IS 10096 (Part 3) :2002

Indian Standard
RECOMMENDATIONS FOR INSPECTION,
TESTING AND MAINTENANCE OF
RADIAL GATES AND ROPE DRUM HOISTS
PART 3 AFTER ERECTION

(Second Revision )

ICS 93.160

0 BIS 2002

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

May 2002 Price Group 4

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Hydraulic Gates and Valves Sectional Committee, WRD 12

FOREWORD
This Indian Standard (Part 3) (Second Revision) was adopted by the Bureau of Indian Standards, after the draft
finalized by the Hydraulic Gates and Valves Sectional Committee had been approved by the Water Resources
Division Council. Noting lack of adequate systematic information on procedures for inspection, testing and
maintenance of radial gates and their hoists after erection, the Hydraulic Gates and Valves Sectional Committee
decided that a set of recommendations on this subject be drawn up for reference and guidance of the personnel
engaged in these duties. This standard has accordingly been prepared @ provide guidelines for radial gates.
This standard has been published in parts. Part 1 deals with inspection, testing and assembly at manufacturing
stage. Part 2 deals with inspection, testing and assembly at the time of erection. Part 3 deals with inspection,
testing and maintenance after erection.
This standard (Part 3) was first published in 1982. In the first revision in 1992, the provision in respect of
inspection was elaborated in detail. This second revision of standard had been taken up to incorporate the
knowledge gained during use of this standard. In this revision an additional clause has been added regarding
maintenance of gates to be operated in winter.
There is no 1S0 standard on the subject. This standard has been prepared taking into consideration the practices
prevalent in the field in India.
The composition of the Committee responsible for the formulation of this standard is given in Annex A.
For the purpose of deciding whether a particular requirement of this standard is complied with, the final value,
observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with
IS 2: 1960 ‘Rules for rounding off numerical values (revised)’. The number of significant places retained in the
rounded off value should be the same as that of the specified value in this standard.
 IS 10096 (Part 3) :2002

Indian Standard
RECOMMENDATIONS FOR INSPECTION,
TESTING AND MAINTENANCE OF
RADIAL GATES AND ROPE DRUM HOISTS
PART 3 AFTER ERECTION

(Second Revision )
1 SCOPE gates, they should be maintained as per
recommendations contained in M 7718.
This standard (Part 3) lays down the recommendations
for inspection, testing and maintenance of radial gates 4 INSPECTION
and their rope drum hoists after erection.
4.1 Periodical inspection of gate installations should
2 REFERENCE be carried out to detect normal wear and tear, defects,
if any. It should be done as and when necessary, but
The Indian Standard given below contains provisions
at least thrice in a year, one being prior to the onset of
which through reference in this text, constitute
monsoon and one immediately after the monsoon and
provisions of this standard. At the time of publication,
one at other times. The gates should be operated up
the edition indicated was valid. All standards are
and down several times to make sure that everything
subject to revision, and parties to agreements based
is in order.
on this standard are encouraged to investigate the
possibility of applying the most recent edition of the 4.2 Inspection work may consist of visual inspection
standard indicated below: of exposed surfaces of embedded parts, such as sill
beam, wall plate including seal seats, gate leaf, arms,
IS No. Title
trunnion assembly, trunnion girders, hoisting
7718:1991 Recommendation for inspection,
equipment, hoist supporting structures and checking
testing and maintenance of fixed
of important dimensions. In cases of inaccessible parts,
wheel and slide gates (/irst revision)
inspection may be necessary by other means like
3 GENERAL
divers, etc.
3.1 Drain holes in the horizontal girders and arms
4.3 Inspection of Radial Gates
should be checked so that they do not get clogged with
silt causing accumulation of water in the horizontal No piece of equipment, however well designed and
girders and arms. sturdy, will run efficiently unless it is well kept and
maintained. Therefore the details of inspection to be
3.2 Rope drums, pulleys and rope connection should
done and the schedule of maintenance are given here.
be checked.
4.3.1 Periodical Inspection
3.3 Functioning of the limit switches, interlocking
devices, indication lamps, etc, should be checked for In order to detect normal wear and tear, defects, if
proper working. any, periodical inspection of gate installation should
be carried out. The periodical inspection of gates and
3.4 The operating systems of the gate should be
checked for their proper functioning. hoists should be done as and when necessary, but at
least thrice a year and corresponding to the periods
3.5 Where stoplogs are provided upstream of radial when the water level in the reservoir is at its highest
and lowest levels.

