Design of Vertical Lift Service Gates of Budaun Irrigation Project

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PROJECT : BUDAUN IRRIGATION PROJECT SUBJECT: DESIGN OF VERTICAL LIFT SERVICE GATES Page No: 1
Design of Vertical Lift Service Gates of Budaun Irrigation Project

1.0 Technical Details :
No of gates required Clear vent width Clear vent height Height of gate Sill level Pond level HFL
Type of gate
: 25Nos : 18000mm : 6200mm : 6500mm : EL 157.100M : EL 163.300M : EL 164.300M : Regulating : EL 167.000M FRL HFL : 6.2M : 7.2M : Up stream : Up stream : 18150mm : 18700mm : 19200mm : 0.3 to 0.7M/min : As per IS 4622 - 2003
Top of pier Design head
Location of skin plate Location of seal
Side seal C/C Track C/C End to end of groove

Hoisting speed
Designed
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2.0
S No. 1 2 3 4 5 6 7
Material:
Components All structural members like skin plate, end box, vertical stiffeners, horizontal girders, Roller track girder, Sill beam seal Crest etc., Rollers and Guide Rollers Roller pins and Guide Roller Pins Roller Track Seal Seats Seals Bearings Proposed Structural Steel Cast Steel Stainless Steel Stainless Steel Stainless Steel Synthetic or Natural Rubber Anti Friction Bearings Remarks IS : 2062 - 2006 Grade E250 QualityB IS 1030 30Cr13 IS : 1570 (Part V) 20Cr13 IS : 1570 (Part V) 04 Cr18 Ni 10 IS : 1570 (Part V) IS : 11855 SKF / FAG / NSK / ZKL
3.0
Permissible 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 Stresses in kg/cm2 Thk < 20mm Thk 20 40mm S.No Type of stresses Factor 2 YP :2550kg/cm YP : 2448kg/cm2 UTS:4180kg/cm2 UTS:4180kg/cm2 1 Direct compression and 0.40YP 1020 979 compression in bending 2 Direct tension and tension in 0.40YP 1020 979 bending 3 Shear Stress 0.30YP 765 734 4 Combined stress 0.50YP 1275 1224 5 Bearing stress 0.45YP 1147 1102 C. 4.0 Bearing stress in concrete = M 250 62kg/cm2 Groove Details :
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C 6 0 0 2 5 0
/ C
1 8 7 0 0
3 5 0
350
1 8 0 0 0
150
500
1650
450
205 900 450 1 9 0 1 6 1 6 16 250 150 100 59

F L O W
580 606 5 0 0 6 0 01 0 0 F E N / F D O T F O S E I D N E D G O U F I D G R E O = O 1 9 1 2 0 V E = 1 9 2 0 0
4.0
Design of Gate Leaf :
16
743
16
50
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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 C/C of tracks Height of gate Design Head FRL HFL
: 18150mm : 18700mm : 6500mm : 6.20M : 7.20M
Water thrust on the gate FRL = wLH2 / 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% > 33 % FRL Condition Element Size
Head Thrust
HFL Condition
Head Thrust
% of Increase HFL Over FRL 19.2%<33 % Designed for FRL Designed for HFL condition with increased stresses
3 6 . 3 0 0 t
Remarks
Bottom 18.15X2.0 Top 18.15X4.5
6.20 188.760t 4.20 160.083t
7.20 5.20
225.06
240.941 50.5%>33 %
4.1
Design of Bottom Element :

6 .2
7 8 . 3 3 3
4.1.1 FRL condition :

4 .2 1 5 2 . 4 6 0 t 4 5 4 2 A 1 0 3 2 0 0 B 5 5
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C/C of seals : 18.15M
RA = 94.238t RB = 94.522t 4.1.2 HFL condition : C/C of seals : 18.15M
3 6 . 3 0 0 t 7 8 . 3 3 3
7 .2
RA = 110.075t RB = 114.985t 4.2 Design of Top Element : C/C of seals : 18.15M

4 .2 M
4 5 4 2 A 1 0 3 2 0 0 B 5 5
4.2.1 FRL condition :

1 6 0 . 0 8 3 t 1 4 0
RC = 94.964t
4 4
2 3 6 4 5 0 c m
1 4 0
5 .2
3 0
1 8 8 . 7 6 0 t
RD = 65.119t 4.2.2 HFL condition : C/C of seals : 18.15M

