7 - Draft Tube Gates

THE DEMOCRATIC SOCIALIST REPUBLIC OF SRI LANKA
MINISTRY OF POWER AND ENERGY

CEYLON ELECTRICITY BOARD
UPPER KOTMALE HYDROPOWER PROJECT

LOT3 HYDROMECHANICAL WORKS
OPERATION & MAINTENANCE MANUAL

7/8 DRAFT TUBE GATES AND HOISTS
Introduction
Introduction
This manual provides safety precautions, operation and maintenance procedures,
and troubleshooting for HYDROMECHANICAL WORKS for UPPER
KOTMALE HYDROPOWER PROJECT.
Read this manual thoroughly before operating, maintaining, and inspecting the
facility.
Always keep this manual nearby so that you can read it anytime.
We shall not be responsible for any personal injury and faults/damages resulting
from any improper operation.
How to use this manual

Since safety precautions for dealing with this facility and equipment are provided
in this manual, be sure to read and understand this manual in conjunction with
other manuals when you operate the facility.
Refer to the relevant manual for each equipment.
Careless operation of this facility and equipment may cause serious

personal injury or death.
This manual should be read and understood before operation and
maintenance.
Make your own rule as to where to put this manual, keep it in a safe
place, and read it periodically.
● Do not operate until you fully understand this manual.

● Always keep this manual nearby, and read it periodically.
● Make sure to read "Chapter 2 Safety" and other safety
precautions in each chapter.
Inspection and maintenance

Be sure to perform operational inspection and periodical inspection to ensure
safe use and to prevent failure of the facility.
Operation
Only authorized personnel can operate, handle, and maintain the facility and
equipment.
KRCS-182MJ

Table of Contents
Introduction............................................................................................... I
1 General.............................................................................................. 1-1
1-1 Draft Tube Gates and Hoists............................................................. 1-2
2 Safety................................................................................................. 2-1
2-1 Alert Symbols and Safety Marks....................................................... 2-3
2-2 Safety Rules..........................................................................................2-4
3 Overview of the Facility................................................................... 3-1

3-1 Overview of the Facility.........................................................................3-2
3-2 Structure of the Gates...........................................................................3-3
4 Operation.......................................................................................... 4-1
4-1 Operation Modes...................................................................................4-2
4-2 Overview of the Control Systems..........................................................4-3
4-3 Local Control Cabinet (LCC) for the Draft Tube Gates (No.1 and No.2)..... 4-6
4-4 Local Operation of the Draft Tube Gates............................................. 4-15
4-5 Local distribution board.......................................................................4-20
5 Steel Structure.................................................................................. 5-1

5-1 Technical Data.......................................................................................5-2
5-2 Design and functional description..........................................................5-3
6 Hoist.................................................................................................. 6-1
6-1 Technical Data.......................................................................................6-2
6-2 Design and Functional Description........................................................6-3
7 Lubrication........................................................................................ 7-1
7-1 Lubricants List....................................................................................... 7-2
7-2 Lubrication Methods..............................................................................7-3
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II
8 Inspection and Maintenance Procedures...................................... 8-1
8-1 Safety Precautions to Observe during Inspection and Maintenance.....8-2
8-2 Overview...............................................................................................8-3
8-3 Guidelines for Inspections and Maintenance........................................ 8-4
8-4 Inspection and Maintenance Checklists................................................8-7
9 Trouble Shooting.............................................................................. 9-1
10 Painting........................................................................................... 10-1
10-1 Painting Specification..........................................................................10-2
11 Spare Parts and Supplied Tools....................................................11-1

11-1 Mechanical equipment........................................................................ 11-2
11-2 Electrical works................................................................................... 11-4
11-3 Maintenance equipment and tool list................................................... 11-6
12 Commercial Equipments and Addresses of Vendors................. 12-1

12-1 MECHANICAL..................................................................................... 12-2
12-2 ELECTRICAL.................................................................................... 12-17
13 Office to Contact for Service Inquires.......................................... 13-1
14 Annex.............................................................................................. 14-1
14-1 Initial Setting of Timer of Water Filling for Draft Tube Gates............. 14-2
KRCS-182MJ
III
1
General
1-
1-1 Draft Tube Gates and Hoists
The draft tube tunnel is placed at the downstream surge chamber of the
powerhouse and consists of two (2) draft tube tunnels, two (2) draft tube gates.
The draft tube gates are a vertical lift slide type gate equipped with two (2)
bypass valves, having a diameter 150 mm, to fill water into the draft tube and
to equalize the water pressure on both sides of the gate leaf before opened.
The valve is operated through a rod connected to the lifting lug and controlled
by the hoist
The gates are used to close each opening of draft tube for inspection,
maintenance and repair of water turbines and generating equipment.
The gate is operated and controlled from Local Control Panel only.
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2
Safety
2-
General notes
This manual describes important matters for the facility to be used safely
and properly, and to prevent personal injury and damages to the facility and
equipment.
Read and understand the following general precautions and “ 2-1 Alert
Symbols and Safety Marks” first. Then read “ 2-2 Safety Rules” where
safety rules to follow are described.
General precautions
● Use of the facility under non-designated product specification may cause
personal injury or failure of the facility or equipment.
When you want to modify the product specification, or transfer and reinstall
the facility, be sure to contact us for technical information.
● Read and understand this manual before conducting operation, handling,

maintenance, and inspection.
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2-
2-1 Alert Symbols and Safety Marks
Alert symbols and safety marks used in this manual

Alert symbols and safety marks are used to call your attention to important
items against damage to persons and property. Strictly follow the instructions.
■ Alert symbols
Indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury.
DANGER
Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not

avoided, could result in minor or moderate injury or
CAUTION property damage*1.
Supplementary information about operation and

explanation is given.
REFERENCE
*1 Property damage means the loss of the facility or the equipment itself and/
or incidental or consequential loss of peripheral facility and equipment.
■ Safety marks
Concrete information is given near the mark.
Mark Meaning
Indicates DON'T.
Indicates DO.
Indicates caution.
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2-
2-2 Safety Rules
General instructions for each work
• Understand the following instructions thoroughly before

starting the work.
Fully understand the descriptions shown in this manual
AL
MANU before operation, inspection, and maintenance of the
facility.
• Conduct "Safety" briefing before operation, inspection, and

maintenance.
When working in a team, insufficient safety knowledge
could result in personal injury.
• Wear proper clothing and protective devices during the work.

A helmet and safety shoes are inevitably necessary for
installation, disassembly and reassembly work.
When approaching mechanical seals, wear safety
glasses to protect your eyes from splashed fluid.
It is necessary to establish your own safety rules for the
facility and follow them.
• Wear a safety belt when working at heights.

Set up scaffolds and safety fences and wear a safety belt
(life line) when working at heights.
• Transportation and electric work should be conducted by the

authorized personnel.
Transportation, installation, piping, wiring, operation,
Authorized handling, maintenance, and inspection work should be
personnel
done by the authorized personnel. Otherwise electric
shock, personal injury, and/or fire may be caused.
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2-
<Unloading, Unpacking, and Installation> - carrying heavy load
• Unloading work should be done by the authorized personnel.

Unloading the equipment from the truck or operating a
crane on the installation should be done by the authorized
Unloader personnel.
• Use the designated lifting device.

Use the lifting device having the specified lifting capacity.
Lift the machine using the lifting lugs attached to the
common bed. Do not use eyebolts attached to the motor
to support the machine weight.
Note: Choose wire size sufficient to bear the load. The

weight is shown in the drawing submitted by us.
• Lift the equipment, taking the center of the gravity and weight
into account.
Lift the equipment horizontally, taking the center of the
gravity and weight into account. Severe personal injury
may result from the fallen object.
• Never stand under the lifted equipment.

Never stand under the lifted equipment during lifting
work.
Severe personal injury may result from the fallen object.
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2-
Before test operation and usual start-up
• Ensure all the bolts tight.

Prior to start-up, ensure all the bolts and nuts and
the pipings of the machine is tightened up. Otherwise
personal injury, mechanical failure or facility damage may
occur.
• Do not operate the machine without safety covers.

If the machine is running without safety covers, the
persons working beside the machine may be caught in
the rotating parts and be injure d.
If the inspection is necessary while the machine is
running, special care must be taken to avoid the physical
contact especially with rotating parts.
• Never touch rotating parts.

Pay special attention not to touch rotating parts while the
machine is running.
Otherwise severe personal injury may occur.
• Do not touch the wire when raising and lowering the gate leaf.
You may be caught in the wire or pulley, and get injured.
Be away from the machine and the wire when raising and
lowering the gate leaf.
• Shut down the machine in case of emergency.

Shut down the machine immediately in case of
emergency to avoid any injury or damage.
EMERGENCY !
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2-
• Do not operate the machine without the interlock.
Removal or modification of the interlock or any change in
the set value can cause an accident.
Never change the set value or operate the machine
Interlock
without the interlock.
M
• Not to get burned.

Do not touch high temperature parts such as bearing
parts.
CAUTION If maintenance or operation is necessary, wear gloves not
to get burned.
• Close terminal boxes.

Close terminal boxes without fail to prevent electrical
shock hazard.
• General preparation.
Prepare washing devices and sheets because the raw
materials such as oil may splash.
Secure the space for placing mechanical parts to
be disassembled or exchanged and the passage for
transportation.
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2-
Maintenance, adjustment, disassembly and reassembly
• Do not conduct maintenance, adjustment, disassembly, and

reassembly work when the line is alive.
Be sure to turn off the power supply before conducting
these works.
Otherwise an electric shock may be caused.
• Take proper countermeasure to avoid unexpected start-up.

When conducting maintenance, inspection, and cleaning,
UNDER INSPECTION
turn off the power supply in the local and main control
DO NOT OPERATE
panels and of the mains, and make sure the machine has
stopped.
ON
Put up a notice such as "UNDER INSPECTION DO NOT
OFF
OPERATE" on the operational panel not to be operated
unexpectedly.
• Follow the diagram when connecting wires between equipments.

Follow the instructions such as diagram and delivery
specifications when connecting wires with the equipment
or with the power supply cable.
Tighten the connecting screws to prevent poor
connection.
Otherwise an electric shock or fire may be caused.
Do not connect the unused terminal with anything.
Otherwise mechanical failure, fire, or electric shock may
be caused.
• Be sure to ground the machine.

Be sure to ground the machine if the earth terminal is
attached.
The earth resistance should be 10Ω or less (class C for
more than 300 V), 100Ω or less (class D for less than
300 V).
Otherwise an electric shock may be caused.
• Do not carry heavy parts to prevent back injury.

Weight of the parts should be taken into account at
disassembly and reassembly. It is necessary to prepare a
CAUTION hoist, lifting tool and wire or chain to prevent back injury.
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2-
• Never use open flame during oil change.
Wipe clean any spilled oil with cloth to prevent fire.
• Secure and note the safety place.

Secure the place of refuge in case of emergency such as
drop of parts, a splash of materials and falling down of
the machine.
• Use genuine parts or those designated by the manufacturer

for replacement.
Warranty cannot be expected if the other parts be used
for replacement, which may damage the equipment.
GENUINE
• Never use open flame when cleaning with solvent.

When cleaning with solvent, ensure that ambient
temperature is not exceeding the ignition point of the
SOLVENT
solvent.
Strictly follow the prevention rules.
The solvent must be handled by the authorized personnel
because it is designated by law as a dangerous article.
• Place the parts in the stable condition.

