ms 12.doc 7.6.13

NEW KHANKI BARRAGE AND AUXILARY WORKS Method Statement - Mechanical Works

MS-12 METHOD STATEMENT FOR MECHANICAL WORKS

Doc No. MS MECHANICAL 12‐ ‐ Rev. 0 Method Statement for Mechanical Works 1 of 27


TABLE OF CONTENTS

Sr. Description Page #1 Objective 32 Scope 33 References 34 Abbreviations / Definitions 45 Responsibilities 46 Procedure 47 Tools and Equipment 258 HSE Instructions 269 Related Documents 27



1. Objective The objective of this method statement is to provide guidelines for the assembly, installation and commissioning of gates at various locations of New Khanki Barrage including the Sluice gate guides, embedded parts, operating gears etc. The relevant equipment / parts shall be delivered to site prefabricated as per approved construction/shop drawings.

2. Scope Gate equipments to be installed and their locations are 1.Radial Gate Equipment for barrage main weir

Gate leaves 60 ft x14ft- 55 nos.Arms & skin plate.Sealing arrangement.Sill beam Side sealing plates and embedded parts.Complete hoisting system with electrification.

2. Radial Gate Equipment at Left & right under sluice portion of Barrage Gate leaves 60 ft x 16.5ft- 10 nos.Arms & skin plate.Sealing arrangement.Sill beam Side sealing plates and embedded parts.

Complete Hoisting system with electrification. 3. Radial Gate Equipment at Head Regulator, left side of main weir at upstream

Gate leaves 30 ft x 11 ft- 6 nos.Arms & skin plate.Sealing arrangement.Sill beams, side & top sealing plates with embedded parts.Complete Hoisting system with electrification.

4. Fish Ladder Slide Gate Equipment at Left & right side of main weir at Downstream

Gate leaves 3.5 ft x 6.5 ft- 02 nos.Skin plate and vertical members.Sealing arrangement.Sill beams & embedded parts.Complete Hoisting system.

5. Stoplog Sets (02 sets) for main barrage gates. 1) Vertical lift stop logs (02 Sets). 2) 60 feet X 20 feet in sections, as approved by the engineer. 3) Embedded metal parts 65 sets. 4) Automatic engagement/disengagement

Stacking yard arrangement. 6. Pumping station. 1) Pumping station’s design will be as per specification of Eng’r. keeping in mind latest tools

and software are used to eliminate any risk in future.2) Designing of Pumping station to feed 100 Cusecs high level channel.

Doc No. MS MECHANICAL 12 ‐ ‐ Rev. 0 Method Statement for Mechanical Works 3 of 27


3. References

Following documents are considered as reference documents:

Applicable codes and standards Steel construction manual, AISC (7th edition). Design of hydraulic steel structures by U.S Army corps of engineers manual EM 1110-2-

2105. Design of spillway tainter gates by U.S Army corps of engineers manual EM1110-2-

2702 1st January 2000. Valves, gates and steel conduits by United States department of the interior bureau of

reclamation. Design of hydraulic gates by Paulo C. F. Erbisti Hand book of hydro-electric engineering by P. S. Nigam Design of concrete structures by Nilson

4. Abbreviations/Definitions

SM Site ManagerPQP Project Quality PlanQIP Quality Inspection PlanI/C In chargeQA&QC Quality Assurance/Quality ControlBBS Bar Bending SchedulePPE Personal Protective EquipmentNGL Natural Ground LevelHSE Health, Safety & EnvironmentBA Business AreaFRM Form

5. Responsibilities

PM/SM will be responsible for the initialization of the work, as well as to manage the resources to perform their respective activities in compliance with the quality, schedule and safety requirements of the project.

Area In charge will ensure that the excavation and backfilling activities are conducted according to this method statement, latest project drawings & specifications.

QA&QC manager will assure that all the relevant work is carried out in conformance with project specification, PQP and QIP.

6. Procedure

This section covers the method of fabrication, erection and installation of gates at various locationsof New Khanki Barrage and pumping station.



6.1. Design & Drawing Of New Gate Equipment

After award of job drawing section of nominated mechanical contractor will start design work on it. Experienced Design Engineers will design/calculation the gate equipment on the basis of provided parameter & technical specifications for under sluice, Head regulator of LCC and fish ladders or any other items.

The design shall be such that to withstand the severe service conditions, ease and clarity of operation, inspection and maintenance, reliability in service.

The drawing & drafts section start working on the basis of given parameters from the Design dept. These drawing are prepared as per standard and shall show all final dimension and tolerances, surface finishes, details of field connections and final weights.

Drawings of the hoisting system for gate operation shall shows all final dimensions and tolerances, surface finishes, details of field connections and final weights, load and foundation bolts.

Slot and Sill beam details showing contact with the embedded sealing faces.

Related technical literature & broachers of standard equipment shall also submitted.

6.2. Design Calculation of Main Weir Gate Equipment

The design calculation & computation of Main Weir Radical gate Equipment in two phases. It includes Structural analysis of gate leaf assembly, hoisting capacity detail design, dogging devices, embedded parts, major structural parts, weight and center of gravity calculations.

In fist phase:

Gate leaf assembly gate arms, horizontal & vertical members, skin plate, Trunion assembly, Embedded parts 1st & 2nd Stage, hoist platform, platform deflection, calculate the hoist load which include horizontal members, lifting eyes, vertical members, horizontal stiffeners, Side sealing.

In 2nd phase:

Design calculation & computation of Hoist machine, it includes required hoisting/operating force calculations, speed reduction, central gearbox calculation, rope drum, couplings bearing blocks bearing pedestal internal shafts of the central gear box, steel wire rope, cross shaft, dial indicator, coupling & electrical equipment limit switches etc.

