Vertical Gates Design

ADO CONMAT INDIA PROJ PROJEC ECT T : BUD BUDAU AUN N IRRI IRRIGA GATI TION ON PROJ PROJEC ECT T

SUBJEC SUBJECT: T: DESIG DESIGN N OF VERTIC VERTICAL AL LIFT LIFT SERV SERVICE ICE GATES GATES

Design of Vertical Lift Service Gates of Budaun Irrigation Project 1.0

Technical Details :

♦ No of gates required

: 25Nos

♦ Clear vent width

: 18000mm

♦ Clear vent height

: 6200mm

♦ Height of gate

: 6500mm

♦ Sill level

: EL 157.100M

♦ Pond level

: EL 163.300M

♦ HFL

: EL 164.300M

♦ Type of gate

: Regulating

♦ Top of pier

: EL 167.000M

♦ Des Design head

FRL

: 6.2M

HFL

: 7.2M

♦ Location of skin plate

: Up stream

♦ Location of seal

: Up stream

♦ Side seal C/C

: 18150mm

♦ Track C/C

: 18700mm

♦ End to end of groove

: 19200mm

♦ Hoisting speed

: 0.3 to 0.7M/min

♦ Designed

: As per IS 4622 - 2003

Page No:1


2.0


Material:

S No.

Components

Proposed

All structural members like like skin plate, end box, vertical stiffeners, horizontal girders,

1

Structural Steel

Roller track girder, Sill beam seal Crest etc., 2

Rollers and Guide Rollers

3

Roller pins and Guide Roller Pins

Stainless Steel

4

Roller Track

Stainless Steel

5

Seal Seats

Stainless Steel

6

Seals

7

Bearings

3.0

Page No:2

Remarks

IS : 2062 - 2006 Grade E250 QualityB

Cast Steel

IS 1030 30Cr 13 13 IS : 1570 (Part V) 20Cr 13 13 IS : 1570 (Part V) 04 Cr 18 18 Ni 10 IS : 1570 (Part V)

Synthetic or

IS : 11855 Natural Rubber Anti Friction SKF / FAG / NSK / ZKL Bearings

Permissible Str Stresses: As per IS:4622 - 2003

I. Embedded Parts & Gate Leaf – As per IS 4622 - Wet and Inaccessible condition 1. Structural steel – IS 2062 – 2006 Grade E250 Quality B S.No

1 2 3 4 5 C. 4.0

Type of stresses

Direct compression and compression in bending Direct tension and tension in bending Shear Stress Combined stress Bearing stress

Factor

YP :2550kg/cm2

YP : 2448kg/cm2

0.40YP

UTS:4180kg/cm2 1020

UTS:4180kg/cm2 979

0.40YP

1020

979

0.30YP 0.50YP 0.45YP

765 1275 1147

734 1224 1102

Bearing stress in concrete = M – 250 – 62kg/cm 2 Groove De Details :

Stresses in kg/cm2 Thk < 20mm Thk 20 – 40mm



C 6 2

5

0

/ C

O

F

V

E

R

O

L

L

E

R

T

R

A

C

Page No:3

K

=

0

0

3

5

0

0 5 3

0 0 5

N

T

=

1

8

0

I D

E

G

U

I D

N

D

O

F

G

0

0

0 5 1

0 5

6 1

5 0 2

0 5 4

0 5 6 1

3 0

4

0

7

9

0 8 6 5 0 6

1

9

0

0 5 4

1

6

1

6 6 1

6 1

9 5 0 0 1 0 5 2

0 5 1

F

5

0 6

4.0

Design of Gate Leaf :

O

W

0 0

F E

L

1

0 / F

N

0

0 O

D

F T

S O

E

E R

= O

1 O

9 V

1 E

2

0 =

1

ADO CONMAT INDIA PROJECT : BUDAUN IRRIGATION PROJECT

SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES

Page No:4

The gate leaf is designed as vertical lift roller gate made out of single Gate with two elements connected with flexible joint. Each element is fitted with 4 rollers working on self aligned spherical roller bearing mounted on stainless steel axle. The axle is made with eccentricity of 5mm for fine adjustment at later date if required. The U/S skin plate is fitted with Bulb type of molded rubber seals for sides and top, flat type of rubber seals for bottom for water tightness. The gate is being operated with Rope drum hoist of adequate capacity. As per specification the gate is to be designed for FRL and to be checked for HFL condition allowing 1.333 times of permissible stresses as per IS 4622.

• C / C of side seals

: 18150mm

• C/C of tracks

: 18700mm

• Height of gate

: 6500mm

• Design Head

FRL

: 6.20M

HFL

: 7.20M

Water thrust on the gate FRL = wLH 2 / 2 = 1 X 18.15 X6.202 / 2 = 348.843t HFL = wLh (H – h / 2) = 1 X 18.15 X 6.5 (7.2 – 6.5/ 2) = 466.001t % increase of load under HFL over FRL = ((466.001 – 348.843) / 348.843) X 100 = 33.58% > 33⅓ % FRL Condition Element

Size

Bottom 18.15X2.0

Head

% of Increase

HFL Condition

Thrust

Head

Thrust

6.20 188.760t

7.20

225.06

HFL Over

Remarks

FRL

19.2%<33⅓ %

Designed for FRL Designed for HFL

Top

18.15X4.5

4.20 160.083t

5.20

240.941 50.5%>33⅓ %

condition with increased stresses

3

4.1

6

Design of Bottom Element :

. 3

0

0

t

7

8

. 3

3

3

4.1.1 FRL condition : 2 . 6

1

5

2

. 4

6

0

t

2 . 4

4 A 4

2

5 B

1

0

3

5

5



Page No:5

C/C of seals : 18.15M

R A = 94.238t RB = 94.522t

4.1.2 HFL condition : 3

6


. 3

0

0

7

8

. 3

t 3

3

2 . 7

1

8

8

. 7

6

0

t

2 . 5

4

R A = 110.075t RB = 114.985t

4.2

4

B

A

2

5

1

0 2

3 0

5

5

0

Design of Top Element :

4.2.1 FRL condition :


1 6 0 . 0 8 3 t 1 4 0 M 2 . 4

RC = 94.964t 4 4

C

D

2 3 6

RD = 65.119t

1 4 0

3 0

4 5 0 c m

4.2.2 HFL condition : 1 8 3 . 0 8 3 t 1 3 0

C/C of seals : 18.15M 2 . 5

5 7 . 1 7 3 t 7 .

