Maskinala Dam State of Karnataka

Guidelines for Instrumentation of Large Dams September 2016

Operation and Maintenance Manual for Maskinala Dam State of Karnataka

Doc. No. CDSO_O&M_KA06HH0209_MASKINALA_DAM KAWRD_01_v2.0

Central Water Commission Ministry of Water Resources, River Development & Ganga Rejuvenation Government of India O & M Manual for Maskinala Dam Front Cover Photograph: Downstream view of Maskinala Dam during flood release. Works carried out under the Dam Rehabilitation & Improvement Project (DRIP) include protection works for Dam revetment for the upstream side and turfing on earthen embankment downstream of the dam, CC road approach roads of the dam; providing head sluice service gates and emergency gates for RBC & LBC; and Installing Piezometer, In- frared auto water level recorder; CCTV surveillance system, solar street lights, barbed GI fencing &other works for security of the dam area..

Dam Safety Rehabilitation Directorate Central Dam Safety Organization Central Water Commission 3rd Floor, New Library Building (Near Sewa Bhawan) R. K. Puram, New Delhi – 110066. Email: [email protected] O & M Manual for Maskinala Dam

Operation and Maintenance Manual

for Maskinala 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

October 2019 New Delhi

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Government of India Central Water Commission Central Dam Safety Organization

Following the intrinsic requirements in the Guidelines for Preparing Operation and Maintenance Manu- als for Dams published in June 2019, this manual has been developed to clearly illustrate the com- plexity and importance of managing operations, inspections and maintenance of any large dam. This model manual has been developed under the Dam Rehabilitation and Improvement Project (DRIP) in collaboration with representatives of the Maskinala Dam Chief Engineer, Karnataka Neeravari Nigam Ltd., Karnataka.

Disclaimer: Maskinala Dam is in no way restricts the dam owner in digressing from her/his responsibilities. The Central Dam Safety Organization or the Central Water Commission cannot be held responsible for the efficacy of this manual developed based solely on documents provided by the dam owner. The Dam Owner and her/his Opera- tors must exercise appropriate discretion when implementing and use of the operation and maintenance manual for managing the workings of the dam and appurtenant structures. The manual serves as a model for the sole purpose of other organization for use in developing their own manual for managing the operation, inspection and maintenance required to be carried out to reduce risks and optimizing performance of their dams.

For any information, please contact: The Director Dam Safety Rehabilitation Directorate Central Dam Safety Organisation Central Water Commission 3rd Floor, New Library Building (Near Sewa Bhawan) R. K. Puram, New Delhi – 110066. Email: [email protected]

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MESSAGE

India 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 Rejuve- nation through the Central Water Commission (CWC), with financial assistance 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 essential for ensuring its safe functioning and for deriving continued benefits. This Operation and Maintenance Manual for Maskinala 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 Maskinala 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 Maskinala Dam on regular basis.

I appreciate the initiative taken by CPMU, DRIP and CWC for developing this comprehensive document for implementation by the engineers and administrators of the Maskinala Dam, TLBC Division No.3, Karnataka Neeravari Nigam, Karnataka.

I also 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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O & M Manual for Maskinala Dam

Team Involved in Preparing this Model O&M Manual

Chief Engineer, Irrigation Central Zone, Munirabad. Superintending Engineer, KNNL, TCC circle Yurmurus. Executive Engineer, KNNL, TLBC NO.3 division, Sindhanur Junior Engineer, KNNL, MaskiNala Project Sub Division, Maski(Draft Dawood sab Development)

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TABLE OF CONTENTS MESSAGE ...... III FOREWORD ...... IV LIST OF FIGURES ...... XII CHAPTER 1. - GENERAL INFORMATION ...... 1 1.1 Introduction ...... 1 1.2 Purpose, Location &Description of Maskinala Dam ...... 1 1.3 Background Details of the Project ...... 2 1.3.1 Dam site Location: ...... 2 1.3.2 Maskinala Reservoir Planning: ...... 2 1.3.3 Main Design Features and Components of Maskinala Dam: ...... 6 1.4 Salient Features of Maskinala Dam ...... 7 1.5 Assignment of Responsibility ...... 8 1.5.1 Roles and Responsibilities of the AEE and AE during Monsoon ...... 9 1.5.2 Roles and Responsibilities of the SE and EE during Monsoon ...... 10 1.5.3 Roles and Responsibilities of the Chief Engineer during Monsoon ..... 10 1.6 Collection & Reporting of Dam and Reservoir Data ...... 11 1.7 Public and Project Staff - Health and Safety ...... 13 1.7.1 Restricted Areas ...... 13 1.7.2 Details of the Security arrangements at Maskinala Dam Site...... 13 1.8 Staff Position, Communication & Warning System ...... 15 1.8.1 Schedule of General Duties for Project Engineers ...... 17 1.8.2 Hydro-Mechanical /Electro-Mechanical Inspections / Checks ...... 19 1.9 Distribution of Operation & Maintenance Manuals ...... 22 1.10 Supporting Documents & Reference Material ...... 23 CHAPTER 2. PROJECT OPERATION ...... 24 2.1 Basic Data ...... 24 2.1.1 Area Capacity curves...... 24 2.1.2 Design Flood and Features Related to Safety ...... 24 2.2 Flood Management at Maskinala Reservoirs ...... 24 2.2.1 Gate Operations: ...... 24 2.2.2 Rule Curve ...... 25 2.2.3 Recommended Gate Operation Procedures for Normal Flow Conditions25 2.2.4 Sequence of Opening or Closing of Gates ...... 27 2.2.5 Inflow Forecasting ...... 29 2.2.6 Methodology of Flood Regulation at Maskinala Reservoir ...... 29

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2.2.6.1 Inflow Computation ...... 29 2.2.6.2 Examples of Inflow Computation ...... 30 Example1...... 30 Example2 ...... 30 2.2.6.3 Example of Computation for Required Gate Opening ...... 30 2.2.7 Summary of Flood Regulation Procedure ...... 30 2.3 Operation of Radial Crest Gates of Maskinala Dam ...... 37 2.3.1 Brief Description...... 37 2.3.3 Salient Features...... 38 2.3.4 Material Specification ...... 39 2.4 Operating Instructions ...... 39 2.4.1 Checklist before Operation ...... 40 2.4.2 Rope Drum Hoisting Arrangements for Radial Crest Gates ...... 41 2.4.2.1 Operational Instructions for Rope drum hoist of Radial Gates of Spillway 41 2.4.2.2 HEAD REGULATORS OF THE CANAl: ...... 42 2.4.2.3 HEAD WORKS: ...... 42 2.5 Condition: ...... 43 2.5.1 General: ...... 43 2.5.2 Deficiencies and problems ...... 43 2.5.3 Potential problems ...... 43 2.5.4 Historical Events ...... 43 2.5.5 Operation: ...... 43 2.5.5.1 General ...... 43 2.5.5.2 Restrictions………………………………………………………………..43 2.5.5.3 Mechanical………………………………………………………………...44 2.5.6 References: ...... 44 2.5.6.1 Reports and Data...... 44 2.5.6.2 Drawings: ...... 44 2.6 ACCESS ROADS…………………………………………………………………..44 2.6.1 Description…………………………………………………………………..44 2.6.2 Condition…………………………………………………………………….45 2.6.3 General………………………………………………………………………45 2.6.4 Deficiencies and problems…………………………………………………..45 2.6.5 References……………………………………………………………………45 2.6.6 Reports and Data……………………………………………………………45

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2.7 Record Keeping ...... 45 CHAPTER 3 - PROJECT INSPECTIONS ...... 46 3.1 Types of Inspections ...... 46 3.1.1 Comprehensive Evaluation Inspections...... 46 3.1.2 Scheduled Inspections ...... 47 3.1.3 Special (Unscheduled) Inspections ...... 47 3.1.4 Informal Inspections ...... 48 3.2 Pre- and Post-Monsoon Checklist and Example of Report Proformas ...... 48 CHAPTER 4 - PROJECT MAINTENANCE ...... 56 4.1 Maintenance Priorities ...... 56 4.1.1 Immediate Maintenance ...... 56 4.1.2 Preventive Maintenance ...... 57 4.1.2.1 Condition Based Maintenance ...... 57 4.1.2.2 Routine Maintenance ...... 57 4.2 Procedures for Routine Maintenance ...... 58 4.2.1 Earthwork ...... 58 4.2.2 Masonry / Concrete Dams & Spillways ...... 62 4.2.3 Gates & Hoisting Equipment ...... 62 4.2.4 Electrically operated fixed hoists ...... 65 4.3 Maintenance of Electrical Components of fixed Rope Drum Hoists………….67 4.4 Spillway Radial Gate……………………………………………………………..68 4.5 Surface Preparation &Painting of HM Works………………………………….69 4.6 Electrical System…………………………………………………………………..73 4.7 Maintenance of Metal Gate Components………………………………………..73 4.8 Access Roads……………………………………………………………………….74 4.9 General Cleaning………………………………………………………………….74 4.10 Materials and Establishment Requirements during Monsoon Period………..74 4.11 General List of Maintenance Records…………………………………………..75 4.12 Preparation of O&M Budget…………………………………………………….75 4.13 Maintenance of Records………………………………………………………….78 CHAPTER 5 - INSTRUMENTATION AND MONITORING ...... 79 5.1 Dam Instrumentation ...... 79 5.1.1 General Information ...... 79 5.1.2 Instruments Embedded in the MaskiNala Earthen Dam ...... 79 5.1.3 Seismological Observations ...... 79

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CHAPTER 6 - PREVIOUS REHABILITATION EFFORTS ...... 80 CHAPTER 7 - UPDATING THE MANUAL ...... 81 APPENDIX 1 ― BASIC DRAWINGS OF MASKINALA DAM ...... 89 APPENDIX 2 ― KEY ELEMENTS OF THE EAP FOR MASKINALA DAM ...... 89 APPENDIX 3 ― MATERIAL REQUIRED FOR MAINTENANCE DURING MONSOON ...... 93 APPENDIX 4― SCHEDULED OR UNSCHEDULED DAM SAFETY INSPECTION FORM ...... 94 APPENDIX 5 – CCTV CAMERA SYSTEM SPECIFICATIONS ...... 115 APPENDIX 6 – HYDRAULIC OIL SERVICING AND MAINTENANCE INSTRUCTIONS...... 117 APPENDIX 7 -- GLOSSARY ...... 119

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List of Tables

TABLE 1 - DETAILS OF DISTRIBUTED WATER TO KARNATAKA 1 TABLE 2 – OVERALL RESPONSIBILITIES FOR MASKINALA DAM 9 TABLE 3 – ROLES & RESPONSIBILITIES OF AEE & AE 10 TABLE 4 – ROLES & RESPONSIBILITIES OF SE & EE 10 TABLE 5 – ROLES & RESPONSIBILITIES OF THE CHIEF ENGINEER 10 TABLE 6 – EXAMPLE PROFORMA FOR RECORDING FLOW DATA 12 TABLE 7 - DISTRIBUTION OF O&M MANUAL AND REVISIONS 23 TABLE 8 – RULE LEVEL ELEVATIONS 26 TABLE 9 - GATE OPERATION SCHEDULE FOR FLOOD REGULATION (AREA CAPACITY TABLE) 31 TABLE 10–SPILLWAY DISCHARGE RATING (WITH FRL = 472.12M) 32 TABLE 11 - RATE OF CHANGE IN STORAGE AT MASKINALA RESERVOIR 33 TABLE 12 –O&M BUDGET COSTS (ANNUAL) 74 TABLE 13 - LOCATIONS AND EXTENTS OF STRUCTURAL MEMBERS 77 TABLE 14 - EMBEDDED INSTRUMENTS 77

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List of Figures

FIGURE 1 - KRISHNA BASIN MAP ...... 5 FIGURE 2 - OVERHEAD IMAGE OF MASKINALA DAM ...... 6 FIGURE 3- LAYOUT OF MASKINALA DAM PREMISES ...... 14 FIGURE 4 - ORGANISATION CHART ...... 17 FIGURE 5 - RATE OF CHANGE FOR RESERVOIR STORAGE ...... 35 FIGURE 6–VIEW OF UPSTREAM RIPRAP MASKINALARESERVOIR ...... 58 FIGURE 7 – DAM CREST PAVED ROAD OVER EMBANKMENT ...... 60 FIGURE 8 – GATE HOISTING ARRANGEMENT OF MASKINALA PROJECT ...... 61

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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 transmis- GPS sion like browsing the web) FRL Full Reservoir Level MWL Maximum Water Level MDDL Minimum Draw Down Level DSL Dead Storage Level SCADA Supervisory Control and Data Acquisition EDA Energy Dissipation Arrangement HM works Hydro-Mechanical works DG set Diesel Generator set RMU Remote Monitoring Unit PC Personal Computer TMC Thousand-Million M3

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CHAPTER 1. - GENERAL INFORMATION

1.1 Introduction This document represents a detailed Operation and Maintenance (O & M) Manual for Maskinala 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, and 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 Maskinala Dam The Maskinala stream which flows in Koppal and Raichur district rises in the hilly region between Kushtagi and Gajendragada, and between Kushtagi and Yalburga at a height of about 685.80 m (2250 Fts.) above mean sea level. The river is a seasonal one. It is a tributary to river Tungabhadra. Since the Maskinala originates in the Kushtagi taluka of (Then Raichur) Koppal district and joins the Tungabhadra river in Manvi taluka of Raichur district, therefore no inter- state problems arise. However, since this valley forms small portion of the Krishna basin (Tungabhadra sub basin) the water proposed to be utilized will be part of the total water allotted for utilization in the Karnataka state from the Krishna basin. ie., an allocation made for Maski- nala Project is 22.08 M.Cum (0.78 TMC). The monsoon period is taken from June to October. The catchment is influenced by three- gauge stations Kushtagi, Ilkal and Lingasugur. The rain fall data for the common period from 1945 to 1977 (32 years) of the three rain gauge stations at Kushtagi, Ilkal and Lingasugur have been considered. Table 1- Details of Distributed Water to Karnataka The total yield arrived at as per Strange’s table considering rain fall i) 1.22 TMC at 75% confidence year ii) An allocation made for Maskinala Project 0.78 TMC

There is no other source of irrigation in this area except harnessing the Maskinala for the purpose. The project is found to be feasible and contributes to the development of the chroni- cally scarcity and famine affected areas and improves the food and employment position. The project is therefore recommended for implementation.

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1.3 Background Details of the Project The Maskinala River is a fairly large tributary to the Tungabhadra river on its left flank. The catchment is an elongated one and the total length of the nala from its origin till it joins at the river Tungabhadra is nearly 132.80 K.M. (83 Miles). In the initial reach i.e. up to nearly 75 K.M. (45 Miles), the nala flows in south west to north west direction and then it takes a turn and flows in south east direction for the remaining length 60.80 K.M. (38 miles) till it joins the Tunga- bhadra river near Edavali village. The area drained up to Maraladinni dam site consists of sand and boulders gravels. Hence the nala carries a fair amount of silt during floods. It can also be seen that the nala is having a gentler slope after the Maraladinni site. The rainfall in the catchment area upstream of the Maraladinni site is mostly confirmed to the monsoon season from June to October. The investigation for an irrigation project was carried out by the special Engineer, Investigation Circle Hyderabad in the year 1944. Three sites appear to have been considered, but the details are not available. After the re-organization of states further works on the investigation of the project was taken up by Executive engineer, Major Irrigation Project Division Dharwad. The records further reveal that a site located one mile upstream of the Maraladinni village was approved by the Executive Engineer during the inspection on 21.05.1969 and the present project is the result of the investigations carried out through several years since then.

