Guidelines for Instrumentation of Large Dams September 2016

Operation and Maintenance Manual for Malaprabha Dam State of

Doc. No. CDSO_O&M_ KA06HH0089_MALAPRABHA_DAM KAWRD_01_v2.0

December _ 2019

O&M Manual for Malaprabha Dam December 2019

Front Cover Photograph: Downstream view of Malaprabha Dam during rehabilitation works carried out under the Dam Rehabilitation & Improvement Project (DRIP). The Scope of Work entailed multiple contracts for works carried out to reduce seepage and leakage within the concrete / masonry structure using curtain grouting, body grouting, strengthening the upstream face, piers and treatment to ogee surface of the dam, improvements of gates, and infrastructure development.

O&M Manual for Malaprabha Dam December 2019

Operation and Maintenance Manual

for Malaprabha Dam

Prepared by the Dam Safety Rehabilitation Directorate with Assistance from

KARNATAKA NEERAVARI NIGAM LIMITED

(A Government of Karnataka undertaking)

State of Karnataka

3rd Floor, New Library Building R. K. Puram New Delhi – 110066

December-2019 New Delhi

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Message has more than 5200 large dams. Their health and safety are of paramount importance for sustainable use of the valuable assets, besides providing protection to the people and property in the downstream areas. The Ministry of Water Resources, River Development & Ganga Rejuvenation through the Central Water Commission (CWC), with financial assis- tance from the World Bank, started the Dam Rehabilitation and Improvement Project (DRIP) to rehabilitate 198 large dam projects in seven states.

For managing a dam in a sustainable and scientific manner, it is very crucial for each dam owner to have dam specific Operation and Maintenance Manual that lays down procedures for the daily upkeep of the dam. An Operation and Maintenance Manual for a dam is essen- tial for ensuring its safe functioning and for deriving continued benefits. This Operation and Maintenance Manual for Malaprabha Dam has been prepared following the Guideline for Preparation Operation and Maintenance Manuals published in January 2018 under DRIP and covers requirements for project Operation, Inspection, Maintenance, Instrumentation and Monitoring the health of Malaprabha Dam both during monsoon and non-monsoon periods.

I recommend the dam officials to use this manual for the efficient and safe Operation and Maintenance of the Malaprabha Dam on regular basis. I compliment all the experts who have contributed to the development of this manual and congratulate the Ministry of Water Resources, River Development & Ganga Rejuvenation, CWC for the initiation of such important policy protocol to address dam safety management in India.

Shri. Rakesh Singh, IAS Principal Secretary Water Resources Department, Karnataka

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FORWARD

This Operation and Maintenance (O&M) Manual developed exclusively for Malaprabha Dam is a detailed set of written descriptions with step-by-step procedures for ensuring that the dam is safely operated, frequently inspected and properly maintained. In this era of shrinking budgets, timely inspection and preventative maintenance is necessary for the safe functioning of the dam and continued productive use of the dam and reservoir.

The format of this manual was prepared following the principles published 2018 CWC guide- lines for operation and maintenance of dam for the use by all Dam Owners in developing their own site-specific manuals. Each section of the document provides the necessary in- structions to operate, inspect and maintain their dam.

It is recommended that all dam officials charged with the operation of their dams to use this manual to ensure their dam is operated and maintained in a sustainable manner and will con- tinue to derive benefits.

Shri. Mallikarjun Gunge, KES Managing Director, KNNL, Bengaluru

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Team Involved in Preparing this O&M Manual

Mahazar Javed Chief Engineer, KNNL, Malaprabha Project Zone, Dharwad

Jagadishkumar Superintending Engineer, KNNL, MLBCC Circle, Naviluteertha Nayak S M Meti Executive Engineer, KNNL, MLBC Division No.2, Naviluteertha

Assistant Executive Engineer I/C, KNNL, LI -2 Sub division, Vivek K Mudigoudar Naviluteertha

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TABLE OF CONTENTS

FORWARD ...... IV

LIST OF FIGURES ...... X

CHAPTER 1. - GENERAL INFORMATION ...... 1 1.1 Introduction ...... 1 1.2 Purpose, Location & Description of Malaprabha Dam ...... 1 1.3 Background Details of the Project ...... 2 1.3.1 Dam site Location: ...... 3 1.3.2 Malaprabha Reservoir Planning: ...... 3 1.3.3 Main Design Features and Components of Malaprabha Dam:...... 9 1.4 Salient Features of Malaprabha Dam ...... 10 1.5 Assignment of Responsibility ...... 13 1.5.1 Roles and Responsibilities of the AEE and AE during Monsoon ...... 14 1.5.2 Roles and Responsibilities of the SE and EE during Monsoon ...... 15 1.5.3 Roles and Responsibilities of the Chief Engineer during Monsoon ...... 16 1.6 Collection & Reporting of Dam and Reservoir Data ...... 17 1.7 Public and Project Staff - Health and Safety ...... 19 1.7.1 Restricted Areas ...... 19 1.7.2 Details of the Security arrangements at Malaprabha Dam Site...... 19 1.8 Staff Position, Communication & Warning System ...... 23 1.8.1 Schedule of General Duties for Project Engineers ...... 27 1.8.2 Electro-Mechanical Inspections / Checks ...... 30 1.9 Distribution of Operation & Maintenance Manuals ...... 34 1.10 Supporting Documents & Reference Material ...... 34

CHAPTER 2. PROJECT OPERATION ...... 35 2.1 Basic Data ...... 35 2.1.1 Area Capacity curves...... 35 2.1.2 Design Flood and Features Related to Safety ...... 35 2.2.1 Gate Operations: ...... 35 2.2.2 Rule Curve ...... 38 2.2.3 Flood Peaks...... 41 2.2.4 Recommended Gate Operation Procedures for Normal Flow Conditions ...... 41 2.2.5 Sequence of Opening or Closing of Gates...... 41 2.2.6 Gate Operation at Malaprabha dam...... 41 2.2.7 Inflow Forecasting ...... 41 2.2.8 Methodology of Flood Regulation at Malaprabha...... 43 2.2.9.1 Inflow Computation...... 44

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2.2.9.2 Examples of Inflow Computation ...... 44 Example1...... 44 Example2 ...... 45 2.2.9.3 Example of Computation for Required Gate Opening ...... 45 2.2.10 Summary of Flood Regulation Procedure...... 45 2.3 Operation of Radial Crest Gates of Malaprabha Dam ...... 49 2.3.1 Brief Description...... 49 2.3.2 Radial Crest Gates – Technical Data...... 50 2.3.3 Salient Features ...... 51 2.3.4 Material Specification ...... 53 2.4 Operating Instructions ...... 53 2.4.1 Checklist Before Operation ...... 53 2.4.2 TROUBLE SHOOTING ...... 55 2.5 Stoplogs ...... 55 2.5.1 Brief Description ...... 55 2.5.2 Technical Data ...... 56 2.5.3 Material Specifications ...... 58 2.5.4 Instructions Before Operating the Stoplog Gate ...... 58 2.6 Handling Equipment ...... 58 2.6.1 100-T Gantry Crane – Brief Description ...... 58 2.6.2 Technical Data ...... 59 2.6.3 Material Specifications ...... 61 2.6.4 Operational Instructions ...... 61 2.6.5 TROUBLE SHOOTING ...... 62 2.6.5.1 Motor ...... 62 2.6.5.2 E.M. BRAKE ...... 62 2.6.5.3 Thrustor Brake ...... 63 2.6.6 Electrical Connections: ...... 63 2.7 CCTv Arrangements…………………………………………………………………………………….65 2.8 RIVER OUTLET WORKS...... 67 2.8.1 Description: ...... 67 2.8.1.1 RIVER SLUICE GATES: ...... 67 2.8.1.2 HEAD REGULATOR: ...... 67 2.8.1.3 HEAD WORKS: ...... 67 2.8.2 Condition: ...... 67 2.8.2.1 General: ...... 67 2.8.2.2 Deficiencies and problems...... 67

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2.8.2.3 Potential problems...... 67 2.8.3 Historical Events...... 68 2.8.4 Operation: ...... 68 2.8.4.1 General ...... 68 2.8.4.2 Restrictions: ...... 68 2.8.4.3 Mechanical: ...... 68 2.8.5 References: ...... 68 2.8.5.1 Reports and Data...... 68 2.8.5.2 Drawings:...... 68 2.9 ACCESS ROADS ...... 69 2.10 Record Keeping ...... 69

CHAPTER 3 - PROJECT INSPECTIONS ...... 71 3.1 Types of Inspections ...... 71 3.1.1 Comprehensive Evaluation Inspections ...... 71 3.1.2 Scheduled Inspections ...... 72 3.1.3 Special (Unscheduled) Inspections ...... 73 3.1.4 Informal Inspections ...... 73 3.2 Pre- and Post-Monsoon Check list and Example of Report Performa ...... 74

CHAPTER 4 - PROJECT MAINTENANCE ...... 83 4.1 Maintenance Priorities ...... 83 4.1.1 Immediate Maintenance ...... 83 4.1.2 Preventive Maintenance ...... 84 4.1.2.1 Condition Based Maintenance ...... 84 4.1.2.2 Routine Maintenance ...... 84 4.2 Procedures for Routine Maintenance ...... 85 4.2.1 Earthwork ...... 85 4.2.2 Masonry / Concrete Dams & Spillways ...... 88 4.2.3 River Sluices ...... 88 4.2.4 Gates & Hoisting Equipment ...... 88 4.2.5 Electrically operated fixed hoists ...... 91 4.3 Electrical Systems ...... 103 4.4 Maintainance of Metal Gate Components...... 104 4.5 Access Roads ...... 104 4.6 General cleaning ...... 104 4.7 Materials and Establishment Requirements during Monsoon Period ...... 104 4.8 General list of Maintainance Records ...... 105 4.9 Preparation of O&M budget ...... 105

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4.10 Maintenance Records ...... 108

CHAPTER 5 - INSTRUMENTATION AND MONITORING ...... 109 5.1 Dam Instrumentation· ...... 109 5.1.1 General Information ...... 109 5.1.2 Embedded Instruments – Concrete/Masonry ...... 109 5.1.3 Seismological Observations ...... 110 5.1.4 Parameters being permanently Monitored ...... 110 5.1.5 Frequency of Monitoring ...... 110

CHAPTER 6 - PREVIOUS REHABILITATION EFFORTS ...... 111

CHAPTER 7 - UPDATING THE MANUAL ...... 113

APPENDIX 1 – BASIC DRAWINGS OF MALAPRABHA DAM ...... 115

APPENDIX 2― KEY ELEMENTS OF MALAPRABHA DAM EAP ...... 123

APPENDIX 3 ― MATERIAL REQUIRED FOR MAINTENANCE DURING MONSOON ...... 133

APPENDIX 4 ― SCHEDULED OR UNSCHEDULED DAM SAFETY INSPECTION ...... 135

FORM ...... 136

APPENDIX 5 – CCTV CAMERA SYSTEM SPECIFICATIONS...... 159

APPENDIX 6 - GLOSSARY...... 165

List of Tables

TABLE 1 - DETAILS OF DISTRIBUTED WATER TO KARNATAKA ...... 2

TABLE 2 – OVERALL RESPONSIBILITIES FOR MALAPRABHA DAM ...... 13

TABLE 3 – ROLES & RESPONSIBILITIES OF AEE & AE ...... 14

TABLE 4 – ROLES & RESPONSIBILITIES OF SE & EE ...... 15

TABLE 5 – ROLES & RESPONSIBILITIES OF THE CHIEF ENGINEER ...... 16

TABLE 6 – EXAMPLE PROFORMA FOR RECORDING FLOW DATA ...... 18

TABLE 7 - DISTRIBUTION OF O&M MANUAL AND REVISIONS ...... 34

TABLE 8 – RULE CURVE ELEVATIONS ...... 38

TABLE 9 – FLOW PEAK DATA ...... 41

TABLE 10 - TABLE SHOWING THE DISCHARGE OF DIFFERENT GATE OPERATION FOR VARIOUS RESERVOIR OPERATING FOR VARIOUS ELEVATION OF MALAPRABHA PROJECT (FOR FRL = 2079.50 FEET) ...... 46

TABLE 11 - STOPLOG DATA ...... 56

TABLE 12 - MATERIAL SPECIFICATIONS ...... 58

TABLE 13 - MALAPRABHA DAM 100-TON GANTRY CRANE DESIGN DATA ...... 59

TABLE 14 – TECHNICAL DETAILS OF IMPORTANT MACHINERY ITEMS ...... 60

TABLE 15 – MATERIALS FOR 100-TON GANTRY CRANE ...... 61

TABLE 16 – TROUBLESHOOTING FOR MOTORS ...... 62

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TABLE 17 - O&M BUDGET COSTS (ANNUAL) ...... 106

TABLE 18 - LOCATIONS AND EXTENTS OF STRUCTURAL MEMBERS ...... 109

TABLE 19 - EMBEDDED INSTRUMENTS...... 109

LIST OF FIGURES

FIGURE 1 - KRISHNA BASIN MAP ...... 5

FIGURE 2 - OVERHEAD IMAGE OF MALAPRABHA DAM ...... 7

FIGURE 3-LAYOUT OF MALAPRABHA DAM PREMISES ...... 21

FIGURE 4 - ORGANISATION CHART ...... 25

FIGURE 5 – MALAPRABHA DAM RULE CURVE ELEVATIONS ...... 39

FIGURE 6 – RADIAL CREST GATE OF MALAPRABHA DAM ...... 49

FIGURE 7 – 100 MT GANTRY CRANE AND STOPLOG GROOVES ...... 59

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Acronyms used in this publication are as follows: BIS Bureau of Indian Standards CDSO Central Dam Safety Organization CWC Central Water Commission SDSO State Dam Safety Organization O&M Operation and Maintenance DRIP Dam Rehabilitation and Improvement Project DSRP Dam Safety Review Panel EAP Emergency Action Plan Global Positioning System (uses GPRS for data trans- GPS mission like browsing the web) FRL Full Reservoir Level MWL Maximum Water Level MDDL Minimum Draw Down Level DSL Dead Storage Level EDA Energy Dissipation Arrangement HM works Hydro-Mechanical works DG set Diesel Generator set PC Personal Computer TMC Thousand-Million Ft3 MCM Million Cubic Meters

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CHAPTER 1. - GENERAL INFORMATION

1.1 Introduction This document represents a detailed Operation and Maintenance (O&M) Manual for Malaprabha Dam, Karnataka, providing written descriptions of procedures for ensuring that the dam operates safely and is kept in a good condition by periodic inspections, repairs, maintenance in a sustainable manner. Timely maintenance is important for the continued safe functioning and productive use of the dam and reservoir. The Manual has been prepared primarily for the dam operation’s staff and their supervisors who are assigned the responsibility for the physical operations and maintenance of the dam. It contains, as a minimum, all information and instructions necessary for them to perform their allotted tasks in a safe manner. In addition to instructions for dam operations staff, the Manual includes all necessary instructions for other staff directly or indirectly involved in operating and maintaining the dam. It is essential that the Manual or a copy of the Manual along with supporting data including the atlas of all drawings and manufacturer’s technical documents is available at site for ready reference.

1.2 Purpose, Location & Description of Malaprabha Dam The construction of Malaprabha dam was completed and the project commissioned in the year 1973. It is constructed across flowing in Krishna basin near Naviluteertha village of taluka in . The dam is located at 760 21’ 00” East Longitude and 150 10’ 00” North. The dam site is accessible by an approach road of length 2.40 km from “ Gate” situated on Saundatti – SH-103, at a distance of 14 km from Saundatti in Belagavi District. The nearest railway station at Dharwad is 50 km from the dam site.

The project was executed with Central assistance under AIBP since 1996-1997 and continued under AIBP and PM package since 2007-2008 for development of canal network. The construction of the main dam and all head works was completed in all respects and water is being impounded every year since 1973.

The river across which the dam is constructed has a total catchment area of 2176 sq km (840 sq miles) up to the dam site. The total yield available from the catchment has been assessed as 1338.12 mcum (47.25 tmc). The reservoir has a gross storage capacity of 1068.41 MCM (37.731 TMC) and live storage capacity of 972.56 MCM (34.346 TMC).

The dam as constructed is a Masonry gravity dam with overflow and non-overflow sections and has a total length of 154.53 m (507 ft). The overflow section has a maximum height of 40.23 m (132 ft) (RL 637.00 m –RL 596.769 m) above lowest river bed level and 43.10 m (142 ft) (RL 637.00 m – RL 593.90 m) above lowest foundation level. Construction of the dam was completed in the year 1973 and is operating since then.

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Surplussing arrangements consist of an overflow section 85.34 m (280 ft) long consisting of 4 bays fitted with radial crest gates of size 15.24 m x 12.91 m (50 ft x 40 ft) each. The total discharging capacity of the spillway is 5239 cumecs (1,85,000 cusecs) under spillage depth of 12.22 m (40 ft). One river sluice of size 1.22 m x 1.83 m (4 ft x 6 ft) with sill at RL 612.008 m (2008 ft) has been provided in the spillway portion. A trajectory bucket has been provided in the downstream to deflect the water flowing down the spillway away from toe of the bucket for dissipation of the energy content of flow by impact on the rocky bed. Till date, a maximum flood discharge of 2634.35 cumecs (93032 cusecs) has passed over the spillway during the year August-2019.

An irrigation head regulator with 2 vents of size 1.80 x 2.75 m (6 ft x 9 ft) fitted with gates eventually passing through a tunnel on the left bank end of the dam is provided. The right bank canal takes off from the head regulator provided in the water spread area of the reservoir on the right bank. It has 2 vents of 2.75 x 3.65 m (9 ft x 12 ft). The discharging capacity of the left bank sluice is 35.40 cumecs and that of the right bank sluice is 63.71 cumecs. Sill level of both sluices is kept at RL 619.323 m (2032 ft). Table 1- Details of Distributed Water to Karnataka i) Out of assessed 65% yield 65 TMC ii) Out of surplus flows 105 TMC iii) Flows made available for Minimum flows in the stream 7 TMC Total 177TMC

Out of the Karnataka's share of water, the Government of Karnataka has allocated 27 TMC of water to Malaprabha Dam. This allocation is to be utilized by for irrigating an area of 196,132 ha in Belgavi, Bagalkot, Dharwad and Gadag Districts including drinking and Indus- trial needs. The total water allocation for Malaprabha Project is thus 27 TMC.

1.3 Background Details of the Project The river Malaprabha is one of the important major rivers flowing through the North Western part of Karnataka, and is a main tributary to the river Krishna. The Malaprabha river has its source near in the Ghats in the Sahyadri about 35.20 kms south west of . The name Malaprabha is probably derived from the word Malapahari, cleanser of sins or the Malaprabha full of mud. The Malaprabha river rises in the at an altitude of 793 m about 16 kms from in Belagavi District of Karnataka State. The river flows in an easterly and then in North Easterly direction and joins the at an elevation of about 488 m about 306 kms from its source.

The river flows practically in easterly direction for a length of 80 kms from its source and then takes a right-angled turn and flows towards south up to Siddhadongar. The river again takes a turn and flows generally in a north easterly direction up to the peacock gorge. The entire valley of the river up to or even Mugutkhan-Hubli consists of hilly terrain

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The river, after flowing east about 136 kms through Belgavi district, forms the boundary be- tween the Ron and Navalgund talukas of Dharwad District, and Badami Taluk of Bijapur District. Beyond Dharwad limits, it passes north east, for about 64 kms through Badami and Hungund taluks of the Bijapur district and joins the Krishna river at Kapila Sangam, 16 kms north of Hungund in Bijapur district.

1.3.1 Dam site Location: Malaprabha Dam is constructed across Malaprabha river flowing in Krishna basin near Naviluteertha village of Saundatti taluk in Belagavi district. The dam is located at 760 21’ 00” East Longitude and 150 10’ 00” North. See location and vicinity map in Figure 1 below.

1.3.2 Malaprabha Reservoir Planning: i) Catchment: The river across which the dam is constructed has a total catchment area of 2176 sq km (840 sq miles) up to the dam site. The bulk of the rainfall occurs in the months of June to October. ii) Yields: The total yield available from the catchment has been assessed as 1338.12 MCM (47.25 TMC). iii) Storage: The Revised design flood review using the PMP values obtained from IMD New Delhi is calculated by the KERS for Malaprabha Reservoir. The Peak value of the esti- mated PMF is 8629 cumecs considering 1-day PMP value and 7515 cumecs considering 2- day PMP value. The routed peak outflow through the spillway is 5037 cumecs during the passage of flood peak. Hence the existing spillway capacity is adequate. The same is vetted by the CWC. The gross storage capacity at FRL of 2079.50 feet is 1068.41 MCM (37.731 TMC) with a live storage of 972.56 MCM (34.346 TMC) and a dead storage of 95.85 MCM (3.385 TMC) at MDDL of 7.129 TMC. The crest level RL of Spillway is 2039.50 feet and that of canals is 2032.00 feet. iv) Water Spread: The reservoir water spread submerges an area of 13578 ha (33526 acres) displacing a population of about 32 villages fully and about 35 villages partially.

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Figure 1 - Krishna Basin Map

Malaprabha Dam

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Figure 2 - Overhead Image of Malaprabha Dam

Note:- Google Map recognizes Malaprabha dam as Naviluteertha dam.

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1.3.3 Main Design Features and Components of Malaprabha Dam: i) Components: The dam as constructed is a Masonry gravity dam with overflow and non overflow sections and has a total length of 154.53 m (507 ft). The overflow section has a maximum height of 40.23 m (132 ft) (RL 637.00 m –RL 596.769 m) above lowest river bed level and 43.10 m (142 ft) (RL 637.00 m – RL 593.90 m) above lowest foundation level. ii) Spillway section (over-flow section): Surplussing arrangements consist of an overflow section 85.34 m (280 ft) consisting of 4 bays fitted with radial crest gates of size 15.24 m x 12.91 m (50 ft x 40 ft) each. The spillway is constructed of stone masonry except for the portion of the ogee on the downstream and the top portion of the crest, are provided with jacket of cement concrete. The total discharging capacity of the spillway is 5239 cumecs (1,85,000 cusecs) under spillage depth of 12.22 m (40 ft). One river sluice of size 1.22 m x 1.83 m (4 ft x 6 ft) with sill at RL 612.008 m (2008 ft) has been provided in the spillway portion. A trajectory bucket has been provided in the downstream to deflect the water flow- ing down the spillway away from toe of the bucket for dissipation of the energy content of flow by impact on the rocky bed. A maximum flood discharge of 2634.35 cumecs (93032 cusecs) has passed over the spillway during August -2019. iii) Masonry non-overflow section: This portion is constructed in un-coursed rubble stone masonry in cement mortar. Length of left Masonry Non-overflow section is 42.67 m and that of right Masonry non-overflow section is 26.52 m. The upstream and downstream faces are provided with 0.65-m thick coursed stone masonry in cement mortar. A drainage gallery of size 1.52-m x 2.28-m is provided in the overflow portion. 37 Nos of foundation drain holes of 76-mm diameter at intervals of 4.00-m c/c are provided in the gallery. A road way 1.52-m wide with handrails is provided in the gallery. iv) River Sluice Gate: Central River Sluice Gates of size 1.22-m by 1.83-m -high are pro- vided for Malaprabha Dam to operate when the water level recedes below the crest level of 612.009 m. For operations of river sluice gates, a 15-T Gantry crane has also been provided. Periodical maintenance such as lubrication, filling of gear oil, etc., are being done annually on a tender basis. Replacements of wire ropes and replacements of rubber seals and painting of river sluice gates are being taken up whenever required on tender basis. vii) Irrigation Sluices: Two (2) irrigation sluices are provided of size 1.80-m-wide by 2.75- m-high with two vents for Malaprabha Left Bank Canal and 2.75-m-wide by 3.65-m-high with two vents for Malaprabha Right Bank Canal. Both the sluices are operated with the help of a 10-T Gantry Crane for release of water to canals. Periodical maintenance of these gates is taken up annually on tender basis which includes items such as lubrication and filling of gear oil, Cardium compound, etc. Replacements of wire ropes, replacements of rubber seals and painting of irrigation sluice gates are being taken up as required on tender basis. The irrigation component is operated and maintained by another internal agency. Maintenance of the 10-T, 15-T and 25-T Gantry is done similar to that of the 100-T Gantry crane as mentioned in the O&M of the Spillway stoplogs, Chapter 4.

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1.4 Salient Features of Malaprabha Dam

Sl. Items Stage I & II No I General

1 Name of the project Malaprabha dam

2 Name of the river Malaprabha river flowing in Krishna basin

3 Location of dam

Near Naviluteertha village of Saundatti a) Village, Taluk and District Taluk in Belagavi District.

b) Longitude 760 21’ 0” East c) Latitude 150 10’ 0” North 4 Year of completion 1973

5 Means of Access The dam site is accessible by an approach road of length 2.40 km from “Vatnal Gate” situated on Saundatti – Gokak SH-103, at a distance of 14 km from Saundatti in Belagavi District. The nearest railway station at Dharwad is 50 km from the dam site.

II Geophysical features

1 Catchment area 2176 sq km (840 sq miles)

2 Nature of catchment The uppermost reaches are hilly and covered with forest area, while the lower reaches have a moderate catchment

3 Climate Moderate

4 Yield at dam site (Annual) 1338.12 mcum (47.25 tmc)

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6 Geological features Granites, gneisses schist’s of Peninsular complex and Dharwarian super group of Archaen to Lower Proterozoics age forms the regional geology and Quartzites of various shades of pink, white and grey belonging to the lower Kaladgis exposed overlaying the older granites and gneisses forms the local geology. III Technical details

a Reservoir

1 Gross storage capacity 1068.41 MCM (37.731 TMC)

2 Dead storage capacity 95.85 MCM (3.385 TMC)

3 Live storage capacity 972.56 MCM (34.346 TMC)

4 Water spread area 13578 ha (33526 acres)

5 Full reservoir level RL 633.832 m (2079.50 ft)

6 Maximum water level RL 633.832 m (2079.50 ft)

7 Top of dam RL 637.00 m (2090.00 ft)

b Dam

1 Type of dam Masonry gravity dam with over flow and non overflow sections

2 Total length of dam 154.53 m (507 ft)

a) Length of spillway section 85.34 m (280 ft)

b) Length of Left masonry non 42.67 m (140 ft) overflow section

c) Length of Right masonry non 26.52 m (87 ft) overflow section

3 Top of dam RL 637.00 m (2090.00 ft)

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4 Top width 6.70 m (22 ft)

5 Lowest foundation level RL 593.90 m (1948.50 ft)

(RL 1906.40 ft in Shear zone)

6 Lowest River bed level RL 596.769 m (1958 ft)

7 Maximum height of dam above 43.10 m (142 ft) lowest foundation level (RL 637.00 m – RL 593.90 m)

8 Maximum height of dam above 40.23 m (132 ft) lowest river bed level (RL 637.00 m – RL 596.769 m)

c Surplussing works

1 Type Ogee spillway with radial crest gates

2 Length 85.34 m (280 ft) fitted with 4 radial gates of size 15.24 m x 12.91 m (50 ft x 40 ft)

3 Maximum designed flood 5239 cumecs

discharge (1,85,000 cusecs)

4 Crest elevation of spillway RL 621.61 m (2039.50 ft)

5 Spillage depth 12.22 m (40 ft)

6 Radial Crest gates 4 Nos. 15.24 x 12.91 m

7 River sluices 1 No 1.22 m x 1.83 m ( 4 ft x 6 ft)

8 River sluice sill level RL 612.008 m (2008 ft)

d Irrigation Sluices LB Sluice RB Sluice

1 Type Head Regulator Head Regulator

2 Vent size 2 vents of 2 vents of 1.80 x 2.75 m 2.75 x 3.65 m

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(6 ft x 9 ft) (9 ft x 12 ft) fitted with fitted with gates gates

3 Sill level RL 619.323 m RL 619.323 m (2032 ft) (2032 ft)

4 Discharge 35.40 cumecs 63.71 cumecs (1250 cusecs) (2250 cusecs)

5 Location At the tunnel Taken out from the water excavated spread area of through the left the reservoir on the right bank bank hillock upstream of dam

6 Command area 47769 ha 121392 ha

7 Command area under 26971 ha foreshore Lift Irrigation (LI)

Schemes (10 No’s)

8 Total command area 196132 ha

1.5 Assignment of Responsibility The Karnataka Neeravari Nigam Ltd (KNNL) is the owner and has the final authority and responsibility for the operation and maintenance of the dam. Identification of all areas of responsibilities connected with the operation and maintenance of the dam are covered in this section. The officer’s responsibilities for the various functions are identified by their designation and, in particular, the responsibilities of operating personnel are specifically identified in below and includes regularly scheduled duties which staff personnel are required to perform as outlined in the following tables: Table 2 – Overall Responsibilities for Malaprabha Dam Sl No Particulars Remarks KARNATAKA NEERAVARI NIGAM LTD 1. Implementing Agency (A Govt of Karnataka Undertaking) Water Recourses Department, Karnataka

2. Project Administration Managing Director, KNNL, Bengaluru Officer in charge Chief Engineer, KNNL, Malaprabha Project Zone, 3. Operations of Equip- Dharwad.

