Govt. of Water Resources Department

IRRIGATION PLANT AND MACHINERY

Water Resources Department, Govt. of AP Srisailam Project

Water Resources Department, Govt. of AP Rivers in Rivers in United A.P.

Water Resources Department, Govt. of AP Rivers in Andhra Pradesh (Present)

Water Resources Department, Govt. of AP Rivers in Andhra Pradesh (Present)

Water Resources Department, Govt. of AP IRRIGATION PROFILE MAP OF NORTH COASTALL DISTRICTS

Water Resources Department, Govt. of AP RIVERS AND PROJECTS IN RAYALASEEMA REGION

Water Resources Department, Govt. of AP WATER

DRINKING & DAILY NEEDS

REQUIRED FOR

INDUSTRIES IRRIGATION

Water Resources Department, Govt. of AP RAIN

Sources TANK of RIVER Water

GROUND

Water Resources Department, Govt. of AP Irrigation Projects

MAJOR MEDIUM

MINOR LIFT

Water Resources Department, Govt. of AP Major Irrigation Reservoirs & Barrages

SRISAILAM RESERVOIR NAGARJUNA SAGAR PRAKASHAM BARRAGE SOMASILA RESERVOIR PENNA BARRAGE YELERU RESERVOIR GOTTA BARRAGE

Water Resources Department, Govt. of AP Medium Irrigation Suvarnamukhi • VENGALARAYASAGAR PROJECT, VIZIANAGARAM DT CHAMPAVATI • ANDRA PROJECT, VIZIANAGARAM DT

SUVARNAMUKHI • MADDUVALASA RESERVOIR PROJECT, SRIKAKULAM

GOSTANI • TATIPUDI RESERVOIR PROJECT, VIZIANAGARAM DT

SARADA • RAIWADA PROJECT, DT

TANDAVA • TANDAVA PROJECT, VISAKHAPATNAM DT

PAMPA • PAMPA PROJECT, ANNAVARAM, EAST GODAVARI DT

TAMMILERU • PROJECT, WEST GODAVARI DT GUNDLAKAMMA • GUNDLAKAMMA PROJECT, PRAKASHAM DT MANNERU • RALLAPADU RESERVOIR PROJECT, PRAKASHAM DT SWARNAMUKHI • VAKADA BARRAGE, NELLORE DT Water Resources Department, Govt. of AP MINOR IRRIGATION

TANK LIFT IRRIGATION IRRIGATION UNDER GROUND ANICUT WATER

Water Resources Department, Govt. of AP Water Resources Department, Govt. of AP Gates-EM Parts (Embedded Metal Parts) Secondary Primary Parts Secondary Parts Parts Radial Gates Vertical Gates (Anchor • Anchor Beams • Sill Beams Plates) • Seal Tracks • Tie Beams • Roller Tracks • Trunnion Boxes- • Guide Tracks Chairs • Corner Protection • Vertical Anchorages Angles • Breast Wall Plates • Wall Plates

Water Resources Department, Govt. of AP The major component of the Vertical lift gates

A. Embedded parts B. Gate leaf i. Block outs and 1st stage embedded parts • Skin plate

ii. 2nd stage embedded parts • Horizontal girders • Sill Beam • End boxes • Side Seal seat • Vertical Stiffeners • Top seal seat • Roller Assemblies • Roller Track • Guide rollers • Side guide assembly • Sealing arrangement • Dogging or latching arrangement • Lifting arrangement

• Ballast if required

Water Resources Department, Govt. of AP Vertical • With Counter Weight Gates • Without Counter Weight

Radial • Rubber Seals • Rollers and Guides Gates • Hoist Brackets

Water Resources Department, Govt. of AP Radial Gates Stop Log Floating • Seals Gate Bulk Head • Guide Rollers • Hoisting Brackets Elements Gates

Water Resources Department, Govt. of AP The major sub assemblies of radial gates

Skin plate assembly with vertical stiffeners.

Side guide assemblies – Lifting bracket – seal assembly.

Horizontal girders

Horizontal girder bracings

Arm assemblies

Trunnion assemblies.

Tie between trunnion Lifting arrangement consists of turn- buckles, equalizer, plates, pins and rope – sockets.

Water Resources Department, Govt. of AP Gate Fabrication

1. Jigs, Fixures, C-Clamps etc 1. Prepare Shop Drawings 2. Cranes-EOT Crane, Movable 2. Prepare Work Schedule- Crane Sequence of Operations 3. Handling of Materials 3. Safety precautions Troleys

1. Marking Operationss 2. Cutting Operations 3. Bends and Distortion Removals (Blacksmith) 4. Welding Operations (Preparation of Joints)

Water Resources Department, Govt. of AP PERSONNELS Technical Inspector Fitter Gas Cutter Welder Black Smith Marker Helpers Riggers Driller Man Mazdoors etc.,

Water Resources Department, Govt. of AP Water Resources Department, Govt. of AP Gates- Hoist Bridges

Walking ED & CD Main Cross Working Bridges Seating Gudders Gudders Platforms & Hand Frames Railing

Water Resources Department, Govt. of AP Water Resources Department, Govt. of AP Hoisting Equipment Central Drive Unit End Drive Unit

Electrical Motor (5 HP, 10 HP, 20 HP and 50 HP) Line Shafts

Radican Unit-Torque Convertor and Speed reducer Plumber Block Support

Electro Mechanical Brakes Cuplings

Dog Clutch Pinion and wheels (P1 – W1, P2 – W2, P3 – W3, W3 Rope Drum)