1
1S 10096 (Part 3) :2002

In short, premonsoon and post-monsoon inspections should be done and the following checks be exercised:

Points to be Inspected Compliance

(1) (2)

1 Inspection of yoke girder, thrust bloc~ trunnion assembly and anchorage

1. Check Nuts and bolts :
a) Trunnion assembly Check for torque
b) Trunnion bracket to yoke girder do
c) Nuts of horizontal and vertical anchorage do
d) Trunnion pin lock plates Check tightness
e) Check shear key if provided behind the trunnion Check for cracks
bracket
f) Nuts of the main tie rods Check for tightness and torque
2. Check the weld between yoke girder and main ties For soundness
3. Check whether yoke girder and thrust block is covered Cover with 3 mm thick M.S. plates if not
so that water does not accumulate in the slots. already covered
4. Check whether trunnion pin ends are covered with Cover it if not already covered
anticorrosive jelly
5. whether flexible sheath cover is provided to prevent do
entry of debris in the trunnion assembly
6. Check the welds of thrust block (with magnifying Check for cracks. Rectify accordingly
glass) (also ensure that the inside is concreted)
7. Check if the oval holes are free Remove debris or other accumulated material
8. Check grease in trunnion assembly Take steps for greasing after removal of dirt,
if any
9. Check the flexible cover Replace, if necessary and clean dirt from pin
surface below the same
.
II Arms

1. Check welding joints of arm to horizontal girder (with Check for cracks: rectify accordingly
magnifying glass, preferably on joints/stiffeners)
2. Check whether drain holes provided in the arms are Clear them if choked up
clear of debris.
3. Check nuts and bolts of arms to horizontal girder Check for tightness and torque
III Horizontal girder
1. Check welding of
a) Stiffeners of horizontal girders Check for crack and other defects and rectify
accordingly
b) Horizontal girder to stiffeners of skin plate do
c) Locking arrangement brackets of skin plates Check for weld crack
d) Check drain holes of horizontal girder Clear them if choked and clean the debris
accumulated regularly
IV Skin plate assembly and rubber seals
1. Check the following welding joints:
a) ‘T’ and skin plate and ribs Check for crack and other defects and rectify,
if necessary
b) Vertical joints of skin plate from upstream side
and downstream side
c) Check lifting bracket and lifting pins for its
soundness
d) Latching brackets to skin plate Check welding with a magnifying glass and
rectify, if required
 IS 10096 (Part 3): 2002

Points to be Inspected Compliance

(1) (2)

2. Theskin plate should beobserved forpitting, scaling Scaling formation should be removed. Pitting
and corrosion on upstream side: should be tilled with weld and grinded for
finish. For corrosion clean it and apply paint.
a) Check the condition of side and bottom rubber If condition is poor, replace same. Check the
seal corner joint and observe leakage cause of undue wear also before replacement
b) All the nuts and bolts fixing rubber seal to skin Check for wear and tear, tightness and
plate replace, if required.
c) Check if there 1sany undesirable material in Remove it (All debris should be periodically
between seal and stainless steel plate, seal and removed from the seal surface)
seal base
d) Check for deformation of seal Study the cause of deformation and recti& it
e) Check soundness of cladding in case of cladded do
rubber seals
f) Check whether there is abnormal abrasion on seal Study the cause of abrasion and rectify it
seat
V Sill beam and wall plates
1. Check the following joints :
a) Wall plate to sill beam Check for crack and other defects and recti~
b) Joints between two segments Rectify the joints using proper welding rods
and grind, as necessary
c) Stainless steel to structural steel do
2. Check wall plate and sill beam for pitting and rusting Pitting is to be tilled in by welding. Rusted
and general conditions portion should be painted after cleaning