1.3.1 Dam site Location: Maskinala dam is situated at Latitude 16° 00’ 40’’ North and Longitude 76° 33’ 30’’ East, in the village area of Maraladinni (Then in Lingasugur Taluk) Maski taluk of Raichur district. See location and vicinity map in Figure 1 below.

1.3.2 Maskinala Reservoir Planning: i). Catchment: The catchment area of the Maskinala at Maskinala (Maraladinni) dam site is 800 sq.-km. (309 Sq-miles). The catchment has the total length of the nala from its origin till it joins at the river Tungabhadra is nearly 132.80 Km (83 Miles).The head reaches of the catch-

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0 Page 2 O & M Manual for Maskinala Dam ment area lie in in the hilly region between Gajendragad, Kushtagi, and between Kushtagi and Yalburga at a height of about 685.80 m (2250 fts.) above mean sea level. The catchment classified as average catchment the rain fall in the catchment area upstream of the Maraladinni site is mostly confirmed to the monsoon season from June to October. and the Nala will be in floods during these months when almost the entire yield is received. ii) Yields: The Maskinala river has not been gauged either at the proposed dam site or at any other point previously, and hence the flow records are not available. Theissanplyagon & Stranges formulas, Khosla formula: The catchment area is influenced by three rain gauge stations i.e. Ilkal, Kushtagi and Lingasugur. Out of these Kushtagi rain gauge station is situated within the catchment and other two just on outskirts of the catchment. As per Theissanplyagon constructed, the catchment area influenced by each of the rain gauge stations are given below.

Rain gauge station Catchment area 1. Kushtagi 462.47 Sq.KM (78.56 Sq.Miles) 2. Ilkal 97.47 Sq.KM (37.64 Sq.Miles) 3. Lingasugur 240.35 Sq.KM (92.80 Sq.Miles) 800.31 Sq.KM (309.00 Sq.Miles)

The Monsoon rain fall is taken at 75% confidence limit. The weighted rain fall has been arrived at after considering the extent of the catchment area influenced by the different rain gauge stations. The total yield arrived at as per Strange’s table considering the catchment as ‘average’ has been distributed in the proportion of monthly rain fall at 75% confidence year. The total yield works out 34.566M (1223.64 M.Cft). iii) Storage: The nala has neither been gauged at the proposed dam site, nor it has been gauged on the downstream or upstream of the dam site. As Instruction of MIPC Chairmen and Technical committee value of C=2000 in Ryve’s formulas, the max. flood discharge works out 2590 cumecs. (91500 cusecs) and was adopted for the design of central spillway. Hence the dam is designed to pass a probable maximum flood of 2590cumecs. The gross storage capacity at FRL of 472.12m is 14.04 MCM (0.50 TMC) with a live storage of 11.38MCM. (0.40 TMC) and a dead storage of 2.66 MCM (0.1 TMC) at MDDL of 463.30 m. The crest level is at R.L 463.626m. iv) Water Spread: The reservoir water spread submerges an area of 172.80 Ha. (427acres ) without affecting any villages.

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MaskiNala Dam

Figure 1 - Krishna Basin Map

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Figure 2 - Overhead Image of MaskiNala Dam

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1.3.3 Main Design Features and Components of Maskinala Dam: i) Components: The dam consists of a spillway portion for a length of 57.00m (From Ch.341.50 Mtrs. to 398.50 Mtrs) in the centre of the Nala gorge, with Earthen Dam on either side. The earthen dam of 265.30 m (Ch. 76.20 m to Ch. 341.50 m) on the left flank, and 491.50 (Ch.398.50 m to Ch.890.00 m) on the right flank. The total length of the dam including all sections is 813.80 m. ii) Earthen Dam: The earthen dam has been designed as Zonal section comprising of hearting and casing materials. It has a maximum height of 23.74 m and top width of 3.66 M at RL 474.880 M. This gives a free board of 2.76 M. For earthen dam portion, necessary cut off trench has been provided to depth of 0.50 H or 0.60 M. in which even is earlier.

1.40 M thick inclined filter is provided to keep the phreatic line well within the section. 1.40 M thick longitudinal drain, cross drain and toe drains are also provided. Lead of the seepage water 2.00 M below rock toe on the downstream side 0.45 M thick revetment over 0.45 M thick filter has also been provided. On left flank from Ch.210.00 M to 300.00 M and right flank from Ch.420.00 M to 570.00 M an impervious blanket of 1.50 M thick has been provided to a width of 4 h to 5 h. Hearting of the dam is provided with the impervious material from borrow area. The hearting section provided has a top width of 2.44 M at RL 472.620 i.e. 0.50 M above M.W.L. 472.120 with side slope 0.50:1. iii) Spillway Dam Section: The Concrete spillway of length 57 M constructed in the gorge portion from Ch.341.50 M to 398.50 M. with 4 Nos of radial crest gates of size 12 m X 8.50 M to surplus a capacity of 2590 Cumecs (91500 Cusecs). At the toe of the spillway, hydraulic jump type horizontal stilling basin with chute blocks, baffle blocks and dentate end sills etc., provided for the purpose of energy dissipation. At the junction of earthen dam and spillway, wing walls are provided on the U/S side and training walls on the D/S side with key wall and abutment black. iv) Irrigation Sluices: Two (2) irrigation sluices one on left side and another on right side are provided. The irrigation sluice consists are one vent of size 1.00 X 0.80 M box type. A central well with provision of emergency gate, and main gate is provided on U/S portion of the sluice barrel for regulating flow though the sluice. Sluice gates operated manually for the sluices release water for the canals.

Periodical maintenance of Spillway radial gates and canal head sluice 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 gates are being taken up as and when required on tender basis.

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1.4 Salient Features of Maskinala Dam Sl. No Items Details A. General On Maskinalanear Maraldinni village in MaskiTaluk (then in Lingasugur Taluk) of Raichur district at: 1 Location of Dam Latitude 16° 00’ 40’’ N Longitude 76° 33’ 30’’ E The site about 1.00 Km from Maraladinni village which is about 14 miles from Lingasugur. And 15.00 KMs from Maski. 2 Means of Access The dam site is approachable by a road taking off from mile No. 10/6 of Lingasugur – Maski – Sindhanur road. (NH 150A) B. Geophysical Features 1 Catchment area 800 Sq.Km. (309.00 Sq Miles) 2 Nature of catchment Average. 3 Climate Moderate. Varies from 63.90°F (in winter) to 103.70°F (in 4 Annual mean temperature Summer) 5 Mean annual precipitation Varying from 18" to 20" Net yield Dam site at 75 % dependabil- 6 34.66M cum (1223 M. cft.) ity 7 Silt charge per year 1.926 Acre ft/sq.mile (0.000083 TMC/Sq Mile) Metamorphic terrain with pink granite, gneisis, 8 Geological features at dam site hornblende, schist and quartzite. C. Technical Details of Dam 1 Gross Storage Capacity 14.04 Mcum (0.50 TMC) 2 Dead Storage 2.42 M.cum (0.10 TMC) 3 Lowest Foundation Level (El.) 445.00 m (1456 ft) 4 Lowest River Bed Level (El.) 452.66 m (1485 ft) 4.a Sill of Irrigation Sluice (El.) 463.30 m (1520 ft) 5 Dead Storage Level at MDDL (El.) 463.30 m (1520 ft) 6 Full Reservoir Level (FRL) (El.) 472.12 m (1549 ft) 7 Maximum Water Level (MWL) (El.) 472.12 m (1549 ft) 8 Crest level (El.) 463.62 m (1521 ft) 9 Top Level of Dam (El.) 474.88 m Earthen Dam 10 Maximum area of water spread 172.80 Ha (1.728 Sq.Km) 11 Length of dam 813.80 m (2670 ft) Maximum height of dam above the 12 29.88 m (98 ft) lowest foundation level Height of dam above the lowest River 13 23.74 m (78 ft) Bed Level 14 Top width of dam 3.66 M (12 ft) 15 Designed flood intensity 2950 cumec (91500 cusecs) 16 No. & size of spillway crest gates 4 Nos. of 12 M x 8.50 M gates Radial Type No. and dimensions of irrigation sluice 2 Nos. of 1.00 m x 0.80 m 17 gates Box type vertical lift D. Details of submergence 1 Total area of submergence (Gross) 142.00 Ha 2 Villages submerge Nil 3 Population affected Nil 4 Road Village road

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1.5 Assignment of Responsibility The Karnataka Neeravari Nigam 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 include regularly scheduled duties which staff personnel are required to perform as outlined in the following tables: Table 2 – Overall Responsibilities for Maskinala Dam Sl No Particulars Remarks KARNATAKA NEERAVARI NIGAM (A Govt of 1. Implementing Agency Karnataka Undertaking) Water Recourses Department, Karnataka Project Administration 2. Managing Director, KNNL, Bengaluru Officer in charge Operations of Equip- 3. Chief Engineer, KNNL, ICZ Munirabad ment at the Dam Reservoir inflow and Executive Engineer, KNNL, TLBC Division, No.3 4. Flood forecasting Sindhanur Authorising spillway 5. Chief Engineer, KNNL, ICZ Munirabad flood releases Executive Engineer, KNNL, TLBC Division, No.3 Sindhanur as per the proceedings of the Irrigation Authorising releases for 6. Consultative Committee meeting (ICC) and in con- irrigation, sultation with Chief Engineer, KNNL, ICZ Munira- bad Assistant Executive Engineer KNNL MNP Sub 7. Recording reservoir Data Division Maski Executive Engineer, KNNL, TLBC Division, No.3 8. Routine inspection Sindhanur Executive Engineer, KNNL, TLBC Division, No.3 9. Maintenance Sindhanur Executive Engineer, KNNL, TLBC Division, No.3 10. Instrumentation Sindhanur Assistant Executive Engineer KNNL MNP Sub Division Maski

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1.5.1 Roles and Responsibilities of the AEE and AE during Monsoon

Table 3 – Roles & Responsibilities of AEE & AE

Step Flood condition assessment, warning, flood mitigation, and other responsibilities Assist the EE/SE/CE to issue notification to the villagers downstream in News- 1. 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- 2. 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 3. on the flood condition Maintain the reservoir water level gauge register and to update on hourly basis dur- 4. ing 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 5. prepare proforma consisting of the status of the reservoir capacity and releases 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- 6. tus of the reservoir twice in the day

7. Maintain the spillway crest gate operation log book

Operate the Spillway crest gates for flood mitigation as per the instructions of the 8. EE/SE/CE and to update the Gate operation Log book Observe the gates and to see that the drain holes are not clogged and floating de- 9. bris is not deposited in the gate components Monitor the condition of the Welding transformers, gas cutting sets, umbrellas, 10. tool kits torches chain blocks ropes balliesetc 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 11. 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 maintained 12. 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 EE/SE/CE in case of any 13. untoward incidents or malfunctioning of the gates of excessive seepages, leakages etc Assist EE/SE/CE to share the flow data and the reservoir storage details to the 14. Media on day to day basis

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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 Step Responsibilities To issue notification to the villagers downstream in Newspapers, Radio, TV News 1. channel to be alert regarding the flood situation Assist the CE to coordinate with the Revenue authorities (District Administration) 2. 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 3. flood condition Submit to the CE on the inflows and releases from the reservoir and status of the 4. reservoir twice in the day Operate the Spillway crest gates for flood mitigation as per the instructions of the 5. CE and to update the Gate operation Log book Observe the Gates ,hoists and handling equipment during operation for the 6. 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 maintained 7. by housekeeping personnel Observe the performance of the Dam and its appurtenant structures / Gates and 8. Hoists during flood water releases and to report to the CE in case of any untoward 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 on 9. 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 Project En- 1. gineers, to the information on the rainfall in the catchment and inflow status at the Nagalapur bridge 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 the 3. inflows, rainfall data, 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. Conduct Pre and Post Monsoon inspections of the Dam

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1.6 Collection & Reporting of Dam and Reservoir Data A proforma is provided to ensure that dates and times for the collection and reporting of vital information is recorded and documented for the record.  Reservoir water surface elevation.  Reservoir inflow.  Spillway outflow.  River releases.  Irrigation releases.  Weather related data  Instrumentation data  Water quality Instructions and a standard Performa for collection and reporting of inflow and outflow data, and other pertinent data is shown in Table 6 below. Records [Logbooks] of the following operations at Maskinala 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, 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 Proforma for recording Flow Data

For the Month of ______Reservoir Capacity Water Inflow in Out Flow in Cusecs Date Time level in TMC Cusecs1 in Mtr. Spillway Gates LBC RBC Total O/F

Footnote 1: To be indirectly calculated as per examples 1 and 2 in Chapter 2, Paragraph 2.2.9.2

Legend  LBC: Left Bank Canal of MNP  RBC: Right Bank Canal of MNP

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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. Electronic kiosks located on the left and right abutment 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 include the following:  Spillway approach areas, chutes and stilling basins.  Control buildings and valve areas.  Intake or outlet channels adjacent to hydraulic structures.  Upstream and downstream slopes/faces of the dam.

1.7.2 Details of the Security arrangements at Maskinala Dam Site The security arrangements are made at Maskinala dam. Since this is a small dam with Gross storage capacity of 0.50 TMC, a limited No. of security personal (Watchmen through Contractor) are deployed at dam round the clock. They are deployed at critical location viz. dam main Entrance, Check posts, Head works etc.

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Figure 3 Layout of MaskiNala 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 referenced in this Manual. Staff positions vary according to requirement during monsoon / non-monsoon periods. An engineering organizational 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 mobile phone sat different locations on the dam. Security staff is deployed to maintain security of the dam. A utility room located on the Left side of the Dam has an equipment room with all essential small tools, welders, chain blocks and ropes, and consumables to facilitate O & M requirements.

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Chief Engineer KNNL

Irrigation Central Zone Munirabad Land Line::08539-270026 email: [email protected]

Superintending Engineer KNNL, T. C.C. Circle Yaramarus Land Line: 08532-251369 e-mail: [email protected]

Executive Engineer KNNL, TLBC Division No.3 Sindhanur Land Line: 08535-220060 e-mail: [email protected]

Assistant Executive Engineer KNNL, MaskiNala Project Sub Division Maski Land Line:08535-220060 Mobile: 9483900555 e-mail: [email protected]

Assistant Engineer Junior Engineer

Figure 4 - Organisation Chart

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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 Maskinala Dam are provided in this section. All activities are to be recorded daily in the Log- book and site registers. DAILY  Visual inspection of dam  Crest of dam (Dam top)  Upstream and downstream faces  Visible portions of foundation and abutments contacts  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-Toe drains, 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, and, during any reservoir filling operations MONTHLY Check condition of: Dam and Reservoir  Reservoir periphery (During Monsoon)  Drainage systems - Toe Drains, etc. (on regular basis from second year onwards after initial reservoir filling)  Measuring devices/Instruments  Security and safety devices – rectification, if needed.  Communication Devices  Status of Vegetation growth  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

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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, EDA, 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  Exercise gate and valves for operational efficiency  Check oil reservoir level in hydraulic 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.