When carrying, unpacking, disassembling and
reassembling, confirm the top and bottom of the
equipment and exercise great caution in preventing the
equipment from falling down and the parts from dropping
or rolling, which may cause serious injury.
Especially, when temporarily placing parts, it is necessary
to clean the floor and to use a wedge.
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2-
• Always observe the state of the wire ropes.
The wire ropes of this facility are always either under
tension or under water. Therefore, damages of the wire
CAUTION ropes such as internal breakage or corrosion may cause
a serious personal injury or death.
Special care should be taken to electric corrosion. If
abnormality occurs such as black discoloration of wire
strands caused by elution of galvanization, immediate
and close investigation is necessary.
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2 - 10
3
Overview of the
Facility
3-
3-1 Overview of the Facility
Objectives of the facility

The list below shows the type, objective and function of each gate.
Gate type Objective and function
The draft tube gate is located in the turbine draft tube of

the hydraulic power plant. This gate is used to close off
the draft tube for inspection and maintenance. In normal
Draft tube gate
operation, the gate is fully opened and the gate leaf is
dogged with the dogging hook. The gate is fully closed
only when the turbine is inspected.
Gate design condition
■ Item 11 Draft tube gates and hoists
Gate type Steel slide gate (w/ water filling valve)

Clear span × gate height 2.5 m × 3.0 m
Quantity 2
Hoist Wire rope lift stationary type
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3-
3-2 Structure of the Gates
■ Draft tube gates and hoists
Local control cabinet
A A
3300
600
400 2300
Removable
side roller path
5500
6000
800 1500
600 1000
48700
Hoisting height 52200
Lifting beam
250 3300 250
200 800
Gate leaf
φ150
By-pass valve
Clear height 3000
FLOW PRESSURE
650 Clrear Span 2500 650
Profile Elevation
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3-
Shotcrete as directed
4000
A A
13500
Consolidation
3000 3000
grouting L =3,000
B B
600
11300 5200 6000
1500
Outline
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3-
24
00
23
00
Draft gates operating floor
35 Upper chamber
00
00
20
0
50
400
00
25
00
25
4000
400
13500
Hoist
8000
View A-A
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3-
4496 9997
800
1485 2200 2500 1500 6000
3000 D Reference line
for draft gate
Shotcrete as directed
0
60
800
Air vent
5000
pipe φ250
14000
33
00
50
00
00
42
00
16
View B-B
51
32
53
31
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3-
■ Hoists for draft tube gate
Local distribution board
400
500
Motor
Chain coupling
Lifter brake Chain coupling
Limit switch
Gear reducer
Drum Position indicator

4800
960
1795
431
404
Wire end Grease pump

Limit switch
800
Gear coupling
3608
PRESSURE
Plan
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3-
296 135
360
810
450
50
1000
2300 400
PRESSURE
242
Profile
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3-
860
Wire rope
Dogging device
3260
1593
807
1100
2392
3800
Elevation
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4
Operation
4-
4-1 Operation Modes
The table below shows the operation modes for each draft tube gates.
LOCATION
GATE OPERATION MODE DFC/
LCC RCC SGOC
OPS
DRAFT TUBE GATES MANUAL
○ × × ×
(No.1-2) (OPEN, STOP, CLOSE)
LCC: LOCAL CONTROL CABINET

RCC: REMOTE CONTROL CABINET
SGOC: SPILLWAY GATE OPERATING CONSOLE
DFC: DAM FACILITY CONTROL BOARD
OPS: OPERATOR’S COMPUTERS
○ : Available × : Not available
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4-
4-2 Overview of the Control Systems
Overall configuration of the control systems

DC24V
SAND FLUSH GATE

AC400/230V
AC400/230V
Local Local Control
Distribution Cabinet Portable Diesel
Board Generator
CVV 2Sq-2c/Optical Cable
AC400/230V
INTAKE DAM CONTROL
BUILDING NO.5 SPILLWAY GATE
AC400/230V
CUBICLE ROOM CONTROL ROOM DC24V Local Control
Cabinet
AC230V DC Distribution AC400/230V

NO.4 SPILLWAY GATE
System for
DC24V Local Control
Spillway Gates Cabinet
NO.3 SPILLWAY GATE

DC Distribution AC400/230V
System DC24V Local Control
AC230V
for Sand Flush Cabinet
Gate CVV 2Sq-2c/Optical Cable
NO.2 SPILLWAY GATE

AC400/230V
DC24V Local Control
DC Distribution Cabinet
AC230V System for CVV 2Sq-2c/Optical Cable
Intake Gate
NO.1 SPILLWAY GATE
AC400/230V
Power DC24V Local Control
Receiving Cabinet
Cubicle AC230V CVV 2Sq-2c/Optical Cable AC230V Sedimentation
Automatic
Control Cabinet CVV 2Sq-4c control box
Melsecnet DC24V
Emergency Stop Ethernet
HUB
MAIN DAM INTAKE GATE
AC230V Spillway Gates
Operating
Local Portable Diesel
Console Local Contro
AC400/230V Distribution Generator
Board Cabinet
RAKING EQUIPMENT
UPS AC400/230V
AC400/230V Loading conveyor

Printer Ethernet
CVV 2Sq-4c control cabinet
AC230V MAIN DAM OUTLET WORKS
AC400/230V AC400/230V
Melsecnet Terminal
AC230V Joint box
AC230V Remote
Local Control DC24V DC Distribution
Control DC24V System for
Cabinet Cabinet Outlet Works Raking machine
control cabinet
TC/TM
Melsecnet (LOT4)
Emergency Stop Electro Grapple
NOTE
1. : Out of scope 7.5kW
2. : KURIMOTO's scope
3. : Temporary
UPPER KOTMALE POWER STATION
UNDER GROUND POWER HOUSE MAIN CONTROL BUILDING

BF1 1F
Power Receiving Power Receiving

Cubicle Cubicle
SWITCHGEAR ROOM
AC400/230V
AC400/230V
Local Distribution Local Distribution

Board Board
No.1 Local No.2 Local Local Control

Control Cabinet Control Cabinet Cabinet
DRAFT TUBE GATE TAILRACE GATE
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4-
Draft tube gate
Local distribution board Local control cabinet
PRESSURE
Plan
Elevation
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PRESSURE
Profile
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4-
4-3 Local Control Cabinet (LCC) for the Draft Tube Gates (No.1 and No.2)
4-3-1 Outline
The outside view and functions of the LCC for the draft tube gate are shown in
this section.
Outside view
Front view Side view
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4-
Monitoring meters
GATE AMMETER
Indicates the current of the
POWER SOURCE VOLTMETER
gate motor.
Indicates the power source
Rated current: . A
voltage.
GATE POSITION
GATE OPERATION TIME
Indicates the position of the
Indicates operating hours of
gate.
the gate.
Indication range:
0 to . m
Indicator Lamps
For details, see pages 4-0
to 4-.
Operating Switches
For details, see pages 4-8
and 4-.
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4-
Operating switches
This section describes the switches used for gate operations.
. RAISE
Gate “RAISE” 4. ALARM STOP
push button switch “ALARM STOP”
push button switch
. STOP
Gate “STOP”
push button switch . RESET
“RESET”
push button switch
. LOWER
Gate “LOWER”
push button switch
. LAMP TEST
“LAMP TEST”
push button switch
. EMERGENCY STOP
“EMERGENCY STOP”
pull button switch
1 Gate “RAISE” push button switch

Press this push button switch to raise the gate.
2 Gate “STOP” push button switch

Press this push button switch to stop the gate.
3 Gate “LOWER” push button switch

Press this push button switch to lower the gate.
4 “ALARM STOP” push button switch

Press this push button switch to stop the alarm buzzer.
When the push button switch is not pressed, the alarm buzzer automatically
stops after the elapse of the preset time.
5 “RESET” push button switch

When a fault indicator lamp is activated by a malfunction, it may remain
on even after the cause of the malfunction has been removed. Use this push
button switch to turn off the indicator lamp.
6 “LAMP TEST” push button switch

Press this push button switch to turn on all indicator lamps.
Check to make sure that there are no burned-out indicator lamps.
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4-
7 “EMERGENCY STOP” pull button switch
Pull this pull button switch to bring a gate to an emergency stop, or in cases
where the operator cannot stop the movement of the gate by pressing the
gate “STOP” push button switch. Pulling this pull button switch stops the
movement of the gate. (In normal operation, press the gate “STOP” push
button switch to stop the movement of the gate, and pull the “EMERGENCY
STOP” pull button switch only in an emergency.)
To reset the “EMERGENCY STOP” pull button switch, see the section
“Emergency stop operation”.
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4-
Indicator lamps
■ SL1
HOOK
MAIN POWER
ＲＡＩＳＩＮＧ RELEASE
SOURCE
POSITION
ＷＷＷ
GATE HOOK
MOTOR ＳＴＯＰ CATCHING
POWER POSITION
ＷＷＷ
BY-PASS VALVE
WATER
ＬＯＷＥＲＩＮＧ FULLY
BALANCED
OPENED
ＷＷＷ
GATE ＦＵＬＬＹ
DOGGED ＬＯＷＥＲＥＤ
ＷＷＷ
Alarm by
Indication on indicator lamp Indicator lamp lights up when
buzzer
MAIN POWER SOURCE Main power is being supplied.
GATE MOTOR POWER Power is being supplied to the hoist motor.
The preset time has elapsed after the by-pass valve was
fully opened.
WATER BALANCED
(The difference between upstream and downstream water
levels is small.)
RAISING (Chime) The gate is moving up.
STOP The gate is stopped.
LOWERING (Chime) The gate is moving down.
The gate is retained by the dogging hooks (dogging
GATE DOGGED
device).
The gate moves up to the fully raised position and the
dogging hooks (dogging device) are automatically opened
HOOK RELEASE POSITION
so that the gate can move from the dogged position to the
fully-closed position.
The gate moves up to the fully raised position and the
dogging hooks (dogging device) are automatically opened
HOOK CATCHING POSITION
so that the gate can move from the fully-closed position to
the dogged position.
BY-PASS VALVE FULLY
The by-pass valve is fully opened.
OPENED
FULLY LOWERED The gate has reached the fully lowered position.
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4 - 10
■ SL2
MOTOR OVER ROPE