Hand Operating Unit Wire Ropes

Water Resources Department, Govt. of AP Gates-Hoisting Equipment

Rope Drum Hoisting Chain Link Hoist Arrangement Arrangement

Screw Rod Hoisting Electrical Arrangement Operation/ Manual Operation Unit

Water Resources Department, Govt. of AP

422 422

400 ROLLER TRACK C/C = 5100 'G' 677.5

200 200 277.5 76

16 VENT 4545

110

275

100

400 400 100 280

8 28

75 RECESS 75

10 RECESS 75

28 422

'H' 125 289 160

200 20

21172

100

250 250 250

40

500 500

400 1250

5000 SIDE SEAL C/C 4650 8 150 100 600 250 DETAIL - K DETAIL - G 50 GUIDE F/F =5400

10 100 100 200 16 200

84 280 20 70 FLOW

100 100

5

250 150

100 100

200 477.5 8900 GROOVE DETAIL

400

21172 21172 DETAIL - H

SS= 8900 'K' 41SPCS 20500 @= 500

E 41SPCS 20500 @= 500 9000 D 272.5 8 SPCS @ 500 = 4000 D 8500

E

9000

8 SPCS @ 1000 = 8000 8SPCS = @1000 8000 8SPCS = @1000

17 SPCS @ 500 = 8500 17SPCS = @ 500 17 SPCS @ 500 = 8500 17SPCS = @ 500

255025 100 50 17.5Ø HOLES L75X75X8 FOR M16 BOLTS

SS= 5000 100 LONG

30° 28

100

150 SILL TO TOP SEAL C/C = 4670 SILL = TO TOP C/C SEAL

FLOW TYPICAL JOINT OF SIDE GUIDE

400 600 250 500

500 61

250 250 250 250

250 220 200 250 10 SPCS @ 500 = 5000 250 200 5500 'D' 50 150 50 35 150 35 16Ø

16Ø 200 GROOVE END TO END = 5900 100 70 ROLLER TRACK C/C = 5100 R32

VENT 4545 62 38 8 TYPE-1 TYPE-2

FOR TRACK & SIDE GUIDE FOR SILL

275

125 150

GUIDE F/F = 5400 10

SIDE SEAL C/C 4650 300

400

1250 1250

70 600

TYP.

140 200

100 10 250 150

250 35 16Ø

677.5 FLOW 677.5

200

220

150

50 330

75 MM DETAIL - D 35

275 RECESS 200 R32 125 130 TYPE-3 GUIDE F/F = 5400 TYPE-4

30 FOR TOP SEAL

400

1250 1250

30

600 130

200 100 3540

250 75 MM RECESS

677.5 677.5 450

1ST STAGE 250

140 2ND STAGE PLAN

NOTE:

1.ALL DIMENSIONS ARE IN MM 35 2.ALL WELDS ARE 6mm FILLET UNLESS 40 300

E F OTHERWISE SPECIFIED

80

220 250 150 3.THE SIDE GUIDE MAY BE IN 6.25M LENGTH. 6 (TYP) 5.B.O.Q GIVEN FOR ONE VENT ONLY,

27 29 150 TOTAL VENTS REQUIRED = 3 VENTS.

30 250

35

50

50

5000 4670

82 50

200 250 100 8 4545 E F

8 X500 C/C = 4000 272.5 4670 DETAILS OF EMBEDDED PARTS & SECTION - EE 4545 SECTION - DD 14735 SUBJECT BLOCKOUTS 75 FOR INTAKE SERVICE GATE SECTION - FF

\\S2\d\final files\NKN\BHME\logo black.bmp BALAJI HYDRO MECH EXPERTS HYDERABAD - 049

DRAWN SANDHYA.G SCALE:

CHECKED& N.K.NAIDU DRG No: Tech. Adviser SUBMITTED (Hydraulic Gates) 4800 10 400 130 325 755 130 375 150 375 995 325 130 700 20 140 SECTION-DD 4670

570 130 490

475 24 20 210 SECTION-XX 120 650 20 SILL TO TOP SEAL = 4670 130 10 390 20 1324 12 369 150 369 12 1438 12 564 12 20 100 SECTION-EE

20 20 330 530 470 650

600 A 600 410 1340 900 1450 700 200 400 200 400 10 250 160 130 325 430 150 130 325 540 325 130 20 20 245 20 245 130 255 255 400 200 200 100 100 50 477.5 477.5 100 100 250 277.5 277.5 50 400 75 20 20 20 280 20 250 3X80=240 130 45

275 195 275 195 S

430 470 50 20 490 50 200 1000 600 632 40 330 530 400

450 10 U/S U/S ELEVATION 65

20 65 210 20 20 650 20 2430 E E 10 20 250 4 SPCS @ 400 @400 = SPCS 4 1600 FLOW FLOW END END TO ENDOF =GROOVE 5500 END TO ENDOF =GROOVE 5500 44X100=4400 C/C C/C OF ROLLER =TRACKS 5100 C/C OF ROLLER =TRACKS 5100 C/C OF SIDE SEALS SIDE OF =C/C 4650 SEALS SIDE OF =C/C 4650 B B VENT = 4545 VENT = 4545 ELEVATION VIEW - VIEW AA PLAN 3000 4860 C/C C/C OF TRACKS = 5100 5360 LIFTING C/C = LIFTING 3200 R1 210 4 SPCS @ 400 @400 = SPCS 4 1600 D/S D/S ELEVATION 25Ø DRAIN HOLES X X 300 400 430 140 C C 130 20 100 30 100 4 20 10 D D A 4800 230X20 230X20 650X12 230X20 250X20 250X20 250X20 300X20 350X20 450X20 8 8 8 5230 TO SILL 12 1. DIMENSIONS ALL ARE MM. NOTE:- 3. B.O.Q SHOWN FOR 1 GATE 1 ONLY FOR SHOWN TOTAL B.O.Q 3. REQ=3. 2. WELDS ALL ARE 6 MMCONTINUOUSFILLET 4. FORTHE DETAILS OF LIFTING REFERBRACKET THE DRG. NO. :BHME-NMHP-INT-SG-504. OTHERWISE UNLESS STATED. 8 650 650 SECTION-BB 450 12 250X20 20 12 10 210 10 20 10 30 90 30 10 20

410 1340 450 150 450 1450 570 SILL TO TOP SEAL = 4670 130

50 130 130 30 90 30 130 80 4X80=320 SECTION-CC 480 490 275 100

20 85 20 \\S2\d\final files\NKN\BHME\logo black.bmp\\S2\d\final SUBJECT DRAWN SUBMITTED CHECKED& 150 410 1340 450 450 1450 570 130 4800 SANDHYA.G (HydraulicGates) Tech. Adviser N.K.NAIDU BALAJI HYDRO MECH EXPERTS DETAILS DETAILS OF GATE LEAF FOR FOR INTAKE SERVICE GATE HYDERABAD - HYDERABAD 049 SCALE: DRG DRG No: 60 80 60 480

