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5 mm
6 mm
1 mm
1 mm
1 mm/m
2 mm
1 mm/m
1 mm
2 mm
the rubber seal of the gate is arranged outside the areas affected by erosion,
all wearing parts are easily replaceable.
2.2 Components
2.2.1 Sealing Frame
The sealing faces shall consist of corrosion-resisting steel plates attached to the front frames and
lintel beam. For the sealing face of the sill beam stainless steel is not required. When the guide
frame has been assembled, the sealing plate surfaces shall be continuous, straight, true and within
the specified tolerances. The minimum thickness of the machined sealing plates shall be 6 mm.
The lintel beam, the sill beam and the front frames shall be true to form and free from any twist
and/or rack to provide a watertight seal with the gate.
2.2.2 Guide ways
The track frames shall be capable of transmitting the water load from the wheels of the gate to the
concrete structure and shall be of stainless steel. The surfaces shall be suitably machined and
hardened to prevent excessive wear.
The side roller paths or guide rails and frames shall have ample strength to resist the load of the
side rollers. The assembled side roller paths or guide rails shall be straight over their entire length
and no offset shall exist at joints.
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The Brinell hardness number of the wheels or rollers shall not exceed 270. The Hertz
stresses must be checked.
The wheel or roller paths shall have a greater hardness than the wheel or rollers but shall not exceed
280 Brinell. Special care shall be taken to ensure against temper brittleness, and to provide
sufficient toughness to withstand impact due to vibration or other movement of the gates.
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hoist shall consist of steel base framework, mechanical equipment, i.e., torque shafts, bearings, gear
reducer units, couplings, screwed spindles, supporting brackets, manual operating device,
mechanical position indicator, etc., electrical equipment such as electric motor, limit switches,
torque switches, electro-magnetic brake, etc., and all other necessary components for safe, proper
and efficient operation of the hoist.
The hoist shall be designed to withstand the maximum hoist load at the specified allowable unit
stress and the factor of safety. The hoist shall also withstand the load due to the maximum hoist
motor torque, without exceeding 90 percent of the yield strength of the material used.
The details of the construction of the hoist, not specified herein, shall be made by the Contractor
upon approval of the Engineer.
2.5.1 Steel Base Framework
The steel base framework shall be of all welded steel construction using rolled structural shapes and
plates. No deflection shall be such as to cause misalignment or overstress of the machinery parts.
Necessary anchor bolts and nuts for the steel base framework shall be supplied by the Contractor.
2.5.2 Mechanical Equipment
i. Torque Shafts
The torque shafts shall be finished commercial steel shaftings. The diameter of the shafts shall not
be less than 50 millimeters.
ii. Bearings
The bearings shall be of self-aligning re-greaseable ball, roller or plane type.
iii. Gear Reducer Units
Gear or worm gear reducers used for the hoist shall be standard high grade reducing units of good
efficiency suitable for long service life and the proportion of the parts therein shall be in accordance
with the best engineering practice
Gear shall be of cast or forged steel with machine-cut teeth.
Gears or worm gears and their supports shall be sufficiently firm to withstand the load imposed
under the most adverse operation of the hoist, and shall be enclosed in oil-tight and weather-proof
cases. Suitable lubrication system shall be furnished for the gear reducer units.
iv. Couplings
Couplings shall be flexible type and shall be provided with the means for field adjustment, and with
suitable means for permanent attachment to torque shaft after field adjustment.
v. Screwed Spindles
The screwed spindles shall be made of corrosion-resisting steel, and shall be provided with
machine-cut square thread of necessary length.
The spindles shall also withstand the thrust force imposed when the gate is closed.
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II.
III.
V.
Intake Gate
IV.
VI.
VII.
IX.
X.
General Items
100 (Hundred) kilograms of grease
Note: "One set" shall mean for one gate / one hoist unit / one local control panel.
2.7.2 Recommended Spare Parts
The Bidders are required to provide list of recommended spare parts. The price shall be quoted
under the respective price schedule for the recommended spare parts.
Check of vibrations, noise, flow oscillations, and other phenomena under various operating
conditions.
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3. STOPLOGS
3.1 General
Stoplogs and bulkheads with guide and sealing frames, storing and dogging devices, hoist and
lifting beam are required at different areas of the spillway, intake and tail-race for isolating other
equipment for purposes of inspection and maintenance.
3.1.1 Scope and Limits Of Supply
The scope of supply includes the following components:
I.
II.