OVERLOAD RAISED OVERLOAD
R R R
EMERGENCY OVER ROPE

STOP LOWERED SLACKED
R R R
MCCB BRAKE EARTH

TRIP TROUBLE LEAKAGE
R R O
R R O
Alarm by
buzzer
MOTOR OVERLOAD ○ Motor overcurrent has been detected.
EMERGENCY STOP ○ The “EMERGENCY STOP” pull button switch is pulled.
MCCB TRIP ○ The MCCB has tripped.
OVER RAISED ○ The gate is in its over raised position.
OVER LOWERED ○ The gate is in its over lowered position.
BRAKE TROUBLE ○ A hydraulic brake failure has been detected.
ROPE OVERLOAD ○ Rope overload has been detected.
ROPE SLACKED ○ Rope slack has been detected.
EARTH LEAKAGE ○ Earth leakage has been detected.
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4 - 11
4-3-2 Internal layout of the LCC
ＡＢ
ＦＬ１０ＷＴＢ
MARK LETTER
ＤＳ
MCCBLA POWER SOURCE ARRESTOR AC400V
MCCBG DRAFT TUBE GATE
Ｒ０１∼１６
ELCB1 OUTLET SOCKET (AC400V)
ELCB2 ACCESSORIES POWER SOURCE
Ｒ１７∼３２
MCCBC THE FIRST TRANSFORMER
MCCBH SPACE HEATER FOR MOTOR
ＭＣＣＢ
Ｇ
ＥＬＣＢＭＣＣＢＥＬＣＢＭＣＣＢＭＣＣＢ
１ＬＡ２ＣＨ
CP1 FLUORESCENT LAMP
CP2 SPACE HEATER
ＣＰ CP3 OUTLET SOCKET (AC230V)
ＬＡ２６ＡＣ／
１２３４５６７
ＥＳＨＤＣ CP4 DRY CONDITIONER
８４
ＭＣＭＣＭＣＭＣ８４ＸＭＸ CP5 CONTROL CIRCUIT (AC230V)
ーＵーＤ −Ｃ −Ｂ
３Ｅ２２
ＰＴＧＭ
CP6 INDICATOR CIRCUIT (DC24V)
CP7 GATE POSITION INDICATOR CIRCUIT (AC100V)
ＣＴＴ０１∼０５
ＣＣ
ＭＣ−Ｈ
ＳＣ
ＰＴＴＲ１
ＴＢ１ＴＢ２
ＳＨ
Ｅ−ＢＵＳ
Internal Layout of the Cabinet Front
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4 - 12
MARK LETTER
MCCBM MAIN POWER SOURCE AC400/230V
ＢＺＣＨ
ＭＣＣＢＲ３３
Ｍ ∼３５
Ｋ
０１
ＺＣＴ１
３Ｅ
ＴＢ３
ＣＯＮ１
ＤＨ
ＣＯＮ２
ＳＨＳＨ
Internal Layout of the Cabinet Left Side Internal Layout of the Cabinet Right Side
Viewed from the direction of "A" Viewed from the direction of "B"
(See page 4-12) (See page 4-12)
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4 - 13
4-3-3 Interlock
The facility is equipped with an interlock system to protect equipment
electrically from damage by operating errors caused by starting conditions,
operation conditions or operators.
○ : Possible to operate × : Impossible to operate
Alarm by Gate
Indication Remarks
buzzer Raise Lower
LEFT ROPE OVERLOAD ◎ × ○
RIGHT ROPE OVERLOAD ◎ × ○
OVER RAISED ◎ × ○
OVER LOWERED ◎ ○ ×
ROPE SLACKED (LEFT) ◎ ○ ×
ROPE SLACKED (RIGHT) ◎ ○ ×
MOTOR OVER LOAD ◎ × ×
MCCB TRIP ◎ × ×
BREAK TROUBLE ◎ × ×
EMERGENCY STOP ◎ × ×
EARTH LEAKAGE ◎ ○ ○
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4 - 14
4-4 Local Operation of the Draft Tube Gates
The draft tube gate is operated from the LCC only.
The gate has no remote control.
4-4-1 Points to be checked before starting operations

Check each gate and areas around the hoist, and make sure that nothing inter-
feres with gate operations.
CAUTION
Points to be checked are shown below.
Check to make sure that all the molded case circuit breakers (MCCBs),
earth leakage circuit breakers (ELCBs), circuit protectors (CPs) installed
in the cabinet are ON.
MCCBM ELCB1 CP1
MCCBLA ELCB2 CP2 (SPACE HEATER)
MCCBG CP3
MCCBH CP4 (DRY CONDITIONER)
MCCBC CP5
CP6
CP7
Check to make sure that the power source voltmeter indicates 400 V.
Check to make sure that the indicator lamps “MAIN POWER SOURCE”
and “GATE MOTOR POWER” are on.
Check to make sure that all fault indicator lamps (red), which light up
when a malfunction is detected, are off.
Press the “LAMP TEST” push button switch to make sure that all
indicator lamps light up.
Check the current position of each gate.
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4 - 15
4-4-2 Local normal operations
The gate leaf of the draft tube gate is usually suspended on the dogging hooks
(dogging device) thus, (the gate is dogged). When the tailrace is inspected, the
gate is fully closed by disengaging the dogging hooks (dogging device). After the
inspection is finished, the gate is opened and the gate leaf is suspended on the
dogging hooks (dogging device).
The operation switches on the LCC are used to attach or detach the dogging
hooks (dogging device).
Each icon indicates the following state:

L Indicator lamp ON, L Indicator lamp OFF, CH Chime
REFERENCE
■ Operation for attaching the dogging hooks (dogging device)

(FULLY LOWERED to GATE DOGGED)
Operating Operation Control cabinet Gate movement
steps
1 Press the gate “RAISE” "RAISE" The gate starts to move

push button switch. up.
L “RAISING” blinks.
CH Chime sounds.
2 When the gate has reached L “RAISING” goes off. The gate stops at the
the “by-pass valve fully “by-pass valve fully
opened” position L “STOP” lights up. opened” position.
L “BY-PASS VALVE FULLY

OPENED” lights up.
L “WATER BALANCED” lights up

after the elapse of the time set
by the timer.
3 Press the gate “RAISE”

push button switch.
"RAISE" The gate starts to move
up.
CH Chime sounds.
Continued to the next page
KRCS-182MJ
4 - 16
steps
4-1 Press the “STOP” push "STOP" The gate stops.

button switch to stop the The gate can be
gate movement. stopped at any position.
L “RAISING” goes off.
L “STOP” lights up.
4-2 When the gate has L “RAISING” goes off. The gate automatically
reached the “hook stops at the “hook
catching” position L “STOP” lights up. catching” position.
The dogging hooks
(dogging device)
L “HOOK CATCHING POSITION” automatically move to
lights up. the “closed” position.
5 Press the “LOWER” push

button switch.
"LOWER" The gate starts to move
down.
L “LOWERING” blinks.
CH Chime sounds.
6 The gate lowers, the

dogging hooks (dogging
L “GATE DOGGED” lights up.
The dogging hooks
(dogging device) are
device) are engaged, and engaged and the gate
the rope gets slack. L “LOWERING” goes off. stops upon detection of
a slack rope.
7 The operation of engaging

the dogging hooks
(dogging device) is
completed.
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4 - 17
■ Operation of detaching the dogging hooks (dogging device)
(GATE DOGGED to FULLY LOWERED)
steps
1 Press the gate “RAISE” "RAISE" The gate starts to move

push button switch. up.
CH Chime sounds.
2 When the gate has reached L “GATE DOGGED” goes off. The gate automatically
the “hook release” position stops at the “hook
L “HOOK RELEASE POSITION” release” position.
lights up. The hook automatically
moves to the “open”
L “RAISING” goes off. position.
3 Press the “LOWER” push

button switch.
"LOWER" The gate starts to move
down.
L “LOWERING” blinks.
CH Chime sounds.
4-1 Press the “STOP” push "STOP" The gate stops.

button switch to stop the The gate can be
gate at an appropriate stopped at any position.
position.
L “LOWERING” goes off.
4-2 If the “STOP” push button

switch is not pressed, the L “FULLY LOWERED” lights up.
The gate moves down
to the “fully lowered”
gate will move down to the position and stops
“fully lowered” position and L “LOWERING” goes off. automatically.
stops automatically.
5 The operation of detaching

the dogging hooks (dogging
device) is completed.
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4 - 18
4-4-3 Emergency stop operation
Perform the following steps to bring a gate to an emergency stop.
■ Emergency stop operation
1 Move aside the cover on the “EMERGENCY STOP” pull button switch
mounted at the front of the LCC.
2 Pull the “EMERGENCY STOP” pull button switch.
3 The gate stops automatically.
4 The alarm buzzer sounds, and the “EMERGENCY STOP” indicator lamp
lights up.
■ Operation for recovery from emergency stop
1 Press the “ALARM STOP” push button switch. The alarm buzzer stops
beeping.
2 Press the “EMERGENCY STOP” pull button switch to release the lock.
3 Press the “RESET” push button switch. The “EMERGENCY STOP”

indicator lamp goes off.
4 After ensuring safety, reset the tripped breaker.
KRCS-182MJ
4 - 19
4-5 Local distribution board
4-5-1 Outline
The outside view and functions of the local distribution board (for draft tube
gate) are shown in this section.
■ Outside view
Front view Side view
KRCS-182MJ
4 - 20
■ Operating switches
This section describes the switches used for gate operations.
Indicator Lamps
. ALARM STOP . LAMP TEST

“ALARM STOP” “LAMP TEST”
push button switch push button switch
1 “ALARM STOP” push button switch

Press this push button switch to stop the alarm buzzer.
When the push button switch is not pressed, the alarm buzzer automatically
stops after the elapse of the preset time.
2 “LAMP TEST” push button switch

Press this push button switch to turn on all indicator lamps.
Check to make sure that there are no burned-out indicator lamps.
■ Indicator lamps
● SL
ＣＯＭＭＥＲＣＩＡＬＥＡＲＴＨ
ＰＯＷＥＲＬＥＡＫＡＧＥ
ＷＯ
ＷＯ
Alarm by
buzzer
COMMERCIAL POWER Commercial power is being supplied.
EARTH LEAKAGE ○ Earth leakage has been detected.
KRCS-182MJ
4 - 21
4-5-2 Internal layout of the local distribution board
MARK LETTER
MCCB MAIN POWER SOURCE
MCCB1 No.1 DRAFT TUBE GATE
MCCB2 No.2 DRAFT TUBE GATE
MCCB3 SPARE(400V)
MCCB4 SPARE(230V)
CP1 SPACE HEATER
CP2 CONTROL CIRCUIT(AC230V)
㧮㨆
ＭＣＣＢＭＣＣＢＭＣＣＢＭＣＣＢＭＣＣＢ

１２３４
ＣＰ
Ｒ０１Ｔ２６２２
１２
ＺＣＴ１ ∼０３０１ＳＨＧＭ
ＴＢ１ＴＢ２
ＳＨＳＨ㧿㧴
Internal Layout of the Cabinet Front
Internal Layout of the Cabinet Left Side Internal Layout of the Cabinet Right Side
4-5-3 Interlock
The facility is equipped with an interlock system to protect equipment
electrically from damage by operating errors caused by starting conditions,
operating conditions or operators.
○ : Possible to operate × : Impossible to operate
Alarm by Gate
Indication Remarks
buzzer Raise Lower
EARTH LEAKAGE ◎ ○ ○
KRCS-182MJ
4 - 22
5
Steel Structure
5-
5-1 Technical Data
5-1-1 Draft tube gates and hoists

Type Steel slide gate
Quantity 2
Clear span of gate 2.5 m
Clear height of gate 3.0 m
Water seal of gate 4 edges rubber seal
Sill elevation EL.683.300 m
KRCS-182MJ
5-
5-2 Design and functional description
5-2-1 Gate
The draft tube gate is used to close each opening of draft tube for inspection,
maintenance and repair of water turbines and generating equipment.
The gate consists of skinplate, main beams, sheave assemblies with lifting beam,
seals, bearing plates, side rollers, bypass valves and taper wedges.
Refer to Drawing No. G07-0064-J000-DG-X to J002-DG-X
5-2-2 Main beams
The main horizontal beams are built-up plate girder structure.
Refer to Drawing No. G07-0064-J001-DG-X
5-2-3 Side rollers
Two (2) side rollers of flanged type are provided on each side of gate to limit the
lateral movement of the gate.
The side rollers consist of stainless steel roller, stainless steel pins and self-
lubricating metal bushing.
Refer to Drawing No. G07-0064-J001-DG-X, J002-DG-X
5-2-4 Gate seals
The gate seals are made of synthetic rubber.
The gate seals are music note type for top and side seal, flat bar shapes for
bottom seal clamped to the upstream face of the gate using stainless steel bars
and stainless steel bolts, nuts.
KRCS-182MJ
5-
5-2-5 Bypass valve
The gate is equipped with two (2) 150 mm diameter bypass valve to fill water
into the draft tube and to equalize the water pressure on both sides of the gate
leaf before it is opened.
The valve is operated through a rod connected to the lifting lug and controlled by
the hoist.
Refer to Drawing No. G07-0064-J001-DG-X, J002-DG-X
5-2-6 Tapered wedges
The wedge-shaped front shoes are furnished on the pressure side of the gate to
press the gate leaf to the sealing frame side for keeping a tight contact between
the seal rubber and the sealing frame in fully closed position under the balanced
water head condition.
5-2-7 Sheave assembly
The sheave assembly comprising stainless steel pins, Vee-grooved sheave and
self lubricating bearings is furnished to the lifting beam on the top of the gate
leaf.
KRCS-182MJ
5-
6
Hoist
6-
6-1 Technical Data
6-1-1 Draft tube gate