5 5

RC = 114.553t 4 4

RD = 126.389t 4.3

Design of Horizontal Girders :

C

2 3 6 4 5 0

0

D

1 7 0


Condition


Page No:6

Load on Girder ‘A’ Load on girder ‘B’ Load on girder ‘C’ Load on girder in t

in t

in t

‘D’ in t

FRL

94.238

94.522

94.964

65.119

HFL

110.075

114.985

114.553

126.389

16.80%<33⅓ %

21.65%<33⅓ %

20.6%<33⅓ %

94%>33⅓ %

% of increase of HFL over FRL

Girder ‘A’, ‘B’ and ‘C’ is designed for FRL condition and Girder ‘D’ is designed for HFL condition

4.3.1 Design of Horizontal Girder ’A’ : (Designed for FRL condition)

Load on horizontal girder ‘A’ = 94964kg 9 4 9 6 4 k g

R A = RB = 47482kg

A

2 7 . 5

l = L

=

1 8 1 5

2 7 . 5

B

1 8 7 0

BM = (94964 / 8) (2 X 1870 – 1815) = 22850713kgcms. It is proposed to provide skin plate out of 16mm plate. After allowing corrosion allowance of 1.5mm, the effective thickness is 14.5mm. The Co-acting width:

L = 1870cm

B1 = 103 / 2 = 51.5cm

L / B1 = 1870 / 51.5 = 36.31

B2 = 42cm

∴ V1 = 0.98

8

8 5

L / B2 = 1870 / 42 = 44.5

4 .

∴ V2 = 0.86

1

3

6 .

0

1

∴ Co-acting width = V1 B1 + V2 B2 = 0.98 X 51.5 + 0.86 X 42 = 88.74cm 2

7

9 .

4 .

6

5

7

7

But as per IS 800 – 1984 cl : 3.5.2.1 the Max. co-acting width of skin plate is 20t to the innermost face of the stiffening. 0 8 1

∴ Co-acting width = 40t + B = 40 X 1.45 + 30 = 88cm Sectional properties are as follows:

1

. 2

3 3 . 9 0 1

6 . 1

2

7



Page No:7

Area = 482.8cm2 IXX

= 2705560cm4

Z1

= 35175cm3

Z2

= 35849cm3

Z3

= 24747cm3

i) Bending stress on U/S of skin plate = 22850713 / 35175 = 650kg/cm2 < 1020kg/cm2 ii) Bending stress on D/S of skin plate =22850713 / 35849 = 637kg/ cm2 < 1020kg/cm2 iii) Bending stress on D/S of flange =22850713 / 24747 = 923kg/ cm2 < 1020kg/cm2 iv) Shear stress = 47482 / (74.3 X 1.2) = 532.5kg/cm 2 < 765kg/cm2 Check for deflection :

Permissible deflection = L / 800 = 1870 / 800 = 2.337cms. Actual deflection = [94964 / (384 X 2047000 X 2705560)] [8 X 1870 3 – 4X1870 X 18152 X 18153] = 1.582cm < 2.337cm. Design of Welds : Weld strength required between Skin Plate and U/S Flange :

F1 = S A y / 2 I = (47482 X 88 X 1.45 X 76.195) / (2 X 2705560) = 85kg/cm length Proposed 6mm fillet having strength of 0.7 X 0.6 X 765 = 321kg/cm length Weld strength required between Web and U/S flange :

F2 = [47482 X (88 X 1.45 + 30 X 1.6) X 75.45] / (2 X 2705560) = 116kg/cm length Proposed 6mm fillet having strength 321kg/cm length Weld strength required between Web and D/S flange :

F3 = [47482 X (30 X 1.6 + 27 X 1.6) X 107.23] / (2 X 2705560) = 80kg/cm length Proposed 6mm fillet having strength 321kg/cm length Weld strength required between D/S flanges :

F4 = (47482 X 27 X 1.6 X 108.23) / (2 X 2705560) = 50kg/cm length Proposed 6mm fillet having strength 321kg/cm length



Page No:8

4.3.2 Design of Horizontal Girder ’B’ : (Designed for FRL condition)

Load on horizontal girder ‘B’ = 94522kg 9 4 5 2 2 k g A

R A = RB = 47261kg

2 7 . 5

l = L

=

1 8 1 5

2 7 . 5

B

1 8 7 0

BM = (94522 / 8) (2 X 1870 – 1815) = 22744356kgcms. It is proposed to provide skin plate out of 16mm plate. After allowing corrosion allowance of 1.5mm, the effective thickness is 14.5mm. Co-acting width:

L = 1870cm

B1 = 103 / 2 = 51.5cm

L / B1 = 1870 / 51.5 = 36.31

∴ V1 = 0.98

L / B2 = 1870 / 50 = 37.4

∴ V2 = 0.86

B2 = 50cm

∴ Co-acting width = 0.98 X 51.5 + 0.86 X 50 = 93.47cm But as per IS 800 – 1984 cl : 3.5.2.1 the Max. co-acting width of skin plate is 20t to the innermost face of the stiffening. 8

∴ Co-acting width = 40t + B = 40 X 1.45 + 30 = 88cm

8 5 4 . 1

3

0 6 . 1

Sectional properties are as follows: 2

7

9 .

2

Area = 482.8cm IXX

= 2705560cm4

Z1

= 35175cm3

Z2

= 35849cm3

4 .

