ZUNGERU Hydropower Plant

Tailrace maintenance gate and gantry crane

 General

• The water diversion and power generation system of Zungeru Hydro Power Station is located on
the left bank of the dam, sixteen (16) intake trash racks are set for sixteen (16) openings, one (1) set
intake maintenance stoplogs for four (4) openings, four (4) intake quick-acting emergency gates for
four (4) openings. Eight (8) tailrace maintenance gates for eight (8) openings are set at the outlet of
the turbine draft tubes.
• The main purpose of tailrace maintenance gate is to retain water after the gate lowers when the
unit needs maintenance and is locked at tailrace platform [EL.155.500] when it is not in use.
• The tailrace maintenance gate adopts submerged openings plane sliding gate. The gate is
lowered (closed) in balance water and raised (opened) in balance water after a bypass water filling
valve fills water for pressure balance. Water head difference for gate raising (opening) is ≤ 2m.
• The hoisting equipment of tailrace maintenance gate is one (1) set of one-way gantry crane with a
capacity of 2 × 500kN. The lifting height is 45m and the lifting height above rail is 5.0m. The tailrace
maintenance gate is operated by a one-way gantry crane equipped with hydraulic automatic lifting
beam.
Tailrace maintenance gate
 Tailrace maintenance gate

^233.000

5717?.3OO

V 171.500

-,50,00c
V155.500
V 152.800

v 148.500

■y 14-5.500

^139.500

V'34.500

V 129.500
Consolidated
Grouting
Depth 15m Consolidated Grouting ^123.500
rainoqe hole Depth 10m
Tailrace maintenance gate
 Tailrace maintenance gate

ISOMETRIC VIEW

Layout of tailrace maintenance gate and gantry crane

 Tailrace maintenance gate

Technical data of tailrace maintenance gate

S.No Item Data
.
1 Opening style Under water
2 Opening size (width x height) 7.042m x 7.5m
3 Design head 43.84 m
4 Operating condition Raised \ lowered in balance water
5 Water-filling way for pressure balance Bypass valve
6 Operating water head difference 2.0 m
7 Type of support Slide way
8 Hoist style Gantry crane
9 Hoist capacity 2x500kN
 Tailrace maintenance gate

Opposite wheel Side wheel device

device
Slide way device
Structure and outline drawing of tailrace maintenance gate
 Tailrace maintenance gate

The tailrace maintenance gate is composed of plane sliding gate, gate embedded parts, gate
leaf and seal devices installed on the gate leaf, slide way devices, side wheel devices, opposite
wheel devices, inter segment connection devices. The gate is manufactured in segments in the
factory and the segments are connected as a whole through the inter segment connection
devices during installation.

The gate is supported by slide way devices. The simply supported side wheel is side support
of the gate and the hinged elastic opposite wheel device is the opposite support of the gate.
The gate slot is type I slot. The embedded parts of the gate slot are in welded steel structures,
including main rail, opposite rail, bottom sill and lintel device.

The gate adopts single lifting point and is equipped with twelve (12) slide way devices, twelve
(12) side wheel devices and twelve (12) opposite wheel devices.
 Tailrace maintenance gate

The slide way devices are installed on the wing of the side beam upstream of the gate leaf and
the opposite wheel devices are installed on the side beam wing on the downstream side of the
gate leaf. The side wheel device is installed on the wing of the gate leaf cross beam.

The gate is sealed on four sides and the seal devices are set at the upstream side of the gate
leaf.
bypass valve and bypass pipeline Tailrace maintenance gate

Vent pipe

The tailrace maintenance gate is equipped with bypass valve and bypass pipeline as the
pressure balance valve of the gate. A vent pipe is set upstream of the gate as air inlet and
exhaust channel during draft tube filling and draining water.
 Tailrace maintenance gate

