SCOPE OF

HYDRO MECHANICAL WORKS

Prepared By:-
Sachin Jain
Certified Energy Manager
Shift In charge, DAM
PROJECT-General Description
BACKGROUND PROJECT PARTICIPANTS
 Conceived by UPPCL in 1980.
 Civil Works L&T (Major)
 Started under PPP by Duncans in 1996.
 Electro Mechanical BHEL
 Taken over by Tata in 2003 as AHPCL.
 Hydro Mechanical Precision
 Taken over by GVK group in 2005
 Penstocks P&R
 Land acquisition 2006
 Construction Start 2007
 Commissioned 2015

MAJOR COMPONENTS SALIENT FEATURES

 Diversion Dam 90m high  Design Capacity 330MW
 Water Conductor 6 Km long  Energy Generation 1397 MU
 Power House 4 x 82.5 MW  Project ownership UPPCL
 Machine Vertical Francis  Concessionaire AHPCL (GVK)
 Concession Period 30 Years
 Project Cost 5,182 Crs
 Power Purchase UPPCL(88%)
 Free Power UK (12%)
PROJECT LAYOUT
De-siliting Basin HRT/ Intake

Power Channel

Power House Dam

Forebay / Intake
HYDRO MECHANICAL -OVERVIEW
Sl.No. Location Item Description Unit Quantity Remark

1 SPILLWAY STOPLOG GATE Set 2

2 SPILLWAY STOPLOG GANTRY CRANE No. 1

3 SPILLWAY RADIAL GATE Nos. 8

Dam
4 Power Pack Nos. 8

5 Hydraulic Cylinder Nos. 16

6 Local Control Panel Nos. 8

7 Trash Rack Panels Nos. 60

INTAKE-
TRASH RACK
8 TRC Machine No. 1

9 HRT INTAKE STOPLOG GATES Set 3

10 HRT INTAKE HRT GANTRY CRANE No. 1

11 HRT INTAKE SERVICE GATES Nos. 6

HYDRO MECHANICAL -OVERVIEW
Sl.No. Location Item Description Unit Quantity Remark

12 Power Pack Nos. 6

13 HRT INTAKE Hydraulic Cylinder Nos. 6

14 Local Control Panel Nos. 6

15 UNDER SLUICE EMERGENCY GATES Nos. 4

16 UNDER SLUICE SERVICE GATES Nos. 4

17 Bulck Head Gate No 1

Dam- Under
18 EOT Crane Nos. 1
Sluice
19 Power Pack Nos. 4

20 Hydraulic Cylinder Nos. 8

21 Local Control Panel Nos. 4

22 Power House DRAFT TUBE GATE Nos. 12

HYDRO MECHANICAL -OVERVIEW
Sl.No. Location Item Description Unit Quantity Remark

23 Power House DRAFT TUBE GANTRY CRANE No. 1

24 FOREBAY INTAKE STOPLOG GATE Set 1

25 FOREBAY INTAKE GANTRY CRANE No. 1

26 FOREBAY INTAKE GATE Nos. 4

Power House
27 Power Pack Nos. 4

28 Hydraulic Cylinder Nos. 4

29 Local Control Panel Nos. 4

30 DESILING BASIN ISOLATING STOPLOG GATE Set 1

31 DESILITING BASIN STOPLOG GANTRY CRANE No. 1

DSB
32 DESILING BASIN FLUSHING GATE Nos. 2

33 Power Pack Nos. 2

HYDRO MECHANICAL -OVERVIEW
Sl.No. Location Item Description Unit Quantity Remark

34 Hydraulic Cylinder Nos. 2

35 Local Control Panel Nos. 2

36 BYPASS STOPLOG GATE No. 1

37 BYPASS STOPLOG GANTRY CRANE No. 1

POWER
38 HOUSE- BY BYPASS AUTOMATIC REGULATING GATE Nos. 3
PASS
39 Power Pack No. 1

40 Hydraulic Cylinder Nos. 3

A Remote Control Panel No. 1

B Common LT Panel No. 1

Control Room
D Dam DC Battery Charging Panel Nos. 2

E Relay Panel Nos. 4

HYDRO MECHANICAL -EQUIPMENTS
The main hydro-mechanical equipments required to manage and control the flow of water are:-

 Radial gates of size 14.5m x 22.067 m provided on the spillway for controlling flood discharge
- 08 Nos.

 Spillway Stoplogs of size 14.5m x 22m consisting of 11 nos. of units each of 2.0m height on the
spillway for inspection and maintenance of the spillway radial gates- 02 Nos.

 Service & Emergency slide type under sluice gates of size 3m x 4m- 4 & 4 Nos.

 Fixed wheel type bulkhead gate of size 5.0m x 5.32m provided for maintenance of Service &
Emergency under sluice gates- 01 No.

 Slide type silt flushing gates of size 2.15m x 2.6m provided for extraction of Silt/sand/gravels from
the desilting basin- 02 Nos.

 Slide type desilting basin stoplog provided for vent size opening of 12m x 10m to isolate the
desilting basin- 01 No.
HYDRO MECHANICAL -EQUIPMENTS
The main hydro-mechanical equipments required to manage and control the flow of water are:-

 HRT Intake slide type stoplog are provided for opening of 5m x 6.2m to isolate the HRT tunnel for
carrying out repairs/maintenance- 03 Nos.

 Fixed wheel type HRT Intake Service Gates of size: 5m x 6.2m- 06 Nos.

