IS 10096 ( Part 3 ) : 1992

RECOMMENDATIONS FOR INSPECTION,

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TESTING AND MAINTENANCE OF RADIAL
GATES AND ROPE DRUM HOISTS
PART 3 AFTER ERECTION

( First Revision )

UDC 621.422-23 : 621.876

@ BIS 1992

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

December 1992 Price Group 4

Hydraulic Gates and Valves Sectional Committee, RVD 12

FOREWORD
This Indian Standard 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 River Valley
Division Council.
Noting lack of adequate systematic information on procedures for inspection, testing and main-
tenance of radial gates land 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

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guidance of the personnel engaged in these duties. This standard has accordingly been prepared
to provide guidelines for radial gates.
This standard is being 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 erec-
tion. Part 3 deals with inspection, testing and maintenance after erection.
This standard ( Part 3 ) was first published in 1982. In this revision provision in respect of
inspection has been further elaborated in detail.
For the purpose of deciding whether a particular requirement of the 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 of 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 ) : 1992

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

( First Revision )
1 SCOPE 4 INSPECTION

This standard (Part 3 ) lays down the 4.1 Periodical inspection of gate installations
recommendations for inpection, -testing and should be carried out to detect normal wear

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maintenance of radial gates and their rope and tear, defects, if any. It should be done as
drum hoists after erection. and when necessary, but at least thrice in an
year, one being prior to the onset of monsoon
2 REFERENCES and one immediately after the mosoon and one
at other times. The gates should be operated
The Indian Standard listed below is a necessary up and down several times to make sure that
adjunct to this standard: everything is in order.

IS No. Title 4.2 Inspection work may consist of visual

inspection of exposed surfaces of embedded
7718 Recommendation for inspec-, parts, such as gate leaf, hoisting equipment, hoist
( Part 3 ) : 1975 tion, testing and maintenance supporting structures and checking of impor-
of fixed wheel and slide gates: tant dimensions. These include sill beams,
Part 3 After erection wall plate consisting of seal, if any, trunnion
girders and gate leaf. In cases of inaccessible
parts, inspection may be necessary by other
3 GENERAL means like divers.
3.1 Drain
_ ___holes _in the horizontal girders and
4.3 Inspection of Radial Gates
arms should be checked so that they do not get
clogged with silt causing accumulation of water No pieces of equipment, however well designed
in the horizontal girders and arms. and sturdy, will run efficiently unless it is well
kept and maintained. Therefore the details of
3.2 Rope drums, pulleys and rope connection inspection to be done and the schedule of
should be checked. maintenance are given here..
4.3.1 Periodical Inspection
3.3 Functioning of the limit switches, inter-
locking devices, indication lamps, etc, should In order to detect normal wear and tear,
be checked for proper working. defects, if any, periodical inspection of gate
installation should be carried out. The perio-
3.4 The operating systems of the gate shquld dical inspection of these gates-and hoist should
be checked for their proper functioning. be done as and when necessary, but .at least
thrice a year and corresponding to the peiiods
3.5 Where stoplogs are provided upstream of when the water level in the reservoir is at its
radial gates, they should be maintained as per highest and lowest levels. In short, pre-
recommendations contained in IS 7718 ( Part 3) : monsoon and post-monsoon inspections should
1975. be done and the following checks be exercised.
iS 10096(Part3):1992

Points to be Inspected Compliance

(1) (2)

I. Inspection of yoke girder thrust block trunnion assembly and anchorage.

1. Check the Nuts and bolts

a) Below trunnion assembly Check for proper functioning

b) Trunnion bracket to yoke girder do
c) Nuts of horizontal and vertical anchors- Check for torque
age
d) Trunnion pin lock plates Check tightness
e) Check shear key if provided behind the Check for cracks
trunnion bracket
f) Nuts of the main tie rods Check for tightness and torque
2. Check the weld between yoke girder and For soundness

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main ties
3. Check whether yoke girder and thrust block Cover with 3 mm thick M.S. plates ifnot
is covered so that water does not accumulate already covered
in the slots
4. Check whether trunnion pin ends are covered Cover it if not already covered
with anticorrosive jelly
5. Check whether flexible sheath cover is do
provided to prevent entry of debris in the
trunnion assembly
6. Check the welds of thrust block ( with Check for cracks. Rectify accordingly
magnifying glass ) ( also ensure that the
inside is concreted )
7. Check if the oval holes are free Remove debris or other accumulated
materials
8. Check grease in trunnion assembly Take steps for greasing after removal of
dirt, if any
9. Check to flexible cover Replace if necessary and clean dirt from
pin surface below the same
II. End arms
1. Check welding-joints of end to horizontal Check for cracks : rectify accordingly
girder ( with magnifying glass, preferably )
on joints/stiffners )
2. Check whether drain holes drilled in the Clear them if checked
end arm are clear at both ends.
3. Check nuts and bolts of end arms to Check for tightness
horizontal girder joints
III. Horizontal girder
1. Check welding of
a) Stiffners of horizontal girders Check for crack and other defects and
rectify accordingly
b) Horizontal girder to stiffeners of skin do
plate

