoplog elements- 01 No.
 20T moving gantry crane is provided at deck level of Forebay Intake Structure to operate stoplog
elements of the Forebay Intake- 01 No.
HYDRO MECHANICAL -EQUIPMENTS
The main hydro-mechanical equipments required to manage and control the flow of water are:-
 20T capacity Gantry Crane travel on rails at deck level of structure with respective detachable type
semi automatic lifting beam for operation of draft tube gates- 01 No
 400T capacity twin cylinder (2x200 MT) Hydraulic Hoists are provided for operation of the Spillway
gates under unbalanced head condition.
 600t capacity double acting hydraulic hoist cylinders installed in gate operation chamber for
operation of service & emergency gates provided in the body of dam.
 170T capacity double acting hydraulic hoist cylinder installed in Silt flushing gate operation
chamber provided in the gate shaft.
 45T capacity Hydraulic Hoist for operation of HRT Service gates.
 40T capacity Hydraulic Hoist for operation of Forbay Service gates.
GATES
A Gate is a closure device in which a leaf is moved across the fluid way from an external position to
control flow of water.

Depending upon the head the gates are also further classified as:
a) Low Head ( Less than 15 meters)

b) Medium head ( Between 15 to 30 meters)

c) High head ( Above 30 meters)
Common Type of Gates in INDIA
Radial Gate
Spillway Crest
Orifice Spillway
Vertical Lift
Gates
Fixed Wheel Type
Gates
Slide Type
Basic IS Codes
 IS 13623
-
Criteria for choice of gates and hoist.
 IS 4622
-
Recommendation for structural design of fixed wheel gates.
 IS 4623
-
Recommendation for structural design of radial gate.
 IS 5620
-
Recommendation for structural design of low head slide gate.
 IS 9349
-
Recommendation for structural design of medium and high slide gate.
 IS 6938
-
Design of Rope drum and chain hoist for hydraulic gates.
 IS 10210
-
Criteria for design of hydraulic hoist for gates.
 IS 11288
-
Recommendation for design of screw hoist and hydraulic gates.
 IS 807
-
Design, erection and testing (structural portion) of cranes and hoist- code of practice.
 IS 3177
-
Code of practice for electric overhead travelling cranes and gantry cranes other than
steel work crane.
 IS 13591
-
Criteria for design of lifting beam.
 IS 11855
-
Guidelines for design and use of different types of rubber seals for hydraulic gates.
CONTINUED…..

IS 15466
-
Rubber seals for hydraulic gates- specification.
 IS 14177
-
Guidelines for painting system for hydraulic gates and hoist.
 IS 800
-
General Construction in Steel- Code of Practice.
 IS 456
-
Code of practice for plain and reinforced concrete.
RADIAL GATE
Definition of Radial gate
“A device used for controlling the flow of water over spillways or into canals by having the upstream
face curved in the form of an arc the center of which is at the center of the gate hinge —called
also tainter gate”
Advantages
• Better discharge characteristics than partial gate openings.
• Low cost.
• Bearings are located out of the water.
• Aesthetics – Does not require an overhead supporting structure (gate tower).
• Does not require gate slots which can become plugged with ice or debris and can cause cavitations.
Disadvantages
• Longer piers.
• Relatively high concentrated loads at the trunnions.
• More complex fabrication than other gate options.
• More complicated dogging system to facilitate maintenance activities.
RADIAL GATE
RADIAL GATE
Radial gate- Structural design
In a radial gate, water pressure is transferred from the curved face to the radial gate arms which
transfer the load to a common bearing on either side of the gate opening.
Load combinations for water control gates can be complex and special care should be taken in
identifying all of the important combinations. Agencies will usually provide guidance (or rigid codes)
on this but here some of the most important ones:
•Dead Load + Impact (during installation, dry testing, or servicing)
•Dead Load + wave load
•Dead Load + Hydrostatic Load corresponding to top of gate
•Dead Load + Hydrostatic Load at design flow level + Ice load
•Dead Load + Hydrostatic Load at spillway design flow (gates open)
•Dead Load + Hydrostatic Load at design flow level + Earthquake force
•Dead Load + Hydrostatic Load at Inflow Design Flow with gates open.
RADIAL GATE
Radial gate- PARTS
Radial gates consist of the following four parts:
•The gate leaf assembly, including the curved skin plate, cross bracing or struts, supporting beams
and girders, and rubber seals.
•Arm assembly, including the arm columns, bracing, and hub.
•Trunnion assembly, including a pin, busing, thrust washers, lubrication provisions, and yoke.
•Trunnion support assembly, including the trunnion beam or anchor block and anchorage system.