Electrically operated, 1 motor - 2 drum, stainless
Type
steel wire rope lift stationary hoist
Quantity of hoists 2
Operating load 65.0 kN
Operating speed 1.0 m/min
Hoisting height 52.2 m
Motor 2.2 kW 50 Hz 6 P
Wire rope (6 × 37) φ 16 SUS 304 SB
KRCS-182MJ
6-
6-2 Design and Functional Description
6-2-1 General
The hoist is the wire rope lift stationary type, 1 motor - 2 drum with torque shaft
transmission, suitably mounted on the operation deck at EL.741.0 m to open,
close and hold the draft tube gate.
The hoist consists of base frameworks, mechanical equipment, i.e., torque shafts,
bearings, gear reducer, lifter brake, couplings, hoist drums, mechanical position
indicator, stainless steel wire ropes, over load and slack load detector and
electrical equipment, i.e., hoist motor, limit switches and controls.
6-2-2 Base frameworks
The frameworks is welded steel structure of built-up shape, and rigidly fixed to
the anchor in the primary concrete at EL.741.0 m.
6-2-3 Dogging device
A dogging device is provided for each hoist to hang the gate leaf for the purpose
of maintenance and repair of the gate leaf above EL.735.5 m.
KRCS-182MJ
6-
7
Lubrication
7-
Lubricants list and lubrication methods are shown below.
7-1 Lubricants List
Wire rope stationary hoist for Draft Tube Gates
Location to be Lubrication Amount

No. Recommended lubricants
supplied methods for One gate
ALVANIA EP GREASE 1 (SHELL)
0.14 kg × 1
1 Chain couplings Grease gun MULTIFAK EP1 (CALTEX)
0.12 kg × 1
MOBILUX EP1 (MOBIL)
OMALA 68 (SHELL)
2 Gear reducer Pouring 110 L × 1
MOBIL SHC 626 (MOBIL)
3 Gear couplings Grease gun MULTIFAK EP1 (CALTEX) 1.0 kg × 2
MOBILUX EP1 (MOBIL)
Manual grease Centralized Optimum
4 MULTIFAK EP1 (CALTEX)
pump lubrication dose
MOBILUX EP1 (MOBIL)
RETINAX GREASE CMX2 (SHELL)
5 Wire rope Coating 2.0 kg × 2
WIROL R-HS (TOKYO ROPE MFG)
Optimum
6 Chain Coating MULTIFAK EP1 (CALTEX)
dose
MOBILUX EP1 (MOBIL)
KRCS-182MJ
7-
7-2 Lubrication Methods
● When changing lubricant, grease, etc. at a lubrication spot, no open

flame is allowed.
DANGER ● Wipe clean any spilled lubricant with a wiping cloth to prevent a fire.
When using a grease gun:

Fill grease until a small amount of grease starts to ooze out from an opening in
the bearing.
To grease nipples
Grease gun
When pouring lubricant:

Pour the specified amount of lubricant while checking the oil gauge.
Oil filling pot
Oil supply port
KRCS-182MJ
7-
When coating:
Brush
Wire rope, gear etc.

Lubricant
When using a centralized lubrication system:
Manual grease pump
KRCS-182MJ
7-
8
Inspection and
Maintenance
Procedures
8-
8-1 Safety Precautions to Observe during Inspection and Maintenance
When performing replacement of parts or other tasks that require disassembly
of parts, carefully read and understand “Chapter 2 Safety”, and observe the
following precautions.
• Ensure safe operation of cranes and safe handling of tools and

fixtures.
When using dangerous equipment or tools,
such as a crane, follow the safety instructions
for them.
WARNING
• Prohibit unsafe actions.

Do not take any dangerous action, such as
leaning forward too much when standing on a
high place.
DANGER
• Firmly secure moving parts before performing your work.

When disassembling a coupling or releasing a
brake, place the gate leaf down on the sill beam
and secure the winding drum so that it does not
WARNING rotate before performing such work.
If a moving part moves while you are performing
such a task, part of your body may get caught
in the moving part, resulting in personal injury
or death.
• Clean up your workplace.

Secure space in your walking path or work
area to walk through safely. If you find any
liquid spilled on the floor, wipe clean because it
makes the floor slippery.
WARNING
KRCS-182MJ
8-
8-2 Overview

Daily checks required for proper maintenance and a procedure for regular
maintenance are shown.
Daily checks and regular inspections/maintenance are performed respectively by
caretakers of the facility and experts.
Inspections and maintenance performed by caretakers

Specific maintenance tasks to be performed by caretakers include daily cleaning
of the facility, simple visual checks and lubrication before operating the gates.
Inspections and maintenance performed by experts

These refer to inspections performed regularly at intervals of one month or one
year and related maintenance.
Inspections are carried out by experts visually and by means of instruments in
accordance with a detailed checklist.
Such inspections involve adjustments and replacement of parts as required. Such
inspections may be performed at the request of a caretaker if deemed necessary.
KRCS-182MJ
8-
8-3 Guidelines for Inspections and Maintenance

Perform the following inspections.
Request experts to perform maintenance on finding any problems.
1 Carefully observe the entire surface of each gate leaf, and make sure that
nothing interferes with gate operations.
2 Check to make sure that each gate groove is free from dirt, dust or other
foreign articles, and that no dust, dirt or other foreign articles are present on
each wire rope.
3 Check to make sure that the surface of each wire rope is free from defects.
4 Check to make sure that the surface of each gate hoist is free from defects.
5 Check the lubrication status, and refill lubricant if low.

For details, see “Chapter 7 Lubrication”.
6 Conduct a performance check on each limit switch to make sure that it

functions properly.
7 Conduct a performance check on all indicators on the control cabinet,

including position indicators and push button switches.
When operating a gate, carefully note the current and voltage readings.
8 Carefully check for any abnormal noise or vibrations during the gate
operation.
KRCS-182MJ
8-
Guidelines for inspections and maintenance performed
by experts
Steel structure
Steel structure shall be visually checked every month for damages.

In case of damages steel structure has to be repaired.
Welded portion
Welded portion shall be visually checked every year for cracks.

In case of cracks welded portion has to be repaired.
Painting
Painting shall be visually checked every month for damage.

In case of damage painting has to be repaired.
Bolts, nuts
Bolts, nuts shall be visually checked every month for damage.

In case of damage bolts, nuts has to be replaced.
Rubber seals
Rubber seals shall be visually checked every month for damage and water
leakage.
In case of damage or water leakage, rubber seals has to be repaired/
replaced.
Side roller bushes
Side roller bushes are maintenance-free.
Sheave bushes
Sheave bushes are maintenance-free.
KRCS-182MJ
8-
Motor
Motor shall be auscultately checked every month.

In case of abnormal sound, motor has to be adjusted/replaced.
Lifter brake
Lifter brake shall be visually checked every month for oil leakage.
In case of oil leakage, lifter brake has to be repaired.
Gear reducer
Gear reducer shall be auscultately checked every month.

In case of abnormal sound, gear reducer has to be adjusted/replaced.
Gear couplings
Gear couplings shall be auscultately checked every month.

In case of abnormal sound, gear couplings has to be adjusted/replaced.
Bearings
Bearings shall be auscultately checked every month.

In case of abnormal sound, bearings has to be adjusted/replaced.
Drums
Drums shall be visually checked every month for damage.

In case of damage drums has to be repaired.
Wire ends
Wire ends shall be visually checked every year for looseness.

In case of looseness wire ends has to be retightened.
Wire ropes
Wire ropes shall be visually checked every month for deformation.

In case of deformation, wire ropes has to be repaired/replaced.
KRCS-182MJ
8-
8-4 Inspection and Maintenance Checklists
This chapter lists the inspection and maintenance items for the equipment shown
below.
Facility name Equipment to be checked
1 Gate leaf
Draft tube gate
2 Guide frame
3 Hoist for draft tube gate Wire rope lift stationary hoist
The definitions of the symbols in the lists are shown below.

E: Visual check M: Measurement
H: Examination by touch and tapping with the fingers
S: Sound check D: Checking of actions W: Disassembly
Unscheduled inspection
(Quake): Only at the time of an earthquake
(Lightning): Only after being struck by lightning
(Flood): Only at the time of a flood
KRCS-182MJ
8-
Draft tube gate
■ Gate leaf
Regular Irregular
Points to be Actions to be
Item Acceptance criteria
checked Monthly Annual taken
Unscheduled Overall
check check
Dirt E E E No adhesion of heavy dirt, oil, etc. Cleaning
Cleaning status Dirt, driftwood, soil,
E E (Flood) E No dirt, driftwood, soil, sand, etc. Cleaning
General
sand, etc.
Damage E E E No damage. Repair
Painting No rusting, blistering, cracks, peeling,
Degradation E E Repair
discoloration, or chalking.
Investigation of
Vibration H H H No abnormal vibration.
the causes
Investigation of
Overall structure Abnormal sound S S S No abnormal sound.
the causes
No abnormal inclination (angled
Angled hanging E (Quake) M Adjustment
hanging).
Deformation E E No deformation. Repair

Decrease in To be judged by the measurement
Skinplates M Repair
thickness result.
Corrosion (pitting) E E No corrosion (pitting). Repair
Gate leaves
Cracks in the
E E No cracks. Repair
welded portions
Deformation E E E No deformation. Repair
Main and support Decrease in M

To be judged by the measurement
Repair
girders thickness result.
Cracks in the
E E No cracks. Repair
welded portions
Looseness, Retightening,
E,H (Quake) E,H No looseness or detachment.
detachment restocking
Bolts, nuts Damage E E E No damage. Replacement
Corrosion (pitting) E E No corrosion (pitting). Replacement

Repair,
Wear or abrasion E M No wear or abrasion.
replacement
Bearings
Sliding plates Repair,

Guide shoes Damage E E (Quake) E No damage.
replacement

Repair,
Damage E E E No damage.
replacement
Sealed portions
Rubber seals
Degradation E E No degradation. Replacement
Repair,
Water leakage E E E To be functioned without any trouble.
replacement
Rubber retainer
plates Repair,
replacement
Repair,
replacement
Repair,
Damage E E (Quake) E No damage.
Lifting beam
replacement
Sheeve, shaft,
bearings
To be lubricated.
Lubrication state E E E Replenishment
No degradiation of lubricants.
Repair,
Rotational state D D D To be ratated correctly.
replacement
KRCS-182MJ
8-
■ Guide frame
Regular Irregular
Unscheduled Overall
check check
Dirt E E E No adhesion of heavy dirt, oil, etc. Cleaning
Cleaning status Dirt, driftwood, soil, No dirt, driftwood, soil, sand, etc. in
E E (Flood) E Cleaning
General
sand, etc. the gate grooves.