 Slide type Forebay Intake stoplog provided for opening of vent size of 4.7 x 5.6m to isolate
Forebay intake to permit maintenance of structure/equipment d/s of the stoplog- 01 No.

 Fixed Wheel type Forbay vertical gates of size: 4.4m x 5.6m- 04 Nos.

 Draft tube gates of size 4.772m x 5.08m are provided to enable the isolation of the draft tube from
the tail water for inspection and maintenance work on the draft tube and turbine runner- 12 Nos.

 Trash racks of size 4.20m x 4.05 m (height 19.7m) in front of HRT intake structure to prevent debris
entering the HRT- (5 x 12) 60 Nos.
HYDRO MECHANICAL -EQUIPMENTS
The main hydro-mechanical equipments required to manage and control the flow of water are:-

 Trash racks of size 4.40m x 4.16 m (height 16.10m) in front of Forebay intake structure to prevent
debris entering the Forebay- (8 x 4) 32 Nos.

 50T capacity Gantry Crane travelling on rails at Dam Top with the respective detachable type semi
automatic lifting beams for operation of Spillway Stoplog Gates and Fixed Wheel Under sluice Bulk
Head Gates- 01 No.

 25T capacity Gantry Crane with requisite lifting beam is provided on deck on out let side of two
desilting basin chambers for operation of desiliting basin isolating stoplogs- 01 No.

 20T capacity gantry crane with requisite lifting beam is provided at deck level of HRT Intake
structure to operate its stoplog elements- 01 No.

 20T moving gantry crane is provided at deck level of Forebay Intake Structure to operate stoplog
elements of the Forebay Intake- 01 No.
HYDRO MECHANICAL -EQUIPMENTS
The main hydro-mechanical equipments required to manage and control the flow of water are:-

 20T capacity Gantry Crane travel on rails at deck level of structure with respective detachable type
semi automatic lifting beam for operation of draft tube gates- 01 No

 400T capacity twin cylinder (2x200 MT) Hydraulic Hoists are provided for operation of the Spillway
gates under unbalanced head condition.

 600t capacity double acting hydraulic hoist cylinders installed in gate operation chamber for
operation of service & emergency gates provided in the body of dam.

 170T capacity double acting hydraulic hoist cylinder installed in Silt flushing gate operation
chamber provided in the gate shaft.

 45T capacity Hydraulic Hoist for operation of HRT Service gates.

 40T capacity Hydraulic Hoist for operation of Forbay Service gates.

GATES
A Gate is a closure device in which a leaf is moved across the fluid way from an external position to
control flow of water.
 Depending upon the head the gates are also further classified as:-
 a) Low Head ( Less than 15 meters)
 b) Medium head ( Between 15 to 30 meters)
 c) High head ( Above 30 meters)

Common Type of Gates in INDIA

Vertical Lift
Radial Gate
Gates

Fixed Wheel Type

Spillway Crest Orifice Spillway Slide Type
Gates
Basic IS Codes
 IS 13623 - Criteria for choice of gates and hoist.
 IS 4622 - Recommendation for structural design of fixed wheel gates.
 IS 4623 - Recommendation for structural design of radial gate.
 IS 5620 - Recommendation for structural design of low head slide gate.
 IS 9349 - Recommendation for structural design of medium and high slide gate.
 IS 6938 - Design of Rope drum and chain hoist for hydraulic gates.
 IS 10210 - Criteria for design of hydraulic hoist for gates.
 IS 11288 - Recommendation for design of screw hoist and hydraulic gates.
 IS 807 - Design, erection and testing (structural portion) of cranes and hoist- code of practice.
 IS 3177 - Code of practice for electric overhead travelling cranes and gantry cranes other than
steel work crane.
 IS 13591 - Criteria for design of lifting beam.
 IS 11855 - Guidelines for design and use of different types of rubber seals for hydraulic gates.
CONTINUED…..
 IS 15466 - Rubber seals for hydraulic gates- specification.
 IS 14177 - Guidelines for painting system for hydraulic gates and hoist.
 IS 800 - General Construction in Steel- Code of Practice.
 IS 456 - Code of practice for plain and reinforced concrete.
RADIAL GATE
Definition of Radial gate

“A device used for controlling the flow of water over spillways or into canals by having the upstream
face curved in the form of an arc the center of which is at the center of the gate hinge —called
also tainter gate”

Advantages
• Better discharge characteristics than partial gate openings.
• Low cost.
• Bearings are located out of the water.
• Aesthetics – Does not require an overhead supporting structure (gate tower).
• Does not require gate slots which can become plugged with ice or debris and can cause cavitations.
Disadvantages
• Longer piers.
• Relatively high concentrated loads at the trunnions.
• More complex fabrication than other gate options.
• More complicated dogging system to facilitate maintenance activities.
RADIAL GATE
RADIAL GATE
Radial gate- Structural design

In a radial gate, water pressure is transferred from the curved face to the radial gate arms which
transfer the load to a common bearing on either side of the gate opening.
Load combinations for water control gates can be complex and special care should be taken in
identifying all of the important combinations. Agencies will usually provide guidance (or rigid codes)
on this but here some of the most important ones:
•Dead Load + Impact (during installation, dry testing, or servicing)
•Dead Load + wave load
•Dead Load + Hydrostatic Load corresponding to top of gate
•Dead Load + Hydrostatic Load at design flow level + Ice load
•Dead Load + Hydrostatic Load at spillway design flow (gates open)
•Dead Load + Hydrostatic Load at design flow level + Earthquake force
•Dead Load + Hydrostatic Load at Inflow Design Flow with gates open.
RADIAL GATE
Radial gate- PARTS