Description of gate structure

Top segment gate Middle gate Bottom gate

leaf leaf leaf
 Tailrace maintenance gate

Gate leaf
• The gate leaf is manufactured in three segments and is a welded composite structure.
• Each segment of gate leaf is composed of panel, cross beam, side beam, lifting lug and
other necessary components. The panel is located on the upstream side of the gate
leaf. Each segment of gate leaf is equipped with lifting lugs. The web of the cross beam
is provided with water leakage holes.
• Each segment of gate leaf is 8.242m wide and panel thickness is 22mm. The top
segment of gate leaf is 2.55m high, the middle gate leaf and bottom gate leaf are 2.65m
high.
• A locking support beam is arranged outside the side beam of each gate leaf, so that the
gate leaf can rest on the locking support beam.
• The alignment device between the gate and the hydraulic lifting beam is set outside the
two lifting lugs of the top segment gate leaf.
Tailrace maintenance gate

Seal device

Gate seal
 Tailrace maintenance gate

• Each segment of tailrace maintenance gate adopts four side seal devices, which are
composed of top seal device, side seal device, bottom seal device and seal device between
gate leaves.
• "P" shape seal device is adopted for top seal and side seal, which are fixed on the upstream
side of the gate leaf panel with bolts and pressing plates. The bottom seal device adopts
stripe seal and is fixed at the bottom of the upstream side of the gate leaf panel with bolts
and pressing plates.
• The customized special-shaped seal is adopted for the seal between gate leaves and is fixed
at the bottom of the top segment gate leaf and the middle segment gate leaf with bolts and
pressing plates.
Tailrace maintenance gate

Locking device
 Tailrace maintenance gate

Lintel device, guide rail and bottom sill

• The gate slot is I-shaped. The embedded parts of gate slot
mainly include main rail, opposite rail, bottom sill, lintel
device, etc.

The lintel device, guide rail and bottom sill are welded by
profile steel and steel plate. After the on-site installation and
adjustment meet the requirements, they shall be embedded in
the concrete foundation in the second casting.

The lintel device is installed on the top of the channel at the

junction with the upstream gate slot as top seal seat. The
bottom sill is installed at the bottom of the gate slot as bottom
seal seat.
 Tailrace maintenance gate
Lintel device, guide rail and bottom sill

The guide rails are installed on both sides of the gate slot
along the channel direction and are divided into main rail (on
the upstream side of the gate slot) and opposite rail (on the
downstream side of the gate slot). The main rail is used for the
main wheel and is also a force transfer member that transfers
the water pressure borne by the gate leaf to the concrete
foundation. It is also a side seal seat. The opposite rail is only
used as the rolling rail of the opposite wheel device.
Gantry crane

10.

1. cable drum
2. hoist mechanism
3. crane travelling mechanism.
4. rail clamp
5. locking system
6. buffer
7. cable drum
8. gantry frame
9. hydraulic lifting beam

driver’s cab 11. electric hoist

12. crane travelling limit system
13. machine house 14. rail & accessory
15. electric system 16. rail brush

2x500 kN gantry crane

 Gantry crane

The 2x500kN one-way tailrace gantry crane is installed on the tailrace platform [EL.159.00m] mainly
for raising the tailrace maintenance gate.
Technical parameters of gantry crane
Lifting capacity 2x500 kN
Lifting height (Above track) 5m
Lifting height (All) 45 m
Lifting speed 0.25 ~ 2.5 m/min
Pulley multiple 2x4
Dia. of drum ^ 800 mm
Wire rope 24ZAB6xK36WS+IWR-1670 ZS
Distance between hoist line 4.65 m
Motor YZRF225M1-6, 2x30Kw 980 r/min
Brake YWZ9-315/E50, 400~630 N.m
Reducer H4S13-250, i=1:250
 Gantry crane

Technical parameters for crane travelling

Travelling speed 2~20 m/min
Crane span 4m
Lifting load while traveling 2x250 kN
Wheel Dia. ^ 710 mm
Rail type QU100
Motor YZPEJ132M-6, 2x5.5Kw 960r/min
Brake With the motor
Reducer DLKA09-YZPEJ132M2-6P, i=1:8.9

Technical parameters for electric hoist

Lifting capacity 3t
Lifting height 12 m
lifting speed 8 m/min
Travelling speed 20 m/min
 Gantry crane