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 Operating equipment of gates and hoists of Spillway  Operating equipment of any other gates and hoists in dam  Spillway catwalk / bridge  Check Gate limit switches and adjust

ANNUAL Spillway & Outlet works  Paint  Metalwork, Gate, Hoists and all exposed metal parts for corrosion  Valves / Control valves  Hydraulic power pack system  Exercise Gates and Valves  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)  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 Hydro-Mechanical /Electro-Mechanical Inspections / Checks The Maskinala Dam is provided with conventional type rope drum hoist arrangements for radial gate operation. Frequency of inspections / checks for these components and necessary actions to be taken up during maintenance 1. Radial Crest Gates - 4 Nos.

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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 to 1 Half Yearly continuous use, pitting and un-necessary cracks due to wear & carrying out requisite repairs, rectification by welding, grinding etc. Removing debris & other foreign material deposited on embedded parts 2 Monthly & 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 trunnion assemblies as well as trunnion chair and lubricate trunnion bearing & 4 Monthly the sliding surface on trunnion chair with specified lubricant/ grade to ensure smooth sliding movement of trunnion. All nuts 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. b. Gate Structure

Sl. Embedded Part Frequency No. Regular inspection of the gate along with the hoist to be carried out daily 1 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 & Trun- 3 nion with the help of magnifying glass for cracks/ defects and rectify the Quarterly 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 defective 5 Quarterly nuts & bolts Check upstream face of Skin plate for pitting, scaling and corrosion. Scaling 6 formations are to be removed. Pitting shall be filled with weld & ground. Yearly Corroded surface shall be cleaned & painted Joints of side & bottom rubber seals to be checked for their proper align- 7 ment and fixing & to be rectified/ adjusted if there is leakage through Monthly joints Nuts & bolts for rubber seal connection to be tightened and damaged nuts 8 Quarterly 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 shall-be 9 carried out after supply of rubber seal by the department free of cost in Quarterly 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. Rope Drum Hoist 4 Sets

Sl. Description Frequency No. Checking of oil level of power packs and pouring of make-up oil as 1 Daily & when required Monthly & during 2 Checking, adjustment & repairing of relief & flow rainy season Checking, adjustment & repairing of pressure switch &, . flow Monthly & during 3 switch, solenoid valves, etc. rainy season Checking, cleaning, etc., of all filters, silica gel etc., & their replace- 4 Weekly ment and when required Checking & repairing & replacement whenever necessary, oil seals, 0- Every 5 rings, ferules, argon welding, etc. of hydraulic pipe lines 2 months Checking of the main and pilot pressure of the system for their de- 6 Weekly sired level & adjustments, required repairing Checking, adjustment & repairing of all measuring system such as 7 Monthly TGSE, etc Checking, repairing and replacement whenever necessary of all 8 Monthly valves, valve seals, couplings of pipe lines, etc Checking, repairing & making good of all electrical wirings & con- 9 Monthly nections of local panels Checking, repairing & making good and replacement of all electrical 10 contractors, timers, limit switches fuses etc. including setting of limit Monthly switches 11 Checking & maintaining hydraulic accumulator charging pressure Weekly Complete trouble shooting of the entire system as and when neces- 12 sary to maintain the same such that the system can be put to opera- Weekly tion at any point of time as per requirement Checking and ensuring perfect lubrication of the entire equipment 13 Monthly with recommended lubricants & methods of the manufacturer. Checking & ensuring adequate hydraulic oil of standard make by 14 Monthly making up short falls if any The maintenance of the equipment cleaning & shall include inspection, checking and ascertaining the deficiencies in the equipment for As per 15 its smooth & trouble free operation. The deficiencies noticed shall be rectified by resorting to cleaning, adjustment, repairs, replace- requirement ment of troubled/ damaged parts as per the requirement Necessary maintenance records are to be prepared as a result of pe- 16 riodical inspection and submitted for deciding actions in respect of Monthly necessary repair/replacement of parts

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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 Sl No Unit Officers Manual Distribution Secretary to Govt, Water Resources Department, VikasaSoudha, 1. 3 Bengaluru 2. Managing Director, KNNL, Bengaluru 3 3. Chief Engineer, KNNL, Irrigation Central Zone Munirabad. 2 4. Library of the Dam Zone, Munirabad 1 Chief Engineer, Water Resources Development Organization, 5. 1 Bengaluru. 6. Director, KERS, K R Sagara. 1 7. Superintending Engineer, SPMU, WRDO, Bengaluru 1 8. Superintending Engineer, KNNL, TCC Circle, Yaramarus 1 9. Library of the TCC Circle, Yaramarus 1 10. Executive Engineer, SPMU, DRIP Bengaluru 1 Deputy Chief Engineer, KNNL, Irrigation Central Zone Muni- 11. 1 rabad. 12. Executive Engineer, KNNL, TLBC Division, No.3 Sindhanur 1 13. Executive Engineer, Monitoring and Evaluation, Bengaluru 1 14. Library of the Dam Division, Sindhanur 1 15. TA to CE, Irrigation Central Zone Munirabad. 1 16. TA to SE, TCC Circle, Yaramarus 1 Assistant Executive Engineer, KNNL, MNP Sub Division, 17. 1 Maski 18. Assistant Engineer-1, MNP Sub Division, Maski 1 19. Junior Engineer-2, MNP Sub Division, Maski 1 20. Technical Section of Central Office 1 21. Technical Section of Circle Office 1 22. Technical Section of Division Office 1

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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 will be available at site in the near future:  Emergency Action Plan (EAP)  Flood forecasting and operating criteria  Basin or river operating plan  Agreements with other user agencies  Irrigation operation plan  Administrative procedures  Reservoir / River pollution contingency plan  Maintenance schedules  Gate Manufacturer’s instructions and drawings  Regional communication directory  Instrumentation reports / results

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CHAPTER 2. PROJECT OPERATION

2.1 Basic Data The Maskinala Dam 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 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 Maskinala Dam tabular and graphical form are shown in Table 10 and Figure 5.

2.1.2 Design Flood and Features Related to Safety The maximum flood design at Maskinala Dam site was earlier fixed at 2590 cumecs. As Instruc- tion of MIPC Chairmen and Technical committee meeting held on 27th Jan 1988, value of C=2000 in Ryve’s formulas, the max. Flood discharge works out 2590 cumecs. (91500 cusecs.) The spillway is designed for this design flood. The design flood has been reviewed under DRIP. The revised design flood worked out to 2351 Cumecs (83035 Cusecs) is communicated vide Chief Engineer WRDO Bengaluru Letter No:CE/WRDO/HYD/TA-2/AE-3/131/DRIP /RFD /Concurrence/2015-16 Dt 05.10.2015. As the spillway was originally designed for 2590 Cumecs (91500 Cusecs) which is higher than the revised flood, the same may be adopted as design flood in dam safety review of the project for DRIP purpose only.

2.2 Flood Management at Maskinala Reservoirs

2.2.1 Gate Operations: During flood season Table (10) & Table (11) are available & the flood control will be done according to Table (10)& (11). Table (10) gives the Elevation – Area – Reservoir capacity & Table (11) gives details of discharges through each vent of gates. There are 4 Radial gates in this dam, which are operated during flood season to discharge the flood water.

Release Operation: There are 2 nos. of Head sluice gates for outlet works; one each for-Left Bank Canal and the Right Bank Canal. Except for flood control purposes, releases from the outlet works shall only be made as required for irrigation purpose.

Also, the water level should not be allowed to go beyond FRL under normal condition (s)

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2.2.2 Rule Curve Although the storage capacity is only 14.04 Mcum, Rule levels have been determined for Maskinala dam.The gross storage of Maskinala Dam at FRL 472.12 m is 14.04 M cum. The Maskinala dam was earlier designed for an inflow flood of 2950 cumecs and as per revised designed flood review studies estimated SPF is 2351cumecs. The flood discharging capacity at FRL is 1500 cumecs. Based on the studies the tentative Rule Levels for Monsoon is as below. Table 8-Rule level Elevations 01/07 01/08 01/09 471.90 m 471.90 m 472.12 m

The detailed guidelines for gate operation : (1) Spillway discharges at different reservoir levels and gate opening and (2) Rate of change in storage to decide inflow based on rise/fall in Reservoir level in unit duration are prepared and indicated in Table above. The flood discharging capacity at FRL is adequate with all the gates open and is 1807 cumecs with three gates in operation (one gate inoperative). No flood storage is available in the reservoir. The flood lift when SPF impinges the reservoir when the reservoir is at FRL and with three gates operative is 0.14 m. Hence it is suggested to keep the reservoir at 0.2 m below the FRL to safely pass the flood without encroaching into the free board. When the proposed rule levels are reached and the position is such that the water is to be stored above the rule level, in that case or water is to be released for the purpose other than irrigation before rule levels are reached, the concurrence from the concerned Chief Engineer may be obtained.While deciding the above parameters, prevailing overall conditions of the rainfall during the monsoon, storage capacity and safety of the dam structure and U/S – D/S structures, flood cushion available in the reservoir above the rule level of the particular time and efficiency of the existing network and flood warning arrangement along with communication system and actual experiences of the same in the past will be critically examined by the concerned officers in consultation with respective Chief Engineer.

2.2.3 Recommended Gate Operation Procedures for Normal Flow Conditions Under normal flow conditions the reservoir is operated according to the Area-Capacity curve elevations.

Vent opening Maskinala Reservoir in feet Discharge through each vent for difference vent levels Reservoir water Reservoir water lev- Reservoir water level level 1548 feet el 1549 feet 1550 feet

1 1563 1657 1752

2 3028 3212 3400

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4 5668 6028 6395

5 6847 7291 7744

6 7997 8526 9067

7 8930 9535 10153

8 9838 10520 11217

9 10616 11597 12383

10 11771 12626 13502

11 12432 13357 14305

12 13034 14030 15049

13 13554 14616 15705

14 14013 15141 16297

15 14391 15581 16802

16 14639 15883 17161

17 14845 16143 17478

18 15029 16384 17777

19 15189 16600 18052

20 15322 16792 18305

21 15437 16967 18543

22 15531 17121 18763

23 15672 17334 19051

24 15864 17608 19412

25 16073 17907 19806

26 16425 18373 20393

27 -- 18831 20980

27.89 -- -- 21451

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MaskiNala Reservoir Raise in Reservoir Inflow in Cusecs Level Per Hour 1548.0 1548.1 695 1548.2 1390 1548.3 2220 1548.4 3050 1548.5 3960 1548.6 4860 1548.7 6110 1548.8 7360 1548.9 8700 1549.0 10140 1549.1 11670 1549.2 13300 1549.3 15110 1549.4 17470 1549.5 20530 1549.6 24280 1549.7 28450 1549.8 33300 1549.9 38860 1550.0 45800

2.2.4 Sequence of Opening or Closing of Gates The end gates normally be opened first to prevent cross- flows striking against the wasll and junctions. After opening the end gates , the gates at the centre should be opened in symmetrical manner starting from the centre towards end through gradual increase in the openings.While closing the gates, the gate that was opened last should be closed first. The procedure to be followed for closing the gates should be generally reverse of the procedure follwoed for opening the gates. Complete closued of the gates accomplished by gradual lowering of the gates by 0.2 to 0.3 m in the proper sequence.

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.

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1570.00 Reservoir Normal Operations Upper Guide Curve based on 1560.00 Historical Data FRL= 1548.95 FEET 1548.951548.951548.951548.951548.951548.951548.951548.95 1550.00 1545.77 1543.64 1539.37 1540.03 1538.55 1537.40 1540.00 1535.76 1536.75 1536.09 1535.76 1533.14 1534.12 1530.51 1530.00 1526.90 1522.64 1521.06 1520.00Reservoir in Levels feet

1510.00

1500.00

Time Fortnight

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2.2.5 Inflow Forecasting Forecast verification criteria: These are an established feature of meteorological and hydrological best practice, through which the forecast output is compared to respectively to observations. Forecast verification is carried out periodically, at the end of a flood season. A number of measures may be employed : Probability of detection(POD), Hit Rule (HR), False Alarm Rate (FAR),The Brierskill- score, Continuous measures, such as Bias (mean error) root mean square error(RMS) and mean abso- lute error (MAE). These are all relative values, i.e.) there is right or wrong score. 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 telecommunication 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 MaskiNala Dam are as listed below Karnataka State: 1) Chief Engineer, ICZ Munirabad. Phone No 08539 - 270026 Mobile No. 9964696492 2) Superintending Engineer, TCC Circle Yaramarus Phone No 08532-251369, Mobile No. 9449973216 3) Executive Engineer, TLBC Division, No.3 Sindhanur Phone No. 08535-220060, Mobile No. 9448438572 4) Asst. Executive Engr. Mobile No 9483900555 Junior Engineer Mobile No. 9483900555

2.2.6 Methodology of Flood Regulation at Maskinala Reservoir The method of flood regulation for Maski Nala Reservoir is as follows. The inflow coming into the reservoir is first estimated by knowing the gauge at Nagalapur bridge which is on upstream of the Maski Nala Dam. (e.g., by Inflow forcasting method). The rate of release required to ensure that the reservoir level does not exceed the maximum permitted (in this case, the FRL) is then calculated and the gates are opened to effect this release. The release required is calculated by the formula.

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

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.

2.2.6.1 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.

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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 Maski Nala reservoir for a rate of rise in reservoir level of 0.10 M/hour. The same information is shown graphically in Figure 6 which can be used for interpolation.

2.2.6.2 Examples of Inflow Computation

Example1.

Let the reservoir level be at 471.00-m· at 10:00AM and 471.10-m at 12.30PM and total outflow be 200 cusecs. Change in level = 471.10-m-471.0-m = +0.10-m. = +10-cm Time interval = 12.50 AM = 150-min. Rate of change in level = (10/150) * 60 = +3.99-cm/hour From Fig. 6, Rate of change in storage for 10-cm/hour at 471-m elevation = 15550-cft/sec. Hence rate of change in storage for level rise of 3.99-cm/hour = 15550*3.99/10 = 6204 cft/sec. Then, Inflow = Outflow + Rate of storage change = 200 + 6204 = 6404. cusecs.

Example2

Let the reservoir level be at 471-m at 8 A.M. and 470.900 m at 9.45A.M. and total outflow be 150 cusecs. Change in level = 470.900 m-471.000 m = -0.10m. = -10cm Time interval = 9.45A.M. -8 AM = 105min. Rate of change in level = (-10/105) * 60 = -5.71cm / hour. From Fig 6, rate of change in storage for 10 cm / hour at 471 m elevation = 15550 cft /sec. Hence rate of change in storage for level fall of 5.71 cm/hour = - 15550 * 5.71/10 = -887.90 cft / sec. Then, inflow = Outflow + Rate of storage change = 150-887.90 = 737.90 cusecs.

2.2.6.3 Example of Computation for Required Gate Opening

Let FRL be 472.12 m, the reservoir level be at 471 m at 10· A.M., 471.10m at 12.30 A.M. and total outflow at 12.30 AM be 200 cusecs. Then, from Example 1 above, the inflow is 6404.00 cusecs.

From Table 12, the opening required for this condition is slightly more than 1.38 m.