Radial gates consist of the following four parts:

•The gate leaf assembly, including the curved skin plate, cross bracing or struts, supporting beams
and girders, and rubber seals.
•Arm assembly, including the arm columns, bracing, and hub.
•Trunnion assembly, including a pin, busing, thrust washers, lubrication provisions, and yoke.
•Trunnion support assembly, including the trunnion beam or anchor block and anchorage system.
RADIAL GATE
Radial gate- Strength Calculation

– Auxiliary horizontal beams – Loads acting on main frameworks

– Beam arrangement and design hydraulic – Arrangement of main vertical beams and arms
pressures – Section properties of horizontal connection beams
– Strength of auxiliary horizontal beams – Sectional properties of arm
– Skin plate – Frameworks
– Bending stresses – Stresses of frameworks
– Correction factor – buckling and stability of buckling
– Hydraulic load acting on skin plate – Trunnion assemblies
– Stresses acting on skin plate – Trunnion pins
– Main vertical beams – Trunnion bearing
– Loads – Bracket
– Bending moment and shearing force – Hoist System
– Sectional modulus and stresses – Operation load
– Hydraulic cylinder
RADIAL GATE
Radial Gate- Bill of Quantity
Total wt. per unit
Sl.No. Description Sub Item Weight (KG) Remark
(BOQ) in KG
Spillway radial Gate 2nd Sill Beam 423.62 Total no of
1 3177.72
Stage EP Wall Plate 2754.1 vents are 8

Horizontal Girders 8204.77

Horizontal Stiffners 1775.7
Gate Leaf Bottom Element Lifting Bracket 5057.6
2 25643.4
Downstream
Skin Plate & Vertical Stiffeners 7646.77
Arm Support 2958.56
Horizontal Stiffeners 1671.04 BOQ for one
Gate Leaf Intermediate
3 10147.4 Gate
Element 2nd Vertical Girders and Skin Platee 8476.36

Gate Leaf Intermediate Horizontal Stiffners 1671.04

4 8965
Element 3rd Vertical Girders and Skin Platee 7293.96
Vertcal Girders 3369.84
Gate Leaf Intermediate
5 Skin Plate and Horizontal 8965.89
Element 4th 5595.96
Stiffeners
RADIAL GATE
Radial Gate- Bill of Quantity

Total wt. per unit

Sl.No. Description Sub Item Weight (KG) Remark
(BOQ) in KG
Vertcal Girders 4043.42
Gate Leaf Intermediate Element
6 Skin Plate and Horizontal 9983
5th 5939.58
Stiffners
Vertcal Girders 3575.04
Gate Leaf Intermediate Element
7 Skin Plate and Horizontal 8520
6th 4944.96
Stiffners
Horizontal Girders 6978.91
Skin Plate and Vertical
Gate Leaf Intermediate Element
8 Stiffeners and horizontal 11274.62 21210.09
7th
stiffeners BOQ for one
Arm Support 2956.56 Gate
Vertcal Girders 3744.22
Gate Leaf Intermediate Element
9 Skin Plate and Horizontal 9154.88
8th 5410.66
Stiffners
Vertcal Girders 3246.08
Gate Leaf Intermediate Element
10 Skin Plate and Horizontal 7545.75
9th 4299.67
Stiffners
Vertcal Girders 2846.17
Gate Leaf Intermediate Element
11 Skin Plate and Horizontal 6778.99
10th 3932.82
Stiffners
RADIAL GATE
Radial Gate- Bill of Quantity
Total wt. per unit
Sl.No. Description Sub Item Weight (KG) Remark
(BOQ) in KG
Gate Arm 88095.54 BOQ shown for
2 sets of arms,
12 Gate Arm and Bracing beam 91955.12
1L+1R for each
Bracing Beam 3859.58
gate
BOQ for one
13 Trunion Hub Trunion Hub 7598.96 15197.92
gate (1L+1R)
Trunion Bracket 6440.99
BOQ for one
14 Trunion Bracket Trunion Bush 539.322 19948.544
gate (1L+1R)
Trunion Pin 2993.96

15 Radial gate Guide roller Guide roller 180.48 180.48

BOQ for one
gate
16 Radial gate seal Seal, Seal Clamp Plates etc 503.66 503.66
RADIAL GATE
Material Specification

Sl.No. Components Material Specification

1 Skin Plate Structural Steel SAILMA 450 HI

Horizontal Girders: End Arm: Arm Bracings, Vertical
2 Structural Steel SAILMA 350 HI.
Stiffeners, Lifting Lug.
3 Trunnion Hub Cast Steel IS: 1030, Gr.280-520

4 Trunnion Bracket Cast Steel IS: 1030

5 Trunnion Pin Corrosion Resistant Steel IS: 1570 20 Cr.13

Self Lubricating Bronze
6 Trunnion Bush ID: 650, OD: 715/780, length 865 mm CSB slide bearing
Bush
7 Seal Seat Stainless Steel IS: 1570
8 Seal Base Structural Steel IS: 2062