6

5

7

7

0 8 1

1

Z3

3

= 24747cm

. 2

3 3 . 9 0 1

i) Bending stress on U/S of skin plate = 22744356 / 35175 = 647kg/cm2 < 1020kg/cm2 ii) Bending stress on D/S of skin plate =22744356 / 35849 = 634kg/ cm2 < 1020kg/cm2 6 . 1

2 27 iii) Bending stress on D/S of flange = 22744356 / 24747 = 919kg/ cm < 1020kg/cm2 3 0 6 . 1

iv) Shear stress = 47261 / (74.3 X 1.2) = 530kg/cm 2 < 765kg/cm2



Page No:9

Check for deflection :





F4 = (47261 X 27 X 1.6 X 108.53) / (2 X 2705560) = 41kg/cm length Proposed 6mm fillet having strength 321kg/cm length 4.3.3 Design of Horizontal Girder ’C’ : (Designed for FRL condition)

Load on horizontal girder ‘A’ = 94964kg 9 4 9 6 4 k g

R A = RB = 47482kg

A

2 7 . 5

l = L

=

1 8 1 5

2 7 . 5

B

1 8 7 0


L = 1870cm

B1 = 236 / 2 = 118cm

B2 = 44cm



L / B1 = 1870 / 118 = 15.84

∴ V1 = 0.955

L / B2 = 1870 / 44 = 42.5

∴ V2 = 0.86

Page No:10

∴ Co-acting width = 0.955 X 118 + 0.86 X 44 = 150cm But as per IS 800 – 1984 cl : 3.5.2.1 the Max. co-acting width of skin plate is 20t to the innermost face of the stiffening.

∴ Co-acting width = 40t + B = 40 X 1.45 + 30 = 88cm 8

Sectional properties are as follows:

8 5 4 . 1

3

0 6 . 1

Area = 482.8cm2 2

7

9 .

4 .

6

5

7

7

4

IXX

= 2705560cm

Z1

= 35175cm3

Z2

= 35849cm3

Z3

= 24747cm3

0 8 1

1

. 2

3 3 . 9 0 1

i) Bending stress on U/S of skin plate = 22850713 / 35175 = 650kg/cm2 < 1020kg/cm2 ii) Bending stress on D/S of skin plate =22850713 / 35849 = 632kg/ cm2 < 1020kg/cm2 6 . 1

2 7 iii) Bending stress on D/S of flange = 22850713 / 24747 = 923kg/ cm2 < 1020kg/cm2 3

2

0

6 . 1

2

iv) Shear stress = 47482 / (74.3 X 1.2) = 533kg/cm < 765kg/cm Check for deflection :


F1 = S A y / 2 I = (47482 X 88 X 1.45 X 76.175) / (2 X 2705560) = 105kg/cm length Proposed 6mm fillet having strength of 0.7 X 0.6 X 765 = 321kg/cm length



Page No:11

Weld strength required between Web and U/S flange :



F4 = (47482 X 27 X 1.6 X 108.53) / (2 X 2705560) = 41kg/cm length Proposed 6mm fillet having strength 321kg/cm length 4.3.4 Design of Horizontal Girder ’D’ :

Load under FRL = 65.119t Load under HFL = 126.289t Load equivalent to FRL under HFL = 126.289 / 1.33 = 94.954t

∴ It is proposed to design for FRL equivalent load of 94.954t Load on horizontal girder ‘D’ = 94954kg 9 4 9 5 4 k g A

R A = RB = 47977kg

2 7 . 5

l = L

=

1 8 1 5

2 7 . 5

B

1 8 7 0


L = 1870cm

B1 = 236 / 2 = 118cm

L / B1 = 1870 / 118 = 15.84

∴ V1 = 0.955

L / B2 = 1870 / 170 = 11

∴ V2 = 0.76

B2 = 170cm

∴ Co-acting width = 0.955 X 118 + 0.76 X 170 = 242cm But as per IS 800 – 1984 cl : 3.5.2.1 the Max. co-acting width of skin plate is 20t to the innermost face of the stiffening.



Page No:12

∴ Co-acting width = 40t + B = 40 X 1.45 + 30 = 88cm Sectional properties are as follows:

8

8 5 4 . 1

3

0 6 . 1

Area = 482.8cm2 2

IXX

= 2705560cm4

Z1

= 35175cm3

Z2

= 35849cm3

7

9 .

4 .

6

5

7

7

0 8 1

Z3

= 24747cm3 1

. 2

i) Bending stress on U/S of skin plate = 22848306 / 35175 = 650kg/cm2 < 1020kg/cm2 3 3 . 9 0 1

ii) Bending stress on D/S of skin plate = 22848306 / 35849 = 637kg/ cm2 < 1020kg/cm2 iii) Bending stress on D/S of flange = 22848306 / 24747 = 923kg/ cm2 < 1020kg/cm2 6 .

2

2 iv) Shear stress = 47977 / (74.3 X 1.2) = 538kg/cm < 765kg/cm 2 7 1

3

0

6 . 1

Check for deflection :

Permissible deflection = L / 800 = 1870 / 800 = 2.337cms. Actual deflection = [94954 / (384 X 2047000 X 2705560)] [8 X 18703 – 4X1870 X 18152 X 18153] = 1.518cm < 2.337cm.

Design of Welds : Weld strength required between Skin Plate and U/S Flange :





Page No:13


F4 = (47977 X 27 X 1.6 X 108.53) / (2 X 2705560) = 42kg/cm length Proposed 6mm fillet having strength 321kg/cm length 4.4

Design of End Box :

The disposition of rollers and horizontal girders are as shown. 4.4.1 Bottom Element :

i)

FRL condition :

R A = 94.162t

9 4 5 2 2 k g

9 4 2 3 8 k g A

1 8

B

6 7 1 0 3

RB = 94.598t

1 8

Max. Roller load = 94.162 / 2 = 47.299t ≈ 47.3t Bending Moment = 94522 X 18 = 1701396kgcm ii)

HFL condition :

R A = 108.756t

1 1 0 0 7 5 k g

1 8

1 1 4 9 8 5 k g A

B

6 7 1 0 3

RB = 116.304t

1 8

Max. Roller load = 116.304 / 2 = 58.152t Equivalent FRL load = 58.152 / 1.33 = 43.723t Bending Moment = 114985 X 18 = 13568230kgcm 4.4.2 Top Element :

i)