2
 IS 100% ( Part 3 ) : 1992

Points to be Inspected Compliance

(1) (2)

c) Locking arrangement brackets of skin Check for weld crack

plates
d) Check drain holes of horizontal girder Clear them if chocked and clean the debris
accumulated regularly
IV. Skin plate assembly and rubber seals
1. Check the following welding joints Check for crack and other defects and
rectify, if necessary
a) ‘T’ and skin plate and ribs
b) Vertical joints of skin plate from
upstream side and down streain side do
c) Check lifting bracket and lifting pins
for its soundness

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d) Latching brackets to skin plate Check welding with a magnifying glass and
rectify, if required
2. The skin plate should be observed for Sealing formation should be removed.
pitting, scaling and corrosion on upstream Pitting should be filled with weld and
side grinded for finish. For corrosion clean it
and apply paint

a) Check the condition of -side and bottom If condition is pcor replace same. check the
rubber seal corner joint and observe cause of undue wear, also before replace-
leakage ment

b) All the nuts and bolts fixing rubber seal Check for wear and tear, tightness and
to skin plate replace, if required

cl Check if there is any undesirable material Remove it ( All rubbish should be periodi-
in between seal and stainless steel plate, cally removed from the seal surface )
seal and skin plate
d) Check for deformation of seal S_tudy the cause of deformation and rectify it

e>Check soundness of cladding

cladded rubber seals
in case of do

f) Check whether there is abnormal abrasion Study the cause of abrasion and rectify it
on seal seat

V. Sill beam and wall plates

1. Check the following joints
a) Wall plate to sill beam Check for crack and other defects rectify
b) Two segments Rectify the joints using proper welding rods
and grid, as necessary
c) Stainless cladding to M. S. plate do

2. Check wall plate and sill beam for pitting Pitting is to be filled in by welding. Rusted
and rusting and general conditions portion should be painted of tex cleaning

VI. Guide roller

1. Check the roller for its movements and Make the roller free if jammed clean and
setting grease
2. Check the nuts and bolts and guide roller Check for wear and tear and tightness

3
IS 10096 ( Part 3 ) : 1992

Points to be Inspected Compliance

(1) (2)

VII. Latching arrangement

1. Check whether latching device functions Check the function by operating lever.
well Rectify the same if movement is not smooth
2. Check ropes, nuts and bolts and studs of Replace ropes and tighten the bolts if
locking devices required
VIII. Wire ropes, hoist, pulleys, sheaves, etc
1. Check for following
a) Check condition of wire rope If the condition is poor, then repIace 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

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b) Check pulley sheave assemblies and Check condition of pins and every year
sockets these should be removed, cleaned and
refitted after lubrication
c) Check turn buckles Check for rusting, jamming in the turn
buckles, and check if the number of threads
hoIding 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 If found loose, tighten the studs provided
fastened to drum for
f) Check for lubrication of wire ropes, if Lubricate ropes
required
IX. Gear train assembly
1. Check for following
a) Check condition of gear and pinions Check uneven wear and contact adjust
properly
b) Checkposition of gears and pinion Bring them to correct position if found
shifted to either side
c) Check shaft and couplings used for Visual inspection and coupling nuts to be
connecting drive unit and gear train checked
X. Drive unit
1. Check for following
a) Check condition and functioning of Replace worn out liner, adjust brake shoes
electro-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 Check for loose connection, proper insula-
motor, brake, starter, limit switch etc. tion (rats and crabs damage the insulation ).
Also check remote control systems, if Overload relay of the starter is to be
provided adjusted, for correct position and should not
be disturbed

4
 IS 10096 ( Part 3 ) : 1992

Points to be Inspected Compliance

(1) (2)

C) Check the connecting arrangement from

adjacent motor
d) Check condition of position indicator Check for its proper function and rectify
and all its accessories
e) Reduction gear box ( worm reducer ) Check for smooth operation and check oil
level
XI. Check nuts and bolts of
1. Check for following
a) Hoist frame
Check for wear and tear and tightness
b) Drive unit
c) Gear boxes Tighten if required or replace for undue
d) Plange coupling 1 wearing

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e) Bearing housing Inspect for cracks in housing and replace, if
f) Foundation bolts of hoist bridge needed