9 Guide Roller Cast Steel IS: 1030, Gr.27-54

10 Roller Bush Aluminum Bronze IS: 305, Gr.AB-2

11 Rubber Seals Rubber IS: 11885

12 Guides & Wall Plate Structural Steel IS: 2062 Structural Steel IS: 2062

13 Thrust Pad Plate Stainless Steel IS: 1570

RADIAL GATE
Salient Features- Spillway Gate

Sl.No. Components Specification

1 Type : Radial

2 Service : Flood Regulation and sluicing from th Diversion Dam

3 MWL : EL 609.80 m

4 FRL : EL 605.50 m

5 Top of gate : EL 605.80 m

6 Sill level : EL 583.433 m

7 Clear width of opening : 14500.00 mm

8 Clear height of opening : 22067.00 mm

9 Number of bays : Eight

10 Number of gates required : Eight

11 C.L. of Trunnion : : EL 595.00 m

12 Design Head : : 22.067 m (w.r.t. FRL)

13 Radius to D/S of skin plate : 26000 mm
RADIAL GATE
Salient Features- Spillway Gate

Sl.No. Components Specification

14 Type of seals : IS:11855

a Side seal : “L” shaped synthetic rubber fluorocarbon cladded.

b Bottom seal : Rubber, Wedge type

15 Hoisting Arrangement : : Single acting Hydraulic Hoist of 400T (2 x 200T) capacity

Main Bearing : Antifriction or self lubricating bearing

16 Standard

a Gate : IS: 4623

b Hydraulic hoist : IS: 10210

c Structure : IS: 800

d Testing Standard : IS: 10096 (Part 3)

RADIAL GATE
Salient Features- Spillway Gate- Hydraulic Hoist

Sl.No. Components Specification

1 No. of Hoists : 8 sets twin cylinder (2 x 200) MT

2 Type of Hoist : Oil Hydraulic Cylinder

3 Hoist Capacity : 2 x 200= 400 MT

4 Vertical Lift of Gate : 20.797 m

5 Designed as per : IS:10210

6 No. of Cylinder : 2 nos. per set of hoist = 2 x 8= 16 nos.

7 Connection to Gate : Clevis and Pin

8 Opening : Electric motor driven fixed displacement oil pump

9 Closing : Gravity closing under controlled oil flow

10 Electric Motor Power Supply : 415V, three phase, 50 HZ

RADIAL GATE
Salient Features- Spillway Gate- Hydraulic Cylinder

Sl.No. Components Specification

1 Type : Rexroth Type- CYCRRMP5/0420/0180/10615A10/X1CRUA WAC

2 Mode of Operation : Single Acting Pulling
3 Bore : 420 mm
4 Rod Diameter : 180 mm

5 Working Stroke : 10415 mm

6 A-piston : 1385 Cm2

7 A-rod : 254 Cm2

8 A-ring : 1131 Cm2

9 F-lifting : 2000 KN

10 F-Lowering : 0 KN
11 V- Lifting : 0.25 M/min

12 V- Lowering : 0.25 M/min

13 T-Lifting : 41.66 min

RADIAL GATE
Salient Features- Spillway Gate- Hydraulic Cylinder

Sl.No. Components Specification

14 T-Lowering : 41.66 min

15 Total Strok Length (incusice Cushioning) : 10615 mm
16 Design Pressure
a Rod Side : 20 MPa

b Bottom Side : 1 Mpa

17 Working Pressure

a Rod Side : 17.7 MPa

b Bottom Side : 1 MPa

18 Test Pressure

a Rod Side : 30 MPa

b Bottom Side : 1.5 MPa

19 Maximum Pulling force : 2000 KN

20 Maximum Pushing force due to system overload : 0 KN

RADIAL GATE
Salient Features- Spillway Gate- Hydraulic Cylinder

Sl.No. Components Specification

21 Maximum speed
a Moving Out : 50 mm/sec
b Moving IN : 50 mm/sec
22 Minimum Speed

a Moving Out : 10 mm/sec

b Moving IN : 10 mm/sec

23 Hydraulic Medium : Mineral Oil ISO VG 46

24 Moving Frequency : TBD/day

25 Mounting Angle Rod to Horizontal : (-) 3.2 degree/ (-) 56.8 degree

26 Design Temperature : 0/+45 deg

27 Lateral Force : 0N

28 Surface condition:Bore:Honed Rod:Hard Chromium Plated : 50 micrometer

RADIAL GATE
Salient Features- Spillway Gate- Power Pack

Sl.No. Components Specification

1 O/A No : AZHV/268
2 Circuit No. : HS-64.3-A3814-3-3
3 Oil Tank Capacity : 4000 L
4 Working Pressure : 196 bar
5 Test Pressure : 294 bar
6 Paint Specification
a RAL NO : 5010
b Shade : Azure Blue

7 Material of Construction

a Tank Material : Mild Steel

b Piping Material : Carbon Steel

8 Working Fluid : ISO VG 46

RADIAL GATE
Salient Features- Spillway Gate- Power Pack

Sl.No. Components Specification

DIN 2391C for tube size upto 42 mm

9 Pipe/Tube dimensional Standard :
ANSI B36.10 for pipe size 48.3 mm and above

ST 37.4/SS304/SS316
10 Pipe/Tube Material Standard : ASTM A 106 B for Carbon steel pipes/ ASTM A 312 for
stainless steel

Walform fitting for internal piping & 24" weld niple for user
termination upto 42 mm
11 Type of Connection :
Flange connection /ANSI 48.3 mm OD pipe/

Apporoximate weight of the whole

12 : 2000 Kg
unit(excluding oil)
RADIAL GATE
Spillway Gate- PHOTO GALLERY
RADIAL GATE
Spillway Gate- PHOTO GALLERY
RADIAL GATE
Spillway Gate- PHOTO GALLERY
RADIAL GATE
Spillway Gate- PHOTO GALLERY
RADIAL GATE
Spillway Gate- PHOTO GALLERY
RADIAL GATE
Spillway Gate- PHOTO GALLERY
RADIAL GATE
Spillway Gate- PHOTO GALLERY
FIXED WHEEL VERTICAL LIFT GATES
The fixed-wheel vertical lift gates comprise of, in general, a structural steel frame consisting of end
vertical girders with properly spaced horizontal girders between them.
The spacing depends on the design water pressure and on dimensions of the gate. The frame is held a
piece by secure welding or riveting.