RADIAL GATE
Radial gate- Strength Calculation
– Auxiliary horizontal beams
– Loads acting on main frameworks
– Beam arrangement and design hydraulic
– Arrangement of main vertical beams and arms
pressures
– Section properties of horizontal connection beams
– Strength of auxiliary horizontal beams
– Sectional properties of arm
– Skin plate
– Frameworks
– Bending stresses
– Stresses of frameworks
– Correction factor
– buckling and stability of buckling
– Hydraulic load acting on skin plate
– Trunnion assemblies
– Stresses acting on skin plate
– Trunnion pins
– Main vertical beams
– Trunnion bearing
– Loads
– Bracket
– Bending moment and shearing force
– Hoist System
– Sectional modulus and stresses
– Operation load
– Hydraulic cylinder
RADIAL GATE
Radial Gate- Bill of Quantity
Sl.No.
Description
1
Spillway radial Gate 2nd
Stage EP
2
Sub Item
Weight (KG)
Sill Beam
423.62
Wall Plate
2754.1
Horizontal Girders
8204.77
Horizontal Stiffners
1775.7
Gate Leaf Bottom Element Lifting Bracket
Downstream
Skin Plate & Vertical Stiffeners
5057.6
Total wt. per unit
(BOQ) in KG
Remark
3177.72
Total no of
vents are 8
25643.4
7646.77
Arm Support
2958.56
Horizontal Stiffeners
1671.04
3
Gate Leaf Intermediate
Element 2nd
Vertical Girders and Skin Platee
8476.36
Horizontal Stiffners
1671.04
4
Gate Leaf Intermediate
Element 3rd
Vertical Girders and Skin Platee
7293.96
Vertcal Girders
3369.84
5
Gate Leaf Intermediate
Element 4th
Skin Plate and Horizontal
Stiffeners
5595.96
10147.4
8965
8965.89
BOQ for one
Gate
RADIAL GATE
Radial Gate- Bill of Quantity
Sl.No.
6
7
8
9
10
11
Description
Sub Item
Vertcal Girders
Gate Leaf Intermediate Element
Skin Plate and Horizontal
5th
Stiffners
Vertcal Girders
Gate Leaf Intermediate Element
Skin Plate and Horizontal
6th
Stiffners
Horizontal Girders
Skin Plate and Vertical
Gate Leaf Intermediate Element
Stiffeners and horizontal
7th
stiffeners
Arm Support
Vertcal Girders
Gate Leaf Intermediate Element
Skin Plate and Horizontal
8th
Stiffners
Vertcal Girders
Gate Leaf Intermediate Element
Skin Plate and Horizontal
9th
Stiffners
Vertcal Girders
Gate Leaf Intermediate Element
Skin Plate and Horizontal
10th
Stiffners
Weight (KG)
Total wt. per unit
(BOQ) in KG
Remark
4043.42
5939.58
9983
3575.04
4944.96
8520
6978.91
11274.62
21210.09
BOQ for one
Gate
2956.56
3744.22
5410.66
9154.88
3246.08
4299.67
7545.75
2846.17
3932.82
6778.99
RADIAL GATE
Radial Gate- Bill of Quantity
Sl.No.
12
13
14
Description
Sub Item
Weight (KG)
Gate Arm
88095.54
Bracing Beam
3859.58
Trunion Hub
7598.96
Trunion Bracket
6440.99
Trunion Bush
539.322
Trunion Pin
2993.96
Gate Arm and Bracing beam
Trunion Hub
Trunion Bracket
Total wt. per unit
(BOQ) in KG
91955.12
15197.92
19948.544
15
Radial gate Guide roller
Guide roller
180.48
180.48
16
Radial gate seal
Seal, Seal Clamp Plates etc
503.66
503.66
Remark
BOQ shown for
2 sets of arms,
1L+1R for each
gate
BOQ for one
gate (1L+1R)
BOQ for one
gate (1L+1R)
BOQ for one
gate
RADIAL GATE
Material Specification
Sl.No.
Components
Material
Specification
1
Skin Plate
Structural Steel
SAILMA 450 HI
2
Horizontal Girders: End Arm: Arm Bracings, Vertical
Stiffeners, Lifting Lug.
Structural Steel
SAILMA 350 HI.
3
Trunnion Hub
Cast Steel
IS: 1030, Gr.280-520
4
Trunnion Bracket
Cast Steel
IS: 1030
5
Trunnion Pin
Corrosion Resistant Steel
IS: 1570 20 Cr.13
6
Trunnion Bush ID: 650, OD: 715/780, length 865 mm
Self Lubricating Bronze
Bush
CSB slide bearing
7
Seal Seat
Stainless Steel
IS: 1570
8
Seal Base
Structural Steel
IS: 2062
9
Guide Roller
Cast Steel
IS: 1030, Gr.27-54
10
Roller Bush
Aluminum Bronze
IS: 305, Gr.AB-2
11
Rubber Seals
Rubber
IS: 11885
12
Guides & Wall Plate Structural Steel IS: 2062
Structural Steel
IS: 2062
13
Thrust Pad Plate
Stainless Steel
IS: 1570
RADIAL GATE
Salient Features- Spillway Gate
Sl.No.
