Solu Hydroelectric Project Technical Specification

Upper Solu Hydro Electric Company (Pvt.) Ltd.
Solu Hydroelectric Project
Distance between side roller path faces

Height of guide frame
Flatness of side and upper sealing frames
Straightness of side and upper sealing frames
Flatness of sill beam surface
Straightness of sill beam surface
Flatness of track frame surfaces
Straightness of track frame surfaces
Straightness of side roller paths
Lot 3: Hydraulic Steel Structures

Part 2, Section II: Technical Specification
5 mm
6 mm
1 mm
1 mm
1 mm/m
2 mm
1 mm/m
1 mm
2 mm
2.1.5 Operational Conditions

The gate shall be suitable for operation at partial opening or full opening. The gate shall be capable
of keeping the fully closed position without water leakage higher than specified, and operating and
discharging water satisfactorily without vibration or other phenomena at full or partial gate
opening.
The gate shall be designed for operation under any headwater level up to 1998.74 masl and the
forces of sediment accumulation in front of the gate.
Special care shall be taken for providing optimum accessibility to all parts as necessary for
inspection, maintenance, repairs, lubrication, painting, etc.
Considering the high frequency of operation intervals and intensity of erosion due to the high
concentration of solids in the flushing water it is most important for the design of the gate that
the rubber seal of the gate is arranged outside the areas affected by erosion,
all wearing parts are easily replaceable.
2.2 Components
2.2.1 Sealing Frame
The sealing faces shall consist of corrosion-resisting steel plates attached to the front frames and
lintel beam. For the sealing face of the sill beam stainless steel is not required. When the guide
frame has been assembled, the sealing plate surfaces shall be continuous, straight, true and within
the specified tolerances. The minimum thickness of the machined sealing plates shall be 6 mm.
The lintel beam, the sill beam and the front frames shall be true to form and free from any twist
and/or rack to provide a watertight seal with the gate.
2.2.2 Guide ways
The track frames shall be capable of transmitting the water load from the wheels of the gate to the
concrete structure and shall be of stainless steel. The surfaces shall be suitably machined and
hardened to prevent excessive wear.
The side roller paths or guide rails and frames shall have ample strength to resist the load of the
side rollers. The assembled side roller paths or guide rails shall be straight over their entire length
and no offset shall exist at joints.
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2.2.3 Gate Frame

The gate frame shall be of welded steel plate construction. It shall include the housing of the gate
leaf, the upstream steel lining, the gate guides, the supporting structure for the hoist spindle and the
gate seals.
The guide ways mounted on the downstream side of the frame shall be replaceable and adjustable.
For installation of the gate frame foundation will be provided in the first stage concrete in such a
way that the gate frame is rigidly fixed during placement of second stage concrete. The steel lined
parts and the frame shall be constructed appropriately stiff. The lateral sealing faces in the gate
frame shall be designed for forces resulting from seals and guides. Safe anchoring to the first stage
concrete shall be provided.
Suitable adjusting screws shall be provided for all parts to be installed in block-outs or on
foundation of the first stage concrete to enable a precise adjustment during the erection stage. All of
the adjusting screws shall have a diameter not less than 20 mm. The Contractor shall be fully
responsible for proper positioning and avoidance of deformation of any and all parts embedded in
the first and second stage concrete until completion of the works.
2.2.4 Gate Leaf
The gate leaf shall be made of solid steel plate without stiffening or shall be of welded construction
with downstream stiffening but with skin plate thick enough to support at both sides the hydrostatic
forces without undue deformation. When moved, the gate seal shall maintain contact with the
stationary lintel and in the guide slots at both sides.
The upstream face of the gate leaf shall be of stainless material of high hardness or provided with
an adequate protection coat of high resistance coating against erosion and shall be as smooth as
possible in order to minimize the wear of the rubber seal fixed upstream of the gate leaf at the gate
frame. Therefore the upstream surface of the gate leaf shall be made with special care, be perfectly
smooth and shall be accurately finished.
In selection of materials special attention should be given to the problem of electrolytic corrosion in
adjacent members made of carbon steel. This would apply especially in case of using stainless steel
for the whole surface of the leaf.
The lower edge of the skin-plate has to be rounded off and chamfered to avoid cutting of the
bottom seal when closing the gate.
2.2.5 Gate Seals
The gate seals shall be of moulded rubber shape, clamped to the upstream face of the gate using
corrosion-resisting steel bolts, nuts and washers with anti-leakage materials. All seals shall be
mounted in such a way as to permit easy replacement and adjustment in the field. Minimum
spacing between clamping bolts shall be 100 mm.
The seals shall be spliced at the corners by shop vulcanizing to provide a single continuous seal.
The tensile strength of all shop splices shall not be less than 50% of tensile strength of the unsliced
material. The side seals and lintel seals shall be of approved music-note shape to activate by the
upstream water pressure. The bottom seal shall be of flat rubber strip.
Water leakage under any head and without use of any additional sealing material shall not exceed
0.1 l/s per m of seal length.
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2.2.6 Guide Rollers