Intake Stoplogs
III.
3 (three) complete sets of stoplogs complete with seals for the intake
3 (three) complete sets of guide and sealing frames, dogging device, including all embedded
parts
1 (one) set of electric motor operated monorail hoist with provision of manual operating
system
1 (one) grappling beam
1 (one) complete set stoplog surface storage devices
1 (one) set of spare parts.
IV.
2 (two) complete set of stoplogs complete with seals for the under sluice
2 (two) complete sets of guide and sealing frames, dogging device, including all embedded
parts
1 (one) set of electric motor operated monorail hoist with provision of manual operating
system
1 (one) grappling beam
1 (one) complete set stoplog surface storage devices,
1 (one) set of spare parts.
2 (two) complete set of stoplogs complete with seals for the draft-tube outlet
2 (two) complete sets of guide and sealing frames, dogging device, including all embedded
parts
1 (one) set of electric motor operated monorail hoist with provision of manual operating
system
1 (one) grappling beam
1 (one) complete set stoplog surface storage devices,
1 (one) set of spare parts.
Tailrace Stoplogs
2 (two) complete set of stoplogs complete with seals for the tailrace outlet
2 (two) complete sets of guide and sealing frames, dogging device, including all embedded
parts
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1 (one) set of electric motor operated monorail hoist with provision of manual operating
system
1 (one) grappling beam
1 (one) complete set stoplog surface storage devices,
1 (one) set of spare parts.
For all the above-mentioned equipment the scope of supply has to include:
all necessary anchors, bolts, screws, framing, pipes, lubricants, temporary and permanent
items for alignment and fixing in and to concrete
all components, devices, items and equipment not mentioned above, but necessary for the
safe and proper manufacture, transport, testing, operation and maintenance.
cable connection to the terminals at the local control cabinets / boards
The limits of supply are as follows:
to Lot 2 - Civil Work:
In-feed terminals for power supply from Lot 4 Electrical and Mechanical Works contractor.
5 mm
5 mm
5 mm
10 mm
1 mm/m
2 mm
1 mm/m
2 mm
5 mm
5 mm
2 mm
5 mm
4 mm
4 mm
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Water-tightness
Under maximum water pressure and without the use of any additional sealing material, the
leakage shall not exceed 0.1 l/s m.
3.1.4 Operating Conditions, Design Criteria
The stoplogs shall be designed for the following conditions as specified hereunder.
I.
II.
Intake Stoplog
Type of stoplog:
Number of stoplog
Number of stoplog panels
Clear span
Clear height
Design water level
Sill level
Design head
Water tightness
III.
IV.
Tailrace Stoplogs
Type of stoplog:
Number of stoplog
Number of stoplog panels
Clear span
Clear height
Design water level
Sill level
Design head
Water tightness
5.31 m
4 Edges seal at upstream
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3.2.4 Seals
The seals shall be molded rubber strips, preferably music-note shapes, clamped to the upstream (or
downstream in certain cases) face of the stoplog panel or bulkhead by means of corrosion-resisting
steel bolts, nuts and washers with anti-leakage materials. The seals shall be spliced at the corners by
shop vulcanizing to provide a single continuous seal. The tensile strength of all shop splices shall
not be less than 50% of the tensile strength of the unsliced materials. The head seals (if any) and the
side seals of music note type or other shape shall be activated by the upstream water pressure and
the bottom seal shall be a plain bar of rubber. The weight of the stoplog panel or bulkhead shall be
transmitted to the sill beam or the stoplog below through the skin plate.
3.2.5 Filling Valves
If necessary, filling valves of not less than 100 mm diameter shall be provided on each stoplog
panel or bulkhead for filling the space between stoplog and following gate or equipment after
completion of inspection and maintenance. The inlets to this valve shall be protected by bar screens
to prevent the ingress of any debris. The filling valve shall be operated by the dead weight of the
grappling beam or when lifting the stoplog panel or bulkhead. The upper ends of valve rods shall be
fixed with the guide lifting lugs for use as lifting points.
Since the water level may reduce during the time when the stoplogs are in use it is possible for the
water level to be below the bypass valves in a section but above the bottom of the section. The
bypass valve therefore shall be as close to the bottom of the section as possible to minimize the
unbalanced water pressure under which the stoplog or bulkhead must be lifted
3.2.6 Storing Devices
Depending on the number of panels per set there are different methods and facilities of storage to
be considered:
Storage in guide frames. This type of storage will be applied for all or bulkhead. They will
be supported by dogging devices on top of the guide frame of the relevant opening to be
closed.