Components
Specification
1
Type
:
Radial
2
Service
:
Flood Regulation and sluicing from th Diversion Dam
3
MWL
:
EL 609.80 m
4
FRL
:
EL 605.50 m
5
Top of gate
:
EL 605.80 m
6
Sill level
:
EL 583.433 m
7
Clear width of opening
:
14500.00 mm
8
Clear height of opening
:
22067.00 mm
9
Number of bays
:
Eight
10
Number of gates required
:
Eight
11
C.L. of Trunnion :
:
EL 595.00 m
12
Design Head :
:
22.067 m (w.r.t. FRL)
13
Radius to D/S of skin plate
:
26000 mm
RADIAL GATE
Salient Features- Spillway Gate
Sl.No.
Components
14
Type of seals
:
IS:11855
a
Side seal
:
“L” shaped synthetic rubber fluorocarbon cladded.
b
Bottom seal
:
Rubber, Wedge type
Hoisting Arrangement :
:
Single acting Hydraulic Hoist of 400T (2 x 200T) capacity
Main Bearing
:
Antifriction or self lubricating bearing
15
16
Specification
Standard
a
Gate
:
IS: 4623
b
Hydraulic hoist
:
IS: 10210
c
Structure
:
IS: 800
d
Testing Standard
:
IS: 10096 (Part 3)
RADIAL GATE
Salient Features- Spillway Gate- Hydraulic Hoist
Sl.No.
Components
1
No. of Hoists
:
8 sets twin cylinder (2 x 200) MT
2
Type of Hoist
:
Oil Hydraulic Cylinder
3
Hoist Capacity
:
2 x 200= 400 MT
4
Vertical Lift of Gate
:
20.797 m
5
Designed as per
:
IS:10210
6
No. of Cylinder
:
2 nos. per set of hoist = 2 x 8= 16 nos.
7
Connection to Gate
:
Clevis and Pin
8
Opening
:
Electric motor driven fixed displacement oil pump
9
Closing
:
Gravity closing under controlled oil flow
Electric Motor Power Supply
:
415V, three phase, 50 HZ
10
Specification
RADIAL GATE
Salient Features- Spillway Gate- Hydraulic Cylinder
Sl.No.
Components
Specification
1
Type
:
Rexroth Type- CYCRRMP5/0420/0180/10615A10/X1CRUA WAC
2
Mode of Operation
:
Single Acting Pulling
3
Bore
:
420 mm
4
Rod Diameter
:
180 mm
5
Working Stroke
:
10415 mm
6
A-piston
:
1385 Cm2
7
A-rod
:
254 Cm2
8
A-ring
:
1131 Cm2
9
F-lifting
:
2000 KN
10
F-Lowering
:
0 KN
11
V- Lifting
:
0.25 M/min
12
V- Lowering
:
0.25 M/min
13
T-Lifting
:
41.66 min
RADIAL GATE
Salient Features- Spillway Gate- Hydraulic Cylinder
Sl.No.
Components
Specification
14
T-Lowering
:
41.66 min
15
Total Strok Length (incusice Cushioning)
:
10615 mm
16
Design Pressure
a
Rod Side
:
20 MPa
b
Bottom Side
:
1 Mpa
17
Working Pressure
a
Rod Side
:
17.7 MPa
b
Bottom Side
:
1 MPa
18
Test Pressure
a
Rod Side
:
30 MPa
b
Bottom Side
:
1.5 MPa
19
Maximum Pulling force
:
2000 KN
20
Maximum Pushing force due to system overload
:
0 KN
RADIAL GATE
Salient Features- Spillway Gate- Hydraulic Cylinder
Sl.No.
21
Components
Specification
Maximum speed
a
Moving Out
:
50 mm/sec
b
Moving IN
:
50 mm/sec
22
Minimum Speed
a
Moving Out
:
10 mm/sec
b
Moving IN
:
10 mm/sec
23
Hydraulic Medium
:
Mineral Oil ISO VG 46
24
Moving Frequency
:
TBD/day
25
Mounting Angle Rod to Horizontal
:
(-) 3.2 degree/ (-) 56.8 degree
26
Design Temperature
:
0/+45 deg
27
Lateral Force
:
0N
28
Surface condition:Bore:Honed Rod:Hard Chromium Plated
:
50 micrometer
RADIAL GATE
Salient Features- Spillway Gate- Power Pack
Sl.No.
Components
Specification
1
O/A No
:
AZHV/268
2
Circuit No.