80 4X80=320 80 12 20 20 HOLES @180 PCD M16 TAPPED 150 100 100 200 25 150 25 25 SECTION AT SPLICE JOINT

Ø80 31 100 100 SIDE GUIDESIDE DETAIL DETAIL-26 ELEVATION 20 20 PLAN 100 150 150 200 200 38 38 20

75 275 195 130

270 40 50 25 55 20 23 30

53 12 30

200 44X100 =440044X100 470 END VIEW 12 30 53

200 23 N N

M16 HOLESTAPPED 50 35 12 12 3 3 20

80 200

POSITIONING OF SIDE GUIDE 28 DETAIL IN A GROOVE 100 35

Ø80 50 43 13 80 53 5 44 150 1 420 DETAIL-27 12 SECTION - NN 12 3

150 20

20 200 3 12 270

60 20 SKIN PLATE 24 30 90 30

50 200 45 TOP DETAILSEAL 127 25

DETAIL -DETAIL 25 75 30 12 DETAIL -DETAIL 52 150 90 200 Ø17.5HOLES 14 120 70 30 30 12 PL 20 PL THK 60 30 150 290 150 30 Ø44

DETAIL-28 650 SQU.40 25 53 L 10 ON 150Ø P.C.D Ø17.5 Ø17.5 HOLES +0.000 10 90 -0.100 20 20 11 MATERIAL : 11 11 100 DETAIL -DETAIL 54

200 200 160 202 45C8 IS200445C8 Ø17.5 HOLES 35 100 DETAIL-29

11 11 150 80 11 SECTION -SECTION LL 20 20 10 30 30 35

60 DETAIL DETAIL - S R31

3

75 Ø44 120° M M 60 280 45

250 3 1.6 75 75 60 30 30 \\S2\d\final files\NKN\BHME\logo black.bmp\\S2\d\final SUBJECT DRAWN SUBMITTED CHECKED& 80 60 4600 CORNER SEAL SEAL CORNER DETAIL 75 120 Ø44 280 4400 SANDHYA.G (HydraulicGates) 250 Tech. Adviser N.K.NAIDU ? OF SEAL K K BALAJI HYDRO MECH EXPERTS JOINT 80 DETAILS DETAILS OF GATE LEAF FOR FOR INTAKE SERVICE GATE M12 BOLTM12 WITH NUTWITH 84 12 20 L HYDERABAD - HYDERABAD 049 14 18 SCALE: DRG DRG No: ? OF SEAL 3mm Comp. SECTION - MM 12 JOINT 75 SECTION - KK Ø44 60 5X45° 20 20 175 105 14 20 14 12

12 20

6mm Comp. 20 6mm Comp. 37 42 38 42 80 5 79 HOLE TO SUIT M8CSK SCREW 4NOS ON 13Ø HOLES FOR 12ØX30 LG 240PCD HEX SCREW 6 NOS-ON 8Ø TAPPED HOLES FOR M12X30 LG DEEPTAPPER 390PCD 8ØCSK SCREW 35 170 HOLES ON 390PCD 6NOS ON 240PCD 4NOS 8 10 ONBOTH SIDES

TRACK C/C = 3800 10 1025 30 275 350 400 (TYP) A

10

Ø275

-0.100

+0.000

Ø162 Ø290

SIDE SEAL C/C = 3200 PCD240 100 100

25 5 15 Ø290

300 172 225 100

10 85 40 35 10

-0.100

+0.000

25

Ø162

Ø450 Ø190

PCD390 PCD240

28 Ø290

450 550

25 301

+0.024 +0.005

Ø275 Ø290 Ø550

300 DETAIL-3

PCD390 PCD340

300 125 DETAIL-10

Ø290 300 300 30 250

100 4MM PRE COMPRESSION

10

100

28

Ø16

13

20 28

6 68 25 (TYP) SKIN PLATE

20 12 180

295 DETAIL-2

240

239

227 1450

199 50 Ø44 50

450

16

Ø16

20 10

40 12

100 DETAIL-1 10 28

MATERIAL : CAST STEEL IS1030 - GRADE 340 - 570W Ø350

7 Ø330

PCD340 80

20 700 150 UTS = 570MPA, HARDNESS : 150 - 170 BHN. 130 150 125

900 5 DETAIL-A

501 10ØHOLER ARE TO BE MADE AT 500C/C SEAL DETAIL

TO PRESSURISE THE SEAL 300 25 16 28 230 28

NOTE:

1.ALL DIMENSIONS ARE IN MM

Ø16 150 2.FINISHED DIMENSIONS ARE SHOWN PROVIDE M/C 28 ALLOWANCES.5MM ON RADIUS,10MM ON BORE 277 750 VENT = 3000 DIAMETER AND 5MM ON FACE. 3.BEARING: SPHERICAL ROLLER BEARING 22232CC/W33, SIDE GUIDE F/F = 4420 160X290X80 MIN STATIC.CAPACITY 1290 KN, END TO END OF GROOVE = 4500 WITH PRESSED STEEL CAGE OF SKF/NTN/NSK/FAG/ZKL MAKE. 4.BOQ SHOWN FOR ONE ROLLER ASSEMBLY TOTAL NOS REQD. 1X8 = 8 NOS. SURGE SHAFT GATE 5.ALL STRUCTURAL STEEL CONFIRMING FLOW GROOVE DETAIL TO IS 2062 - 2006 GRADE E- 250 QUALITY B.

184 184 113 55 OF BEARING

Ø6

+0.021 +0.003

160

Ø120 Ø100 Ø120 Ø170 SQ70 Ø6 DETAILS OF ROLLER ASSEMBLY TITLE FOR SURGE SHAFT GATE BALAJI HYDRO MECH EXPERTS 5MM ECCENTRICITY 1213 46 58 55 40 30 43 46 25 368 HYDERABAD - 049 END VIEW DRG No: DETAIL - 5 DRAWN NAGA.K MATERIAL:20CR13 IS1570 PART REV NO : SCALE : CHECKED& N.K.NAIDU Tech. Adviser SUBMITTED (Hydraulic Gates) DATE : MAY 2009 140 M16X22 DEEP TAPPED HOLES ON 330 PCD 6 NOS. 10 12

Ø9 CSK HOLES A ON 200 PCD 4 NOS.