FRL condition : 6 5 1 1 9 k g

9 4 9 6 4 k g

R A = 97.650t

1 8

C

2 0 0 2 3 6

RB = 62.433t Max. Roller load = 97.650 / 3 = 48.825t ≈ 48.9t say 50t Bending Moment = 94964 X 18 = 1709352kgcm

D

1 8


ii)


Page No:14

HFL condition : 1 2 6 3 8 9 k g

1 1 4 5 5 3 k g

R A = 113488kg

1 8

C

2 0 0 2 3 6

D

1 8

RB = 127454kg Max. Roller load = 127.454 / 2 = 63.727t Equivalent FRL load = 63.727 / 1.33 = 47.9t ≈ 48.0t Bending Moment = 126389 X 18 = 2275002kgcm Proposed 785 X 16mm plate for end box. ZXX = (4 X 1.6 X 54 2) / 6 = 3110cm3 Bending stress FRL = 1709352 / 3100 = 551kg/cm2 < 1020kg/cm2

P

L

1

6

T + H

1K 2 . m 4 5

5 .

HFL = 2275002 / 3100

8 7

= 734kg/cm2 < 1527kg/cm2

4

Max. Roller load = 50,000kg

5 . 0 2

Shear stress

FRL = 50000 / (2 X 54 X 1.6)

8

= 289kg/cm2 < 765kg/cm2 Bearing stress FRL = 50000 / (2 X 8 X 2.8) = 1116kg/cm 2 < 1147kg/cm2 4.5

Design of Roller :

Max Roller load FRL = 50t Material cast steel IS : 1030 Grade 340 - 570W Permissible stress = 1.6 X 570 X (10.2 / 1000) = 9.30t/cm 2 Proposed 450φ X 130mm tread width roller.

σC = 0.418 4.6

(50.00 X 2047) / (22.5 X 13) = 7.82t/cm2 < 9.30t/cm2

Design of Bearings :

Max. Roller load = 50000kg Min Bearing Static capacity required = 50000 X 1.5 X 9.81= 735750N

Proposed Spherical Roller Bearing 22226E : ID = 130, OD = 230, Thk = 64 with pressed steel cage having Static capacity = 930KN

m


4.7


Page No:15

Design of Roller Axle :

Material proposed Stainless steel : 20Cr13 IS:1570 part-V Yp = 490MPa

UTS = 690MPa

Permissible stress :

Bending = 2000kg/cm2 = 1500kg/cm2

Shear

5 0 0 0 0 k g

R A = RB = 25000kg

A

7 .6

6 .4 2 1 .6

7 .6

B

BM = (50000 / 8) (2 X 19.2 – 6.4) = 230000kgcm Proposed 130φ at bearing and 80φ at end box. ZXX = 216cm3 Area = 50cm2 Bending stress = 230000 / 216 = 1065kg/cm 2 < 2000kg/cm2 Shear stress

= 25000 / 50 = 500kg/cm2 < 1500kg/cm2

Design of girder at curtailment :

4.8

1 8 7 0 0 A

L i f it n g

B

C

/C

= 1 2 6 0 0

0

3 0 0 1 8 9

7

3

5

4

A 1 0 5

1

8

S P C S

@

3 5 0

=

8 7 5 0

3

6

6

1

1

6

W E B S T I F F N E R

6 1 8 1

1

1 0

1 0

7 6

7

4 5 0

2 5

0

7

B

1 4 6 0 0 1 4 7 0 0

1 5 5 0

1 5 5 0

Max. horizontal girder reaction = 94.964t 7 5

R A = RB = 47482kg

A

B 9 4 9 6 4 k g

4 5 A

2 7 .5

l = L A

B

=

1 8 1 5 1 8 7 0

2 7 .5 B



Page No:16

At Section AA :

Bending moment = 47482 X 45 – [(94964 / 1815) X (45 – 27.5) 2 / 2]= 2128678kgcm

Sectional properties at section ‘AA’ are as follows : 8

8

5 4 .

2

Area = 312.76cm

1

3

0

9 0 .

4

IXX

= 29703cm

Z1

= 12327cm3

1

4 2

. 2

4

6 .

6 .

1

2 2

3 . 4 7

Z2

= 13120cm3

Z3

= 5415cm3

6 8 . 4 5

6 . 1

3

0

i) Bending stress on U/S of skin plate = 2128678 / 12327 = 173kg/cm2 < 1020kg/cm2 ii) Bending stress on D/S of skin plate= 2128678 / 13120 = 162kg/ cm2 < 1020kg/cm2 iii) Bending stress on D/S of flange = 2128678 / 5415 = 393kg/ cm2 < 1020kg/cm2 iv) Shear stress = 47482 / (74.3 X 1.2) = 533kg/cm2 < 765kg/cm2 At section BB :

Bending moment = 47482 X 117.5 – [(94964 / 1815) X (175 – 27.5) 2 / 2] = 7740187kgcm Sectional properties at section ‘BB’ are as follows : 8

8 5 4 . 1

3

2

Area = 419.2cm

0 6 . 1

IXX

= 1707036cm4

3 0 . 9 5

Z1

= 28915cm3

Z2

= 29646cm3

1

. 2

8 5 . 7 5

0 . 3 6 1

Z3

3

= 15716cm

2 6 . 8 0 1

i) Bending stress on U/S of skin plate = 7740187 / 28915 = 268kg/cm2 < 1020kg/cm2 ii) Bending stress on D/S of skin plate= 7740187 / 29646 = 261kg/ cm2 < 1020kg/cm2 6 .

iii) Bending stress on D/S of flange = 7740187 / 15716 = 492kg/ cm2 < 1020kg/cm2 3 0 1



Page No:17

iv) Shear stress = 47482 / (74.3 X 1.2) = 243kg/cm2 < 765kg/cm2

5.0

Design of Skin Plate and Vertical Stiffeners :

The Skin plate and disposition of vertical stiffeners are as shown.