Each gate shall be provided with two adjustable guide rollers on each side of stainless steel for
lateral guidance of the gate. The rollers shall be made of stainless steel and shall have selflubricated bearings, well protected by grease filling and rubber seals, running on stainless steel
spindles. The guide rollers shall be adjusted to approximately 2 mm clearance to frame and guides.
With the gate in top position, the two lower guide wheels on each side shall still be engaged.
2.2.7 Guide Shoes
Each guide shoe shall consist of guide shoe base plate and ribs with supports. The guide shoe shall
be of approved material. The guide shoe shall be hardened to value rather lower than the Brinell
hardness number of guide frames.
2.2.8 Embedded Parts
At the bottom and at both sides of each gate, the guiding and sealing components shall be
embedded in concrete. The sealing faces and guide-ways of the guide rollers shall be made of
stainless steel.
Blockouts will be left in the first stage concrete in such a way that completely plane surfaces are
obtained after embedment of sealing faces in concrete. The steel lined parts shall be constructed
appropriately stiff. The lateral sealing faces shall be designed for forces resulting from seals and
guide rollers and consequently a suitable connection to the first stage concrete shall be provided.
The sealing face at the bottom shall be dimensioned for the dead weight of the gate and provisions
shall be made where necessary for construction joints where these cross the sill.
Suitable adjusting screws and bolts shall be provided for all parts to be installed in blockouts of the
first stage concrete to enable a precise adjustment during the erection stage. All of the adjusting
screws shall have a diameter not less than 20 mm. The Contractor shall be fully responsible for
proper positioning of all parts embedded in the first and the second stage concrete until completion
of the Works.
2.2.9 Wheels
Fixed axle wheels shall be of cast steel, fitted with roller bearings and suitably sealed to efficiently
exclude dirt, moisture and water under all conditions of hydraulic head. The treads, bore and faces
of the hubs shall be machined. The axles shall be of stainless steel. If more than two wheels are
used per side of each gate unit, they shall be suitably articulated or mounted on eccentric shafts to
ensure that the load is equally distributed on the wheels. The wheel shall be cross radi-used, or the
bearings of the spherical type to allow for gate deflection. Where spherical bearings are used to
allow for gate deflection, guides for the wheels shall be provided in the gate wheel beams to
prevent cross-tracking.
As an additional alternative the Bidder/Contractor may offer a wheel design with self-lubricating,
maintenance free slide bearings instead of roller bearings.
The fixed axle wheels shall be of ample diameter and width of tread to ensure that the pressure
between the wheel or roller and the fixed path is within the following limits:
The Brinell hardness number of the wheels or rollers shall not exceed 270. The Hertz
stresses must be checked.
The wheel or roller paths shall have a greater hardness than the wheel or rollers but shall not exceed
280 Brinell. Special care shall be taken to ensure against temper brittleness, and to provide
sufficient toughness to withstand impact due to vibration or other movement of the gates.
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2.2.10 Lifting Beam

The lifting beam shall be of all welded construction and shall be provided on the top of the gate
leaf. The lifting beam shall be provided with lifting attachments for connection of the hoist
spindles.
2.2.11 Grating
The gratings with their frames shall be provided on deck to cover the gate slot.
2.3 Ladders, Platforms, Handrails

Ladders, stairs and platforms shall be provided on the gates to enable easy inspection and
maintenance. All ladders shall be caged, or half-cages whenever possible and the platforms shall be
provided with handrails and handgrips.
2.4 Control and Protection Devices