6.3. Design Calculation of Under Sluice Gate Equipment

The design calculation & computation of Main Weir Radial gate Equipment in two phases In first Phase:



Gate leaf assembly, gate arms, horizontal & vertical members, skin plate, Trunion assembly, Embedded parts 1st & 2nd stage, hoist platform, platform deflection, calculate the hoist load

In 2nd phase:

Design calculation & computation of Hoist machine, it includes required hoisting/operating force calculations, speed reduction, central gearbox calculation, rope drum, couplings bearing blocks bearing pedestal internal shafts of the central gear box, steel wire rope, cross shaft, dial indicator, coupling & electrical equipment limit switches etc.

6.4. Design Calculation of Gate Equipment for Head Regulator of LCC

The design calculation & computation of embedded parts, gate leaf assembly, and Trunnion assembly skin plate, end plate and horizontal member etc.

Design calculation & computation of Hoist machine, hoist plate form rope drum & steel rope,

6.5. Design calculation of Stop Log

Two sets of stop logs will be required for under sluice & main weir gate. The size of stop logs will be 60 feet X 20 feet. Team of Experienced Design Engineers will do design calculation of the stop logs on the basis of provided parameter, technical specifications and as per direction of the engineer.

6.6. Design calculation, procurement and installation of pumping station

Pumping station’s design will be as per specification of Eng’r. keeping in mind latest tools and software are used to eliminate any risk in future.

6.7. Design calculation of fish ladder gates

Fish ladder gate’s design will be as per specification of Eng’r. keeping in mind latest tools and software are used to eliminate any risk which can create some trouble in future.

After proper documentation these drawings and calculation design shall be submitted to the consultant for the verification and necessary adjustments. Fabrication work in the shop will be started against approved design only.

6.8. Fabrication

6.8.1. Radial Gate

6.8.1.1.Manufacturing process

The manufacturing process is as follows:

Gate leaf: technological design→ lofting → cutting → edge shaving → parts Assembling → welding → correcting → assembling → inspection → welding →Disassembling → panel correcting → assembling

Arm: technological design→ lofting → cutting → edge shaving → parts assembling → welding → correcting →assembling

Trunnion: casting → paging → bottom machining → lineation → bearing machining → lining → fine machining

Final assembling: vertical assembling → lineation → machining → Inspection → painting→ transportation



6.8.1.2. Equipments employed in manufacturing

1 numerical control cutting machine2 multi burner cutting machine3 semiautomatic cutting machine4 shearing machine5 nine rolls plate-leveling machine6 four rolls rolling machine7 shape rectifying machine8 500t open side press9 12M edge shaver10 6M table planning machine 11 T612 horizontal boring machine 12 2012 table planning machine 13 3.4M vertical lathe14grinder 15 driller16 mechanical power head17 automatic submerged-arc welding machine 18 multi-head arc welding machine19 median frequency heat treating facility

6.8.2. Essential Instruction of Technology

6.8.2.1. Check of drawings

20 CO2 shield welding machine21 heat treating facility22 ST arc furnace23 centrifugal filler24 chrome-plating bath25 face miller26 30t gantry crane 27 5T/30T gantry crane28 bridge crane29 ultrasonic flaw detector30 X-ray flaw detector31 S3 balance level32 J2 theodolite33 detection tools 34 5Mx7Mx20m leer35 10t/30t 50t double-bridge crane36 far IR hot plate37 other tools38 super-large type numerical control boring-

milling machine

After received the drawings, technicians will check them according to specification and process and make technical documents. People from correlative branches will be organized to evaluate and check the key parts to make sure that the process is reasonable and reliable to meet inspecting requirement.

6.8.2.2. Lofting

Before cutting, the drawings must be lofted at the ratio of 1:1 to check the size and make templates. Cutting and templates making are controlled by calculating string length. Shrinkage mass is calculated by radius of curvature to insure lofting precision. Anti-deformation method is taken in the process in consideration of lofting precision, welding and distortion. Templates include the following kinds:

1. Skin plating positive camber template 2. Plate lengthened within a radius of curvature of the inner and outer arc template 3. Face arc template 4. Arc template for up and bottom flanges of side beam 5. Side beam arc template 6. Gusset template for arm. 7. Two-section templates for flanges of arm (used to check the length of up and down sternum).



8. All the gusset plate, ribbed plate template, the lofting of arm should be according to size in the drawing. Cutting should be in accordance with template. Template accuracy should be ≤ 0.5mm.The template should be marked central line and screw axis line

6.8.2.3. Material

1.All materials must be companied with mill certificate.2. All materials should be consistent with the requirements of the contract and drawings.

Materials without quality certification will not be used in this project. 3. If, for any reason, written materials specified in the drawings cannot be

provided, "material substitution list" should be submitted to supervising engineers and design institute 42 days before manufacturing stating the type of the materials cannot be bought and type and specification of the substitute material and test material. Only after the approval of the design institute and supervising engineers and being reported and check by the owner can the substitute materials be used.

6.8.2.4. Cutting

1. Before Cutting, all plates should be leveled by nine-roller leveling machine. Shapes should be rectified by shape rectifier. After leveling, embossing stylus is used to curve the cutting line, machining line, inspection line and each line should be marked with locating point. Cutting is to carry out after passing inspection.

2. Splice joints of plate should avoid stress concentration parts. Cross weld is not allowed. The distance between the parallel welding lines should be in accordance with bidding documents and specifications. Welding lines of all the plates should be tested according to welding specification.

3. Certain shrinkage mass and process allowance should be reserved during Cutting and becorrected in erection.

4. The templates of all the web plates of side beams and intermediate longitudinal beam should be made at enlarged details while the cutting program is written. Cutting is performed by numerical control cutting machine (cutting lines should be checked by large scale template beforehand).

5. Cutting of face plate should be in accordance with drawings. Adjacent parallel butting welds shall be staggered. The space length should be consistent with the bidding document and specification.

6. Before cutting of arm, lofting should be carried out at the ratio of 1:1in accordance with size in the drawings to insure the right size of different parts. Welding shrinkage space should be reserved at the length direction. Side slop groove of web plate is done by edge shaver.

