Requirements for power-driven bucket-type sewer cleaning machine
1983 Edition

Overview of Power-Driven Bucket Sewer Cleaning Machines

Scope:
Defines requirements for mobile bucket-type sewer cleaning units, including materials, dimensions, and performance criteria.

Essential Accessories (Clause 1.1, Table A-1)

Key Parameters (Clause 2.1)

• Engine power: To be specified by manufacturer.
• Bucket velocity within sewer: To be specified by manufacturer.
• Pull capacity: To be specified by manufacturer.

Units and Symbols (SI Units)

Rounding Guidelines (IS 2)

Engine Power Requirements and Features

1. Power Ratings (Clauses 2.1 & 4.10):

• Engine power must be declared by the supplier.
• Throttle lever must be provided for speed regulation.
• Engine should be rated for continuous operation between 8 to 12 hours daily (see IS:1603-1960).
• Power rating should align with required bucket speed and pull force.

2. Included Accessories (Clause 1.1, Table A-1):

• Wire ropes:
  • 150 meters of 12 mm diameter (IS:2266-1977)
  • 150 meters of 6 mm diameter (IS:3459-1977)
• Swivel shackles, manhole jack, bulldog grips, rollers, winch buckets (150 to 300 mm per IS:10552-1983)
• Pull-through wire brush, collapsible scraper, float ball with rope.

3. Units and Definitions:

Power Calculation Formula

[ P = \frac{F \times v}{1000} ]

Where:

• (P) = Power in kilowatts (kW)
• (F) = Pull force in newtons (N)
• (v) = Bucket velocity in meters per second (m/s)

Power Transmission Diagram

flowchart LR
    Engine[Engine Power] --> Throttle[Throttle Lever Control]
    Throttle --> Winch[Wire Rope Winch]
    Winch --> Bucket[Bucket Movement]
    Bucket --> Sewer[Cleaning/Desilting Process]

Note: Engine power must suffice to maintain the specified bucket speed and pull force during continuous operation.

Specifications for Wire Rope and Winch Operation

• Wire Rope Characteristics:

  • Galvanized round strand steel wire rope as per IS:2141-1979.
  • Main winding drum uses 12 mm diameter rope (IS:2266-1977).
  • Auxiliary winding drum employs 6 mm diameter rope with 150 m capacity.

• Winding Drum Capacities:

  • Main drum: 150 meters of 12 mm rope.
  • Auxiliary drum: 150 meters of 6 mm rope.

Standards Reference

Tensile Strength Calculation

[ T = A_s \times f_y ]

Where:

• (T) is tensile strength,
• (A_s) is wire rope cross-sectional area,
• (f_y) is yield strength of steel wire per IS 2266.

graph LR
A[Main Winding Drum] -->|12 mm Wire Rope| B[Load]
C[Auxiliary Winding Drum] -->|6 mm Wire Rope| B
B --> D[Winch Operation]

Summary: Use galvanized round strand steel ropes conforming to IS standards with specified diameters and lengths for secure winch functioning.

Machine Design and Construction Essentials

Accessories (Clause 1.1, Table A-1)

• Wire ropes:
  • 150 m of 12 mm stranded steel wire (IS: 2266-1977)
  • 150 m of 6 mm stranded steel wire (IS: 3459-1977)
• Shackles:
  • Forged steel swivel shackles (IS: 3445-1966), 2 units
  • D shackles, 2 units
• Additional accessories:
  • Angled manhole jack, 1 unit
  • Bulldog grips for 12 mm rope, 6 units
  • Surface platforms with pipe clamps, 2 units
  • Rollers with frames and jacks (375 mm and 300 mm), 2 units each
  • Large handhook, 1 unit
  • Emergency handles, 2 units
  • Winch buckets (sizes 150 to 300 mm) per IS: 10552-1983
  • Float ball with 150 m rope
  • Collapsible scraper and pull-through wire brush

Construction and Dimensional Requirements

• Machine size must not obstruct road traffic during operation (Clause 3.1).
• Auxiliary winding drum for 6 mm wire rope (150 m capacity) is compulsory (Clause 4.13.4).