Description of crane
The gantry crane consists of gantry, operator
cabin, crane travelling mechanism, anemometer,
lightning rod, 30kN maintenance crane, machine
house, rail clamp, grounding device, cable drum,
hydraulic automatic lifting beam, rail, stop,
embedded parts and crane power supply device,
electric drive and control equipment.
 Gantry crane
Hoisting mechanism

1. left frame
2. left winding drum system
3. fixed pulley device
4. balance pulley device
5. right frame
6. right winding drum system
7. movable pulley device
8. motor
9. brake
10. coupling
11. gearbox
12. synchronizing shaft
13. coupling
14. wire rope
15. load sensor
 Gantry crane
Hoisting mechanism
 Gantry crane

Hoisting mechanism

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 Gantry crane

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Brake
 Gantry crane

Crane travel mechanism

7800

The crane traveling mechanism is equipped with 4 groups of wheels, including 2 driving wheel groups, 2 slave
wheel groups, 4 groups of wheels are arranged symmetrically.
The driving wheels are driven by a "three-in-one" power unit composed of motors, brakes and gear boxes. When
the motor is powered on, the brake is released. The output shaft of the motor transfers the torque to the gearbox.
After gear reduction, the gear box passes the torque to the low speed shaft.
 Gantry crane

Lifting device
The gantry crane is equipped with 1 hydraulic lifting beam and is used to lift the tailrace maintenance gate.

The hydraulic lifting beam is composed of a beam body, a hydraulic pin inserting device installed on the beam
body, hydraulic pump unit, signal device, underwater fast electric cable plug, support guide, underwater camera,
etc.

The beam body is a beam shape lifting tool welded by steel plate and is a box girder structure. There is a taper
positioning sleeve and one pin inserting oil cylinder respectively at the left and right at the bottom of the beam
body.
 Gantry crane
Lifting device

When the lifting beam is lowered to the top of the gate in place, the alignment signal indicator is on.
The pin inserting cylinder starts to push the pin to connect the gate.
When the pin passes through the lifting lugs of the gate in place, the pin-in-place switch is connected
 Gantry crane

and the pin-in-place indicator is on.

After the pressure before and after the gate is balanced, the gate is lifted out of the gate slot.
 Gantry crane

Arrangement drawing of operating console

The operating table is provided with crane and hoist main controller, selector switches, buttons and
indicators.
LEFT CONTROL RIGHT CONTROL
DESK DESK

Down

O LKs

Crane
L
Left J Crane Right
Up
LK
Control Rod of lifting mechanism
Control Rod of Crane

1 2
PAI PAI
12

SB5 SB6
3 4 56
HLO H
HL03 HL04 3456
l L02

7 8 9 10 HLl HL2 SB7 SB8

HP0 HI 7 8 9 10
HL07 HL08
5 .06
SB3 SB4 SAI SA2
1
11 13 14
2 11 12 13 14
HL0 H
HLll HL12 SI SB2 SBl SA
9 L 10
 Gantry crane

Elements of left operating console

No. Code Name Description No. Code Name Description

1 PA1 Buzzer Fault alarm 8 HL06 Indicator Wear the pin in place of right side

2 PA2 Buzzer Limiter alarm 9 HL07 Indicator Out of pin in place of left side
3 HL01 Indicator Anemometer alarm 10 HL08 Indicator Out of pin in place of right side
Oil pump working of hydraulic
4 HL02 Indicator 11 HL09 Indicator Rail clamp release
lifting beam

5 HL03 Indicator Fall in place of the left side 12 HL10 Indicator Crane travelling allowed
6 HL04 Indicator Fall in place of the right side 13 HL11 Indicator Motor heating

7 HL05 Indicator Wear the pin in place of lift side 14 HL12 Indicator Water filling indicator
 Gantry crane

Elements of right operating console

No. Code Name Description No. Code Name Description

1 SB5 Select switch Water filling switch 8 SB4 Button Fault reset

2 SB6 Select switch Rail clamp switch 9 SA1 Select switch Standby 1 (Reserve 1)

3 HL1 Indicator Power supply indicator 10 SA2 Select switch Standby 2 (Reserve 2)

4 HL2 Indicator Working indicator 11 S1 Button Emergency stop button

5 SB7 Button Standby 1 (Reserve 1) 12 SB2 Button Stop

6 SB8 Button Standby 2 (Reserve 2) 13 SB1 Button Starting

7 SB3 Select switch Motor heating 14 SA Key switch Electric lock

Electrical equipment of gantry crane

The electrical system of the crane consists of electrical equipment and electrical wiring.
 Gantry crane