Storage in storage slots. This type of storage will be applied for the stoplogs of the flushing
channel. The storage slots are provided with appropriately located dogging devices.
3.2.7 Embedded Parts
Each guide frame shall consist of the sealing frames, sill beam, lintel beam (if any), track frames,
side guide frames, front frames and all other necessary components.
Sealing frames
The sealing frames shall be provided with corrosion-resisting steel plates on both sides and at the
lintel (if any). For the bottom sealing face no corrosion resisting steel is required. When the guide
frames have been assembled, the sealing surfaces shall be continuous, straight and in the same
plane. The minimum thickness of the sealing plates shall be 6.0 mm.
Sill Beams
The sill beams shall be straight and true to provide a close fit with the bottom of the lowest stoplog
panel. The sill beams shall be conservatively designed to be able to transfer all loads on it to the
concrete structure.
Track Frames
The track frames shall be capable of transmitting the water load on the stoplog to the concrete
structures. The surfaces of the track frames shall be attached with corrosion resisting steel plates of
not less than 6 mm thickness, and be true and flat.
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3.3 Installation
3.3.1 Guide Frames
The guide frames shall be assembled in their blackouts in accordance with the final approved
drawings, brought to line and grade within the tolerances specified and firmly secured in place.
Alignment bolts or other necessary devices shall be used to install the guide frames at
corresponding accurate position.
Connections between the guide frames, anchor materials and the alignment device shall be
adjustable and firmly tightened to hold the guide frames securely in position while concrete is being
placed in the block outs. Additional bracing shall be provided where necessary to ensure the
required alignment. Extreme care shall be taken to ensure that the guiding, bearing and sealing
surfaces lie in a true plane within the tolerance specified.
Placement of concrete in the block outs shall not proceed until the guide frames have been
completely assembled and secured. During placing the concrete, alignment tolerances shall be
checked and remedial action taken if readings indicate that displacement has occurred.
3.3.2 Stoplog and Bulkhead
Each stoplog element complete with seals, front rollers and side rollers shall be assembled and
erected in accordance with the details shown an the final approved drawings.
Joints shall be watertight where required. The bottom of the stoplog when erected shall be in true
alignment to ensure a tight and even bearing of the rubber seal on the embedded sill beam or
element below. The sides of the stoplog shall be in true alignment so that the rubber seals, when
installed, shall have a tight and even bearing on the sealing surfaces embedded in the concrete. The
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stoplog shall be assembled and erected within the shop tolerance necessary to meet the specified
tolerances.
1 (one) set of side seals for each stoplog or bulkhead with 20% (twenty) of the screws and
nuts,
1 (one) set ordinary bottom seals for each stoplog or bulkhead,
1 (one) set of guiding rollers for each stoplog or bulkhead,
1 (one) set of bearings, bushing and pins for the hoisting beams.
1 (one) set of limit switch and relay of each type to be used
1 (one) set of contactors for hoisting, travelling and translation of the mono-rail hoist
Hoisting rope of proper length of type used
5 (five) grease nipples and/or cups for each size and type and grease gun with appropriate
nozzle
1 (set) of driving motor complete with accessories
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assembled, each stoplog element shall be checked for dimensions, tolerances and accuracy of
alignment. Any error or misalignment discovered shall be promptly corrected.
The seals shall be fitted to their supports during the shop assembly. Parts shall be clearly match
marked before disassembly for transportation. Sealing frames, track frames, side guide frames,
front guide frames and sill beams for the guide frames shall be checked by means of straight edge
and feeler gauge. All dimensions of the guide frames that correspond to the stoplog dimensions
shall be checked, and any error or misalignment discovered shall be corrected.
The function of all grappling beams shall be checked also.
Painting tests shall be include the following:
The peeling test for dried films an the constructions shall be carried out not earlier than 7
days after application of final coat to allow full curing of the paint film.
The dried films shall be checked by holiday detector for pinholes at any time after painting
work be finished.
The thickness of dried films shall be measured by elco-meter after painting work is finished
to a check point in every one square meter, or the area where the Engineer so requests.
general outline drawing in scale showing the stoplogs and bulkheads with embedded parts
typical cross section of side seal, bottom seal, lintel seal (if any) and wheel assembly
reference list of comparable or identical equipment supplied by the Bidder. Indicate
responsibility for design and manufacture.
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