END TO END = 5500 ROLLER TRACK C/C = 5100±2.0 10 28 32 70 5

102

-0.100

-0.100 +0.000

+0.000 5 12

Ø132 Ø220 Ø230

Ø230 Ø220 Ø260 Ø330 Ø230 Ø210 Ø160 Ø200 Ø330 Ø390 Ø200 Ø132 Ø230

Ø450 -0.024 478 +0.005 VENT : 4545

200 278 Ø230

160

8

20 23

50 20 22 Ø17.5 HOLES DETAIL - 5 DETAIL - 9

10 6 NOS ON 330 PCD 20 GROOVE ON PCD DETAIL - 2

245 260 FOR Ø5 'O' RING 195 DETAIL - 1 NOTE: MATERIAL : CAST STEEL IS:1030 Gr 280 - 520W 1. ALL DIMENSIONS ARE IN MM.

HARDNESS : 150 - 170 BHN 2.5

400 2. FINISHED DIMENSIONS ARE SHOWN PROVIDE M/C ALLOWANCES 5MM ON RADIUS AND 10MM & DIA 5MM ON FACE. 3. BEARING : SPHIRICAL ROLLER BEARING 22226E CC ID:130,OD:230 64 THK STATIC CAPACITY 930KN WITH PRESSED STEEL CAGE OF

2.5 SKF / NSK / NTN / FAG/ZKL. 4. B.O.Q GIVEN FOR ONE ROLLER ASSEMBLY ONLY. 3.5 260Ø

470 NOS. REQD: 3X8 = 24 NOS. 600 DETAIL-A

20

275 310

28 155 155 50 130 10 10 13 ? OF BEARING 10 10 12 32 98 32 25 41 32 25 TAPPED HOLE SUIT 8 8 75 140 Ø6 GREESE NIPPLE 20 12 200 12 20 200 SQU.40

12 Ø6

Ø8

-0.004

+0.024

-0.004

+0.024

20

Ø80 Ø60 Ø80

60

14

Ø140 SQR40

60 Ø130 10 Ø130 Ø6 120° VENT : 4545 42 42 52.5 5MM ECCENTRICITY 5MM ECCENTRICITY SIDE SEAL C/C = 4650±2.0

END VIEW DETAIL - 3 MATERIAL : CORROSION RESISTANCE STEEL 20Cr13 IS 1570 PART V HARDNESS : 150 - 170 BHN FLOW GROOVE DETAILS

DETAILS OF ROLLER ASSEMBLY SUBJECT FOR INTAKE SERVICE GATE

\\S2\d\final files\NKN\BHME\logo black.bmp BALAJI HYDRO MECH EXPERTS HYDERABAD - 049

DRAWN SANDHYA.G SCALE:

CHECKED& N.K.NAIDU DRG No: Tech. Adviser SUBMITTED (Hydraulic Gates) EL +1665.000M EL +1665.000M

TOP OF GROOVE TOP OF GROOVE 1025 250 250 ROLLER TRACK C/C=3800

10 275 350 400 ?100X100X10

100

450 VENT = 3000

550

100

200

84

200

1450 450

250

900

250 147 SPCS 147 @500=73500

END TO END GROOVE = 4500

300 150

GROOVE DETAIL 275 FLOW

100 300

10

10 159 SPCS 159 @500=79500

159 SPCS 159 @ 500=79500 Ø16

Ø16 250 250 200 EL +1591.500M

TOP OF TRACK

50 50

R32 R32

250 250 500

450 450

100 100

300 100

TYPE-1 TYPE-2

300 200

E 10

500 4 SPCS @ 500=2000 500

60° 10 Ø16

250 200 50 150

300 250 6500

E 200

50

100

11 SPCS 11 =5500 @500 SPCS 12 @ 500=6000

12 SPCS 12 =6000 @ 500 R32 80

50 150 100

DETAIL-5 300

VENT 3000 100 6 SPCS 6 3000 @ 500 =

450 450 300 150 TYPE-3 SILLTO TOP 3100 SILL FLOW

84 EL 1585.000M EL 1585.000M F SILL LEVEL 34 SILL LEVEL L

500 O

250 250 250 250

W 400

200 200 X

275 250 8 SPCS @ 500=4000 250 275 400 5050

SECTION-AA

1025 75 200 C/C OF TRACK 3800 275 350 400 300 130 195 16 400 NOTE:

450 VENT 3000

550 1.ALL DIMENSIONS ARE IN MM 84 A 2.ALL WELDS ARE 6mm FILLET UNLESS 100 A

OTHERWISE SPECIFIED

1450 450 450 3.B.O.Q GIVEN FOR ONE SET ONLY, 250 8 SPCS@ 500=4000 250 DETAIL-X

300 1. TAIL RACE GATE

300 END TO END OF GROOVE 4500 TOTAL SETS REQUIRED = 1 SET. 400 450 4. STRUCTURAL STEEL CONFIRMING TO

275 PLAN 275 IS2062 - 2006 GRADE - E = 250 - B. 150

100 BLOCK OUT DETAILS TITLE FOR SURGE SHAFT GATE 400

SECTION-EE BALAJI HYDRO MECH EXPERTS HYDERABAD - 049

VENT3000 = DRG No:

DRAWN NAGA.K SILL3100 TO TOP SEAL = C/C REV NO : SCALE : CHECKED& N.K.NAIDU Tech. Adviser SUBMITTED (Hydraulic Gates) DATE : JAN 2009 C2 C1 D G

1450 900 A A 250 159 SPCS @ 500 C/C = 79500 250 450 450 11 SPCS @ 500 C/C = 5500 900 550 10 900 550 900 550 400 500 500 150

150 300 450 100 450 275 275 84 625 625 6 (TYP) 250 350 1025 1025 90 10 10 40 6 (TYP) 250 6 (TYP) 40 N

Ø16 6 (TYP) 750

25 Ø16 300 300 275 275 Y 10 75 100 ( ( (

25 250 ( FROM EL 1588.000M TO EL 1588.000M 1591.500M EL FROM ( ) SURGE GROOVESHAFT GATE DETAIL FROM EL 1591.500M TO EL EL TO 1665.000M 1591.500M EL FROM EL TO 1591.500M 1588.000M EL FROM EL TO 1588.000M 1585.000M EL FROM F F EL +1665.000M EL

6500 GROOVE OFTOP GUIDE GUIDE F/F = 4420 GUIDE F/F = 4420 EL 1585.000M EL SILL SILL LEVEL 40 EL +1591.500M EL 5 = 5 2500 SPCS@500 25 G 80 TRACKOF TOP Ø17 HOLES FOR M16X75 LG HEX LG BOLTS FORHEX HOLES M16X75Ø17 WITHNUTWASHER & @ C/C 250 75 40 END ENDOF END TO GROVE4500 6 (TYP) (TYP) 6 C/C C/C SIDE OF 3200 SEAL C/C SIDE OF 3200 SEAL