The electrical system of the gantry crane is mainly composed of the electrical drive system of the
hoisting mechanism, electrical drive system of crane traveling mechanism, hydraulic lifting beam
drive system, gantry crane operation control system, gantry crane lighting control system, safety
monitoring management system, grounding system, etc.
Main electrical equipment includes: one power supply / PLC control cabinet A1, one hoisting / lifting
beam control cabinet A2, one crane control cabinet A3, operator cabin lighting box (+ C1), machine
house lighting box (+ C2), operator cabin console, etc.
The power supply / PLC control cabinet A1 is placed in the machine house. The first function is for
on-off control of power supply, protection against circuit overcurrent, short circuit, voltage loss and
various action interlocking. The second function is to collect the limit protection signal of each
mechanism and the control signal of operating console through the PLC in the cabinet for logic
control and system monitoring of each mechanism of gantry crane.
 Gantry crane

Electrical equipment of gantry crane

The lifting beam control cabinet A2 is placed in the machine house. The main components in the
cabinet include main lifting frequency converter, lifting brake contactor and lifting motor fan
contactor, to control the hoisting mechanism and lifting beam.
Crane control cabinet A3 is placed in the machine house and is mainly equipped with crane
frequency converter, crane brake contactor and crane motor fan contactor. It is used for left and right
traveling and limit travel control of crane, zero position protection, interlocking control between rail
clamp and traveling mechanism, etc.
The operator cabin lighting box C1 is placed in the operator cabin, mainly includes circuit breakers
for controlling floodlights, ladder lighting, operator cabin lighting, and power sockets.
The lighting box C2 of the machine house is placed in the machine house and is used for controlling
the work lighting, ventilation and maintenance power of the machine house. .
 Gantry crane

Electrical equipment of gantry crane

The safety monitoring and management system uses the load opening instrument, lifting beam
signal display instrument and camera of the hoisting mechanism to display the working status and
fault alarm of lifting and lifting beam mechanism respectively.

Each control cabinet of the gantry crane is equipped with a temperature and humidity controller,
which is used for dehumidification and heating in automatic control cabinet. The temperature and
humidity signal detected by the sensor is sent to the temperature and humidity controller. When the
humidity exceeds setting value, the controller outputs signal and the heater works automatically.
When the temperature after heating is higher than the setting value, the heater stops automatically.
 Gantry crane

Safety operation requirements of gantry crane

(1) The operator must have certain training and have post card, good operation skills, and have read
the operation manual and maintenance manual carefully, understand the various performance,
structure and maintenance requirements of the crane.
(2) The use, repair and maintenance of all outpurchasing parts shall be carried out in accordance
with the requirements of the manufacturer's instructions.
(3) In case of strong wind or thunder, the gantry crane should be stopped. Pay attention to the
weather forecast. If the wind may reach more than 10 levels of gales, reliable safety measures should
be taken before strong wind comes.
(4) In accordance with the maintenance requirements, do regular lubrication, inspection and
commissioning work.
 Gantry crane

Safety operation requirements of gantry crane

(5) The operator cabin coordinates with the ground commanders, follows the commander signal
before proceeding. However, command violating safety procedures and potentially dangerous
incidents shall be refused.
(6) Before each start, a warning signal must be emitted for movement.
(7) Overloading is not allowed.
(8)When the operator operates the crane, the speed shall be accelerated gear by gear. The speed
shifting should be smooth. Under normal operation, when the operating direction of each mechanism
is changed, the handle should be put back to zero position, pause for while and then is put into
reverse operation. It is not allowed to change directly the handle direction.
Safety operation requirements of gantry crane