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ment at the Dam

Executive Engineer, KNNL,MLBC Dn-2 Navilut- 4. Reservoir inflow and eertha. Flood forecasting

Chief Engineer, KNNL, Malaprabha Project Zone, 5. Authorising spillway Dharwad. flood releases Chief Engineer, KNNL, Malaprabha Project Zone, Authorising releases for Dharwad as per the proceedings of the Irrigation 6. various purposes like Consultative Committee meeting (ICC) and in con- irrigation, water sup- sultation with Managing Director,KNNL Benga- plyhydro-power, etc luru

Executive Engineer, KNNL,MLBC Dn-2 Navilut- 7. Recording reservoir Da- eertha ta Executive Engineer, KNNL,MLBC Dn-2 Navilut- 8. Routine inspection eertha Executive Engineer, KNNL,MLBC Dn-2 Navilut- 9. Maintenance eertha. Executive Engineer, KNNL,MLBC Dn-2 Navilut- 10. Instrumentation eertha

1.5.1 Roles and Responsibilities of the AEE and AE during Monsoon Table 3 – Roles & Responsibilities of AEE & AE Flood condition assessment, warning, flood mitigation, and other responsi- Step bilities Coordinate with the Project Engineers upstream of the dam at Khanapur rain 1. gauge station on the rainfall in the catchment and inflow status at the initial river path (Khanapur) and to bring it to the notice of the EE/SE/CE Assist the EE/SE/CE to issue notification to the villagers downstream in News- 2. papers, Radio, TV News channel to be alert regarding the flood situation Assist the EE/SE/CE to coordinate with the Revenue authorities (District Ad- 3. ministration) to alert the downstream villagers to evacuate the flood zone to prevent loss of life and live stock Assist the EE/SE/CE to coordinate with the CWC flood monitoring authorities 4. on the flood condition Maintain the reservoir water level gauge register and to update on hourly basis 5. during floods. and to bring to the notice of EE/SE/CE Assess the inflows in the reservoir as per the approved reservoir operation and to prepare performa consisting of the status of the reservoir capacity and releas- 6. es from the reservoir as per the standard Performa and to submit to the EE/SE/CE Submit to the EE/SE/CE on the inflows and releases from the reservoir and sta- 7. tus of the reservoir twice in the day 8. Maintain the spillway crest gate operation log book 9. Operate the Spillway crest gates for flood mitigation as per the instructions of

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the EE/SE/CE and to update the Gate operation Log book Observe the seepages in the drainage Gallery with respect to the reservoir head and record the seepages in the infiltration gallery and to immediately bring to 10. the notice of the EE/SE/CE in case of excessive seepage, leakage in any specif- ic blocks and porous drains Maintain the pump operation log books for the dewatering pumps in the drain- 11. age gallery and to submit to EE/SE/CE Observe the gates and to see that the drain holes are not clogged and floating 12. debris is not deposited in the gate components Monitor the condition of the Welding transformers, gas cutting sets, umbrellas, 13. tool kits, torches, chain blocks, ropes, ballies etc on daily basis and to see that things are in place to handle any emergency situation Observe the Gates, hoists and handling equipment during operation for the 14. smooth movements and to immediately report any untoward excessive sounds in the motors, pumps or vibrations in the gate Observe the dam top, catwalk, approach roads are well maintained by house- 15. keeping personnel Observe the performance of the Dam and its appurtenant structures / Gates and Hoists during flood water releases and to report to the EE/SE/CE in case of any 16. untoward incidents or malfunctioning of the gates of excessive seepages, leakages etc Assist EE/SE/CE to coordinate with the downstream Narayanpur Dam Project 17. Engineers and getting the flow data Assist EE/SE/CE to share the flow data and the reservoir storage details to the 18. Media on day to day basis

1.5.2 Roles and Responsibilities of the SE and EE during Monsoon Table 4 – Roles & Responsibilities of SE & EE Flood condition assessment, warning, flood mitigation and other responsi- Step bilities Coordinate with the Project Engineers upstream of the dam at Khanapur rain 1. gauge station on the rainfall in the catchment and inflow status at the initial river path (Khanapur) and to bring it to the notice of the CE. To issue notification to the villagers downstream in Newspapers, Radio, TV 2. News channel to be alert regarding the flood situation Assist the CE to coordinate with the Revenue authorities (District Administra- 3. tion) to alert the downstream villagers to evacuate the flood zone to prevent loss of life and live stock Assist the CE to coordinate with the CWC flood monitoring authorities on the 4. flood condition Submit to the CE on the inflows and releases from the reservoir and status of 5. the reservoir twice in the day Operate the Spillway crest gates for flood mitigation as per the instructions of 6. the CE and to update the Gate operation Log book Observe the seepages in the drainage Gallery with respect to the reservoir head 7. and record the seepages in the infiltration gallery and to immediately bring to the notice of the CE in case of excessive seepage, leakage in any specific blocks

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and porous drains Observe the Gates ,hoists and handling equipment during operation for the 8. smooth movements and to immediately report any untoward excessive sounds in the motors, pumps or vibrations in the gate Observe the dam top, embankment, catwalk, approach roads are well main- 9. tained by housekeeping personnel Observe the performance of the Dam and its appurtenant structures / Gates and Hoists during flood water releases and to report to the CE incase of any unto- 10. ward incidents or malfunctioning of the gates of excessive seepages, leakages etc Assist CE to share the flow data and the reservoir storage details to the Media 11. on day to day basis

1.5.3 Roles and Responsibilities of the Chief Engineer during Monsoon Table 5 – Roles & Responsibilities of the Chief Engineer Step Flood condition assessment, warning and flood mitigation To issue notification to the villagers downstream in Newspapers, Radio, TV News channel to be alert regarding the flood situation based on the input by the 1. Project Engineers upstream of the dam at Khanapur rain gauge station on the rainfall in the catchment and inflow status at the initial river path (Khanapur) and also to Coordinate with the Revenue authorities (District Administration) 2. Coordinate with the CWC flood monitoring authorities on the flood condition Issue necessary instructions to the engineers to Operate the reservoir based on 3. the inflows,rainfall data,releases from the upstream reservoirs and status of the reservoir Observe the performance of the Dam and its appurtenant structures / Gates and 4. Hoists during flood water releases and to issue necessary instructions to the AEE/EE/SE 5. Coordinate with the downstream Narayanpur Dam Project Engineers 6. Conduct Pre and Post Monsoon inspections of the Dam

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1.6 Collection & Reporting of Dam and Reservoir Data A performa is provided to ensure that dates and times for the collection and reporting of vital information is recorded and documented for the record (see Table 6).  Reservoir water surface elevation.  Reservoir inflow.  Spillway outflow.  River releases.  Irrigation, water supply and hydropower releases.  Weather related data  Instrumentation data  Water quality Instructions and a standard proforma for collection and reporting of inflow and outflow data, and other pertinent data, is shown in Figure 6 below. Records [Logbooks] of the following operations at Malaprabha Dam are to be maintained in a chronological manner for reference. These records are helpful for identifying preventative maintenance measures that may need to be taken up, troubleshooting the cause of potential equipment failure and documenting development of any unusual conditions.  Date and Time  Attendance statement during normal operations – both during monsoon and non- monsoon periods.  Operations of the spillway gates and outlet works.  Operating hours of mechanical equipment.  Testing / Operation of spillway gates, stop-logs and associated controls.  Testing/operation of Outlet gates, valves and associated controls,  Maintenance activities carried out.  Reservoir and dam inspections.  Unusual conditions or occurrences, including acts of vandalism.  Attendance statement at the dam during emergency operations.  Changes to normal operating procedures.  Communication network checks.  Safety and special instructions.  Names of officers and staff carrying out inspections and maintenance.  Any other item pertaining to the operation and maintenance of the dam.

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Table 6–Example Performa for recording Flow Data

For the Month of ______

Out Flow in Cusecs Wa-

ter Inflow in Cu- Reservoir Date Time level MLB SPILL- Capacity in secs1 in MRBC LIS Water Supply Total O/F TMC C WAY Feet

Footnote 1: To be indirectly calculated as per examples 1 and 2 in Chapter 2,

Legend  MLBC: Malaprabha Left Bank Canal.  MRBC: Malaprabha Right Bank Canal.  LIS : Lift Irrigation Schemes.

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1.7 Public and Project Staff - Health and Safety As safety of Project Staff is of prime concern, safety instructions & protection measures at the dam are carried out by all staff / project personnel. Check points located in the dam premises provide public notices of events and status of security of the dam and downstream river conditions.

1.7.1 Restricted Areas Certain areas of the dam and reservoir are restricted for entry of the general public. The purpose of restrictions is for security of the dam, public safety and uninterrupted safe operation of the dam. Restricted areas will include the following:  Upstream and downstream faces of dam.  Confined spaces such as adits, galleries, etc.  Spillway approach areas, chutes and stilling basins.  Control buildings and valve areas.  Intake or outlet channels adjacent to electro-mechanical functioning equipment and structures.

1.7.2 Details of the Security arrangements at Malaprabha Dam Site. The security arrangements of Malaprabha Dam are entrusted to a private Security Agency on tender Basis with a total strength of 27 Security personnel. 1. Security Supervisor.

One Security Supervisor is in charge of the overall security arrangements. 2. Security Guards.

Security Guards are deployed 24/7 at the critical location viz., dam main entrances, control room, gallery audits, check posts, head works etc.

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Figure 3 Layout of Malaprabha Dam Premises

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1.8 Staff Position, Communication & Warning System The number & description of operating unit personnel posted/placed at different locations of the dam are noted in supporting documents and referenced in this Manual. Staff positions vary according to requirement during monsoon / non-monsoon periods. An engineering organisational chart is shown in Figure 4 below. The means of communications both in normal and emergency situations are identified in the Communication Directory found below. Available communication means including landline, mobile phones, wireless sets, at different locations on the dam. A utility room located on the right bank of Malaprabha Dam has an equipment room with all essential small tools, welders, gas cutter sets, chain blocks and ropes, space for the hydraulic hoist, dewatering pumps, weather gear, and consumables to facilitate O&M requirements. A brief description of the warning systems including alarms at the dam is mentioned in the Manual. This includes information on downstream inundation areas during scheduled or unscheduled release of flood outflows from the spillway. Basic facilities like communication facilities, sirens, hooters etc. are provided.

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Figure 4 - Organization Chart Of Malaprabha Dam

Chief Engineer

KNNL, Malaprabha Project Zone Dharwad. Office Phone:0836-2447793 Email:[email protected]

Superintending Engineer Superintending Engineer KNNL, MLBC Circle Naviluteertha. KNNL, MRBC Circle Dharwad. Office Phone:08330-224500 Office Phone:0836- Email:[email protected] Email:[email protected]

Executive Engineer KNNL, MLBC Dn-2 Naviluteertha. Dam Division Office Phone:08330-224516 Email:[email protected]

Assistant Executive Engineer KNNL,LI Sub Dn-2 Naviluteertha. Dam Sub Division Office Phone:08330-224524 Email:[email protected]

Assistant Engineer, Assistant Engineer, Mechanical Engineer Civil Engineer

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1.8.1 Schedule of General Duties for Project Engineers Schedules of duties being performed by the staff assigned to various locations and components of Malaprabha Dam are provided in this section. All activities are to be recorded daily in the Logbook and site registers. DAILY  Visual inspection of dam  Crest of dam (Dam top)  Upstream and downstream faces  Visible portions of foundation and abutments contacts  Galleries

 Record water surface elevation. (during monsoon on hourly basis)  Record reservoir inflow and spillway discharge. (during monsoon on hourly basis)  Record releases from outlets /sluices.  Record seepage from drainage systems, Gallery drains etc. on daily basis  Record meteorological data.  Check security and safety devices.  Complete logbook / site registers which should include the above information WEEKLY Electrical System  Standby generator (DG Sets)  Run for 15-30 min to achieve recommended operating temperature  Check status of batteries and keep them charged.  Check Fuel Supply  Drainage systems - Toe drains, Gallery drains etc., and, during any reservoir filling operations MONTHLY Check condition of: Dam and Reservoir  Reservoir periphery (During Monsoon)  Drainage systems - Toe Drains, Gallery drains etc.  Measuring devices/Instruments  Security and safety devices – rectification, if needed.  Communication Devices  Status of Vegetation growth

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 Check Sign/Warning display boards near vulnerable locations are in place and updated as necessary Mechanical/Electrical System  Replace fuses/light bulbs, as necessary  Inspect and maintain ventilation system; check for and remove any obstructions  Cleaning of control panel boards QUARTERLY Outlet Works  Availability of updated operating instruction  Check gate air vents  Clean gate control switchboxes  Check operation of gates and valves  Grease gate hanger / dogging arrangements

Check  Check condition of trash rack of intake structure  Check condition of Outlet works &the Energy Dissipation Arrangement (EDA)

Spillway  Check for debris in inlet channel  Check operation of gates  Check for damages in spillway glacis, d/s area, etc.  Check and clear spillway bridge drains  Clean inside of motor control cabinet and remove debris, insect (bee nests), nests, rodents and bird nests Other works  Check for adherence to instrumentation schedule  Record pertinent information in Operation Log  Check conditions of V-notch weirs/other seepage measuring devices

BI-ANNUAL Spillway & outlet works  Check paint on gates and other areas of corrosion  Check lubrication of wire ropes and application of cardium compound.  Check mechanical hoist bearings and flexible coupling bearings  Check gear systems

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 Exercise gate and valves for operational efficiency  Check oil reservoir level in lubricating system and top up as necessary  Check pressure release valve and clean any debris, dirt, other foreign objects as necessary  Lubricate gate rollers  Check rubber seals and seal clamp bar

Electrical System and Equipment  Change oil in stand by generator  Check exposed electrical wiring of :  Operating equipment of gates/valves/hoists of Outlet works.  Operating equipment of gates and hoists of Spillway  Operating equipment of any other gates and hoists in dam  Spillway catwalk / bridge  Dam Gallery  Check Gate limit switches and adjust ANNUAL Spillway &Outlet works  Paint  Metalwork, Gate, Hoists and all exposed metal parts for corrosion  Valves / Control valves  Gate lifting Mechanism system  Exercise Gates.  Examine stilling basin / energy dissipation arrangement and d/s channel & carry out rectification works, as necessary.  Check metal welds for damages/cracks in Gates, Hoist platform, Radial Gate Tie flats, Trunnion Girders/supports etc.

Electrical  Check electrical conduits, pull-boxes and switches for:  Outlet works valve house  Gates & hoists  Spillway bridge  Gallery FIVE YEAR (PERIODIC)

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 Inspect intake structures, trash racks and stilling basin / energy dissipation arrangement, which normally are underwater; less frequent if experience indicates. This may need to be done by carrying out dewatering or by divers/remote operated vehicle (ROV) as necessary.  Review Dam operation procedures and EAP and update as necessary.

1.8.2 Electro-Mechanical Inspections / Checks Special duties performed for E-M operating personnel works are given in this section. Frequency of inspections / checks for Electro-mechanical components and necessary actions to be taken up during maintenance. 1. Radial Crest Gates - 4 Nos. a. Embedded Parts

Sl. Embedded Part Frequency No. Checking of seal beams. Seal Seats, Guide track & all other exposed embedded parts with respect to their alignment, distortion :if any due 1 Half Yearly to continuous use, pitting and un-necessary cracks due to wear & car- rying out requisite repairs, rectification by welding, grinding etc. Removing debris & other foreign material deposited on embedded 2 Monthly parts & cleaning the same 3 All cracks & defective weld joints to be ascertained & rectified. Half Yearly All dirt, debris, grit, foreign material etc. to be removed from trun- nion assemblies as well as trunnion chair and lubricate trunnion bear- 4 Monthly ing & the sliding surface on trunnion chair with specified lubricant/ grade to ensure smooth sliding movement of trunnion. All nut bolts connecting Trunnion Assembly & Trunnion Chair and 5 Trunnion & Yoke, girder Trunnion pin lock plate to be checked & Monthly Tightened and replacement the same if found defective.

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b. Gate Structure Sl. Embedded Part Frequency No.

Regular inspection of the gate along with the hoist to be carried out 1 Daily daily to ensure that there is no unusual development/ observation

2 Check all welding for soundness & rectify defects Quarterly Check welding between arms & horizontal girders as well as arms & 3 Trunnion with the help of magnifying glass for cracks/ defects and Quarterly rectify the defects. Clean all drain boles including those in end arms, horizontal girders 4 Quarterly & Trunnion Check all nuts & bolts provided and tighten them, and replace the de- 5 Quarterly fective nuts & bolts Check upstream face of Skin plate for pitting, scaling and corrosion. Scaling formation are to be removed. Pitting shall be filled with weld 6 & ground. Corroded surface shall be cleaned & painted Yearly

Joints of side & bottom rubber seals to be checked for their proper 7 alignment and fixing & to be rectified/ adjusted if there is leakage Monthly through joints Nuts & bolts for rubber seal connection to be tightened and damaged 8 Quarterly nuts and bolts to be replaced

The excessive or widespread leakages if any shall be reported to the engineer in charge. If the seals are required to be replaced the same 9 shall-be carried out after supply of rubber seal by the department free Quarterly of cost in case the change of rubber seals is more than once during total maintenance period of five years 10 The guide roller pin is to be lubricated Quarterly

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2. Electro-mechanical Hoist -4 Sets

Sl. Description Frequency No. 1 Check the wire rope and hoist drum . Daily Monthly & 2 Lubricate the frictional parts of the gear system periodically. during rainy season Checking, cleaning, etc., in the hoist mechanism spares & their 3 Weekly replacement and when required Checking, repairing and replacement whenever necessary of all 4 Monthly Joints , couplings of line shafts, etc Checking, repairing & making good of all electrical wirings & 5 Monthly connections of local panels Checking, repairing & making good and replacement of all elec- 6 trical contactors, timers, limit switches, fuses etc. including set- Monthly ting of limit switches Complete trouble shooting of the entire system as and when nec- 7 essary to maintain the same such that the system can be put to op- Weekly eration at any point of time as per requirement Checking and ensuring perfect lubrication of the entire equipment 8 Monthly with recommended lubricants & methods of the manufacturer. The maintenance of the equipment cleaning & shall include in- spection, checking and ascertaining the deficiencies in the equip- ment for its smooth & trouble free operation. The deficiencies no- As per 9 ticed shall be rectified by resorting to cleaning, adjustment, re- requirement pairs, replacement of troubled/ damaged parts as per the require- ment Necessary maintenance records are to be prepared as a result of 10 periodical inspection and submitted for deciding actions in re- Monthly spect of necessary repair/replacement of parts

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3. Stop Logs Embedded parts (Gate 1 set)

Sl. Description Frequency No. Inspection, checking of sill beams, side seals, guide track and other exposed embedded parts with respect to their alignment cracks, dis- 1 tortion, pitting, uneven surface due to wear & tear. and ascertaining Half Yearly defects. Carrying out requisite repair/rectification by welding, grinding etc. as per requirement Removal of debris and other foreign material deposited on the E.P. 2 Quarterly and cleaning the same All cracks & defective weld joints of E. P. to be ascertained & rec- 3 Quarterly tified by respective welding

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1.9 Distribution of Operation & Maintenance Manuals The list of unit officers to whom the O&M Manual is required to be distributed is shown in the table below. Table 7 - Distribution of O&M Manual and Revisions Number of Manual Sl No Unit Officers Distribution Secretary to Govt, Water Resources Department, Vi- 1. 3 kasaSoudha, Bengaluru 2. Managing Director, KNNL, Bengaluru 1 3. Chief Engineer, KNNL,MPZ Dharwad 2 4. Library of the Dam Zone, Dharwad 1 Chief Engineer, Water Resources Development Or- 5. 1 ganization, Bengaluru. 6. Director, KERS, K R Sagara. 1 7. Superintending Engineer, SPMU, WRDO, Bengaluru 1 Superintending Engineer, KNNL,MLBC Circle Navi- 8. 1 luteertha 9. Library of the Dam Circle, Naviluteertha 1 10. Executive Engineer, SPMU, DRIP Bengaluru 1 Deputy Chief Engineer, KNNL,Malaprabha Dam 11. 1 Zone, Dharwad Executive Engineer, KNNL,MLBC Dn-2 Navilut- 12. 1 eertha Executive Engineer, Monitoring and Evaluation, 13. 1 Bengaluru 14. Library of the Dam Division, Naviluteertha 1 Assistant Executive Engineer, KNNL,LI-2 Sub Dn 15. 1 Naviluteertha

1.10 Supporting Documents & Reference Material This O&M Manual is the key instruction document. Supporting documents and necessary instructions for all phases of the operation, inspection and maintenance of the dam, reservoir and appurtenant works shown below are available at the dam control room:  Emergency Action Plan (EAP)  Maintenance schedules  Flood forecasting and operating cri-  Gate Manufacturer’s instructions teria and drawings  Basin or river operating plan  Regional communication directory  Interstate agreements  Instrumentation reports / results  Agreements with other user agen- cies  Power station operation plan  Irrigation operation plan  Domestic / industrial water suppl operating instructions  Administrative procedures  Reservoir / River pollution contin- gency plan

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2.1 Basic Data The Malaprabha operation plan consists of step-by-step instructions for operating the dam and reservoir during routine (normal) and emergency conditions. The operating procedures for normal operations are discussed in in this chapter including operating criteria for the reservoir, spillway & outlets. The operation of a dam involves regulation of its reservoir as per project specific requirements. This includes the use of area capacity curves and design flood; both are described below.

2.1.1 Area Capacity curves. The area capacity curves for Malaprabha Dam are shown in Table 7.

2.1.2 Design Flood and Features Related to Safety The maximum flood design at Malaprabha Dam site was earlier fixed at 5238.56 Cu- mecs. The Revised design flood review using the PMP values i.e 1-day PMP as 25.5 cm & 2-day PMP as 46.7 cm obtained from IMD New Delhi is calculated by the KERS for Mal- aprabha Reservoir. The Peak value of the estimated inflow PMF is 8629 cumecs considering 1-day PMP value and 7515 cumecs considering 2-day PMP value. As per KERS flood routing report, the peak outflow through the spillway for the re- vised design flood is 5037 cumec corresponding to revised MWL of 2079.5 ft (633.80 m). Hence the existing spillway capacity is adequate. The same is vetted by CWC. The dam top level is at 2090.0 ft (637.00 m), hence, the available freeboard above the MWL is 3.2 m, which fulfills the minimum 1.0 m freeboard requirement for concrete/masonry dam as per IS 6512. 2.2 Flood Management at Malaprabha Reservoirs

2.2.1 Gate Operations:

The Gate Operation Schedule of Malaprabha Dam is very simple and it does not involve too much calculation to be done at the field level and is also very easy for adoption by the lower level field staff. The spillway gates shall be normally opertaed as per the Rule Curve provided under section 2.2.2.

The inflow computation and computation of required gate opening with examples. Overall the report is very simple and operation can be carried out by the lower-level field staff very easily.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 35 O&M Manual for Malaprabha Dam December 2019 Reservoir Elevation – Area - Capacity

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2.2.2 Rule Curve Under the project , working tables for the Malaprabha reservoir were prepared for the FRL at 2079.50 feet. In the rule curve (also called guide curves or operation curve) elevations were developed as shown in the table below.

Table 8 – Rule Curve Elevations

Upper Limit (Year 1994) Lower Limit (Year 1996) Month/ 5% anuual probability of exceedance 75% annual probability of exceedance Fortnight Feet Meter Feet Meter Jun-1F 2035.69 620.47 2035.69 620.47 Jun-2F 2045.95 623.60 2035.95 620.55 July-1F 2067.30 630.11 2042.25 622.47 July-2F 2078.55.30 633.54 2042.85 622.66 Aug-1F 2077.16 633.11 2055.35 626.47 Aug-2F 2078.88 633.64 2059.00 627.58 Sep-1F 2078.783 633.61 2059.55 627.75 Sep-2F 2078.75 633.60 2060.80 628.13 Oct-1F 2077.95 633.35 2062.55 628.66 Oct-2F 2079.05 633.69 2065.95 629.70 Nov-1F 2078.95 633.66 2070.20 630.99 Nov-2F 2078.40 633.49 2069.18 630.68 Dec-1F 2078.68 633.58 2066.51 629.87 Dec-2F 2075.75 632.68 2063.36 628.91 Jan-1F 2060.75 628.11 2040.78 622.02 Jan-2F 2056.5 626.82 2038.39 621.30 Feb-1F 2051.15 625.19 2038.04 621.19 Feb-2F 2046.85 623.87 2037.73 621.10 Mar-1F 2041.55 622.26 2037.71 621.09 Mar-2F 2037.50 621.03 2037.40 620.99 April-1F 2036.78 620.81 2036.78 620.81 April-2F 2036.46 620.71 2036.46 620.71 May-1F 2036.16 620.62 2036.16 620.62 May-2F 2035.93 620.55 2035.93 620.55

(Note: 1F- First 15 days; 2F- Second 15 days )

These elevations are the target reservoir levels to be achieved at the end of respective fifteen days during June to May . The rule curve elevations are shown graphically on the following page in Figure 5.

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Figure 5 – Malaprabha Dam Rule Curve Elevations

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Recommended Monthly Water releases through the sluices

Individual Demands of various canals under Malaprabha Project in Mcft

Sl.No. Particulars June July August September October

21 to 21 to 21 to 21 to 21 to 1 to 10 11 to 20 1 to 10 11 to 20 1 to 10 11 to 20 1 to 10 11 to 20 1 to 10 11 to 20 end end end end end 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 MRB Canal 422.50 422.50 422.50 422.50 422.50 422.50 422.50 422.50 422.50 422.50 422.50 422.50 422.50 422.50 422.50 2 N.B. Canal 648.90 648.90 648.90 648.90 648.90 648.90 648.90 648.90 648.90 648.90 648.90 648.90 648.90 648.90 648.90 3 KRB Canal 67.40 67.40 67.40 67.40 67.40 67.40 67.40 67.40 67.40 67.40 67.40 67.40 67.40 67.40 67.40 MLB Canal 4 & 130.00 130.00 132.00 350.00 350.00 350.00 369.00 369.00 371.00 437.00 437.00 438.00 478.00 478.00 478.00 LIS Munoli Rt. 5 Branch Ca- 7.00 7.00 9.00 20.00 20.00 21.00 21.00 21.00 23.00 25.00 25.00 27.00 28.00 28.00 28.00 nal

Head Regu- 6 23.00 23.00 25.00 65.00 65.00 67.00 64.00 64.00 66.00 65.00 65.00 67.00 73.00 73.00 75.00 lator for LIS

7 Other 7 LIS 57.00 57.00 59.00 157.00 157.00 158.00 155.00 155.00 155.00 156.00 156.00 158.00 175.00 175.00 177.00 Evaporation 8 43.20 43.20 43.20 43.20 43.20 47.52 43.20 43.20 47.52 43.20 43.20 43.20 43.20 43.20 47.52 Losses KUWS HBL 9 27.65 27.65 27.65 27.65 27.65 30.41 27.65 27.65 30.41 27.65 27.65 27.65 27.65 27.65 30.41 DWD 1426.65 1426.65 1426.65 1801.65 1801.65 1812.73 1818.45 1818.45 1831.73 1892.65 1892.65 1899.65 1963.65 1963.65 1974.73

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2.2.3 Flood Peaks. The flood peaks shown in the table below are as follows:

Table 9 –Flow Peak Data Peak Flow Return Period Years Cumecs. Cusecs.

Original PMF 5037 177882

Based on this, applying the Goodrich method for flood frequencies, flood -works out to 177882 cusecs. Hence, inflows less than 177882 cusecs are considered as normal, and the gates are operated as recommended in earlier and subsequent paragraphs. For inflows exceeding 177882 cusecs, it is recommended that the flood regulator procedure described in subsequent paragraphs be followed. After the flood subsides, normal operation isresumed.

2.2.4 Recommended Gate Operation Procedures for Normal Flow Conditions Under normal flow conditions (i.e for inflow less than 177882 cusecs), the reservoir is operated according to the rule curve elevations.

2.2.5 Sequence of Opening or Closing of Gates. Of the 4 crest gates, it is recommended that all 4 gates be operated for releasing water over the spillway. The gates are numbered 1 to 4.

If, even when water is being released at full capacity, the reservoir level tends to rise above 2079.50 Feet (2079.50 is the highest FRL) ,the crest gates should be opened, starting With the end gates first (i.e., gate No.1 and 4), then the gates remaining at the center (gates 2 and 3) should be opened. If the release over the spillway is to be further increased, the gates are opened further in a similar manner, no gate opening being more than 0.4m. Further opening of gates, if required is done in the same way, keeping the difference in the openings of any two adjacent gates- not more than 0.2m.