VI Guide roller
1. Check the roller for its movements and setting Make the roller free. If jammed, clean and
grease
2. Check the nuts and bolts of guide roller assembly Check for wear and tear and tightness
VII Latching arrangement
1. Check whether latching device fimctions well Check the fimction by operating lever.
Recti& the same if movement is not smooth
2. Check nuts and bolts and studs of locking devices Tighten the bolts if required
3. Check the drain holes Clean them if required
VIII Wire ropes, hoist, pulleys, sheaves, etc
1. Check for following :
a) Check condition of wire rope If the condition is poor, then replace the wire
rope and if 10 percent broken wires are
within the length of one meter and more than
20 percent broken wire within the length of
10 m wire ropes should be replaced
b) Check pulley, sheave assemblies and sockets Check the condition of pins and every year
these should be removed, cleaned and refitted
afler lubrication
c) Check turn buckles Check for rusting, jamming in the turn
buckles, and check if the number of threads
holding the rope are adequate
d) Check tension of wire ropes Adjust both wire ropes for equal tension
e) Check if end of wire rope is properly fastened to If found loose, tighten the studs provided for
drum
f-) Check for lubrication of wire ropes, if required Lubricate ropes

3
IS 10096 (Part 3) :2002

Points to be Inspected Compliance

(1) (2)
IX Gear train assembly
1. Check the following:
a) Check the condition of gear and pinions Check uneven wear and contact, adjust
properly
b) Check position of gears and pinion Bring them to correct position if found
shifted to either side
c) Check shaft and couplings used for connecting Visual inspection and coupling nuts to be
drive unit and gear train checked
X Drive unit
1. Check the following:
a) Check the condition and functioning of electro- Replace worn out liner, adjust brake shoes
magnetic brake carefully, so that both the shoes hold the
drum when supply is cut off or both the shoes
should move out simultaneously if switched
on. Brake drum and liner should always be
free from grease, oil, etc
b) Check all electrical connection of hoist motor, Check for loose connection, proper insulation
brake, starter, limit switch, etc. Also check (rats and crabs damage the insulation)
remote control systems, if provided Overload relay of the starter is to be adjusted,
for correct position and should not be
disturbed
c) Check the connecting arrangement from adjacent
motor
d) Check the condition of position indicator and all Check for its proper function and rectifi
its accessories
e) Reduction gear box (worm reducer) Check for smooth operation and check oil
level
XI Check nuts and bolts of the following:
a) Hoist frame Check for wear and tear and tightness
b) Drive unit }
c) Gear boxes Tighten if required or replace if undue
d) Flange coupling } wearing noticed
e) Bearing housing Inspect for cracks in housing and replace, if
f) Foundation bolts of hoist bridge } needed check foundation bolts and tighten if
required

4.3.2 General 5 TESTING

Inspection to check that: 5.1 The gate should be tested for its travel up and
down to see that it moves smoothly without excessive
a) The gate operation should be trouble free and
sway throughout the length of travel.
there should not be unusual sound,
5.2 The operation should be trouble-free and there
b) On load (that is, when there is water) there
should not be any unusual sound. There should not be
should be no undue vibrations in the gate and
any undue pressure or extra efforts when the gate is
the structure.
operated under no load condition.
c) Observe the current drawn by motor at the time
Any extra current being taken by the motor should be
of lifting of gate. If any excessive current
taken note of.
drawn is noticed, operation of hoist should be
stopped immediately and reason for the same 5.3 On load (that is, when there is water) there should
may be investigated for lubrication of various be no undue vibrations in the gate and structure during
parts of gates and hoists and rectified. operation of the gate. In case vibrations are noticed,
the positions of gate openings and water levels should
d) Check the supply voltage.
be noted and the reasons thereof should be investigated.
e) Check the lubrication at various points.
5.4 Based on the inspection and testing, suitable
0 Check the condition ofpaintihg of vaiious parts. remedial measures should be taken (see 6).
 IS 10096 (Part 3) :2002