Each gate shall be provided with a local control panel, installed in the hoist deck. For constructional
requirements Clause 56 of General Specification shall apply.
All the Gates shall be operated and controlled electrically by an operator from the local control
cabinet or box and manually by wheel. The emergency operation of the under sluice gate, intake
gate and low pressure penstock gate will be performed from the control room. Opening degree
indication of Under Sluice Gates, Intake Gate, Low Pressure Penstock Inlet Gate shall be
transmitted to the control room of the powerhouse.
The local control panel shall include main isolating breakers for motor control, space heater,
current voltmeter and ammeter with selector switches, function annunciator block, fault annunciator
block, gate position indicators and all equipment required to provide reliable and fail-safe operation
under the specified service conditions.
The function annunciator lamps shall include but not be limited to, power on, control circuit on,
space heater on, gate opening, gate closing, gate fully closed, gate fully open, local/manual
operation, remote/automatic operation.
The separate fault annunciator lamps shall include but not be limited to, general fault, motor
overheated, mechanical overload, motor over current, upper over-run, lower over-run, skew error,
hand drive unlocked, gate docked and any other malfunction of the automatic control.
The gate position shall be permanently displayed on a dial type indicator and separate lamps shall
be provided below the indicator to show that the gate has reached the preset position.
For each gate one gate position transmitter shall be provided. The transmitter shall contain a multiturn capacitive instrument and shall be housed in a water and weatherproof enclosure. The position
indicators (analog and digital) shall indicate the exact gate opening at 10 mm intervals in 4 digits.
The indicators shall be located on the local control panel, the spillway control room and the
powerhouse.
2.5 Hoist Equipment

Each gate shall be lifted and lowered by Electrical screw spindle hoist with provision of manual
operation. The hoist shall be designed to raise, lower and hold each gate in any position between
fully closed and opened position and under any combination of upstream and downstream water
levels within limiting flow conditions as ascertained and proposed by the Bidder/Contractor. The
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hoist shall consist of steel base framework, mechanical equipment, i.e., torque shafts, bearings, gear
reducer units, couplings, screwed spindles, supporting brackets, manual operating device,
mechanical position indicator, etc., electrical equipment such as electric motor, limit switches,
torque switches, electro-magnetic brake, etc., and all other necessary components for safe, proper
and efficient operation of the hoist.
The hoist shall be designed to withstand the maximum hoist load at the specified allowable unit
stress and the factor of safety. The hoist shall also withstand the load due to the maximum hoist
motor torque, without exceeding 90 percent of the yield strength of the material used.
The details of the construction of the hoist, not specified herein, shall be made by the Contractor
upon approval of the Engineer.
2.5.1 Steel Base Framework
The steel base framework shall be of all welded steel construction using rolled structural shapes and
plates. No deflection shall be such as to cause misalignment or overstress of the machinery parts.
Necessary anchor bolts and nuts for the steel base framework shall be supplied by the Contractor.
2.5.2 Mechanical Equipment
i. Torque Shafts
The torque shafts shall be finished commercial steel shaftings. The diameter of the shafts shall not
be less than 50 millimeters.
ii. Bearings
The bearings shall be of self-aligning re-greaseable ball, roller or plane type.
iii. Gear Reducer Units
Gear or worm gear reducers used for the hoist shall be standard high grade reducing units of good
efficiency suitable for long service life and the proportion of the parts therein shall be in accordance
with the best engineering practice
Gear shall be of cast or forged steel with machine-cut teeth.
Gears or worm gears and their supports shall be sufficiently firm to withstand the load imposed
under the most adverse operation of the hoist, and shall be enclosed in oil-tight and weather-proof
cases. Suitable lubrication system shall be furnished for the gear reducer units.
iv. Couplings
Couplings shall be flexible type and shall be provided with the means for field adjustment, and with
suitable means for permanent attachment to torque shaft after field adjustment.
v. Screwed Spindles
The screwed spindles shall be made of corrosion-resisting steel, and shall be provided with
machine-cut square thread of necessary length.
The spindles shall also withstand the thrust force imposed when the gate is closed.
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vi. Stranded Rope:

Ropes used for hoisting the gates shall be made of suitable corrosion resisting material and shall be
suitable to withstand the most adverse operating condition.
vii. Manual Operating Device
The diameter of the handle shall be approximate 600 millimeters and manual handling force shall
be less than 10 kilogram force per operator.
The handle shall be so installed that the handle center is located at the range of 600 to 800
millimeter high on the concrete deck. The handle shall be furnished with suitable locking device for
locking the handle while the handle is out of work
viii. Gate Position Indicator
A Mechanical gate position indicator shall be mounted on the hoist and be easily readable dial type
having one pointer.
The dial plate shall be of stainless steel or brass with engraved markings. Such main parts to be
incorporated in the indicator as gears, pinions, bushings, pins, etc. shall be made of anti-corrosive
materials. The dial and points: shall be mounted in a dust-tight and weather-proof enclosure, and
shall be capable of reading the gate opening by 10 centimeters.
2.6 Tools and Maintenance Devices

All tools, devices and equipment for proper handling, assembly, erection, maintenance and
disassembly of any part of the gates and associated equipment shall be supplied. All such tools,
devices and equipment shall be stamped or marked for identification.
An itemized list of these special tools, devices and equipment furnished shall be submitted with the
Bid.
2.7 Spare Parts

2.7.1 Mandatory Spare Parts
The following spare parts that comprise the total quantity required for different gates and hoist
called for under this specification shall be furnished and their itemized cost entered in the price list:
I.
Under Sluice Gates

2 (two) sets of rubber sealings (undrilled)
2 (two) lateral guide rollers
2 (two) sets of bushings including seals used
20% of all bolts, nuts, etc. for the seals
1 (one) set of driving motors
1 (one) set of motor contactors
1 (one) set of stop switches
1 (one) set of relays
1 position indicators with cables
2 (two) sets of lighting and indicator lamps, fuses and switches
5 (five) grease nipples and/or cups for each size and type and grease gun with appropriate
nozzle
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II.
No.1 Gravel Trap Gate
III.
1 (one) set of rubber sealings (undrilled)

1 (one) lateral guide roller
1 (one) set of bushings including seals used
nozzle
No.2 Gravel Trap Gate
V.

nozzle
Intake Gate
IV.


nozzle
Desander Inlet Gates

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nozzle
VI.
Desander Outlet Gates

nozzle
VII.

Desander Flushing Gates
4 (four) sets of rubber sealings (undrilled)

2 (two) sets of bushings including seals used
2 (two) sets of motor contactors
2 (two) sets of stop switches
2 (two) sets of relays
4 (four) sets of lighting and indicator lamps, fuses and switches
nozzle
VIII. Head Pond Flushing Valve
IX.
1 (one) set of bushings including seals and pickings used

Low Pressure Penstock Inlet Gate
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X.


nozzle
General Items
100 (Hundred) kilograms of grease
Note: "One set" shall mean for one gate / one hoist unit / one local control panel.
2.7.2 Recommended Spare Parts
The Bidders are required to provide list of recommended spare parts. The price shall be quoted
under the respective price schedule for the recommended spare parts.
2.8 Shop Assembly and Tests

See Chapter 1.6.
2.9 Site Tests

After completion of the installation at site, all tests shall be performed completely by the Contractor
at its cost and expense (see also Chapter 1.7). The tests on completion shall consist of precommissioning tests and commissioning tests.
Pre-Commissioning Test
The Pre-Commissioning tests shall include, but not be limited to, the following:
inspection by water jet and feeler gauge measurement of satisfactory sealing of all gate seals
radiographic or ultrasonic examination of any site welds in load carrying members, other
than seal welds
insulation resistance tests on all site installed wiring and electrical connections
setting of limit switches, indicator and control equipment
inspection of satisfactory installation of all components.
Commissioning Tests
The commissioning tests shall include, but not be limited to, the following:
measurement of operation speed (opening and closing)
check of power consumption of electric motor
check of accuracy of indication; limit setting of alarm signals etc.
check of water leakage from closed gate (leakages out of specified values to be repaired at
once)
check of general satisfactory operation
check of satisfactory operation for controlling the water discharge by the gates under any
water level
check of automatic operation of the gates using simulated water levels.
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Check of vibrations, noise, flow oscillations, and other phenomena under various operating
conditions.
2.10 Particular Bid Documents