2.2.7 Summary of Flood Regulation Procedure The flood regulation procedures at Maski Nala can be summarized in the

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0 Page 30 O & M Manual for Maskinala Dam following 4 steps:

1. Observe the reservoir level at 1 hour intervals. 2. Determine the total outflow occurring at all outlets (including spillway, canals) 3. Determine the inflow of water in the Reservoir for every hour with Reservoir operation shedule – I 4. Determine the gate opening / vents with the Reservoir operation shedule –II and accordingly operate the gates.

Table 9- Elevation – Area – Reservoir Capacity

Elevation-Area-Capacity

(Maski Nala Dam Project) Elevation Area Capacity (ft) (Msqft) (MCft) 1550 27.89 615.67 1549 24.75 484.17 1545 17.68 378.67 1540 14.77 297.67 1535 12.53 229.5 1530 10.48 172.04 1525 8.7 124.17 1520 6.92 85.22 1515 4.96 55.67 1510 3.12 35.67 1505 2.28 22.22 1500 1.76 12.17 1495 1 5.37 1490 0.48 1.72 1485 0.16 1.17 1481.83 0 0

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0 Page 31 O & M Manual for Maskinala Dam Present Elevation-Area-Capacity Curve (Maskinala Dam Project) 30 25 20 Area 15(Msqft) 10 5 0 1560 1560 1550 1550 1540 1540 1530 1530 1520 1520 1510 1510 1500 1500

Elevation (ft) Elevation 1490 1490 Elevation (m)Elevation 1480 1480 1470 1470 0 100 200 300 400 500 600 700 Capacity (MCft)

Table 10- Spillway Discharge Rating (with FRL=472.12M):

Sl.No. Discharge through Each Vent @ FRL Water Level Spillage in Meters Discharge in Cusecs 1 463.62 -- -- 2 463.70 0.08 21.00 3 463.80 0.18 70.89 4 463.90 0.28 137.32 5 464.00 0.38 216.74 6 464.10 0.48 307.18 7 464.20 0.58 407.33 8 464.30 0.68 516.23 9 464.40 0.78 633.12 10 464.50 0.88 757.42 11 464.60 0.98 888.62 12 464.70 1.08 1026.31 13 464.80 1.18 1170.11 14 464.90 1.28 1301.69

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0 Page 32 O & M Manual for Maskinala Dam 15 465.00 1.38 1474.84 16 465.10 1.48 1635.32 17 465.20 1.58 1720.54 18 465.30 1.68 2015.79 19 465.40 1.78 2145.76 20 465.50 1.88 2325.10 21 465.60 1.98 2508.74 22 465.70 2.08 2696.52 23 465.80 2.18 2888.30 24 465.90 2.28 3083.96 25 466.00 2.38 3283.36

Statement Showing The Rate of Inflow for every 0.10Mtr. Rise in Water Level of The Reservoir per Hour.

Table 11 - Rate of change of storage

Ogee Sill Level :- 463.62 M F.R.L:- 472.12 M

Raise in Reservoir Level Inflow in Cusecs Per Hour 470.000 470.100 1550 470.200 3100 470.300 4660 470.400 6220 470.500 7780 470.600 9330 470.700 10890 470.800 12440 470.900 14000 471.000 15550 471.100 17890 471.200 20220

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0 Page 33 O & M Manual for Maskinala Dam 471.300 22550 471.400 24890 471.500 27220 471.600 29550 471.700 31890 471.800 34220 471.900 36550 472.000 38890 472.100 43890 472.120 44890

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0 Page 34 O & M Manual for Maskinala Dam

Rate of Change for Reservoir Storage 50000

45000

40000

35000

30000

25000

(Cusecs) 20000

15000

10000

5000

0 Rate of Change Increase (+) or Decrease (-) For 10 cm/hour Change in Level Level in Change cm/hour 10 For (-) Decrease or (+) Increase Change of Rate

Reservoir Levels in Meters

Figure 5- Rate of Change for Reservoir Storage

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2.3 Operation of Radial Crest Gates of Maskinala Dam

2.3.1 Brief Description. Crest Gates of Maski Nala Dam have been designed with spillway crest of 463.62 m and FRL of 472.12 m. 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 Radial Crest Gates of this Project involving 4 Nos. of Gates of Size 12.00 X 8.50 mtr, being provided with the conventional Electro-mechanical Rope drum hoist. This is simplicity in operation and maintenance, and also the initial cost is not so high.

The crest gates of Maski Nala Dam spillway were designed and fabricated for the full height of 8.973 m corresponding to FRL 472.27 m. The frame of the gate, consisting of inclined arms, horizontal girders and the stiffeners have been erected as designed and fabricated for the full height. The top horizontal girder, as per design up to the full height is located.

2.3.2 Radial Crest Gates – Technical Data

1. The spillway Radial Gate consist of an upstream curved skin plate of varying thickness from 12 to 10 mm, stiffened with vertical stiffener out of ISMB 450 x 150 girder and spaced 45.00Cms center to center. 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 10 to 12 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 Guide rollers made of Cast steel IS 1030 are fitted along with the curved edges at either sides and along the sides of each Gates near the rubber seals. A curved steel Channel embedded in the face

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 37 O & M Manual for Maskinala Dam of the pier adjacent to each Gate to serve as Track for the guide rollers. 6. Trunnion Assembly The trunnion assembly consists of cast steel IS 1030 trunnion hub to which the arms of the gates are rigidly connected to ensure full transfer of load. High resistance steel castings for trunnion pins of 375 mm dia with bush bearings of size 37.50 cm I.D. are used. 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 and side seals

2.3.3 Salient Features

Feature Description Sl. No.

i. Type of gate Spillway Crest Radial gate

ii. Size of Gate 1200 mm x 8500 mm

iii. No. of Gates 4 Nos (Gate 1 to 4)

iv. Clear vent of opening 12000 mm

a) Local Control Panel v. Operation Arrangement b) Manual Operation

vi. Gate position Indicator a) Gauge Indicator at Gate Location

Crest level of spillway EL 463.620 M

Sill level of Gate El 463.147 M

C. L. of trunnion EL 466.450 M

Top of Gate El 472.270 M

FRL EL 472.12 M

MWL EL.472.12 M Radius to inside of skin Plate 11000 mm

Design Head 8.973 M

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 38 O & M Manual for Maskinala Dam 2.3.4 Material Specification

Sl. Description Material Specification No. IS 2062 Y.P.:2400 Skin plate, Horizontal Girders, End Kg/cm2 /U.T.S.:4200 Arms, Arm Bracings, Vertical Stiffen- Structural steel Kg/ cm2 ers, Lifting Lug Yoke, and Anchor Girder, Rest Chair, Tie Beam, etc.

IS 1030 Y.P.:2750 Trunnion Hub Cast Steel Kg/cm2 /U.T.S.:5500 Kg/ cm2 Structural Trunnion Bracket IS 2062/IS 1030 Steel/Cast Steel

Trunnion Pin Forged Steel IS 2004

IS 305 UTS 5100 Trunnion Bushing Aluminum Bronze Kg/cm2 S:arnless Steel Seal Sea IS .1570 Plates Seal Base Structural Steel IS 2062

Guide Roller Cast Steel Is 1030 Gr 23-45

Roller Bushing Bronze IS 305

Rubber Seal Rubber Seals IS 11855

2.4 Operating Instructions The Gates are operated by rope-drum hoisting system. 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 are 15 minutes. The limit switches mounted on each hoist unit.

Each hoist can be operated from the unit control cabinet located · in the hoist operating chamber. Each control panel contains the necessary main line fuse and switch, reversing contacts and relay, overload relays, WRC-Fuses, indicating lamps, etc. Necessary inter-locking arrangement is provided to disengage the hoist machinery from electric circuit when manual operation is in progress. Hoist is also provided with a throttle valve to adjust the opening and closing times and designed to limit the normal closing time of 15 minutes.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 39 O & M Manual for Maskinala Dam 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 operation (function) to stop the hoist automatically when Step 3 Limit Switch the gate reaches the fully opened or fully closed position

All nuts, bolts and screws shall be checked for wear, Step 4 Nut & Bolts 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 ensure that the proper Hydraulic Oil of Ser- vosystem-68 (IOC) or Euklo-68 (HP) or AVLON-68 (TWL) is used and should be filled to the desired level Step 6 Oil level in hoist cylinders. The oil should not be allowed to be mixed up with water for which· necessary pre- caution has to be ensured during operation and maintenance of gates.

To check and apply the high pressure lubricating Trunnion Lu- Step 7 grease in trunnion bushing from the hole provided in brication 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, etc. In case of Step 8 Control Panel any contact chatter, clean the magnet surface and try again. If the chattering continues, check the coil voltage and replace the contact / coil, if necessary

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 40 O & M Manual for Maskinala Dam 2.4.2 Rope Drum Hoisting Arrangements for Radial Crest Gates The hoist is electrically operated rope drum type of suitable for radial gates of size 12.00 M x 8.50 M. The hoist unit consists of two end gear boxes and an end driver unit. The Motor is of 3 phases 50 cycles 400/440 volts totally enclosed having starting torque not less than 150% of normal running torque. The drive unit has a worn reduction of suitable capacity. The drive unit is of Electro-Magnetic brake of suitable size, which grip on while the motor is switched off.

Arrangement for manually operating the gates provided in the unit to operate the gates in case of power failure. Transmission shafts or line shafting with coupling connect the gear boxes have spur gear reduction, the gears made of cast steel, cast steel drum housed in each and gear reduction unit to receive the wire ropes connecting the gate and hoist. The wire is adequate in size and constructions 6 x 37 having a fiber core.

A dial gauge to indicate the gate position is provided in the central drive unit. The unit has limit switches for the gate closed position and gate fully opened position. In this position the gate operations automatically stop due to limit switches cutting of power supply to motor. Each end box and end drive unit have steel covers for protection from rain and dust etc.,

The lifting speed of the hoist is 0.30 M to 0.50 M per minute. Each end gear box will be driven either by one drive unit or two independent driven units. These two separate individual gears are used at either end to synchronize by electrical system.

2.4.2.1 Operational Instructions for Rope drum hoist of Radial Gates of Spillway Gates Operation Sequence  JOB NO: 96-MN-16:  Switch “ON” main in corner switch “FSU” (fuse switch unit) and checkup 415 voltages.  Switch on FSU on the local control panel  Switch on MCB & C-SW on the local control panel  Power supply bulb R,Y,B, glows  Control supply bulb ‘L’ glows  During rain/winter switch on MCB-1, MCB-2 to warm up control panel components and the motor winding for 15 minutes before starting gate operation.

 LOWERING OF RADIAL GATE:  Press ‘PB-2’ PUSH button.  Contractor ‘C-2’ energises.  Electromagnetic brakes AC EM Brake shoes release drum.  Motor ‘M’ starts functioning. Lamp “L2” starts flickering.  Radial gates start lowering.  Gates rests on sill beam and limit switch L/S-2, NC contact opens.  Contractor ‘C2’ opens, AC EM Brake shoes holds drum and motor ‘M’ stop functioning Lamps glows.

 LIFTING OF RADIAL GATES:  Press ‘PB-1’ push button.  Contract ‘C1’ energises.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 41 O & M Manual for Maskinala Dam  Electromagnetic brakes AC EM Brake shoes release drum.  Motor ‘M’ starts functioning. Lamp “L” starts flickering.  Radial gates start lifting.  Gates reaches maximum limit and limit switch L/S-1, NC contact opens.  Contractor ‘C1’ opens, AC EM Brake shoes holds drum and motor ‘M’ starts functioning Lamp ‘L1’ glows.  To stop the Radial gate at required position, press ‘SPB’, C1/C2 contactor opens and motor ‘M’ stops functioning.

2.4.2.2 HEAD REGULATORS OF THE CANAL:

RBC sluice LBC Sluice

Two head Regulator are provided, one for RBC canal with 1 No. of irrigation sluice gates of size 1.00 M x 0.80 M. another for LBC canal with 1 No. of irrigation sluice gates of size 1.00 M x 0.80 M.

2.4.2.3 HEAD WORKS: a) MASKI NALA PROJECT RIGHT BANK CANAL (RBC): The RBC head work is constructed at ch:638.00 of right bank, with 1 No. of irrigation sluice gate of size 1.00 M x 0.80 M. and discharge of 0.776 Cumecs (24.42 Cusecs). The sill levels of the canal is kept at RL 463.30 m

b) MASKI NALA PROJECT LEFT BANK CANAL (LBC): The LBC head work is constructed at ch: 148.00 of left bank, with 1 No. of irrigation sluice gate of size 1.00 M x 0.80 M. and discharge of 0.776 Cumecs (24.42 Cusecs). The sill levels of the canal is kept at RL 463.30 m

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 42 O & M Manual for Maskinala Dam 2.5 Condition:

2.5.1 General: Above mentioned structures are in good conditions. Both the Head Works are commissioned and water is being let out to canals by gravitation flow and working satisfactorily.

2.5.2 Deficiencies and problems The head sluice gates of RBC & LBC were replaced with new gates under DRIP.

2.5.3 Potential problems Potential problems are not come across.

2.5.4 Historical Events (Maximum releases to date, modifications, damage reports, examinations, etc,).

MNP Left Bank Canal MNP Right Bank Canal

a) Length 10.00. 11.50 ( Km) b) Capacity 1.485 0.776 ( Cumecs) c) Area 1940 1061 irrigated / contemplated in hectares

The details of length of canals discharge and area contemplated for 2 canals under Maskinala Dam is narrated above.

2.5.5 Operation:

2.5.5.1 General Water will be released at downstream side through spillway when the water in reservoir reaches alarming level (RL 472.00 m). The water is being let out through the irrigation sluice gates for RBC and LBC for irrigation purpose.

2.5.5.2 Restrictions:

There are no restrictions for operation of irrigation sluice gates as per water requirements in RBC and LBC.

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2.5.5.3 Mechanical:

Irrigation Sluice Gates are box type vertical lift gates and are operated manually. Irrigation Sluice Gates are box type vertical lift gates and are operated manually.

2.5.6 References:

2.5.6.1 Reports and Data. 1) MNP 3rd Revised Estimate 2003 2) MNP DATA BOOK -2008

2.5.6.2 Drawings: 1) General Layout plan showing locations of Left & Right Head Works 2) Drawings enclosed vide ANNEXURE -II. 2.5.6.3 POWER: 250 KVA Transformer is provided by KPTCL for power supply for HM works. 1 No. of 100 KVA Kirloskar Generators old & 1 No. 100 KVA New Mahindra Generator also available at Dam site.

2.6 ACCESS ROADS 2.6.1 Description

(Type of road, length, bridges, maintaining agency, etc.) Type of road: Asphalt road. Length: 8.00 km

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 44 O & M Manual for Maskinala Dam Bridges: Nil Maintaining agency: Maintaining departmentally.