4 5 0

1 5 5 0

1 4 7 0 0 1 4 6 0 0

1 5 5 0 7 5 0 1

1

8

7

1 0

6

W E B S T I F F N E

6

R

1 0 6

1

1

6

8

1

1 0

1 8 9 3 0 0

2 5

7

S P C S

@

3 5 0

=

8 7 5 0

5

1 8 7 0 0

F L O W

5.1

Design of Skin plate & Vertical Stiffeners below Girder ‘A’ :

Head to the center of the panel = 6.2 – (0.42 / 2) = 5.99M ie., p = 0.599kg/cm2

s

1 2 y

5

5 .

1

7 1

s

1 3 y

s

1 2 x

2 4

s

7 2

s

5 .

1 1 x

4 2

1 3 x

=

s

a

b

=

1 1 y

3 5

b

=

3 5

b/a = 35 / 27 = 1.296

‘K’ value for b/a = 1.296 is

± σ11X = ± 22.68

± σ11Y = ± 13.23

± σ12X = ± 16.44

± σ12Y = ± 55.44

± σ13X = ± 50.16

± σ13Y = ± 15.44



Page No:18

Bending stress in skin plate :

σb = [(K / 100) X ((p X a 2) / s2)] = [(K / 100) X (0.599 X 27 2) / 1.452] = 2.077K kg/cm 2 2

2

± σ11Y = ± 27kg/cm < 1020kg/cm

2

2

2

± σ12Y = ± 115kg/cm < 1020kg/cm

± σ11X = ± 47kg/cm < 1020kg/cm

2

± σ12X = ± 34kg/cm < 1020kg/cm 2

2

2

2

2

± σ13X = ± 104kg/cm < 1020kg/cm

2

± σ13Y = ± 32kg/cm < 1020kg/cm

Check for combined stress : Max on D/S of skin plate 2

2

Σx = 637 + 34 = 671kg/cm < 1020kg/cm 2

2

Σy = - 115kg/cm < 1020kg/cm 2

2

2

2

σC = √ 671 + 115 + 671 X 115 = 735kg/cm < 1910kg/cm Design of vertical stiffener :

Head to the center of the panel = 0.599kg/cm 2

w

W1 = 2 X ½ X 17.5 2 X 0.599 = 183kg

w

1

2

W2 = 2 X 24.5 X 17.5 X 0.599 = 514kg

5 . 7 1

R A = 697kg

A

2 4 . 5

1 7 . 5 4 2

Point of application = (½ X 17.5 3 X ⅔) + (24.5 X 17.5 X 33) / [(17.5 2 / 2) + (24.5 X 17.5)] = 27.386cm BM = 697 X 27.386 – [183 (27.386 – 17.5 X ⅔) + (514 / 19.5) X (9.886 2 / 2)] = 14923kgcm The co-acting width of skin plate :

L = 42

B = 17.5

L/B = 2.4

∴ V = 0.348

2VB = 2 X 0.348 X 17.5 = 12.18cm ≈ 12cm



It is proposed 200 X 10mm plate as stiffeners. 1

Area = 37.40cm2

2 5 4 . 1

6 4 .

IXX = 1740cm4

6

Z1 = 269cm3

1

. 0

0 2

9 9 . 4

3

Z2 = 116cm

1

Bending stress in compression = 14923 / 269 = - 55kg/cm2 < 1020kg/cm2 Bending stress in tension = 14923 / 116 = 129kg/cm2 < 1020kg/cm2 Check for combined stress : 2

2

Σx = - 32 – 55 = - 87kg/cm < 1020kg/cm 2

2

Σy = 104kg/cm < 1020kg/cm

σC = √ 872 + 1042 + 87 X 104 = 166kg/cm2 < 1275kg/cm2 5.2

Design of Skin plate and Vertical stiffener between Girder ‘A’ & ‘B’ :

Head to the center of the panel = 6.2 – (0.42 + 1.03 / 2) = 5.265M ie., p = 0.527kg/cm 2 s 4 y

5

5 .

1

7 1

s 4 x

s 2 y

s 3 y

3 0 1

s 2 x

= 8 b

8

8 6

s 3 x

= b

5 . 7 1

a

=

3 5

b/a = 88 / 35 = 2.514

a

=

3 5


Page No:19



± σ2X = ± 25.00

± σ2Y = ± 7.91

± σ3X = ± 50.00

± σ3Y = ± 15.00

± σ4X = ± 10.29

± σ4Y = ± 34.30

Page No:20



2

± σ2X = ± 77kg/cm < 1020kg/cm 2

2

± σ3X = ± 154kg/cm < 1020kg/cm 2

2

2

2

2

± σ2Y = ± 24kg/cm < 1020kg/cm ± σ2Y = ± 46kg/cm < 1020kg/cm

2

2

± σ4X = ± 32kg/cm < 1020kg/cm

2

± σ2Y = ± 105kg/cm < 1020kg/cm

Check for combined stress : Max. of D/S of skin plate 2

2

Σx = 637 + 32 = 669kg/cm < 1020kg/cm 2

2

Σy = - 105kg/cm < 1020kg/cm 2

2

2

2

σC = √ 669 + 105 + 669 X 105 = 727kg/cm < 1275kg/cm Design of vertical stiffeners :

Head to the centre of the panel = 0.527kg/cm 2 W

3

W

4

W

3

2

W3 = 2 X ½ X 17.5 X 0.527 = 161kg 5 .

W4 = 2 X 68 X 17.5 X 0.527 = 1254kg

7 1

B

RB = RC = 788kg

1 7 . 5

6 8 1 0 3

BM = 788 X 51.5 – (161 X 39.833 + (1254 / 2) (68 / 4) = 23510kgcm

The co-acting width of skin plate :

C

1 7 . 5



L = 103

B = 17.5

L/B = 103 / 17.5 = 5.886

∴ V = 0.834

Page No:21

2VB = 2 X 0.834 X 17.5 = 29.19cm ≈ 29cm It is proposed 200 X 10mm plate as stiffeners. 2 9 2

5

Area = 62.05cm

4 . 1

8 1 . 4

IXX = 2233cm4 Z1 = 534cm3

7

1 . 0

2 .