Further to the particulars called for in the foregoing clauses and sub clauses the Bidder shall furnish
with its bid the following additional documents:
general outline drawing in scale showing the gate

typical cross section of side seal, bottom seal and bearings
reference list of comparable or identical equipment supplied by the Bidder
Indicate responsibility for design and manufacture.
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3. STOPLOGS
3.1 General
Stoplogs and bulkheads with guide and sealing frames, storing and dogging devices, hoist and
lifting beam are required at different areas of the spillway, intake and tail-race for isolating other
equipment for purposes of inspection and maintenance.
3.1.1 Scope and Limits Of Supply
The scope of supply includes the following components:
I.
Under Sluice Stoplogs
II.
Intake Stoplogs
III.
3 (three) complete sets of stoplogs complete with seals for the intake
3 (three) complete sets of guide and sealing frames, dogging device, including all embedded
parts
1 (one) set of electric motor operated monorail hoist with provision of manual operating
system
1 (one) grappling beam
1 (one) complete set stoplog surface storage devices
1 (one) set of spare parts.
Draft Tube Bulkhead Gates
IV.
2 (two) complete set of stoplogs complete with seals for the under sluice
2 (two) complete sets of guide and sealing frames, dogging device, including all embedded
parts
system
1 (one) complete set stoplog surface storage devices,
2 (two) complete set of stoplogs complete with seals for the draft-tube outlet
parts
system
Tailrace Stoplogs
2 (two) complete set of stoplogs complete with seals for the tailrace outlet
parts
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system
For all the above-mentioned equipment the scope of supply has to include:
all necessary anchors, bolts, screws, framing, pipes, lubricants, temporary and permanent
items for alignment and fixing in and to concrete
all components, devices, items and equipment not mentioned above, but necessary for the
safe and proper manufacture, transport, testing, operation and maintenance.
cable connection to the terminals at the local control cabinets / boards
The limits of supply are as follows:
to Lot 2 - Civil Work:
Concreting of all parts to be embedded. Supply, installation, alignment and monitoring of

these parts during concreting will be done by the Lot -3 HSS Contractor.
to Lot 4 Electrical and Mechanical Works:
In-feed terminals for power supply from Lot 4 Electrical and Mechanical Works contractor.
3.1.2 General Arrangement

The general arrangement of the different stoplogs and bulkhead and hoist is shown on the
corresponding drawings.
3.1.3 Tolerances
In addition to the tolerances stated in the relevant Standards the following limits shall apply, unless
the Contractor's design requires smaller tolerances to be ordered by the Engineer.
Embedded Parts
Clear span
Sealing span
Distance center to center of track frame
Height of guide frame
Flatness of sill beam surface
Straightness of sill beam surface
Flatness of sealing surfaces
Straightness of sealing surfaces
5 mm
5 mm
5 mm
10 mm
1 mm/m
2 mm
1 mm/m
2 mm
Stoplog and bulkhead leafs

Length
Height
Depth
Diagonal length difference
Distance between lifting lugs
Distance between sealing rubbers
5 mm
5 mm
2 mm
5 mm
4 mm
4 mm
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Water-tightness
Under maximum water pressure and without the use of any additional sealing material, the
leakage shall not exceed 0.1 l/s m.
3.1.4 Operating Conditions, Design Criteria
The stoplogs shall be designed for the following conditions as specified hereunder.
I.
Under Sluice Stoplog

Type of stoplog:
Number of stoplog
Number of stoplog panels
Clear span
Clear height
Design water level
Sill level
Design head
Water tightness
II.
Intake Stoplog
Type of stoplog:
Number of stoplog
Clear span
Clear height
Design water level
Sill level
Design head
Water tightness
III.
sliding gate type

Three (3)
one to two
4.3 m
1.2 m
1998.74 masl
1994.4 masl
4.34 m
4 Edges seal at upstream
Draft-tube Bulkhead Gates

Type of bulkhead:
Number of stoplog
Clear span of opening
Clear height of opening
Design water level
Sill level
Design head
Water tightness
IV.
sliding gate type