7. After cutting, transfer the quality control number, then report to inspector to check the quality according to code and make to the next procedure if it is qualified.

6.8.2.5. Primary Assembling

Primary assembling is carried out on the platform which should be leveled to insure flatness less than 2mm.



a. Main lateral beam: The main beam adopts box structure.

o The groove of web plate is machined by 12M edge shaver.

o Assembling of main beam should be in accordance with process drawing. After assembling andwelding correction, cutting is implemented with consideration of welding shrinkage and beamlength during secondary assembling.

b. Side beam and intermediate longitudinal beam-

o Side beam adopts box-type and intermediate longitudinal girder is T shape.

o Cutting with template (Cutting is controlled by numerical control cutting machine and tested bytemplate)

o Assembling and welding would be in accordance with drawing and specification.

o Before assembling of side beam and intermediate beam, web plates would be arced and rear wingplate be assembled and coded.

o Templates will be used to insure radian after welding.

c. Horizontal Secondary Beam

o Horizontal secondary beam will be aligned by shape rectifier machine after cutting.

d. Skin Plate

o The skin plate of gate leaf shall be purchased in fixed size to minimize splice welding. Attentionwill be paid to the distance between paralleled weld seams. Cross welds is strictly forbidden.

o After Cutting, the skin plate is handled by four-roller rolling machine and corrected by templatesto insure radian.

o According to the drawings, radius of curvature is adjusted and template is used to check theradian.

o Skin plates will be welded on arc platform and tested and corrected by templates. Straightness istested by leveling ruler.

e. Gate Leaf: (The special platform shown as following)

o Before scribbling in skin plates, radius and straightness must meet requirement. Axis linewill be marked first and then position line of main beam, side beam, and intermediatelongitudinal beam, horizontal side beam and top and bottom girder.



o Accessories for main beam, horizontal side beam, longitudinal beam and size beam are first assembled and welded after inspection. Welding will be carried out strictly in accordance with specification from the center to around to reduce distortion.

o Main beam of gate leaf will be leveled if radian and straightness of skin plates are qualified. Processing line, checking line and compensation line (with the help of technician) of main beam and rear flange will be machined.

o Final assembling will be implemented if the above process is finished and qualified.

f. Arm

o Arm adopts box structure. Operation platform will be built during manufacturing and leveledby level instrument.

o Arm will be integrated manufactured. Extra thickness for front and rear end plates of armwill be reserved. After assembling of arm and gate leaf, processing line will bemarked according to arc radius of skin plate to make sure the length can meet therequirement of trunnion axis and radius of curvature of the outer edge of face plate.

o Plummet will be erected in the platform according to drawing. Reasonable welding measures will be taken to avoid distortion. The waist line (axis) of rear end plate and box structure should be vertical and the front space should be insured. Attention must be paid to the positioning dimension of front and rear end plates.

g. Supporting Trunnion

o The materials of trunnion and trunnion seat are cast steel and are in accordance with GeneralSteel Castings Specification; the chemical composition, mechanical properties and testingmethods and standards are in accordance with General Specification of Cast Carbon Steel.

o The chemical composition and mechanical properties of trunnion and trunnion seat, should meetthe specification after normalizing treatment.

o Steel castings should be first visual checked. No cracks and shrinkage are allowed on root trunnion corner and pressure-containing surface. Reliable repair welding will be made when casting defects within allowable extant and be implemented after the approval of supervisor engineer. The quality of repair welding should meet design requirement and be recorded. The entire repair welding of steel castings should be consistent with relevant provisions specified.

o Steel castings, after passing inspection, will be machined in accordance with drawings and putinto the assembly shop to be assembled if qualified.

o Steel forges of trunnion axis will be machined in accordance with forging relevant provisions;Material of trunnion axis is 2Cr13 Steel and chromium plated. The chemical composition andmechanical properties of which meet the requirements.

o Steel forges of trunnion axis will be machined in consistent with drawings to insure quality.

o Axis surface is rustproof by chromium plating and is machined finely.



o Before trunnion assembly, matching surfaces must be washed by clean coal oil and be applied with clean grease lubricant.

o Defects of trunnion axis should not be repaired by welding.

6.8.2.6. Final Assembling

o Final assembling is to check whether the size meet the requirement of drawings and specification and mark processing lines, water seal lines and side wheel lines preciously. Measures included are as follows:

o First, lofting is launched at the assembling site including positioning lines of gate leaf bottom, width and center lines of gate leaf, position lines of the Projection of arm body center lines and the centerlines of the two trunnion points and the middle point of center distance.

o Arm includes two arm bodies, end plates, all posts and diagonal braces and gussets etc. These parts are assembled at assembling site with finishing allowance reserved and fixed and spot welded after qualified.

o Assembling the arms with bottom section of gate leaf which 'radian and straightness are corrected and the contact face between rear flange and arm is machined. Take the center line of arm and gate leaf as horizontal, and make it vertical with beam machining surface and assemble gate leafs and machined trunnion afterward.

o Fully adjustment is taken so that allowance such as coaxiality of two axis and deviation between axis center and outer radius could meet the specification to insure finishing allowance. (After process plate thickness no less than that specified in the drawings).

o Layout lines: hole lines of water seal will be marked on the basis of gate leaf center; lifting lug machining lines and check lines on the basis of root edge; machining and check lines of front end of arm on the basis of machining surface of rear flange of main beam; machining and check lines of rear end of arm on the basis of machining surface of trunnion; Positioning lines of connection holes of the rear flange plate on the basis of front-end of arm; Positioning lines of side wheel on the basis of root edge.

o Machining: After the disassembly of the gate body, it is adjusted according to checking lines. Front and rear end of arm is manufactured by boring-milling machine and checked. Lifting lugs are machined according to processing lines.

o Marking: When assembling, reliable spot welding of the positioning plate are marked andlabeled, after passing inspection.