(TYP) 28 300 SIDEGUIDE F/F 4420 PLAN AT-C2C2PLAN 10 AT-C1C1PLAN C/C C/C TRACK3800 OF C/C TRACK3800 OF 350 8 8 @500=4000 SPCS PLAN PLAN AT-DD SECTION-AA E E END TO END OF GROOVE =END END4500 TOOF GROOVE VENT VENT 3000 VENT 3000 1025 1025 3800 3000 4500 3000 ? END ENDOF END TO 4500GROVE ENDOF END TO 4500GROVE 875 200 EL +1591.500M EL GROOVE LINERS GROOVE 750 EL +1588.000M EL 300

300 900

SILL TO TOP SILL C/C=3100 OFTOP GUIDE F/F = 4420F/FGUIDE = ROLLER TRACKROLLER3800 C/C= Ø16 20 400 B B 25 172 B B 10 100 ) ) ) FLOW 300 300 FLOW FLOW

10 750 750 750 SIDE SEAL C/C = 3200SEAL C/C = SIDE ?

150 6500 350 100X100X10 250 625 625 VENT = 3000=VENT (TYP) 6 275 275 275 275 155 FLOW 250 450 450 450 450 450 525 1450 1450 250 12 SPCS @500=6000 250 73500 975 A A C1 C2 D

550 80000 100 450 400 6500 100 250 12 SPCS@500=6000 RECESS

10 250 400 6 (TYP) 450 25 100 SECTION-BB FOR LOCATIONFOR BOLTSM16HEX 275 634 Ø16 75 400 225

100 650 10 75

75 40 40 450 366 L K 84 975 40 900 625 816 25 80 10 300 300 (TYP) 100

10 100 150 (TYP) 2366TO 6 X 280 390 28 300 25 300 150 100 FLOW 1025 SECTION-GG 1500TO

10 12 SPCS @ 500 = 6000 ? 250 300 OF SURGE OF SHAFT WELLSURGE Ø16 40 300 EL +1665.000M EL TOP OF GROOVE OFTOP

Ø16 250 159 SPCS @ 500 =79500 250 25 ? DETAIL-X EL +1591.500M EL OF SURGE OF SHAFT WELLSURGE 300 GROOVE LINERS GROOVE 84 150 10 PLAN 28 20 150 125 200 TOP OFTOP 400 W O F L 20 172 400 10 250 1450 250 10 100 350 130 10 EL 1585.000MEL 900 550

SILL LEVEL 150 300 450 100 450

? 250 100X100X10 10 10 90 250 (TYP) 150 6 6 (TYP)

SIDE SEAL C/C = 3200±2SEAL C/C = SIDE Ø16 F F 25 Ø16 275 275 150 80000 10 100 25 EL 1588.100MEL 25 ( FROM EL 1585.000M TO EL 1585.000M 1588.000M EL FROM ( ) SURGE GROOVESHAFT GATE DETAIL

Ø16 84 5 SPCS @C/C500 =SPCS 5 2500 250 6 (TYP) ? 40 100X100X10 80 80 40

Ø16 6 (TYP) 250 (TYP) 6 165

SILL TO TOP SEAL C/C = 3100 (TYP) 10

353 350 DETAIL-Y END TO END OF GROOVE =END END4500 TOOF GROOVE 275 VENT = 3000 250 1025 315 10 300

100 50 5 10 80 200

400 110 150 750 75 80 75 250 28 40 GUIDE F/F = 4420F/FGUIDE = SECTION-EE 130 Ø16 ROLLER TRACKROLLER3800 C/C= Ø16 75 400 75 75 28 400 100 10 25 172

73500 100 300 225 25 2 100 195 Ø16 2 SIDE SEAL C/C = 3200SEAL C/C = SIDE ? 25 100X100X10 60°10 (TYP) VENT = 3000=VENT DRAWN CHECKED& SUBMITTED TITLE

100 300 FLOW

SILL BEAM BEAM ISMB250X125 SILL 301 400 30

125 1.ALL DIMENSIONS ARE IN1.ALL ARE MM.DIMENSIONS NOTE: 6.THIS DRAWING IS PREPARED 6.THISBASED DRAWING IS ONPREPARED 5.STRUCTURAL CONFIRMING STEEL 3.THE JOINT IN THE SIDE BE MAY GUIDE 2.ALL 6mm WELDS ARE FILLET UNLESS 4.B.O.Q ONLY,FOR GIVEN VENT ONE SPECIFY DRG NO:1059 - C1095,1059 - NO:1059 DRG - SPECIFY C1095. - E = GRADE 2006 - 250 IS2062 TO - B. TOTAL= REQUIRED 1 VENTS VENT. 5 AT M PROVIDED EVERY LENGTHS. SPECIFIED. OTHERWISE 300 150 (HydraulicGates) 110 LONG 110 L75X75X8 SESHU.Y Tech. Adviser Tech. N.K.NAIDU 25 BALAJI HYDRO BALAJI MECH EXPERTS DETAILS OFEMBEDDED PARTS 100 LONG 100 L75X75X8 40 40 25 25 DETAIL-N SILL TO TOP OF TRACK = 6500 150 FORSURGE SHAFTGATE 110 TYPICAL JOINT OF TYPICAL JOINT REV NO : 60 DATE JAN2009 : DRG No: (5M HEIGHT) 40 40 150 ELEVATION SIDE GUIDESIDE 25

HYDERABAD -049 VENT = 3000 50 150 25 5 PLAN FOR M16 BOLTSM16 FOR DETAIL-K 100 100 50 40 25 17.5Ø HOLES 17.5Ø DETAIL-L 150 25 SECTION-FF 25

10

60 75 300 10 30° FOR M16 BOLTSM16 FOR 100 50 40 17.5Ø HOLES 17.5Ø

40 6500 73500 30°

40 40 5 50 150 50

SCALE : 5000 5000 3600 20 28 25

100 10

6400 F

SILL TO TOP SEAL C/C = 3100 200

E E 495 545 500 495 565 500 450 450 44 4X95=380 5X90=450 4X100=400 4X95=380 5X95=475 5X80=400 65 65 385 395 X 143

28 240 350 235 65 500 230 65 65 65 20 50 85 135 300 55 40 71 50 45 40 60 60 50 35 12 55 28 SECTION-AA SILL TO TOP SEAL C/C = 3100 200 35 6mm 6mm COMP