2.6.2 Condition:

2.6.3 General: Road is in good condition

2.6.4 Deficiencies and problems Surrounding villagers are using the same road.

2.6.5 References

2.6.6 Reports and Data Land pertaining to road 8.00 KM is purchased by Department

2.7 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, hydro- power 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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CHAPTER 3 - PROJECT INSPECTIONS

The current practice of Inspection at Maskinala dam envisages the Sub division Officer to carryout pre-monsoon and post-monsoon inspections. The checklist proforma included in this chapter is cur- rently in use at Maskinala dam. However, an overview of the various types of inspections to be carried out at Maskinala Dam is given below. An effective inspection program is essential to identify problems and to keep Maskinala 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 available for being carried out at Maskinala 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 regula- tions, etc. Typical inspection elements and the detail of the safety inspections are provided below as per ‘Guideline for Safety Inspection of Dams’ (CWC 2018). A checklist has been modified from the guideline to fit Maskinala 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 for each dam 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 appurtenant works.  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 Maskinala Dam consists of five major parts:

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 46 O & M Manual for Maskinala Dam 2. 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 . 3. Inspection of the dam and its appurtenant works. 4. To review the results and reports of additional field investigations & laboratory testing as required. 5. Review of design studies e.g., review of design flood, checking of the adequacy of spillway capacity, freeboard requirements, dam stability, and any special study as required. 6. 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;

 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

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 47 O & M Manual for Maskinala Dam 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_Events.pd f.

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 Maski Nala 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 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 Checklist and Example of Report Proformas Detailed checklists are required to ensure the health of the dam continues to operate in satisfactory and safe condition. Details of the inspection must be in alignment with the DHARMA approved checklist attached to this document.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 48 O & M Manual for Maskinala Dam 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 MaskiNala Project 2. Purpose of Project Irrigation 3. Name of Dam MaskiNala DAM. 4. Year of Completion 2003 5. First filling (years / levels) 2003 (RL.471.300 M) 6. Benefits accrued: a) Irrigation Irrigation b) Water Supply Nil c) Power Nil d) Other benefits Nil

7. Important Controlling Levels ( in meters)

a) Top of dam 474.880 M. b) Maximum Water Level 472.120 M. c) Full Reservoir Level 472.120 M d) Sill level of Irrigation sluices 463.300 M. e) Spillway crest level 463.62 M. f) Minimum draw down level 463.300 M. g) Lowest river bed level 452.660 M. h) Deepest foundation level 445.000 M.

8. Important Salient Features

a) Dead Storage Capacity 86.00 M.Cum (at MDDL, 463.30 M) b) Area of foreshore at F.R.L 1.728 Sq.Km. Design flood adopted c) (PMF / SPF / Any other) PMF-2351Cumecs. Or 83035 Cusecs Give relevant magnitude Design spillway discharge capacity and d) Ogee type Spill Way 2590 Cumecs. type of spillway Type, number and size of spillway RADIAL TYPE, 4 numbers of 12M X 8.50 e) gates. M size.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 49 O & M Manual for Maskinala Dam 1 1a 1b 2 3 f) Height of the dam in meters. i) above deepest foundation 29.88 M ii) Above lowest river bed 23.74 M h) Gross storages capacity in million cubic meters i) At F.R.L. 496.00 M.Cum (0.50 TMC) ii) At M.W.L 496.00 M.Cum (0.50 TMC) i) Length of the dam (at crest) in meters. 813.80 Mtr. 1) Shri, S H Manjappa, Chief Engineer, KNNL, ICZ Munirabad 2) Shri. RajashekharAmbanna, Superintending Engineer, KNNL, Name and designation of the inspecting TCC Circle, Yaramarus 9. 3) Shri, B Eranna, Officer Executive Engineer KNNL, (I/C) TLBC Division No. 3 Sindhanur 4) Shri, Dawood sab, Assistant Executive Engineer (I/C) KNNL MNP Sub division Maski. Date of inspection and the corresponding res- 10. ervoir water level. Date of Inspection : 1) Chief Engineer, KNNL, ICZ Munirabad Reservoir Level: M 2) Superintending Engineer, KNNL,TCC cir- Date of Inspection :

cle, Yaramarus Reservoir Level: M 3) Executive Engineer, KNNL, TLBC Divi- Date of Inspection : Reservoir

sion No.3 Sindhanur. Level: M Maximum: M ______Maximum and minimum water levels reached Dt: ______11. during the last season with dates Minimum: M______Dt: ______Maximum overflow during preceding mon- Max. outflow : cusecs ______12. soon with dates. Dt: ______: . History of past distress, if any, and brief details 13. No such events observed. of remedial measures carried out. Does the officer-in-charge of the operation 14. and maintenance of dam possess all the rec- Yes ords as given in the Annexure-I. When and by whom the dam was inspected 15. ------immediately preceding this inspection? Are the items pointed out during the last in- 16. spection properly attended to? ------(If not state deficiencies yet to be corrected).

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 50 O & M Manual for Maskinala Dam 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 Maskinala Dam

Sl. No. in the National Register of Large Project Identification Code PIC 2 Dam KA06HH0209

3 Dam features

a) Date of Completion 2003

Location

b) i) Longitude 76° 33’ 30’’ E

ii) Latitude 16° 00’ 40’’ N

c) Height of Dam 29.88 Mtr. above the lowest foundation

Gross Capacity 0.50 TMC ft. (496.00 MCUM) d) (Gated/Un gated) Gated Whether the Dam is provided with e) Drainage Gallery not provided. Drainage Gallery or not. Type of Dam: Earthen Dam: Spillway: Gated spillway with 4 Nos of Radial 4 Main Component of Dam Crest gates of size 12 m X 8.50 m. Length of concrete spillway dam-57 m Length of L/s Earthen Embankment -265.30 M Length of Right Earthen Embankment-491.50 M 5 Date of Inspection

6 Inspecting Officer Chief Engineer, KNNL ICZ Munirabad

7 Observations/Significant Deficiencies Noticed

I Inadequate Spillway.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 51 O & M Manual for Maskinala Dam

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_KA06 MH0209_Maski nala Dam_v1.0 Page 52 O & M Manual for Maskinala Dam 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 Ac- XII tion 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 performance 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, In-charge of dam. in-charge of dam. In-charge of dam.

Certified that the Health Status Report of MASKI NALA DAM is furnished after a thorough review of the same by the technical wing of the zone (this has reference to para 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_KA06 MH0209_Maski nala Dam_v1.0 Page 53 O & M Manual for Maskinala Dam

APPENDIX-1 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-2 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.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 54 O & M Manual for Maskinala Dam APPENDIX-3 Categorization 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 have 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_KA06 MH0209_Maski nala Dam_v1.0 Page 55 O & M Manual for Maskinala Dam CHAPTER 4 - PROJECT MAINTENANCE

A good maintenance program protects Maskinala Dam against accelerating deterioration, prolongs its life, and greatly reduces the chance of failure. Nearly all the components of Maski Nala 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 Maski Nala 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 inoperable 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. 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 controlled release of floods through the spillway.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 56 O & M Manual for Maskinala Dam 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 include 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 pri- or 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.  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.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 57 O & M Manual for Maskinala Dam  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 includes 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. 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

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 58 O & M Manual for Maskinala Dam

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. Upstream Riprap The upstream face is protected against wave erosion. Rip-rap is provided for the purpose with filter layers below. Nonetheless, erosion can still occur in existing riprap. Water running down the slope under the riprap can erode the finer filter materials under the riprap and soils leaving voids and loss of grade. Wave run-up will also under- mine the filter layer especially along the full Figure 6– View of upstream riprap Maskinala Reservoir Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 59 O & M Manual for Maskinala Dam reservoir level and over time wash out finer material. This can be checked through observance of linear embankment settlement. Sections of riprap that have slumped downward are often signs of this kind of erosion. When erosion occurs on the upstream slope of a dam, repairs should be made as soon as possible. Repairs can be made following the same design details as provided in the embankment section. Proper preparation of the surfaces of the existing embankment as described in the earlier paragraph for placement and compaction of embankment. Please refer to IS 8237- Code of practice for protection of Slopes for Reservoir Embankments is recommended to be reviewed and followed for carrying out this repair work. 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 topiping 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 (bea- ver, 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 publica- tions, the mud pack is generally made by adding water to 90% earth & 10% cement mixture until slur-

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 60 O & M Manual for Maskinala Dam ry or thin cement consistency is attained. For bigger holes, bentonite coated stones can also be used. All entrances should be plug ed 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 earthworms, 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. 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 sur- faced 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 se- Figure 7– Dam Crest Paved Road vere erosion over embankment kept maintained to minimized damages to the embankment structure

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 61 O & M Manual for Maskinala Dam 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 Maski nala 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 cavitation’s, abrasion, un-symmetrical flows, unfavorable down-stream conditions)  Vegetation growth in unattended areas such as spillway, spillway channel, etc.  Seepage on the downstream face of the dam.  Cleaning and removal of leached deposits from choked porous and foundation drains.  Repair to upstream face of dams in case the damaged, leading to increased seepage.  Ensuring safe access and 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 approachable to repair deteriorated areas. For remedial measures of problems of special nature advice of experienced engineers /Panel of Ex- perts needs to be obtained

4.2.3 Gates & Hoisting Equipment The safe and satisfactory operation of Maskinala 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 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 dis- Figure 8 – Gate hoisting arrangement of Maskinala Project charges, exercising of gates should preferably be car-

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 62 O & M Manual for Maskinala Dam ried 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 rectifica- tions 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 crea- tion 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. 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:

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 63 O & M Manual for Maskinala Dam 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. Fur- ther 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 blocks 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_KA06 MH0209_Maski nala Dam_v1.0 Page 64 O & M Manual for Maskinala Dam 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.

4.2.4 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.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 65 O & M Manual for Maskinala Dam 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. 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 rais- ing 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.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 66 O & M Manual for Maskinala Dam 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. 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. 4.3. 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.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 67 O & M Manual for Maskinala Dam xxii) Blow out windings thoroughly by clean and dry air. The pressure shall not be so high that insulation may get damaged. 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 todry- 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 var- nish. 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 4.4 Spillway Radial Gate

Sl. Parts to be Mode of Lubricant Frequency .No. Lubricated Lubrication 1. Gate Wheel Bear- Pressure Grease Servo Gear 20/Or Once in three months as per ings Gun Bearing Grease site condition. 2. Guide Shoe Pressure Grease Grease Once in three months as per Gun site condition. 3. Hoisting Wire Hand Applied Servo Coat-120 Once in a year before mon- Rope Or Cardium Com- soon. pound 4. Worm Reducer Oil bath. Servo HP-30 Indicator level to be maintained always. 5. Gear Wheels Hand Applied Chassis Grease Once in Six months as per site condition. 6. Drum Shaft Pressure Grease Chassis Grease Once in three months as per

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 68 O & M Manual for Maskinala Dam Gun site condition. 7. Lifting Arrange- Hand Applied MP Grease Once in six months as per ment site condition before monsoon sets in 8. Hand Operation Hand Applied Servolin-140 Once in three months as per Mechanism & site condition before mon- other relating parts soon sets in.

A. MAINTENANCE OF WIRE ROPE Frequently the inspection of the entire length of rope is necessary. Watch constantly for broken wires, excessive wear and lubrication, see that the number of broken wires does not exceed as laid down in dif-

ferent 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.

B. 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.

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 new- ly 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

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 69 O & M Manual for Maskinala Dam 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. • 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,

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 70 O & M Manual for Maskinala Dam 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. b) Machinery: Except machined surfaces all surfaces of machinery including gear- ing, 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. c) 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.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 71 O & M Manual for Maskinala Dam 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. 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 de- scaled 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 Electrometer.  Inspection of general appearance of finished work. b) General:

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 72 O & M Manual for Maskinala Dam 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. 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. 4.6 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 antifreeze 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 and replaced / repaired where needed. The recommendations of the manufacturer should also be referred to. 4.7 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.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 73 O & M Manual for Maskinala Dam 4.8 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 auto- mobiles 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 .

Main entrance Access Road should be made. If un- stable conditions develop assistance of experienced Engi- neers/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. 4.9 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. 4.10 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 are enclosed in the O&M Manual. At Maskinala 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_KA06 MH0209_Maski nala Dam_v1.0 Page 74 O & M Manual for Maskinala Dam 4.11 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 includes 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.

4.12 Preparation of O & M budget The O & M budget for Maskinala dam essentially include 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 Reim- bursement, LTC, Leave Encashment, Pension benefits, TA and DA , etc. (as applicable). 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, Sanitary 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, Repair/replacement of gates seals & wire ropes, POL for pumps & generator sets, Electricity 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_KA06 MH0209_Maski nala Dam_v1.0 Page 75 O & M Manual for Maskinala Dam Table 12 - O&M Budget Costs (Annual) CURRENT PREVIOUS YEAR BUDG- SL. BUDGET ITEM YEAR COST (Rs ET REMARKS NO. in Lakhs) (YR ______) (Rs in Lakhs)

A. ESTABLISHMENT

SALARY OF REGULAR STAFF IN- 1 47.60 89.70 CLUDING ALL OTHER BENEFITS

2 TRAVEL EXPENSES 5.30 44.00

3 OFFICE EXPENSES 2.50 7.40

4 MOTOR VEHICLE EXPENSES 6.00 6.00

MAINTENANCE OF OFFICE & COL- 5 6.00 10.00 ONY COMPLEX

SUB-TOTAL – A 67.4 157.1

B. WORKS

1 CIVIL

1.1 CONCRETE / MASONRY DAM - -

1.2 EARTHEN DAM 64.00 25.00

INTAKE / OUTLETS IN EARTHEN 1.3 - - DAMS

SLUICES IN CONCRETE / MASONRY 1.4 - - DAMS

APPROACH / INSPECTION ROADS 1.5 100.00 - WITHIN DAM AREA

2 HYDRO-MECHANICAL

2.1 SPILLWAY GATES & HOISTS 17.00 10.00

SPILLWAY STOP-LOG & GANTRY 2.2 - - CRANE

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 76 O & M Manual for Maskinala Dam OUTLETS IN EARTHEN DAMS - 2.3 SERVICE / EMERGENCY GATES & 10.00 12.00 HOISTS SLUICES IN CONCRETE / MASONRY 2.4 DAMS – SERVICE / EMERGENCY - - GATES & HOISTS

3 ELECTRICAL

ELECTRICAL FITTINGS, MOTORS, 3.1 3.00 1.50 CONTROLS FOR ALL GATE HOISTS

3.2 POWER SUPPLY LINES - 0.50

ELECTRICAL FITTINGS ON DAM 3.3 14.50 3.00 TOP, DAM GALLERIES, ETC.

STANDBY POWER / DIESEL GEN- 3.4 9.63 - ERATOR

3.4 REMOTE CONTROL/CCTV 5.98 0.50

4 INSTRUMENTATION 17.25 15.00

5 MISCELLANEOUS WORKS 85.23 30.00

SALARY OF WORK- CHARGED Annual Dam 6 STAFF INCLUDING ALL BENE- 10.00 15.00 Maintenance by FITS Agency MATERIALS TO BE STORED 7 - - BEFORE MONSOON

SUB-TOTAL – B 330.61 112.00

CONTINGENCY (10%) ON SUB- 8 39.80 26.91 TOTAL OF A & B 9 TOOLS & PLANTS -

SUB-TOTAL- C -

10 TOTAL ANNUAL COST 437.81 296.01

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 77 O & M Manual for Maskinala Dam 4.13 Maintenance Records Maintenance records are of utmost importance. A record shall be kept for all maintenance activities, both immediate and preventive maintenance works. Information that must be recorded includes, but not limited to, the following:  Date and time of maintenance,  Weather conditions,  The type of maintenance,  Name of person or contractor performing maintenance,  Description of work performed,  The length of time it took to complete the work with dates,  Equipment and materials used, and  Before and after photographs.