:
HS-64.3-A3814-3-3
3
Oil Tank Capacity
:
4000 L
4
Working Pressure
:
196 bar
5
Test Pressure
:
294 bar
6
Paint Specification
a
RAL NO
:
5010
b
Shade
:
Azure Blue
7
Material of Construction
a
Tank Material
:
Mild Steel
b
Piping Material
:
Carbon Steel
8
Working Fluid
:
ISO VG 46
RADIAL GATE
Salient Features- Spillway Gate- Power Pack
Sl.No.
Components
Specification
DIN 2391C for tube size upto 42 mm
9
Pipe/Tube dimensional Standard
:
ANSI B36.10 for pipe size 48.3 mm and above
ST 37.4/SS304/SS316
10
Pipe/Tube Material Standard
:
ASTM A 106 B for Carbon steel pipes/ ASTM A 312 for
stainless steel
Walform fitting for internal piping & 24" weld niple for user
termination upto 42 mm
11
Type of Connection
:
Flange connection /ANSI 48.3 mm OD pipe/
12
Apporoximate weight of the whole
unit(excluding oil)
:
2000 Kg
RADIAL GATE
Spillway Gate- PHOTO GALLERY
RADIAL GATE
Spillway Gate- PHOTO GALLERY
RADIAL GATE
Spillway Gate- PHOTO GALLERY
RADIAL GATE
Spillway Gate- PHOTO GALLERY
RADIAL GATE
Spillway Gate- PHOTO GALLERY
RADIAL GATE
Spillway Gate- PHOTO GALLERY
RADIAL GATE
Spillway Gate- PHOTO GALLERY
FIXED WHEEL VERTICAL LIFT GATES
The fixed-wheel vertical lift gates comprise of, in general, a structural steel frame consisting of end
vertical girders with properly spaced horizontal girders between them.
The spacing depends on the design water pressure and on dimensions of the gate. The frame is held a
piece by secure welding or riveting.
Skin plate protects the structural framework from damage due to ice and heavy debris, minimizes
downpull, reduces corrosion and facilitates maintenance. However, in some cases as in the case of
fixed wheel gates moving on track provided on the face of the dam, skin plate is provided on the
downstream side. In exceptional cases, skin plate is provided on both downstream side and upstream
sides, if the down stream water is above sill. In such cases the gates maybe fully or partially buoyant.
In case of fully buoyant gates, buoyancy shall be taken into account in determining the net balance of
vertical forces and addition of ballast may be necessary to ensure lowering without difficulty. This
problem is absent in the case of flooded gates but greater care against corrosion becomes necessary.
The wheels are mounted on the end girders.
The bottom of gate should be so shaped that satisfactory performance and freedom from harmful
vibrations are attained under all conditions of operation apart from minimizing downpull. A typical
arrangement of various components of gate is shown in Figure 24. Detailed design of this type of gates
has been published by the Bureau of Indian Standards code IS: 4622-2003 “Recommendations for
structural design of fixed wheel gates”.
VERTCAL LIFT GATE
HRT Service Gate- Bill of Quantity
Sl.
No.
Description
Sub Item
Track cum side seal seat
1
HRT intake gate Guide
2nd stage EP Sill beam
Total Wt.
Total wt. of
Weight (KG) per unit
Total
all quantity
(BOQ) in KG Quantity
in KG
4078.88
1727.18
239.27
Top seal seat
7793.01
Horizontal girders
9318.52
Vertical stiffeners, skin plate,
HRT intake gate
lifting hook and guide shoes
2
leaf
assembly
Roller Weight
Seal clamp plate and seal
Supporting structure
HRT intake gate
3
hydraulic hoist Dogging arrangement
Remark
13838.34
6 sets
83030.04
8294.38
19270.65
6 nos.
115623.9
1503.26
6 nos.
9019.56
1329.00
328.75
1061.26
442.00
BOQ given for
one set of
groove, Total
sets of
grooves are 6
VERTCAL LIFT GATE
Material Specification
Sl.No.
Components
Material
Specification
1
Gate leaf, seal clamps & other structural parts
Structural Steel
IS: 2062
2
Track bases, seal seat bases, sill beam, guide
& other embedded parts
Structural Steel
IS: 2062
3
Wheel
Forged Steel
4
Wheel pin
5
Roller Track
6
Seal seats
Stainless Steel
7
Guide shoe
Structural Steel
IS: 2062
8
Guide roller pin
IS:1570 (Part 5)-20 Cr 13
(AISI 420)
9
Guide roller bush
Corrosion Resistant Steel/
Stainless Steel
Self Lubricating Bronze
Bush
10
Seal fasteners
Corrosion Resistant Steel
/ Stainless Steel
Corrosion Resistant Steel
/ Stainless Steel
Stainless Steel
IS: 2004 Class 4 OR EN8
BHN = 175
IS:1570 (Part 5) -20 Cr 13
(AISI 420)
IS:1570 (Part 5) - 20 Cr 13
( AISI 420 )/ BHN 225 min.