4.3.2 General - Inspection to check that: gate. In case vibrations are noticed, the posi-
tions of gate openings and water levels should
a) The gate operation should be trouble be noted and the reasons thereof should be
free and there should not be unusual investigated.
sound.
5.4 Based on the inspection and testing, suita-
b) On load ( that is, when there is water ) ble remedial measures should be taken ( see 6 ).
there should be no undue vibrations in
the gate and the structure. 5.5 Trouble Locating Chart
cl Observe the current drawn by motor at
the time of lifting of gate. If any excessive Trouble Probable Reasons
current drawn is noticed, operation of
hoist should be stopped immediately and 1. Gate does not 1. No supply
reason for the same may be investigated rise
for lubrication of various parts of gates
2. Obstruction in rubber
and hoists and rectified.
seals
4 Check the supply voltage. 3. Obstruction in guide
e) Check the lubrication at various points. rollers
f 1 Check the condition of painting at vari- 4. Fault in electric motor
ous parts. 5. Fault in wiring
6. Blown out fuse
5 TESTING
7. Brake shoes jammed
5.1 The gate should be tested for its travel up 8. Wire rope broken
and down to see that it moves smoothly with- 9. Malfunctioning of elec-
out excessive sway throughout the travel. trical contacts -due to
5.2 The operation should be trouble-free and any reason
there should not be any unusual sound. There 2. Gate vibrates or 1. Lack of lubrication in
should not be any undue pressure or extra produces noise trunnion and guide
efforts when the gate is operated under no load rollers
condition. Any extra current being taken by 2. Rope length not identi-
the motor should be taken note of. cal on both sides
5.3 On load ( that is, when there is water) 3. Lack of lubrication or
there should be no undue vibrations in the fault in wire rope pulley
gate and structure during operation of the sheave arrangements
IS 10096( .Part 3 ) :1992

c) Trunion bearing should be greased wher-

Trouble Probable Reasons
ever required. Keeping trunnion bearings
in perfdct working condition is very
3. Motor does not 1. No Supply importaqt. All other bolted connections
function should also be checked for proper tight-
2. Starter not in order ness.
3. Blown out fuses in
switches d) Bolts and trunnion bearing housing
should be tightened wherever required.
4. Low voltage
5. All fuses are not e) The sealb of the gate should be checked
wor~lng for wear and tear and deterioration.
These should be acljusted/replaced, as
4. Starter not 1. No supply to starter and when necessary.
working 2. Fixed and moving con- f) Wire ropes should be properly greased.
tacts not in order
3. Limit switch engaged !3) Oil level in the worm reduction unit
should be maintained by suitable replen-
5. Unusual sound Verify the spot and attend ishment. Oil seals should also be

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replaced. if required. Lubrication of

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to the following
other parts of the hoists, such as chains
1. Mis-alignment of any in operating, position, indicators arid
particular component limit switches should also be done.
2. Shearing of connecting h) The stroke of the brake should be reset
bolts and nuts to compensate for lining wear. Worn
3. Lack of lubrication out brake linings should be replaced in
time.
4. Entry of anv extraneous
matt_er into- guide roller j) Flexible couplings should be adjusted, if
assembly or pulley required.
sheaves or trunnion
assembly k) Repairs and replacement of electrical
relays a]id controls should be attended to.
ml Maintenance of alternative sources of
6 MAINTENANCE power, such as diesel generating sets and
alternative drives wherever provided
6.1 The maintenance of radial gates and their should -be carried out.
hoists mechanism should be done regularly.
Reference should be made to manufacturer’s n) The list of essential spare parts to be
instructions for detailed maintenance and kept available should be reviewed and
servicing Of hoists. Proper record of inspection, updated periodically. The availability of
tetiing and maintenance should be made by the essential spare parts should be ensured.
project authorities. The condition of spares should be
checked periodically and protective coat-
6.2 The following maintenance works should ing given before use.
be attended to:
P) Lubrication details:
a) Defective welded should be chipped out 1. Grease — Multipurpose
and it should be rewelded. Damaged
nuts, bolts, rivets, screws, etc should — Bearing grease
be replaced. Any pitting should be filled
up by welding and finished by grinding, Applicable points:
if necessary.
1. Pulley sheaves
b) The gate leaf, exposed embedded metal 2. Pulley brackets
parts, hoists and hoist -supporting struc-
ture, etc, should be thoroughly cleaned 3. Guide rollers
and repainted when required. While 4. Trunnion assembly
deciding about repainting, the original
5. -Rope drums
painting system adopted should be kept
in view. 6. Line shaft bearings

6
 7. Matching teeth of gear box assem- Applicable points:
bly 1. Reduction gear box
Once before rainy season or as
required Level up the gear box before operation.

2. Cardium compound 4. Mobil oil

Applicable points: Applicable points:

1. Wire ropes 1. All rubbing surfaces and oiling

points
Once in every season after cleaning of 2. .AAshzints located in brass/metal
wire ropes or as required.
3. H. P. 90 Gear oil Carefully once/twice a year.

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Revision of Indian Standards

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any, are issued from~time to time. Users of Indian Standards should ascertain that they are in
possession of the latest amendments or edition. Comments on this Indian Standard may be
sent to BIS giving the following reference:

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Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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