Deformation E (Quake) E No deformation. Repair
Damage E E (Quake) E No damage. Repair

Rails
Removable guides
Corrosion (pitting) E E Corrosion (pitting) Repair

Cracks in the
E (Quake) E No cracks. Repair
welded portions
Sills Damage E E No damage. Repair

(Quake)
(Flood)
Embedded portions
Side guides (Quake)

(Flood)
(Quake)
(Flood)
Lintel beams (Quake)
(Flood)
(Quake)
(Flood)
Concrete
(Quake)
Water leakage E E To be functioned without any trouble. Repair
(Flood)
KRCS-182MJ
8-
Hoist for draft tube gate
■ Wire rope lift stationary hoist
Regular Irregular
Unscheduled Overall
check check
Cleaning status Dirt E E E No adhesion of heavy dirt, oil, etc. Cleaning

General

Investigation of
the causes
Overall structure
Investigation of
Abnormal sound S S S No abnormal sound.
the causes
Deflection E (Quake) E No deflection. Repair
Structure
Frames Deformation E (Quake) E No deformation. Repair

Cracks in the
E (Quake) E No cracks. Repair
welded portions

Adjustment,
replacement
Adjustment,
replacement
Increase in Investigation of
H M M No abnormal temperature rise.
temperature the causes
Power equipment
No large fluctuation. The values

Investigation of
Current values E M (Lightning) M should be under the rated current
Main power the causes
values.
source
The values during operation should
Investigation of
Voltage values E M (Lightning) M be within a range of ±10% of the rated
the causes
voltage.
The values should be measured with
Insulation resistance
M (Lightning) M an insulation resistance tester and be Replacement
values
5 MΩ or more.
No damage or abnormal wear on the
Internal state W Replacement
components.
To be operated without fail and be
Operating state E D D Adjustment
stopped instantly.
Adequate clearance should be Adjustment,
Lining clearance M (Quake) M
provided. replacement
No abnormal or biased wear or Adjustment,
Lining wear M M
abrasion. replacement
Adjustment,
Drum damage E (Quake) E No damage.
replacement
Braking devices
Cleaning status of
Magnetic brake E E E No adhesion of heavy dirt, oil, etc. Cleaning
the braking devices
Electro-hydraulic
Oil leakage E E (Quake) E No leakage of oil. Repair
brake
The level should be within the
Insulating oil level E E Replenishment
specified range on the oil level gauge.
degradation of No significant cloudiness. No white
E E Replacement
insulating oil turbidity.
The values should be measured with
Insulation resistance
M (Lightning) M an insulation resistance tester and be Replacement
values
1 MΩ or more.
components.
KRCS-182MJ
8 - 10
Regular Irregular
Unscheduled Overall
check check
Adjustment,
replacement
Adjustment,
replacement
Reduction gear

Reduction gear Oil leakage E E (Quake) E No leakage of oil. Repair
The level should be within the
Lubricant level E E Replenishment
specified range on the oil level gauge.
Degradation of No significant cloudiness. No white
E E Replacement
lubricants turbidity.
components.
Adjustment,
repair
Adjustment,
repair
Bearings
Power transmission elements
Adjustment,
Misalignment M No abnormal misalignment.
repair
To be lubricated. No degradation of
Lubrication state E E Replenishment
lubricants.
Repair,
replacement
Adjustment,
replacement
Adjustment,
replacement
Flexible couplings
Adjustment,
(Roller chain Misalignment M No abnormal misalignment.
repair
couplings)
To be lubricated. No degradation of Replenishment,
Lubrication state E E
lubricants. replacement
components.
Drum Damage E (Quake) E No damage. Repair

No abnormal wear on the rope
Wear or abrasion E M Repair
grooves.
Drum shaft
Damage E (Quake) E No damage. Repair
Drum rope Looseness, Retightening,
E (Quake) E No looseness or detachment.
adjusting device detachment restocking
Gate leaf drive
Adhesion of dirt or
E E (Flood) E No dirt, dust, etc. on the ropes. Cleaning
foreign matter
(Quake) No irregularly protruded, partially Repair,
Deformation E E E
(Flood) cage-shaped or kinked strands. replacement
Repair,
Rusting E E No rusting.
replacement
Wire ropes Wear or abrasion M M No abnormal wear or abrasion. Replacement
(Quake)
Wire breakage E E No abnormal wire breakage. Replacement
(Flood)
Lubrication state E E E
No corrosion or disconnection inside.
Internal state M Replacement
No large reduction in strength.
KRCS-182MJ
8 - 11
Regular Irregular
Unscheduled Overall
check check
Lock nuts E E (Quake) E No looseness. Retightening
Repair,
Socket E (Quake) E No disconnected cotter pins.
replacement
Wire rope The right and left ropes should have
adjusting device Rope length E (Quake) E the same amount of slack during the Adjustment
closed state.
Protective devices

Lubrication state E E
Operating state E D (Lightning) D To be operated correctly as specified. Adjustment
Limit switch box
Deformation E E (Quake) E No deformation. Replacement
(planetary gear)
Damage E E (Quake) E No damage. Replacement
Operating state E D (Lightning) D To be operated correctly as specified. Adjustment

Direct-acting limit
Deformation E E (Quake) E No deformation. Replacement
switches
Damage E E (Quake) E No damage. Replacement
Dogging device
The dogging operation should be

Operating state D D Adjustment
performed smoothly.
Dogging device
To be lubricated. No degradation of
Lubrication state E E Replenishment
lubricants.
Position indicators
The indicated position should match

Operating state E D D Adjustment
the actual lifting height.
Mechanical
section The display window should be
Mist on the indicator Cleaning,
E E transparent and have a reasonable
face replacement
level of visibility.
Repair,
replacement
Lubrication
Operating state D D Proper pressure should be generated. Replacement
pumps
The level should be adequate. No Replenishment,
Oil level E E
white turbidity. replacement
Lubricators
Lubrication pipes Damage E E No damage. Repair
Oil leakage E E No leakage of oil. Repair
Distribution Damage E E E No damage. Replacement

valves Operating state D D To be operated. Replacement
KRCS-182MJ
8 - 12
Elements to Controlled Control
Criteria for acceptance
Checkpoints be controlled (inspected) at the (inspection) Action
or rejection
(inspected) following intervals method
General Cleaning Monthly Visual check There should be no dirt, stains or Wipe off with a wiping cloth, or
status damage on the voltmeter, ammeter, replace.
position indicator and other Wipe them clean with a removing
instruments. brush or a wiping cloth.
There should be no other dust on Apply lubricant for smooth
them. opening an closing.
There should be no excessive forces
on the gate hinge, and the gate hinge
should be in perfect condition.
Dry condition Monthly Visual check Open the cover and inspect the Replace any defective dust
of internal and check by internal parts visually and by touch. packings. Open the cover, and dry
parts touch They should be dry. the internal parts on a fine day.
If heaters are installed, replace
any defective heaters.
Painting Annually Visual check There should be no rust, blisters, Touch up or paint the entire
peelings or cracks. surface.
Indicator lamps Indicator At each Visual check When an indicator lamp is activated, it Replace any burned out lamps.
lamps operation should light up. If there no burned out lamps, it is
All indicator lamps should light up either the indicator lamp device or
when the LAMP TEST push button the circuit that has failed. Repair
switch is turned ON. or replace.
Position indicator Operation At each Visual The actual gate position (or the Adjust so that the indicator
operation check and position signal transmitted) should readings match the actual gate
measurement match the indicated position. position.
(1) Replace any broken power fuses.
(2) Repair any detached wires.
Push button Operation At each Visual check The push button switches should Replace any defective push
switches operation properly function when operated to button switches with new ones.
open, stop or close the gate. The push
button switches should also function
properly when operated to open or
close the rest hook.
Electromagnetic Operating Semiannually Contactor There should be no booming sound As dirt and dust build up inside
contactors status activation generated during operation or other the magnet, remove them or
abnormal sound (buzzer-like sound). replace the magnet with a new
If the contactor, when switched on, one.
starts vibrating, during which it turns This is mainly due to an abnormal
on and off several times before going drop of power source voltage
into operation, it has a problem. caused by the starting current
of the motor. Check the power
source.
Auxiliary relays Operating Semiannually Relay There should be no booming sound Check to make sure that the
status activation generated during operation or other wires and relay unit are secured
abnormal sound (buzzer-like sound). firmly. If the control circuit voltage
If the relay, when switched on, starts is normal, the relay unit must be
vibrating, during which it turns on and defective. Replace it with a new
off several times before going into one.
operation, it has a problem.
Molded case Operating Semiannually Breaker There should be no booming sound Replace any defective MCCBs
circuit breakers status activation generated during operation or other with new ones.
(MCCBs) abnormal sound (buzzer-like sound).
There should be no smell like
something is burning.
KRCS-182MJ
8 - 13
or rejection
Bolts Looseness Annually Use of a test There should be no loose bolts. Tighten additionally.
hammer
3E relays Operating Semiannually Visual check Open the cover, push the green test Replace any defective relays with
status button to activate the relay. The relay new ones.
should function properly. Push the
orange button to reset.
Voltmeter Voltage Annually Annually Compare the measurements with Replace with a new voltmeter or
values Comparison those by reference instruments (with an ammeter.
with values accuracy of class 1.5). Measurement
Ammeter Current measured errors should not exceed 2.5%.
values by reference
instruments
Wiring Connection Annually Visual check There should be no loose terminals. Replace with a new wire.
status of and check by There should be no broken wires at
terminals touch the terminal end due to vibration or
corrosion.
Check by pulling the wires lightly.
Wiring status Annually Visual check The sheath should be free from any Replace with a new wire.
damage by heat.
Insulation Insulation Annually Measurement The values should be 5 MΩ or greater. Remove any visible dirt or dust.
resistance If this fails to cure the problem,
values remove and adjust equipment that
appears to be faulty, and repair or
Ground Annually Measurement The values should be 10 ohms or
replace it.
resistance less for motors with a rated voltage of
Wipe clean the external lead-out
values 300V or greater.
terminal block.
The values should be 100 ohms or
Re-terminate the cables.
less for motors with a rated voltage of
300V or less.
Lighting inside the Operating Annually Visual check If the lighting does not turn on, the Replace with new lighting.
cabinet status by opening fluorescent lamp is not installed
and closing securely or the glow lamp is defective.
the main door
Space heater Operating Annually Visual check If the heater is operating when the Replace the heater if the heater
status by switching outdoor temperature is below the wire is broken.
ON/OFF temperature set by the thermostat, If the thermostat is defective,
the thermostat is also in good working replace it too.
order.
KRCS-182MJ
8 - 14
Checking painted surfaces
or rejection
Girders Corrosion Annually Visual check Determine the level of paint film Determine the scope of the
Skinplates Blisters degradation based on the criteria repainting based on the
Guides Peelings given in the following table. conditions for repainting given in
Gate guides Cracks the table below.
Hoists Fragility
Others
■ Criteria used to determine paint film degradation levels

Elements
Degra- Corrosion Blisters Peelings Cracks Fragility
dation level
A No spots No spots No spots No spots No spots
B A few spots A few spots A few spots A few spots A few spots
C Many spots Many spots Many spots Many spots Many spots
Extremely Extremely Extremely Extremely Extremely