IS: 1570 (Part 5) 04 Cr 19
Ni 9 / AISI 304
Standard make
IS: 1570 (Part 5)04 Cr 19 Ni
9 / AISI 304
VERTCAL LIFT GATE
Material Specification
Sl.No.
Components
Material
Specification
11
Top seal
Teflon cladded solid double stem
50x50x14
IS: 11855
12
Side seals
Teflon cladded solid
double stem 150x50x14
IS: 11855
13
Bottom seal
13 Flat Type 100x20
IS: 11855
VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate)
Sl.No.
Components
Specification
1
Type
:
Fixed wheel- downstram sealing
2
Service
:
Guard and isolating gate for headrace tunnels. Unbalanced opening for
headrace filling. Closure against maximum flow.
3
Clear width of opening
:
5000 mm
4
Clear height of opening
:
6200 mm
5
MWL
:
EL 609.80 m
6
FRL
:
EL 605.50 m
7
Sill level
:
EL 591.30 m
8
Design head
:
18.50 m
9
C/C of side seal seats
:
5150 mm
10
C/C of side tracks
:
5600 mm
11
Type of gate
:
Fixed Wheel Type
12
Type of seals
:
IS:11855
13
Operation
:
Unbalanced head conditions.
VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate)
Sl.No.
Components
Specification
14
Maximum Flow
:
119.3 Cumecs per gate
15
Hoisting Arrangement
:
Single acting Hydraulic Hoist of 45T capacity.
16
Seals
:
Sides and top:- Fluorocarbon nosed, double leg rubber. Bottom - flat
rubber strip
17
Standards
:
IS:4622, IS:10210
18
Testing Standards
:
IS: 7718
VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate)-Hydraulic Cylinder
Sl.No.
Components
Specification
1
Type
:
Rexroth Type- CYCIME7/200/100/6400A10/X1CLSATAC
2
Mode of Operation
:
Single Acting Pulling
3
Bore
:
200 mm
4
Rod Diameter
:
100 mm
5
A-piston
:
314 Cm2
6
A-rod
:
79 Cm2
7
A-ring
:
235 Cm2
8
F-lifting
:
450 KN
9
F-Lowering
:
0 KN
10
V- Lifting
:
0.62 M/min
11
V- Lowering
:
0.62 M/min
12
V- Emergency Lowering
:
6.20 M/min
13
T-Lifting
:
10 min
VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate) - Hydraulic Cylinder
Sl.No.
Components
Specification
14
T-Lowering
:
10 min
15
T- Lowering(Emergency)
:
01 Min
16
Total Stroke Length (inclusive Cushioning)
:
6400 mm
17
Design Pressure
a
Rod Side
:
20 MPa
b
Bottom Side
:
1 Mpa
18
Working Pressure
a
Rod Side
:
19.1 MPa
b
Bottom Side
:
1 MPa
19
Test Pressure
a
Rod Side
:
30 MPa
b
Bottom Side
:
1.5 MPa
Maximum Pulling force
:
450 KN
20
VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate) - Hydraulic Cylinder
Sl.No.
Components
21
Maximum Pushing force due to system overload
22
Energy to be Cushioned
Specification
: 0 KN
a
Rod Side
: 85 K Joule
b
Bottom Side
: 0 K Joule
23
Maximum speed
a
Moving Out
: 100 mm/sec
b
Moving IN
: 10 mm/sec
24
Minimum Speed
a
Moving Out
: 10 mm/sec
b
Moving IN
: 1 mm/sec
25
Hydraulic Medium
: Mineral Oil ISO VG 32
26
Moving Frequency
: TBD/day
27
Mounting Angle Rod to Horizontal
: 90 degree
28
Design Temperature
: 0/+45 deg
VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate) – Power Pack
Components
Sl.No.
Specification
1
O/A No
:
AZHV/268
2
Circuit No.
:
HS-64.3-A3813-3-4
3
Oil Tank Capacity
:
400 L
4
Working Pressure
:
187 bar
5
Test Pressure
:
280 bar
6
Paint Specification
a
RAL NO
:
5010
b
Shade
:
Azure Blue
7
Material of Construction
a
Tank Material
:
Mild Steel
b
Piping Material
:
Carbon Steel
8
Working Fluid
:
ISO VG 46
9
Pipe/Tube dimensional Standard
:
DIN 2391C for tube size upto 42 mm
ANSI B36.10 for pipe size 48.3 mm and above
VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate) – Power Pack
Sl.No.