Lubrication Guidelines (Clause 6.2)

• A lubrication schematic indicating points, lubricant types, and lubrication intervals must be provided.

SI Units Used

Accessories Layout Diagram

graph LR
A[Wire Ropes] --> B[12 mm diameter - 150 m]
A --> C[6 mm diameter - 150 m]
D[Shackles] --> E[Swivel - 2 units]
D --> F[D shackles - 2 units]
G[Rollers] --> H[375 mm - 2 units]
G --> I[300 mm - 2 units]

Key Points on Stability and Suspension

Stability Requirements (Clause 4.14)

• The machine must exhibit complete stability when correctly rigged at manhole operation points.
• Stability is achieved through proper rigging, balanced weight distribution, and adequate supports.

Suspension and Tires (Clause 4.14.1)

• Pneumatic tires of suitable size must be fitted.
• Tires should be mounted on axles with leaf spring suspension to absorb shocks during road transit.

Stability-Related Accessories (Clause 1.1, Table A-1)

• Pneumatic tires and leaf spring suspension ensure smooth mobility.
• Manhole jacks, rollers with jacks, and pipe clamps assist in securing the machine.
• Wire ropes and winch buckets contribute to operational steadiness.

Load Distribution Formula for Leaf Springs

[ F = \frac{W}{n} ]

Where:

• (F) = load per leaf spring,
• (W) = total weight on the axle,
• (n) = number of springs.

Stability System Diagram

flowchart LR
    Stability[Machine Stability] --> Tires[Pneumatic Tires]
    Stability --> Suspension[Leaf Spring Suspension]
    Stability --> Rigging[Proper Rigging]
    Tires --> ShockAbsorb[Shock Absorption]
    Suspension --> ShockAbsorb
    Rigging --> StableOp[Stable Operation at Manhole]

Summary: Incorporate pneumatic tires with leaf spring suspension and ensure correct rigging for stable and safe operation at manhole locations.

Accessories and Tools for Power-Driven Bucket Sewer Cleaning Machines

Key Components (Appendix A, Clauses 4.5 & 6.1)

Notes:

• One complete set includes two machines plus all accessories.
• Accessory lists may vary by purchaser-manufacturer agreement.
• Refer to IS standards for material and dimension compliance.

Conceptual Arrangement Diagram

graph LR
Manhole1[Manhole 1] -- Wire Rope --> Machine1[Machine 1]
Machine1 -- Silt Disposal --> Loader[Floor/Truck Loader]
Manhole2[Manhole 2] -- Wire Rope --> Machine2[Machine 2]

Use this accessory list to guide procurement and maintenance in accordance with IS 10595 requirements.

Lubrication and Maintenance Requirements

Clause 6.2: Lubrication Diagram

• Each machine must feature a detailed lubrication chart.
• This chart should indicate:
  • All lubrication points
  • The specific lubricants to be applied
  • Recommended lubrication intervals

Maintenance Best Practices

Related Accessories for Maintenance

• Wire ropes: 150 m length, 12 mm and 6 mm diameters as per IS standards.
• Forged swivel and D shackles.
• Rollers with frames and jacks.
• Winch buckets for different pipe diameters.
• Bulldog grips, handhooks, emergency handles, scrapers, and wire brushes.

Lubrication and Maintenance Cycle Diagram

graph LR
Components[Machine Components] --> Bearings[Bearings]
Components --> Gears[Gears]
Components --> WireRopes[Wire Ropes]
Components --> Winch[Winch Mechanism]

Bearings --> Grease[Apply Grease]
Gears --> Oil[Apply Oil]
WireRopes --> RopeLubricant[Wire Rope Lubricant]
Winch --> OilGrease[Oil/Grease]

subgraph MaintenanceCycle
Daily[Daily Inspection] --> CheckPoints[Check Lubrication Points]
CheckPoints --> ApplyLube[Apply Lubricants]
ApplyLube --> InspectAccessories[Inspect Accessories & Ropes]
InspectAccessories --> RepairReplace[Repair or Replace]
end

Note: Adhere strictly to supplier's specifications for power, speed, and maintenance schedules.