(9) In operation, the operator shall always pay attention to following cases: if the motor and
electrical equipment have abnormal sound. if there are any abnormal heating in the motor and all
 Gantry crane

bearings. In case of abnormal case, stop the crane immediately to remove the fault.
(10) When the gantry crane is running, the operator cannot leave the operator cabin.
(11) In case of emergency, stop the crane immediately by pressing the emergency stop button on the
operating console or front panel of the control cabinet to cut off the main power supply.
(12) When the gantry crane is going to stop after work, the lifting tool shall rise to the upper limit.
Move the control handle to zero position. Apply the track clamp and anchor device, and disconnect
the main power supply.
(13) After operation, the operator shall hand over the gantry crane handover minute book to the
successor operator, and report the problems found in the operation to the department concerned
and the successor operator.
Operation of gantry crane

For safety reason, the control systems for main hoist, aux. hoist, traversing mechanism and traveling
mechanism are interlocked each other, any two mechanisms can not be operated at same time.
 Gantry crane

Before operation, the unloaded hydraulic gripper beam to be used should be tested on the dam, in
which the hydraulic gripper beam should be subjected to the telescopic action of the hydraulic
cylinder, checking that the cable and oil pipe joints should be intact and that the hydraulic cylinder
action should be normal. Otherwise, treatment must be carried out to avoid water seepage failures in
various parts of the hydraulic system after the gripper beam has entered the water.

Operation of crane travel

The crane traveling mechanism is operated in the operator cabin and is operated by the main
controller (-LKd) on the left operating console.
When operating the crane, the door of the operator cabin and the safety door switch of each railing
must be closed, otherwise, the crane cannot be operated due to safety protection.
Before operating the crane, first remove the crane anchor bolt, then turn the RAIL CLAMP selector (-
SB6) on the right operating console to the "Release" position. When the rail clamp and anchor bolt
are fully released, rail clamp release indicator (-HL09) is normally ON. The crane can be operated
 Gantry crane

only after the rail clamp and anchor bolt are loosened in place.
The operation direction of the main controller is left and right. Pull the handle to the left, the gantry
crane moves to the left. Push the handle to the right, the gantry crane moves to the right. There are
four steps on the left and four steps on the right. The speed increases step by step. The handle can
be turned to any step according to the requirements of speed.
Operation of crane travel

Before the gantry crane moves each time, press the foot switch and the warning bell rings to remind
the personnel around the gantry crane to pay attention. At this time, the gantry crane will run.
Release the foot switch to stop the warning bell.
When the gantry crane traveling mechanism is running, the audible and visual alarms at both ends of
the end beam send out audible and visual alarms.
When the left or right movement reaches the limit position, the buzzer (-PA2) lights up and gives an
alarm. However, it is forbidden to quickly reverse direction.
 Gantry crane

Operation of crane travel

(1) Zero reset

Before crane traveling operation, if the main controller (-LKd) handle is not in the zero step, it should
be turned back to zero step first.
The indicator "Crane Traveling Allowed" (-HL10) on the right console is normally on, indicating that
the crane traveling zero position protection is normal and the crane can be operated. If the indicator
"Crane Traveling Allowed" (-HL10) is OFF, it indicates the crane traveling zero position protection
takes action, there is fault or protection takes action, check the reason before operation. (2)
Operation of crane traveling leftward
Pull the main controller handle (-LKd) from the zero position to the left step by step, the gantry crane
moves to the left.
When the gantry crane moves left at the limit position, it stops automatically and the buzzer (-PA2)
on the operating console rings. At this time, the gantry crane can only move to the right.
 Gantry crane

Operation of crane travel

(3) Operation of crane traveling rightward

Push the main controller handle (-LKd) from the zero position to the right step by step, the gantry
crane moves to the right.
When the gantry crane moves right to the limit position, it stops automatically and the buzzer (-PA2)
on the operating console rings. At this time, the gantry crane can only move to the left.
(4) Operation of stop
When the gantry crane needs to stop running after it moves left and right to the required position,
pull the main controller (-LKd) handle back to the zero position, the gantry crane stops.
Operation of the hoist mechanism