D
many spots many spots many spots many spots many spots
■ Conditions for repainting

Elements
Degra- Condition of paint film Applicable scope of repainting
dation level
A No problems No need for repainting
Only the top coat has undergone

B Repaint the top coat.
degradation.
Not only the top coat but also part

C of the base coat has undergone Repaint both the top and base coats.
degradation.
Both the top and base coats have

D Repaint both the top and base coats.
undergone degradation.
KRCS-182MJ
8 - 15
9
Trouble Shooting
9-
The facility turns on the fault indicator lamps (red, orange) and activates the
buzzer if a fault occurs in any of its devices or if the emergency stop is activated.
Identify the causes of malfunctions based on the indicator lamps, and take
corrective actions and steps to restore normal operation. The buzzer can be
stopped in the following way.
To stop the buzzer, press the “ALARM STOP” push button switch.
The buzzer will stop automatically after the elapse of the time set by the timer (30
seconds; the preset time can be changed).
1. If “EMERGENCY STOP” is detected

Cause Description
Emergency stop is The gate will stop automatically if the
required. “EMERGENCY STOP” pull button switch is
pulled by an operator to ensure safety.
Actions: 1. Press the “ALARM STOP” push button switch to stop the buzzer from
beeping.
2. Press the “RESET” push button switch on the local control panel to
turn off the “EMERGENCY STOP” indicator lamp. If the indicator lamp
does not turn off, release the lock of the “EMERGENCY STOP” pull
button switch.
3. Eliminate the cause of the emergency stop.
4. Confirm the safety, and then reset the tripped breaker.
2. If “EARTH LEAKAGE” is detected

Cause Description
Earth leakage is If earth leakage occurs in the electrical circuit,
detected. an alarm buzzer sounds but the operation is
continued. Earth leakage can cause electrical
shock. Take measures to protect yourself against
electrical shock (rubber boots, gloves, etc.)
before starting operation.
Actions: 1. The equipment or cables seem to have an insulation failure. Measure

insulation resistance to identify the defective part.
KRCS-182MJ
9-
3. If “MCCB TRIP” is detected
Cause Description
The motor breaker has If any of the followings is detected, the MCCB
tripped. trips and the motor stops.
1) The “EMERGENCY STOP” pull button switch
is pulled.
2) Short circuit in the local control panel
3) Short circuit of the cable from the local control
panel
4) Short circuit in the motor
Actions: 1. If the “EMERGENCY STOP” pull button switch is pulled, refer to the
section 1. “If EMERGENCY STOP is detected”.
2. Inspect the inside of the local control panel visually for burnt wires.
3. If any burnt part is found, replace it with a new one.
4. If there is no burnt part, turn off all the breakers and then inspect the
tripped circuit in detail.
5. Identify the defective part by measuring insulation resistance and
replace it with a new one.
6. If the cause cannot be identified, please contact us.
4. If “OVER RAISED” is detected

Cause Description
The gate is raised If the gate reaches its over raised position, the
exceeding the fully raised gate is stopped as it is in the upper limit position.
position. 1) The fully raised position limit switch is
defective.
2) The auxiliary relay is broken and the control
circuit is defective.
Actions: 1. Check that the limit switches (fully opened, fully raised) have no
problems.
If the cause cannot be identified, please contact us.
5. If “MOTOR OVERLOAD” is detected

Cause Description
Overcurrent in the motor If the motor is overloaded, the protective relay
is detected. trips and the motor stops.
Actions: 1. Inspect that there is no foreign matter caught between the gate guide
and the roller.
2. Press the “RESET” push button switch on the protective relay in the
control cabinet.
3. After inspection, perform operation again to check that the motor will
not be overloaded.
4. If overcurrent in the motor still persists, please contact us.
KRCS-182MJ
9-
6. If “OVER LOWERED” is detected
Cause Description
The gate is in its over If the gate reaches its over lowered position, the
lowered position. gate is stopped as it is in the lower limit position.
1) The fully lowered position limit switch is
defective.
2) The auxiliary relay is broken and the control
circuit is defective.
Actions: 1. Check that the limit switches (fully closed, fully lowered) have no
problems.
If the cause cannot be identified, please contact us.
7. If “BRAKE TROUBLE” is detected

Cause Description
The hydraulic brake is If the hydraulic brake is overloaded, the thermal
defective. relay trips and an error is detected.
Actions: 1. Inspect that there is no foreign matter caught in the hydraulic brake
drive.
2. Press the “RESET” push button switch on the thermal relay in the
control cabinet.
3. After inspection, perform the gate operation again to check that the
brake will not be overloaded.
4. If overcurrent in the brake still persists, please contact us.
8. If “ROPE OVERLOAD” is detected

Cause Description
The rope is overloaded. If foreign matter is caught between the gate
guide and the roller while the gate is raised
and the load greater than the specified value is
applied to the wire rope, the wire rope overload
detector is activated to stop the gate movement.
Actions: 1. As a temporary solution, lower the gate slightly.

2. Then, perform inspection to be sure that no foreign matter is caught.
3. After inspection, perform the raising operation again to check that the
rope will not be overloaded.
KRCS-182MJ
9-
9. If “ROPE SLACKED” is detected
Cause Description
Rope slack If the gate comes to rest on stones or logs while
it is lowered or if the wire rope tension is less
than the specified value, the slack wire detector
is activated to stop the gate movement.
Actions: 1. As a temporary solution, raise the gate slightly.

2. Then, perform inspection to be sure that it does not rest on stones or
logs.
3. After inspection, perform the lowering operation again to check that
the rope will not be slacked.
4. If the rope goes slack again, please contact us.
KRCS-182MJ
9-
10
Painting
10 -
10-1 Painting Specification
Table 1 Classified Painting
Paint schedule
Equipment Classification Portion Final color Remarks
(*1)
B-1 Black
Gate Leaves
Bypass valve inside A-1 Black
Except for
Exposed portion A-2 Black
Guide Frame stainless steel
Item 11 Draft
Tube Gates and Embedded portion Primer only —
Hoists Exposed support frame B-2 D19-75X (*2)
Mechanical device B-3 or D-1 D19-75X
Hoists
Local control panel D-2 D25-70B (*2)
Dogging device B-4 D19-75X
*1: Paint Schedule: Shown in Table1.1 to 2.3

*2: JPMA Standard Paint Colors 2007-D
KRCS-182MJ
10 -
Table 1.1 Gates Equipment (*6)
Painting Schedule (A)

A-2 (*5)
Location of Nature of paint Coating Std. DFT
Process
workshop Paint products interval (μ)
Sa 2 1/2 of SIS 05 5900

Mill Shop Surface Preparation ~4H (*3) —
(Blast Clearing of Grade)
Sa 2 1/2 of SIS 05 5900 See

Surface Preparation —
(Blast Cleaning of Grade) (*4) Table 4.1
Epoxy Resin Zinc Rich Primer 8H~
1st (Under) Coat 50
EP-03AA 6M (*1)
Manufacturer’s Epoxy Resin Zinc Rich Primer

2nd (Under) Coat 8H~6M 50
Shop EP-03AA
3rd (Intermediate) Coal-Tar Epoxy Resin Paint 18H~
150
Coat EP-06 5D (*2)
Coal-Tar Epoxy Resin Paint
4th (Finish) Coat 150
EP-06
Surface Preparation St 3 By Powertool
Same as the Manufacturer’s
1st (Under) Coat 8H~6M 50
Shop Painting

Site Shop Painting
3rd (Intermediate) Same as the Manufacturer’s

18H~5D 150
Coat Shop Painting

Shop Painting
Total Dry Film Thickness 400
*1: “M” means a Month.

*2: “D” means a Day.
*3: “H” means an Hour.
*4: Blast Cleaning of grade Sa2 1/2 shall be applied to the welded parts and damaged parts of mill
shop primer at the manufacture's shop.
*5: A-2 is shown in Table 1 Classified Painting.
*6: YUNG CHI PAINT & VARNISH MGF. CO.,LTD.
26, YEH HAI 3RD ROAD KAOHSIUNG. TAIWAN
TEL +886-7-871-3181
KRCS-182MJ
10 -
Painting Schedule (B)

B-1 (*5)
Process
Sa 2 1/2 of SIS 05 5900

Sa 2 1/2 of SIS 05 5900 See

1st (Under) Coat 50
EP-03AA 6M (*1)
Non Bleed Type Tar Epoxy Resin Paint 18H~
2nd (Under) Coat 100
Manufacturer’s EP-10 5D (*2)
Shop Non Bleed Type Tar Epoxy Resin Paint
3rd (Under) Coat 18H~5D 100
EP-10
4th (Intermediate) Epoxy Resin Paint
18H~5D 40
Coat EP-04
Epoxy Resin Paint
EP-04

Shop Painting

2nd (Under) Coat 18H~5D 100
Shop Painting
Site
Shop Painting
4th (Intermediate) Same as the Manufacturer’s

8H~5D 40
Coat Shop Painting

Shop Painting

*5: B-1 is shown in Table 1 Classified Painting.
*6: YUNG CHI PAINT & VARNISH MGF. CO.,LTD.
26, YEH HAI 3RD ROAD KAOHSIUNG. TAIWAN
TEL +886-7-871-3181
KRCS-182MJ
10 -
Painting Schedule (A)

A-1 (*5)
Process
Sa 2 1/2 of SIS 05 5900

Sa 2 1/2 of SIS 05 5900 See

1st (Under) Coat 50
ZETTAR EP-2HB 6M (*1)
Manufacturer’s Epoxy Resin Zinc Rich Primer

Shop ZETTAR EP-2HB
3rd (Intermediate) Coal-Tar Epoxy Resin Paint 24H~
150
Coat SDC COAT#402T ECO 7D (*2)
Coal-Tar Epoxy Resin Paint
SDC COAT#402T ECO
Shop Painting

Site Shop Painting
3rd (Intermediate) Same as the Manufacturer’s

24H~7D 150
Coat Shop Painting

Shop Painting

*5: A-1 is shown in Table 1 Classified Painting.
*6: DAI NIPPON TORYO CO.,LTD.
6-1-124, NISHIKUJYO KONOHANA-KU OSAKA JAPAN
TEL +81-6-6466-6661
KRCS-182MJ
10 -
Painting Schedule (B)

B-2, B-3, B-4 (*5)
Process
Sa 2 1/2 of SIS 05 5900

Sa 2 1/2 of SIS 05 5900 See

1st (Under) Coat 50
ZETTAR EP-2HB 6M (*1)
Non Bleed Type Tar Epoxy Resin Paint 24H~
2nd (Under) Coat 100
Manufacturer’s EPOALL #65 7D (*2)
Shop Non Bleed Type Tar Epoxy Resin Paint
EPOALL #65
4th (Intermediate) Epoxy Resin Paint
24H~7D 40
Coat EPONICS #20
Epoxy Resin Paint
EPONICS #20
Shop Painting

2nd (Under) Coat 24H~7D 100
Shop Painting
Site Same as the Manufacturer’s
Shop Painting
4th (Intermediate) Same as the Manufacturer’s

24H~7D 40
Coat Shop Painting

Shop Painting

*5: B-2 to 4 are shown in Table 1 Classified Painting.
*6: DAI NIPPON TORYO CO.,LTD.
6-1-124, NISHIKUJYO KONOHANA-KU OSAKA JAPAN
TEL +81-6-6466-6661
KRCS-182MJ
10 -
Table 2.3 Gates Equipment
Painting Schedule (D)