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

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 78 O & M Manual for Maskinala Dam CHAPTER 5 - INSTRUMENTATION AND MONITORING

5.1 Dam Instrumentation

5.1.1 General Information This section identifies the location and chainages of each of the 3 structural components of the dam: Table 13 -Locations and Extents of Structural Members

From Chainage To Chainage

Left Earthen Embankment 0.00 Mtrs 341.50 Mtrs

Central Spillway 341.50 Mtrs 398.50 Mtrs 398.50 Mtrs 813.0 trs Right Earthen Embankment

5.1.2 Instruments Embedded in the Maskinala Earthen Dam Table 14- Embedded Instruments

Sl. No. of instruments Type of instruments Chainage No embedded Ch: 200 L/S 1. Electrical piezometer 3 Ch: 300 R/S Ch: 500 R/S Ch: 327 L/S 2. “V” Notches 3 Ch: 418 R/S Ch: 757 R/S

5.1.3 Seismological Observations Maskinala Dam is situated in the seismic Zone-II. The work of conducting study under action plan for implementation on National water policy 2002 and technical preparedness for DDSA-2002 has been entrusted to WAPCOS, New Delhi vide work order No. 2097 dated: 08-12-2014. Necessary steps will be taken in consultation with WAPCOS, New Delhi to strengthen the dam section under seismic conditions if stability analysis so warrants.

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 79 O & M Manual for Maskinala Dam CHAPTER 6 - PREVIOUS REHABILITATION EFFORTS

Before DRIP, maintenance activities were limited to routine greasing, oiling, and patch painting of hydro-mechanical devices; routine repair of electrical systems; routine mowing, vegetation removal, repair of eroded section, etc. Under DRIP, major Rehabilitation Works have been carried out at a total cost of about INR 4.06 Crores (with some activities still ongoing during the preparation of this O & M manual). The rehabilitation works under DRIP include: Estimate Sl. No. Description of item amount (Rs) Package-1 1 Providing and construction of revetment for the upstream side of the dam (selected reaches) and turfing on earthen embankment 6400000.00 down of stream of the dam 2 Construction of CC road on top of the roadway of dam and ap- 10000000.00 proach roads of the dam. 2 Providing head sluice service gates and emergency gates for RBC 1000000.00 & LBC of MNP dam. 3 Providing Cleaning and painting of crest radial gates no. from 1 to 4 and painting to hand rails gates,head sluice room, hoist structure 1700000.00 & walkway of spillway of MNP. 4 Providing barbed GI fencing & other security works to Maskinala 8300000.00 project. 5 Procurement of standby one set of wire rope. 223500.00 6 Procurement of 100KVA new generator.. 890000.00 7 Providing fixing and installation of Electrical Piezometers at ch:200m, 300m &500m and Infrared automatic water level record- 1725000.00 er. 8 Providing fixing and installation of solar CCTV surveillance system 2450000.00 and solar street lights for watch and ward of Maskinala dam. CONSULTANCY SERVICES 10 Consultancy service for computation of SPF, Design flood studies, 2500000.00 flood routing study and preparation of EAP, Dam break analysis, Preparation of Inundation maps stability analysis of dam including hydrodynamic forces due to earth quake. 11 Providing and supplying MAHINDRA make Jeep (2 Nos) 2400000.00 12 Provision towards Contingency (Variation, Price escalation & Ten- 3043500.00 der premium.) TOTAL 40632000.00

Doc. No. CDSO_O&M_KA06 MH0209_Maski nala Dam_v1.0 Page 80 O & M Manual for Maskinala Dam CHAPTER 7 - UPDATING THE MANUAL

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 data/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 which 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 MASKINALA DAM

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Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 89 O & M Manual for Maskinala Dam 3. Responsibilities 3.1. Dam Owner’s Responsibilities The dam owner, Karnataka Water Resource Department, and Karnataka Neeravri Nigam limited 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. Assistant Executive Engineer/Executive engineer

 Collection of real time information of rainfall in the catchment and inflow status at the Nagalapur gauge point and to bring it to the notice of the SE/CE.  Assist the SE/CE to issue notification to the villagers downstream through Newspapers, Radio, TV News channel to be alert regarding the flood releases.  Assist the SE/CE to coordinate with the Revenue authorities (District Administration) to alert the downstream people.  Maintain the reservoir water level gauge register and to update on hourly basis during floods and to bring to the notice of SE/CE.  Assess the inflows in the reservoir as per the approved reservoir operation and to prepare proforma consisting of the status of the reservoir capacity and releases from the reservoir as per the standard Performa and to submit the same to the SE/CE  Reporting inflows and releases from the reservoir and status of the reservoir twice in the day to the SE/CE.  Operate the Spillway crest gates for flood mitigation as per the instructions of the SE/CE and to update the Gate operation Log book.  Observe the seepages in the V-notches with respect to the reservoir head and record the seepages and to immediately bring to the notice of the SE/CE in case of any abnormal variation in seepage, leakage in any specific blocks and toe drains.  Observe the gates and floating debris are not deposited in the gate components.  Monitor the condition of the Welding transformers, gas-cutting sets, umbrellas, tool kits torches chain blocks ropes ballistic on daily basis and to see that things are in place to handle any emergency.  Observe the Gates, hoists and handling equipment during operation of gates for their smooth movements and to immediately report any untoward excessive sounds in the motors, pumps or vibrations in the gate to SE/CE  Observe the dam top, embankment, catwalk, approach roads etc., and ensure that all well maintained 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 SE/CE in case of any untoward incidents or malfunctioning of the gates of excessive seepages, leakages etc.  Inspect spillway abutments and piers regularly. If anything found awkward inform the same to SE/CE.  Prepare estimates and to take approval from SE/CE and contact Contractors if requires Immedi- ate repair to be attended.

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 90 O & M Manual for Maskinala Dam Responsibilities of Superintending Engineer The responsibilities of the above said officers is as described below  To ensure that the EAP is updated by Executive Engineer, KNNL, TLBC Division No. 3 Sindhanur and Assistant Executive Engineer, KNNL, Maskinala Project Sub Division Maski, periodically.  To review annually to ensure that the contact details are current details as described in the notification flow chart.  Directing and initiating appropriate action during emergency ,such as opening or closing water outlets and remedial construction activities such as earth moving etc.  To keep in contact with all the members of the notification flow chart and update them regarding the situation of the dam.  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 necessary for maintaining the health status of dam.  Contact the Deputy Commissioner Raichur and Superintendent of Police of respective districts to inform regarding the Emergency condition

The Chief Engineer is responsible for directing specific, incident appropriate actions during an emergency, such as opening or closing water outlets and remedial construction activities such as earth moving, etc. Specific scenarios are not listed in this EAP.

Responsibilities of Managing Director

 Inspecting the dams once in a year.  Providing Funds for normal operation expense and for any immediate repair works as per the site requirement based on the estimates submitted by CE.  Deputing design wing officials or the technical experts as and when required and requested by CE. S.D.S.O.

 Check the pre monsoon and post monsoon reports and identify the problems which are need to be attended and provide suitable remedial measures.

 Making suitable arrangements to DSRP officials for inspection as and when required.  Reporting problems faced of forecasted to CDSO. Responsibilities of CWC officials  To conduct studies on dam safety aspects for the existing dam and standardize the instruments for the dam safety measures.  Statement Showing The Rate of outflow for every 0.08 mt Rise in Water Level The Res- ervoir per Hour.  Ogee Sill Level: - 463.62 Mtr. F.R.L:- 472.12Mtrt

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Sl. No. Discharge through each vent @ FRL

Water Level Spillage in Meters Discharge in Cusecs

1 463.62 -- -- 2 463.70 0.08 21.00 3 463.80 0.18 70.89 4 463.90 0.28 137.32 5 464.00 0.38 216.74 6 464.10 0.48 307.18 7 464.20 0.58 407.33 8 464.30 0.68 516.23 9 464.40 0.78 633.12 10 464.50 0.88 757.42 11 464.60 0.98 888.62 12 464.70 1.08 1026.31 13 464.80 1.18 1170.11 14 464.90 1.28 1301.69 15 465.00 1.38 1474.84 16 465.10 1.48 1635.32 17 465.20 1.58 1720.54 18 465.30 1.68 2015.79 19 465.40 1.78 2145.76 20 465.50 1.88 2325.10

21 465.60 1.98 2508.74 22 465.70 2.08 2696.52 23 465.80 2.18 2888.30 24 465.90 2.28 3083.96 25 466.00 2.38 3283.36

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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. 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 : 1 iv. Night Vision Goggles : 2 v. Dragon Lights : 5 vi. Search Lights : 5 vii. Communication Systems (local walkie-talkie) : 3 viii. Rain coat: : 10 ix. Gum boots: : 10 x. Danger Zone Light: Strips : 5 xi. Flares : 25

2. Leaks I Gunny Bags : 200 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 : Collection of 2 to 4 m3 every km. for

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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).

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 94 O & M Manual for Maskinala Dam Scheduled / Unscheduled Dam Safety Inspection Form Part 1a - Inspection Details:

Dam Name: Project ID Code (PIC):

Dam Type: Dam Purpose:

Dam Owner: Hazard Classification:

Dam Operator: Inspection by:

City/State/PIN: Date of Inspection:

District: Reservoir Level:

Latitude: Auxiliary Spillway Level:

Longitude: Weather Conditions:

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

Part 2a - Inspection Checklist:

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SN Inspection Item Responsea Remarks Conditionb

Y N NA

A Reservoir

A1.1 General Condition

1.1.1 Is the reservoir water level unusually high or low?

1.1.2 Are there signs of decline in water quality? Unsatisfactory/Poor/ Fair/Satisfactory

1.1.3 Are there signs of recent sediment deposition?

1.1.4 Is floating debris present?

Are there people or livestock in and around reser- 1.1.5 voir?

1.1.6 Any other issues?

B Dam and Dam Reach (Embankment)

B1.1 General Condition Any major alterations or changes to the dam since

1.1.1 the last inspection? Is there any new nearby development in the down- 1.1.2 stream floodplain? Any misalignment of poles, fencing or walls due to 1.1.3 dam movement?

B1.2 Upstream Slope

1.2.1 Any signs of bulging or concavity (depressions)?

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SN Inspection Item Responsea Remarks Conditionb

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?

Presence of undulations, local depressions or heav- 1.3.3 ing?

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?

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SN Inspection Item Responsea Remarks Conditionb

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

1.4.10 Any other degradation to slope protection (turfing)?

1.4.11 Any other issues?

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SN Inspection Item Responsea Remarks Conditionb

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

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)?

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SN Inspection Item Responsea Remarks Conditionb

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)?

2.2.3 Is cracking present (structural, thermal, along 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 2.2.6 and/orwaterstops?

2.2.7 Any other issues?

B2.3 Crest of Dam

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SN Inspection Item Responsea Remarks Conditionb

Evidence of differential settlement (dis- 2.3.1 placed/offset/open joints)? Presence of cracking (structural, thermal, along 2.3.2 joints)? Profuse growth of weeds/grass/plants at any loca- 2.3.3 tion?

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)? 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?

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SN Inspection Item Responsea Remarks Conditionb

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?

Profuse growth of weeds/grass/plants at any loca- 2.5.3 tion?

2.5.4 Any other issues?

C1 Gallery/Shaft and Drainage (Embankment)

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)?

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SN Inspection Item Responsea Remarks Conditionb

Excessive seepage/sweating at any location along 1.2.5 gallery/shaft?

1.2.6 Significant leakage at any location along gallery/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? Presence of debris or profuse growth of 1.3.3 weeds/bushes 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

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SN Inspection Item Responsea Remarks Conditionb

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)? 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 2.2.9 gallery/shaft?

2.2.10 Significant leakage at any location along gallery/shaft?

2.2.11 Any other issues?

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 2.3.3 blocked/having reduced section?

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SN Inspection Item Responsea Remarks Conditionb

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

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? Excessive seepage/sweating at any location on spill- 1.1.10 way glacis?

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SN Inspection Item Responsea Remarks Conditionb

1.1.11 Significant leakage at any location on spillway glacis?

1.1.12 Any other issues?

D1.2 Energy Dissipation Structure

1.2.1 Any problems inspecting energy dissipation structure?

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? Any problems with under-drainage (blockage of open 1.2.10 drain holes)?

1.2.11 Any other issues?

E1 Intake/Outlet and Water Conveyance Structure

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SN Inspection Item Responsea Remarks Conditionb

E1.1 Intake/Outlet Structure Any problems inspecting intake/outlet structure (obstruct- 1.1.1 ed/unsafe access)? Any obstructions in, upstream or downstream of in- 1.1.2 take/outlet structure?

Evidence of abrasion, cavitation or scour on intake/outlet 1.1.3 structure? Any evidence of structural distress (displaced/offset/open 1.1.4 joints, cracking)? Any evidence of surface defects and/or concrete/masonry 1.1.5 deterioration?

1.1.6 Any other issues?

E1.2 Water Conveyance Structure

Any problems inspecting intake/outlet structure (obstruct-

1.2.1 ed/unsafe access)? Any obstructions in, upstream or downstream of water 1.2.2 conveyance structure?

1.2.3 Evidence of abrasion, cavitation or scour on structure?

Any evidence of structural distress (displaced/offset/open 1.2.4 joints, cracking)?

Any evidence of surface defects and/or material deteriora- 1.2.5 tion? Any evidence of seepage or leakage from water convey- 1.2.6 ance structure? 1.2.7 Any other issues?

F1 Hydro-Mechanical Component and Turbine/Pump

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SN Inspection Item Responsea Remarks Conditionb

F1.1 Gates, Stop Logs and Bulk Heads

Any problems inspecting gate/stop log/bulk head (ob- 1.1.1 structed/unsafe access)? Any issues with storage of equipment (emergency stop 1.1.2 logs, and gate leaves)?

Missing or inadequate spare parts (particularly requiring 1.1.3 regular replacement)? Any deterioration of equipment (connecting bolts, welds, 1.1.4 surface, paint work?) Any obstructions preventing or impairing smooth opera- 1.1.5 tion? Any problems with the rollers (not touching tracks, inade- 1.1.6 quate lubrication)? Any problems with the seals (damage, weathering, gaps 1.1.7 with bearing surface)?

1.1.8 Any other issues?

F1.2 Hoists, Cranes and Operating Mechanisms

Any problems inspecting hoist/crane/operating mecha- 1.2.1 nism? Missing or inadequate spare parts (particularly requiring

1.2.2 regular replacement)? Any deterioration of equipment (connecting bolts, welds, 1.2.3 surface, paint work?) Any wear or damage to wire cables and other moving 1.2.4 parts? Any obstructions preventing or impairing smooth opera- 1.2.5 tion?

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SN Inspection Item Responsea Remarks Conditionb

Missing or inadequate provision of back-up/standby pow- 1.2.6 er supply? Any health and safety concerns (e.g. lack of "danger" sign 1.2.7 during maintenance)?

1.2.8 Any other issues?

F1.3 Valves

1.3.1 Any problems inspecting valve?

Any obstructions preventing or impairing smooth opera- 1.3.2 tion?

1.3.3 Any deterioration of valve and associated equipment?

1.3.4 Any other issues?

F1.4 Trash Racks

1.4.1 Any problems inspecting trash rack?

1.4.2 Problems of excessive debris and/or inadequate cleaning?

Any deterioration of trash rack (rust, corrosion, and dam- 1.4.3 aged blades)?