6.8.2.7. Process Assurance Measures

6.8.2.7.1. Upper plate of ally arm and main beam



o The machining lines for machining surface of rear flange of main beam will be scribbled on platform after assembling welding of gate leaf. Correcting the datum lines and checking lines, the machining the surface together with gate leaf to ensure it meet the requirements Ra=12.5 pm.

o When assembling, adjustment joints are used to adjust contact face.

o Margin of error of multicutter over large surface is strictly controlled to below 0.10mm.

o After passing inspection, processing line of upper plate of ally arm is marked on the basis of operation surface of rear wing plate of main beam and processing line of end plate of ally arm is marked on the basis of operation surface of trunnion.

6.8.2.7.2. Control of radius of curvature

o Gate leaf adopts anti deformation measures According to our past experience in the manufacture of radial gate, after welding, the radius of curvature will be less, so we take efforts to increase the radius of curvature as anti-distortion measures to ensure the radius of curvature of the gate leaf after welding is within ± 3.0mm.

o Control of side beam radian Cutting of side beam is consistent with template. Finishing allowance is reserved for the straight part which is machined as per processing line. Arc side is cut by guide semiautomatic cuffing machine. (Cutting precision and smoothness in accordance with gas cutting specification).

6.8.2.7.3. Control of radius of curvature of vertical assembling

o The upper joint of first section of arm is considered as adjustment seam to balance the deviation.

o After assembling, the big surface between second section of arm and trunnion is machined withprocessing line.

o Dummy shaft is prepared for convenient manufacturing and precious measurement of radiuscurvature.

6.8.2.7.4. Welding control of gate

o All welding materials should be in accordance with drawings. If not specified by drawing, welding materials with hardness matching that of the base metal will be used. Welding of stainless steel should adapt matching stainless steel welding rod.

o DESCON has a special welding rod storage house with baking equipment. There are full-time staffs in charge of preserving, baking, handling and recycling of welding rod and keeping records and also strict rules and regulations to ensure the right use baking and use of welding rods.

o The process of welding should be implemented according to drawings and SL36 as well as welding procedure laboratory specialized by our lab Welding methods are submerged arc welding, C02 gas protection welding and manual arc welding. Welding of type I and type 11 welds should only be performed by technicians passing exam and holding relevant certificate. Only technicians qualified in horizontal, vertical, cross and overhead four positions welding can



carry out any position welding. Weld quality should be in accordance with the regulations or the 100% pass the ultrasonic inspection. All welding shall be conducted appearance inspection. Welding seams in the project are as follows:

o Type I weld Butt weld of main beam, arm and web plate and flange of side beam are type I weld Butt weld between lifting lug and main beam Composite welds of arm and connection plate;

o Type II welding seam

o Butt weld of skin plate;

o Composite weld and fillet weld of main beam, flange and web of arm;

o Composite weld of flange and web of main trusses of arm;

o Butt weld of connection plate between sections and arm.

o DESCON has strong advantages in metal structure welding and welder management. Our company possesses a specialized welding lab which can perform a variety of tests to guide the production welding and is responsible for training welders. Our company got manufacturing license for type I and type 11 pressure vessel in the 1980s. Our employees including many experienced welders holding pressure vessel welding certificate and certificate issued by Minister of Water Resources of P. R. China and Electric power over hydraulic metal works. Trough years of experience, the welding lab has conducted 100 WPS & PQR and submit technology assessment reports to owners for approval including WPS of stainless steel 1Crl8Nr9Ti, SUS321+16Mn composite plate which played a crucial role in guiding welding practice; welding experiment and assessment for Q345C, stainless steel Cr18Nr9Ti in water diversion radial gate of three-gorge project in 1999 and Q345D in Xiaolangdi Key Water Control Project in 2000.We possess mature welding process for material Q345B.

6.9. Radial Gate Embedded Parts

6.9.1. Manufacturing process

6.9.1.1. Check of drawings

After received the drawings, technicians will check them according to specification and process and make technical document to insure good quality.

6.9.1.2. Lofting

Radius guide plate will be lofted and made template in the ratio of 1:1. Slot positioning hole andend plate processing hole are marked on template for convenience machining.

6.9.1.3. Cutting

1. All the material must be new with quality certificate.



2. Materials should be consistent with drawing. Any substitute material must be approval by the designing department and in accordance with ISO9000.

3. Cutting of stainless steel is controlled by numerical control and plasma cutting machine.

4. After Cutting, plate need to be leveled and shape be aligned.

6.9.1.4. Welding of gate slot

1. All welding materials should be in accordance with drawings. If not specified by drawing, welding materials with hardness matching that of the base metal will be used. Welding of stainless steel should adapt matching stainless steel welding rod. Welding material should meet specification and have quality certificate.

2. DESCON Engineering Limited has a special welding rod storage house with baking equipment. There are full-time staffs in charge of preserving, baking, handling and recycling of welding rod and keeping records and also strict rules and regulations to ensure the right use baking and use of welding rods.

3. The process of welding should be implemented. Welding methods are submerged arc welding, C02 gas protection welding and manual arc welding. All welding shall be conducted appearance inspection.

4. Welding material must be selected in accordance with drawings and theprincipal of hardness match.

5. Before use, welding rod should be kept in heated vessel drying and welding wire shall be clear of surface oil and impurities.

6. Welding sequence is chosen on the basis of gate slot structure and groove type. Methods such as balanced welding, backsetp welding, multilayer and multi pass welding and anti distortion measures are taken to reduce welding distortion and welding stress. The type and size of groove welding seam should be in accordance with drawings. If not specified in drawings.

7. Avoid generating arc at none welding points of groove when welding. Tack welding, locating plate welding and welding of other temporary parts should be treated with care as formal welding.

6.8.3.1.5. Manufacturing of different parts

6.9.1.5.1. Side guide

Among the embedded parts of gate, side guide is one of parts that are difficult to manufacture. Our company has produced similar parts in projects such as the Three Gorges and Xiaolangdi and accumulated mature manufacturing experience.