During the recession part of the inflow hydrograph, it may be necessary to close the crest gates in order to maintain the reservoir level at the rule curve elevation. In such a case, the closure of the gates should be done in the reverse order; the gate opened last being closed first, the entire operation being such that the difference between the adjacent gate openings never exceed 0.2-m.

2.2.6 Gate Operation at Malaprabha dam. The spillway gates shall normally be opertaed as per the Rule Curve provided under section 2.2.2 and spillway discharge rates given in Table 10 below.

2.2.7 Inflow Forecasting The gross storage of Malaprabha Dam at FRL 2079.50 Feet is 37.731 TMC. The Mal- aprabha Dam revised design flood has been calculated for a probable maximum flood (PMF) of 5037 cumecs or 1.78 lakhs cusecs against the designed flood discharge capacity of

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 41 O&M Manual for Malaprabha Dam December 2019 5238.57 cumecs or 1.85 Lakhs cusecs. The storage in Malaprabha Dam has commenced since 1973. During monsoon, incident rains in the catchment area can cause the flash floods in Mal- aprabha river. These floods may lead to problems like people getting displaced from their homes, huge damage to crops and other assets. The floods can have disastrous impact on the environment also. Adequate measures are required to be taken up in advance to control and regulate the flow water in the river. The following measures are essential for effective management of floods in Malaprabha River during the monsoons. 1) Nomination of liaising officers for respective reservoirs. 2) Sharing of Sub-basin wise directory of concerned officers responsible for flood management. 3) Exchange of data regarding rainfall, releases from dams, reservoir water levels. 4) Reservoir operation schedules.

Exchange of data regarding rainfall, releases from dams, reservoir water levels. During monsoon daily water releases from the Dams/Barrages at 7 hrs. & 18 hrs. in normal situation and hourly data exchange during heavy floods is necessary. In this regard, the data is required to be established. The data regarding exchange floods is made available to the Revenue authorities and public by broadcasting in AIR, TV and publication in new papers. The list of rain gauges in the catchment of Malaprabha basin and daily rainfall is to be collected by concerned offices. It will helpful for prediction of probable floods in the river. Flood warning system in catchment area: The monitoring of the inflow from the upstream of Malaprabha reservoir is very crucial to quantify the inflow of floods into Malaprabha dam. The gauging agencies on upstream of the Malaprabha Dam will be coordinated to assist in the flood forecasting accordingly, se- quence of opening or closing of gates will be taken up in accordance with the approved gate operation schedule. Flood communication system: The widely time tested Communication to reach every corner of the flood affected zones have been radio and television and private media for the people to move to safer places by themselves in an emergency. Communication is very important in such occasions. These days due to revolution in the tel- ecommunication system, there is available, network of mobile phones. Advantage of this facility will be taken. Mobile numbers of all such staff will be listed and made available to all the personnel who have been assigned duty of disaster management. Following liaising officers for flood co-ordination of Malaprabha Dam are as listed be- low Karnataka State: 1) Chief Engineer, Phone No. 0836-2447793 Mobile No. 9845951357 2) Superintending Engineer, Phone No. 08330-224500 Mobile No. 9448641777 2) Executive Engineer, MLBC Dn-2, Malaprabha , Phone No. 08330-224516 Mobile No. 9008288188 Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 42 O&M Manual for Malaprabha Dam December 2019 4) Asst. Ex Engr. Mobile No. 9986172727 5) Asst. Engr Mobile No. 9986172727 District Administration Belgaum, Bagalkot.

2.2.8 Methodology of Flood Regulation at Malaprabha. The method of flood regulation developed by the U.S Army Corps of Engineers (vide "Reservoir Regulation"), U.S Army corps of Engineers Manual No. EM 1110-2- 3600 ) is adopted here. It does not require a forecast of the flood, and hence can be used when the only information available is what can be observed at the dam. In this method, the inflow coming into the reservoir is first estimated (e.g., by the reservoir gauging method). It is assumed that further inflows would decrease according to the hydrograph recession equation.

1 ) q1 = qo K (1)

Where q0and q1are the inflows at time 0 and t respectively (time 0 corresponds to a reference discharge on the recession limb of the hydrograph) and K is the recession constant. With this assumption,·the volume of remaining water of the flood which would flow into the reservoir is calculated by integration. The rate of release required to ensure that the reservoir level does not exceed the maximum permitted (inthis case, the FRL)is then calculated and the gates are opened to effect this release. The releaserequirediscalculatedbytheformula.

S A = 2Ts [(Q 1 - Q 2 – Q 2 l o g e (Q l Q 2 ) ] ( 2 )

WhereSA=availablestorage,i.e,Maximum storage minus Current Storage at the prevailing reservoir elevation Q1= inflow

Q2= release required

Ts=ratio of change in storage to change in discharge during recession.

The available storage space SA isgivenby

SA=SFRL-Sl (3)

WhereS1andSFRLarethecapacityofthereservoirat theprevailingleveland FRL, respectively.

Substituting from eq.(3) and rearranging eq. (2) becomes.

Q2 = Q1- (SFRL- S1) / (2Ts)- Q2loge (Q1Q2) (4)

In eq. (4), the required release Q2 can be determined if all other quantities are known. The values of SFRL and S1 can be read from the elevation capacity tables of the reservoir since the FRL and prevailing reservoir level are known. The inflow Q1 is equal to the current outflow plus the rate of increase in storage (minus if the level is decreasing).

The rate of change of storage can be calculated from the observed change in reservoir level over, say, the past one hour, and the elevation- capacity tables. Ts is equal to-1/logeK.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 43 O&M Manual for Malaprabha Dam December 2019 This can be found from the hydrograph of a large flood, say the PMF hydrograph. The PMF hydrograph was made available by the Project Authorities. For the present case, the best curve which fits the recession limb follows tbe equation

q = 75489(0.7625)-t, where q is in cumecs and t in days.

The value of K is therefore 0.7625, and the value of Ts comes to 3.689 days. Thus, Q2 can be calculated from eq. (4), but since it occurs on both sides of the equation, a method such as the Newton - Raphson method has to be used. The procedure adopted here is to determine Q2 for a given reservoir level for a range of inflows. The resulting solution is shown in Table 9 for FRL of 2079.50 Feet.

When flood is regulated by this method, there servoir comesto the FRL shortly after the peak has passed and remains there after.

2.2.9.1 Inflow Computation Inflow into reservoirs is normally estimated by the reservoir gauging method (also called the rise and fall method or inflow-outflow method). All the outflows are added together and to it the rate of rise in storage (Positive if the level rises, and negative if it falls) is added . Expressed as an equation, this will be.

Inflow (cusecs) = Total outflow(cusecs)+Rate of increase in storage(cusecs)

The rate of increase (or decrease) in storage can be determined from the observed rate of increase (or decrease) in reservoir level and the elevation capacity tables. For easy computation. Table 11 has been developed showing the rate of change of storage in the Malaprabha reservoir for a rate of rise in reservoir level of 1-cm/hour. The sameinformation is shown graphically in Figure6 which can be used for interpolation.

2.2.9.2 Examples of Inflow Computation Example-1.

Let the reservoir level be at 2070.00 Feet at 07:00 AM and 2071.00 Feet at 07:00 AM next day and total outflow be 3000 cusecs . Change in level = 2071.00 Feet -2070.00 Feet = +1.00Feet Time interval = 24 Hrs. From the area capacity Table Capacity at RL 2071 = 26956.36 Mcft or 26.956 TMC Capacity at RL 2070 = 25873.66 Mcft or 25.873 TMC Therefore rate of storage change = 26.956 – 25.873 = 1.083 TMC or 12534.64 cusecs Then, Inflow = Outflow + Rate of storage change = 3000 + 12534.64 = 15534.64. cusecs.

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Example-2

Let the reservoir level be at 2070.00 Feet at 07:00 AM and 2069.00 Feet at 07:00 AM next day and inflow be + 15000 cusecs. Change in level = 2069.00 Feet -2070.00 Feet = - 1.00Feet Time interval = 24 Hrs. From the area capacity Table Capacity at RL 2069 = 24826.60 Mcft or 24.826 TMC Capacity at RL 2070 = 25873.66 Mcft or 25.873 TMC Therefore rate of storage change = 24.826 – 25.873 = -1.047 TMC or -12117.98 cusecs Then, Net Inflow = Outflow + Rate of storage change = -12117.98 + 15000 = 2882.02 cusecs.

2.2.9.3 Example of Computation for Required Gate Opening Let FRL be 2079.50Feet , the reservoir level be at 2070.00 Feet at 07:00 AM and 2071.00 Feet at 07:00 AM next day and total outflow at be 3000 cusecs. Then, from Example 1 above, the inflow is 15534.64 cusecs.

From Table 10 (bottom part), the opening required for this condition is slightly more than 9.14 Feet.

2.2.10 Summary of Flood Regulation Procedure. The flood regulation procedures at Malaprabha can be summarized in the following 5 steps: · 1 Observe the reservoir level at 1 hour intervals. 2 Determine the total outflow occurring at all outlets (including river sluices, canals, spillway, turbines) 3 Estimate the inflow by the method given in Para 2.4.9 using Fig. 1 4 Determine the gate opening from discharge table the bottom i.e Table 10 as the case maybe. 5 Open all 4 gates to the extent required in the proper sequence as described in Para 2.2.6.

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Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 46 O&M Manual for Malaprabha Dam December 2019 Table 10: Table showing the discharge of Different Crest Gate operation for various reservoir operating for various elevation of Malaprabha Project (for FRL = 2079.50 Feet) – All Gates Opened Condition

Sl Reservoir No Level 2079.50 2077.50 2075.50 2073.50 2071.50 2069.50 2067.50 1 2 3 4 5 6 7 8 9 Gate Bottom Elevation 1 2039.50 0 0 0 0 0 0 0 2 2040.50 7841 7415 7207 7001 6797 6392 6191 3 2041.50 14010 13380 12980 12610 12480 12390 12240 4 2042.50 20680 19800 18370 17840 17660 17240 16830 5 2043.50 26380 25590 24630 24020 23090 22330 21480 6 2047.50 57350 49550 48750 46800 45270 43920 42980 7 2051.50 73720 71680 69680 67260 66620 63370 61240 8 2055.50 97140 91980 89350 86960 83390 81770 77130 9 2059.50 119200 116000 112900 109000 105900 104000 0 10 2063.50 143800 139000 0 0 0 0 0 11 2065.50 188300 155000 0 0 0 0 0

Sl Reservoir No Level 2065.50 2063.50 2061.50 2059.50 2057.50 2055.50 2053.50 1 2 10 11 12 13 14 15 16 Gate Bottom Elevation 1 2039.50 0 0 0 0 0 0 0 2 2040.50 5998 5899 5707 5231 5047 4642 4237 3 2041.50 11740 11020 10575 10130 9686 9046 8164 4 2042.50 16550 15600 14200 13530 12980 12740 11380 5 2043.50 20830 19650 18930 17800 16630 16280 14930 6 2047.50 41850 40180 38360 35670 33390 30280 28320 7 2051.50 58290 54980 58550 48960 47400 30980 0 8 2055.50 76210 0 0 0 0 0 0 9 2059.50 0 0 0 0 0 0 0 10 2063.50 0 0 0 0 0 0 0 11 2065.50 0 0 0 0 0 0 0 Sl Reservoir No Level 2051.50 2049.50 2047.50 2045.50 2043.50 2041.50 1 2 17 18 19 20 21 22 Gate Bottom Elevation 1 2039.50 0 0 0 0 0 0 2 2040.50 3898 3560 3281 3002 2860 1719 3 2041.50 7523 7061 5998 4326 3232 0 4 2042.50 11260 10190 8935 7001 0 0 5 2043.50 13370 12360 10770 0 0 0 6 2047.50 27670 0 0 0 0 0 7 2051.50 0 0 0 0 0 0 8 2055.50 0 0 0 0 0 0 9 2059.50 0 0 0 0 0 0 10 2063.50 0 0 0 0 0 0 11 2065.50 0 0 0 0 0 0

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2.3 Operation of Radial Crest Gates of Malaprabha Dam

2.3.1 Brief Description. Crest Gates of Malaprabha Dam have been designed with spillway crest of 2039.50 feet and FRL of 2079.50 feet. The basic principal of the design is that the water pressure is transferred to piers and abutments through skin plates, stiffeners horizontal girders, arms, trunion, tie flats and anchor girders. The skin plates between bottom and top horizontal girders is designed as supported on the girders. The portion below the bottom horizontal girder up to sill beam and above top horizontal girder and up to FRL is designed as cantilever.

In order to make design structurally sound and most economical, appropriate elevation for three horizontal girders have been chosen. The hoist mechanism involved is the conventional Electro-mechanical Rope drum hoist. There are 4 Nos of radila crest gates of size 50 feet wide x 40 feet height.

The crest gates of Malaprabha Dam spillway were designed and fabricated for the full height of 40 feet corresponding to FRL 2079.50 feet.

Fig : 6 Radial Crest Gate of Malaprabha dam.

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2.3.2 Radial Crest Gates – Technical Data 1. The spillway Radial Gate consist of an upstream curved skin plate of varying thickness from 14 mm to 10 mm, stiffened by suitably spaced vertical 500 ISMB (1/2 cut) stiffeners. 2. The sill beam, wall plates are provided with suitable anchorage for a rigid connection to the spillway crest and the piers Suitable stainless steel plates are welded on the wall plate to match with the rubber seals. The sill beam embedded in the spillway crest are provided sealing surfaces of stainless steel to match with the rubber seal on the bottom of the gates. 3. The gate consists of structural steel frame formed by three (3) main horizontal girders supported by radial arms at each end. These inclined radial arms in turn transmit the load to trunnion brackets installed on trunnion girder spanning between the piers. The water load is transferred through girders to end arms, trunnion brackets, to concrete beam and is finally transferred to pier concrete.

4. Gate Assembly The skin plate of the gate consists of a 10 to 14-mm-thick stainless steel on the u/s side. The skin plate is stiffened by radial shaped vertical stiffeners. which rests on horizontal girders. The vertical stiffeners rest on horizontal girders . which are mounted on suitably braced inclined arms fixed to the trunnion assembly. The skin plate is supported on 3 main horizontal girders which are in turn, supported on a frame of inclined arms. The end arms pivot on trunnion pins mounted on trunnion brackets fixed to the Yoke girder and resting on rest beam (chair) plate. The water load is transferred to pier concrete through Anchor bars welded to anchor girder embedded in pier concrete. The horizontal force due to arm inclination is taken by stiffened D/s flange of horizontal girder at the junction level. This force is taken by the trunnion tie connecting the two trunnion hub limbs.

5. Guide Roller Assembly Each gate has been provided with 3 guide rollers of size dia 130-mm O.D. x 76 mm I.D. x 90 mm width on each side, to check side sway. In fully open position of the gate, two no. guide rollers on each side rests on the wall plate. The rollers are provided with plain bronze bushings turning on fixed pins. The roller pin is 60-mm-dia and is hard chromium- plated with thickness of 40microns The rollers are adjustable and removable type.

6. Trunnion Assembly The trunnion assembly consists of a single piece cast steel trunnion hub having 10 680 mm and 00 I 030 mm, to which the arms of the gates are rigidly connected to ensure full transfer of load. 580-dia. Stainless steel trunnion pins with bush bearings of size 580 I.D. x 680 O.D. are used. The trunnion pins are hard chromium plated to 40 microns The trunnion pins connect trunnion hub to radial arms.

7. Seal Arrangement The radial gate is seated at the bottom by contact of bottom edge of skin plate and wedge type bottom seal of 16-mm-thickness and side seals of thickness 16 mm (Z- Type).

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 50 O&M Manual for Malaprabha Dam December 2019 2.3.3 Salient Features Sl. No. Feature Description i. Type of gate Spillway Crest Radial gate ii. Size of Gate 50 Feet x 40 Feet iii. No. of Gates 4 Nos (Gate 1 to 4) iv. Clear width of opening 50 Feet a) Motorized rope drum hoist. v. Operation Arrangement b) Manual Operation a) Mechanical Dial Indicator at Gate Location vi. Gate position Indicator

Crest level of spillway EL 2039.50 Feet Top of Gate El 2079.50 Feet FRL EL 2079.50 Feet MWL EL.2079.50 Feet Design Head 40 Feet or 12.19 M

NOTE: 4 Nos. of 50 Feet wide and 40 Feet height gate. (Picture showing Radial gate and its rope drum type hoist)

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(Picture showing Control Panel for Radial and Sluice Gates)

(Picture showing Rope drum type hoist for Sluice gates)

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 52 O&M Manual for Malaprabha Dam December 2019 2.3.4 Material Specification Sl. Description Material Specification No. Skin plate, Horizontal Girders, End Arms, Arm Bracings, Vertical Stiff- 1 Structural steel IS 2062 GrA / BrB. eners, Lifting Lug Yoke, and Anchor Girder, Rest Chair, Tie Beam, etc. 2 Trunnion Hub Cast Steel IS 1030 Gr 23-45 3 Trunnion Bracket Structural Steel IS 2062 4 Trunnion Pin Forged Steel IS 2004 Gr 2 5 Trunn1on Bushing Aluminum Bronze IS 305 Gr AB 2 6 Seal Sea S:arnless Steel Plates IS .1570 7 Seal Base Structural Steel IS 2062 8 Guide Roller Cast Steel Is 1030 Gr 23-45 9 Roller Bushing Bronze IS 305 10 Rubber Seal Rubber Seals IS 11855

2.4 Operating Instructions The Gates are operated by motorized rope drum type hoist mechanism. The hoists are capable of fully opening or fully closing the gates holding them fully opened or in any intermediate position, during either the opening or closing operation. The closing time and the opening time is 15 minutes. The limit switches mounted on each hoist unit are set to stop the hoist automatically when the units reach the fully opened or fully closed position.

Each hoist can be operated from the unit control cabinet located in the hoist operat- ing chamber. Necessary inter-locking arrangement is provided to disengage the hoist machinery from electric circuit when manual operation is in progress.

2.4.1 Checklist Before Operation The following steps are to be taken before operation of the gates to ensure these eight critical functions are in good working condition.

Sequence Description Actions to be carried out The seal clamp fixing should be such as to ensure that Step 1 Seal Clamp the side seals are flexible enough The location and alignment of guide rollers should be Step 2 Guide Roller checked. Limit Switches shall. be checked for satisfactory op- Step 3 Limit Switch eration (function) to stop the hoist automatically

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 53 O&M Manual for Malaprabha Dam December 2019 when the gate. reaches the fully opened or ful- ly closed position All nuts, bolts and screws shall be checked for Step 4 Nut & Bolts wear, tear and tightness Gate pin, connecting pin and all other pins should Step 5 Pins be in proper position and ensure that the nuts and split pins are tight and proper To check and apply the high pressure lubricating Trunnion Step 6 grease in trunnion bushing from the hole provided Lubrication in trunnion hub Control Panel shall be checked for its suitability for the purpose envisaged. The check may include items such as weather proofing, conducting wires, Step 7 Control Panel etc. In case of any contact chatter, clean the mag- net surface and try again. If the chattering con- tinues, check the coil voltage and replace the contact / coil, if necessary

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2.4.2 TROUBLE SHOOTING For trouble shooting of the major components like Motors, etc., brief observations and possi- ble causes are shown below. These can be used as a “first-sight” trouble-shooting of the above stated components. Observations of potentially defective or failing parts/equipment is critical to maintain a safely operated dam. Electrical motor. Excessive Noise - Damaged bearings. - Improper assembly of rotor, fan cover etc. - Excessive speed.

2.5 Stoplogs

2.5.1 Brief Description

Photo 1. Stoplog Elements in Dogged Position when not in use.

There is one set of stop logs for spillway gates consisting of 7 number interchangeable units and one non-interchangeable bottom unit. Each unit is of fixed wheel type vertical lift gate having downstream skin plate supported on two horizontal girders which are welded to end vertical box girders and stiffened by suitable stiffeners. Each end of the vertical girders car- ries two-wheel assemblies. The stiffeners transfer the load to the main horizontal girders which are welded to end vertical box girder having wheel assemblies. The music note type of rubber seals are provided on the downstream on both sides of ele- ments for water tightness. Bottom seal is flat rubber seal. Each unit (elements) is provided

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 55 O&M Manual for Malaprabha Dam December 2019 with 4 nos of guide shoes attached to the two ends of the vertical girders to guide the stop log units while lowering and raising operations. The top most element is raised under unbalanced head condition, while all other units (ele- ments) are raised under balanced head condition. Lowering of each unit (element) is done in balanced head condition. The lowering and raising of elements is done by 100 t. gantry crane through automatic engaging and disengaging type lifting beam connected to gantry crane hook, The stoplog units shall be operated under balanced head condition except for the top unit and shall be used only for the maintenance/ inspection of spillway crest gates.

2.5.2 Technical Data Table 11 - Stoplog Data Sl. Description Specification No. 1 Clear opening width 50 Feet 2 C/c of side seal seats 50 Feet 3 C/c of tracks (wheels) 50 Feet 4 Design Head 12.19 M 5 Type of unit Fixed wheel type vertical Lift Gate 6 Sill level EL 2039.50 Feet 7 Full reservoir Level EL 2079.50 Feet 8 Top of pier EL 2081.00 Feet Location of skin plates 9 D/s Skin plate & sealing and seals 10 No. of openings 4 1 set consisting of 7 units. One non- interchangeable bottom Unit and 6 nos. Inter- 11 No. of stop log changeable units of equal heights. Size of each units 50 feet x 40 feet.

Notes: Operating Condition: (A) Lowering : Under balanced head (B) Raising : Top Unit - under Unbalanced head:

Design Considerations:

All structural components : Dry and accessible.

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2.5.3 Material Specifications Table 12 - Material Specifications Components Materials Specification Skin plate, stiffeners, Horizontal girders, tracks, Base, seal seat ba- Structural steel IS 2062 ses, Sill beam, seal clamp, Guide and guide shoes Seal seats SS Gr4 Cr 19 nilo IS 1570 Seals Rubber IS 11588 Nut & Bolts MS IS 1363/1364 A. Wheel track plate CRS Gr20 Cr13 IS 1570 B. Base plate MS IS 2062 Lifting Bracket MS IS 2062 Hook Forged Steel IS 1875 Grc-c30 Bushing Al-Bronze IS 305 Gr AB-1 Hook Pin CRS IS 1570 Spherical Roller Bearings No. ZKL/NTN/NSK or Equiv-

22328CC alent Corrosion resistance Steel Wheel pins IS 1570 20cr-13 Wheels Cast steel IS 1030 Gr27-55

2.5.4 Instructions Before Operating the Stoplog Gate (1) To ensure that all the rollers/wheel fixed for rolling on track plate should be in one line and the same are in contact with the track plate. (2) To ensure the side seals in contact with the side seal seat. (3) The location and adjustment of guide shoes should be checked to ensure non- interference with guide during operation. (4) Water jet to be sprayed over rubber seals of the seals are dry. (5) The stoplog units to be lowered and raised for number of times to ensure that the gate is not jammed or stuck-up and ensure that the motor of the crane hoist is not over loaded. (6) Limit switch in hoist shall be checked for satisfactory operation. (7) All nut, bolts and screws shall be checked for wear, tear and tightness.

2.6 Handling Equipment

2.6.1 100-T Gantry Crane – Brief Description The Crane is Class-2 as per IS 807 of the outdoor Travelling type with rope drum hoist mounted on movable trolley at top of the crane structure. The gantry crane structure com- prises of two portal frames each bearing top portal beam on which the rail is fixed for the movement of the trolley. The two legs of the portal are connected at the bottom to wheel bo- gie meant for longitudinal travel of the crane. The portal beams are connected with U/s. & D/s. tie beams to prevent skewing of gantry structure the operation the crane is completely electrical with 400/440V, 3 Phase, 50 Hz and the power supply is made available from the plug receptacles located at suitable intervals along with the crane runway. To facilitate a bet- ter control of the crane, an operation for the electrical equipment on the crane is provided. In Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 58 O&M Manual for Malaprabha Dam December 2019 the operator's cabin along with the control panel having all electrical controls and safety de- vices for main hoist, C.T. Drive and L.T Drive mechanism and have indicating lights for the various operations. The crane is made to stop at the centre of each span stop log with the help of limit switches provided along the travels.

Fig : 7 : 100 MT Gantry Crane and Stoplog Grooves.

2.6.2 Technical Data Table 13 – Malaprabha Dam 100-Ton Gantry Crane Design Data Sl. No. Item Specifications 1 Capacity of Crane 100-Tons 2 Class of Crane Class-2 per IS 807-1976 3 Wheel base 7500 mm 4 Gauge of Crane 5500 mm 5 Total Lift 24 M 6 Hoisting speed 1.5 Metre/ minute+/- 5% 7 Trolley Speed Travel 3.0 M/Minute +/- 5% 8 Cross travel speed 8.0 M/Minute +/- 5% Height of Crane 9 5 M above Sill 10 Type of Hook Eye hook Electrically operated outdoor Travelling 11 Type of Crane Gantry. 12 Duty Factor 1.2 as per IS 3177-1977 13 Power Supply AC 400/440 Volt, 3 Phase, 50 Cycles 14 Rope Falls 4 Nos. – 2 falls per drum)

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 59 O&M Manual for Malaprabha Dam December 2019 Table 14 – Technical Details of Important Machinery Items Sl. Item Description Make No 26mm.dia,6x36 construction fibre core, un-galvanised, ordinary BHARAT 1 Wire Rope lay wire ropes with designation of 1960 N/mm conforming to WIRE IS 2266-1977 ROPE TCFC, Crane Duty Slipring Induction Motor, reversible service CROMP- with shaft extension having 13.2 KW (17.5 HP) capacity at 40% 2 Hoist Motor TON CDF, 968 RPM, Class-B insulation, AC-3 phase 440/410V, 50 Hz GREAVES supply, frame size CDW-180-L POT/FLT = 2.75 Single phase, AC Electro Magnetic Brake, solenoid operated, spring set with hand release lever having brake drum dia as 250 IND CON- 3 E. M. Brake mm shoe of 108mm and braking torque of 2270 KgCm at 50% coil TROLS rating, ASM-25 Hydraulic ATM 25-18 type with Brake Drum of 250mm and braking torque IND CON- 4 Thruster brake of 2200 KgCm TROLS Worm Reducer, normal ratio 50:1 normal input rpm 1000 Type 5 Gear Box and size FU type, Size 10 HP Rating of Gear Box 19.5 HP output SHANTHI torque - 490 da Nm Plummer Block Plummer Block having SNA 522 with bearing No. 2222K adopter 6 and bearing for STD sleeve H-322, locating ring 2 FRR-13/200P 2nd Shaft Plummer Block Plummer Block having SNA 516 with bearing No. 2216K, Sleeve 7 and bearing for STD H-318, locating ring 2 FRB-12.5/ 130P 3rd Shaft TCFC, Slipring, Crane, Duty Motor having 2.2 K capacity at 40% CROMP- Motor for C.T 8 CDF, 855 rpm Class-8 working on 410/440\1, 3 phase, 50 Hz, TON Drive A.C. supply, frame size of Motor -112 GREAVES ASM-15, 150mm brake drum dia, solenoid operated, spring set, E.M. Brake for IND CON- 9 single phase, A.C. Electro Magnetic Brake having 650 KgCm C.T. Driver TROLS braking capacity @ 100% coil rating Plummer Block and Plummer block SNA 513 Tc with bearing No. 1213K with locating 10 bearing for STD ring 2FRB-14/120 Pinion Shaft. for C.T. Drive Bearing for SNA 516 - bearing 1216K adopter sleeve H316-2ring FRB 11 - Wheel shaft 16/140P. Wheel bearing Spherical Roller Bearing No.73026CC/width-52mm ID/OD- 12 NSK/NTN for L. T. drive 130/200mm 2 Nos. TCFC; Slipring Crane Duty Motor each having 4 KW @ CROMP- Motor for L. 13 40% CDF, 890 RPM, working on 415/440V, 3 Phase, 50 Hz AC TON- T. Drive Electric supply, Motor frame size-130M (ILT 2133-6) GREAVES E. M. Brake 150mm dia brake drum (flexible coupling type) 70mm shoe width, IND CON- 14 for ASM-15 single-phase, AC solenoid operated, spring set E.M Brake having TROL L.T. Drive breaking torque capacity of 850 KgCm @ 100% coil rating Reduction Ra- 15 tio for L.T. Two stage reduction box 300 HN NU-TECK Drive Bearing for Spherical Roller 2 Nos. deed groove ball bearing No.6014, width 16 L.T. Gear NSK-NTN 20mm ID/OD-70/110-mm. Wheel W 1 Worm reducer 17 Warm Reducer 60:1, Size 400 VCT NU-TECK for C.T. Drive

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2.6.3 Material Specifications Table 15 – Materials for 100-Ton Gantry Crane

Item Material Specification Rope Drum Cast Steel IS 1030 Gr.27-54 Gear Cast Steel IS 1030 Gr.27-54 Pinion Forged Steel IS 1875 Class-4 Drum Shaft Forged steel C 30 or En8 Wheel bearing No. - - Bronze Bushing Al-Bronze IS 305 Gr. AB-1 Floating Shaft M.S. IS 226 C.T. Wheel Cast Steel IS 1030 Gr.27-54 L.T.Wheel Cast Steel IS 1030 Gr.27-54

2.6.4 Operational Instructions Before the stoplogs are to be operated, the gantry crane should be brought in position so that it is directly over the gate groove. Lower the lifting beam until the hook of the lifting beam will engage the gate automatically as the lifting beam seats on the gate due to link mecha- nism. While lowering the stoplog, the stoplog seats on the sill beam, load on the lifting beam is released and it will disengage automatically due to counterweight and the link mechanism. The lifting beam is of automatic engaging and disengaging type.