The main hosting mechanism is operated in the operator cabin and is operated by the main
controller (-LKs) on the right console.
The operation direction of the main controller is forward and backward. Push the handle forward to
 Gantry crane

lower the hook. Pull the handle backward to lift the hook. There are four steps for lifting and four
steps for lowering. The speed increases step by step. The handle can be turned to any step
according to the speed requirements.
(1) Zero reset
Before operating the hoisting mechanism, if the main controller (-LKs) handle is not in the zero
step, it should be pulled back to zero.
Operation of the hoist mechanism

(2) Operation of lifting

Pull the main controller (-LKs) handle back from the zero position step by step. The hook rises.
When the hook rises to the upper limit, it automatically stops and the buzzer (-PA2) on the operating
console rings, only the lowering operation can be performed at this time. If the hook load exceeds
110% of the rated load, the hoist mechanism stops lifting due to overload, the falling control is not
affected at this time and the object can fall.
(3) Operation of lowering
 Gantry crane

Push the main controller (-LKs) handle forward step by step from the zero position, the hook falls.
When the hook moves downward to the lower limit, it stops automatically and the buzzer (-PA2) on
the operating console rings. At this time, the hook can move upward only.
Operation of the hoist mechanism

(4) Operation of stop

When the hoisting mechanism needs to stop lifting after the hook rises and falls to the required
position, pull the main controller -LKs handle back to the zero position, the hoisting mechanism
stops running.

Notice:
Before a heavy object is lifted every time, the "hook test" operation must be carried out first, that is, pull the
main controller (-LKs) handle back to the zero position when the object is about 100mm away from the
ground. After confirming that there is no fault, continue the lifting or lowering operation.
 Gantry crane

Operation of lifting beam

The operating switches and indicators of the hydraulic automatic lifting beam are installed on the
right console. The automatic lifting beam shall cooperate with the main hook.
(1) Inserting of lifting pin
The hook shall move slowly when the hook is lowered close to the gate. When the locating pin shaft
on the lifting beam is inserted into the locating hole on the gate in place, "Left descent in place"
indicator (-HL03) and "Right descent in place" indicator (-HL04) are ON. At this time, turn the
"Through pin / Release pin" knob (-SA1) to the "Through pin" position for pin inserting.
When the pin is in place, the "Left through pin" indicator (-HL05) and "Right through pin" indicator (-
HL06) on the console are ON. Turn the "Through pin / Release pin" knob (-1SA1) to the middle
position, at this time, the main hook can be lifted for lifting the gate.
Operation of lifting beam

(2) Withdrawing of lifting pin

 Gantry crane

When the gate is in position, turn the "Through pin / Release pin" knob (-SA1) to the "Release pin"
position for withdrawing the pin.
When the pin is in place, "Left release pin" indicator (-HL07) and "Right release pin" indicator (-
HL08) are on, then turn the "Through pin / Release pin" knob (-SA1) back to the middle position.
 Operation

Raising / lowering of tailrace maintenance gate

Raising the tailrace maintenance gate

(1) Confirm the relative condition meeting the gantry crane operation, such as weather, wind
speed, power supply, etc.
(2) Start the gantry crane and move it to the storage position of the hydraulic lifting beam. Install
the hydraulic lifting beam to the lifting rod of the hoisting mechanism. Power on to check and
confirm that the pin inserting and withdrawing of the lifting beam are normal, then lift the lifting
beam above the safe height.
(3) Move the gantry crane to the position where the gate needs to be raised. Operate the hoisting
mechanism to let the lifting tool fall slowly. Make the hydraulic lifting beam and its guide wheel
enter the gate slot and fall onto the gate leaf along the slot.
(4) Turn the "Through pin / Release pin" knob (-SA1) to the "Through pin" position. After the lifting
beam lifting rod passes through the gate lifting hole, turn the "Through pin / Release pin" knob (-
1SA1) to the middle position.
 Operation