1. Equipment needed: nine-roller leveling machine, shearer, 6M planer, face miller, oil press, gantry milling machine etc.

2. Steel plate will be leveled by nine-roller leveling machine to reduce both distortion and internal stress of steel plate.

3. Cutting; Rivet shall make the templates and cut the materials according to part drawing at the ratio of 1:1.



4. The curing of stainless steel plate is controlled by numerical control cutting machine and plasma cutting machine .the length is decided by detail drawing.

5. Different parts will be welded, assembled and leveled by riveter and welder after which steel angle and steel bars are welded.

6. Machined surface and processing lines of side guide shall be marked on platform. 7. Stainless steel machined surface of side guide is machined by planer and be polished to Ra3.2µm.

8. Processing lines and checking lines of different parts will be marked. ends will be machined by facing milling machine.

9. Trial assemble each section of side guide after correcting on platform and drill the hole after scribbling in match for guide plates.

10. Pre-assembling of side guide simple platform will be built and leveled; Put side guide plate symmetrically on the platform and check. Scribbling whole lines with another

and drilling after disassembling.

6.9.1.5.2. Bottom sill

1. Cutting of welded parts and stainless steel composite plate should in accordance with drawing.

2. Bottom sill will be welded and assembled on specialized platform according to drawing and welding process.

3. Processing line of water seal surface is marked which leveled and machined by planer with roughness degree Ra25µm.

4. There is partial curved surface at the ground sill that need air hole (M22) and will be blocked after installation.

6.9.1.5.3. Locking

1. Different parts will be machined in consistent of drawings and be assembled to insure flexible tumbling.

6.9.1.5.4. Check and acceptance Ex-works

1. Different parts will be pre- assembled respectively according to drawings. Dislocation of machined surface between adjacent parts is no more than 0.5mm and none machined 2.0mm with gentle transition.

2. Allowable deviation of embedded parts must follow drawing and specification. 3. Make code after assembling and submit "code position of embedded parts" to

owner.

6.9.1.5.5. Transportation

1. Supporting to embedded parts should be provided in case of separate transportation and pilling to avoid distortion. Machining surface should be packed and transported with code. Fastenin.

6.10. Fixed Winch Hoist



6.10..1.Introduction:

1. Main technical parameters of the winch hoist: Refer to Bidding Diagram. 2. Components of the winch hoist: The winch hoist is mainly composed of the

rack, the lifting mechanism, the electric drive and control equipment as well as the necessary affiliated equipment.

3. Major standards and specifications used by our company for manufacturing: 4. Requirements stipulated by the technical clauses in the tender documents and the

related Chinese National Standards.

6.10..2.General technical requirements for manufacturing the winch hoist

6.10..2.1. Materials

1. The materials used to manufacture the winch hoist must not only accord with the requirements for the materials specified in the design drawing and the technological regulation, but also have the quality certificate. Any material without the quality certificate or with incomplete certifying documents shall not be used until it has been inspected and verified as qualified.

2. If any materials and specifications that are not in line with that defined in the drawings and the technologic process are to be used during the manufacturing process, it is necessary to fill in “Material Change Notice”. The materials cannot be used until approval is given by design persons or the responsible technologist. During the cutting of main force bearing materials, the material markings (such as the quality control number, the furnace batch number) should be transferred onto each part made out of them.

6.10..2.2. Marking-off, laying-off, shearing and correcting of steel structural parts

1. Flattening and marking-off: The flattening work shall be done on the 9-roller flattening machine. The marking-off process shall be done after flattening according to the drawing & technological requirements.

2. Laying-off: Flame cutting: For webs and fenders or materials of large size (length ≥ 10000 mm), the laying-off process shall be performed through NC or semi-automatic cutting machines while for other materials, it may be performed through manual cutting or mechanical cutting. The allowed deviation for part cutting and the marking-off stock-line shall be: Manual cutting: +2mm, Mechanical cutting: Precise cutting: +1 mm+1.5mm. The slag shall be removed after cutting. If there is such phenomenon as crack, slag inclusion, deoxidized article, air hole, groove, notch, it is necessary to address those defects according to the specifications, and the non-contact surfaces shall be polished using grinding wheels.

3. Mechanical shearing The shearing shall not be performed when the environment temperature is below 20°C in the case of the common carbon structural steel, and when the environment temperature is below 15°C in the case of the low alloy structuralsteel.After shearing, all the edges should not have any crack or truncation which is larger than1 mm. The burrs shall be cleaned up.



4. Correcting the heating temperature for the flame correcting shall be selected according to the steel's properties, but in any case not exceeding 900 °C. The low alloy structural steel shall be cooled slowly after heating and correction.

6.10..2.3.Hole Drilling

1. Hole drilling deviation within the same group of the distancedeviation between any two holes: on-provided holes: ± 1 mm.The deviationbetween two adjacent holes: ±0.7mm.Within the same group of provided holes: The distance deviation between any two holes: ±2mm.There should be no crack, burrs, or truncation which is larger than 1 mm. The truncation caused by cleaning shall not be greater than 1.5mm, and all the burrs shall be cleaned up.

6.10..2.4. Welding Seam

1. Classification and verification of welding seams.

6.10.2.5. Class I welding

1. Butt welded seams for fixed pulley support beams, reel seam: support beam webs and fenders.

2. Butt welded seams for the reel body. 3. Butt welded seam for the lifting eye plate.

6.10.2.6. Class II welding

1. Fillet welded seams for fixed pulley support beams, reel seam: support beams. 2. Fillet welded seam for lifting eye plates. 3. Class III welding other welding seams not belonging to Class I and Class

II.seam:

6.10.2.7. General requirements for manufacturing parts and components

1. General requirements for manufacturing parts and components shall be implemented as per the related regulations and requirements described in Specifications for Manufacturing, . Installation and Acceptance of Winch Hoist Used For Water Conservancy And Hydroelectric Projects.