Skin plate protects the structural framework from damage due to ice and heavy debris, minimizes
downpull, reduces corrosion and facilitates maintenance. However, in some cases as in the case of
fixed wheel gates moving on track provided on the face of the dam, skin plate is provided on the
downstream side. In exceptional cases, skin plate is provided on both downstream side and upstream
sides, if the down stream water is above sill. In such cases the gates maybe fully or partially buoyant.

In case of fully buoyant gates, buoyancy shall be taken into account in determining the net balance of
vertical forces and addition of ballast may be necessary to ensure lowering without difficulty. This
problem is absent in the case of flooded gates but greater care against corrosion becomes necessary.
The wheels are mounted on the end girders.

The bottom of gate should be so shaped that satisfactory performance and freedom from harmful
vibrations are attained under all conditions of operation apart from minimizing downpull. A typical
arrangement of various components of gate is shown in Figure 24. Detailed design of this type of gates
has been published by the Bureau of Indian Standards code IS: 4622-2003 “Recommendations for
structural design of fixed wheel gates”.
VERTCAL LIFT GATE
HRT Service Gate- Bill of Quantity
Total Wt.
Total wt. of
Sl. Description Sub Item Weight (KG) per unit Total
all quantity Remark
No. (BOQ) in KG Quantity
in KG

Track cum side seal seat 4078.88

HRT intake gate Guide 1727.18

1 13838.34 6 sets 83030.04
2nd stage EP Sill beam 239.27
Top seal seat 7793.01
Horizontal girders 9318.52 BOQ given for
one set of
Vertical stiffeners, skin plate,
HRT intake gate 8294.38 groove, Total
lifting hook and guide shoes
2 leaf 19270.65 6 nos. 115623.9 sets of
assembly Roller Weight 1329.00 grooves are 6

Seal clamp plate and seal 328.75

Supporting structure 1061.26
HRT intake gate
3 1503.26 6 nos. 9019.56
hydraulic hoist Dogging arrangement 442.00
VERTCAL LIFT GATE
Material Specification
Sl.No. Components Material Specification

1 Gate leaf, seal clamps & other structural parts Structural Steel IS: 2062
Track bases, seal seat bases, sill beam, guide
2 Structural Steel IS: 2062
& other embedded parts
IS: 2004 Class 4 OR EN8
3 Wheel Forged Steel
BHN = 175
Corrosion Resistant Steel IS:1570 (Part 5) -20 Cr 13
4 Wheel pin
/ Stainless Steel (AISI 420)
Corrosion Resistant Steel IS:1570 (Part 5) - 20 Cr 13
5 Roller Track
/ Stainless Steel ( AISI 420 )/ BHN 225 min.
IS: 1570 (Part 5) 04 Cr 19
6 Seal seats Stainless Steel
Ni 9 / AISI 304
7 Guide shoe Structural Steel IS: 2062
Corrosion Resistant Steel/ IS:1570 (Part 5)-20 Cr 13
8 Guide roller pin
Stainless Steel (AISI 420)
Self Lubricating Bronze
9 Guide roller bush Standard make
Bush
IS: 1570 (Part 5)04 Cr 19 Ni
10 Seal fasteners Stainless Steel
9 / AISI 304
VERTCAL LIFT GATE
Material Specification
Sl.No. Components Material Specification

Teflon cladded solid double stem

11 Top seal IS: 11855
50x50x14

Teflon cladded solid

12 Side seals IS: 11855
double stem 150x50x14

13 Bottom seal 13 Flat Type 100x20 IS: 11855

VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate)

Sl.No. Components Specification

1 Type : Fixed wheel- downstram sealing

Guard and isolating gate for headrace tunnels. Unbalanced opening for
2 Service :
headrace filling. Closure against maximum flow.
3 Clear width of opening : 5000 mm
4 Clear height of opening : 6200 mm
5 MWL : EL 609.80 m
6 FRL : EL 605.50 m
7 Sill level : EL 591.30 m
8 Design head : 18.50 m
9 C/C of side seal seats : 5150 mm

10 C/C of side tracks : 5600 mm

11 Type of gate : Fixed Wheel Type

12 Type of seals : IS:11855

13 Operation : Unbalanced head conditions.

VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate)

Sl.No. Components Specification

14 Maximum Flow : 119.3 Cumecs per gate

15 Hoisting Arrangement : Single acting Hydraulic Hoist of 45T capacity.

Sides and top:- Fluorocarbon nosed, double leg rubber. Bottom - flat
16 Seals :
rubber strip

17 Standards : IS:4622, IS:10210

18 Testing Standards : IS: 7718

VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate)-Hydraulic Cylinder

Sl.No. Components Specification

1 Type : Rexroth Type- CYCIME7/200/100/6400A10/X1CLSATAC

2 Mode of Operation : Single Acting Pulling
3 Bore : 200 mm
4 Rod Diameter : 100 mm
5 A-piston : 314 Cm2
6 A-rod : 79 Cm2
7 A-ring : 235 Cm2
8 F-lifting : 450 KN
9 F-Lowering : 0 KN