Raising / lowering of tailrace maintenance gate

Raising the tailrace maintenance gate

(5) Open the bypass valve to fill water to the draft tube. After the pressure in front and rear of the
gate is balanced, operate the gantry crane to lift the gate to the top.
(6) After the gate is placed on the locking beam, turn the "Through pin / Release pin" knob (-SA1)
to the "Release pin" position to pull the lifting beam lifting rod out of the gate lifting hole.
(7) After the lifting beam withdraws the pin in place, turn the "Through pin / Release pin" knob (-
SA1) to the middle position, then lift the lifting beam.
(8) Move the gantry crane to unload the lifting beam to the storage position.
(9) Move the gantry crane to the parking bay. Lift the hook to a specified height; Lock the rail
clamps; Reset the handle; Cut off the power supply; Insert the anchor device.
 Operation

Raising / lowering of tailrace maintenance gate

Lowering the tailrace maintenance gate

(1) Confirm the relative condition meeting the gantry crane operation, such as weather, wind speed, power
supply, etc.
(2) Start the gantry crane, move to the storage position of the hydraulic pick-up beam, Install the hydraulic
lifting beam on the hoisting mechanism lifting rod; Power on to check and confirm that the pin inserting and
withdrawing of the lifting beam are normal, Then lift the lifting beam above the safe height.
(3)Move the gantry crane to the slot where the tailrace maintenance gate will be stored. Operate the
hoisting mechanism to let the lifting tool fall slowly, and the hydraulic lifting beam and guide wheel can enter
the gate slot and lower on the gate along the slot.
(4) Turn the "Through pin / Release pin" knob (-SA1) to the "Through pin" position. After the lifting beam
lifting rod passes through the gate lifting hole, turn the "Through pin / Release pin" knob (- 1SA1) to the
middle position.
 Operation

Raising / lowering of tailrace maintenance gate

Lowering the tailrace maintenance gate

(5) Lift the lifting beam and remove the locking beam.
(6) After the gate is placed on the bottom sill along the gate slot, turn the "Through pin / Release pin" knob
(-SA1) to the "Release pin" position. Pull the lifting beam lifting rod out of the gate lifting hole.
(7) After the lifting beam retracts the pin in place, turn the "Through pin / Release pin" knob (-SA1) to the
middle position, then lift the lifting beam.
(8) Move the gantry crane to the pick-up beam storage position and remove the lifting beam.
(9) Move the gantry crane to the parking bay and lift the hook to a specified height. Lock the rail clamps;
Reset the handle; Cut off the power supply; Insert the anchor device.
 Maintenance
Gate maintenance
Routine Maintenance
• (1) Routine maintenance interval: It mainly includes tightening, adjusting and lubricating which shall
be done once every month.
• (2) Temporary repair: It refers to the non-scheduled repair on specific faults at any time.

• (3) Routine maintenance items of the gate

• 1) Remove trash from the gate grid beams, gate slot, head sill etc. The normal operation
of the gate shall not be affected.
• 2) Check and tighten the bolts at connection positions, such as water-seal bolt, lug bolts, etc.

Gate maintenance
Routine Maintenance
• 3) Check the rotation condition of the side rollers. The rollers can rotate flexibly, no jamming.
 Maintenance
• 4) Check the wear of the forward and reverse sliders for damage.

• 5) Inspect all main welds on the gate leaf, the gate leaf and other structures whether they are deformed,
loosen weld, crack and other defects.

• 6) Check the water-seal for tightness on the water-seal seat, water-seal worn-out and aging,
and water-seal local damage. The bolts fixing water-seal member shall not loose fall off and be damaged.

Gate maintenance

Minor repair
1 - 2 times of minor repairs in every year in general.
Items of minor repair:
(1) Finish the items of routine maintenance.
(2) Check, repair or replace the water-seal partially damaged. The water leakage of the gate water seal after
repairing shall not exceed 0.1L/ s.m.
(3)Check or replace the seriously rusted or damaged bolts of the gate, forward slide block, reverse slide block,
side guide wheel and water stop system.
 Maintenance
(4) Check and weld by repair the gas cavities at water flowing area. The surface of the area repaired shall be
smooth, no uneven area.
(5) Local serious rusty welded joint processing.
(6) The rusted areas on the gate leaf, embedded part shall be painted with rust-proof material.
Gate maintenance