D-1, D-2 (*1)
Process
In Accordance with the

manufacturer’s standard practice,
Painting — —
subject to the approval of the
Engineer
Total Dry Film Thickness — —
*1: D-1 to 2 are shown in Table 1 Classified Painting.
KRCS-182MJ
10 -
11
Spare Parts and
Supplied Tools
11 -
11-1 Mechanical equipment
Draft tube gates
1. Rubber seals with fixing bolts, nuts and washers
Part No. Part name Type/dimension Material Q'ty Remarks Drawing No.
Chloroprene with
10-1-1 Top rubber seal Music note type 1 Undrilled G07-0064-J002-DG-X
teflon coating
10-1-2 Bottom rubber seal Flat bar shape Chloroprene 1 Undrilled Ditto
Chloroprene with
10-1-3 Side rubber seal Music note type 2 Undrilled Ditto
teflon coating
With seal
10-1-4 Hex-HD’ bolt, nut M16×85 SUS304 9 sets ―
washer
With seal
10-1-5 Hex-HD’ bolt, nut M16×70 SUS304 3 sets ―
washer
10-1-6 Hex-HD’ bolt, nut M16×100 SUS304 1 set ―
2. Motor for hoist
Part No. Part name Manufacturer Spec./model number Q'ty Remarks Drawing No.
MITSUBISHI 2.2 kW, 6P, AC400V, IP54, INS
10-2-1 Electric motor 1 G07-0064-J005-DG-X
ELECTRIC 50 Hz class / F
3. Limit switch
Part No. Part name Manufacturer Spec./model number Q'ty Remarks Drawing No.
For
detection
10-3-1 Limit switch YAMATAKE 1LS19-J 3 ―
of upper
limit
For over
load and
10-3-2 Limit switch YAMATAKE 1LS19-J 4 slack ―
load
detector
KRCS-182MJ
11 -
Grease
1. Grease
Part No. Part name Manufacturer Spec./model number Q'ty Remarks

For draft
12-1-1 Grease SHELL ALVANIA EP GREASE R0 5 kg
tube gates
Notice: Storage locations for spare parts

Do not store Rubber Seals and Mechanical Parts in the following locations. Otherwise, it
may cause Rubber Seal to deteriorate quickly and Mechanical Parts to early break down.
1) Locations subject to direct sunlight and rain.
) Locations subject to an ambient temperature range not within 0 degrees C to 55
degrees C.
3) Locations subject to rapid temperature changes and resulting in condensation or
locations with relative humidity ranges not within 10 % to 90 %.
4) Locations subject to corrosive or inflammable gas.
5) Locations subject to excessive dust, salinity, or metal powder.
6) Locations subject to vibration or shock affecting the mechanical parts.
7) Locations subject to water, oil, or chemical sprayed on the rubber seals and
mechanical parts.
The following parts shall be stored in the room with an air condition:
[ Parts Numbers ]
10-2-1, 10-3-1, 10-3-2
KRCS-182MJ
11 -
11-2 Electrical works
Draft tube gates
1. Local control cabinet
No. Item Rating Model No. Manufacturer Q'ty Remarks Drawing No.
G07-0074-
Main: 400V/coil: AC230V SC-05RM Fuji 1
501-05-DG-X
1 Motor Contactor Main: 400V/coil: AC230V SC-05 Fuji 1 Ditto
Main: 400V/coil: AC230V SW-05 Fuji 1 Ditto
Main: 230V/coil: AC230V SC-05 Fuji 1 Ditto
Coil: AC230V HH54P-L Fuji 1 Ditto

2 Auxiliary relays
Coil: AC400V SH-4 Fuji 1 Ditto
3 Fuse element AC600V, 2A CD-3F Fuji 1 Ditto
LED unit, DC24V, White UA-27FD8A-4W Kimuden 1 Ditto

Indicator lamps
4 LED unit, DC24V, Red UA-27FD8A-4R Kimuden 1 Ditto
(LED element)
LED unit, DC24V, Orange UA-27FD8A-4O Kimuden 1 Ditto
Push button_1a1b, Black ABN111B IDEC 1 Ditto
Push button_1a1b, Red ABN111R IDEC 1 Ditto
Push button_1a1b, Green ABN111G IDEC 1 Ditto

5 Switches
Push button_1a1b, Yellow ABN111Y IDEC 1 Ditto
Push-pull switch_round
ATN2111R IDEC 1 Ditto
(pull to operate), 1a1b, Red
AC220/230V, 100W SHC4-2210-T Shinohara 1 Ditto

6 Space heater Thermostatic Switch_0 to
E5L-A4 Omron 1 Ditto
50 deg C
7 Fluorescent lamp AC230V, 10W FC1012GL Odelic 1 Ditto
KRCS-182MJ
11 -
2. Local distribution board
No. Item Rating Model No. Manufacturer Q'ty Remarks Drawing No.
G07-0074-
4P 400AF/250-400AT SA404E-K Fuji 1
704-05-DC-X
4P 225AF/175AT SA204R-KA Fuji 1 Ditto
4P 100AF/100AT EA104B-KA Fuji 1 Ditto

Molded case circuit 4P 100AF/100AT EA104B Fuji 1 Ditto
1
breaker
4P 100AF/50AT EA104B Fuji 1 Ditto
4P 50AF/50AT SA54B Fuji 1 Ditto
4P 50AF/30AT SA54B Fuji 1 Ditto
2P 30AF/15AT EA32AC Fuji 1 Ditto
2 Auxiliary relays Coil: AC230V HH54P-L Fuji 1 Ditto
Earth leakage relay_

3 Protection relay E40P0 Fuji 1 Ditto
AC230V, 100/200mA
Indicator lamps LED unit, DC24V, White UA-27FD8A-4W Kimuden 1 Ditto

4
(LED element) LED unit, DC24V, Orange UA-27FD8A-4O Kimuden 1 Ditto
Push button_1a1b, Black ABN111B IDEC 1 Ditto

5 Switches
Push button_1a1b, Yellow ABN111Y IDEC 1 Ditto
Space Heater_
SHC4-2210-T Shinohara 1 Ditto
Space heater with AC220/230V, 100W
6
thermostatic switch Thermostatic Switch_0 to
E5L-A4 Omron 1 Ditto
50 deg C
7 Fluorescent lamp AC230V, 10W FC1012GL Odelic 1 Ditto
Notice: Storage locations for spare parts

Do not use or store Electrical Parts in the following locations and conditions. Otherwise, it
may cause Electrical Parts to early break down.
All parts descried in this Spare Parts List shall be stored in the room with an air
conditioner.
1) Locations subject to direct sunlight and rain.
) Locations subject to an ambient temperature range not within 0 degrees C to 55
degrees C.
3) Locations subject to rapid temperature changes and resulting in condensation or
locations with relative humidity ranges not within 10% to 90%.
4) Locations subject to corrosive or inflammable gas.
5) Locations subject to excessive dust, salinity, or metal powder.
6) Locations subject to vibration or shock affecting the electrical parts.
7) Locations subject to water, oil, or chemical sprayed on the electrical parts.
8) Locations subject to excess of altitude 2000m (6562 feet).
9) Locations subject to the condition under pressure higher than the atmospheric
pressure of altitude 0m.
KRCS-182MJ
11 -
11-3 Maintenance equipment and tool list
ITEM 1 General tools
Item No. Description Detail Q'ty Remarkss

For 1 set
10×12 mm
11×13 mm
1.1 Double open end wrenches 14×17 mm 2 sets
17×19 mm
22×24 mm
30×32 mm
Iron frame with horizontal
1.2 Iron level 1
vial and plumb vial
1.3 Side cutting pliers Material: steel 1
For 1 set
-5.5×75
-6×100
1.4 Screw driver -8×150 1 set
+1×75
+2×100
+3×150
1.5 Wire brushes Material: steel 10
1.6 Hammers 1 pound 2
1.7 Bench vise with swivel base Material: iron 1
1.8 Oil jack Lifting power: 10 tons 1

For 1 set (5 kinds)
Flat
Half circle
1.9 File set 1 set
Circle
Square
Triangle
1.10 Hack saw frame with blade Material: steel 1
1.11 Oil gum Manual type oil pump 1
1.12 Grease gum Manual type grease gum 1 set

For 1 set
1.13 Punch set for rubber seal 9/16 in, 5/8 in, 3/4 in, 1 set
7/8 in, 1-1/8 in
1.14 Shackle SC - 18 4
KRCS-182MJ
11 -
ITEM 2 Cargo work tools

Rated load: 3.2 tons
2.1 Lever block 1
Lift: 1.5 m
2.2 Chain block 1
Lift: 3.0 m
Hook type, 1 sheave
2.3 Snatch block 1
For 1 set
Dimension: φ16×10.0 m
2.4 Wire rope Material: Steel 1 set
Both end: Lock proofing
Quantity: 4 lines
ITEM 3 Measuring instruments
3.1 Vernier caliper Measuring range: 300 mm 1

Straight rule
3.2 Steel rule 1
Measuring range: 1.5 m
Feeler gauge
3.3 Thickness gauge Measuring range: 1 set
0.03 mm to 1.0 mm
3.4 Stop watch Digital Stop Watch 1
ITEM 4 Electrical measuring instruments

Function:
True RMS multi-meter with
4 DC V, AC V, 1 SANWA: RD701
clip-on ammeter
DC A, AC A, Hz, Ω
Measuring range:
500V/1000 MΩ,
4.1 Insulation Tester 1 SANWA: DM5218S
250V/500 MΩ,
125V/200 MΩ
Measuring range:
Digital Earth resistance 0 to 20 Ω
4.2 1 KYORITSU: 4105A-H
measuring equipment 0 to 200 Ω
0 to 2000 Ω
KRCS-182MJ
11 -
ITEM 5 Lockable cabinet