Components
Specification
ST 37.4/SS304/SS316
10
Pipe/Tube Material Standard
:
11
Type of Connection
:
ASTM A 106 B for Carbon steel pipes/ ASTM A 312 for stainless
steel
Walform fitting for internal piping & 24" weld nipple for user
termination up to 42 mm
Flange connections /ANSI 48.3 mm OD pipe/
12
Approximate weight of the whole
unit(excluding oil)
:
1000 Kg
HRT INTAKE GATE
Service Gate- PHOTO GALLERY
HRT INTAKE GATE
Service Gate- PHOTO GALLERY
HRT INTAKE GATE
Service Gate- PHOTO GALLERY
SLIDE GATES
Slide gates, as the name implies, are the gates in which the operating member (that is, gate leaf) slides
on the sealing surfaces provided on the frame. In most cases, the sealing surfaces are also the loadbearing surface. Slide gates may be with or without top seal depending whether these are used in a
close conduit or as crest gate.
Bulk head or stop-logs
These are usually located at the upstream end of river outlet conduits or penstocks where in addition
some other equipment is used to cut off flow and are subjected to relatively high heads.
Emergency or guard gates
These are designed to be operated under unbalanced head, that is, with water flowing through the
conduit or sluice but are not meant for regulation. These are kept either fully opened or fully closed
and are not operated at part gate opening.
Regulating gates
These are used for regulating flow of water. These are also operated under unbalanced head condition
and are designed to be operated at any gate opening.
SLIDE GATES
A typical installation of a slide gate is shown in Figure. These consist of a gate leaf and embedded
parts. These embedded parts serve the following purposes:
 Transmit water load on the gate leaf to the supporting concrete (structure),
 Guide the gate leaf during operation, and Provide sealing surface.
The following Bureau of Indian Standards codes may be referred to while designing slide gates:
 IS: 5620-1985 “Recommendations for structural design criteria for low head slide gates”.
 IS: 9349-1986 “Recommendations for structural design of medium and high head slide gates”.
SLIDE GATES
SLIDE GATE- UNDER SLUICE
Service & Emergency Gate- PHOTO GALLERY
SLIDE GATE- UNDER SLUICE
Service & Emergency Gate- PHOTO GALLERY
SLIDE GATE- UNDER SLUICE
Bulk Head Gate- PHOTO GALLERY
SLIDE GATE- UNDER SLUICE
Bulk Head Gate- PHOTO GALLERY
SLIDE GATE- UNDER SLUICE
PHOTO GALLERY
SPILLWAY STOPLOG GATES
Two set of Slide Type Stop log gates with eight sets of embedded parts for a opening of size -14500 mm x 22000
mm (w x h) consisting of eleven equal size units for eight openings. These are required for inspection and
maintenance of the radial gates and are proposed on the upstream side. The size of each unit shall be 14500 mm
x 2000 mm (w x h).
The stop logs are designed in accordance with IS: 5620-1985 for hydro-static head of 21.342 m corresponding to
FRL EL605.50 m and checked for MWL and seismic forces. The Stoplog units consist of downstream skin plate
and downstream sealing with horizontal girders, vertical stiffeners and end girders.
The stoplogs shall be operated under balanced head conditions which will be achieved by the crack opening of
top unit about 150 to 200mm. and through a lifting beam having automatic engaging & disengaging device and a
Gantry Crane of 50T capacity.
SPILLWAY STOPLOG GATES
Spillway Stop log Gate- Bill of Quantity
Sl. Description
No.
Sub Item
Top cum side seal seat
1 2nd Stage EP Guide
Sill beam and groove rest beam
Horizontal Girders
Gate Leaf
2 Intermediate Skin plate, vertical stiffners
elements
Seals and Seal clamp plates
Weight (KG)
Total Wt. per
Total wt. of
unit (BOQ) in
Total
all quantity
KG
Quantity
in KG
Remark
5992.23
2147.37
8740.33
69922.64
BOQ for one
bay
600.73
13175.34
22681.18
9505.84
2089.12
8 Sets
2089.12
11
249492.98
Elements
BOQ for one
element
11
22980.32
Elements
SPILLWAY STOPLOG GATES
Salient Features- Stoplog Gate
Sl.No.
Components
Specification
1
Type
:
Vertical laef- downstream sealing
2
Service
:
For isolation of a spillway gate. Balanced operation only
3
Clear width of opening
:
14500 mm
4
Height of gate
:
22000 mm
5
MWL
:
EL 609.80 m
6
FRL
:
EL 605.50 m
7
Sill level
:
EL 584.50 m
8
Design head
:
21.342 m
9
C/C of side seal seats
:
14650 mm
10
C/C of Side tracks
:
15150 mm
11
Type of stoplogs
:
Sliding Type
SPILLWAY STOPLOG GATES
Salient Features- Stoplog Gate
Sl.No.