Two (2)
one to two
3.0 m
3.2 m
1998.74 masl
1993.3 masl
5.44 m
4Edges seal at downstream
sliding gate type with filling valve

Two sets
One to two
3.5 m
1.6 m
1770.86 masl
1761.38 masl
9.48 m
4 Edges seal at downstream towards the
power house
Tailrace Stoplogs
Type of stoplog:
Number of stoplog
Clear span
Clear height
Design water level
Sill level
sliding gate type

Two sets
One to two
3.6 m
1.2 m
1770.86 masl
1765.55 masl
Page 24

Design head
Water tightness

5.31 m
4 Edges seal at upstream
3.2 Construction of the Stop Logs

3.2.1 Stoplog Panel
Each stoplog panel or bulkhead shall consist of skin plate, main beams, vertical members, bearing
plates, seals, filling, bypass and/or emptying valves (as necessary), side rollers or guide blocks,
front spring loaded rollers, lifting lugs and all other necessary components. If not specified
otherwise, each stoplog panel or bulkhead shall be completely interchangeable with another for
easy operation.
All welds shall be continuous and the size of fillet welds shall approximate to the thickness of the
thinnest member of the joint.
In order to lift up each stoplog panel or bulkhead under balanced head condition, filling valves shall
be provided (if necessary) in some stoplog elements or bulkhead for filling the space between the
stoplog and following gate. Each stoplog panel or bulkhead shall have front rollers to hold them in
a vertically aligned position in the slot to ensure complete water tightness.
Each stoplog shall incorporate a landing sensing device operating on the grappling beam hooks
such that the hooks shall only release when the stoplog is in a solid position. This is to prevent
accidental release should the stoplog element or bulkhead jams in its guides for any reason whilst
being lowered.
The skin plate shall be located at the upstream side of each stoplog panel or bulkhead, if not
otherwise required. The minimum thickness of skin plate shall be 10 mm.
Each stoplog panel or bulkhead shall be equipped with lifting lugs on the top. The lugs shall be
designed to ensure that the grappling hooks of the lifting beam can catch and release the pins of the
lifting lugs. The Bidder shall add additional or alternate lifting arrangements, if necessary, for
hoisting stoplogs into and out of the downstream access shaft storage device.
3.2.2 Front Rollers
Spring loaded front rollers shall be fitted on the downstream side-end beams of each stoplog panel
or bulkhead to ensure that the seals are operative due to upstream water pressure. The rollers shall
be provided with self-lubricating bushings and washers. The roller pins shall be of stainless steel.
Each roller and pin shall be designed to resist the imposed load due to the stoplog elements
becoming jammed in the guide slots. In case the space between stoplog and following gate or
equipment is emptied, the whole water load shall be transmitted by means of the side end plate of
each element to the built-in parts of the guide frames.
3.2.3 Side Rollers / Guide Blocks
The side rollers or guide blocks shall be provided on each side of the stoplog or bulkhead leaf to
limit lateral movement of the stoplog. The rollers shall be provided with self-lubricating bushings
and location washers. The roller pins shall be of stainless steel. Each roller and pin as well as the
necessary built-in parts shall be designed to resist the imposed load due to the stoplog becoming
jammed in the guide slot.
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3.2.4 Seals
The seals shall be molded rubber strips, preferably music-note shapes, clamped to the upstream (or
downstream in certain cases) face of the stoplog panel or bulkhead by means of corrosion-resisting
steel bolts, nuts and washers with anti-leakage materials. The seals shall be spliced at the corners by
shop vulcanizing to provide a single continuous seal. The tensile strength of all shop splices shall
not be less than 50% of the tensile strength of the unsliced materials. The head seals (if any) and the
side seals of music note type or other shape shall be activated by the upstream water pressure and
the bottom seal shall be a plain bar of rubber. The weight of the stoplog panel or bulkhead shall be
transmitted to the sill beam or the stoplog below through the skin plate.
3.2.5 Filling Valves
If necessary, filling valves of not less than 100 mm diameter shall be provided on each stoplog
panel or bulkhead for filling the space between stoplog and following gate or equipment after
completion of inspection and maintenance. The inlets to this valve shall be protected by bar screens
to prevent the ingress of any debris. The filling valve shall be operated by the dead weight of the
grappling beam or when lifting the stoplog panel or bulkhead. The upper ends of valve rods shall be
fixed with the guide lifting lugs for use as lifting points.
Since the water level may reduce during the time when the stoplogs are in use it is possible for the
water level to be below the bypass valves in a section but above the bottom of the section. The
bypass valve therefore shall be as close to the bottom of the section as possible to minimize the
unbalanced water pressure under which the stoplog or bulkhead must be lifted
3.2.6 Storing Devices
Depending on the number of panels per set there are different methods and facilities of storage to
be considered:
Storage in guide frames. This type of storage will be applied for all or bulkhead. They will
be supported by dogging devices on top of the guide frame of the relevant opening to be
closed.
Storage in storage slots. This type of storage will be applied for the stoplogs of the flushing
channel. The storage slots are provided with appropriately located dogging devices.
3.2.7 Embedded Parts
Each guide frame shall consist of the sealing frames, sill beam, lintel beam (if any), track frames,
side guide frames, front frames and all other necessary components.
Sealing frames
The sealing frames shall be provided with corrosion-resisting steel plates on both sides and at the
lintel (if any). For the bottom sealing face no corrosion resisting steel is required. When the guide
frames have been assembled, the sealing surfaces shall be continuous, straight and in the same
plane. The minimum thickness of the sealing plates shall be 6.0 mm.
Sill Beams
The sill beams shall be straight and true to provide a close fit with the bottom of the lowest stoplog
panel. The sill beams shall be conservatively designed to be able to transfer all loads on it to the
concrete structure.
Track Frames
The track frames shall be capable of transmitting the water load on the stoplog to the concrete
structures. The surfaces of the track frames shall be attached with corrosion resisting steel plates of
not less than 6 mm thickness, and be true and flat.
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Front Roller Frames