6.10.2.8. Process flow of the winch hoist manufacturing

Process flow chart for the winch hoist



6.10..2.9. Method to control the height difference between two lifting-points on the winch hoist

1. During the operation of the winch hoist, it is important tool the height difference between the two lifting-points so that the gate can operate smoothly in the gate groove. Our factory controls the heights of the two lifting points of the winch hoist during the manufacturing process through the following methods.

2. Controlling the bottom diameter error of left and right reel rope races: 3. During the precise machining of left and right reels, first control the machining

error of O.D. of the rope race to be up to h7, making the O.D. difference between two reels is as small as possible;

4. During the machining of rope races, use the rope race template measurement to coordinate the machining, with the gap between the template and the rope race to be controlled within 0.1 mm;

5. After the machining of the reel, use dedicated measuring tools for the rope race bottom diameter to measure the rope race bottom diameter so as to control it to be within h8, and measure the cylindricity of the bottom diameter as well;



6. Controlling the rotation speed difference between the two motors: 7. Purchase the motors of the same batch when motors need to be purchased;

Measure the rotation speed of the motor after being delivered to the factory 8. When purchasing the steel ropes, the two steel ropes for the same winch hoist

should be cut from the same reel.

6.10..2.10. Assembly

1. General requirements on assembly 2. All parts must be verified to be qualified, and outsourced parts/cooperation parts

shall not be assembled unless they have certificate documents. 3. The burrs on parts shall be cleaned up before assembling. 4. The shaft holes of all shafts shall be blown, before assembly, by the compressed

air to blow dirt away from inside the axle hole. 5. The scarlet oil-proof paint shall be applied, before assembly, on all non-

machined surfaces of pulleys and the reducer's internal cavity. 6. Tightening all fastening bolts after each part and component is in place and

aligned. 7. The spring washer must entirely contact with the nut and the part support

surface. 8. Motors and reducers must first go through the appearance test and operation test

before assembly. 9. Assembling the reel device The reel device is mainly composed of the reel, the

reel coupling, the bearing seat and etc.After all machined parts, outsourced parts are verified as qualified, perform the assembly and fill the lubrication grease into each bearing. Wait for the final assembly.

10. Movable pulley blocks and fixed pulley blocks After all machined parts, outsourced parts are verified as qualified perform the assembly and fill the defined amount of lubrication grease into shaft sleeves. Wait for the final assembly.

11. Assembly The assembly of the lifting mechanism shall be performed on the rack. After the rack is located, scribe the positioning line for each component after the rack is aligned. After they are tested to be qualified, then install, in turn, the reel device, reducer, the coupling, motor, the synch shaft, brake, the fixed pulley and etc.. Use measuring tools such as theodolite, plumb, ruler and etc to respectively verify the items such as the reel horizontal tilt, the vertical tilt, the synch axle horizontal/vertical tilt, the brake clearance and etc. After being verified as qualified, the machine shall perform the trial operation in the idle mode, and then finally set the positioning block.

6.10..2.11. Trial operation

1. Perform the trial operation in the idle mode in the forward and the reverse directions for 30 minute each, and check the exposed gear engagement, the brake shoe's release opening and the brake operation and etc. And check if the radial run-out of the braking wheel is within the tolerance range, the 'coupling concentricity, the reducer operation, the noise, tightness at each seal and the appearance quality. Test the motor's operation smoothness, the 3-phase current



Equilibrium value, and check if there is any abnormal heated phenomenon and etc.

6.10.2.12.ERECTION

1. A working group comprising a Supervisor, a lifting equipment operator, riggers and a HSE supervisor shall carry out equipment for fabrication and erection. The responsibilities of each personnel of the working group shall be clearly defined. The operators shall be in possession of the necessary licenses.

6.10.2.13.General

1. Lifting of the equipment shall be done using appropriate lifting lugs, installed on the equipment.

2. In general slinging of equipment shall be done using according to centre of gravity line and of the slinging zones marked by the Fabricators. Whenever these indication mark is missing, the Fabricators shall be requested to specify them.

3. Loose parts/assemblies on the equipment shall be checked and removed prior to lifting.

4. When positioning the slings, it shall be ensured that the slings and / or lifting belts have a free course during the lifting phase without interference by the equipment parts (supports, pre-assembled parts etc.) If required, spreader beams of approved design and size shall be used.

5. Adequacy of slings shall be checked considering the deflection or distortion of the equipment while lifting.

6. Lifting shall not be done during rain or wind speed exceeding the limit specified in the crane data.

7. The weight of lift shall be verified prior to lifting. 8. Pre-lift checklist shall be prepared for critical lifts.

6.10.2.14. Documentation to be Prepared

1. The rigging study will consist of following information. 2. The complete lift plan with relevant verification of lift capacity in crane chart

justifying HSE limits of the operation. 3. Size and rating of each rigging gears e.g. Slings, shackles and spreader beam etc. 4. The certification of crane, shackles, sling and spreader beams . 5. Lifting capacity of crane slings, shackles, lifting belt etc. shall be checked and

verified by the rigging engineer. 6. Layout and elevation drawings of lift. 7. Layout of work areas required at site. 8. Clearance of dimensions of boom for installation and any temporary structure. 9. Crane maneuvering shall be indicated wherever space restrictions are

encountered.

6.10.2.15.Lifting Lugs



1. In general it is forbidden to use lifting lugs not specifically indicated in the Fabrication drawing. The un-identified lifting lugs (temporary made on site) shall be used only, if there are separately approved by the Erection Supervisor.

2. All lifting lugs shall be visually inspected before the lifts in order to ascertain their integrity and the absence of any damage suffered during transport.

3. The orientation and sizes of equipment lifting lugs shown on the Fabrication drawing shall be checked.

4. During rigging slings and lifting gears shall be such that the direction of the lifting lug is in line with the direction of the lug designed for.