5.5 Trouble Locating Chart

Trouble Probable Reasons

(1) (2)

1. Gate does not rise 1.- No supply or low voltage (supply)

2. Obstruction in rubber seals
3. Obstruction in guide rollers
4. Fault in electric motor
5. Fault in wiring
6. Blown out fuse
7. Brake shoes jammed
8. Wire rope broken
9. Malfimctioning of electrical contacts due to any
reason
2. Gate vibrates or produces noise 1; Lack of lubrication in trunnion and guide rollers
2. Rope length not identical on both sides
3. Lack of lubrication or fault in wire rope pulley
sheave arrangements
3. Motor does not function 1. No Sllpply
2. Starter not in order
3. Blown out fhses in switches
4. Low voltage
5, All fuses are not working
4. Starter not working 1. No supply to starter
2. Fixed and moving contacts not in order
3. Limit switch engaged
5. Unusual sound Verify the spot and attend to the following: ----
1, Mis-alignment of any particular component
2. Shearing of connecting bolts and nuts ,,
‘4 .’

3. Lack of lubrication ‘{

4. Entry of any extraneous matter into guide roller

assembly or pulley sheaves or trunnion
assembly.

6 MAINTENANCE should be thoroughly cleaned and repainted

6.1 The maintenance of radial gates and their hoists
when required. While deciding about repaint-
mechanism should be done regularly. Reference should ing, the original painting system adopted
be made to manufacturer’s instructions for detailed should be kept in view.
maintenance and servicing of hoists. Proper record c) Trunnion bearing should be greased wher-
of inspection, testing and maintenance should be made ever required. Keeping trunnion bearings in
by the project authorities. perfect working condition is very important.
All other bolted connections should also be
6.2 The following maintenance works should be checked for proper tightness.
attended to:
d) Bolts and trunnion bearing housing should
a) Defective weld should be chipped out and it be tightened wherever required.
should be rewelded. Damaged nuts, bolts, e) The seals of the gate should be checked for
rivets, screws, etc, should be replaced, Any wear and tear and deterioration. These should
pitting should be filled up by welding and be adjustedheplaced, as and when necessary.
finished by grinding, if necessary.
o Wire ropes should be properly greased.
b) The gate leaf, exposed embedded metal parts,
g) Oil level in the worm reduction unit should
hoists and hoist supporting structure, etc,
5
IS 10096 (Part 3) :2002

be maintained by suitable replenishment. Oil v) Rope drums

seals should also be replaced, if required. vi) Line shaft bearings
Lubrication of other parts of the hoists, such vii) Matching teeth of gear box assembly
as chains, position indicators and limit Once before rainy season or as required
switches should also be done. 2) Cardium compound
h) The stroke of the brake should be reset to Application points:
compensate for lining wear. Worn out brake Wire ropes
linings should be replaced in time.
Once in every season after cleaning of wire
j) Flexible couplings should be adjusted, if re- ropes or as required
quired.
3) H.P. 90 Gear oil
k) Repairs and replacement of electrical relays
Application points:
and controls should be attended to.
i) Reduction gear box
m) Maintenance of alternative sources of power,
such as diesel generating sets and alterna- Level up the gear box before operation
tive drives wherever provided should be car- 4) Mobil oil
ried out. Application points:
n) The list of essential spare parts to be kept i) All rubbing surfaces and oiling points
available should be reviewed and updated ii) At points located in brass/metal bushes
periodically. The availability of essential Once/twice a year.
spare parts should be ensured. The condition 6.3 In case of gates to be operated during winter,
of spares should be checked periodically and generally water leaking through water tight parts gets
protective coating given before use. frozen and grows to be ice lumps. Chances are that
P) Lubrication details: such ice lumps adhere to the gate leaf or embedded
1) Grease — Multipurpose parts causing troubles. Therefore in case of such gates !