0 2

7 1

Z2 = 129cm3

Bending stress in compression = 23510 / 534 = - 44kg/cm 2 < 1020kg/cm2 Bending stress in tension = 23510 / 129 = 182kg/cm 2 < 1020kg/cm2

Check for combined stress : 2

2

Σx = - 46 - 44 = - 90kg/cm < 1020kg/cm 2

2

Σy = + 154kg/cm < 1020kg/cm 2

2

2

2

σC = √ 90 + 154 + 90 X 154 = 214kg/cm < 1275kg/cm 5.3

Design of Skin plate and vertical stiffener above Girder ‘B’ :

Head to the center of the panel : 6.2 – (0.42 + 1.03 + 0.55 / 2) = 4.475M ie., p = 0.448kg/cm2

s 1

0

6 y

4 = b

s 1

s 1

8 x

s 1

8 y

5 .

6 x

7 3

5 5

s 1 5 1

s 1

7 x 5 .

7 y

7 1

a

= 3 5

a

=

3 5



b/a = 40 / 35 = 1.143


± σ16X = ± 19.46

± σ16Y = ± 11.95

± σ17X = ± 9.17

± σ17Y = ± 30.57

± σ18X = ± 32.13

± σ18Y = ± 9.64

Page No:22



2

2

2

2

2

± σ16X = ± 51kg/cm < 1020kg/cm

2

2

2

2

2

2

± σ16Y = ± 31kg/cm < 1020kg/cm

± σ17X = ± 24kg/cm < 1020kg/cm

± σ17Y = ± 80kg/cm < 1020kg/cm

± σ18X = ± 84kg/cm < 1020kg/cm

± σ18Y = ± 25kg/cm < 1020kg/cm

Check for combined stress : Max. on D/S of skin plate. 2

25

Σx = 634 + 25 = 659kg/cm < 1020kg/cm 2

2

Σy = - 84kg/cm < 1020kg/cm 2

2

2

2

σc = √ 659 + 84 + 659 X 84 = 705kg/cm < 1275kg/cm Design of vertical stiffeners :

w

Head to the centre of the panel = 0.448kg/cm 2

5

w

6

W5 = 2 X ½ X 17.5 2 X 0.448 = 307kg 5 . 7

W6 = 2 X 37.5 X 17.5 X 0.448 = 588kg RD = 895kg Point of application

1

D 1 7 . 5

3 7 . 5 5 5



Page No:23

= (½ X 17.5 3 X ⅔ + 37.5 X 17.5 X 36.25) / [(17.5 2 / 2) + (37.5 X 17.5)] = 31.599cm BM = 895 X 31.599 – [307 (31.599 – 17.5 X ⅔) + (588 / 37.5) X (14.099 2 / 2)] = 20603kgcm The co-acting width of skin plate :

L = 55

B = 17.5

∴ V = 0.432

L/B = 3.142

2VB = 2 X 0.432 X 17.5 = 15.12cm ≈ 15cm It is proposed 200 X 10mm plate as stiffeners. Area = 41.75cm2

1

5 5 4 . 1

6

IXX = 1869cm4

8 . 5

Z1 = 319cm3

1

9

0

. 0

2

5 . 5

Z2 = 120cm3

1

Bending stress in compression = 20603 / 319 = - 65kg/cm 2 < 1020kg/cm2 Bending stress in tension = 20603 / 120 = 172kg/cm 2 < 1020kg/cm2 Check for combined stress : 2

2

Σx = - 25 - 65 = - 90kg/cm < 1020kg/cm 2

2

Σy = + 84kg/cm < 1020kg/cm 2

2

2

2

σC = √ 90 + 84 + 90 X 84 = 151kg/cm < 1275kg/cm nd

Note : There is no need to check 2 element for bending moment in skin plate and short

stiffeners since the head is less than bottom element. How ever it is proposed to provided stiffeners similar to that of bottom element.

6.0

Design of embedded parts :

Max. roller load = 50000kg 6.1.

Design of Thickness of roller track plate : (When track with line contact)

t

= 6 X 0.786 X 1.55 √ (P / l X r / E) Where l = tread width in mm = 130



Page No:24

P = Wheel load in N = 490500N r = radius of the wheel = 225mm E = Modulus of elasticity = 200810.7N/mm 2 t = 6 X 0.786 X 1.55 √ (490500 / 130) X (225 / 200810.7) = 15.03mm As per technical specification minimum thickness of track plate is 20mm. Proposed 200 X 20mm thick as track plate after machining. Material 20 Cr 13 IS 1570 Part V Hardness 200 to 220BHN 6.3

Design of Roller Track :

The section proposed is as follows

2

0 0 . 2

Area = 282cm2

2 .

8

3

4 . 7 1

IXX = 68991cm4 5 3

Z1 = 3946cm3

3

. 2

2 7 . 4 2

0 .

Z2 = 2791cm3

2

2

6.2.1

5

Checking the Bearing stress in concrete :

σb = 0.2813 X P[EC / (ES X I X w2)] 1/3 P =Roller load = 50000kg EC = Young’s modulus of concrete (M 200) ES = Young’s modulus of steel

(Ec / Es = 1/8.98)

I = Moment of Inertia = 68991cm 4 w = width of plate contact with concrete = 25cm

σb = 0.2813 X 50000 [(1/8.98) X (1 / 68991) X (1 / 25 2)] 1/3 = 19.297kg/cm2 < 52kg/cm2 6.2.2 Check for Bending stress :

σb = 0.5 X (50000 / 2791) [8.98 X 68991 / 25] 1/3 = 261kg/cm2 < 979kg/cm2 6.2.3 Check for Shear stress in web :

Shear stress in web = 50000 / (2 X 35 X 3.2) = 223kg/cm 2 < 893 kg/cm2



Page No:25

6.2.4 Check for Web Compression : 50000kg

wheel load = 50000kg Web thickness = 32mm

0 . 2

Under 45° dispersion of load

4 5 °

2 . 3

Web Compressive Stress = 50000 / (10.4 X 3.2) = 1502kg/cm2 < 1958kg/cm2

10.4cm

6.2.5 Check for Pressure distribution under track :

Length of influence of pressure under track L = 3/2 X P / pw = (3 / 2) X 50000 / (17.07 X 25) = 175cm The rollers are spaced at 74cm apart hence the pressure distribution under track will even overlap. Max. Stress = 17.07 X 2 = 34.14kg/cm 2 < 62kg/cm2 6.2.6 Check for Shear stress in concrete :