The following Steps to be checked/inspected/ensured 1. All the gear and pinions to be lubricated with grease. 2. Ensure proper meshing of gear and pinion 3. Rope clamp to be checked and ensure that the same are properly fixed and tight. 4 All fasteners of hoist assembly should be checked for tightness. 5. E.M. Brake shall be checked for alignment and to be ensure that mechanically brake is ON when power supply is cut off and when power supply is ON the plunger will be operated and shoes will be open i.e., Brake is released electrically. 6. Traverse of rope to be checked. 7. All nuts, bolts and screws shall be checked for wear, tear and tightness. 8. To ensure that the lubricating oil of specified gravity and make should be filled to the de- sired level in worm reducer and gear box.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 61 O&M Manual for Malaprabha Dam December 2019 2.6.5 TROUBLE SHOOTING

2.6.5.1 Motor Table 16 – Troubleshooting for Motors TROUBLE CAUSES DIAGNOSIS 1. Motor fails to start A) No power A) Check power supply B) Single phasing of B) Check blown fuse or Power circuit dead line and re- place if necessary C) Single phasing of- C) Ensure that all finger Motor starter contact simultane- ously when closed. D) Tripping of over D) Ensure that the sys- load Protecting de- tem is not overload- vice as open circuit ed , if not try to of contracts close the protecting device 2. Motor Vibrators A) Ball Bearing dam- A) Replace the Bearings aged Indicated through Rattling noise of the Ma- chine during Run- ning 3. Motor slows down or stops A) Phase drop out A) Switch off and check and fuses replace if required 4. Fuses fail when motor starts A) Fuses too weak A) Replace with Cor- rectly rated fuses. B) Short circuit in Mo- B) check for short Cir- tor cuit and rewinding Nec- essary

2.6.5.2 E.M. BRAKE TROUBLE CAUSES DIAGNOSIS 1. Brake does not Hold A) Clearance of brake shoes A) Adjust with the help of Drum coupling to Machine with brake drum coupling feeler too much. B) Brake liner worn out B) Replace complete liner set. C) Fault solenoid coil. C) Replace the coil.

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2.6.5.3 Thrustor Brake TROUBLE CAUSES DIAGNOSIS Thruster Brake does not A) Less oil in cylinder A) Fill the required Quantities hold of oil B) Clearance of Brake B) Adjust the clearance with Shoes with Brake Drum the help of feeler gauge coupling too Much C) Brake liner worn out C) Replace complete liner set. D) Faulty solenoid coil D) Replace the coil.

2.6.6 Electrical Connections: Figure below shows the schematic layout details of the Electrical power connections for the Gates and the Switches. The PLCs /Gates were already wired. It is shown here as a continuity and relevance to the current project. The switches are connected in the following manner with the Group of three switches con- nected to each DB through a MCB The following figures show the Electrical connections in detail.

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Electrical Connection Layout

Main Power supply control Panel

Switch -1 Switch -2 Switch -3 Switch -4 Hoist Hoist Hoist Hoist Motor -1 Motor -2 Motor -3 Motor -4

Radial Radial Radial Radial Crest Crest Crest Crest Gate - 1 Gate - Gate - Gate - 4 3 2

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2.7 CCTV Arrangements

1. CCTV DO’S AND DON’TS DO’S:  Before use of the system read carefully all instructions and operational manuals  When you want to switch off the system first switch off all individual switches of the equipment and then switch off the sub MCBs and the Main MCB  When you switch on the system first switch on the Main MCB and after the Sub MCB and then individual switches of the equipment  Keep the equipment free of dust  Use dry cloth for cleaning f equipment

DON’TS  Never switch off the system only through the Main MCB

 Never switch on the system only through the Main MCB

 Don’t place anything on the operating console which might flow and fall inside of the equipment

 Don’t use liquid cleaner on the equipment

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Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 66 O&M Manual for Malaprabha Dam December 2019 2.8 RIVER OUTLET WORKS.

2.8.1 Description: Intake channel, intake structure, trash racks, closure method, upstream conveyance structure, gate chamber, downstream conveyance structure, control structure, stilling basin, exit channel, power sources, diversion during construction, bypass system).

2.8.1.1 RIVER SLUICE GATES: The Malaprabha dam is provided with 1 No of River Sluice Gates of size 6 M x 4 M in centre pier and Gantry Crane of 15 T capacity is commissioned for the operation of gate (i.e. Stop log or emergency gate).

2.8.1.2 HEAD REGULATOR: Head Regulator at Left bank and Right bank provided for MLBC and MRBC canal are provided. MLBC head regulator consists of 2 vents with gates of size 9 feet x 6 feet with one emergency gate of same size. MRBC head regulator consists of two vents with 2 gates of size 12 feet x 9 feet.

2.8.1.3 HEAD WORKS: a) MALAPRAHA LEFT BANK CANAL (MLBC): The MLBC head work is constructed on left bank of the dam. The head work is a framed structure. The jack well is rectangular type with canal bed level at 2032.00 Feet RL. The total length of MLBC canal is 150 Kms.

b) MALAPRABHA RIGHT BANK CANAL HEAD WORKS: The MRBC head work is constructed on right bank about 7 Km away from the dam near Jogulbhavi (upstream of dam, at right bank of the reservoir). The head work is a framed structure. The jack well is rectangular type with canal bed level at 2032.00 Feet RL. The total length of MRBC canal is 142 Kms.

2.8.2 Condition:

2.8.2.1 General: Above mentioned structures are in good conditions and water has been released at downstream side for irrigation and drinking purpose.

2.8.2.2 Deficiencies and problems. No deficiencies are noticed since commissioning.

2.8.2.3 Potential problems. No potential problems are not come across.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 67 O&M Manual for Malaprabha Dam December 2019 2.8.3 Historical Events. (Maximum releases to date, modifications, damage reports, examinations, etc,). Malaprabha Left Malaprabha Right Naragund

Bank Canal Bank Canal Branch Canal a) Length 150 142 48 ( Km) b) Capacity 1250 1500 750 ( cusecs) c) Area irrigated / con- 47769 121392 templated in hectares

The details of length of canals, discharge and area contemplated for 3 major canals un- der Malaprabha Dam is narrated below.

2.8.4 Operation:

2.8.4.1 General Water is released to the downstream command of Malaprabha as per the decision and discussion of Irrigation Consultation Committee through MLBC, MRBC, NBC and foreshore LIS for irrigation purpose as per the availability of water in the reservoir. The water required for drinking purpose is conserved.

2.8.4.2 Restrictions: There are no restrictions for operation of crest gates and as well as irrigation sluice gates as per water requirements from the downstream command area.

2.8.4.3 Mechanical: Radial Crest Gates and Irrigation Sluice Gates are operated by electrical power and incase of power failure, these gates can be operated through generators or manually.

2.8.5 References:

2.8.5.1 Reports and Data. 1) Malaprabha Project Report 2008

2.8.5.2 Drawings: 1) General Layout plan showing locations of Left & Right Head Works 2) Drawing of River Sluice is enclosed vide ANNEXURE -II.

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(Type of road, length, bridges, maintaining agency, etc.) Type of road : Asphalt road. Length : Gondi road 3.50 Km; Vatnal Road 3.50 Km; Main road from IB-1.8 Km.

Bridges : Nil Maintaining agency : Maintaining departmentally.

2.9.2 Condition: General: Road is in good condition

2.9.3 Deficiencies and problems Nil.

2.10 Record Keeping Operating a dam includes keeping accurate records of items pertaining to project operation. These include but not limited to the following:- 1. Rainfall and Reservoir Levels – On daily basis during non-monsoon and on hourly basis during monsoon. (see Chapters 2, 3 and 4 for detailed instructions and procedures) 2. Release through outlet/sluices on daily basis for irrigation, water supply, hydropower etc. 3. Outflows through spillway during monsoon on hourly basis. 4. Records of drawdown with reservoir levels, quantity of water released, drawdown rates, reason for drawdown. 5. Other Procedures – Maintain a complete record of all operating procedures for gates, sluices and remote-control operating system.

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Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 70 O&M Manual for Malaprabha Dam December 2019 CHAPTER 3 - PROJECT INSPECTIONS

The current practice of Inspection at Malaprabha dam envisages the Subdivision Officers to carryout pre-monsoon and post-monsoon inspections. The check list performa included in this chapter is currently in use at Malaprabha dam. Detailed description on project inspections is available in the Guideline for Safety Inspection of dams (Doc No. CDSO_GUD_DS_07_ v1.0), CWC 2018 (https://damsafety.in/ecm-includes/PDFs/Guidelines_for_Safety_Inspection_of_Dams.pdf). However an overview of the various types of inspections to be carried out at Malaprabha dam is given below. Note that for uploading Inspection Data into DHARMA, the Inspection Instructions & Forms given in the aforementioned Guideline for Safety Inspection of Dams must be used (see Appendix 5)).An effective inspection program is essential to identify problems and to keep Malaprabha Dam in a good and healthy condition This Chapter provides guidance on carrying out other inspections. 3.1 Types of Inspections Four different types of dam safety inspections are being carried out at Malaprabha Dam. These include, but not limited, to the following: 1. Comprehensive evaluation inspections 2. Scheduled inspections (Pre & Post monsoon inspections & other scheduled inspections) 3. Special (unscheduled) inspections 4. Informal inspections The frequency of each type of inspection depends on the condition of the dam and State DSO regulations, etc. Typical inspection elements and the detail of the safety inspections are provided below. More detailed descriptions are given in the ‘Guideline for Safety Inspection of Dams’ (CWC 2018). A checklist has been modified from the guideline to fit Malaprabha requirements and is found in Appendix 5. This comphrehensive checklist allows for recording the status of each item being inspected and the overall condition of the equipment along with any consequential risks the condition may have on the health of the dam.

3.1.1 Comprehensive Evaluation Inspections For comprehensive dam safety evaluation, an independent panel of experts known as Dam Safety Review Panel (DSRP) needs to be constituted for determining the condition of the dam and appurtenant works. The panel will undertake evaluation of the dam once in 10 years or on occurrence of any extreme hydrological or seismic event or any unusual condition of the dam or in the reservoir rim. The terms of reference of the comprehensive dam safety evaluation shall include but not be limited to; 1. General assessment of hydrologic and hydraulic conditions, review of design flood, flood routing for revised design flood and mitigation measures.  Review and analysis of available data of dam design including seismic safety, construction, operation maintenance and performance of dam structure and appur- tenant works.

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 Evaluation of procedures for operation, maintenance and inspection of dam and to suggest improvements / modifications.  Evaluation of any possible hazardous threat to the dam structure such as dam abutment slope stability failure or slope failures along the reservoir periphery. A comprehensive evaluation inspection of Malaprabha consists of five major parts: 1. Review of project records (i.e. study of all design / construction records/drawings, history of the dam’s performance, past inspection notes/reports, notes on distress observed/ any rehabilitation measures undertaken earlier, instrumentation data and its interpretation including . 2. Inspection of the dam and its appurtenant works. 3. To review the results and reports of additional field investigations & laboratory testing as required. 4. Review of design studies e.g. review of design flood, checking of the adequacy of spillway capacity, freeboard requirements, dam stability , any special study as required. 5. Preparation of a detailed report of the inspection.

3.1.2 Scheduled Inspections Scheduled inspections shall consist of Pre-monsoon & Post-monsoon inspection and any other inspections carried out by the State Dam Safety Organisation / any Expert panels constituted by the dam owner. These inspections are performed to gather information on the current condition of the dam and its appurtenant works. This information is then used to establish needed repairs and repair schedules, and to assess the safety and operational adequacy of the dam. Scheduled inspections are also performed to evaluate previous repairs. The purpose of scheduled inspections is to keep the dam and its appurtenant structures in good operating condition and to maintain a safe structure. As such, these inspections and timely maintenance will minimize long-term costs and will extend the life of the dam. Scheduled inspections are performed more frequently than comprehensive evaluation inspections to detect at an early stage any developments that may be detrimental to the dam. These inspections involve assessing operational capability as well as structural stability and detection of any problems and to correct them before the conditions worsen. The field examinations should be made by the personnel assigned responsibility for monitoring the safety of the dam. If the dam or appurtenant works have instrumentation, the individual responsible for monitoring should analyze measurements as they are received and include an evaluation of that data. Dam Inspection Report or an inspection brief should be prepared following the field visit (Dam Inspection Report is recommended). Scheduled inspections include the following four components as a minimum:

 File review of past inspection reports, monitoring data, photographs, maintenance records, or other pertinent data as may be required;

 Visual inspection of the dam and its appurtenant works;

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 72 O&M Manual for Malaprabha Dam December 2019  Preparation of a report or inspection brief, with relevant documentation and photographs. The report should be filed in the dam owner’s project files.

3.1.3 Special (Unscheduled) Inspections Special inspections may need to be performed to resolve specific concerns or conditions at the site on an unscheduled basis. Special inspections are not regularly scheduled activities, but are usually made before or immediately after the dam or appurtenant works have been subjected to unusual events or conditions, such as an unusually high flood or a significant earthquake. These inspections are to be carried out after an initial assessment based on informal inspection carried out by project personnel reveal dam safety related concerns like cracking in the dam, damages, erosion/ scour, undermining/ piping/ sink holes/ liquefaction or any such undesirable feature. A special inspection may also be performed during an emergency, such as an impending dam breach, to evaluate specific areas or concerns. They are also made when the ongoing surveillance program identifies a condition or a trend that appears to warrant a special evaluation. Special inspections should focus on those dam components that are affected by the unusual event and should include at least three elements: 1) review of relevant files or data, 2) visual inspection, and 3) report preparation. More detailed site investigations / studies may be required (such as drilling, surveys, or seepage flow estimates) if the special inspection reveals the need for the same. Photographic documentation is to be included as part of the inspection. Japan Water Agency (JWA) has developed a system of carrying out inspections after an earthquake event for Ichari Dam, Uttarakhand. For details refer “Inspection Manual for Dam Field Engineers after Seismic Events, Ichari Dam, Uttarakhand (CDSO_GUD_DS_0_v1.0, September 2017). The manual is available at the following link: https://damsafety.in/ecm- includes/PDFs/Inspection_Manual_for_Dam_Field_Engineers_After_Seismic_Eve nts.pdf.

3.1.4 Informal Inspections The last type of inspection, an informal inspection, is a continuing effort by on-site personnel (dam owners/operators and maintenance personnel) performed during their routine duties. Informal inspections are critical to the proper operation and maintenance of the dam. They consist of frequent observations of the general appearance and functioning of the dam and appurtenant structures. Operators, maintenance crews, or other staff who are posted at Malaprabha dam site conduct informal inspections. These people are the “first-line of defense” in assuring safe dam conditions, and it is their responsibility to be familiar with all aspects of the dam. Their vigilance in walking the dam, checking the operating equipment, and noting changes in conditions may prevent serious mishaps or even dam failures. Informal inspections are important and are performed at every available opportunity. These inspections may only cover one or two dam components as the occasion presents itself, or they may cover the entire dam and its appurtenant structures. The informal inspections are not as detailed as comprehensive evaluation, scheduled, and special inspections and will only require that a formal report is submitted to the dam owner’s project files if a condition is detected that

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 73 O&M Manual for Malaprabha Dam December 2019 might endanger the dam. Report is to be submitted detailing the condition discovered along with photographs, time, reswervoir water level (RWL), etc. 3.2 Pre- and Post-Monsoon Check list and Example of Report Performa Detailed check lists are required to ensure the health of the dam continues to operates in sat- isfactory and safe condition. Details of the inspection must be in alignment with the DHARMA approved checklist attached to this document (see Appendix 5).

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 74 O&M Manual for Malaprabha Dam December 2019 PRO-FORMA FOR PERIODICAL INSPECTION OF LARGE DAMS GENERAL Date of Inspection: ______Sl. Item of Inspection Remarks No. 1 1a 1b 2 3 1. Name of project Malaprabha Dam Project 2. Purpose of Project Irrigation and Drinking 3. Name of Dam MALAPRABHA DAM. 4. Year of Completion 1972-73 5. First filling (years / levels) 1972-73 Rl-2046.25 Feet 6. Benefits accrued: a) Irrigation Irrigation b) Water Supply Yes c) Power Nil d) Other benefits Nil

7. Important Controlling Levels ( in meters)

a) Top of dam 2090.00 Feet. b) Maximum Water Level 2079.50 Feet. c) Full Reservoir Level 2079.50 Feet d) Sill level of Irrigation sluices 2032.00 Feet. e) Sill level of River sluice Gate 2008.00 Feet f) Spillway crest level 2039.50 Feet. g) Minimum draw down level 2044.00 Feet. h) Lowest riverbed level 1958.00 Feet. 1948.50 Feet i) Deepest foundation level 1906.40 Feet in shear zone.

8. Important Salient Features

a) Dead Storage Capacity 3.385 TMC (at MDDL, 2032.00 Feet) b) Area of foreshore at F.R. L 13578 Ha. Design flood adopted c) (PMF / SPF / Any other) PMF-5038 Cumecs. Give relevant magnitude Design spillway discharge capacity and Ogee type Spill Way 5239 Cu- d) type of spillway mecs. 8 8a 8b 2 3

e) Type, number and size of spillway gates. RADIAL TYPE, 4 numbers of 15.24 Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 75 O&M Manual for Malaprabha Dam December 2019 m x 12.91 m (50 ft x 40 ft). Location, sill level and capacity of low level River Sluice 1 No; 1.22 m x 1.83 m (4 f) outlets and scouring sluices. ft x 6 ft) g) Height of the dam in meters. i) above deepest foundation 43.10 M ii) Above lowest river bed 40.23M h) Gross storages capacity in million cubic meters i) At F.R.L. 37.731 TMC ii) At M.W.L 37.731 TMC i) Length of the dam (at crest) in meters. 154.53 Mtr. 1) Chief Engineer, KNNL, Mal- aprabha Dam Zone Dharwad. 9. Name and designation of the inspecting officer 2) Superintending Engineer, KNNL,MLBC Circle ,Naviluteertha. 3) E.E.,MLBC Dn-2 Naviluteertha. Date of inspection and the corresponding reservoir 10. water level.

1) Chief Engineer, KNNL, Malaprabha Dam Zone Date of Inspection :

Dharwad. Reservoir Level: M

2) Superintending Engineer, KNNL, MLBC Circle, Date of Inspection :

Naviluteertha Reservoir Level: M

Date of Inspection: Reser- 3) E.E., MLBC Dn-2 Naviluteertha voir Level: M

Maximum: M ______Maximum and minimum water levels reached dur- Dt: ______11. ing the last season with dates Minimum: M______Dt: ______

Maximum overflow during preceding monsoon Max. outflow : cusecs ______12. with dates. Dt: ______: . History of past distress, if any, and brief details of 13. No such events observed. remedial measures carried out. Does the officer-in-charge of the operation and 14. maintenance of dam possess all the records as giv- en in the Annexure-I.

When and by whom the dam was inspected imme- 15. ------diately preceding this inspection?

Are the items pointed out during the last inspection 16. properly attended to? ------(If not state deficiencies yet to be corrected).

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 76 O&M Manual for Malaprabha Dam December 2019 REVISED PRO-FORMAT FOR HEALTH STATUS REPORT OF LARGE DAMS (Keeping in view CWC letter No. 627-56 dt. 28-08-2002)

Sl. Items of the Reply No. “Health Status Report”

1 Name of Dam Malaprabha Dam

Sl. No. in the National Register of Large Project Identification Code PIC 2 Dam KA06HH0089

3 Dam features

a) Date of Completion 1973.

Location

b) i) Longitude 760 21’ 0” East

0 ii) Latitude 15 10’ 0” North 43.10 Mtr. above the lowest founda- c) Height of Dam tion Gross Capacity 37.731 TMC ft. d) (Gated/Un gated) Gated Whether the Dam is provided with Provided with Drainage Gallery of e) Drainage Gallery or not. size 1.60 m X 2.40 m Type of Dam: Masonry Dam: Spillway: Gated spillway with 4 Nos of Radial Crest gates of size 15.24 m x 12.91 m. 4 Main Component of Dam Length of spillway dam-85.34 Mtr. Length of Left Masonry non- overflow Dam- 42.67 mtr. Length of Right Masonry non- overflow Dam- 26.52 mtr.

5 Date of Inspection

Chief Engineer, KNNL,Malaprabha 6 Inspecting Officer Project zone,Dharwad.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 77 O&M Manual for Malaprabha Dam December 2019

7 Observations/Significant Deficiencies Noticed

I Inadequate Spillway.

II Inadequate free-board

Cracks in Masonry / Concrete / III Earth Dam

Masonry/concrete dams a) and

Structural cracking in earth b) dams

IV Inadequate

a) Flood forecasting system

b) Flood warning system

c) Communication

V Excessive seepage through,

a) Drainage holes

b) Porous pipes

c) Downstream face of dam

d) Downstream area etc.

Development of high uplift e) pressure

VI Excessive leaching

VII Choking of porous drains.

VIII Choking of drainage holes

IX Mal-operation of gates

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 78 O&M Manual for Malaprabha Dam December 2019 Non-availability of standby/ alter- X native source of power Structural Review indicating ten- XI sion on the upstream face of dam

Non-availability of Emergency XII Action Plan.

8 Performance of Dam

Based on Instruments installed in the dam

(Water Level Recorder, V-notch, etc.,)

Of Meteorological Instruments installed in the catchment area and reservoirs of Dams.

Is the hydraulic performance in agreement

with the results of model studies?

Any other issue / issues pertaining to per- formance of dam which the Engineer-in-

Chief / Chief Engineer in-charge of dam desires to include. 9 Remedial Measures Suggested.

10 Remarks

11 Action Taken Report.

Assistant Exe Engineer , Executive Engineer Superintending Engineer Dam Sub Division , in-charge of dam. in-charge of dam.

Certified that the Health Status Report of MALAPRABHA DAM is furnished after a thorough review of the same by the technical wing of the zone (this has reference to pa- ra 18.3.5 of the Proceedings of 18th meeting of SLDSC).

Engineer-in-Chief / Chief Engineer in-charge of dam.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 79 O&M Manual for Malaprabha Dam December 2019

THIS PAGE LEFT BLANK INTENTIONAL

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 80 O&M Manual for Malaprabha Dam December 2019

APPENDIX-4 Performance of Dam Instruments

Sl. Name of Dam Name of Instrument No. of Instru- Performance Status of data Analysis Remarks No. with location ments

1 2 3 4 5 6 7 Separate Sheets Enclosed. (Vide Annexure-1)

Asst Exe Engr, Executive Engineer Superintending Engineer Engineer-in-Chief / Chief Engineer in-charge of dam. in-charge of dam. in-charge of dam in-charge of dam.

APPENDIX-7 Performance of Meteorological Instruments pertaining to Large Dams in Karnataka

Sl. Name of Dam with No. of In- Status of data Name of Instrument Performance Remarks No. location struments Analysis 1 2 3 4 5 6 7 Details to be furnished by WRDO Bangalore.

Engineer-in-Chief, Water Resources Development Organization, Bangalore.

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APPENDIX-9 Categorisation of Deficiencies (Keeping in view CWC letter No. 627-56 dt. 28-08-2002)

Category No.* Criteria for categorization

Category No. (1) Dams with major deficiency which may lead to dam failure

Category No. (2) Dams with rectifiable deficiency which needs immediate attention.

Dams with minor / no deficiencies has been noticed. Category No. (3)

* Category Number is to be furnished in the ‘remarks’ column of the Health Status Report.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 82 O&M Manual for Malaprabha Dam December 2019 CHAPTER 4 - PROJECT MAINTENANCE

A good maintenance program protects Malaprabha Dam against accelerating deterioration, prolongs its life, and greatly reduce the chance of failure. Nearly all the components of Malaprabha Dam and its materials are susceptible to damage and deterioration if not well maintained. Moreover, the cost of a proper maintenance program is small compared to the costs of major repairs, loss of life and property and litigation. Preventative maintenance not only protects the dam and its owner but the public as well. If maintenance of a dam is neglected the consequences and costs will multiply. Preventive maintenance assures that a dam and reservoir are in good working condition and prevents more harmful conditions from developing. Individual maintenance tasks are noted, with a description of the area where the maintenance is to be performed, the schedule for performing the tasks, and reporting procedures. Typical routine maintenance tasks performed includes mowing grass, removing vegetation, bushes and trees, removing litter and other debris, re-grading the crest and/or access roads, repairing fencing to keep livestock off the dam, etc. Other maintenance works that need to be performed on the embankment includes restoration of embankment to its design section, seepage problems, erosion, displaced riprap, cracking in embankment etc. In concrete / masonry dams there may be issues like cracking and disintegration in concrete, choking of drainage holes in dam body/ foundation, damages to spillway glacis/piers/energy dissipaters due to abrasion/ cavitation/unsymmetrical flows, damages to pointing on upstream & downstream faces of masonry dams, heavy seepages through some drains in foundation/inspection galleries etc. A basic maintenance program has been developed primarily based on systematic and frequent inspections. 4.1 Maintenance Priorities For Malaprabha Dam, maintenance activities require to be prioriitized as immediate maintenance or preventative maintenance.

4.1.1 Immediate Maintenance The following conditions are critical and call for immediate attention & reservoir lowering, if warranted. These conditions may include, but are not limited to:

 The dam is about to be overtopped or being overtopped during high flood.

 The dam is about to be breached by erosion, slope failure etc.

 The dam showing signs of piping or internal erosion indicated by increasingly cloudy seepage or other symptoms.

 The spillway being blocked or with some in operable gates.

 Evidence of excessive seepage appearing anywhere on the dam site, e.g.,the Embankment becomes saturated, defective water stops, etc., and seepage exiting on the downstream face is increasing in volume.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 83 O&M Manual for Malaprabha Dam December 2019 Although the remedy for some critical problems may be obvious (such as clearing a blocked spillway or repairing the spillway gates so that they are in working condition), the problems listed above generally demand the services of experienced engineers/expert panels familiar with the design, construction and maintenance of dams. The emergency action plan (EAP) should be activated when any of the above conditions are noted. Note also that the “blue” conditions of the EAP are also applicable during con-trolled release of floods through the spillway.

4.1.2 Preventive Maintenance This can be further classified as Condition based Maintenance and Routine Maintenance.

4.1.2.1 Condition Based Maintenance The following maintenance should be completed as soon as possible after the defective condition is noted. These includes but are not limited to:  Remove all vegetation and bushes from the dam and restoring any eroded areas and to establish a good grass cover.  Fill animal burrows.  Restore and reseed eroded areas and gullies on embankment.  Repair of defective gates, valves, and other hydro-mechanical equipment.  Repair any concrete or metal components that have deteriorated.  Cleaning of the choked drainage holes in the dam body/ foundations in concrete / masonry dams.  Repair any damages on spillway glacis, piers, energy dissipaters, training/divide walls, downstream areas etc.  Repairs on the upstream face of masonry dams, in case the pointing is damaged, due to which there is increased seepage.  Controlling any heavy seepage in the foundation/ inspection galleries in Concrete/Masonry dams from drainage holes.  Repairs of any cracks/cavities/joints in concrete/masonry dams/structures. However, many of these works will require the services of experienced engineers/expert panels.

4.1.2.2 Routine Maintenance Several tasks should be performed on a continuous basis. These include but are not limited to the following:  Routine mowing, restore and reseed eroded areas and gullies on downstream face of the left flank embankment and general maintenance including repairs/cleaning of surface drains on downstream face and in the downstream area.  Maintenance and treatment of any cracks/joints/ cavities in Concrete/Masonry dams and spillways based on the recommendations of experienced engineers / expert panels.  Observation of any springs or seepage areas, comparing quantity and quality (clarity) with prior observations in the embankment.  Monitoring of downstream development which could have an impact on the dam and its hazard category.  Maintenance of Electrical & Hydro-Mechanical equipment and systems e. g. Servicing of spillway gates & stop logs, hoisting arrangements, gantry crane, gates/hoist of outlet works/sluices & stand by generator.  Maintaining proper lighting at dam top, galleries, etc.  Monitoring of seepage in galleries.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 84 O&M Manual for Malaprabha Dam December 2019  Monitoring/ cleaning & removal of leached deposits in porous concrete / formed drains in dam body and foundation drainage holes.  Maintenance of all dam roads & access roads.  Operation of electrical and mechanical equipment and systems including exercising gates & valves.  To keep the gate slots clear of silt/debris.  Maintenance/testing of monitoring equipment (instruments) and safety alarms.  Testing of security equipment.  Testing of communication equipment.  Any other maintenance considered necessary. 4.2 Procedures for Routine Maintenance The O&M Manual includes detailed instructions and schedules for performing periodic maintenance works at the site. This include maintenance of the dam, the appurtenant works, and the reservoir areas. Methodology / Specifications for carrying out maintenance works of general & recurring nature should be included in the Manual. Dam repairs are scheduled based on severity of the problem, available resources, and weather conditions. For example, if a severe settlement problem (more than envisaged in designs) or cracking is detected on the crest of the dam, it should have a high priority since further degradation could lead to dam breaching. The causes of all major issues / problems should be identified and evaluated by experienced engineers/ Expert Panels so that appropriate remedial measures can be finalized. Correcting minor rill erosion on the downstream slope could be assigned a low priority since it is not a dam safety concern. This type of repair will also be weather dependent, since grass can only be planted during specific times of the year, and the embankment should be dry so that more damage is not inflicted to the embankment slopes.