The front roller frames shall have ample strength to resist the load from the front rollers. The
surfaces of these frames shall be attached with corrosion resisting steel plates of not less than 6 mm
thickness, and be true and flat.
Side Frames
The side guide frames shall have ample strength to resist the load from the side rollers or guide
blocks of each stoplog panel and grapping beam. The assembled side roller paths or guide rails,
having corrosion resisting steel bars, and shall be straight over their entire length and no offset shall
exist at joints.
3.2.8 Grappling Beam
The automatic grappling beams shall be reliable in operation. They shall be guided by the side
guides and upstream sealing faces provided for the stoplogs or bulkhead. Guidance shall be by
rollers attached to its ends, and these shall have rubber (or composition) types to avoid damage to
the faces of the built-in guides, particularly the stoplog sealing face. Automatic engaging and
disengaging shall be ensured by means of weights and links or similar means, and shall not rely
upon rope operation from the operating platform level. It shall also contain the lower sheaves of the
hoist rope. Slings necessary for removing the covers of storage pits or slots shall also be provided.
The grappling beams shall be arranged to operate in conjunction with the stoplog landing sensing
devices mentioned before in order to ensure against accidental release.
3.3 Installation
3.3.1 Guide Frames
The guide frames shall be assembled in their blackouts in accordance with the final approved
drawings, brought to line and grade within the tolerances specified and firmly secured in place.
Alignment bolts or other necessary devices shall be used to install the guide frames at
corresponding accurate position.
Connections between the guide frames, anchor materials and the alignment device shall be
adjustable and firmly tightened to hold the guide frames securely in position while concrete is being
placed in the block outs. Additional bracing shall be provided where necessary to ensure the
required alignment. Extreme care shall be taken to ensure that the guiding, bearing and sealing
surfaces lie in a true plane within the tolerance specified.
Placement of concrete in the block outs shall not proceed until the guide frames have been
completely assembled and secured. During placing the concrete, alignment tolerances shall be
checked and remedial action taken if readings indicate that displacement has occurred.
3.3.2 Stoplog and Bulkhead
Each stoplog element complete with seals, front rollers and side rollers shall be assembled and
erected in accordance with the details shown an the final approved drawings.
Joints shall be watertight where required. The bottom of the stoplog when erected shall be in true
alignment to ensure a tight and even bearing of the rubber seal on the embedded sill beam or
element below. The sides of the stoplog shall be in true alignment so that the rubber seals, when
installed, shall have a tight and even bearing on the sealing surfaces embedded in the concrete. The
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stoplog shall be assembled and erected within the shop tolerance necessary to meet the specified
tolerances.
3.4 Control and Protection Devices