28 20

495 545 500 495 565 500 28 ELEVATION D/S F

130 68 12 20 19 SPCS @ 70 @ = 1330SPCS 19 28 10 10 280 18X80 = 1440 = 18X80 10

414 210 45° 12 16 FLOW 700 190 16 10 10 10

20 20 28 PLAN G G 10 VENT =3000 VENT C/C OF TRACKS =OF 3800C/C 100

130 @350 = 28008SPCS 28 178 232 270 260 255 270 295 270 28X100 = = 2800 28X100

SIDE GUIDESIDE =4420 F/F 28 4086 A A 16 C/C SIDE OF =SEAL3200 35 40 2800 28 700 28 150 Ø40 DRAIN HOLE LIFTING C/C = 2100LIFTING B B 10

47 490

250 20 U/S ELEVATION U/S 250 C C 20

100 20 476

800 135 SECTION-CC 100

SILL TO TOP SEAL C/C = 3100 200 420 20 6mm 6mm COMP 130 280 28

495 545 500 495 565 500 500 28 D D 150 150 400 150 150 130 28 10 100 280

250 130

70 260 190 230 16 28

130

45° 28 300 12 20 28 115 175 210 230

16 28 610 780 775 785 200 863

12 12 12 150 1390 1760 350 185 20 28 28 12 500 800 155 28 540 240 SECTION-BB 900 3300 6mm 6mm COMP 28 150 1390 1760 250 330 12 250

28 Y

385 5 200 5 700 700

280 16 1.ALL DIMENSIONSARE MM NOTE:- DRAWN 5.ALL STRUCTURAL STEEL CONFIRMING TO ISSTEEL 2062STRUCTURAL GR5.ALL E 250 B. 3.B.O.Q SHOWN FOR ONE GATE ASSEMBLY 6.TFC = TEFLONCLADED.6.TFC CHECKED& 2.ALL WELDS FILLET ARE 6 CONTINUOUSMM SUBMITTED 4.THE CGACTUALARRIVEDTHE IS CG TENTATIVE. IS TO BE ARRIVEDCOMPLETION AFTER FABRICATIONOF OF GATE. ONLY, TOTALNO. OF GATES = 1 NO. UNLESS OTHERWISE STATED TITLE

300 28 28 28 28 240 240 240 13 150 150 150 150 (Hydraulic Gates)(Hydraulic SESHU.Y Tech. Tech. Adviser N.K.NAIDU 240 240 280 BALAJI HYDROMECH EXPERTS 395 395 VIED-EE DETAILS DETAILS OF GATE ASSEMBLY

1540 1760 755 780 FOR FOR SURGE SHAFT GATE 6mm 6mm COMP REV NOREV : DATE : JAN DATE : 2009 DRG No:DRG

BHME- 150 150 150 150 540 540 SECTION-DD 385 385 HYDERABAD - 049HYDERABAD 240 240 28 280

12 740 12

PES 45° - 780 BHEP-SSG 12 12 R1 540 760 780 775 785 200 540 12 28 SCALE :

-

803 SHEET 1OF2 12

3300 END TO END OF GROOVE = 4500

SIDE SEAL C/C = 3200

350 300 100 4086 30 90 30

20 TRACK C/C =3800

10 30

300 SIDE SEAL C/C = 3200 130 28

68 50 Ø44 50 80

12 12 28 90

150

3150

240

239

227

95

450

395 3300

J

95 280 12 130 500 40 66

2 3016

H 66 H

700

900

95

150

40

84

80 84

5 44 45°

529 540 3MM COMP.OF SIDESEAL 40 6MM COMP. 80 235 130 55 80 80 80

385 R50

4

450 30 28 230 28 DETAIL-X J 12 20 6mm COMP 28 230 28 150

12 3514

SECTION-JJ DETAIL-38

28

28

11 28 FLOW

VENT = 3000 780 130

150 80

TRACK C/C = 3800 20

SIDEGUIDE F/F = 4420 20 50

5 350 2680 2 12 GROOVE DETAIL 16 R22

180 3016 25 65 65 85 85 25 45 25

SECTION-HH 50

90

65

180 Ø44

28 65

50 350 20 80 ?

OF SEAL JOINT 80 20 12

Ø44 35

90 50 50 ? 200

45 OF SEAL JOINT

SILL3100 TO = TOP SEAL C/C

16

50

50

2843 20 DETAIL-51

Ø10 50 Ø44 50

28 180 12 180

Ø44 Ø10

50 130 DETAIL OF LH CORNER SEAL 130 Ø44 TFC 1.6mm THK 180 R9.5 50 120° Ø15 3514

50 16

20 SIDE SEAL 15 11 318 11 15

25 130 25 11

180

-0.100 +0.000

DETAIL-Y 3100 SILL = TO TOP C/C SEAL

DETAIL-49&50 70 11

Ø17.5HOLES 370 DETAIL-44 MATERIAL: FORGED STEEL 45C8 IS:2004 OR En9 27 3460 50

2

2 3

5

13 16 50 25 60 25 M16TAPPED HOLES L 80 110 ON110PCD DETAIL-45 175 175

3 Ø17.5 HOLES 16 ON 200Ø P.C.D 65 130 135 28X100 = 2800

16 Ø200

280 75

293 487

180

270

120

180

Ø70

250 SQ70 R60

180 780

16 75 1760 108

PL 20 THK 180 350 DETAIL-8 DETAIL-7

65 80 30 175

280 1540 30 80 30

? 12

L 28 28 28 C.G OF GATE

28 230 28 13 755 12

SECTION-FF 780

270

180 120 260 VIEW - LL 180 R60 R52

28

3 3 350 140 M16TAPPED HOLES Ø17.5 HOLES

40 DETAIL-9 DETAIL-10

M16TAPPED HOLES 180

120 NOTE:- 1000 Ø72 1.ALL DIMENSIONS ARE MM Ø72 2.ALL WELDS ARE 6 MM FILLET CONTINUOUS UNLESS OTHERWISE STATED

3.B.O.Q SHOWN FOR ONE GATE ASSEMBLY

60

180 180

40 ONLY, TOTAL NO. OF GATES = 1 NO. 4.THE CG ARRIVED IS TENTATIVE. THE ACTUAL CG IS TO BE ARRIVED AFTER COMPLETION OF FABRICATION OF GATE. 16 16 5.ALL STRUCTURAL STEEL CONFIRMING TO IS 2062 GR E 250 B. 108 6.TFC = TEFLON CLADED.