3

5

1

2

. 5

Roller load = 50000kg Bearing stress in concrete 17.07kg/cm2

. 9 1 0 2 X

Length of shear = √ 2 X (10.9 + 47.5) = 82.59cm

v

3

Shear stress = Bearing stress in concrete X width of track

. 2

2 X Length of Shear 2

= (17.07 X 25) / (2 X 82.59)

5

= 2.6kg/cm2 < 5.0kg/cm2 Permissible punching shear as per IS800 clause 7 . 5 X 4 2

v

6.2.7 Design of welds in roller track :

Max. shear force = 25000kg IXX of section = 23454cm4 a.

Weld between track plate and U/S flange : F1 = SAy / 2I = (25000 X 20 X 2 X 16.48) / (2 X 68991) = 119kg/cm length Proposed 6mm fillet weld having strength of 308kg/cm length


b.


Page No:26

Weld between U/S flange and web : F2 = SAy / 2I = [25000 (20 X 2 + 25 X 3.2) 15.4 / (2 X 68991)] = 335kg/cm length Proposed 8mm fillet weld having strength of 896kg/cm length

c.

Weld between web and D/S flange : F3 = SAy / 2I = (25000 X 25 X 2.0 X 23.72) / (2 X 68991) = 215kg/cm length Proposed 6mm fillet weld having strength of 411kg/cm length

7.0

Check for Earthquake effect :

Due to horizontal acceleration, there will be an instantaneous hydro dynamic pressure exerted on the gate in addition to hydro static pressure. The direction of the hydro dynamic force is opposite to the direction that of earthquake acceleration. Based on the assumption that water is incompressible, the hydrodynamic pressure at depth y below the reservoir surface shall be determined as follows. (Cl. 7.2 of IS : 1893 – 1984).



Page No:27

P = CSαnWh Where P = Hydrodynamic pressure in kg/cm2 at a depth y.

αn = Design horizontal seismic co-efficient = βIαo – (cl. 3.4.2.3 –a of IS 1893) = 1 X 3 X 0.02 = 0.06 CS = Co-efficient which varies with shape and depth. = (Cm / 2) {(y / h) (2 – y / h) + √ (y / h) (2 – y / h)} Cm = 0.73 from table – 10 of IS 1893, y = 3.8M, h = 3.8M = (0.73 / 2) {1 X (2 – 1) + √ 1 (2 – 1)} = 0.73 W = Unit weight of water = 1000kg/m 3 h = Depth of reservoir = 6.5M.

P = 0.73 X 0.06 X 1000 X 6.5 = 284.7kg/cm = 0.2847t/M 2

Hence percentage of increase in pressure = (0.2847 / 6.5) X 100 = 4.42%

Permissible increase in stresses = 33.33% > 4.42% L I F T IN G C / C = 1 2 6 0 0

M16 HEX SCREW FOR

As earthquake forces are not critical and do not govern the L O Cdesign, K I N G & 1 7 .check 5 Ø H O L E Sfor I N -L O C K P L A T E ( T Y P )

stresses shall not be made for this condition. 10

10

1860

380

0 1

550

550

380

300

7 5 . 57 5 . 5 0 5 2 1 0 9 0 4 2

0 4 4

5 2 Ø 1

0 5 2

0 8 2

0 5 1

0 9

12

0 5

0 0 3

280

8.0

0 Design of lifting arrangement : 8 3

400

Hoist capacity = 55t

155

R

0 0 5

Ø 1 0each D R A I Nlifting H O L E side = 27.5t Load on 0 0 2

0 0 1

2 1

1 2

0 8 2

0 8 1

1 2

1 0 0

1 2

1 0 0 1 0 2 0 0 0

2 0 0 2 0

280

2 0

4 0 9 0 4 5

400 5 4 3

10

600

2 1

0 1

5


8.1


Page No:28

Design of pulley pin :

Load on pulley shaft = SWL + self weight of pulley = 13750 + 105 = 13855kg 1 3 8 5 5k g

R A = RB = 6927.5kg

A

2 .3

1 3

2 .3

17 .6

Bending moment = (13855 / 8) (2 X 17.6 – 13) = 38448kgcm Proposed shaft φ 125mm. Material IS 2062 ZXX = 192cm3

A = 123cm2

Bending stress = 38448 / 192 = 200kg/cm 2 < 836kg/cm2 Shear stress = 6927.5 / 123 = 56kg/cm 2 < 765kg/cm2 8.2

Design of cheek plate :

p = 13855 / (12.5 X 2.6) = 426kg/cm 2

13855kg

Max. tearing stress

1016

σT = p {[(2R)2 + d2] / [(2R) 2 - d2]}

0 5 1

= 426 [(302 + 12.52) / (30 2 – 12.52)] = 605kg/cm2 < 0.66 X 2550 X 0.95 / 0.11 155



Page No:29

= 1453kg/cm2 8.3

Design of Pin – 2 : 1 3 8 5 5 k g

1 3 8 5 5 k g

b

a C

2

RC = RD = 13855kg

1 7 .6 21 .6

2

D

Bending moment = 13855 X 2 = 27710kgcm Proposed 125mmφ Pin Material IS 2062 ZXX = 192cm3 Area = 123cm2 Bending stress = 27710 / 192 = 144kg/cm 2 < 836kg/cm2 Shear stress = 13855 / 123 = 113kg/cm 2 < 765kg/cm2 200R

8.4

Design of Bracket welded to girder :

p = 13855 / (12.5 X 2) = 554.2kg/cm 2 Max. tearing stress along AB

Ø 125

σT = p {[(2R)2 + d2] / [(2R) 2 - d2]} = 554.2 [(302 + 12.52) / (30 2 – 12.52)] = 674kg/cm2 < 1453kg/cm2 8.5