4.2.1 Earthwork The surfaces of an earthen dam may deteriorate due to several reasons. For example, wave action may cut into the upstream slope, vehicles may cause ruts in the crest or slopes, trails left by livestock can result in erosion, or runoff waters may leave erosion gullies on the downstream slope. Other special problems, such as shrinkage cracks or rodent damage, may also occur. Damage of this nature must be repaired constantly. The maintenance procedures described here are effective in repairing minor earthwork problems. However, this section is not intended to be a technical guide, and the methods discussed should not be used to solve serious problems. Conditions such as embankment slides, structural cracking, and sinkholes threaten the immediate safety of a dam and require immediate repair under the directions of experienced engineers/Expert panels. The material selected for repairing embankments should be free from vegetation, organic materials, trash, and large rocks. If flow-resistant portions such as the core of an embankment dam are being repaired, materials that are high in clay or silt content should be used. If the area is to be free draining or highly permeable (such as pervious shell of an embankment dam) the material should have a higher percentage of sand and gravel. It is usually satisfactory to replace or repair damaged areas with soils like those originally in place. An important soil property affecting compaction is moisture content. Soils that are too dry or too wet do not compact well. One may test repair material by squeezing it into a tight ball. If the sample keeps its shape without cracking and falling apart (which means it is too dry), and without depositing excess water onto the hand (which means it is too wet), the moisture content is near the proper level. Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 85 O&M Manual for Malaprabha Dam December 2019 Before placement of earth, the repair area needs to be prepared by removing all inappropriate material. All vegetation, such as bushes, roots, and tree stumps, along with any large rocks or trash need to be removed. Also, unsuitable earth, such as organic or loose soils, should be removed, so that the work surface consists of exposed, firm, clean embankment material. Following cleanup, shape and dress the affected area so that the new fill can be placed and compacted in horizontal lifts to the level specified in the technical specifications. Also it must be properly keyed (benched) with the existing material for which proper construction practices ae carried out to “knit” the new fill in to the existing soils to ensure proper bonding. This can be accomplished by using the following simple procedures 1. Scarify the existing soil layer 2. Place new moisturized soils in loose layers up to 20 centimeters thick 3. Compact to required density at optimum moisture content (OMC) 4. Scarify compacted layer 10 centimeters 5. Moisturize the layer before placement of soils 6. Compact 7. Continue process until lines and grades are accomplished. Overbuild can be trimmed back to design lines and grades 8. Seed of turf the fill to minimize erosion processes 9. Water routinely to ensure turf root system is fully developed. Erosion is one of the most common maintenance problems at embankment structures. Erosion is a natural process and its continuous forces will eventually wear down almost any surface or structure. Periodic and prompt maintenance is essential to prevent continuous deterioration and possible failure.Turfing, free from weeds and deleterious materials, is an effective means of preventing erosion.Rills and gullies should be filled with suitable soil, compacted, and then seeded or turfed as necessary. Large eroded gullies can be slowed by stacking bales of hay or straw across the gully until permanent repairs can be made. Erosion is also common at the point where an embankment and the concrete walls of a spillway or other structure meet. Poor compaction adjacent to such walls during construction and later settlement can result in an area along the wall that is lower than the grade of the embankment.People often walk along these walls, wearing down the vegetative cover. Workable solutions include re-grading the area so that it slopes away from the wall, adding more resistant surface protection, or constructing steps.Steps can be provided / constructed at regular intervals along the length of the dam for going from downstream toe to the dam top. All vehicular traffic, except for maintenance, should be restricted from the dam. Paths due to pedestrian, livestock, or vehicular traffic (two and four-wheeled) are a problem on many embankments. If a path has become established, vegetation will not provide adequate protection and more durable cover will be required unless traffic is eliminated. Stones may be used effectively to cover such footpaths. Runoff often concentrates along embankment slopes where the hinge point on the crest is lower than the surrounding crest and runoff ponds in these low areas. The concentrated runoff flows downs the slope cutting the soils and forming rills and gullies resulting in loss of design lines and grades and affecting stability of the structure.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 86 O&M Manual for Malaprabha Dam December 2019 Controlling Vegetation Keep the entire dam clear of unwanted vegetation such as bushes or trees. Excessive growth may cause several problems:  It can obscure the surface of an embankment and not allow proper inspection of the dam.  Large trees can be uprooted by high wind or erosion and leave large voids that can lead to breaching of the dam.  Some root systems can decay and rot, creating passageways for water, leading to piping erosion.  Growing root systems can lift concrete slabs or structures.  Rodent habitats can develop undetected. All bushes/trees should be as far as possible removed by root to prevent re growth. The resulting voids must be backfilled with suitable, well-compacted soils. It is recommended to remove the plants/vegetation at their early stage to prevent or minimize their growing into big trees/bushes, etc. In cases where trees and bushes cannot be removed, the root systems should be treated with environmentally-friendly herbicides (properly selected and applied) to retard further growth. Concerned Government Agencies must be consulted for selection of appropriate herbicides & their use for control of vegetation on dam structures or any water bodies. Controlling Animal Damage Livestock are not allowed to graze on the embankment section of the dam. When soil is wet, livestock can damage vegetation and disrupt the uniformity of the surface. Moreover, livestock tend to walk in established paths and thus can promote erosion. The burrows and tunnels of burrowing animals (beaver, muskrat, groundhogs and others) weaken earthen embankments and serve as pathways for seepage from the reservoir. Large burrows found on the embankment should be filled by mud packing. This method involves placing vent pipe in a vertical position over the entrance of the den. Making sure that the pipe connection to the den does not leak, the mud-pack mixture is poured into the pipe until the burrow and pipe are filled with the soil-water mixture. The pipe is removed and more dry earth is tamped into the entrance. As per some US publications, the mud pack is generally made by adding water to 90% earth & 10% cement mixture until a slurry or thin cement consistency is attained. For bigger holes, bentonite coated stones can also be used. All entrances should be plugged with well-compacted earth and grassy vegetation re-established. Dens should be eliminated without delay. Different repair measures will be necessary if a dam has been damaged by extensive small or large rodent tunneling activity. The area around the entrance can be excavated and then backfilled with impervious material. This will plug the passage entrance to prevent water entry and saturation of the embankment. Controlling Ants and Termites (White Ants) Ants and termites have become one of the most serious pests for Embankment dams. They both need water to survive and have been found on most of the embankment dams in India. These insects can create problems in the dam itself and with any of its electrical components. In some habitats, ants and termites can move as much or more soil as earth worms, thereby reducing soil compaction. Nest galleries can penetrate in a V-shaped pattern below the nest, penetrating as much as more than one meter deep in the soil. These galleries can create pathways for surface water to penetrate in the dam, resulting in internal erosion and collapse of the surface.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 87 O&M Manual for Malaprabha Dam December 2019 Ants and termites left undisturbed can build mounds that can become quite large. These can create problems for mowing. However, frequent mowing can induce the colonies to migrate to neighboring, undisturbed areas. There are many options for managing ants and termites. Use only pesticides labeled as suitable for the location you want to treat. Make every effort to avoid contaminating water with pesticides and ensure . Controlling Damage from Vehicular Traffic As mentioned earlier, vehicles driving across an embankment dam can create ruts in the crest if it is not surfaced with roadway material and sometimes even when sealed with flexible pavement, especially when the embankment is saturated and overweight trucks use the road. The ruts can then collect water and cause saturation and softening of the dam. Other ruts may be formed by tractors or other off-road vehicles such as motorbikes are allowed to drive up and down the embankment face; these can direct runoff resulting in severe erosion. Vehicles, except for maintenance, are restricted on the dam top and kept out by fences or barricades. Any ruts should be repaired as soon as possible. .

4.2.2 Masonry / Concrete Dams & Spillways Various issues/problems that may require maintenance/repairs on the Malaprabha Concrete/Masonry Dam and Spillway include but not limited to:  Damages on spillway glacis, spillway piers, training/divide walls, energy dissipaters, downstream areas (probable causes are cavitations’, abrasion, un-symmetrical flows, unfavorable down-stream conditions)  Vegetation growth in unattended areas such as spillway, spillway channel, etc.  Seepage in the galleries and on the downstream face of the dam.  Cleaning and removal of leached deposits from choked porous and foundation drains.  Repair to upstream face of masonry dams in case the pointing is damaged, leading to increased seepage.  Ensuring safe access to and within the gallery, lighting is also required as well as all outside areas during the evening hours.  Ensuring the dam is behaving as designed based on instrumentation programs.  Periodic maintenance should be performed of all concrete surfaces which are ap- proachable to repair deteriorated areas. For remedial measures of problems of special nature advice of experienced engineers /Panel of Experts needs to be obtained

4.2.3 River Sluices The sluices should be inspected thoroughly once a year for any damages such as cracks and seepage. As regards to Hydro-mechanical works, reference may be referred to the appropriate paragraphs in this chapter.

4.2.4 Gates & Hoisting Equipment The safe and satisfactory operation of Malaprabha Dam depends on proper operation of its Gates &Hoisting Equipment. Maintaining spillway gates in working condition is critical for dam safety and is to be assigned the highest priority. If routine inspection of the Hydro-Mechanical Equipment shows the need for maintenance, the work should be completed as soon as possible. The simplest procedure to ensure smooth

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 88 O&M Manual for Malaprabha Dam December 2019 operation of gates is to operate them through their full range at least once, and preferably twice annually (before monsoon & after monsoon keeping a gap of at least six months). Because operating gates under full reservoir pressure can result in large discharges, exercising of gates should preferably be carried out during dry conditions or lean times of the year using the stop-logs/ emergency gates. Commonly used Gates and Hoists including their inspection / maintenance requirements are discussed below. The aspects to be inspected and maintained periodically for ensuring proper operation of these gates are as under: i) The gate slot and bottom platform/sill beam should be cleaned periodically. Scales formed over the embedded parts should be removed. Second-stage concrete should be checked for any development of cracks / leakages and repairs should be attended to immediately. ii) 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. All drain holes provided in the gate assembly should be cleaned. iii) Rubber seals should be smoothed, if required, for proper alignment. All nuts and bolts fixing the seal to the gate should be tightened uniformly to required torques. Seals, if found damaged or found leaking excessively should be adjusted, repaired or replaced as considered necessary. iv) The wheel shall be rotated to check their free movement. Gate roller bearings and guide roller bushes should be properly lubricated. Whenever necessary these should be opened for rectifications of defects, cleaning and lubrication and should thereafter be refitted. These may be replaced if repairs are not possible. v) Hoisting connection of the gate leaf should be lubricated where necessary and defects if any should be rectified. vi) All nuts, bolts, check nuts and cotter pins of the lifting devices should be checked periodically. vii) All components should be greased and lubricated. Recommended and approved oils and grease only should be used. viii) 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. ix) Where filling valves are provided as part of the gate structure, all the nuts, bolts, check nuts etc. should be tightened. x) All welds shall be checked for cracks/ damages. Any weld that might have become defective should be chipped out and redone following the relevant codal provisions. Damaged nuts, bolts, rivets, screws etc. should be replaced without delay. xi) The filling-in valves allow passage of water when it is lifted by lifting beam & crane due to creation of space between stem seat and exit passage liner. The springs and associated components should be checked periodically for damages and replaced if necessary. xii) The guide-assemblies, wheel-assemblies and sealing-assemblies shall be cleared off grit, sand or any other foreign material. xiii) The wheel pin shall be coated with corrosion resistant compound.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 89 O&M Manual for Malaprabha Dam December 2019 xiv) All nuts and bolts shall be tightened. The aspects to be inspected and maintained periodically for ensuring proper operation of these gates are as under : a) Rubber Seals: i) 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. However, measures like tightening of bolts are carried out. Further adjustment is carried out during annual maintenance. ii) If leakage is excessive & immediate repair is considered necessary, the stop log gates shall be dropped and seals repaired or replaced. NOTE: - During monsoon period, stop log gates shall NEVER be lowered in spite of heavy leakage through seals. b) Trunnion block assembly and 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 not. If not, cover it with mild steel plates. (iv) Cover the trunnion pin with anti- corrosive jelly. (v) 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) Gate structures: i) Check all the welds for soundness and rectify defects. ii) Check welds between arms and horizontal girders as well as between latching bracket and skin plate with the help of magnifying glass 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. Replace damaged ones. v) Check upstream face of skin plate for pitting, scaling and corrosion. Scaling may be filled with weld and grinded. Corroded surface shall be cleaned and painted. d) Embedded Parts: 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. e) General Maintenance: i) Defective welding should be chipped out and it should be re-welded duly following the relevant codal provision (IS: 10096, Part-3). ii) Damaged nuts, bolts, rivets, screws etc. should be replaced. iii) Any pitting should be filled up by welding and finished by grinding if necessary.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 90 O&M Manual for Malaprabha Dam December 2019 iv) 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. v) Trunnion bearing should be greased as and when required. Keeping trunnion bearings in perfect working condition is very important. All other bolted connections should also be checked up for proper tightness. vi) Bolts and trunnion bearing housing should be tightened wherever required. vii) The seals of the gate should be checked for wear and tear and deterioration. These should be adjusted/replaced as and when necessary. viii) The wall plates, sill beams shall be checked and repaired if necessary. ix) Wire ropes should be properly lubricated. x) 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. xi) The stroke of the brake should be reset to compensate for lining wear. Worn out brake linings should be replaced in time. xii) Flexible couplings should be adjusted if required. xiii) Repairs and replacements of all electrical relays and controls should be attended to. xiv) Maintenance of alternative sources of Power such as Diesel Generating sets and alternative drives wherever provided should be carried out. xv) 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.

4.2.5 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 brake and other electrical equipment. c) The aspects to be inspected and maintained periodically for ensuring proper operation of Rope drum hoists are as under; i. Entrance to all hoist platforms shall be kept locked. All keys shall remain with the shift supervisor. ii. A cursory daily inspection shall be made of hoist and gate to ensure that there is no unusual happening. iii. Clean all hoisting equipment and hoist platform. iv. Check oil level in gearboxes and replenish as and when required with oil of proper grade.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 91 O&M Manual for Malaprabha Dam December 2019 v. Apply grease of suitable grade by grease gun. vi. Lubricate all bearings, bushings, pins, linkages etc. vii.Check all the fuses on the power lines. viii.All bolts and nuts on gear boxes, hoist drum and shaft couplings should be checked for tightness. ix. Check the supply voltage. x. 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. xi. All the geared couplings shall be greased. xiii. Raise and lower the gate by hoist motor and check for smooth, and trouble free operation of gate without excessive vibration. xiv. 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. xv. Check the condition of painting of various components and remove rust wherever noticed and repaint the portion after proper cleaning as per painting schedule. xvi. All trash, sediments and any other foreign material shall be cleared off the lifting rope and lifting attachment. xvii. All ropes shall be checked for wear and tear and if broken wires are noticed, the rope shall be replaced. xviii. All the wire ropes shall be checked and all visible oxidation shall be removed. xix. All wire ropes shall be greased with cardium compound. xx. Check the overload relays for proper functioning. xxi. 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. xxii. Check the pulleys, sheaves and turn-buckles. xxiii. 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. xxiv. Adjust the rope tension of wires if unequal. xxv. Check for all gears and pinions for uneven wear and adjust for proper contact. Grease the gears. Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 92 O&M Manual for Malaprabha Dam December 2019 xxvi. Repaint the hoist components, hoisting platform and its supporting structures as per requirement. xxvii. The periodic maintenance of commercial equipment like motors, brakes, thrusts etc. shall be carried out as per manufacturers operation and maintenance manual. 2.00. Maintenance of Electrical components of Fixed Rope Drum Hoists: a). The electrical components to be inspected and maintained periodically are as under; i) Starters should be cleaned free of moisture and dust. ii) Each individual contactor should be tried by hand to make sure that it operates freely. iii) All wearing parts should be examined in order to take note of any wear which may have occurred during operation. iv) If the contactor hums, the contact faces should be cleaned. (v) Examine all connections to see that no wires are broken and no connections are loose. vi) 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. vii) 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. viii) The contact tips should be kept free from burns or pits by smoothening with fine sand paper or emery paper. ix) Replace the contact tips which have worn away half-way. x) Do not lubricate the contacts. xi) 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. xii) Examine earth connections and motor leads. xiii) Examine motor windings for overheating xiv) Examine control equipment’s xv) Examine starting equipment for burnt contacts xvi) Check and tighten all nuts and bolts xvii) Clean and tighten all terminals and screw connections all contact surfaces shall be made clean and smooth. xviii) Lubricate the bearings xix) Overhaul the controllers xx) Inspect and clean circuit breakers. xxi) Wipe brush holders and check bedding of brushes. xxii) Blow out windings thoroughly by clean and dry air. The pressure shall not be so high that insulation may get damaged.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 93 O&M Manual for Malaprabha Dam December 2019 xxiii) Check the insulation resistance of the motor between any terminal and the frame. If the measured resistance is less than the prescribed 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. WARNING: The complete motor shall never be put in an oven for drying as that may melt the grease out of bearings. xxiv) Coat the windings with an approved high temperature resisting insulation enamel or varnish. xxv) Over haul the motor, if required. xxvi) Check the switch fuse units and renew, if required. xxvii) Check resistance or earth connections. xxviii) Check air gap. b) Solenoid Operated Brakes i) All fixing bolts shall be checked and tightened at least once in three months. ii) The magnet stroke should be reset to compensate for wear. iii) Re-adjust the brake when the magnet stroke reaches the value given on the instruction plate. iv) Brake lining should be checked and replaced when required. v) Examine all electrical leads and connections. vi) Rubber bushes or couplings should be checked and replaced if defective. vii) The pins should be tightened. viii) Brake drum shall be cleaned to remove any dust or grease. Stop logs, lifting beam & gantry crane 3.0 Spillway Stoplogs, Lifting Beam & Radial Gate A. MAINTENANCE OF STOPLOGS

a. Regular Maintenance 1. For gear and pinion, grease or lubricating compound shall be frequently used for the smooth operation 2. Wire Rope should be kept lubricated on regular basis with cadmium compound. 3. Damaged nuts, bolts etc. should be replaced 4. Oil level in the gear box and worm reducer should maintained. 5. Electromagnetic brake should be checked regularly and plunger to be cleaned dry to ensure proper functioning. The break shop to be cleaned.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 94 O&M Manual for Malaprabha Dam December 2019 b. Periodical Maintenance 1. Wire Rope should be examined for rusting, broken strands etc. and the wire rope at both the ends of the gate should have equal initial tension. 2. All nuts, bolts and screws shall be checked for wear, tear and tightness 3. Drain oil from gear box once in every 6 months and replace with relevant grade. 4. Ensure proper meshing of gear and pinion. 5. Location and adjustment of guide shoe should be checked. 6. Check E.M. Brake and thruster brake properly functioning. 7. All the moving parts should be properly lubricated. 8. The fuses are to be checked and replaced when they are worn-out. Replacements of fuses are necessary when they emit smell or get over heated. Care should be taken to select the correct size of fuses. B. MAINTENANCE GANTRY CRANE Hoisting trolley of the Gantry cranes is built on top of a wheeled mobile gantry structure travelling over fixed rails and is used to straddle an object or load over a workspace. Following aspects need to be considered and attended to during maintenance; 1. Oil level in the gear boxes. It is very important to ensure that the correct oil level is maintained. Over filling causes overheating and leakage, therefore, care should be taken that the breather holes are not clogged by any foreign material like dust, paint etc. 2. The insulation resistance of motor windings. In case it is found to have dropped below a prescribed value, the motor should be dried prior to putting back in service. If weak insulation becomes a regular feature, the winding should be given a good coat of insulating varnish after the motor has been dried. 3. Checking of all the electrical connections. 4. Lubrication of each part of crane 5. Removal of any loose/foreign material along the rail track 6. Actuating tests of limit switches 7. Actuating tests of brakes. 8. All fuses in the control panel should be checked and if necessary, it should be replaced. 9. Necessary terminal connections of motors, brakes etc. is to be checked. 10. Overload relay should be checked. 11. Visual inspection of wire ropes for any snapped loose wire and its proper lubrication. 12. Checking of rope clamps on the drum and tightening of bolts if required. 13. Gearbox assembly should not have any leakage of oil. 14. Unusual noise/vibration if any should be checked and rectified before operation.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 95 O&M Manual for Malaprabha Dam December 2019 C. MAINTENANCE OF MOTOR Motors shall be blown out at regularly intervals to keep its ventilating passage clear, particu- larly when operating in dirty atmosphere. Moisture, oil, dirt, grease and carbon or metallic dust are the principal causes of break down. The motor therefore be kept clean and dry and must be kept free from oil and greases, damp and dirt, periodical cleaning with dry compressed air with a brush is necessary. The motor required be examining and dismantling from time to time and frequency of ser- vice cleaning will depend upon the conditions under which the motor operates. During peri- odical cleaning care shall be taken to clean air passage in the starter and motor of any accu- mulated dirt. Terminals and screw connections shall be kept clean and tight. If they become dirty or cor- roded, they shall be disconnected and all contact surfaces made clean and smooth. Bad con- tact leads to sparking and ultimate breakdown.

D. LUBRICATION AND MAINTENANCE OF REDUCTION GEAR UNIT 1.Satisfactory performance of grease required that the lubricating oil kept be clean, and free from dirt, grit, moisture and sludge. Depending upon operating conditions the oil eventually becomes contaminated and should be drained periodically. During operation the oil level should be periodically checked, too high-level results loss of power and oil leakage, too low oil results in friction in bearings and on gear teeth causing overheating. Use proper graded oil. 2. Oil level should be checked with the help of dipstick or the oil indicator and should be topped up, if necessary. 3. Where the bearings of the unit are greases lubricated, the same should be filled with the top of grease gun. 4. Care should be taken that the breather holes are not clogged by any foreign materials, like dust, paint etc. 5. During cleaning gear casing should be flushed with the same sort oil that is used under working Conditions. If encasing is opened for cleaning all sealing compound must be re- moved.

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E. LUBRICATION CHART PART LUBRICATION FOR FREQUENCY 1. Hoist Brake Hand oiled points One in a month Fulcrum pins 2. Long travel Hand oiled points One in a month Brake fulcrum Pins 3. Motors: Hoist Long travel End Bearing Replace once in six Months and renew Once in a year. 4. Long travel Grease Nipples Repack once in Six Shaft Plummer Blocks Months and renew Once in a year. 5. Gear Boxes Gear Boxes Check oil level once A month and top up As necessary. 6. Pinion & Gear Gears & Pinions Every 3 Months. Wheels 7. Wire Rope Full Wire (Cardium Compound) Every year preferably before onset of Monsoon

F. MAINTENANCE OF BEARING Like all other important machine components ball and roller bearings must occasionally be cleaned and examined. In many cases it is permissible to let the bearing run for considerable / longer time before carrying out inspections, especially the conditions of the bearings can be ascertained, during service for example, by listening to the sound produced during running, checking the tem- perature of noting the colour of the lubricant. While spirit good quality paraffin, petrol or benzene may be recommended as suitable for cleaning roller bearings. Bearing should not be allowed to stand dry for any length of time after they have cleaned out, should be oiled and greased immediately when this is done, the bearings should be rotated several times to that oil or grease can reach all vital parts and thereby protect the bearings from rust. For sheaves, oiling the bearing at frequent interval and checking that they rotate freely must be done. A seized-up sheaves may ruin a rope very speedily. Care should be taken to see that the rope does not foul in flat against any obstacle in its way.

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G. MAINTENANCE OF WIRE ROPE Frequently the inspection of the entire length of rope is necessary. Watch constantly for bro- ken wires, excessive wear and lubrication, see that the number of broken wires does not ex- ceed as laid down in different regulation. Prompt attention must be given to a broken wire in a rope otherwise damage to other wires and serious accidents may results. Cleaning wire rope with brush or compressed air and giving it a light coating of special wire rope dressing is essential. This lubricant puts a protective film on each individual wire, repels water and stops corrosion.

H. CHECK FOR THE TIGHTNESS OF THE BOLTS 1. Fixing bolts of motor and reduction gears. 2. Plummer Block base Bolts. 3. Bolts of all Coupling. 4. Inspect the keys in the Couplings for its correct position once in every six months. 5. The wire Rope and is fixed over the winding drum by weans of clamps and bolts. These are to be checked for its tightness periodically. ADDITIONAL MAINTENANCE ITEMS FOR STOPLOGS The stop log units being in pieces, the top non-interchangeable unit with unique features as well as the other interchangeable units are stored in the grooves in various spans / bays. The following aspects are to be considered and attended to during maintenance: 1. Defective / damaged / cracked welding should be cutout and re-welded. 2. Damaged nuts, bolts, screws etc. should be replaced. 3. The gate leaf should be thoroughly cleaned and repainted whenever necessary 4. Rubber seals should be ground, if required to bring it in to alignment. All nuts and bolts for fixing seals to gate should be tightened uniformly. Seals when damaged or found leaking excessively should be adjusted or replaced as and when considered necessary. 5. All components should be greased and lubricated with the recommended oil and grease only. 6. The roller assembly should be adjusted by the eccentricity provision to ensure that all the rollers rest uniformly on track plates particularly in the closed position of the stop log gate. 7. The drain holes in horizontal girders should be cleaned. 8. It should be ensured that no bearing is overheated. 9. The gate slots should be kept cleaned. The scaling over the embedded parts should be removed. Since normally the stop logs remain in hanging position, for any routine maintenance, these are required to be raised up to the top of pier or deck level to rest on the dogging beam with the help of the gantry crane and lifting beam. Thereafter, if required, it is further raised at a slow speed from safety point of view, it is to be ensured that these units do not foul or hit

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 98 O&M Manual for Malaprabha Dam December 2019 legs / columns of the gantry crane. Thereafter, the gate can be rested on the deck level for necessary maintenance, servicing, repairs or replacement of its component parts. After com- pletion of maintenance, the stop log units are shifted back to their original dogged position. I. LIFTING BEAM Lifting beam is used for both raising & lowering of Spillway stop log units with the use of Gantry crane. Lifting Beam shall mainly comprise of two number structural steel channels or fabricated channels with back to back connection to make it a single fabricated structural frame. Two side guide rollers/shoes shall be provided on each side of the lifting beam. The depth of lifting beam /frame should be sufficient to accommodate to rollers on each side lo- cated at sufficient distance from one another to enable proper guided movement. The depth of lifting beam shall not be less than one tenth of the length / span of the lifting beam or 500 mm whichever is more. Lifting beam hook mechanism shall provide for automatic engagement and release of the equipment to be handled manually by movement of the hook block. The two hooks shall be mechanically linked together for simultaneous operation. All rotating parts of the lifting beam shall be provided with corrosion resistant steel pins and aluminum bronze bushing /roller bearings. All nuts, bolts and washers and retaining devices for pins shall be of corro- sion resistant steel. Following issues need to be considered and attended to during maintenance; 1. Bush bearing of lifting attachment and various pulleys /sheaves wheel gears etc. should be properly lubricated. 2. Whenever it is felt that friction in the bearing has increased, these should be taken out for cleaning and lubrication and should be refitted properly. These should be replaced, if found beyond repair. 4.5 Surface Preparation and Painting of HM Works i) Protection of painted surfaces is considered essential for protection & enhancement of service life. Gates, their embedded parts, gate leaf, hoists and its supporting structures need to be protected against corrosion due to climatic condition, weathering, biochemical reaction and abrasion etc. This equipment is likely to deteriorate or get damaged to any extent that the replacement of parts may become necessary and such replacement may become difficult and costly. ii) Surface preparation & Painting requirements: Painting for hydro-mechanical works is to be carried out as prescribed in IS 14177 for both newly manufactured as well as old & used gates, hoists and associated works after proper surface preparation. The preparation includes thorough cleaning, smoothing irregular surfaces, rusted surfaces, weld spatters, oil, grease, dirt, earlier applied damaged layers of primers/ paint by use of mechanical tools, by use of solvents, wire brush etc. The sand / grit blasting process is used for surface preparation to a level of Sa 2½ of the Swedish standard. iii) Surfaces not requiring painting & their protection during surface preparation, painting & transportation process: a) The following surfaces are not to be painted unless or otherwise specified: • Machine finished or similar surface • Surfaces which will be in contact with concrete • Stainless steel overlay surfaces.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 99 O&M Manual for Malaprabha Dam December 2019 • Surfaces in sliding or rolling contact • Galvanized surfaces, brass and bronze surfaces. • Aluminum alloy surfaces

b) The Surfaces of stainless steel, nickel, bronze and machined surface adjacent to metal work being cleaned or painted shall be protected by using sticky protective tape or by other suitable means over the surfaces not to be painted. c) All embedded parts which come in contact with concrete shall be cleaned as detailed above and given two coats of cement latex to prevent rusting during the shipment while awaiting installation. iv) Application of primer &finish coats on embedded parts and gates: a) EMBEDDED PARTS: • The prescribed primer shall be applied as soon as the surface preparation is complete and prior to the development of surface rusting and within the specified time prescribed by Indian Standards or the Paint Manufacturer. In case there is lapse of considerable time beyond the prescribed time limit, the surfaces shall be again cleaned prior to priming. • Two coats of zinc rich primer with epoxy resin shall be applied to all embedded parts surfaces which are not in contact with concrete and shall remain exposed to atmosphere or submerged in water to obtain a dry film thickness of 75 microns. • This shall be followed by three coats at an interval of 24hours of coal-tar blend epoxy resin so as to get a dry film thickness of 80 microns in each coat. Total dry film thickness of paint shall not be less than 300 microns. b) GATES: Primer Coat: • Over the prepared surface one coat of inorganic zinc silicate primer giving a dry film thickness of 70 ± 5 microns should be applied. Alternatively two coats of zinc rich primer, which should contain not less than 85% zinc on dry film should be applied to give a total dry film thickness of 75 ± 5 microns. Finished paint: • Two coats of solvent less coal tar epoxy paints. These shall be applied at an interval of about 24 hours. Each coat shall give a dry film thickness of 150±5 microns. The total dry film thickness of all the coats including primer coating shall not be less than 350 microns. v) Hoist and supporting structure: a) Structural components: Primer coats of zinc phosphate primer shall be applied to give a dry film thickness of 40±5 microns. Final Coats: One coat of alkalized based micaceous iron oxide paint to give a dry film thickness of 65 ± 5 microns followed by two coats of synthetic enamel paint confirming to IS 2932 – 1974 to give a dry film thickness of 25 ± 5 microns per coat. The interval between each coat shall be 24hours. The total dry thickness of all coats of paint including the primer coat shall not be less than 175 microns. Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 100 O&M Manual for Malaprabha Dam December 2019 c) Machinery: Except machined surfaces all surfaces of machinery including gearing, housing, shafting, bearing pedestals etc., shall be given: Primer coats: One coat of zinc phosphate primer paint to give minimum film thickness of 50 microns. Motors and other bought out items shall be painted if necessary. Finished coats: The finished paint shall consists of three coats of aluminum paint confirming to IS2339 – 1963 or synthetic enamel paint confirming to IS 2932 – 1977 to give a dry film thickness of 25±5 microns per coat to obtain a total minimum dry film thickness of 125 microns.