6.10.2.16.Rigging Study

1. The lift shall be planned after visiting the site prior to commencement of erection works considering the shape, size and dimensions of the equipment and Access Roads etc.

6.10.2.17. Lifting Cranes and Equipment

1. All cranes shall be approved, tested and certified in accordance with project requirement. All certificates of conformity shall be valid.

2. Whenever a defect that may entail risks during the lifting phase is noted, all necessary corrective actions shall be taken prior to the lift.

3. While calculating the final weight to be lifted, the following items shall be included:

a. Crane Hook block Weight b. Various accessories including chain block, spreader beams etc. c. All rigging gears weight d. Lifting material weight

6.10.2.18. Steel Ropes, Slings, Pulleys, Guys and Accessories

1. The Dimensions, characteristics and fabrication of steel ropes shall be adequate to support the maximum load envisaged by the lifting plan.

2. The slings and shackles shall be in good conditions, with their dimensions and capacities identified and accompanied by current certificates of conformity.

3. The spreader beam condition shall be checked before use, if required.

6.11. Installation Of Equipment (Gate - Sill Beam, Side Seal Plates, Guide Channels, Skin Plates And

Arms)

1. According to the Approved drawings of Grooves channel embedded in concretes and the anchor bolts to be welded there.



2. The foundation elevations, dimensions and position of the anchor bolts shall be checked against equipment base plate. Centrelines, benchmark and levels shall be clearly marked on the erection site.

3. Gate Leaf and arms shift to site from fabrication shop. 4. The Gate leaf lifts by the crane with lifting beams. 5. Gate Leaf lower in side seal plates with the help of crane and chain block. 6. Complete the erection of arms with yoke. 7. Arms attached with gate leaf by bolts. 8. All bolts of arms and yoke shall be cleaned and lubricated with a mixture of grease and graphite.

6.12. Fabrication and Installation Of Stoplogs Stoplog use for the maintenance of the gates. Their fabrication will be done as per approved

design. Stoplog,install between piers of upstream side. By the help of two vertical steel grooves

embedded in the piers. Engagement/disengagement done by lifting beam and hoisting system. Its Engagement/disengagement facility provides on all the bays. After usage stoplogs will

store in stacking yard. It will be better to provide stoplogs on both upstream and downstream side to isolate the gate for maintenance

6.13. Checking before Installation of Equipment 1. Check the weight, orientation and centre of gravity of the equipment.

2. Confirm the correct elevation and installation direction. Consult construction / shop drawing, if there is any confusion.

3. Ensure whether supporting structure is required or not, to achieve the desired elevation.

4. Check that the equipment base plate Anchor Plate hole corresponds to that shown on the equipment supplier’s Fabrication drawing.

5. Inspect the condition of slings and lifting lugs and certificates of conformity. 6. Check the crane operation prior to lift brakes, clutch and all the control and safety devices.

7. Clean the bottom surface of the equipment Anchor Plates. 8. Clean the foundation bolts. 6.14.Equipment Erection 1. Load shall not be suspended in dangerous positions during the lift operation. 2. Shim plates of correct size and quality shall be used during the positioning and leveling of the equipment.

3. Shim plates and wedges shall not be replaced by pieces of wood and / or concrete blocks.

4. The protection coring on the equipment shall not be removed without client’s consent.

5. Care shall be taken during the erection of equipment to avoid damage to the bolts and threading.

6. Shim plates and Wedges shall be installed on foundation base between the anchor bolts for leveling of the equipment.

7. Where the distance between the anchor bolts exceeds 800mm, additional plates and wedges shall be installed between the anchor bolts.



6.15. Levelling and Alignment

1. All the equipment installed shall be leveled and plumbed in correct position. 2. Base plates shall be centered and leveled according to the relevant drawing and

specifications. 3. Prior to grouting / placing of second stage concrete preliminary shaft alignment

shall be carried out to ensure that the shaft alignment is achieved without any difficulty after grouting / concreting.

4. After curing of anchor bolts grout, concrete nuts of anchor bolts shall be tightened and base plate shall be re-levelled and re-centred.

6.16. Alignment before Installation of Hoist Cables (Wire Rope)

1. First alignment of shaft/ coupling shall be carried out without installation of Hoist Cables and following points shall be considered:

2. The distance between shaft ends / coupling hubs shall be checked in accordance with manufacturer drawings and shall be adjusted within the given tolerances.

3. Alignment off-set at ambient temperature shall be given considering potential movements such as thermal expansion of equipment during operation and hydraulic loading etc.

4. If motor does not have thrust bearings, the motor shaft shall be properly adjusted to its magnetic centre.

5. A check advice shall be submitted to client/ Consultant about the time of inspection for the alignment check.

6.17. Testing of Gate Material

1. All materials or parts used in the Gate Equipment shall be as per the specified standards. Mill certificates shall be submitted in support of this. If required, testing may be arranged from an independent laboratory to the satisfaction of the Engineer.

6.18. Fixing of Embedded Parts

1. Welding pads, Guide Channel and Sill Beams shall be fixed with the form work at precise location as per the shop drawings and embedded in the primary concrete of slabs and piers etc. in the block outs as per drawings, the block outs shall follow sequence shall then follow for installing of the Sill / Side/Top Seals, Anchor Bolts and Grove Guides.

2. Precise position of alignment studs shall be marked on each Welded Pad to match the hole / slot in the brackets / plates to be fixed.

3. The alignments of side seal plates shall be fitted in correct position and rechecked.

4. Prefabricated Sill / Side Assembly/Yoke shall be placed in position.



5. Horizontal and vertical alignment line and levels shall be precisely checked and adjusted by survey instruments or line strings in accordance with the specified tolerances as per Technical specification jointly with the consultant / Client’s representative.

6. The Bolts shall be tightened and the line & levels shall be rechecked. 7. Joint survey records for the survey shall be maintained by the Contractor /

Consultants. 8. Second Stage Concrete shall be placed with the prior approval of the

Consultants.