Components
Specification
12
Type of seals
:
IS:11855
(i)
Side & Top seals
:
Solid music note type
(ii)
Bottom seals
:
Wedge Type
13
Operation
:
Balanced head conditions achieved with the help crack opening
about150mm to 200mm of top unit.
14
Hoisting Arrangement
:
A detachable type semi automatic lifting beam with a gantry crane of
50T capacity.
15
Standards
:
IS:5620,IS:13591, IS:3177, IS:800 & IS:807
16
Testing Standards
:
IS: 7718
:
7 stoplog units are to be stored on dogging arrangement
provided on groove opening on 7 bays and balance will be stored in
the gate storage area provided on the non overflow blocks
beyond spillway openings.
17
Storage of stoplog units
SPILLWAY STOPLOG GATE
PHOTO GALLERY
SPILLWAY STOPLOG GATE
PHOTO GALLERY
HYDRAULIC CYLINDER
Cylinder Technology- BOSCH REXROTH
A controlled spillway in a dam has radial gates to regulate the water flow through the dam. This gate
design allows nearly the full height of the dam to be used for water storage year-round, and flood
waters can be released as required by opening one or more gates. Opening and closing of the gates will
be done mechanically, by winches or by large hydraulic cylinders.
Cylinder
Radial gate cylinders are used for lifting, lowering and holding the radial gate, which rotates around a
central pivot point. Due to the natural tendency for lowering by its own weight, the cylinders are
designed only for pulling to open the gate. The synchronized cylinders can subsequently control the
lowering in an accurate way.
Technical data (most common projects)
Fluids: Mineral oil / bio degradable oil
Pressure range 140 to 220 bar
Operation temperature -20 °C to 60°C
HYDRAULIC CYLINDER
Cylinder technology- BOSCH REXROTH- TYPE CODE
The following table shows the type code that creates the basis for your specific large hydraulic cylinder.
Each code marks a basic specification. All specifications applicable in your cylinder are explained below
Type code
Field
Type
Field 1
Field 2
Field 3
Field 4
Field 5
Field 6
Field 7
Field 8
1
2
3
4
5
CY CRR
Type Designation
Application Code
External Mounting Shell
Side
Bore Dimension
Rod dimension
Stroke Length
Cylinder Construction
Revision Index
6
7
8
A
10
9
10
11
12
13
14
U
A
15
16
17
18
CY
Cylinders with a single rod
CRR Radial gate cylinder
MP5/
Clevis on bottom with spherical bearing/ Trunnion on shell
MT4
Bore range from 200 mm – 700 mm Specific dimensions on
request
Rod range from 90 mm – 400 mm Specific dimensions on
request.
On request. References up to 16,500 mm
A
Bolted connection
10
HYDRAULIC CYLINDER
Cylinder technology- BOSCH REXROTH- TYPE CODE
Type code
1
Field
Type
2
3
4
5
CY CRR
Field 9
Field 10
Field 11
Field 12
Field 13
Field 14
Field 15
Field 16
Field 17
Oil connections rod &
bottom side
Position Oil Connection
Piston rod surface
Mounting rod side
Cushioning
Sealing system
Position sensor system
Option 1
Option 2
Field 18 Country code
6
7
8
A
10
A/D/X
9
10
11
12
13
14
U
A
15
16
17
18
BSP/SAE, 6000 PSI/Others
1/2/3/4
0°/90 °/180°/ 270 °/ X (Other)
/5
Enduroq 2000 / Enduroq 2200 / Chromium (only for
Q/R/C
stainless steel piston rod material)
Male clevis with spherical bearing/Female clevis/
L/R/X
Other
U
Not applicable
A
Chevron seals
C/T/W CIMS / Other positioning sensor / No option
A/Y/W/X
N/C
Maintenance free bearing / Rod extension /
None / Other
Netherlands / China
HYDRAULIC CYLINDER
Cylinder technology- BOSCH REXROTH- Standard Dimensions
Based on technical knowhow and experience the table below to help for selects the size of cylinder.
This table shows the approximate sizes of hydraulic cylinders along with the pulling force they can
deliver at a nominal pressure of 200 bar. The results are applicable to trunnion mounted cylinders and
bottom eye mounted cylinders and are independent of stroke- and built-in length
Piston
Piston rod
Area ratio
Areas
Force at 200 bar1
Ø mm
Ø mm
φ A1/A3
Piston A1 mm2
Rod A2 mm2
Annulus A3 mm2
Pulling F3 kN
220
100
1,48
38.013
7.854
30.159
603
250
125
1,46
49.087
12.272
36.816
736
280
140
1,48
61.575
15.394
46.181
924
320
160
1,46
80.425
20.106
60.319
1.206
360
180
1,45
101.788
25.447
76.341
1.527
400
200
1,43
125.664
31.416
94.248
1.885
450
220
1,45
159.043
38.013
121.03
2.421
500
250
1,46
196.35
49.087
147.262
2.945
550
300
1,42
237.583
70.686
166.897
3.338
600
320
1,40
282.743
80.425
202.319
4.046
650
340
1,38
331.831
90.792
241.039
4.821
700
360
1,36
384.845
101.788
283.057
5.661
A2
A1
A3
HYDRAULIC CYLINDER
Cylinder technology- BOSCH REXROTH- Standard Dimensions
Gate cylinder include manifold and stainless steel piping, all produced and designed by Bosch Rexroth.