10 V- Lifting : 0.62 M/min

11 V- Lowering : 0.62 M/min

12 V- Emergency Lowering : 6.20 M/min

13 T-Lifting : 10 min
VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate) - Hydraulic Cylinder

Sl.No. Components Specification

14 T-Lowering : 10 min
15 T- Lowering(Emergency) : 01 Min
16 Total Stroke Length (inclusive Cushioning) : 6400 mm
17 Design Pressure
a Rod Side : 20 MPa
b Bottom Side : 1 Mpa
18 Working Pressure
a Rod Side : 19.1 MPa
b Bottom Side : 1 MPa
19 Test Pressure
a Rod Side : 30 MPa
b Bottom Side : 1.5 MPa
20 Maximum Pulling force : 450 KN
VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate) - Hydraulic Cylinder

Sl.No. Components Specification

21 Maximum Pushing force due to system overload : 0 KN

22 Energy to be Cushioned
a Rod Side : 85 K Joule
b Bottom Side : 0 K Joule
23 Maximum speed
a Moving Out : 100 mm/sec
b Moving IN : 10 mm/sec
24 Minimum Speed
a Moving Out : 10 mm/sec
b Moving IN : 1 mm/sec
25 Hydraulic Medium : Mineral Oil ISO VG 32
26 Moving Frequency : TBD/day
27 Mounting Angle Rod to Horizontal : 90 degree
28 Design Temperature : 0/+45 deg
VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate) – Power Pack
Components
Sl.No. Specification

1 O/A No : AZHV/268
2 Circuit No. : HS-64.3-A3813-3-4
3 Oil Tank Capacity : 400 L
4 Working Pressure : 187 bar
5 Test Pressure : 280 bar
6 Paint Specification
a RAL NO : 5010
b Shade : Azure Blue
7 Material of Construction
a Tank Material : Mild Steel
b Piping Material : Carbon Steel
8 Working Fluid : ISO VG 46
DIN 2391C for tube size upto 42 mm
9 Pipe/Tube dimensional Standard :
ANSI B36.10 for pipe size 48.3 mm and above
VERTCAL LIFT GATE
Salient Features- HRT Service Gate (Vertical Lift Gate) – Power Pack

Sl.No. Components Specification

10 Pipe/Tube Material Standard
11 Type of Connection
Approximate weight of the whole
12
unit(excluding oil)
ST 37.4/SS304/SS316
: ASTM A 106 B for Carbon steel pipes/ ASTM A 312 for stainless
steel
Walform fitting for internal piping & 24" weld nipple for user
: termination up to 42 mm
Flange connections /ANSI 48.3 mm OD pipe/
: 1000 Kg
HRT INTAKE GATE
Service Gate- PHOTO GALLERY
HRT INTAKE GATE
Service Gate- PHOTO GALLERY
HRT INTAKE GATE
Service Gate- PHOTO GALLERY
SLIDE GATES
Slide gates, as the name implies, are the gates in which the operating member (that is, gate leaf) slides
on the sealing surfaces provided on the frame. In most cases, the sealing surfaces are also the load-
bearing surface. Slide gates may be with or without top seal depending whether these are used in a
close conduit or as crest gate.

Bulk head or stop-logs

These are usually located at the upstream end of river outlet conduits or penstocks where in addition
some other equipment is used to cut off flow and are subjected to relatively high heads.

Emergency or guard gates

These are designed to be operated under unbalanced head, that is, with water flowing through the
conduit or sluice but are not meant for regulation. These are kept either fully opened or fully closed
and are not operated at part gate opening.

Regulating gates
These are used for regulating flow of water. These are also operated under unbalanced head condition
and are designed to be operated at any gate opening.
SLIDE GATES
A typical installation of a slide gate is shown in Figure. These consist of a gate leaf and embedded
parts. These embedded parts serve the following purposes:
 Transmit water load on the gate leaf to the supporting concrete (structure),
 Guide the gate leaf during operation, and Provide sealing surface.

The following Bureau of Indian Standards codes may be referred to while designing slide gates:
 IS: 5620-1985 “Recommendations for structural design criteria for low head slide gates”.
 IS: 9349-1986 “Recommendations for structural design of medium and high head slide gates”.
SLIDE GATES
SLIDE GATE- UNDER SLUICE
Service & Emergency Gate- PHOTO GALLERY
SLIDE GATE- UNDER SLUICE
Service & Emergency Gate- PHOTO GALLERY
SLIDE GATE- UNDER SLUICE
Bulk Head Gate- PHOTO GALLERY
SLIDE GATE- UNDER SLUICE
Bulk Head Gate- PHOTO GALLERY
SLIDE GATE- UNDER SLUICE
PHOTO GALLERY
SPILLWAY STOPLOG GATES
Two set of Slide Type Stop log gates with eight sets of embedded parts for a opening of size -14500 mm x 22000
mm (w x h) consisting of eleven equal size units for eight openings. These are required for inspection and
maintenance of the radial gates and are proposed on the upstream side. The size of each unit shall be 14500 mm
x 2000 mm (w x h).

The stop logs are designed in accordance with IS: 5620-1985 for hydro-static head of 21.342 m corresponding to
FRL EL605.50 m and checked for MWL and seismic forces. The Stoplog units consist of downstream skin plate
and downstream sealing with horizontal girders, vertical stiffeners and end girders.