Steel cabinet
5 Lockable cabinet 1
Size: 880H×900W×465D
KRCS-182MJ
11 -
KRCS-182MJ
11 -
12
Commercial
Equipments and
Addresses of Vendors
12 -
12-1 MECHANICAL
No.of Tel.
No. Manufacture Address Material & Equipment
No.of Fax
KINTETSU-DOJIMA
MITSUBISI
BUILDING, 2-2, DOJIMA- +81-6-6347-2841
ELECTRIC
2-CHOME, KITA-KU, +81-6-6347-2560
CORPORATION
1 OSAKA, JAPAN MOTOR
7-5-30, FUKUSHIMA,
MANSEI +81-6-6454-8229
FUKUSHIMA-KU,
CORPORATION +81-6-6454-8633
OSAKA, JAPAN
4-2-14, KAWARAMACHI,
MEIDENSHA +81-6-6203-5261
CYUOU-KU, OSAKA,
JAPAN
2 LIFTER BRAKE
2-13-6, NISHI-NAGASU-
ITOH DENKI CO, +81-6-6401-8161
CHO, AMAGASAKI-CITY,
LTD. +81-6-6401-3051
HYOGO, JAPAN
RSE
1-15-13, AKAI, DAITO- +81-72-869-6788
3 ENGINEERING GEAR REDUCER
CITY, OSAKA, JAPAN +81-72-869-6787
CO., LTD.
2-6-17, KITAHAMA,
OSAKA CHAIN & +81-6-6222-3046
4 CYUOU-KU, OSAKA, GEAR COUPLING
MACHINERY, LTD. +81-6-6222-5716
JAPAN
28-1, ICHIDA-
TSUBAKIMOTO ICHINOTUBO, +81-749-22-2001
5 CHAIN COUPLING
SPROCKET CO. KUMIYAMA-CYO, KUZE- +81-749-23-1757
GUN, KYOTO, JAPAN
TESAC 1-4-24, SINMACHI,
+81-6-6578-5520 STAINLESS WIRE
6 WIREROPE CO., NISHI-KU, OSAKA,
+81-6-6578-5525 ROPE
LTD. JAPAN
TOKAI BANE 3-7-27, SAGISU, OVER LOAD AND
+81-6-6453-3120
7 MANUFACTURING FUKUSHIMA-KU, SLACK LOAD
+81-6-6453-6181
CO., LTD. OSAKA, JAPAN DETECTOR
IHI COMPRESSOR 1-7-12, SINONOME,
+81-3-6703-0350
8 AND MACHINERY KOUTOU-KU, TOKYO, GREASE PUMP
+81-3-6703-0353
CO., LTD. JAPAN
1131, HIGASHI-NONAMI-
MIYABE IRON +81-749-22-2001
9 CHO, HIKONE-CITY, BYPASS VALVE
WORKS CO, LTD. +81-749-23-1757
SHIGA, JAPAN
1-4-5, UCHI-KANDA,
TAKUWA +81-3-3291-5873
10 CHIYODA-KU, TOKYO, LIMIT SWITCH
JAPAN
1-4-5, UCHI-KANDA,
TAKUWA CHIYODA-KU, TOKYO, +81-3-3291-5873 POSITION
11
CORPORATION JAPAN +81-3-3291-5226 INDICATOR
KRCS-182MJ
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Contents (Mechanical)
Item Model No. Index No.
Spillway Gates and Hoists

1) Hydraulic cylinders for Gates 1
a. Spillway Gates
b. Spillway gate with Flap
2) Oil Pump Equipments for Gates U08H015-OH 2
1
3) Oil Pump Equipments for Gate with Flap U08H016-OH 3
4) Position Indicator RTX1120 4
5) Synchro Transmitter NTX210-86A 5
6) Power Cylinder LPE100-L-K 6
Spillway Stoplog and Mobile Crane
1) Bypass valve φ150 7
2
2) Stainless Wire Rope 6×37 φ44 8
3) Rough Terrain Crane GR-300EX 9
Sand Flush Gate and Hoist
1) Hydraulic Cylinder 10
3 2) Oil Pump Equipment U08H036-OH 11
3) Position Indicator RTX1110 12
4) Screw Jack NJ40-D-M 13
Stoplog for Sand Flush Gate
4
1) Stainless Wire Rope 6×37 φ44 14
Main Dam Outlet Works
1) Hydraulic Cylinders 15
a. Main Service Gate
b. Main Guard Gate
c. Sub Service Gate
d. Sub Guard Gate
2) Oil Pump Equipment U08H043-OH 16
3) Air Valves 17
a. Main Guard Gate
5 b. Sub Guard Gate
4) Sluice Valves 18
a. Main Guard Gate
b. Sub Guard Gate
5) Gate Position Indicators RTX1110-010 19
a. Service Gate
b. Guard Gate
6) Grating 20
7) Expansion Joint 21
Main Dam Intake Gate and Hoist
6 1) Hydraulic Cylinder 22
2) Oil Pump Equipment U08H046-OH 23
KRCS-182MJ
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Main Dam Intake Trashracks and Raking Equipment

1) Grab 24
2) Reduction Motor 25
a. Hoisting CHHM15-6225DB-165
b. Traveling CHHM5-6140-43
c. Belt Conveyor CNHM1-6120-87
d. Loading Conveyor CHHM5-6180DB-87
3) Power Cylinders and Seats 26
a. Hoisting LPTB4000L8VLPC
LPTB2000L4V-1
b. Hopper LPTB1000 L10VLJ
4) Potentiometer for Hoisting Mechanism NTX3000 27
5) Load Cell for Hoisting Mechanism 28
7
6) Chain Coupling 29
a. Hoisting CR6022
b. Traveling CR6018
7) Pillow Block Bearings 30
a. Hoisting UCP319, UCP313
b. Traveling UCP313
c. Belt Conveyor UCP211
8) Bearing Seat 31
a. Traveling UCFC213
b. Belt Conveyor UCT310
9) Reels for Traveling Mechanism 32
ECS-1030-6SUS
ECS-230-20SUS
10) Water Level Detector 33
Headrace Tunnel Access Door and Drain Facilities
8
1) Drain Valves φ400 34
Draft Tube Gates and Hoists
1) Motor 2.2 kW 6 P 50 Hz 35
2) Lifter Brake BMS5-1316UPST 36
3) Gear Reducer EB-811 37
4) Gear Coupling GC-SSM-315 38
5) Chain Coupling CR-5014, CR-5016 39
9
6) Stainless Wire Rope 6×37 φ16 SB Type 40
7) Over Load and Slack Load Detector GR-30 41
8) Grease Pump MP-113 42
9) Bypass Valve φ150 43
10) Limit Switch MD-200 44
11) Position Indicator STX-120 45
KRCS-182MJ
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Tailrace Gate and Hoist

1) Motor 1.5 kW 6 P 50 Hz 46
2) Lifter Brake BMS5-1316UPST 47
3) Gear Reducer FB-1120 48
4) Gear Coupling GC-SSM-355 49
10 5) Chain Coupling CR-5014, CR-5016 50
6) Stainless Wire Rope 6×37 φ25 SB Type 51
7) Over Load and Slack Load Detector GR-70 52
8) Grease Pump MP-113 53
9) Limit Switch MD-200 54
10) Position Indicator STX-120 55
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12-2 ELECTRICAL
No.of Tel.
Manufacture Address Person in Charge
No.of Fax
No. Material & Equipment
No.of Tel.
Agent Address Person in Charge
No.of Fax
3-2-16, OHMORIKITA,
EBARA DENSAN OHTA-KU, TOKYO, +81-3-6384-8475
LTD. JAPAN +81-3-5493-0802 CONTROL CABINET &
1 MR.SASAKI LOCAL DISTRIBUTION
BOARD
KRCS-182MJ
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Contents (Electrical)
Spillway Gate Operating Console

1
Data Logger and Remote Control System for Spillway gates 1
DC Distribution Board
1) Spillway Gates 2
2
2) Sand Flush Gate 3
Outlet Works
Main Dam Intake Gate
3 Portable Diesel Generator 4
4 Sedimentation Detector 5
Main Instruments of Control Cabinets
1) Motor Protective Relay 6
2) Timer H3YN-4 7
3) Timer MS4S series 8
4) Digital Timer 9
5) Weekly Timer 10
6) Time Counter 11
5 7) AC Current Transducer 12
8) AC Voltage Transducer 13
9) Dry Conditioner 14
10) Chime 15
11) PLC CPU unit 16
12) PLC MELSECNET/H card 17
13) PLC ETHERNET card 18
14) PLC analog I/O card 19
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13
Office to Contact
for Service Inquires
13 -
If you have any inquires about the facility and equipment, please contact the
following office together with the name of the facility.
Name of the facility

The project for UPPER KOTMALE HYDROPOWER PROJECT LOT3
HYDROMECHANICAL WORKS
Contact infomation
KURIMOTO, LTD.
Steel Structure Projects Management Division
Machinery System Consolidated Division
12-9, Kitahorie 1-chome Nishi-ku, Osaka, Japan
TEL: +81-6-6538-7690
FAX: +81-6-6538-7749
KRCS-182MJ
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14
Annex
14 -
14-1 Initial Setting of Timer of Water Filling for Draft Tube Gates
1. Condition
Water Level: High Water Level is Full Supply Level W.L. 703.0
Low Water Level is Top elevation of bank W.L. 699.0
Draft Tube gates and Tailrace Gate shall be closed during the maintenance
work in progress.
2. Draft Tube Gate

(1) Elevation of Bypass valve m 685.95
(2) Diameter and Number of Bypass valve Φ150 × 2
(3) Flow coefficient of Bypass valve C 0.60
Flow coefficient of Submerged flow: 0.98 × C
(4) Area of Bypass Valve A m2 0.0353
(5) Volume of Filling Water
Tube Diameter m Φ3.0
Tube Length m 77.01
3
Volume V m 509 (Open Air)
35.4 (Under Water)
(6) Velocity of Bypass valve Flow V m/s (Free flow)
F.S.L 18.3
L.W.L 16.0
(7) Filling Time T = V/(CAV × 3600) hour
F.S.L 0.39 H
L.W.L 0.45 H
3. Setting Time
Draft Tube Gates: High & Low Water Level 1 Hour
Setting method of timer is shown below.

Commercial Equipment (Electrical) Index No.8 Timer - 2
KRCS-182MJ
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7 - Draft Tube Gates

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7 - Draft Tube Gates

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THE DEMOCRATIC SOCIALIST REPUBLIC OF SRI LANKA

MINISTRY OF POWER AND ENERGY

UPPER KOTMALE HYDROPOWER PROJECT

OPERATION & MAINTENANCE MANUAL

How to use this manual

Careless operation of this facility and equipment may cause serious

● Do not operate until you fully understand this manual.

Inspection and maintenance

3 Overview of the Facility................................................................... 3-1

5 Steel Structure.................................................................................. 5-1

9 Trouble Shooting.............................................................................. 9-1

11 Spare Parts and Supplied Tools....................................................11-1

12 Commercial Equipments and Addresses of Vendors................. 12-1

13 Office to Contact for Service Inquires.......................................... 13-1

● Read and understand this manual before conducting operation, handling,

Alert symbols and safety marks used in this manual

Indicates an imminently hazardous situation which, if not

Indicates a potentially hazardous situation which, if not

Indicates a potentially hazardous situation which, if not

Supplementary information about operation and

General instructions for each work

• Understand the following instructions thoroughly before

• Conduct "Safety" briefing before operation, inspection, and

• Wear proper clothing and protective devices during the work.

• Wear a safety belt when working at heights.

• Transportation and electric work should be conducted by the

• Unloading work should be done by the authorized personnel.

• Use the designated lifting device.

Note: Choose wire size sufficient to bear the load. The

• Never stand under the lifted equipment.

• Ensure all the bolts tight.

• Do not operate the machine without safety covers.

• Never touch rotating parts.

• Shut down the machine in case of emergency.

• Not to get burned.

• Close terminal boxes.

• Do not conduct maintenance, adjustment, disassembly, and

• Take proper countermeasure to avoid unexpected start-up.

• Follow the diagram when connecting wires between equipments.

• Be sure to ground the machine.

• Do not carry heavy parts to prevent back injury.

• Secure and note the safety place.

• Use genuine parts or those designated by the manufacturer

• Never use open flame when cleaning with solvent.

• Place the parts in the stable condition.

Objectives of the facility

Gate type Objective and function

The draft tube gate is located in the turbine draft tube of

Gate design condition

■ Item 11 Draft tube gates and hoists

Gate type Steel slide gate (w/ water filling valve)

Hoisting height 52200

650 Clrear Span 2500 650

11300 5200 6000

Local control cabinet

Local distribution board

Lifter brake Chain coupling

Drum Position indicator

Wire end Grease pump

LCC: LOCAL CONTROL CABINET

Overall configuration of the control systems

SAND FLUSH GATE

. ALARM STOP . LAMP TEST

ＭＣＣＢＭＣＣＢＭＣＣＢＭＣＣＢＭＣＣＢ