28 180 DETAIL-43 DETAILS OF GATE ASSEMBLY SECTION-GG TITLE DETAIL-42 FOR SURGE SHAFT GATE BALAJI HYDRO MECH EXPERTS HYDERABAD - 049 DRG No: DRAWN SESHU.Y BHME-PES-BHEP-SSG-803 SHEET 2OF2

REV NO : R1 SCALE : CHECKED& N.K.NAIDU Tech. Adviser SUBMITTED (Hydraulic Gates) DATE : JAN 2009 1450

SECTION-CC 900 550 Ø100 150 300 450 100 450

2 Ø16 150 Ø16 Ø16

277 25 275 150 100 25 295 DISC 40 C C 6 (TYP) 5 ( FROM EL 1585.000M TO EL1588.000M1585.000M TO EL ( FROM ) SURGE SHAFTGATE GROOVE DETAIL Ø41 240 28 300 25 28 350 20 1025 16 300 100 230 END TO END OF GROOVEOF END TO END = 4500 300 750

+0.015 100 250

Ø60+0.002 28 SIDE GUIDE4420 = F/F

BRONZE BUSHINGSECTION-EE +0.025

MATERIAL: Ø40 +0.000 13 28

172 400

15 10 20 AL BRONZE 305AL IS GRADE AB1 100 SKIN PLATE

239 300 225 TRACKC/C =3800 3X20 = 603X20 = 199 100 90

12 C/C SEAL = 3200 SIDE

25 VENT = 3000VENT = 501 227 68 (TYP) 10 FLOW 20 15

301 10 30 2X45° 10 10 150 28 700 28 300 PLAN 25 E E 40

Ø130 95 Ø60 Ø40 5 55 -0.015 48 34 R5 Ø60+0.004 207 20 Ø40 92 8 SECTION-DD 112 ELEVATION END VIEW 16 350 4 90 50

30

105 105 255 270

32 MATERIAL: 17 143 DETAILS OF GUIDEOF DETAILS ROLLER 3 8 GRADE IS1030 280-520WSTEEL CAST BRONZE BUSHINGBRONZE MATERIAL: Ø80 OF TRACK ? 15 SCREW DURING ASSEMBLY DURING SCREW T WITH BUSH APPED

2X45° Ø100 STAIN LESS STEEL 04 STEEL CR18 LESS STAIN Ni10 1570 IS PART HOLE FOR GRUBØ6

Ø8 DETAILS OFPIN 120 12 96 12 60 M12 TAPPED TAPPED HOLESM12 GUIDE SHOE SECTIONAL SHOE GUIDE 28 48 48 120 170 34 34 12 40 PLAN GUIDE SHOE ELEVATION SHOE GUIDE Ø6 140 140 Ø40 PLAN-AA Ø40 D D 92 92 6 MM1.5GROOVE; DEEP

85 Ø17.5 75 16 16 V 7 30 30 105 105 30 37 270 170 A

Ø40

14 21 160 DRAWN CHECKED& SUBMITTED TITLE B B 15 12 25 30 END VIEW 96 KEEPER PLATE Ø13.5HOLES 170 110 1.ALLIN DIMENSIONSARE MM NOTE: 3.B.O.Q GUIDEROLLER3.B.O.Q SHOWN FORONE SIDE ASSEMBLY. 2.FINISHEDDIMENSIONS SHOWNARE PROVIDE M/C 4.ALL STRUCTURALCONFIRMING STEEL TO2062 IS - 2006GRADEE -250B. TOTALNOS REQD. =1X4= 4 NOS. NOS. REQUIRED=4 NOS FOR GATE. DIAMETER AND5MM ON FACE. ALLOWANCES.5MM ONRADIUS,10MM ON BORE (HydraulicGates) DETAILS OF Tech. AdviserTech. N.K.NAIDU NAGA.K 60 90 BALAJI HYDRO MECH HYDRO BALAJI EXPERTS 30 25 12 FOR SURGE SHAFT SURGE FOR GATE DATE :MAY 2009 REV NOREV : DRG No: SIDE GUIDE HYDERABAD - HYDERABAD 049 15 30 210 30

270 SECTION-BB ROLLER ASSY. 8 SCALE :

35 GATES OPERATION, MAINTENANCE AND REPAIRS-RENEWALS GATES ERECTION CHECKING OF COMPONENTS

1. Through with CDO Drawings 2. Piers orientation (Civil Structure) / Alignment 3. Dimensional accuracy 4. Suitability of components 5. Quantity /Quality of materials 6. Horizontal / Vertical / oblique positions accordingly 7. Horizontal Girder / Arm Girder / Joint Positions 8. Arm / Trunnion / Seating positions 9. Anchor rods / Trunnion Joints 10. Trunnion Box / Trunnion Bracket position 11.Gate lifting Brackets Position GATES ERECTION CHECKING OF COMPONENTS

12. Bottom sill – Top seal positions (Civil Structure) 13. Wall plates locations – Block outs in piers 14. Lifting Hook / wire rope position / Brackets 15. Gate seating positions 16. Grooves maximum – Minimum gap available (vertical gates) 17. Check concrete bulging/ projections 18. Vertical position of seal track 19. Roller Track 20. Guide tracks 21.Breast wall plates 22.Trash racks provided or not (for sluice gates) ERECTION EQUIPMENT

1. Sling ropes D-Shackles 2. U clams 3. Chain pulley Blocks 4. Wire rope pulleys 5. Power winches 6. Handling tools and equipment 7. Tirfers, Derricks and Gantry's 8. Access and approach roads. OPERATION OF GATES

1. Check and ascertain the condition of Gates and equipment in tact or not 2. Water Regulation / Releases (Gate opening) 3. Flood control / Regulation of flood 4. Gates operation schedule issued by CDO 5. No sudden releases of high flood 6. Observe Down Stream effects OPERATION OF GATES

7. Human life – Cattle life – Down-stream and if any ongoing works safety 8. Flood Information – Indication by Radio, T.V, Siren 9. Flow observations – Guide bunds 10.Scours any in Aprons 11.Retaining walls – effecting of retaining walls 12.Checking any effecting of abetments and ogee portions 13. Gauges to know up-stream and down-stream water levels MAINTENANCE STAFF