6.19. Installation of Hoist Machinery

1. Following hoist machinery is to be installed at the stated locations. 2. Hoisting system, reduction gear box & Motors for Under Sluice Gate (10 Nos.) 3. Hoisting system, reduction gear box & Motors for Main weir Gate (55 Nos.) 4. Hoisting system, reduction gear box & Motors for Head Regulator Gate (06

Nos.) 5. Hoisting system, reduction gear box for Fish ladder Gate (02 Nos.) 6. Detailed shop drawings for the Hoist Platforms / Pedestal Bases along with the

location and details of Shaft support Brackets shall be prepared and approved by the Consultants.

7. Hoist Platforms of Gratings shall be prefabricated, assembled and installed at desired locations.

8. Hoist Machinery shall be transported to the site and shall be installed. 9. Hoist shall finally be connected to the gates through Steel Wire Ropes / Stem

rods.

6.20. Painting 1. All parts of the equipment shall be given one coat of the specified paint in the

workshop soon after manufacture. Second and final coat of the paint shall be applied after site assembly and installation.

2. Surfaces to be painted shall be cleaned by Sand blasting before applying paint. The removal of oil and grease shall, in general, be accomplished before mechanical cleaning is started. When specified, blast cleaning shall be done in accordance with SSPC-SP-10. Surface preparation and paint application shall be done after the parts are completely finished and checked in shop assembly.

3. Paint materials shall be as per the specification.

6.21. Testing and Commissioning



1. All the welds shall be precisely inspected for continuity & soundness and ground or blended to assure required weld thickness. The welds in skin Plates shall be subjected to non-destructive ultrasonic examination/ radiographic examination as per specification.

6.22. Trial operation:

1. A schedule for trial operation of each gate / equipment shall be prepared and approved by the Engineer / Consultants. The equipment shall be inspected and test run as per specification and any defects noticed shall be remedied.

6.23. Final Commissioning Tests

1. A programme for final commissioning tests shall be made as per Technical Specifications and tests shall be carried out under the supervision of the consultants under actual operating conditions.

7. Tools And Equipments

Cranes 10/50 Ton Crane 70-Ton to 150-Ton Tractor/Trailer Welding Transformer Scaffolding Tool Box/Hand Tools Lifting Jacks Welding gauges Vernier Callipers Bevel Check gauge Welding Helmets/Safety gear/Dust Masks/Fire Extinguisher/ Personal Protection Equipment etc.

Compressor Rigging Tools Lifting Beam (if required) Man basket Survey Instruments Painting equipment

Man Power:

Erection Supervisor Quality Control Inspector Fixers/Mechanics Helpers Health safety (HSE) Supervisor Crane Operator



Crane Riggers Welders Painters

Recommended Work Shop Equipments, Spare Parts Electric welding plant 400amps 1 needed Mobile welding Plant 1 needed Air Compressor 130 cfm 1 needed Air Compressor 300 cfm 1 needed Shaper-18 inch stroke 1 needed Surface Grinder 1 needed Metal Cutting Band Saw Electric 1 needed Electric Drill ¾ Inch 2 needed Lathe 12-inch Swing 1 needed Jack 30 ton 2 needed Battery Charger 1 needed Snap-on Tool Sets 2 needed Motor Boats 35 ft long, draught 2.5 ft(petrol operated) 1 needed Farm tractors 65-100 hp 1 needed Trolleys 15 ft long to be toed by tractor 2 needed Water tank with sprinkler attachment 1 needed Electric Generators 10 KVA(220 volts,50~) 2 needed Electrical engine operated generators 50KVA(220-440volts,50~ ) 2 needed Hand Talkie 5 miles range 4 needed Electric Welding Plant(three phase) 1 needed

PUMPS SPARE PARTS bearing, Gland Packing. GATES SPARE PARTS Nuts Bolts, Rubber seals, Welding Electrode, Lubricating oil/grease. Maintenance tool set, steel cabinet for tools, wire rope, turn buckles, spare

electric motors for hoisting system. PUMPING HOUSE DIESEL Complete set of spare parts for 1000 hrs operation

GENERATOR SPARE PARTS

8. HSE Instructions

1. During Modification and Execution of the job all measures shall be adopted to ensure safe working.

2. All personnel involved will use necessary Personal Protection Equipment (PPE).

3. The workers shall be made aware of Health Safety Environment (HSE) equipments related to this activity through daily, weekly and monthly briefings.

4. HSE notice board shall be installed.

5. No smoking shall be permitted in restricted spaces.



6. HSE Inspectors prior to use shall inspect all equipment.

7. During transportation of the equipment it shall be properly supported and tied on the Trailer.

8. Crane lift checklist shall be used.

9. The area shall be barricaded to prevent user-authorized entry only.

10. Only personnel directly involved in the project shall be inside barricaded area.

11. Correct rigging procedure should be observed.

12. Access and good housekeeping should be maintained at site.

13. Proper ventilation and oxygen level shall be maintained in confined spaces.

14. Fire extinguisher should be available in working area.

15. When working on height, proper fall protection measure shall be taken.

16. All access ladders and scaffoldings shall be secured and tagged before use.

17. Proper storage, handling and use of gas cylinder shall be observed.

18. All cylinders shall be kept in trolleys and in an uptight position.

19. Welding sets should be checked and maintained regularly for wear and tear.

20. Waste Management should be strictly followed to keep the job site neat and clean.

9. RELATED DOCUMENTS

QA&QC/FRM-08 Corrective Action Request (CAR) form

QA&QC/FRM-206 Request / Report for Inspection / Test

Construction Drawings

Shop Drawings

Technical Specifications

ms 12.doc 7.6.13

Documents

embedded parts

mechanical works docno

main barrage gates

radial gate equipment

sealing plates

embedded metal parts

barrage main weirgate

relevant equipment parts