Control and protection devices, if necessary for operation, shall be included in the scope of supply.
3.5 Hoist Equipment

The Contractor shall provide suitable Monorail Type Hoist to raise and lower the stoplogs or
bulkhead.
Bidder has to provide design and construction details of all arrangements for the stoplog storage
arrangements.
3.6 Tools and Maintenance Devices

All tools, devices and equipment for proper handling, assembly, erection, maintenance and
disassembly of any part of stoplogs or bulkhead and associated equipment shall be supplied. All
such tools, devices and equipment shall be stamped or marked for identification.
An itemized list of these special tools, devices and equipment furnished shall be submitted with the
Bid.
3.7 Spare Parts

3.7.1 Mandatory Spare Parts
The following spare parts shall be furnished for each stoplog and bulkhead and their itemized cost
entered in the Price Schedule.
1 (one) set of side seals for each stoplog or bulkhead with 20% (twenty) of the screws and
nuts,
1 (one) set ordinary bottom seals for each stoplog or bulkhead,
1 (one) set of guiding rollers for each stoplog or bulkhead,
1 (one) set of bearings, bushing and pins for the hoisting beams.
1 (one) set of limit switch and relay of each type to be used
1 (one) set of contactors for hoisting, travelling and translation of the mono-rail hoist
Hoisting rope of proper length of type used
nozzle
1 (set) of driving motor complete with accessories
3.7.2 Recommended Spare Parts

The Bids are required to provide list of recommended spare parts. The price shall be quoted under
the respective price schedule for the recommended spare parts.
3.8 Shop Assembly and Tests

Each stoplog panel including seals, bearing plates and side rollers shall be assembled in the
Workshop in the approximate position that they will have after installation at the site. While
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assembled, each stoplog element shall be checked for dimensions, tolerances and accuracy of
alignment. Any error or misalignment discovered shall be promptly corrected.
The seals shall be fitted to their supports during the shop assembly. Parts shall be clearly match
marked before disassembly for transportation. Sealing frames, track frames, side guide frames,
front guide frames and sill beams for the guide frames shall be checked by means of straight edge
and feeler gauge. All dimensions of the guide frames that correspond to the stoplog dimensions
shall be checked, and any error or misalignment discovered shall be corrected.
The function of all grappling beams shall be checked also.
Painting tests shall be include the following:
The peeling test for dried films an the constructions shall be carried out not earlier than 7
days after application of final coat to allow full curing of the paint film.
The dried films shall be checked by holiday detector for pinholes at any time after painting
work be finished.
The thickness of dried films shall be measured by elco-meter after painting work is finished
to a check point in every one square meter, or the area where the Engineer so requests.
3.9 Site Tests

After completion of the installation work at the site, all tests shall be performed completely by the
Contractor at its cost and expenses (see also Chapter 1.7). The tests on completion shall be precommissioning tests and commissioning tests.
Pre-Commissioning Test
The Pre-Commissioning tests shall include, but not be limited to the, following:
inspection by feeler gauge measurement of satisfactory sealing of all seals
radiographic or ultrasonic examination of any site welds in load carrying members, other
than seal welds
inspection of satisfactory installation of all components, especially function of seals and
grappling beams.
Commissioning Tests
The commissioning tests shall include, but not be limited to the following:
check of water leakage from the seals (leakage above the specified tolerances to be repaired
at once)
check of general satisfactory operation
check of satisfactory operation of all handling procedures by using the grappling beam
under maximum water level.
3.10 Particular Bid Documents

Further to the particulars called for in the foregoing clauses and sub-clauses the Bidder shall be
furnish with its Bid the following additional documents:
general outline drawing in scale showing the stoplogs and bulkheads with embedded parts
typical cross section of side seal, bottom seal, lintel seal (if any) and wheel assembly
reference list of comparable or identical equipment supplied by the Bidder. Indicate
responsibility for design and manufacture.
Page 29

Solu Hydroelectric Project Technical Specification

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Upper Solu Hydro Electric Company (Pvt.) Ltd.