1. Technical Inspector 2. Gates Operator 3. Fitter 4. Electrician 5. Helpers 6. Watch and ward / Security staff MAINTENANCE 1. Keep clean all the components / Compartments and generator rooms cable ducts, switch gear rooms and flood control rooms. 2. Remove all rubble / Jammed materials between the rollers and roller tracks and top of the top seal (trash) 3. Grease all moving parts and bearings and gear wheels 4. Grease all the plumber block units 5. Fill with gear oil to the Gauge level for worm reducer (radicon units) 6. Remove insect nets and Honey bee combs etc., 7. Apply cardium compound to the wire ropes MAINTENANCE

8. Protect from monkeys, rattles, Bats, Bird Nets etc. 9. Providing lights for illumination for hoist Bridge, Road Bridge and upstream, down-stream and approach roads. 10. Provide a separate store room adjacent to 11. Generator room to store POLs and other maintenance equipment and spare parts. 12. Take up timely painting works. 13. Provide drain holes on hoist Bridge and Gate compartments wherever necessary. GATES MAINTENANCE CHECKING OF CRITICAL POINTS

1. Hoisting ropes position 2. Gate Traversing position Seating position on sill (while closing) 3. Turn Buckle – Self alignment Brackets 4. Torque transmission shafts and keys (line shafts) 5. Counter weight connecting Rope sockets and turn buckles. 6. Rope connected I- Boards and to Rope drum fixing points 7. Movement of roller cage / Rollers 8. Observe Rolling movement / Sliding movement of Rollers GATES MAINTENANCE CHECKING OF CRITICAL POINTS

9. Gate Guide brackets position and fouling of guide tracks 10. Seals movement on seal tracks 11. Breast wall seating / Seal seating position 12. Hoist motor –CD- ED units movement and Retainers 13. Position of gear wheels and fixing shafts 14. Standby Generator (HSD oil 100 lts spare) 15. Main control Panel Boards (Electrical) 16. Sub Control Panel Boards 17. Individual Control Panel Boards GATES MAINTENANCE SAFETY EQUIPMENT 1. First aid Box 2. Safety belts 3. Safety shoes (gum boots) 4. Safety Helmets 5. Hand gloves (Shock proof) 6. Rubber mats 7. Rain coats 8. Torch Lights 9. Emergency lamps 10. Ladders 11. Manila ropes 12. Drinking water 13. Rest Rooms and Toilets PREVENTIVE MATERIALS

1. Hoist Motor 2. EM Break unit and coils 3. Break liners and Break unit springs 4. Gate Rubber seals and Bolt and nuts as per drawing – 1 set 5. Link pins and wire rope sockets, Gate lifting brackets 6. Motor Starter unit 7. Over load relays PREVENTIVE MATERIALS

8. Motor Starter contact points 9. Limit switches 10. Rope guides / Brackets (Thimbles and U clams) 11. Rubber bushes for couplings 12. Keys for line shafts and gear wheel shafts. 13. One set of wire ropes 14. One set of Plumber blocks 15. Electrical cables 16.One set of Fan belts for Generator MAINTENANCE OF RECORDS (GATES AND EQUIPMENT) 1. Gates operation manual 2. Gates maintenance manual 3. Gates history book 4. Gates operation log book 5. VIP’s / Expert Committees / Dam safety Committee / Inspection Registers / comments / Suggestions. Generator log book MAINTENANCE OF RECORDS (GATES AND EQUIPMENT)

6.Generator History book 7. 7F Materials (Maintenance materials available at Project site) 8. Safety equipment available at Project site. 9. Tools and tackles available at Project site. 10. Preventive materials / buffer stock available at Project site. 11. Drawings – 1 set 12. Catchment area – Rain fall – Observations 13.Flood discharge Register One set of Wire ropes One set of Gate rubber seals One standby electrical motor (Hoist) One Motor starter Unit Over Load Relays Radicon Unit Electrical Main switches Welding Plant Gas cutting equipment Steel Material and Plates (Limited) Standby Generator Set

Water Resources Department, Govt. of AP PREVENTIVE MANAGEMENT HARDSHIPS ENCOUNTERED

Godavari Raiwada Thandava Thandava Floods 1986 Project Project Project

Counter Weight Gate Eastern Right Head Head Sluice Delta Canal No-3 fall Sluice Heavy Gates, Wire down due to Gate (Low Leakage due Ropes failed Slippage of Level) to Secondary for all the wire rope Srucked Concrete Three gates from socket

Water Resources Department, Govt. of AP HARDSHIPS ENCOUNTERED

Thandava Thandava Pampa Musi Scour Project Project Reservoir Sluice

Counter Counter Out Flank weight weight fall reservoir Gate Failed due to Lack disconnected down due depleted to slippage of for closed due to non- of plumber Maintenance gate no.2, operation block bolt of (improper of the gear balancing) generator wheel shaft & Gates

Water Resources Department, Govt. of AP HARDSHIPS ENCOUNTERED

Annamayya Kadiyam Rallapadu Project Project

Out flank Gates Not Reservoir Radial Gate operated due depleted due Dislocated to lack of to non- maintenance operation of (Rajampet, (Adhilabad Generator & Kadapa) District) Gates

Water Resources Department, Govt. of AP Checking the Components for keeping intact Lubricating the components to avoid friction Cleaning the components Painting the components to avoid rust Observe corrosion & weathering action Checking the Life period and Aging Checking of gear messing uniformly Checking the Electrical cables and wires Checking for proper ventilation for Light & Sound Checking of all metal contacts and rubbing of parts

Water Resources Department, Govt. of AP Checking the Generator working condition Checking the batteries working condition Checking the battery charger condition Checking HSD oil availability Checking the Main Control Panels Checking the Isolators overload relays Checking the Sub distribution Panels Checking the Individual Control Boards Checking the Motors and starters working condition Checking the hoist bridge lighting, road bridge and project site illumination

Water Resources Department, Govt. of AP Fire Extinguishers CC Cameras Siren Adequate Lighting Gates Operation schedule Up stream/Down stream Gauges First Aid Box Suitable tools and equipment Rubber Mats Manila Ropes, Ladders Rubber Hand Gloves Emergency Lights Helmet Drinking water facility Safety Belts Toilets Gun Boots Project site display Rain Coats Hand Sticks and Vigils

Water Resources Department, Govt. of AP Thank you

Water Resources Department, Govt. of AP