1.4.4 Any other issues?

F1.5 Trash Rack Cleaning Machines

1.5.1 Any problems inspecting trash rack cleaning machine?

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SN Inspection Item Responsea Remarks Conditionb

Missing or inadequate spare parts (particularly requiring 1.5.2 regular replacement)? Any deterioration of equipment (connecting bolts, welds, 1.5.3 surface, paint work?) Any wear or damage to wire cables and other moving 1.5.4 parts? Any obstructions preventing or impairing smooth opera- 1.5.5 tion?

Missing or inadequate provision of back-up/standby pow- 1.5.6 er supply? Any health and safety concerns (e.g. lack of "danger" sign 1.5.7 during maintenance)?

1.5.8 Any other issues?

F1.6 Turbines

1.6.1 Any problems inspecting turbine?

Any obstructions preventing or impairing smooth opera- 1.6.2 tion? Any deterioration of turbine, blades and associated equip- 1.6.3 ment?

1.6.4 Any other issues?

F1.7 Pumps

1.7.1 Any problems inspecting pump?

Any obstructions preventing or impairing smooth opera- 1.7.2 tion?

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SN Inspection Item Responsea Remarks Conditionb

1.7.3 Any deterioration of pump and associated equipment?

1.7.4 Any other issues?

G1 Access Road

G1.1 General Condition Any problems ensuring security of dam site (including 1.1.1 gates and fencing)? Any obstructions along or at entrance to access road 1.1.2 (temporary or long-term)? Any slope stability issues (road embankment or adjacent 1.1.3 slopes)?

Profuse growth of weeds/grass on or in vicinity of access 1.1.4 road? Any drainage problems (standing water on or adjacent to 1.1.5 road)? Any other degradation to road surface (ruts, potholes, 1.1.6 cavities, cracking)? 1.1.7 Any other issues?

H1 Instrumentation

H1.1 General Condition

Any problems inspecting instrument (obstructed/unsafe 1.1.1 access)?

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 111 O & M Manual for Maskinala Dam

SN Inspection Item Responsea Remarks Conditionb

Is the instrument vulnerable to damage or theft (inade- 1.1.2 quate protection)? Any problems ensuring correct functioning of instrument 1.1.3 (lighting, ventilation)? Any evidence of degradation to condition of instrument 1.1.4 (rusting, vandalism)? Any evidence of instrument not working (decommis- 1.1.5 sioned, broken)?

1.1.6 Any other issues?

I1 Other Appartenant Structures (Flexi-Component)

I1.1 Bridges and Catwalks Any problems inspecting bridge or catwalk (obstruct- 1.1.1 ed/unsafe access)? Any security issues relating to unauthorized access (e.g. for

1.1.2 gate operation)?

1.1.3 Are the decking, girders and supports structurally sound?

Any evidence of defects or deterioration of steel, concrete 1.1.4 or paint work?

1.1.5 Any other issues?

I1.2 Guide Walls

Any problems inspecting guide wall (obstructed/unsafe 1.2.1 access)? Any problem with drainage from behind wall (e.g. blocked 1.2.2 weep holes)?

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SN Inspection Item Responsea Remarks Conditionb

Any evidence of scour, foundation erosion or undercut- 1.2.3 ting?

1.2.4 Any signs of differential settlement, cracking or tilting?

1.2.5 Any other issues?

I1.3 Miscellaneous

1.3.1 Any other issues? (please specify part)

J1 Emergency Preparedness

J1.1 Emergency Action Plan

Is the Emergency Action Plan (EAP) still pending, inade- 1.1.1 quate or outdated? If not, are any dam staff unaware or insufficiently conver- 1.1.2 sant with the EAP? Any concerned authorities unaware or insufficiently con- 1.1.3 versant with the EAP? Do the communication directories/contact details require 1.1.4 updating? Any problems accessing or operating the communica- 1.1.5 tion/warning system?

1.1.6 Any other issues?

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SN Inspection Item Responsea Remarks Conditionb

a. Respond either yes (Y), no (N) or not applicable (NA). b. Condition: 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, hydrologic, 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 SN Remedial Measures Suggested Categorya Deficiencies Noticed

a Category 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.

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 114 O & M Manual for Maskinala Dam APPENDIX 5 – CCTV CAMERA SYSTEM SPECIFICATIONS

CCTV Products and its Specifications: Hikvision 4-Channel HD Turbo DVR: • Support both HD-TVI /analog and AHD. • Full channel recording at up to 1080P lite resolution • HDMI and VGA output at up to 1920×1080P resolution • Long transmission distance over coax cable • Support 4/8/16-ch synchronous playback at 720P resolution

Hikvision PTZ Camera: Model: DS-2AE5123T1-A720P,23X • 1/3'' Progressive Scan CMOS • 1280×720:30fps • 23X Optical Zoom • Focus: 4.0-92mm • Digital Zoom: 16X • Pan range 360 degrees endless • Tilt range: -15~90 degrees • Up to 150m IR distance • 3D intelligent positioning function • Turbo HD and CVBS dual output

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 115 O & M Manual for Maskinala Dam Hikvision 5MP HD Camera • 5 Megapixel high-performance CMOS • Analog HD output, up to 5MP resolution • 2.8-12mm motorized vari-focal lens • True Day/Night • OSD menu, DNR, Smart IR • EXIR technology, up to 20m IR distance • IP67 weatherproof

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 116 O & M Manual for Maskinala Dam APPENDIX 6 – HYDRAULIC OIL SERVICING AND MAINTENANCE INSTRUCTIONS

A8.1 CONTAMINATION CONTROL: Not Applicable A8.2 DETERMINATION OF BX VALUE Not Applicable A8.3 FILTRATION REQUIREMENT: Not Applicable A8.4 FLUID: Not Applicable A8.5 VISCOSITY: Not Applicable A8.6 EFFECT OF TEMPERATURE ON OIL : Not Applicable A8.6.1 Instruction For Industrial valves. Not Applicable A8.6.2 Selection Diagram Not Applicable A8.7 SEALS Not Applicable A8.8 MAINTENANCE INSTRUCTIONS: A8.8.1 Instructions For Hydraulic Systems : Not Applicable. A8.8.2 Instructions for Proportional Valves Not Applicable A8.8.3 Instruction On Electro-Hydraulic Servo & High-Response Control Valves: Not Applicable A8.8.4 Instructions For Cylinders: Not Applicable A8.9 SERVICE MONITORING OF HYDRAULIC OILS

A8.9.1 Introduction

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 117 O & M Manual for Maskinala Dam Not Applicable A8.9.2 Why Hydraulic oils Deteriorate Not Applicable. A8.9.3 Simple Monitoring Of Hydraulic Oils Not Applicable A8.9.3.1 Appearance: A8.9.3.1.1 Has the oil darkened when compared to an unused sample of oil? Has the oil developed a burnt, sour odour? Not Applicable. A8.9.3.1.2 Is the oil clear or opaque? Not Applicable. A8.9.3.1.3 Are there signs of free water at the bottle? Not Applicable A8.9.3.1.4 Have any solids dropped out on the bottom of the bottle? Not Applicable A8.9.3.2 Foaming Not Applicable. A8.9.3.3 Viscosity Not Applicable A8.9.3.4 Acidity Not Applicable A8.9.3.5 Microscopic Examination of Deposits Not Applicable A8.9.4.0 Case History Not Applicable A8.5.0 Sampling Frequency Not Applicable A8.6.0 Summary Not Applicable

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 118 O & M Manual for Maskinala Dam APPENDIX 7 - GLOSSARY

Dam – any artificial barrier including appurte- nances by one or more persons trained in this nant works constructed across rivers or tribu- respect and includes investigation of the non- taries thereof with a view to impound or divert overflow portion, spillways, abutments, stilling water; includes barrage, weir and similar water basin, piers, bridge, downstream toe, drainage impounding structures but does not include galleries, operation of mechanical systems (in- water conveyance structures such as canal, aq- cluding gates and its components, drive units, ueduct and navigation channel and flow regu- cranes), interior of outlet conduits, instrumen- lation structures such as flood embankments, tation records, and record-keeping arrange- dikes, and guide bunds. ments. Dam failure – failures in the structures or op- Dam owner – the Central Government or a eration of a dam which may lead to State Government or public sector undertak- theuncontrolled release of impounded water ing or local authority or company and any or resulting in downstream flooding affecting the all of such persons or organizations, who own, life and property of the people. control, operate or maintain a specified dam. Dam incident – all problems occurring to a Dam safety – the practice of ensuring the in- dam that has not degraded into ‘dam failure’ tegrity and viability of dams such that they do and including the following: not present unacceptable risks to the public, a) Structural damage to the dam and appur- property, and the environment. It requires the tenant works; collective application of engineering principles b) Unusual readings of instruments in the and experience, and a philosophy of risk man- dam; agement that recognizes that a dam is a struc- c) Unusual seepage or leakage through the ture whose safe function is not explicitly de- dam body; termined by its original design and construc- d) Change in the seepage or leakage regime; tion. It also includes all actions taken to identi- e) Boiling or artesian conditions noticed be- fy or predict deficiencies and consequences low an earth dam; related to failure, and to document, publicize, f) Stoppage or reduction in seepage or leak- and reduce, eliminate, or remediate to the ex- age from the foundation or body of the tent reasonably possible, any unacceptable dam into any of the galleries, for dams risks. with such galleries; Decommission― Taking a dam out of service g) Malfunctioning or inappropriate in an environmentally sound and safe manner operation of gates; or converting it to another purpose.

h) Occurrence of any flood, the peak of Design life― the intended period that the which exceeds the available flood dis- dam will function successfully with only rou- charge capacity or 70% of the approved tine maintenance; determined during design design flood; phase. i) Occurrence of a flood, which resulted in encroachment on the available freeboard, Distress condition – the occurrence or po- or the adopted design freeboard; tential development of such conditions in the j) Erosion in the near vicinity, up to five dam or appurtenance or its reservoir or reser- hundred meters, downstream of the voir rim, which if left unattended to, may im- spillway, waste weir, etc.; and pede the safe operation of dam for its intended k) Any other event that prudence suggests benefits or may pose unacceptable risks to the would have a significant unfavorable im- life and property of people downstream. pact on dam safety. Documentation – all permanent records con- Dam inspection – on-site visual examination cerning investigation, design, construction, of all components of dam and its appurte- operation, performance, maintenance and safety of dams and includes design memorandum,

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 119 O & M Manual for Maskinala Dam construction drawings, geological reports, re- Replacement― the removal of a structure or ports of specialized studies simulating struc- component and installation of a similar, func- tural and hydraulic response of the dam, tional structure or component. changes made in design and drawings, quality Service Life― the actual period after con- control records, emergency action plan, opera- struction of a dam, during which the practice tion and maintenance manual, instrumentation functions adequately and safely with only rou- readings, inspection and testing reports, opera- tine maintenance; determined by on-site re- tional reports, and dam safety review reports; view. Emergency Action Plan(EAP)― a plan of Abutment―that part of a valley side against action to be taken to reduce the potential for which a dam is constructed. Right and left damage to property and loss of life in the area abutments are those on respective sides of the affected by failure of a dam or other potential- of an observer looking downstream. ly hazardous practice. Air-Vent Pipe―a pipe designed to provide air Hazard Classification― a system that cate- to the outlet conduit to reduce turbulence dur- gorizes dams according to the degree of ad- ing release of water and safeguard against verse incremental consequences of a failure or damages due to cavitation. improper operation of the dam. CWC classi- fies dam hazards as “low”, “significant”, or Appurtenant Structures―ancillary features of “high”. a dam, such as the outlet, spillway, energy dissipation arrangement powerhouse, tunnels, etc. Maintenance― the recurring activities necessary to retain or restore a dam in a safe and Arch Dam―a concrete or masonry dam that functioning condition, including the manage- is curved to transmit the major part of the wa- ment of vegetation, the repair or replacement ter pressure to the abutments. of failed components, the prevention or treat- Backwater Curve―the longitudinal profile of ment of deterioration, and the repair of dam- the water surface in an open channel where ages caused by flooding or vandalism. the depth of flow has been increased by an Operation― the administration, management, obstruction, an increase in channel roughness, and performance of maintenance activities a decrease in channel width, or a flattening of necessary to keep a dam safe and functioning the bed slope. as planned. Base Width (Base Thickness)―the maxi- Program ― any authorized activity used to mum width or thickness of a dam measured implement and carry out goals, actions, and horizontally between upstream and down- objectives contained within the authorizing stream faces and normal (perpendicular) to the legislation. axis of the dam but excluding projections for outlets, etc. Program Life― the period in a contract, conservation plan, or plan during which the con- Berm―a horizontal step or bench in the slop- servation practice or conservation system shall ing profile of an embankment dam. be maintained and used for the intended pur- Upstream Blanket―an impervious layer pose; determined by program requirements. placed on the reservoir floor upstream of a Rehabilitation― the completion of all work dam. In case of an embankment dam, the necessary to extend the service life of the prac- blanket may be connected to the impermeable tice or component and meet applicable safety element in a dam. and performance standards. Buttress dam―a dam consisting of a water- Repair― actions to restore deteriorated, dam- tight upstream face supported at intervals on aged, or failed damor its component to an ac- the downstream side by a series of buttresses. ceptable by meeting functional condition. Cofferdam―a temporary structure enclosing all or part of a construction area so that construction can proceed in a dry area.

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 120 O & M Manual for Maskinala Dam Concrete Lift―in concrete works the vertical Dike (Levee)―a long low embankment distance between successive horizontal con- whose height is usually less than 5 m and struction joints. whose length is more than 10 times the maxi- ConduitOutlet Works―a closed conduit for mum height. Usually applied to embankments conveying discharge through or under a dam or structures built to protect land from flood- for different project purposes. ing. If built of concrete or masonry, the structure is usually referred to as a flood wall. Also, Consolidation Grouting (Blanket Grout- used to describe embankments that block are- ing)―theinjection of grout to consolidate a as on a reservoir rim that are lower than the layer of the foundation, resulting in greater top of the main dam and that are quite long. In impermeability, strength, or both. the Mississippi River basin, where the old Construction Joint―the interface between French word levee has survived, the term now two successive placing or pours of concrete applies to flood-protecting embankments where a bond, not permanent separation, is whose height can average up to 15 m. intended. Diversion channel, canal, or tunnel―a wa- Core Wall―a wall built of impervious materi- terway used to divert water from its natural al, usually concrete or asphaltic concrete, in the course. These terms are generally applied to body of an embankment dam to prevent leak- temporary structures such as those designed to age. bypass water around a dam site during construction. “Channel’ is normally used instead Crest Length―the length of the dam at its of “canal” when the waterway is crest (dam top) top of a dam, including the short.Occasionally these terms are applied to length of the spillway, powerhouse, navigation permanent structures. lock, fish pass, etc., where these structures form part of the length of a dam. If detached Drainage area―an area that drains naturally from a dam, these structures should not be to a point on a river. included. Drainage layer or blanket―a layer of perme- Crest of dam―Used to indicate the “top of able material in a dam to relieve pore pressure dam”. To avoid confusion to indicate the crest or to facilitate drainage of fill. of spillway and top of dam may be used. Relief well―vertical wells or boreholes, con- Culvert―a drain or waterway built under a structed downstream of an embankment dam road, railway, or embankment, usually consist- to relieve the pressure from confined pervious ing of a pipe or covered conduits layers in foundation overlaid by an impervious layer to arrest boiling. Cutoff―an impervious construction or material which reduces seepage through the founda- Drawdown―the lowering of water surface tion material. level due to release of water from a reservoir. Cutoff trench―an excavation later to be filled Earthen dam or earth filleddam―see embank- with impervious material to form a cutoff. ment dam. Cutoff wall―a wall of impervious material Embankment dam (Fill dam)― any dam (e.g., concrete, asphaltic concrete, steel-sheet constructed of excavated natural materials. piling) built into the foundation to reduce Earth dam (Earth filldam)―An embank- seepage under the dam. ment dam in which more than 50 percent of Dead storage―the storage that lies below the the total volume is formed of compacted fine- invert of the lowest outlet and that, therefore, grained material obtained from a borrow area. cannot be withdrawn from the reservoir. Homogeneous earth filldam― an embank- Design flood―see spillway design flood. ment dam constructed of similar earth material throughout, except internal drains or drainage Diaphragm―see membrane. blankets; distinguished from a zoned earth fill dam.