Photo 1 – MLBC Canal Regulator Gate with epoxy paint Applied

d) Machined surfaces: All machined surfaces of ferrous metal including screw threads which will be exposed during shipment or installation shall be cleaned by suitable solvent and given a heavy uniform coating of gasoline soluble removable rust preventive compound or equivalent. Machined surfaces shall be protected with the adhesive tapes or other suitable means during the cleaning and painting operation of other components. vi) Application of paint: Mix the contents thoroughly as directed by paint manufacturer before and during use. Painting at shop can be done by any of the three methods namely Brush / roller, Conventional spray, Airless spray etc. The paint can be made to suit the adopted method. But once the gate and equipment is in erected position the general method adopted is only brush / roller. In case of spray lot of precautions are to be taken.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 101 O&M Manual for Malaprabha Dam December 2019 For More details: Refer IS: 14177 Part (II) – 1971. Appendix A – Brushing of paint Appendix B – Spraying of paint Appendix C – Spray painting defects: Causes and remedies. Removal of old paint / rust and carrying out fresh painting: The carrying out of fresh painting is to be considered under the following conditions: • The rusting is noticed all over the surface or • Rusting is severe or • Cracking and blistering has damaged the primer coat exposing the metal and is noticed all over the surface or • The paint film has eroded badly, the scrap of entire paint film to the base metal and carry out fresh painting. Note: In case of maintenance and renovation: Refer IS 14177 (Part II) – 1971 for checking and repainting. vii) Removal of old paint for repainting: Caution should be exercised while removing the old paint. The surfaces shall be de-rusted and descaled by either mechanically by one or more of the methods, namely: a) Wire brushing, Scraping, and chipping. Sand papering or cleaning with steel wool or abrasive paper b) Power tool cleaning c) Flame cleaning d) Sand blasting or shot blasting and e) Chemical rust removal. Note: The method of application shall be decided based on conditions existing. After cleaning painting is to be carried out as originally proposed. Some are painted without removal of old paint and rusting this will amounts to no painting and deteriorate faster than the original one. viii) Inspection and testing of painting of H. M works: a) The following steps are involved in inspection of painting:  General inspection before and during painting  Viscosity test of paints  Paint thickness test – using Elco-meter.  Inspection of general appearance of finished work. b) General: The aim of inspection and testing is to ascertain whether the recommended practice is being employed correctly during every stage of application and whether the final results fulfill the object of painting. Any test carried out should be of non – destructive nature or, if it is of destructive nature, it should be either restricted to areas which can be restored without marring the general appearances or be such that it is possible to restore easily without necessitating a complete repetition of the work.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 102 O&M Manual for Malaprabha Dam December 2019 c) Inspection of surfaces prior to painting: Inspection methods will depend on whether it is to be painted for the first time or is to be repainted. d) New Works (Not previously painted): The following shall be decided by inspection:  The method of pre cleaning feasible or recommended;  The intermediate protective treatments to be applied, if found necessary;  The final painting schedule and the specifications for the paint for ensuring the particular performance;  The method of application, whether by brush, roller or spray. e) Old Work (Which requires repainting): The following shall be decided by inspection:  Whether the entire existing paint requires removal; and/or  Whether repainting without paint removal would be adequate.

4.3 Electrical System Electricity is typically used at a dam for lighting and to operate the gates, hoists, recording equipment, and other miscellaneous equipment. It is important that the Electrical system be well maintained, including a thorough check of fuses and a test of the system to ensure that all parts are properly functioning. The system should be free from moisture and dirt, and wiring should be checked for corrosion and mineral deposits. All necessary repairs should be carried out immediately and records of the works kept. Maintain generators used for auxiliary emergency power -- change the oil, check the batteries and anti-freeze and make sure fuel is readily available. Monitoring devices usually do not need routine maintenance. Open areas are particularly susceptible to vandalism. As such all electrical fittings like bulbs, lights, loose wires etc. in open areas should be checked routinely andreplaced / repairedwhere needed. The recommendations of the manufacturer should also be referred to.

Photo 2- Maintaining the CCTV Camera located on the dam upstream side.

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4.4 Maintenance of Metal Gate Components All exposed, bare ferrous metal of an outlet installation, whether submerged or exposed to air, will tend to rust. To prevent corrosion, exposed ferrous metals must be either appropriately painted (following the paint manufacturer’s directions) or heavily greased in respect of moving parts & on surfaces like guides & track seats on which there is movement of gates. When areas are repainted, it should be ensured that paint is not applied to gate seats, wedges, or stems (where they pass through the stem guides), or on other friction surfaces where paint could cause binding. Heavy grease should be applied on friction surfaces to avoid binding. As rust is especially damaging to contact surfaces, existing rust is to be removed before periodic application of grease. 4.5 Access Roads For a dam to be operated and maintained, there must be a safe means of access to it at all times. Access road surfaces must be maintained to allow safe passage of automobiles and any required equipment for servicing the dam in any weather conditions. Routine observations of any cut and fill slopes along the sides of the road should be made. If unstable conditions develop assistance of experienced Engineers/Expert Panels should be obtained and remedial measures initiated. Drains are required to be provided and maintained along roads to remove surface and subsurface drainage. This will prolong the life of the road and help reduce deterioration from rutting. Road surfacing should be repaired or replaced as necessary to maintain the required traffic loadings. In most cases, specialized contractors will be required to perform this maintenance. 4.6 General Cleaning As already suggested, for proper operation of spillways, sluiceways, approach channels, inlet and outlet structures, stilling basin / energy dissipation arrangements, discharge conduit, dam slopes, trash racks, debris control devices etc., regular and thorough cleaning and removal of debris is necessary. Cleaning is especially important after large floods, which tend to send more debris into the reservoir. 4.7 Materials and Establishment Requirements during Monsoon Period Materials required during monsoon period for both immediate maintenance and preventive maintenance must be stocked in adequate quantities for emergency situations that may arise. Needful instructions in this regard is enclosed in the O&M Manual. At Malaprabha Dam, a 24/7 hour patrol schedule is carried out during monsoon period. At the same time the additional management requirements during monsoon period are enhanced.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 104 O&M Manual for Malaprabha Dam December 2019 4.8 General List of Maintenance Records Maintenance records are of utmost importance. Records are kept of all maintenance activities, both immediate and preventive maintenance works. Essential information to be recorded include the following:  Date and time of maintenance,  Weather conditions,  Type of maintenance,  Name of person, title and / or contractor performing maintenance,  Description of work performed,  Length of time it took to complete the work with dates,  Equipment and materials used, and  Before and after dated photographs. The data is recorded by the person responsible for maintenance. 4.9 Preparation of O&M budget The O&M budget for Malaprabha dam includes but not limited to the following items: i) Establishment Cost of Regular Staff - Salaries and allowances, Bonus, Medical Reimbursement, LTC, Leave Encashment, pension benefits, etc. (as applicable). ii) Establishment Cost of Work charged Staff - Salaries and allowances, Bonus, Medical Reimbursement, LTC, Leave Encashment, Pension benefits, TA and DA , etc. (as ap- plicable). iii) Establishment Cost of Daily wage Staff - Salaries and allowances, TA and DA etc. (as applicable). iv) Office Expenses – Rent for office, Telephone/Mobile/any other Telecommunication bills, Electricity bills, water bills, Office stationery, Day to day office requirements. v) Motor Vehicles - Running and Maintenance cost of inspection vehicles, Cost of hiring of vehicles as required vi) Maintenance of Colony - Maintenance of staff quarters, colony roads, Electricity, San- itary and Water supply systems etc. vii) T&P - T&P requirements for offices, colony, works etc. as applicable. viii) Works -Painting, oiling, greasing, overhauling of HM equipment’s, Re- pair/replacement of gates seals & wire ropes, POL for pumps & generator sets, Elec- tricity charges and maintenance of Electric systems of dam site, specific requirements for all Civil, H.M & Electrical maintenance works, vegetation removal and mowing of turfing on earth dams, maintenance/cleaning of drains in dam, maintenance of lift/elevators in dam (as applicable), maintenance of access roads & basic facilities, provision for flood contingency works during monsoon, unforeseen events/items (about 10% of the cost of works) etc.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 105 O&M Manual for Malaprabha Dam December 2019 Table 17 - O&M BUDGET COSTS (ANNUAL) CURRENT PREVIOUS YEAR SL. YEAR COST BUDGET ITEM BUDGET REMARKS NO. (YR_ 2018-19) (YR _2019-20) (Rs) (Rs)

A. ESTABLISHMENT

SALARY OF REGULAR 1 STAFF INCLUDING ALL 10000000.00 12000000.00 OTHER BENEFITS

2 TRAVEL EXPENSES 20000.00 25000.00

3 OFFICE EXPENSES 200000.00 350000.00

MOTOR VEHICLE EX- 4 500000.00 600000.00 PENSES MAINTENANCE OF OF- 5 FICE & COLONY COM- 1000000.00 1500000.00 PLEX

SUB-TOTAL - A 11720000.00 14475000.00

B. WORKS

1 CIVIL

CONCRETE / MASONRY 1.1 500000.00 1000000.00 DAM

1.2 EARTHEN DAM 0.00 0.00

INTAKE / OUTLETS IN 1.3 0.00 0.00 EARTHEN DAMS SLUICES IN CONCRETE / 1.4 1500000.00 2000000.00 MASONRY DAMS APPROACH / INSPECTION 1.5 ROADS WITHIN DAM AR- 500000.00 1000000.00 EA

2 HYDRO-MECHANICAL

SPILLWAY GATES & 2.1 500000.00 1000000.00 HOISTS

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SPILLWAY STOP-LOG & 2.2 200000.00 300000.00 GANTRY CRANE OUTLETS IN EARTHEN 2.3 DAMS - SERVICE / EMER- 0.00 0.00 GENCY GATES & HOISTS SLUICES IN CONCRETE / MASONRY DAMS – SER- 2.4 500000.00 800000.00 VICE / EMERGENCY GATES & HOISTS

3 ELECTRICAL

ELECTRICAL FITTINGS, 3.1 MOTORS, CONTROLS FOR 500000.00 800000.00 ALL GATE HOISTS

3.2 POWER SUPPLY LINES 200000.00 300000.00

ELECTRICAL FITTINGS 3.3 ON DAM TOP, DAM GAL- 200000.00 500000.00 LERIES, ETC. STANDBY POWER / DIE- 3.4 200000.00 300000.00 SEL GENERATOR

3.4 REMOTE CONTROL/CCTV

4 INSTRUMENTATION

5 MISCELLANEOUS WORKS 200000.00 500000.00 SALARY OF WORK- 6 CHARGED STAFF INCLUD- 0.00 0.00 ING ALL BENEFITS MATERIALS TO BE STORED 7 200000.00 300000.00 BEFORE MONSOON

SUB-TOTAL - B 5200000.00 8800000.00

CONTINGENCY (10%) ON 8 SUB-TOTAL OF A & B 9 TOOLS & PLANTS SUB-TOTAL- C 500000.00 800000.00

10 TOTAL ANNUAL COST 122900000.00 24075000.00

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The data should be recorded by the person responsible for maintenance.

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5.1 Dam Instrumentation:

5.1.1 General Information This section identifies the location and chainages of each of the 4 structural components of the dam: Table 18 -Locations and Extents of Structural Members

From Chainage To Chainage

Right Non –over flow section 0.00 m 26.52 m

Over-flow Section 26.52 m 111.86 m

Left Non-Overflow Section 111.86 m 154.53 m

5.1.2 Embedded Instruments – Concrete/Masonry The various instruments have been embedded in both the masonry / concrete section. Table 19- Embedded Instruments (Appendix – 4) Sl.N Name of Name of In- Number Performance Status of Dats Re- o Dam strument of In- Analysis marks* with lo- stru- cation ments. 1 2 3 4 5 6 7 Mal- As per aprabha DSRP Dam , Variation in committee Drainage 1 No is instru- 1) Thermometers 8 Readings are ob- Gallery. Working ments not served. in work-

ing condi- tion 2) Pore 4 2 Nos are 2 Nos. As per DSRP committee instru- Pressure are not working ments not meter working in work- ing condi- tion

3) stress 5 Nos all are not - Meters working As per

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 109 O&M Manual for Malaprabha Dam December 2019 DSRP committee instru- ments not in work- ing condi- tion As per DSRP Rock committee Not instru- 4) Compression 1 No - displacement working ments not meter in work- ing condi- tion

NOTE: Please note that all instruments indicated in Tables 19 are not in working order. The Cross-arm instruments require new measuring instru- ments to monitor settlement of the embankment. 5.1.3 Seismological Observations A seismological observatory is proposed to be established at Malaprabha Dam

5.1.4 Parameters being permanently Monitored Observations of the following parameters need to be continued but not limited to; • Water levels in the reservoir. • Hydro-meteorological observations. • Seepage observations using V-notches/ weirs etc. • Displacements in the dam by means of survey observations using prism/paper targets fixed at structures, tilt meters or repaired plumb lines, etc. • Uplift pressures at dam base using stand pipes in Gravity dams. In case some of the instruments are not in working condition following are some of the steps to be done; i) In case connecting cables of the non-working instruments are accessible, the manufacturer of the said instruments should be approached for checking and rectification of the installations to make instruments work. ii) In case the embedded non-working instruments cannot be repaired, the same are to be abandoned. 5.1.5 Frequency of Monitoring As a rule of thumb, simple visual observations should be made during each visit to the dam and not less than monthly. Immediate readings should be taken following a storm or earth- quake. Suggested frequency of measurements is given in the following table. These are gen- erally as per the Guidelines on Instrumentation for dams (CWC).

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Before DRIP, maintenance activities were limited to routine greasing, oiling, and patch painting of hydro-mechanical devices; routine repair of electrical systems; gallery drainage; routine mowing, vegetation removal, repair of eroded section, etc. Apart from these routine maintenance activities, no major rehabilitation was carried before the involvement of DRIP.

Under DRIP, major Rehabilitation Works have been carried out at a total cost of about INR 23.50Crores (with some activities still ongoing during the preparation of this O&M manual). The rehabilitation works under DRIP include:

Costs (INR) Estimated Cost Name of Work (in Lakhs)

Rehabilitation works of Malaprabha Dam by cleaning of porous holes, cleaning of Foundation drain holes and providing Deep curtain grouting to 881.17 upstream foundation rock of Malaprabha dam. (Package-I)

Rehabilitation works of Malaprabha Dam by providing upstream surface treatment to masonry section, piers and spillway section upstream and 440.19 downstream of Malaprabha Dam. (Package II)

Rehabilitation works of Malaprabha Dam by improvements of gates and other electromechanical components and Improvements to stop-log and 499.79 gantry crane system of Malaprabha Dam. (PACKAGE III)

Rehabilitation works of Malaprabha Dam by providing electrification, fencing, providing and fixing CC camera arrangement to Malaprabha 125.14 Dam. (PACKAGE IV) Rehabilitation Works of Malaprabha Dam under Infrastructural Develop- ment and Institutional Strengthening by Providing New Office Block and 82.48 Dam Monitoring Station at Malaprabha Dam Site (PACKAGE V)

TOTAL 2028.77

Other non-structural measures under DRIP include preparation of inundation maps and Emergency Action Plan (EAP).

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As features of the dam and appurtenant structures change occasionally, the O&M Manual must be edited and portions rewritten to reflect these changes. This important task is often ignored. Updating information in the O&M Manual should be done whenever major changes like construction of an additional spillway, construction of dam on the upstream etc. take place. Aspects to be considered when updating include:  Increase/decrease in the frequency of an inspection or the maintenance routine based on additional data/ experience acquired.  Changes in the operation and/or maintenance procedures based on additional da- ta/experience acquired.  Alterations to the project data because of changes/modifications in the dam by way of additional spillway etc.

All up-dates/revisions of the O&M Manual need to be sent to all the locations/addresses to whom the copies of the original O&M Manual had been sent earlier. It is recommended that O&M Manuals be reviewed/ updated after every 10 years by the respective Dam Owners.

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APPENDIX 1 – BASIC DRAWINGS OF MALAPRABHA DAM

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Radial Crest Gate of Malaprabha Dam (50 Feet x 40 feet.

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APPENDIX2― KEY ELEMENTS OF MALAPRABHA DAM EAP

A2.1 Malaprabha Dam: Watch condition notification flowchart. Office of Karnataka Water Resources Department (SDSO) Name : Sri Prabhakar Hammigi Name : Sri Madhav Title : Chief Engineer Title : Superintending Engineer Mob: 9448068249 Mob:9448270489 Off No : 08022259985 Off No:08022259985 Email:[email protected] email:[email protected]

Office of Chief Engineer, MPZ Name : Sri Rajesh Name : Sri Biradar Title : Chief Engineer Title : Deputy Chief Engineer Mob : 9449842483 Mob:9448092192 Off No : 0836-2447793 Off No:0836-2447793 Email:[email protected] Email:[email protected]

Office of Superintending Engineer Expert Panel Name :J R Hegde Name: Sri S L Shivprasad & Sri Bendre Title : Superintending Engineer Title: Retd Chief Engineer’s, KPCL Mob: 9448641777 Mob:9845106536 & 9731966682 respectively. Off No:08330-224500 Email:[email protected] Email:[email protected]

Office of Executive Engineer (Dam) Name :Basanagouda Patil Name: V K Kulkarni Title : Executive Engineer Title: Technical Assistant Mob: 9008288188 Mob: 9880057925 Off No:08330-224516 Off No:08330-224516 Email:[email protected] Email:[email protected]

Office of Assistant Executive Engineer (Dam) Name :V K Mudigoudar Name :M F Hemmardi Title : Assistant Executive Engineer Title : SDA ( Dam Sub Dn) Mob: 9986172727 Mob: 9964263762 Off No:08330-224524 Off No:08330-224524 Email:[email protected] Email:[email protected]

Notification Flow direction

1- Order of Notification

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A 2.2 Sample Public Announcements

Note: These messages are communicated to downstream residents to alert the public of impending danger. The Executive Engineer, KNNL, MLBC Dn-2 Naviluteertha should coordinate with the India Meteorological Department, the Belagavi district Disaster Management Authority, and the District Magistrates/Collectors for Belagavi, prior to release. Messages can be communicated via radio, television, bulk SMSs of local mobile networks, and other media outlets. Announcement for a Slowly Developing “Watch” Condition (BLUE Emergency Level) Executive Engineer, KNNL, MLBC Dn-2 Naviluteertha has declared a BLUE Level “Watch” condition for Malaprabha Dam, Project Identification Code KA06HH0089 as of [time and date]. [Briefly describe the problem or condition.] Although there is no immediate danger of the dam failing, [Describe what actions are being taken to monitor and control the situation.] [State the quantity of any releases from the reservoir.] Announcement for a Worsening “Watch” Condition (BLUE Emergency Level) Executive Engineer, KNNL, MLBC Dn-2 Naviluteertha has declared a BLUE Level “Watch” condition for Malaprabha Dam, Project Identification Code KA06HH0089 as of [time and date]. [Briefly describe the problem or condition.] Although there is no immediate danger of the dam failing a possibility now exists that the dam will fail if correction efforts are unsuccessful. [ Describe what actions are being taken to monitor and correct the situa- tion.] [State the quantity of any releases from the reservoir]. Additional news will be made available as soon as it is received. Announcement for a Probable “Failure” Condition (ORANGE Emergency Level) Urgent! This is an emergency message. Executive Engineer, KNNL, MLBC Dn-2 Navilut- eertha has announced that Malaprabha Dam, Project Identification Code KA06HH0089 is probably going to fail. [Describe what actions are being taken to monitor and control the situation.] It is possible that the dam will fail in [##] hours. Residents in low lying areas along the Malaprabha stream and as well as the town of Munoli, Ramdurga, Badami and all habitations along the river bank should prepare for immediate evacuation. Additional news will be made available as soon as it is received. Announcement of an Impending “Failure” Condition (RED Emergency Level) Emergency! This is an emergency message. Malaprabha Dam, Project Identification Code KA06HH0089 is going to fail at any moment. Residents who have not yet done so should immediately evacuate the city of Munoli and low-lying areas along the Malaprabha stream. The flood waters have already reached [Highway] and [Road]. Additional news will be made available as soon as it is received. Announcement of an Ongoing “Failure” Condition (RED Emergency Level) Emergency! This is an emergency message. Malaprabha Dam, Project Identification Code KA06HH0089 failed at [time and date]. Residents who have not yet done so should immedi- ately evacuate the city of Munoli, Ramdurga and low-lying areas along the Malaprabha Stream. The flood waters have already reached [Highway] and [Road]. Additional news will be made available as soon as it is received.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 124 O&M Manual for Malaprabha Dam December 2019 A 2.3 Evidence of Distress Gen- Specific Emergency Emergency action Equip- Data to eral ob- observation condition ment, record serva- level material, tion and supplies Small boils, no in- Closely check all of down- None Site and crease of water stream toe, especially in the location, flow, flowing clear vicinity of boil for addition- approx- water. al boils, wet spots, sink- imate BLUE holes, or seepage. Closely flow monitor entire area for changes or flow rate in- creases. Large or additional Initiate 24-hour surveil- Sand- Site and boils near previous- lance. Monitor as described bags, fil- location, ly identified ones, above. Construct sandbag ter cloth approx- without increasing ring dikes around boils, to imate flow rate, but carry- cover them with water to flow BLUE ing small amount of retard the movement of soil soil particles. particles. Filter cloth may be used to retard soil Boils Boils movement, but do not retard the flow of water. Large or additional Continue 24-hour surveil- Sand- Site and boils near previous- lance. Continue monitoring bags, location, ly identified ones, and remedial action as de- pump approx- increasing flow ORANGE scribed above. Initiate imate rate, carrying soil emergency lowering of the flow particles. reservoir. Issue a warning to downstream residents. Rapidly increasing Downstream evacuation. Dozer, Site and size of boils and Employ all available shovels, location, flow increasing and RED equipment to attempt to source of approx- muddy water. construct a large ring dike earth fill imate around the boil area. flow Minor seepage of Closely check entire em- Wooden Site, clear water at toe, bankment for other seepage stakes, location, on slope of em- areas. Use wooden stakes or flagging approx- bankment, or at the BLUE flagging to delineate seep- imate abutments. age area. Try to channel and flow measure flow. Look for up- stream whirlpools.

Seepage Seepage Additional seepage Initiate 24-hour surveil- Dozer, Site, areas observed lance. Monitor as described shovels location, flowing clear water BLUE above. Construct measuring approx- and/or increasing weir and channel all seep- imate flow rate. age through weir. Attempt flow to determine source of

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Seriously or rapidly Continue 24-hour monitor- Dozer, Site lo- increasing seepage, ing and remedial action as shovels, cation, under-seepage, or described above. Initiate source of approx- drain flow. ORANGE emergency lowering of the fill mate- imate reservoir. Construct a large rial flow ring dike around the seep- age area. Additional seepage Downstream evacuation. Dozer, Site lo- areas with rapid Employ all available shovels, cation, increase in flow RED equipment to attempt to source of approx- and muddy water. construct a large ring dike fill mate- imate around the seepage area. rial flow Skin slide or slough Examine rest of embank- Stakes, Distance on slope of em- ment for other slides. Place tape between bankment. No fur- stakes in slide material and measure stakes ther movement of BLUE adjacent to it for determin- slide and embank- ing if further movement is ment crest not de- taking place. graded. Slide or erosion Initiate 24-hour surveil- Dozer, Distance involving large lance. Mobilize all available shovels, between mass of material, resources and equipment for sources stakes crest of embank- repair operations to increase of fill ment is degraded, BLUE freeboard and to protect the material, no movement or exposed embankment mate- sandbags very slow continu- rial. Start filling sandbags ing movement. and stockpile near slide ar- ea. Slide or erosion Continue monitoring and Dozer, Distance involving large remedial actions as de- shovels, between

Slides or severe erosion or severeerosion Slides mass of material, scribed above. Place addi- source of stakes crest of embank- ORANGE tional material at the toe of fill mate- ment is degraded, the slope to stop the slide. rial, progressively in- pump creasing in size. Slide or erosion Downstream evacuation. Dozer, Distance involving large Utilize all available equip- shovels, between mass of material, ment and personnel to sand- stakes crest of embank- RED sandbag the degraded slide bags, ment is severely area to prevent it from over- pump degraded, move- topping. ment of slide is Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 126 O&M Manual for Malaprabha Dam December 2019 Gen- Specific Emergency Emergency action Equip- Data to eral ob- observation condition ment, record serva- level material, tion and supplies continuing and may reach pool level. Sinkholes any- Carefully walk the entire Stakes, Size, whereon the em- embankment and down- flagging location bankmentor within stream area looking for ad- BLUE 150 metresdown- ditional sinkholes, move- stream from the ment, or seepage. toe. Sinkholes with cor- Initiate 24-hour surveil- Dozer, Size, responding seepage lance. Monitor as above. shovels, location anywhere on the Construct sandbag dike pump embankment or BLUE around the seepage exit downstream from point to reduce the flow the toe. rate. Start filling sandbags and stockpile near sinkhole.