The stoplogs shall be operated under balanced head conditions which will be achieved by the crack opening of
top unit about 150 to 200mm. and through a lifting beam having automatic engaging & disengaging device and a
Gantry Crane of 50T capacity.
SPILLWAY STOPLOG GATES
Spillway Stop log Gate- Bill of Quantity

Total Wt. per

Total wt. of
Sl. Description Sub Item Weight (KG) unit (BOQ) in Total
all quantity Remark
No. KG Quantity
in KG

Top cum side seal seat 5992.23

1 2nd Stage EP Guide 2147.37 8740.33 8 Sets 69922.64

BOQ for one
Sill beam and groove rest beam 600.73 bay

Horizontal Girders 13175.34

11
Gate Leaf 22681.18 249492.98
Elements BOQ for one
2 Intermediate Skin plate, vertical stiffners 9505.84
element
elements
11
Seals and Seal clamp plates 2089.12 2089.12 22980.32
Elements
SPILLWAY STOPLOG GATES
Salient Features- Stoplog Gate
Sl.No. Components Specification

1 Type : Vertical laef- downstream sealing

2 Service : For isolation of a spillway gate. Balanced operation only

3 Clear width of opening : 14500 mm

4 Height of gate : 22000 mm

5 MWL : EL 609.80 m

6 FRL : EL 605.50 m

7 Sill level : EL 584.50 m

8 Design head : 21.342 m

9 C/C of side seal seats : 14650 mm

10 C/C of Side tracks : 15150 mm

11 Type of stoplogs : Sliding Type

SPILLWAY STOPLOG GATES
Salient Features- Stoplog Gate

Sl.No. Components Specification

12 Type of seals : IS:11855

(i) Side & Top seals : Solid music note type

(ii) Bottom seals : Wedge Type

Balanced head conditions achieved with the help crack opening

13 Operation :
about150mm to 200mm of top unit.
A detachable type semi automatic lifting beam with a gantry crane of
14 Hoisting Arrangement :
50T capacity.

15 Standards : IS:5620,IS:13591, IS:3177, IS:800 & IS:807

16 Testing Standards : IS: 7718

7 stoplog units are to be stored on dogging arrangement

provided on groove opening on 7 bays and balance will be stored in
17 Storage of stoplog units :
the gate storage area provided on the non overflow blocks
beyond spillway openings.
SPILLWAY STOPLOG GATE
PHOTO GALLERY
SPILLWAY STOPLOG GATE
PHOTO GALLERY
HYDRAULIC CYLINDER
Cylinder Technology- BOSCH REXROTH

A controlled spillway in a dam has radial gates to regulate the water flow through the dam. This gate
design allows nearly the full height of the dam to be used for water storage year-round, and flood
waters can be released as required by opening one or more gates. Opening and closing of the gates will
be done mechanically, by winches or by large hydraulic cylinders.

Cylinder

Radial gate cylinders are used for lifting, lowering and holding the radial gate, which rotates around a
central pivot point. Due to the natural tendency for lowering by its own weight, the cylinders are
designed only for pulling to open the gate. The synchronized cylinders can subsequently control the
lowering in an accurate way.

Technical data (most common projects)

Fluids: Mineral oil / bio degradable oil

Pressure range 140 to 220 bar
Operation temperature -20 °C to 60°C
HYDRAULIC CYLINDER
Cylinder technology- BOSCH REXROTH- TYPE CODE

The following table shows the type code that creates the basis for your specific large hydraulic cylinder.
Each code marks a basic specification. All specifications applicable in your cylinder are explained below

Type code

Field 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Type CY CRR A 10 U A

Field 1 Type Designation CY Cylinders with a single rod

Field 2 Application Code CRR Radial gate cylinder
External Mounting Shell MP5/
Field 3 Clevis on bottom with spherical bearing/ Trunnion on shell
Side MT4
Bore Dimension Bore range from 200 mm – 700 mm Specific dimensions on
Field 4
request
Rod dimension Rod range from 90 mm – 400 mm Specific dimensions on
Field 5
request.
Field 6 Stroke Length On request. References up to 16,500 mm
Field 7 Cylinder Construction A Bolted connection
Field 8 Revision Index 10
HYDRAULIC CYLINDER
Cylinder technology- BOSCH REXROTH- TYPE CODE
Type code

Field 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Type CY CRR A 10 U A

Oil connections rod &

Field 9 A/D/X BSP/SAE, 6000 PSI/Others
bottom side
Position Oil Connection 1/2/3/4
Field 10 0°/90 °/180°/ 270 °/ X (Other)
/5
Piston rod surface Enduroq 2000 / Enduroq 2200 / Chromium (only for
Field 11 Q/R/C
stainless steel piston rod material)
Mounting rod side Male clevis with spherical bearing/Female clevis/
Field 12 L/R/X
Other
Field 13 Cushioning U Not applicable
Field 14 Sealing system A Chevron seals
Field 15 Position sensor system C/T/W CIMS / Other positioning sensor / No option
Field 16 Option 1
Option 2 Maintenance free bearing / Rod extension /
Field 17 A/Y/W/X
None / Other
Field 18 Country code N/C Netherlands / China
HYDRAULIC CYLINDER
Cylinder technology- BOSCH REXROTH- Standard Dimensions