following remedial measures shall be taken in addition

— Bearing grease
to the maintenance work given in 6.2.
Application points:
i) Pulley sheaves a) Water leakage shall be prevented.
ii) Pulley brackets b) Ice at gate leaf and embedded parts may be
iii) Guide rollers removed by the manual or by any anti-
iv) Trunnion assembly freezing method without damaging gate
components.
 ),

i+<

IS 10096 (Part 3) :2002

ANNEX A
(Foreword)
COMMITTEE COMPOSITION

Hydraulic Gates and Valves Sectional Committee, WRD 12

Organization Representative(s)

In Personal Capacity (2047, Pocke/ 2, Sector D, k’asant Kunj, SHroN. VlsmvANAmAN (Chairman)
New Delhi 110 070)

Bhakra Beas Management Board, Narrgal DEPUTYCHIEFENGINEER

EXECUTIVE (Alternate)
ENGINEER

Bharat Heavy Electncals Ltd, Bhopal SHIUA.S. SRIVASTAVA

SHrGS.R. RATHORS(A/ternate)

Central Water and Power P.esearch Station, Pune SHFGR. M. KHATSUP.IA

SHRIR.M. SINNARKAR
(Mfernute)

Central Water Commission, New Delhi DIRECTOR(GATES- E&NE)

DIRECTOR
(GATEs-NW&S) (Alternate)

Cimrnco Ltd, Bharatpur EXECUTtVE

PRESIDENT
SR MANAGER(DESIGN)(Mrernate)

Gea Energy System (India) Ltd, New Delhi SHRIK.C. BAHETV

SHIUA. G. K. MURTY(Alternate)

Haryana State Minor Irrigation (Tubewell), Chandigarh SHSUS. P. GUFTA

SHat R. S.CHAUHAN
(Afternate)

Himachal Pradesh State Electricity Board, Sundemagar CHIEFENGINEER

(DESIGN)
(PLNG) DESIGNCIVILII (Alternate)
DIRECS’OR

Irrigation Department, Govt of Maharashtra, Nasik %U v.c. %5LKE

Irrigation Department, Govt of Punjab, Chandigarh CHIEFENGINEER
[RSDD]
---
(M&E) (Alternate)
DIRECTOR

Irrigation Department, Govt of Uttar Pradesh, Roorkee CHIEFENGINEER

(DESIGN)ANDDIRECTOR
SUPEIUNTENDSNG (Alternale)
ENGINEER

National Hydroelectric Power Corporation Ltd, Faridabad SHRIA. K. SACHDEVA

SHRIG. S. SHARMA(Alternate)

Orissa Construction Corporation Ltd, Bhubhaneshwas DIRSCTOR

[MECHANICAL]
SEmortMANAGER(DESIGN)(Affemate)

Public Works Department, Government ofTamil Nadu, Chennai SHIUM. DURAUSAJ

(Alternate)
SsnGT. KSUSHANASWAMY

Texmaco Ltd. Kolkata SHRIS. R. S.INHA

SHSU (Alternate)
UDAYANBANERJEE

Triveni Structural Ltd. Allahabad SHFU

J. P. M[SHRA
SHRIB. P. SINOH(Alternate)

Tungabhadra Steel Products Ltd, Bellary SHSUG.S.ANNIGEJU

SHRtN. KANNAIAHNAIDU(Alternate)

Water Resources Development Training Centre, RGGrkee PROFGOPALCHAUHAN

BIS Directorate General Siira S.S. SETHI,Director & Head (WRD)

[Representing Director General (Ex-oflcio)]

A4ember-Secretaw
Stnu KULDEEP
SIR;SU
Deputy Director (WRD), BIS

7
Bureau of Indian Standards

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This Indian Standard has been developed from I)OC No. :WRD 12 (285).

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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