Sinkholes Sinkholes Large sinkholes Continue monitoring and Sand- Size, with corresponding remedial action as described bags, location seepage anywhere above. Utilize sandbags to dozer, ORANGE on the embankment increase the freeboard on pump or downstreamfrom the dam if necessary. the toe. Sinkholes rapidly Downstream evacuation. Dozer, Size, getting worse, Utilize all available equip- shovels, location seepage flowing RED ment and personnel to at- pump muddy water and tempt to construct a large increasing flow. ring dike around the area. Obvious settlement Look for bulges on slope or None Size, of the crest of the changes in crest alignment. location embankment, espe- BLUE cially adjacent to concrete structures. Settlement of crest Initiate 24-hour surveil- Sand- Size, of embankment that lance. Mobilize all available bags, location is progressing, es- resources for repair opera- dozer, pecially adjacent to tions to increase freeboard. shovels, concrete structures BLUE Fill and stockpile sandbags. source of Settlement Settlement or if any corre- Identify any boils near set- fill mate- sponding seepage is tlement points for flowing rial present. material and pursue action for boils. Settlement of crest Continue monitoring and Sand- Size, of embankment that ORANGE remedial actions as de- bags, location is rapidly progress- scribed above. Use sand- shovels,

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 127 O&M Manual for Malaprabha Dam December 2019 Gen- Specific Emergency Emergency action Equip- Data to eral ob- observation condition ment, record serva- level material, tion and supplies ing especially adja- bags to increase the free- dozer, cent to concrete board on the dam if neces- source of structures or if any sary. fill mate- corresponding rial seepage is flowing muddy water or increasing flow. Progressing settle- Downstream evacuation. Dozer, Size, ment that is ex- Utilize all available equip- shovels, location pected to degrade ment and personnel to build source of the embankment to up the crest in the area that fill mate- RED reservoir level. is settling. Identify any rial, boils near settlement points sandbags for flowing material and pursue action for boils. Cracks in the em- Walk on entire crest and Stakes, Size, bankment crest BLUE slope and check for addi- tape location or on slopes. tional cracking. measure Numerous cracks in Initiate 24-hour surveil- Stakes, Size, crest that are en- lance. Carefully monitor tape location larging, especially and measure cracking to measure, those perpendicular determine the speed and dozer, to the centerline of extent of the problem. Mo- shovels, BLUE the dam. bilize to fill cracks. Cracks source of parallel to the centerline fill mate- indicate a slide. Follow re- rial medial action for slides. Large cracks in the Continue monitoring and Dozer, Size, Cracking Cracking crest that are rapid- remedial action as described shovels, location ly enlarging, espe- above. source of cially those per- ORANGE fill mate- pendicular rial to the centerline of the dam. Cracking that ex- Downstream evacuation. Dozer, Size, tends to pool eleva- Continue remedial actions shovels, location tion. RED as described above. source of fill mate- rial Minor cracking Immediately install measur- Crack Size, and/or movement. BLUE ing device to monitor Moni- location movement. tors, ing or ing move- ment of ment concrete stakes,

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Major cracking Downstream evacuation. Dozer, Size, and/or movement Dam failure is imminent. shovels, location, RED Continue monitoring and rock flow remedial actions as de- rate scribed above. Whirlpool in the Downstream evacuation. Dozer, Size, lake in the vicinity Attempt to plug the en- fill mate- location, of the embankment trance of the whirlpool with rial, flow riprap from the slope of the sand- rate RED embankment. Search down- bags, fil- stream for an exit point and ter cloth, construct a ring dike to re- straw, tard the flow of soil parti- rocks Upstream whirlpool Upstream whirlpool cles. Structural member Initiate 24-hour surveil- Crane Type of of a gate or gate lance. Immediately place and prob- operator broken or stop logs in front of gate welder lem, lo- severely damaged ORANGE and initiate necessary ac- cation gate gate so as to prevent op- tions to get gate repaired. eration Malfunction ofMalfunction of the gate Lake level rising Initiate 24-hour surveillance Lake and rain continuing of lake level and rainfall. level, BLUE Generate inflow forecasts rainfall Rapidly Rapidly

rising lake rising every 12 hours.

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Overtopping Overtopping embankment with Width development of of RED head-cuts encroach- breach ing on the dam as it en- crest, or significant larges. movement of sec- tions of concrete or masonry portions of the dam. When the inflow Warn the downstream of Mass Number being received in reservoir habitations. Clear carriers of peo- the reservoir is the low-lying habitations such as ple from 5000 cusecs along the river bank. tippers shifted. to 1000 cusecs and and BLUE outflow released to trucks for river is ranging be- evacua- tween 5000 cusecs tion. to 10000 cusecs at FRL. When the inflow Evacuate the people down- Mass Number flow. being received in stream of reservoir establish carriers of peo- the reservoir is barricade along the road such as ple from 10000 cusecs crossings. Shift the people tippers shifted. to 30000 cusecs to safe zones till the flood and and outflow re- ORANGE situation reduces. trucks for leased to river is evacua- ranging between tion. 10000 cusecs to 30000 cusecs at Large Controlled release form in- reservoir during heavy Large release Controlled FRL.

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A 2.4 Dam Owner’s Responsibilities The dam owner, Karnataka Water Resources Department (KWRD) and Chief Engineer, KNNL, Malaprabha Project Zone Dharwad, are responsible for all dam operation and maintenance. The EAP will not designate a specific person for a specific responsibility but instead will designate the person’s duties or job description. 3.1.1 Emergency planning Manager Responsibilities: Responsibilities of Executive Engineer and Assistant Executive Engineer of Dam. The Executive Engineer, KNNL, MLBC Dn-2 Naviluteertha in co-ordination with Assistant Executive Engineer, LI-2 Sub Dn, Naviluteertha are the first line of dam observers, and are the persons responsible for initiating and implementation of EAP. The brief responsibilities are as listed below. a). Implementation of EAP. b). To conduct routine inspection of dams. c). To classify the events into the emergency alerts. d). To ensure that the current approved version of the EAP is functional and available to all stakeholders. e). To ensure effective transmission of hydro-mechanical and flow data. f). To periodically carryout pre-monsoon and post-monsoon inspection as per the standard maintenance manual of dams. g). To periodically check the electromechanical operations of gate’s hoists, clean the down- stream water way ,so as to dissipate the water smoothly in case of large flood water dis- charge from reservoir during heavy floods. h). The Executive Engineer,KNNL ,MLBC Dn-2 Naviluteertha is responsible for collecting weather forecasts and the inflow forecasts and alerting of any potential emergency situation. i). The Executive Engineer, KNNL, MLBC Dn-2 Naviluteertha is responsible for conducting routine dam maintenance, such as annual weed control, conducting dam integrity inspections, and notifying Karnataka Water Resources Department (KWRD) of any potential emergency situations.

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 131 O&M Manual for Malaprabha Dam December 2019 j). The Executive Engineer, KNNL, MLBC Dn-2 Naviluteertha is responsible for contacting emergency personnel should a dam failure be imminent. k). The Executive Engineer, KNNL, MLBC Dn-2 Naviluteertha is responsible for informing State Disaster Management Authorities and District Disaster Management Authorities and notify in case of failure or should a dam failure be imminent. Responsibilities of Superintending Engineers and Chief Engineer of Malaprabha Dam. The Chief Engineer, Malaprabha Project Zone Dharwad in co-ordination with Superintending Engineer, MLBCC circle Naviluteertha are in the second line of dam observ- ers responsible for Emergency planning. The responsibilities of the above said officers is as described below. a) To ensure that the EAP is updated by Executive Engineer, MLBCC, Dn-2 Naviluteertha and Assistant Executive Engineer, LI-2 Sub Dn Naviluteertha periodically. b) To review annually to ensure that the contact details are current details as described in the notification flow chart. c) Directing and initiating appropriate action during emergency, such as opening or closing water outlets and remedial construction activities such as earth moving etc. d) To keep in contact with all the members of the notification flow chart and update them regarding the situation of the dam. e) To invite experts (Structural, chemical, Electromechanical, Geological etc) to the dam who can anticipate the flow data, seepage data etc into useful suggestions which are neces- sary for maintaining the health status of dam. f) Contact the Deputy Commissioner’s (Belgavi, Bagalkot, Bijapur, Dharwad) and Superintendent of Police of respective districts to inform regarding the Emergency condition.

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APPENDIX 3 ― MATERIAL REQUIRED FOR MAINTENANCE DURING MONSOON

Materials during monsoon period should be stocked in adequate quantity as experience shows them to be necessary. Particular care should be taken that the required materials are distributed with careful fore-thought so as to be readily available everywhere, particularly at dangerous sites. The quantity of materials required depends on importance or dangerousness of the dam and the distances of the dam from the nearest stations at which these can be purchased. This will need to be worked out by the respective dam owners / state govt. as per their experience & documented in the O & M Manual for the dams. The following norms have been prescribed by the Govt. of Madhya Pradesh for their projects during monsoon period. 1. Patrolling i. Torches: 1 for each Executive Engineer, Assistant Engineer, Sub-Engineer and 2 in spare. ii. Cells: 1fill and 2 spare sets iii. Binoculars 6 iv. Night Vision Goggles 2 v. Dragon Lights 10 vi. Search Lights 15 vii. Communication Systems (local walkie-talkie) 8 viii. Rain coat: 20 ix. Gum boots: 20 x. Danger Zone Light: Strips 10 xi. Flares 50

2. Leaks i Gunny Bags 500 ii. Stakes 60 to 120 stakes per km. iii. Baskets 1 Basket of toot per beldar &one spare. iv. Sutli (Twine) 0.5kg per 100bags v. Needles ½ dozen with each work mestry vi. Sand Collectionof2to4m3everykm.for

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Appendix 4 ― Scheduled or Unscheduled Dam Safety Inspection Form A form designed for use during scheduled dam safety inspections – which includes pre- and post-monsoon inspections – follows. The form contains a comprehensive checklist (Part 2a) of items that are found at dams that need to be evaluated during a safety inspection. The checklist consists of (1) a series of questions that need to be answered as Yes/No/Not Applicable for each inspection item, (2) a remarks box in which critical aspects can be commented upon following each question, and (3) a final condition assessment (Unsatisfactory/Poor/Fair/Satisfactory) for that inspection item. Not all inspection items will be found at a dam. The form concludes with a Consolidated Dam Health Status Report (Part 2b).

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Scheduled / Unscheduled Dam Safety Inspection Form Part 1a - Inspection Details: Project ID Code Dam Name: (PIC): Dam Type: Dam Purpose:

Dam Owner: Hazard Classification:

Dam Operator: Inspection by:

City/State/PIN: Date of Inspection:

District: Reservoir Level: Auxiliary Spillway Latitude: Level: Longitude: Weather Conditions:

Part 1b - Inspection Remarks: Please provide any additional information or comments not covered by Part 1a form above.

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Part 2a - Inspection Checklist:

SN Inspection Item Responsea Remarks Conditionb

Y N NA

A Reservoir A1. General Condition 1 1.1. Is the reservoir water level unusually high or

1 low? 1.1. Are there signs of decline in water quality? Unsatisfactory/Poor/ 2 Fair/Satisfactory 1.1. Are there signs of recent sediment deposition? 3 1.1. Is floating debris present? 4 1.1. Are there people or livestock in and around res-

5 ervoir? 1.1. Any other issues? 6 B Dam and Dam Reach (Embankment) B1. General Condition 1 1.1. Any major alterations or changes to the dam

1 since the last inspection? 1.1. Is there any new nearby development in the

2 downstream floodplain? 1.1. Any misalignment of poles, fencing or walls due

3 to dam movement?

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SN Inspection Item Responsea Remarks Conditionb

B1.2 Upstream Slope

1.2.1 Any signs of bulging or concavity (depressions)?

1.2.2 Presence of longitudinal or transverse cracks?

1.2.3 Any signs of distress to the stability of slopes?

1.2.4 Any other signs of structural distress or instability?

Trees or profuse growth of weeds/bushes at any loca- 1.2.5 tion?

1.2.6 Is there evidence of livestock on the upstream slope?

Are ants, termites, crabs or other burrowing animals 1.2.7 present?

1.2.8 Any degradation to slope protection (rip-rap)?

1.2.9 Any other issues?

B1.3 Crest of Dam

1.3.1 Any signs of excessive or uneven settlement?

1.3.2 Presence of longitudinal or transverse cracks?

1.3.3 Presence of undulations, local depressions or heaving?

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SN Inspection Item Responsea Remarks Conditionb

1.3.4 Any degradation to access road (sealed/unsealed)?

1.3.5 Evidence of livestock on dam crest?

Trees or profuse growth of weeds/bushes at any loca- 1.3.6 tion?

Any degradation to edges of dam crest or reduction in 1.3.7 width? Any degradation to upstream parapet or downstream 1.3.8 curb wall?

1.3.9 Any other issues?

B1.4 Downstream Slope

1.4.1 Any signs of bulging or concavity (depressions)?

Any wet patches (seepage), concentrated leaks or evi- 1.4.2 dence of boiling?

1.4.3 Presence of longitudinal or transverse cracks?

1.4.4 Any signs of distress to the stability of slopes?

Are of rain cuts/erosion channels present at any loca- 1.4.5 tion?

1.4.6 Any other signs of structural distress or instability?

Trees or profuse growth of weeds/bushes at any loca- 1.4.7 tion?

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SN Inspection Item Responsea Remarks Conditionb

Is there evidence of livestock on the downstream 1.4.8 slope? Are ants, termites, crabs or other burrowing animals 1.4.9 present?

1.4.1 Any other degradation to slope protection (turfing)? 0 1.4.1 Any other issues? 1 B1.5 Breaching Section

1.5.1 Any difficulties in accessing the breaching section?

1.5.2 Evidence of recent degradation?

1.5.3 Any other issues?

B1.6 Junction with Masonry/Concrete Dam Section Any presence of leaks, springs or wet spots in the 1.6.1 vicinity of the junction?

Any presence of cracking, settlement or upheaval of 1.6.2 earthwork?

1.6.3 Any evidence of erosion or slope instability?

1.6.4 Any other issues?

B1.7 Abutment Contacts

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SN Inspection Item Responsea Remarks Conditionb

Any presence of leaks, springs or wet spots in the 1.7.1 vicinity of the abutment? Any presence of cracking, settlement or upheaval of 1.7.2 earthwork?

1.7.3 Any evidence of erosion or slope instability?

1.7.4 Trees or profuse growth of weeds/bushes?

Any degradation to up/downstream slope protection 1.7.5 (rip-rap, turfing)?

1.7.6 Any other issues?

B2 Dam and Dam Block/Reach (Concrete/Masonry)

B2.1 General Condition Any major alterations or changes to the dam since the

2.1.1 last inspection? Is there any new nearby development in the down- 2.1.2 stream floodplain? Any misalignment of poles, fencing or walls due to 2.1.3 dam movement? B2.2 Upstream Face

Evidence of surface defects (honeycombing, staining, 2.2.1 stratification)? Concrete/masonry deterioration (spalling, leaching, 2.2.2 disintegration)?

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SN Inspection Item Responsea Remarks Conditionb

Is cracking present (structural, thermal, along 2.2.3 joints)? Evidence of differential settlement (dis- 2.2.4 placed/offset/open joints)?

Presence of vegetation (growth in joints between 2.2.5 blocks)? Evidence of any other damage to joints and/or water- 2.2.6 stops?

2.2.7 Any other issues?

B2.3 Crest of Dam Evidence of differential settlement (dis- 2.3.1 placed/offset/open joints)? Presence of cracking (structural, thermal, along 2.3.2 joints)?

2.3.3 Profuse growth of weeds/grass/plants at any location?

2.3.4 Any degradation to access road?

Any degradation to upstream parapet or downstream 2.3.5 curb wall?

2.3.6 Any other issues?

B2.4 Downstream Face

Evidence of surface defects (honey-combing, staining, 2.4.1 stratification)?

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SN Inspection Item Responsea Remarks Conditionb

Concrete/masonry deterioration (spalling, leaching, 2.4.2 disintegration)? Presence of cracking (structural, thermal, along 2.4.3 joints)? Evidence of differential settlement (dis- 2.4.4 placed/offset/open joints)? Presence of vegetation (growth in joints between 2.4.5 blocks)? Evidence of any other damage to joints and/or water- 2.4.6 stops? Excessive seepage/sweating at any location on down- 2.4.7 stream face? Significant leakage at any location on downstream 2.4.8 face?

2.4.9 Any other issues?

B2.5 Abutment Contacts Any presence of leaks, springs or wet spots in vicinity 2.5.1 of abutment?

2.5.2 Any presence of cracking or settlement?

2.5.3 Profuse growth of weeds/grass/plants at any location?

2.5.4 Any other issues?

C1 Gallery/Shaft and Drainage (Embankment)

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SN Inspection Item Responsea Remarks Conditionb

C1.1 General Condition

Slushy condition or water logging immediately down- 1.1.1 stream of dam?

1.1.2 Any evidence of boiling in vicinity of dam toe?

C1.2 Gallery/Shaft Condition Any problems accessing or inspecting gallery/shaft 1.2.1 (obstruction)? Any safety issues (inadequate handrails, lighting or 1.2.2 ventilation)? Problems of inadequate drainage (slippery stairs, wa-

1.2.3 ter logging of gallery)? Evidence of differential settlement (dis- 1.2.4 placed/offset/open joints)? Excessive seepage/sweating at any location along gal- 1.2.5 lery/shaft? Significant leakage at any location along gal- 1.2.6 lery/shaft?

1.2.7 Any other issues?

C1.3 Drain Condition

1.3.1 Is the flow in the drain unusually high or low?

Any reduction/deterioration in the drain section or 1.3.2 slope?

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SN Inspection Item Responsea Remarks Conditionb

Presence of debris or profuse growth of weeds/bushes 1.3.3 at any location?

1.3.4 Any other obstruction to the flow of the drain?

1.3.5 Is the flow in the drain noticeably sporadic/irregular?

Does the drainage water have high turbidity (high 1.3.6 sediment load)?

1.3.7 Any other issues?

C2 Gallery/Shaft and Drainage (Concrete/Masonry)

C2.1 General Condition Slushy condition or water logging just downstream of 2.1.1 dam? C2.2 Gallery/Shaft Condition Any problems accessing or inspecting gallery/shaft

2.2.1 (obstruction)? Any safety issues (inadequate handrails, lighting or 2.2.2 ventilation)? Problems of inadequate drainage (slippery stairs, wa- 2.2.3 ter logging of gallery)? Evidence of surface defects (honeycombing, staining, 2.2.4 stratification)? Concrete/masonry deterioration (spalling, leaching, 2.2.5 disintegration)?

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SN Inspection Item Responsea Remarks Conditionb

Presence of cracking (structural, thermal, along 2.2.6 joints)? Evidence of differential settlement (dis- 2.2.7 placed/offset/open joints)? Evidence of any other damage to joints and/or water- 2.2.8 stops? Excessive seepage/sweating at any location along gal- 2.2.9 lery/shaft? 2.2.1 Significant leakage at any location along gal-

0 lery/shaft? 2.2.1 Any other issues? 1 C2.3 Drain Condition

2.3.1 Is the flow in the drain unusually high or low?

2.3.2 Presence of calcium or other deposits in drain?

Any other evidence of the drain being blocked/having 2.3.3 reduced section?

2.3.4 Is the flow in the drain noticeably sporadic/irregular?

Does the drainage water have unusual color (leach- 2.3.5 ate)?

2.3.6 Any other issues?

D1 Spillway and Energy Dissipation Structure

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SN Inspection Item Responsea Remarks Conditionb

1.1 Spillway Any problems inspecting spillway (obstructed access, 1.1.1 damaged catwalk)? Any obstructions in or immediately downstream of 1.1.2 the spillway? Evidence of abrasion, cavitation or scour on glacis 1.1.3 (e.g. exposed reinforcement)?

1.1.4 Presence of displaced, offset or open joints?

Presence of cracking (structural, thermal, along 1.1.5 joints)? Evidence of surface defects (honeycombing, staining, 1.1.6 stratification)? Concrete/masonry deterioration (spalling, leaching, 1.1.7 disintegration)? Presence of vegetation (growth in joints between 1.1.8 blocks)? Evidence of any other damage to joints and/or water 1.1.9 stops? 1.1.1 Excessive seepage/sweating at any location on spill-

0 way glacis? 1.1.1 Significant leakage at any location on spillway glacis? 1 1.1.1 Any other issues? 2 D1.2 Energy Dissipation Structure

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SN Inspection Item Responsea Remarks Conditionb

Any problems inspecting energy dissipation struc- 1.2.1 ture? Any obstructions in or immediately downstream of 1.2.2 dissipation structure? Evidence of abrasion, cavitation or scour on dissipa- 1.2.3 tion structure?

1.2.4 Presence of displaced, offset or open joints?

Presence of cracking (structural, thermal, along 1.2.5 joints)? Evidence of surface defects (honeycombing, staining, 1.2.6 stratification)? Concrete/masonry deterioration (spalling, leaching, 1.2.7 disintegration)? Presence of vegetation (growth in joints between 1.2.8 blocks)? Evidence of any other damage to joints and/or water- 1.2.9 stops? 1.2.1 Any problems with under-drainage (blockage of open

0 drain holes)? 1.2.1 Any other issues? 1 E1 Intake/Outlet and Water Conveyance Structure E1. Intake/Outlet Structure 1 1.1. Any problems inspecting intake/outlet structure (ob-

1 structed/unsafe access)?

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SN Inspection Item Responsea Remarks Conditionb

1.1. Any obstructions in, upstream or downstream of in-

2 take/outlet structure? 1.1. Evidence of abrasion, cavitation or scour on in-

3 take/outlet structure? 1.1. Any evidence of structural distress (dis-

4 placed/offset/open joints, cracking)? 1.1. Any evidence of surface defects and/or con-

5 crete/masonry deterioration? 1.1. Any other issues? 6 E1. Water Conveyance Structure 2 1.2. Any problems inspecting intake/outlet structure (ob-

1 structed/unsafe access)? 1.2. Any obstructions in, upstream or downstream of wa-

2 ter conveyance structure? 1.2. Evidence of abrasion, cavitation or scour on struc-

3 ture? 1.2. Any evidence of structural distress (dis-

4 placed/offset/open joints, cracking)? 1.2. Any evidence of surface defects and/or material dete-

5 rioration? 1.2. Any evidence of seepage or leakage from water con-

6 veyance structure? 1.2. Any other issues? 7 F1 Hydro-Mechanical Component and Turbine/Pump

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SN Inspection Item Responsea Remarks Conditionb

F1. Gates, Stop Logs and Bulk Heads 1 1.1. Any problems inspecting gate/stop log/bulk head (ob-

1 structed/unsafe access)? 1.1. Any issues with storage of equipment (emergency stop

2 logs, and gate leaves)?

1.1. Missing or inadequate spare parts (particularly re-

3 quiring regular replacement)? 1.1. Any deterioration of equipment (connecting bolts,

4 welds, surface, paint work?) 1.1. Any obstructions preventing or impairing smooth op-

5 eration? 1.1. Any problems with the rollers (not touching tracks,

6 inadequate lubrication)? 1.1. Any problems with the seals (damage, weathering,

7 gaps with bearing surface)? 1.1. Any other issues? 8 F1. Hoists, Cranes and Operating Mechanisms 2 1.2. Any problems inspecting hoist/crane/operating mech-

1 anism?

1.2. Missing or inadequate spare parts (particularly re-

2 quiring regular replacement)? 1.2. Any deterioration of equipment (connecting bolts,

3 welds, surface, paint work?) 1.2. Any wear or damage to wire cables and other moving

4 parts?

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SN Inspection Item Responsea Remarks Conditionb

1.2. Any obstructions preventing or impairing smooth op-

5 eration? 1.2. Missing or inadequate provision of back-up/standby

6 power supply? 1.2. Any health and safety concerns (e.g. lack of "danger"

7 sign during maintenance)? 1.2. Any other issues? 8 F1. Valves 3 1.3. Any problems inspecting valve? 1 1.3. Any obstructions preventing or impairing smooth op-

2 eration? 1.3. Any deterioration of valve and associated equipment? 3 1.3. Any other issues? 4 F1. Trash Racks 4 1.4. Any problems inspecting trash rack? 1

1.4. Problems of excessive debris and/or inadequate clean-

2 ing? 1.4. Any deterioration of trash rack (rust, corrosion, and

3 damaged blades)? 1.4. Any other issues? 4

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SN Inspection Item Responsea Remarks Conditionb

F1. Trash Rack Cleaning Machines 5 1.5. Any problems inspecting trash rack cleaning ma-

1 chine? 1.5. Missing or inadequate spare parts (particularly re-

2 quiring regular replacement)? 1.5. Any deterioration of equipment (connecting bolts,

3 welds, surface, paint work?) 1.5. Any wear or damage to wire cables and other moving

4 parts? 1.5. Any obstructions preventing or impairing smooth op-

5 eration?

1.5. Missing or inadequate provision of back-up/standby

6 power supply? 1.5. Any health and safety concerns (e.g. lack of "danger"

7 sign during maintenance)? 1.5. Any other issues? 8 F1. Turbines 6 1.6. Any problems inspecting turbine? 1

1.6. Any obstructions preventing or impairing smooth op-

2 eration? 1.6. Any deterioration of turbine, blades and associated

3 equipment? 1.6. Any other issues? 4

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SN Inspection Item Responsea Remarks Conditionb

F1. Pumps 7

1.7. Any problems inspecting pump? 1 1.7. Any obstructions preventing or impairing smooth op-

2 eration? 1.7. Any deterioration of pump and associated equipment? 3 1.7. Any other issues? 4 G1 Access Road G1. General Condition 1 1.1. Any problems ensuring security of dam site (including

1 gates and fencing)? 1.1. Any obstructions along or at entrance to access road

2 (temporary or long-term)? 1.1. Any slope stability issues (road embankment or adja-

3 cent slopes)? 1.1. Profuse growth of weeds/grass on or in vicinity of ac-

4 cess road? 1.1. Any drainage problems (standing water on or adja-

5 cent to road)? 1.1. Any other degradation to road surface (ruts, potholes,

6 cavities, cracking)? 1.1. Any other issues? 7

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SN Inspection Item Responsea Remarks Conditionb

H1 Instrumentation H1. General Condition 1 1.1. Any problems inspecting instrument (obstruct-

1 ed/unsafe access)? 1.1. Is the instrument vulnerable to damage or theft (inad-

2 equate protection)? 1.1. Any problems ensuring correct functioning of instru-

3 ment (lighting, ventilation)? 1.1. Any evidence of degradation to condition of instru-

4 ment (rusting, vandalism)? 1.1. Any evidence of instrument not working (decommis-

5 sioned, broken)? 1.1. Any other issues? 6 I1 Other Appurtenant Structures (Flexi-Component)

I1.1 Bridges and Catwalks 1.1. Any problems inspecting bridge or catwalk (obstruct-

1 ed/unsafe access)? 1.1. Any security issues relating to unauthorized access

2 (e.g. for gate operation)? 1.1. Are the decking, girders and supports structurally

3 sound?

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SN Inspection Item Responsea Remarks Conditionb

1.1. Any evidence of defects or deterioration of steel, con-

4 crete or paint work? 1.1. Any other issues? 5 I1.2 Guide Walls 1.2. Any problems inspecting guide wall (obstruct-

1 ed/unsafe access)? 1.2. Any problem with drainage from behind wall (e.g.

2 blocked weep holes)? 1.2. Any evidence of scour, foundation erosion or under-

3 cutting? 1.2. Any signs of differential settlement, cracking or tilt-

4 ing? 1.2. Any other issues? 5

I1.3 Miscellaneous 1.3. Any other issues? (please specify part) 1 J1 Emergency Preparedness

J1.1 Emergency Action Plan

1.1. Is the Emergency Action Plan (EAP) still pending,

1 inadequate or outdated? 1.1. If not, are any dam staff unaware or insufficiently

2 conversant with the EAP?

1.1. Any concerned authorities unaware or insufficiently

3 conversant with the EAP?

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SN Inspection Item Responsea Remarks Conditionb

1.1. Do the communication directories/contact details re-

4 quire updating? 1.1. Any problems accessing or operating the communica-

5 tion/warning system? 1.1. Any other issues? 6

aRespond either yes (Y), no (N) or not applicable (NA). bCondition: Please rate the condition as either Satisfactory, Fair, Poor or Unsatisfactory as described below: 1. Satisfactory - No existing or potential dam safety deficiencies are recognized. Acceptable performance is expected under all loading conditions (static, hydro- logic, seismic) in accordance with the applicable regulatory criteria or tolerable risk guidelines. 2. Fair - No existing dam safety deficiencies are recognized for normal loading conditions. Rare or extreme hydrologic and/or seismic events may result in a dam safety deficiency. Risk may be in the range to take further action. 3. Poor - A dam safety deficiency is recognized for loading conditions which may realistically occur. Remedial action is necessary. Poor may also be used when uncertainties exist as to critical analysis parameters which identify a potential dam safety deficiency. Further investigations and studies are necessary. 4. Unsatisfactory - A dam safety deficiency is recognized that requires immediate or emergency remedial action for problem resolution.