Major repair
It is the periodic inspection and restorative repair in the life cycle, so that the gate is up to the original safe,
reliable and good operating performance. The major repair shall be carried out once in 6- 10 every years in
general.
(1) Marks for major repair on the gate
1) Gate water seal leakage is serious and affects the normal operation of the gate.
2) Gate panel, grid and other parts are deformed.
3) The gate is corroded seriously. The side roller can not rotate. Water-seal is aged or worn out seriously.
4) The forward slider is severely worn, damaged or aged.
Gate maintenance
 Maintenance
Major repair
(2) Items of major repair
1) All items of minor repair
2) Gate panel, grid and other parts deformed and seriously rusty shall be reinforced.
3) Overhaul, replace or repair the damaged parts of the forward slider, reverse slider and side wheel.
4) Replace all water stops, forward sliders and reverse sliders that are worn to the service limit or have been
aged.
5) Inspect axle and axle sleeve at moving areas. Replace or repair seriously worn out parts.
6) Rust cleaning, surface anti-corrosive treatment.
Maintenance of gantry crane

Maintenance system of gantry crane

The running state of gantry crane is directly related to personal and equipment safety. Therefore, the
management and maintenance of gantry crane is one of the important links to ensure safe operation.
The maintenance of gantry crane is divided into daily maintenance, class I maintenance and class II
 Maintenance
maintenance.
Routine Maintenance
As daily maintenance, the gantry crane should be maintained once a day, that is, before work or after work.
According to the actual use frequency, the frequency of daily maintenance can be appropriately reduced, but at
least once a week.
Maintenance of gantry crane

Maintenance system of gantry crane

Class I maintenance
Maintenance frequency: Once a month.
(1) Check whether all external bolts and nuts of the gantry crane are fastened.
(2) For the "three-in-one" device of crane and trolley operating mechanism, the maintenance shall be carried
out according to the instructions. The maintenance on the gear box of hoisting mechanism shall also be carried
out according to the instructions. Check the oil quantity of gearbox. The amount of lubricating oil filled in the
gear box shall be filled according to the nameplate or oil mark of the oil level gauge.
 Maintenance
(3) Check the condition of each lubricating part and fill lubricating grease in time.
Maintenance of gantry crane

Maintenance system of gantry crane

Class I maintenance
(4) Check all electrical insulation. Measure the resistance of any two grounding points of the gantry crane, the
resistance shall be less than 0.5. The insulation of the cable to the ground shall be bigger than 1M; Insulation
resistance of hoisting motor, crane running motor and the electric control cabinet shall not be less than 1M.
(5) Check whether the wire screws of all control cabinets and terminals are fastened.
(6) Check the lubrication of the brake hydraulic pusher. If the oil is found to be deteriorated, replace the
lubricating oil. If the oil quantity is insufficient, add oil to the standard value.
Maintenance of gantry crane

Maintenance system of gantry crane

 Maintenance
Class II maintenance
Maintenance frequency: Once every six months.
(1) Perform the above class I maintenance.
(2) Remove the dirt on the grease surface. Dismantle the mechanism and wash the rolling bearing with
kerosene; add grease.
(3) Check the insulation of all electrical equipment. Measure the resistance of any two grounding points of the
gantry crane, the resistance shall be less than 0.5. The insulation of the cable to the ground shall be bigger than
1M. Insulation resistance of hoisting motor, crane running motor and electric control cabinet shall not be less
than 1M.
 Maintenance

Maintenance of gantry crane

Maintenance system of gantry crane

Class II maintenance
(4) Check the bearing condition of the fixed pulley of the gantry crane, add grease.
(5) Check whether the screws and control cabinets are fastened.
(6) Check the lubricating oil quantity of the gearbox, oil quantity and lubrication of hydraulic
pusher. If the oil quality is found to be deteriorated, replace the lubricating oil. If the oil
quantity is insufficient, add oil to the standard position.
 Maintenance of wire rope
If one of the following situations occurs, the steel wire rope must be replaced.
 Maintenance of wire rope
If one of the following situations occurs, the steel wire rope must be replaced.
 Maintenance of wire rope
If one of the following situations occurs, the steel wire rope must be replaced.
 Maintenance of wire rope
If one of the following situations occurs, the steel wire rope must be replaced.
END