Design of weld between bracket and horizontal girder web :

Length of weld = 2 X 60 = 120cm Load per cm length of weld = 13855 / 120 = 115kg/cm length. Proposed 6mm fillet weld having strength of 428kg/cm length. 9.0

Design of Dogging Beam :

The arrangement of dogging beam is shown in Drg. No. BHME - GEI – RGB-VGB -105. Self weight of gate = 55500kg The beam is supporting the gate on either side of gate at end box over the vent. Load acting on beam with impact = 55500 X 1.1 / 2 = 30525kg The loading on the beam is as follows : 3 0 5 2 5 k g

A

3 5

8 0 1 5 0

3 5



Page No:30

R A = RB = 15262.5kg Bending moment = (30525 / 8) (2 X 150 – 80) = 839438kgcm Proposed beam having following section :

1

1

0 . 2

2

Area = 108.0cm IXX = 7472cm4

4

0 .

2

0 2

ZXX = 623cm3 0 . 2

Bending stress = 839438 / 623 = 1347kg/cm 2 < 1580kg/cm2

7 1

. 8 . 16

. 6

Shear stress = 15262.5 / (2 X 20 X 1.6) = 238kg/cm 2 < 1020kg/cm2 10.0

Design of Spice Joint :

Hoist capacity = 55t It is proposed to design the splice joint between the elements for a Max. load of 55t. The bolts provided in the joint are in double shear. No. of bolts provided in the joint = 360Nos. Dia of bolts proposed = 16mm F = (2 X π X d2 / 4) X f s X n f n = 4F / (2 X π X d2 X n) = 4 X 55000 / (2 X π X 1.6 X 360) = 61 < 720kg/cm2 10.0 S.No

Gate weight C.G calculations: Description

1

Skin plate

2

End Box

Size 2000 X 16 – 18950 4500 X 16 – 18950 785 X 16 – 2000 785 X 16 – 4500 190 X 10 – 785 300 X 10 – 300 140 X 10 – 280

Nos 1 1 4 4 20 16 8

Weight 4760.2 10710.5 788.8 1774.7 234.2 113.0 24.6

x 0.8 0.8 40.85 40.85 40.85 59.60 61.00

Wx 3808.0 8568.0 32222.0 72496.0 9566.0 6737.0 1502.0


3

Horizontal girder

4

Vertical stiffener

5

Roller assembly

6 7

Side guide Top channel

8

Splice plate

9

Typical joints

10

Seal assembly

11 12

Lifting Arrangement with bottom block Fasteners


280φ X 20 thick 300 X 16 – 18478 1800 X 12 – 18478 300 X 16 – 19130 270 X 16 – 14600 130 X 10 – 1616 1816 X 10 – 6500 200 X 10 – 6500 150 X 16 – 3200 450 Ø roller 140 thread width with 22226E bearing and 140Ø axle – 213kg/asm 40kg/assy ISMC 250 X 82 - 18478 160 X 16 – 18360 160 X 16 – 700 200 X 10 – 1700 150 X 16 – 460 44Ø X 127 – 6500 60 x 10 – 6500 90 x 14 flat seal – 18100 80 x 10 – 18100 20 x 20 – 8100

8

98.4

59.60

5869.0

4 4 4 4 32 5 40 5

2785.0 12532.5 2883.3 1980.5 527.8 4633.0 4082.0 301.4

2.4 93.2 184.0 185.6 102.4 92.4 11.2 184.0

6684.0 1168029.0 530527.0 367581.0 54047.0 428089.0 45718.0 113835.0

8

1704.0

59.6

101558.0

4 1 2 4 4 5 2 4 1 1 1

160.0 632.0 737.9 56.3 106.8 43.3 58.5 122.5 50.0 113.7 56.8

38.9 13.7 ---40.85 92.8 174.3 ----------------

6224.0 8658.0 ----2298.0 9911.0 7547.0 ----------------

1500kg/assembly

2

3000.0

----

----

200kg

1

200.0 55271.7

----

---2991474.0

x = 2991474.0 / 52271.7 = 57.2cm

11.0

Page No:31

Adopted 57cm.

Hoist Capacity Calculations:

1)

Weight of gate: 55500kg

2)

Water thrust on the gate = 348843kg

3)

Roller friction F = P/R(fa X r + fr) Where F = Roller friction in kg P = Water thrust =348843kg R = 22.5cm fa = Coeff. of friction = 0.015 for Antifriction bearing r = 9cm (Bearing ID 130, OD 230 and 64thick)



Page No:32

fr = 0.1

∴ F = (348843 / 22.5) (0.015 X 9 + 0.1) = 3643kg 4)

Seal friction: Side seal friction: 2 X µ X b X h X l = (2 X 1.5 X 4.4 X 0.31 X 620) = 2537kg

5)

Friction due to seal pre compression = 2 X 620 X 1 X 1.5 = 1860kg

6)

Guide friction = (55500 / 100) X 5 = 2775kg

Note : No check is required for self closing since the self weight of gate is more than

frictions and seating pressure required. A CWT of 50t including counter weight box is provided to reduce the hoist weight 25t since it is connected in two falls. Hoist capacity required:

Self weight of gate

:

55,500.00

Roller Friction Seal Friction

: :

3,643.00 2,537.00

Friction due to seal pre compression Guide friction

: :

1,860.00 2,775.00

:

66,315.00 13,263.00

Add 20% reserve capacity

79,578.00 Less

- 25,000.00 54,578.00

Proposed 55t Rope Drum hoist for operation of the same. 12.0

Design of Counter weight Box:

7

The counter weight box including self wt. = 50000kg

1

5

. 5

0 . 1

Designed for with impact load of 55000kg It is proposed to suspend the counter weight at 1750mm span.

7 1

0

. 0

1

5 5 0 0 0 k g

R A = RB = 27500kg

A

7 0

1 7 5 0 1 8 9 0

1

7 0

0 3 1

Bending moment = 27500 X [(1750 / 2) – (1890 / 4)] = 11068750kgcm

0 . 1

. 0

. 5

Vertical Gates Design

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