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 121 O & M Manual for Maskinala Dam Hydraulic fill dam―an embankment dam mum water level. Flood surcharge cannot be constructed of materials, often dredged, that retained in the reservoir but will flow over the are conveyed and placed by suspension in spillway until the controlled retention water flowing water. level is reached. Rock fill dam―an embankment dam in which Flood wall―a concrete wall constructed adja- more than 50 percent of the total volume cent to a stream to prevent flooding of proper- comprises compacted or dumped pervious ty on the landward side of the wall, normally natural or crushed rock. constructed in lieu of or to supplement a levee Rolled fill dam―an embankment dam of where the land required for levee construction earth or rock in which the material is placed in is expensive or not available. layers and compacted using rollers or rolling Foundation of dam―the natural material on equipment. which the dam structure is placed. Zoned embankment dam―an embankment Freeboard―the vertical distance between a decomposed of zones of materials selected for stated reservoir level and the top of a different degrees of porosity, permeability and dam.Normal freeboard is the vertical distance density. between Full Reservoir Level (FRL) and the top of the dam. Minimum freeboard is the ver- Emergency spillway―see spillway. ticaldistance between the Maximum Water Face―the external surface of a structure, e.g., Level (MWL) and the top of the dam. the surface of a wall of a dam. Gallery―(a) a passageway within the body of a Failure―the uncontrolled release of water dam or abutment, hence the terms grouting from a dam. gallery, inspection galleryand drainage gallery Filter (filter zone)―A band or zone of granu- (b) a long and rather narrow hall, hence the lar material that is incorporated into a dam and following terms for a power plant viz.valve is graded (either naturally or by selection) to gallery, transformer gallery andbus bar gallery. allow seepage to flow across or down the filter Gate―a device in which a leaf or member is without causing the migration of material from moved across the waterway from an external zones adjacent to it. position to control or stop the flow. Flashboards―a length of timber, concrete, or Bulkhead gate―a gate used either for tempo- steel placed on the crest of a spillway to raise rary closure of a channel or conduit to empty the retention water level but that may be it for inspection or maintenance or for closure quickly removed in the event of a flood, either against flowing water when the head difference by a tripping device or by deliberately designed is small, e.g., for diversion tunnel closure. Alt- failure of the flashboard or its supports. hough a bulkhead gate is usually opened and Floodplain―an area adjoining a body of water closed under nearly balanced pressures, it nev- or natural stream that has been, or may be, ertheless may be capable of withstanding a covered by flood water. high pressure differential when in the closed position. Floodplain management―a management program to reduce the consequences of flood- Crest gate (spillway gate)―a gate on the ing, either by natural runoff or by dam failure, crest of a spillway to control overflow or res- to existing and future properties in a flood- ervoir water level. plain. Emergency gate―a standby or reserve gate Flood routing―the determination of the at- which is lowers only for repairing / servicing tenuating effect of storage on a flood passing of the service gate. through a valley, channel, or reservoir. Fixed wheel gate (fixed-roller gate, fixed- Flood surcharge―the volume or space in a axle gate)―a gate having wheels or rollers reservoir between the controlled retention wa- mounted on the end posts of the gate. The ter level (Full Reservoir Level) and the maxi-

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 122 O & M Manual for Maskinala Dam wheels move against rails fixed in side grooves Hydrograph―a graphic representation of dis- or gate guides. charge, stage, or other hydraulic property with Flap gate―a gate hinged along one edge, usu- respect to time for a point on a stream. (At ally either the top or bottom edge. Examples times the term is applied to the phenomenon of bottom-hinged flap gates are tilting gates the graphic representation describes; hence a and belly gates, so called due to their shape in flood hydrograph is the passage of a flood dis- cross-section. charge past the observation point.) Flood gate―a gate to control flood release Inclinometer―an instrument, usually consisting of a metal or plastic tube inserted in a drill from a reservoir. hole and a sensitized monitor either lowered Guard gate(guard valve)―a gate or valve into the tube or fixed within it. The monitor that operates fully open or closed. It may func- measures at different points the tube’s inclination as a secondary device for shutting off the tion to the vertical. By integration, the lateral flow of water in case the primary closure deposition at various levels of the tube may be vice becomes inoperable but is usually operat- found relative to a point, usually the top or ed under conditions of balanced pressure and bottom of the tube, assumed to be fixed. The no flow. system may be used to measure settlement. Outlet gate―a gate controlling the outflow of Intake―any structure in a reservoir, dam, or water from a reservoir. river through which water can be drawn into Radial gate (Taintergate)―a gate with a an aqueduct. curved upstream plate and radial arms hinged Internal Erosion―see piping. to piers or other supporting structures. Inundation map―a map delineating the area Service/Regulating gate(regulating that would be inundated in case of a failure. valve)―a gate or valve that operates under full pressure and flow to throttle and vary the rate Leakage―Uncontrolled loss of water by flow of discharge. through a hole or crack. Slide gate (sluice gate)―a gate that can be Lining― a coating of asphaltic concrete, rein- opened or closed by sliding it in supporting forced or unreinforced concrete, shotcrete, guides. rubber or plastic on a canal, tunnel etc. to provide water tightness, prevent erosion, reduce Gravity dam―a dam constructed of concrete, friction, or support the periphery of structure. masonry, or both that relies on its weight for May also refer to lining, such as steel or con- stability. crete, of outlet pipe or conduit. Grout cap―a pad or wall constructed to facili- Low-level outlet (bottom outlet)―an open- tate pressure grouting of the grout curtain being at a lowlevel from a reservoir generally neath it. used for emptying or for scouring sediment Grout curtain (grout cutoff)―a barrier pro- and sometimes for irrigation releases. duced byinjecting grout into a vertical zone, Masonry dam―a dam constructed mainly of usually narrow horizontally, in the foundation stone, brick, or concrete blocks that may or to reduce seepage under a dam. may not be joined with mortar. A dam having Height above lowest foundation―the max- only a masonry facing should not be referred imum heightfrom the lowest point of the gen- to as a masonry dam. eral foundation to the top of the dam. Maximum cross-section of dam―a cross- Hydraulic height―the height to which water section of a dam at the point of its maximum rises behind a dam and the difference between height. the lowest point in the original streambed at Maximum water level―the maximum water the axis of the dam and the maximum control- level, including flood surcharge, the dam is lable water surface. designed to withstand.

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 123 O & M Manual for Maskinala Dam Membrane (Diaphragm)―a sheet or thin Pore Pressure―the interstitial pressure of wa- zone or facing made of a flexible material, ter within a mass of soil, rock, or concrete. sometimes referred to as a diaphragm wall or Pressure Cell―an instrument for measuring diaphragm. pressure within a mass of soil, rock, or con- Minimum operating level―the lowest level crete or at an interface between one and the to which the reservoir is drawn down under other. normal operating conditions. Pressure Relief Pipes―Pipes used to relieve Morning glory spillway―see spillway. uplift or pore water pressure in a dam’s foun- Full Reservoir Level (FRL)/Normal water dation or structure. level―for a reservoir with un-gated spillway it Probable Maximum Flood (PMF)―a flood is the spillway crest level. For a reservoir, that would result from the most severe combi- whose outflow is controlled wholly or partly nation of critical meteorological and hydrolog- by movable gates, siphons or other means, it is ical conditions possible in the region. the maximum level to which water can be Probable Maximum Precipitation stored under normal operating conditions, ex- (PMP)―the maximum amount and duration clusive of any provision for flood surcharge. of precipitation that can be expected to occur One-Hundred Year (100-Year) Exceedance on a drainage basin. Interval― the flood magnitude expected to be Pumped storage reservoir―a reservoir filled equaled or exceeded on the average of once in entirely or mainly with water pumped from 100 years. It may also be expressed as an ex- outside its natural drainage area. ceedance frequency, i.e. a percent chance of being exceeded in any given year. Regulating dam―a dam impounding a reservoir from which water is released to regulate Outlet―an opening through which water can be freely discharged from a reservoir. Reservoir area―the surface area of a reservoir when filled to controlled retention level. Overflow dam―a dam designed to be overtopped. Reservoir routing―the computation by which the interrelated effects of the inflow hy- Parapet Wall―a solid wall built along the top drograph, reservoir storage, and discharge of a dam for ornament, for the safety of vehi- from the reservoir are evaluated. cles and pedestrians, or to prevent overtop- ping. Reservoir surface―the surface of a reservoir at any level. Peak Flow―the maximum instantaneous discharge that occurs during a flood. It coincides Riprap―a layer of large stones, broken rock, with the peak of a flood hydrograph. or precast blocks placed randomly on the upstream slope of an embankment dam, on a Pervious Zone―a part of the cross-section of reservoir shore, or on the sides of a channel as an embankment dam comprising material of a protection against wave action. Large riprap high permeability. is sometimes referred to as armoring. Phreatic Surface―thetop most flow line in an Risk assessment―as applied to dam safety, embankment dam. the process of identifying the likelihood and Piezometer―an instrument for measuring consequences of dam failure to provide the pore water pressure within soil, rock, or con- basis for informed decisions on a course of crete. action. Piping―the progressive development of in- Rock fill Dam―see embankment dam. ternal erosion by seepage, appearing down- Roll Crete or Roller-Compacted Con- stream as a hole or seam discharging water that creteAno-slump concrete that can be hauled contains soil particles. in dump trucks, spread with a bulldozer or grader, and compacted with a vibratory roller.

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 124 O & M Manual for Maskinala Dam Seepage―the interstitial movement of water Side Channel Spillway―a spillway whose that may take place through a dam, its founda- crest is roughly parallel to the channel immedi- tion, or its abutments. ately downstream of the spillway. Sill―(a) A submerged structure across a river Siphon Spillway―a spillway with one or more to control the water level upstream. (b) The siphons built at crest level. This type of spill- crest of a spillway. (c) A horizontal gate seat- way is sometimes used for providing automatic ing, made of wood, stone, concrete or metal at surface-level regulation within narrow limits or the invert of any opening or gap in a structure, when considerable discharge capacity is neces- hence the expressions gate sill and stop log sill. sary within a short period. Slope―(a) the side of a hill or mountain. (b) Spillway Channel (Spillway Tunnel)―a The inclined face of a cutting or canal or em- channel or tunnel conveying water from the bankment. (c) Inclination from the horizontal. spillway to the river downstream. In the United States, it is measured as the ratio Stilling Basin―a basin constructed to dissi- of the number of units of horizontal distance pate the energy of fast-flowing water, e.g., to the number of corresponding units of verti- from a spillway or bottom outlet, and to pro- cal distance. The term is used in English for tect the riverbed from erosion. any inclination and is expressed as a percentage when the slope is gentle, in which case the Stop logs―large logs or timber or steel beams term gradient is also used. placed on top of each other with their ends held in guides on each side of a channel or Slope Protection―the protection of a slope conduit providing a cheaper or easily handled against wave action or erosion. temporary closure than a bulkhead gate. Sluiceway―see low-level outlet. Storage―the retention of water or delay of Spillway―a structure over or through which runoff either by planned operation, as in a res- flood flows are discharged. If the flow is con- ervoir, or by temporary filling of overflow are- trolled by gates, it is a controlled spillway; if as, as in the progression of a flood crest the elevation of the spillway crest is the only through a natural stream channel. control, it is an uncontrolled spillway. Tailrace―the tunnel, channel or conduit that Auxiliary Spillway (Emergency Spill- conveys the discharge from the turbine to the way)―a secondary spillway designed to oper- river, hence the terms tailrace tunnel and tail- ate only during exceptionally large floods. race canal. Fuse-Plug Spillway―an auxiliary or emer- Tail water Level―the level of water in the gency spillway comprising a low embankment tailrace at the nearest free surface to the tur- or a natural saddle designed to be overtopped bine or in the discharge channel immediately and eroded away during a rare and exception- downstream of the dam. ally large flood. Toe of Dam―the junction of the downstream Primary Spillway(Principal Spillway)―the face of a dam with the ground surface, referred principal or first-used spillway during flood to as the downstream toe. For an embankment flows. dam the junction of upstream face with Shaft Spillway (Morning Glory Spillway)―a ground surface is called the upstream toe. vertical or inclined shaft into which flood wa- Top of Dam―the elevation of the uppermost ter spills and then is conducted through, un- surface of a dam, usually a road or walkway, der, or around a dam by means of a conduit or excluding any parapet wall, railings, etc. tunnel. If the upper part of the shaft is splayed Top Thickness (Top Width)―the thickness out and terminates in a circular horizontal or width of a dam at the level of the top of the weir, it is termed a “bell mouth” or “morning dam. In general, “thickness” is used for gravity glory” spillway. and arch dams, “width” for other dams.

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 125 O & M Manual for Maskinala Dam Transition Zone (Semi-pervious Zone)―a part of the cross-section of a zoned embankment dam comprising material of intermediate size between that of an impervious zone and that of a permeable zone. Trash rack―a screen located at an intake to prevent the ingress of debris.

Tunnel―a long underground excavation usually having a uniform cross-section. Types of tunnel include: headrace tunnel, pressure tunnel, collecting tunnel, diversion tunnel, power tunnel, tailrace tunnel, navigation tunnel, access tunnel, scour tunnel, draw-off tunnel, and spillway tunnel. Under seepage―the interstitial movement of water through a foundation. Uplift―the upward pressure in the pores of a material (interstitial pressure) or on the base of a structure. Upstream Blanket―see blanket. Valve―a device fitted to a pipeline or orifice in which the closure member is either rotated or moved transversely or longitudinally in the waterway to control or stop the flow. Water stop―a strip of metal, rubber or other material used to prevent leakage through joints between adjacent sections of concrete. Weir―(a) a low dam or wall built across a stream to raise the upstream water level, called fixed-crest weir when uncontrolled. (b) A structure built across a stream or channel for measuring flow, sometimes called a measuring weir or gauging weir. Types of weir include broad-crested weir, sharp-crested weir, drowned weir, and submerged weir.

Doc. No. CDSO_O&M_KA06 MH0209_Maskinala Dam_v2.0Doc Page 126 O & M Manual for Maskinala Dam

Central Dam Safety Organization 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 encour- age professional excellence. Transparency: Ensure clear, accurate and complete information in communications with stakeholders and take all decisions openly based on reliable information. 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 functioning 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 satis- faction of our customers.

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