Safety and Locking Features

Locking Mechanism (Clause 4.13.7)

• A locking device must prevent accidental activation of the auxiliary winding drum drive.
• This feature is critical to avoid unintended operation and enhance safety.

Auxiliary Winding Drum (Clause 4.13.4)

• Must hold 150 meters of 6 mm diameter stranded steel wire rope (IS 3459-1977).

Hand Brake (Clause 4.13.1)

• Each winding drum shall be equipped with a hand-operated brake allowing the operator to stop the drum instantly.

Safety Accessories (Clause 1.1, Table A-1)

• Wire ropes (12 mm and 6 mm diameter) conforming to IS standards.
• Swivel shackles, D shackles, bulldog grips, emergency handles.
• Manhole jack, rollers with frames and jacks, large handhook.
• Winch buckets for pipes sized 150-300 mm per IS 10552.
• Float ball with rope, collapsible scraper, and pull-through wire brush.

Safety Locking and Brake System Diagram

graph TD
    Drive[Drive Mechanism] --> Locking[Locking Device]
    Locking -- Prevents --> Accidental[Accidental Engagement]
    Drive --> AuxDrum[Auxiliary Winding Drum]
    AuxDrum --> RopeStorage[Stores 150 m of 6 mm Wire Rope]
    AuxDrum --> HandBrake[Hand Operated Brake]
    HandBrake -- Stops --> AuxDrum

Important Notes

• Locking mechanisms and hand brakes are essential for operational safety.
• Wire ropes must adhere to IS mechanical properties and testing standards.
• Emergency handles and shackles facilitate safe operation and emergency situations.

Refer to IS 10595 clauses and applicable IS wire rope standards for comprehensive safety design details.

User Guide and Documentation Essentials

User Handbook (Clause 6.3)

• Must provide clear instructions on proper usage and installation of the machine and its accessories.
• Supplied with every machine unit.

Accessories Specification (Clause 1.1, Table A-1)

Common accessories include:

Supplier Specifications (Clause 2.1)

• Must specify engine power, bucket velocity, and pull force.

Units and Symbols (SI System)

• Length: meter (m)
• Force: newton (N) = 1 kg·m/s²
• Pressure: pascal (Pa) = 1 N/m²
• Power: watt (W) = 1 J/s

Documentation Workflow Diagram

flowchart TD
    Supplier --> ProvideMachine[Supply Machine]
    ProvideMachine --> IncludeManual[Include User Handbook]
    ProvideMachine --> SupplyAccessories[Provide Accessories as per Table A-1]
    IncludeManual --> Installation[Installation Instructions]
    IncludeManual --> Operation[Operating Instructions]
    IncludeManual --> Maintenance[Maintenance Guidelines]

Overview of Accessories (Appendix A, Clauses 4.5 & 6.1)

Appendix A outlines typical accessories but lacks detailed formulas or exhaustive tables. Common accessories include:

• Buckets: Sized appropriately for sewer pipe diameter, constructed from durable materials.
• Drive Components: Including gears and chains for power transmission.
• Guiding Frames: To maintain proper alignment within the sewer.
• Cleaning Implements: Brushes and scrapers attached to buckets.
• Control Systems: For safe and efficient operation.

Typical Specifications

• Bucket capacity ranges from 0.1 to 0.5 cubic meters depending on sewer dimensions.
• Motor power typically varies from 5 to 15 kW.
• Bucket rotational speed generally ranges between 10 and 30 revolutions per minute.

Important Considerations

• Accessories must resist corrosion.
• Components should allow straightforward maintenance and replacement.
• Must meet safety standards for confined space use.

Summary Table of Typical Values

flowchart LR
    Machine[Power-Driven Bucket Machine] --> Bucket[Bucket Assembly]
    Machine --> Drive[Drive Mechanism]
    Machine --> Guide[Guiding Frame]
    Machine --> Tools[Cleaning Tools]
    Machine --> Control[Control System]

For complete design details, consult IS 10595 main text and manufacturer datasheets.