Together with position measurement equipment (integrated or external) the movement of the cylinder
can be controlled in detail.
HYDRAULIC CYLINDER
Cylinder technology- BOSCH REXROTH- MOUNTING STYLE
The mounting style represents the cylinder’s connection to the radial gate and interface with the dam
structure. The mounting style and position have effect on the cylinder’s behavior.
Mounting Position Optimization
With the required input, like e.g. gate radius, drive torque, position of gate pivot point and available
area for position of cylinder mounting in the dam structure, we determine the maximum and minimum
forces on the cylinder (at angle), calculate guide bearing pressure and deflection of the cylinder and
thus optimize the complete design of the cylinder. This results in a cost effective design, from which
we all benefit.
Shell Side
 The Clevis with spherical bearing MP5 mounting style is an clevis connection with a spherical bearing. The
special bearings reduce side forces (introducing wear) caused by small misalignments between dam and gate.
Bosch Rexroth only works with premium suppliers of spherical bearings.
 The Trunnion mounting MT4 mounting style is a connection in the form of a trunnion. This extra connection
creates extra stability and less deflection.
MP5
MT4
HYDRAULIC CYLINDER
Rod Side
 The female clevis is a double bladed connection that requires a male clevis
equipped with a spherical bearing to be mounted on your radial gate. This
connection is locked with a pin.
 The male clevis is a single bladed connection, mounted on your radial gate
with a female clevis. This connection is locked with a pin.
Cylinder integrated measuring system
The Bosch Rexroth cylinder integrated measuring system (CIMS), provides a highly reliable solution to
measure the movement of a hydraulic cylinder. Fully integrated in the hydraulic cylinder, CIMS requires
the application of the Enduroq 2000 series rod surface technology, as grooves underneath this coating
are measured by using magnetic sensor elements
HYDRAULIC CYLINDER
Chevron sealing technology
To form the large hydraulic cylinders tribological system, each cylinder is equipped with a scraper,
seals and bearing strips
SCRAPER
Scrapers prevent dirt from being dragged into the hydraulic cylinder. Bosch Rexroth offers two types of
scrapers: standard and special self lubricated. Self lubricating scrapers are used in applications with
insufficient lubrication properties of the hydraulic fluid.
Standard scraper
Self lubricated scraper
Bearing strips
Bearing strips are used to ensure low friction between the moving parts in the cylinder. They reduce
wear and increase the cylinder’s lifetime.
Self lubricated
Standard
HYDRAULIC CYLINDER
Chevron seals
Chevron seals are used to seal off piston rods and pistons in hydraulic cylinders, preventing oil loss
from the hydraulic system. With its robust design, Chevron Seals have been developed to withstand
heavily damaged surfaces of the counter parts.
Chevron seals are designed for applications with a long lifetime and few movement. Performing best at
medium speeds (>0,05 m/sec - <0,5 m/sec), the minimum life time under normal circumstances is
500 km of piston rod movement. Finally, Chevron seals are maintenance friendly. Bosch Rexroth uses
two different types of materials to get the best fit with your application:
NBR-fabric material is designed for piston rods with chromium surface technology. It gives very good
wear resistance and has no delamination.
UHMWPE material is developed for the piston rods with Enduroq 2000 series surface technology.
produced with a special process that gives a very good wear and creep resistance.
NBR-fabric
UHMWPE material
HYDRAULIC CYLINDER
Deflection simulation
The DBR is used to calculate the deflection and buckling safety of hydraulic cylinders. Typical for the
radial gate is that its cylinder’s angle changes when lifting the gate. The more the gate is lifted, the
more horizontal your cylinder has to transfer its force. As the picture below shows, this angle change
increases the stress on the piston rod and the seals.
DSB STOPLOG GATE
Photo Gallery
DSB GANTRY CRANE
Photo Gallery
DAM VIEW
Photo Gallery
DAM VIEW
Photographs- Downstream Side
DAM UPSTREAM VIEW
Photographs- Reservoir Pounding
DAM VIEW
Photographs
POWER HOUSE VIEW
Photographs
BYPASS GATES
Photo Gallery
BYPASS GATES
Photo Gallery
BYPASS GATES
Photo Gallery
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