Part 2b – Consolidated Dam Health Status Report:

Observations/Significant Sl No. Remedial Measures Suggested Categorya Deficiencies Noticed

1

2

3

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4

aCategory I – deficiencies which may lead to failure; Category II – major deficiencies requiring prompt remedial measures; Category III – minor remedial measures which are rectifiable during the year

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APPENDIX 5 – CCTV CAMERA SYSTEM SPECIFICATIONS

DH-SD6982/82A-HN

2Mp Full HD Network PTZ Dome Camera

Features

 4.7mm ~ 94.0mm(20x)optical zoom  H.264 & MJPEG dual-stream encoding and JPEG image capture  Max 25/30fps@1080p resolution  WDR(DWDR), Day/Night(ICR), DNR (2D&3D),Auto iris, Auto focus, AWB, AGC,BLC  Multiple network monitoring: Web viewer, CMS(DSS/PSS) & DMSS  Max 240°/s pan speed, 360° endless pan rotation  Up to 255 presets, 5 auto scan, 8 tour, 5 pattern  Built-in 7/2 alarm in/out  Support intelligent 3D positioning with DH-SD protocol  Micro SD memory, IP66  IR LEDs up to 100m

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DH-SD6982/82A-HN

Dimensions (mm)

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DH-SD6982/82A-HN Technical Specifications

Model DH-SD6982-HN DH-SD6982A-HN

Camera Image Sensor 1/3” Exmor CMOS

Effective Pixels 1944(H) x 1092(V), 2 Megapixels Scanning System Progressive Electronic Shutter Speed 1/1 to 1/10,000 s 1/1 ~ 1/30,000s Min. Illumination Color: 0.5 [email protected] Color: [email protected] B/W: 0.095 [email protected] B/W: [email protected] S/N Ratio More than 50dB Video Output BNC(1.0Vp-p/75Ω), PAL / NTSC

Camera Features Max. IR LEDs Length 100m

Day/Night Auto(ICR) / Color / B/W

BLC / HLC /DWDR (Digital Backlight Compensation BLC / HLC / WDR WDR) White Balance Auto, ATW, Indoor, Outdoor, Manual Gain Control Auto / Manual

Noise Reduction 2D / 3D Privacy Masking Up to 24 areas Digital Zoom 12x 16x Lens Focal Length 4.7mm ~ 94.0mm(20x Optical zoom) Max Aperture F1.6 ~ F3.5 Focus Control Auto / Manual

Angle of View H: 55.4°~2.9° H: 58.2° ~ 2.9° Close Focus Distance 10mm ~ 800mm 10mm~ 1000mm

PTZ Pan/Tilt Range Pan: 0° ~ 360° endless; Tilt: -2° ~ 90°, auto flip 180° Manual Control Speed Pan: 0.1° ~160° /s; Tilt: 0.1° ~120° /s Preset Speed Pan: 240° /s; Tilt: 200° /s Preset 80(DH-SD), 255(Pelco-P/D) PTZ Mode 5 Pattern, 8 Tour, Auto Pan, Auto Scan Speed Setup Human-oriented focal length/ speed adaptation Power up Action Auto restore to previous PTZ and lens status after power failure Activate Preset/Pan/Scan/Tour/Pattern if there is no command in the Idle Motion specified period Time Task Auto activation of Preset/Pan/Scan/Tour/Pattern by preset-time Protocol DH-SD, Pelco-P/D (Auto recognition) Video Compression H.264 / MJPEG

Resolution 1080P(1920×1080) / 720P(1280×720) / D1(704×576/704×480) / CIF(352×288/352×240)

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DH-SD6982/82A-HN Frame Rate Main Stream 1080P/720P(1 ~ 25/30fps)

Sub Stream D1/CIF(1 ~ 25/30fps) Bit Rate H.264: 56K ~ 8192Kbps, MJPEG: 56K ~ 20480Kbps

Audio Compression G.711a / G.711u(32kbps)/PCM(128kbps)

Interface 1/1 channel In/Out Network Ethernet RJ-45 (10/100Base-T) IPv4/IPv6, HTTP, HTTPS, SSL, TCP/IP, UDP, UPnP, ICMP, IGMP, Protocol SNMP, RTSP, RTP, SMTP, NTP, DHCP, DNS, PPPOE, DDNS, FTP, IP Filter, QoS, Bonjour ONVIF ONVIF Ver. 2.0 conformance Max. User Access 20 users

Smart Phone iPhone, iPad, Android, Windows Phone Auxiliary Interface Memory Slot Micro SD, Max 32GB

RS485 1

Alarm 7/2 channel In/Out General Power Supply AC 24V/3A (±10%) / DC12V optional

Power Consumption 17W/35W(IR LEDs on, Heater on) Working Environment -40ºC ~ 60ºC / Less than 90% RH

Ingress Protection IP66 Dimensions Φ229.6(mm) x 381.5(mm)

Weight 7.0kg

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 162 O&M Manual for Malaprabha Dam December 2019 Data storage server NAS Specifications:-

Make SYNOLOGY

Model DS-1512+

CPU Frequency 2.13Ghz Dual Core Processor

Memory 1GB DDR3 Memory

Internal HDD Bays 5 * 3.5” Hot Swap Bays Support SATA-II HDD

Internal Storage 15Tb (3Tb * 5) RAW Capacity

Ext. Device Interface 2* USB 3.0 Ports + 4 * USB 2.0 Ports

RAID Level RAID 0,1,10,5,6, RAID 5 + Hot Spare & JBOD Gigabit LAN Two Gigabit Ethernet ports File System Support EXT4, (FAT/NTFS) Read Only Networking Protocol CIFS, AFP, FTP, Telnet, SSH, NFS OS Support / Windows, Linux / Mac Clients System Compatibility NAS Management (Embedded) USER creations, Full ADS integration, RAID Man- agement, Built in Firewall, FTP Server, SNMP & HTTPS Support, iSCSI support, Resource Monitor- ing, HDD S.M.A.R.T, Web Based File Management, Network Recycle Bin, Schedule Power ON/OFF Link Aggregation, Print Server. Max. No. of Bays Up to 15 Bays by Stacking 2 * DX513 Expansion Units Max. Storage Up to 60TB RAW Power Consumption Max. 60W Access Form Factor Desktop Size 157mm x 248mm x 233mm Warranty 3 Years

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APPENDIX 6 - GLOSSARY

Dam – any artificial barrier including ap- Dam inspection – on-site visual examina- purtenant works constructed across rivers tion of all components of dam and its ap- or tributaries thereof with a view to im- purtenances by one or more persons pound or divert water; includes barrage, trained in this respect and includes inves- weir and similar water impounding struc- tigation of the non-overflow portion, tures but does not include water convey- spillways, abutments, stilling basin, piers, ance structures such as canal, aqueduct bridge, downstream toe, drainage galler- and navigation channel and flow regula- ies, operation of mechanical systems (in- tion structures such as flood embank- cluding gates and its components, drive ments, dikes, and guide bunds. units, cranes), interior of outlet conduits, Dam failure – failures in the structures or instrumentation records, and record- operation of a dam which may lead to keeping arrangements. theuncontrolled release of impounded wa- Dam owner – the Central Government or ter resulting in downstream flooding af- a State Government or public sector un- fecting the life and property of the people. dertaking or local authority or company Dam incident – all problems occurring to and any or all of such persons or a dam that has not degraded into ‘dam organizations, who own, control, operate failure’ and including the following: or maintain a specified dam. a) Structural damage to the dam and ap- Dam safety – the practice of ensuring the purtenant works; integrity and viability of dams such that b) Unusual readings of instruments in they do not present unacceptable risks to the dam; the public, property, and the environment. c) Unusual seepage or leakage through It requires the collective application of en- the dam body; gineering principles and experience, and a d) Change in the seepage or leakage re- philosophy of risk management that rec- gime; ognizes that a dam is a structure whose e) Boiling or artesian conditions noticed safe function is not explicitly determined below an earth dam; by its original design and construction. It f) Stoppage or reduction in seepage or also includes all actions taken to identify leakage from the foundation or body or predict deficiencies and consequences of the dam into any of the galleries, related to failure, and to document, publi- for dams with such galleries; cize, and reduce, eliminate, or remediate g) Malfunctioning or inappropriate to the extent reasonably possible, any un- operation of gates; acceptable risks. h) Occurrence of any flood, the peak of Decommission― Taking a dam out of which exceeds the available flood service in an environmentally sound and discharge capacity or 70% of the ap- safe manner or converting it to another proved design flood; purpose.

i)Occurrence of a flood, which resulted Design life― the intended period that the in encroachment on the available dam will function successfully with only freeboard, or the adopted design free- routine maintenance; determined during board; design phase. j) Erosion in the near vicinity, up to five hundred meters, downstream of the Distress condition – the occurrence or spillway, waste weir, etc.; and potential development of such conditions k) Any other event that prudence sug- in the dam or appurtenance or its reservoir gests would have a significant unfa- or reservoir rim, which if left unattended vorable impact on dam safety. to, may impede the safe operation of dam Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 165 O&M Manual for Malaprabha Dam December 2019 for its intended benefits or may pose unac- the intended purpose; determined by pro- ceptable risks to the life and property of gram requirements. people downstream. Rehabilitation― the completion of all Documentation – all permanent records work necessary to extend the service life concerning investigation, design, construc- of the practice or component and meet ap- tion, operation, performance, maintenance plicable safety and performance standards. and safety of dams and includes design Repair― actions to restore deteriorated, memorandum, construction drawings, geo- damaged, or failed damor its component to logical reports, reports of specialized stud- an acceptable by meeting functional con- ies simulating structural and hydraulic re- dition. sponse of the dam, changes made in de- sign and drawings, quality control records, Replacement― the removal of a structure emergency action plan, operation and or component and installation of a similar, maintenance manual, instrumentation functional structure or component. readings, inspection and testing reports, Service Life― the actual period after con- operational reports, and dam safety review struction of a dam, during which the prac- reports; tice functions adequately and safely with Emergency Action Plan(EAP)― a plan only routine maintenance; determined by of action to be taken to reduce the poten- on-site review. tial for damage to property and loss of life Abutment―that part of a valley side against in the area affected by failure of a dam or which a dam is constructed. Right and left other potentially hazardous practice. abutments are those on respective sides of the of an Hazard Classification― a system that observer looking downstream. categorizes dams according to the degree Air-Vent Pipe―a pipe designed to provide air to of adverse incremental consequences of a the outlet conduit to reduce turbulence during failure or improper operation of the dam. release of water and safeguard against damages CWC classifies dam hazards as “low”, due to cavitation. “significant”, or “high”. Appurtenant Structures―ancillary features of a Maintenance― the recurring activities dam, such as the outlet, spillway, energy necessary to retain or restore a dam in a dissipation arrangement powerhouse, tunnels, etc. safe and functioning condition, including Arch Dam―a concrete or masonry dam that is the management of vegetation, the repair curved to transmit the major part of the water or replacement of failed components, the pressure to the abutments. prevention or treatment of deterioration, Backwater Curve―the longitudinal profile of the and the repair of damages caused by water surface in an open channel where the depth flooding or vandalism. of flow has been increased by an obstruction, an Operation― the administration, man- increase in channel roughness, a decrease in agement, and performance of maintenance channel width, or a flattening of the bed slope. activities necessary to keep a dam safe and Base Width (Base Thickness)―the maximum functioning as planned. width or thickness of a dam measured horizontally between upstream and downstream faces and Program ― any authorized activity used normal (perpendicular) to the axis of the dam but to implement and carry out goals, actions, excluding projections for outlets, etc. and objectives contained within the au- thorizing legislation. Berm―a horizontal step or bench in the sloping profile of an embankment dam. Program Life― the period in a contract, conservation plan, or plan during which Upstream Blanket―an impervious layer placed the conservation practice or conservation on the reservoir floor upstream of a dam. In case of system shall be maintained and used for an embankment dam, the blanket may be connected to the impermeable element in a dam.

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Buttress dam―a dam consisting of a watertight Dike (Levee)―a long low embankment whose upstream face supported at intervals on the height is usually less than 5 m and whose length is downstream side by a series of buttresses. more than 10 times the maximum height. Usually applied to embankments or structures built to Cofferdam―a temporary structure enclosing all or protect land from flooding. If built of concrete or part of a construction area so that construction can masonry, the structure is usually referred to as a proceed in a dry area. flood wall. Also, used to describe embankments Concrete Lift―in concrete works the vertical that block areas on a reservoir rim that are lower distance between successive horizontal than the top of the main dam and that are quite construction joints. long. In the Mississippi River basin, where the old French word levee has survived, the term now ConduitOutlet Works―a closed conduit for conveying discharge through or under a dam for applies to flood-protecting embankments whose height can average up to 15 m. different project purposes. Diversion channel, canal, or tunnel―a waterway Consolidation Grouting (Blanket Grouting)―theinjection of grout to consolidate a used to divert water from its natural course. These terms are generally applied to temporary structures layer of the foundation, resulting in greater such as those designed to bypass water around a impermeability, strength, or both. dam site during construction. “Channel’ is Construction Joint―the interface between two normally used instead of “canal” when the successive placings or pours of concrete where a waterway is short.Occasionally these terms are bond, not permanent separation, is intended. applied to permanent structures. Core Wall―a wall built of impervious material, Drainage area―an area that drains naturally to a usually concrete or asphaltic concrete, in the body point on a river. of an embankment dam to prevent leakage. Drainage layer or blanket―a layer of permeable Crest Length―the length of the dam at its crest material in a dam to relieve pore pressure or to (dam top) top of a dam, including the length of the facilitate drainage of fill. spillway, powerhouse, navigation lock, fish pass, etc., where these structures form part of the length Relief well―vertical wells or boreholes, constructed downstream of an embankment dam to of a dam. If detached from a dam, these structures relieve the pressure from confined pervious layers should not be included. in foundation overlaid by an impervious layer to Crest of dam―Used to indicate the “top of dam”. arrest boiling. To avoid confusion to indicate the crest of spillway Drawdown―the lowering of water surface level and top of dam may be used. due to release of water from a reservoir. Culvert―a drain or waterway built under a road, Earthen dam or earth filleddam―see embankment railway, or embankment, usually consisting of a dam. pipe or covered conduits Cutoff―an impervious construction or material Embankment dam (Fill dam)― any dam which reduces seepage through the foundation constructed of excavated natural materials. material. Earth dam (Earth filldam)―An embankment Cutoff trench―an excavation later to be filled dam in which more than 50 percent of the total volume is formed of compacted fine-grained with impervious material to form a cutoff. material obtained from a borrow area. Cutoff wall―a wall of impervious material (e.g., concrete, asphaltic concrete, steel-sheet piling) Homogeneous earth filldam― an embankment dam constructed of similar earth material built into the foundation to reduce seepage under throughout, except internal drains or drainage the dam. blankets; distinguished from a zoned earth fill dam. Dead storage―the storage that lies below the Hydraulic fill dam―an embankment dam invert of the lowest outlet and that, therefore, constructed of materials, often dredged, that are cannot be withdrawn from the reservoir. conveyed and placed by suspension in flowing Design flood―see spillway design flood. water. Diaphragm―see membrane. Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 167 O&M Manual for Malaprabha Dam December 2019

Rock fill dam―an embankment dam in which required for levee construction is expensive or not more than 50 percent of the total volume comprises available. compacted or dumped pervious natural or crushed Foundation of dam―the natural material on rock. which the dam structure is placed. Rolled fill dam―an embankment dam of earth or Freeboard―the vertical distance between a stated rock in which the material is placed in layers and reservoir level and the top of a dam.Normal compacted using rollers or rolling equipment. freeboard is the vertical distance between Full Zoned embankment dam―an embankment Reservoir Level (FRL) and the top of the dam. damcomposed of zones of materials selected for Minimum freeboard is the verticaldistance between different degrees of porosity, permeability and the Maximum Water Level (MWL) and the top of density. the dam. Emergency spillway―see spillway. Gallery―(a) a passageway within the body of a dam or abutment, hence the terms grouting gallery, Face―the external surface of a structure, e.g., the inspection galleryand drainage gallery (b) a long surface of a wall of a dam. and rather narrow hall, hence the following terms Failure―the uncontrolled release of water from a for a power plant viz.valve gallery, transformer dam. gallery andbus bar gallery. Filter (filter zone)―A band or zone of granular Gate―a device in which a leaf or member is material that is incorporated into a dam and is moved across the waterway from an external graded (either naturally or by selection) to allow position to control or stop the flow. seepage to flow across or down the filter without Bulkhead gate―a gate used either for temporary causing the migration of material from zones closure of a channel or conduit to empty it for adjacent to it. inspection or maintenance or for closure against Flashboards―a length of timber, concrete, or flowing water when the head difference is small, steel placed on the crest of a spillway to raise the e.g., for diversion tunnel closure. Although a retention water level but that may be quickly bulkhead gate is usually opened and closed under removed in the event of a flood, either by a nearly balanced pressures, it nevertheless may be tripping device or by deliberately designed failure capable of withstanding a high pressure differential of the flashboard or its supports. when in the closed position. Floodplain―an area adjoining a body of water or Crest gate (spillway gate)―a gate on the crest of natural stream that has been, or may be, covered by a spillway to control overflow or reservoir water flood water. level. Floodplain management―a management Emergency gate―a standby or reserve gate which program to reduce the consequences of flooding, is lowers only for repairing / servicing of the either by natural runoff or by dam failure, to service gate. existing and future properties in a floodplain. Fixed wheel gate (fixed-roller gate, fixed-axle Flood routing―the determination of the gate)―a gate having wheels or rollers mounted on attenuating effect of storage on a flood passing the end posts of the gate. The wheels move against through a valley, channel, or reservoir. rails fixed in side grooves or gate guides. Flood surcharge―the volume or space in a Flap gate―a gate hinged along one edge, usually reservoir between the controlled retention water either the top or bottom edge. Examples of bottom- level (Full Reservoir Level) and the maximum hinged flap gates are tilting gates and belly gates, water level. Flood surcharge cannot be retained in so called due to their shape in cross-section. the reservoir but will flow over the spillway until Flood gate―a gate to control flood release from a the controlled retention water level is reached. reservoir. Flood wall―a concrete wall constructed adjacent Guard gate(guard valve)―a gate or valve that to a stream to prevent flooding of property on the operates fully open or closed. It may function as a landward side of the wall, normally constructed in secondary device for shutting off the flow of water lieu of or to supplement a levee where the land in case the primary closure device becomes

Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 168 O&M Manual for Malaprabha Dam December 2019 inoperable but is usually operated under conditions Inundation map―a map delineating the area that of balanced pressure and no flow. would be inundated in case of a failure. Outlet gate―a gate controlling the outflow of Leakage―Uncontrolled loss of water by flow water from a reservoir. through a hole or crack. Radial gate (Tainter gate)―a gate with a curved Lining― a coating of asphaltic concrete, upstream plate and radial arms hinged to piers or reinforced or unreinforced concrete, shotcrete, other supporting structures. rubber or plastic on a canal, tunnel etc. to provide water tightness, prevent erosion, reduce friction, or Service/Regulating gate(regulating valve)―a support the periphery of structure. May also refer gate or valve that operates under full pressure and to lining, such as steel or concrete, of outlet pipe or flow to throttle and vary the rate of discharge. conduit. Slide gate (sluice gate)―a gate that can be opened Low-level outlet (bottom outlet)―an opening at a or closed by sliding it in supporting guides. lowlevel from a reservoir generally used for Gravity dam―a dam constructed of concrete, emptying or for scouring sediment and sometimes masonry, or both that relies on its weight for for irrigation releases. stability. Masonry dam―a dam constructed mainly of Grout cap―a pad or wall constructed to facilitate stone, brick, or concrete blocks that may or may pressure grouting of the grout curtain beneath it. not be joined with mortar. A dam having only a masonry facing should not be referred to as a Grout curtain (grout cutoff)―a barrier produced byinjecting grout into a vertical zone, usually masonry dam. narrow horizontally, in the foundation to reduce Maximum cross-section of dam―a cross-section seepage under a dam. of a dam at the point of its maximum height. Height above lowest foundation―the maximum Maximum water level―the maximum water heightfrom the lowest point of the general level, including flood surcharge, the dam is foundation to the top of the dam. designed to withstand. Hydraulic height―the height to which water rises Membrane (Diaphragm)―a sheet or thin zone or behind a dam and the difference between the facing made of a flexible material, sometimes lowest point in the original streambed at the axis of referred to as a diaphragm wall or diaphragm. the dam and the maximum controllable water Minimum operating level―the lowest level to surface. which the reservoir is drawn down under normal Hydrograph―a graphic representation of operating conditions. discharge, stage, or other hydraulic property with Morning glory spillway―see spillway. respect to time for a point on a stream. (At times the term is applied to the phenomenon the graphic Full Reservoir Level (FRL)/Normal water representation describes; hence a flood hydrograph level―for a reservoir with un-gated spillway it is is the passage of a flood discharge past the the spillway crest level. For a reservoir, whose observation point.) outflow is controlled wholly or partly by movable gates, siphons or other means, it is the maximum Inclinometer―an instrument, usually consisting level to which water can be stored under normal of a metal or plastic tube inserted in a drill hole and operating conditions, exclusive of any provision a sensitized monitor either lowered into the tube or for flood surcharge. fixed within it. The monitor measures at different points the tube’s inclination to the vertical. By One-Hundred Year (100-Year) Exceedance integration, the lateral position at various levels of Interval― the flood magnitude expected to be the tube may be found relative to a point, usually equaled or exceeded on the average of once in 100 the top or bottom of the tube, assumed to be fixed. years. It may also be expressed as an exceedance The system may be used to measure settlement. frequency, i.e. a percent chance of being exceeded in any given year. Intake―any structure in a reservoir, dam, or river through which water can be drawn into an Outlet―an opening through which water can be aqueduct. freely discharged from a reservoir. Internal Erosion―see piping. Overflow dam―a dam designed to be overtopped. Doc. No. CDSO_O&M_KA06HH0089_Malaprabha Dam_v1.0 Page 169 O&M Manual for Malaprabha Dam December 2019

Parapet Wall―a solid wall built along the top of a slope of an embankment dam, on a reservoir shore, dam for ornament, for the safety of vehicles and or on the sides of a channel as a protection against pedestrians, or to prevent overtopping. wave action. Large riprap is sometimes referred to as armoring. Peak Flow―the maximum instantaneous discharge that occurs during a flood. It coincides Risk assessment―as applied to dam safety, the with the peak of a flood hydrograph. process of identifying the likelihood and consequences of dam failure to provide the basis Pervious Zone―a part of the cross-section of an for informed decisions on a course of action. embankment dam comprising material of high permeability. Rock fill Dam―see embankment dam. Phreatic Surface―thetop most flow line in an Roll Crete or Roller-Compacted ConcreteAno- embankment dam. slump concrete that can be hauled in dump trucks, spread with a bulldozer or grader, and compacted Piezometer―an instrument for measuring pore with a vibratory roller. water pressure within soil, rock, or concrete. Seepage―the interstitial movement of water that Piping―the progressive development of internal may take place through a dam, its foundation, or its erosion by seepage, appearing downstream as a abutments. hole or seam discharging water that contains soil particles. Sill―(a) A submerged structure across a river to control the water level upstream. (b) The crest of a Pore Pressure―the interstitial pressure of water spillway. (c) A horizontal gate seating, made of within a mass of soil, rock, or concrete. wood, stone, concrete or metal at the invert of any Pressure Cell―an instrument for measuring opening or gap in a structure, hence the pressure within a mass of soil, rock, or concrete or expressions gate sill and stop log sill. at an interface between one and the other. Slope―(a) the side of a hill or mountain. (b) The Pressure Relief Pipes―Pipes used to relieve uplift inclined face of a cutting or canal or embankment. or pore water pressure in a dam’s foundation or (c) Inclination from the horizontal. In the United structure. States, it is measured as the ratio of the number of Probable Maximum Flood (PMF)―a flood that units of horizontal distance to the number of corresponding units of vertical distance. The term would result from the most severe combination of is used in English for any inclination and is critical meteorologic and hydrologic conditions expressed as a percentage when the slope is gentle, possible in the region. in which case the term gradient is also used. Probable Maximum Precipitation (PMP)―the Slope Protection―the protection of a slope maximum amount and duration of precipitation that can be expected to occur on a drainage basin. against wave action or erosion. Pumped storage reservoir―a reservoir filled Sluiceway―see low-level outlet. entirely or mainly with water pumped from outside Spillway―a structure over or through which flood its natural drainage area. flows are discharged. If the flow is controlled by gates, it is a controlled spillway; if the elevation of Regulating dam―a dam impounding a reservoir the spillway crest is the only control, it is an from which water is released to regulate uncontrolled spillway. Reservoir area―the surface area of a reservoir Auxiliary Spillway (Emergency Spillway)―a when filled to controlled retention level. secondary spillway designed to operate only during Reservoir routing―the computation by which the exceptionally large floods. interrelated effects of the inflow hydrograph, Fuse-Plug Spillway―an auxiliary or emergency reservoir storage, and discharge from the reservoir spillway comprising a low embankment or a are evaluated. natural saddle designed to be overtopped and Reservoir surface―the surface of a reservoir at eroded away during a rare and exceptionally large any level. flood. Riprap―a layer of large stones, broken rock, or Primary Spillway(Principal Spillway)―the precast blocks placed randomly on the upstream principal or first-used spillway during flood flows.

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Shaft Spillway (Morning Glory Spillway)―a Top of Dam―the elevation of the uppermost vertical or inclined shaft into which flood water surface of a dam, usually a road or walkway, spills and then is conducted through, under, or excluding any parapet wall, railings, etc. around a dam by means of a conduit or tunnel. If Top Thickness (Top Width)―the thickness or the upper part of the shaft is splayed out and width of a dam at the level of the top of the dam. In terminates in a circular horizontal weir, it is termed general, “thickness” is used for gravity and arch a “bell mouth” or “morning glory” spillway. dams, “width” for other dams. Side Channel Spillway―a spillway whose crest is Transition Zone (Semi-pervious Zone)―a part roughly parallel to the channel immediately of the cross-section of a zoned embankment dam downstream of the spillway. comprising material of intermediate size between Siphon Spillway―a spillway with one or more that of an impervious zone and that of a permeable siphons built at crest level. This type of spillway is zone. sometimes used for providing automatic surface- Trash rack―a screen located at an intake to level regulation within narrow limits or when prevent the ingress of debris. considerable discharge capacity is necessary within a short period. Tunnel―a long underground excavation usually having a uniform cross-section. Types of tunnel Spillway Channel (Spillway Tunnel)―a channel include: headrace tunnel, pressure tunnel, or tunnel conveying water from the spillway to the collecting tunnel, diversion tunnel, power tunnel, river downstream. tailrace tunnel, navigation tunnel, access tunnel, Stilling Basin―a basin constructed to dissipate the scour tunnel, draw-off tunnel, and spillway tunnel. energy of fast-flowing water, e.g., from a spillway Under seepage―the interstitial movement of or bottom outlet, and to protect the riverbed from water through a foundation. erosion. Uplift―the upward pressure in the pores of a Stop logs―large logs or timber or steel beams material (interstitial pressure) or on the base of a placed on top of each other with their ends held in structure. guides on each side of a channel or conduit providing a cheaper or easily handled temporary Upstream Blanket―see blanket. closure than a bulkhead gate. Valve―a device fitted to a pipeline or orifice in Storage―the retention of water or delay of runoff which the closure member is either rotated or either by planned operation, as in a reservoir, or by moved transversely or longitudinally in the temporary filling of overflow areas, as in the waterway to control or stop the flow. progression of a flood crest through a natural Water stop―a strip of metal, rubber or other stream channel. material used to prevent leakage through joints Tailrace―the tunnel, channel or conduit that between adjacent sections of concrete. conveys the discharge from the turbine to the river, Weir―(a) a low dam or wall built across a stream hence the terms tailrace tunnel and tailrace canal. to raise the upstream water level, called fixed-crest Tail water Level―the level of water in the tailrace weir when uncontrolled. (b) A structure built at the nearest free surface to the turbine or in the across a stream or channel for measuring flow, discharge channel immediately downstream of the sometimes called a measuring weir or gauging dam. weir. Types of weir include broad-crested weir, sharp-crested weir, drowned weir, and submerged Toe of Dam―the junction of the downstream face weir. of a dam with the ground surface, referred to as the downstream toe. For an embankment dam the junction of upstream face with ground surface is called the upstream toe.

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Central Dam Safety Organisation Central Water Commission

Vision To remain as a premier organisation with best technical and managerial ex- pertise for providing advisory services on matters relating to dam safety. Mission To provide expert services to State Dam Safety Organisations, dam owners, dam operating agencies and others concerned for ensuring safe functioning of dams with a view to protect human life, property and the environment. Values Integrity: Act with integrity and honesty in all our actions and practices. Commitment: Ensure good working conditions for employees and encourage professional excellence. Transparency: Ensure clear, accurate and complete information in communi- cations with stakeholders and take all decisions openly based on reliable in- formation. Quality of service: Provide state-of-the-art technical and managerial services within agreed time frame. Striving towards excellence: Promote continual improvement as an integral part of our working and strive towards excellence in all our endeavours.

Quality Policy We provide technical and managerial assistance to dam owners and State Dam Safety Organizations for proper surveillance, inspection, operation and maintenance of all dams and appurtenant works in India to ensure safe func- tioning of dams and protecting human life, property and the environment. We develop and nurture competent manpower and equip ourselves with state of the art technical infrastructure to provide expert services to all stakeholders. We continually improve our systems, processes and services to ensure satisfac- tion of our customers.

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