Based on technical knowhow and experience the table below to help for selects the size of cylinder.
This table shows the approximate sizes of hydraulic cylinders along with the pulling force they can
deliver at a nominal pressure of 200 bar. The results are applicable to trunnion mounted cylinders and
bottom eye mounted cylinders and are independent of stroke- and built-in length

Piston Piston rod Area ratio Areas Force at 200 bar1

Ø mm Ø mm φ A1/A3 Piston A1 mm2 Rod A2 mm2 Annulus A3 mm2 Pulling F3 kN

220 100 1,48 38.013 7.854 30.159 603

250 125 1,46 49.087 12.272 36.816 736
280 140 1,48 61.575 15.394 46.181 924
320 160 1,46 80.425 20.106 60.319 1.206
360 180 1,45 101.788 25.447 76.341 1.527
400 200 1,43 125.664 31.416 94.248 1.885
450 220 1,45 159.043 38.013 121.03 2.421
500 250 1,46 196.35 49.087 147.262 2.945
550 300 1,42 237.583 70.686 166.897 3.338
600 320 1,40 282.743 80.425 202.319 4.046
650 340 1,38 331.831 90.792 241.039 4.821
700 360 1,36 384.845 101.788 A2 283.057 5.661

A1

A3
HYDRAULIC CYLINDER
Cylinder technology- BOSCH REXROTH- Standard Dimensions

Gate cylinder include manifold and stainless steel piping, all produced and designed by Bosch Rexroth.
Together with position measurement equipment (integrated or external) the movement of the cylinder
can be controlled in detail.
HYDRAULIC CYLINDER
Cylinder technology- BOSCH REXROTH- MOUNTING STYLE

The mounting style represents the cylinder’s connection to the radial gate and interface with the dam
structure. The mounting style and position have effect on the cylinder’s behavior.

Mounting Position Optimization

With the required input, like e.g. gate radius, drive torque, position of gate pivot point and available
area for position of cylinder mounting in the dam structure, we determine the maximum and minimum
forces on the cylinder (at angle), calculate guide bearing pressure and deflection of the cylinder and
thus optimize the complete design of the cylinder. This results in a cost effective design, from which
we all benefit.

Shell Side
 The Clevis with spherical bearing MP5 mounting style is an clevis connection with a spherical bearing. The
special bearings reduce side forces (introducing wear) caused by small misalignments between dam and gate.
Bosch Rexroth only works with premium suppliers of spherical bearings.

 The Trunnion mounting MT4 mounting style is a connection in the form of a trunnion. This extra connection
creates extra stability and less deflection.

MT4
MP5
HYDRAULIC CYLINDER
Rod Side

 The female clevis is a double bladed connection that requires a male clevis
equipped with a spherical bearing to be mounted on your radial gate. This
connection is locked with a pin.

 The male clevis is a single bladed connection, mounted on your radial gate
with a female clevis. This connection is locked with a pin.

Cylinder integrated measuring system

The Bosch Rexroth cylinder integrated measuring system (CIMS), provides a highly reliable solution to
measure the movement of a hydraulic cylinder. Fully integrated in the hydraulic cylinder, CIMS requires
the application of the Enduroq 2000 series rod surface technology, as grooves underneath this coating
are measured by using magnetic sensor elements
HYDRAULIC CYLINDER
Chevron sealing technology
To form the large hydraulic cylinders tribological system, each cylinder is equipped with a scraper,
seals and bearing strips

SCRAPER
Scrapers prevent dirt from being dragged into the hydraulic cylinder. Bosch Rexroth offers two types of
scrapers: standard and special self lubricated. Self lubricating scrapers are used in applications with
insufficient lubrication properties of the hydraulic fluid.

Standard scraper Self lubricated scraper

Bearing strips
Bearing strips are used to ensure low friction between the moving parts in the cylinder. They reduce
wear and increase the cylinder’s lifetime.

Self lubricated Standard

HYDRAULIC CYLINDER
Chevron seals
Chevron seals are used to seal off piston rods and pistons in hydraulic cylinders, preventing oil loss
from the hydraulic system. With its robust design, Chevron Seals have been developed to withstand
heavily damaged surfaces of the counter parts.
Chevron seals are designed for applications with a long lifetime and few movement. Performing best at
medium speeds (>0,05 m/sec - <0,5 m/sec), the minimum life time under normal circumstances is
500 km of piston rod movement. Finally, Chevron seals are maintenance friendly. Bosch Rexroth uses
two different types of materials to get the best fit with your application:

NBR-fabric material is designed for piston rods with chromium surface technology. It gives very good
wear resistance and has no delamination.

UHMWPE material is developed for the piston rods with Enduroq 2000 series surface technology.
produced with a special process that gives a very good wear and creep resistance.

NBR-fabric UHMWPE material

HYDRAULIC CYLINDER
Deflection simulation

The DBR is used to calculate the deflection and buckling safety of hydraulic cylinders. Typical for the
radial gate is that its cylinder’s angle changes when lifting the gate. The more the gate is lifted, the
more horizontal your cylinder has to transfer its force. As the picture below shows, this angle change
increases the stress on the piston rod and the seals.
DSB STOPLOG GATE
Photo Gallery
DSB GANTRY CRANE
Photo Gallery
DAM VIEW
Photo Gallery
DAM VIEW
Photographs- Downstream Side
DAM UPSTREAM VIEW
Photographs- Reservoir Pounding
DAM VIEW
Photographs
POWER HOUSE VIEW
Photographs
BYPASS GATES
Photo Gallery
BYPASS GATES
Photo Gallery
BYPASS GATES
Photo Gallery