5 .2
1 8 3 . 0 8 3 t 1 3 0
5 7 . 1 7 3 t 5 5
RC = 114.553t
4 4
RD = 126.389t
2 3 6 4 5 0
1 7 0
4.3
Design of Horizontal Girders :
0 .7
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Condition FRL HFL % of increase of HFL over FRL
Load on Girder A Load on girder B Load on girder C Load on girder in t 94.238 110.075 16.80%<33 % in t 94.522 114.985 21.65%<33 % in t 94.964 114.553 20.6%<33 % D in t 65.119 126.389 94%>33 %
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
RA = RB = 47482kg
2 7 .5
l = L =
1 8 1 5 1 8 7 0
2 7 .5
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 L / B1 = 1870 / 51.5 = 36.31 L / B2 = 1870 / 42 = 44.5 B1 = 103 / 2 = 51.5cm V1 = 0.98 V2 = 0.86
3 0 8 8
B2 = 42cm
1 .4 5 1 . 2 1 0 9 .3 3 7 0 1 .6 1 .6 2 3 180 7 5 .4 7 1 .6
Co-acting width = V1 B1 + V2 B2 = 0.98 X 51.5 + 0.86 X 42 = 88.74cm 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 Sectional properties are as follows:
7 6 .9 2
ADO CONMAT INDIA

Area = 482.8cm2 IXX Z1 Z2 Z3 = 2705560cm4 = 35175cm3 = 35849cm3 = 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 18703 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
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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
RA = RB = 47261kg
2 7 .5
l = L =
1 8 1 5 1 8 7 0
2 7 .5
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 L / B1 = 1870 / 51.5 = 36.31 L / B2 = 1870 / 50 = 37.4 B1 = 103 / 2 = 51.5cm V1 = 0.98 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. Co-acting width = 40t + B = 40 X 1.45 + 30 = 88cm Sectional properties are as follows:
7 6 .9 2 3 0 1 .6 1 .4 5 1 . 2 1 .6 1 .6 180 1 0 9 .3 3 7 5 .4 7 8 8
Area = 482.8cm2 IXX Z1 Z2 Z3 = 2705560cm4 = 35175cm3 = 35849cm3 = 24747cm

3
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
2 iii) Bending stress on D/S of flange = 22744356 / 24747 = 919kg/ cm270 < 1020kg/cm2 3
iv) Shear stress = 47261 / (74.3 X 1.2) = 530kg/cm 2 < 765kg/cm2
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Check for deflection : Permissible deflection = L / 800 = 1870 / 800 = 2.337cms. Actual deflection = [94522 / (384 X 2047000 X 2705560)] [8 X 18703 4X1870 X 18152 X 18153] = 1.492cm < 2.337cm. Design of Welds : Weld strength required between Skin Plate and U/S Flange : F1 = S A y / 2 I = (47261 X 88 X 1.45 X 76.795) / (2 X 2705560) = 86kg/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 = [47261 X (88 X 1.45 + 30 X 1.6) X 75.45] / (2 X 2705560) = 112kg/cm length Proposed 6mm fillet having strength 321kg/cm length Weld strength required between Web and D/S flange : F3 = [47261 X (30 X 1.6 + 27 X 1.6) X 107.73] / (2 X 2705560) = 105kg/cm length Proposed 6mm fillet having strength 321kg/cm length Weld strength required between D/S flanges : 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
RA = RB = 47482kg
2 7 .5
l = L =
1 8 1 5 1 8 7 0
2 7 .5
BM = (94964 / 8) (2 X 1870 1815) = 22850713kgcms. It is proposed to provide skin plate out of 12mm plate. After allowing corrosion allowance of 1.5mm, the effective thickness is 10.5mm. Co-acting width: L = 1870cm B1 = 236 / 2 = 118cm B2 = 44cm
ADO CONMAT INDIA

L / B1 = 1870 / 118 = 15.84 L / B2 = 1870 / 44 = 42.5
V1 = 0.955 V2 = 0.86
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 Sectional properties are as follows: Area = 482.8cm2
7 6 .9 2 1 .4 5 1 . 2 1 0 9 .3 3 1 .6 1 .6 180 3 0 7 5 .4 7 1 .6 8 8 3 0
IXX Z1 Z2 Z3
= 2705560cm4 = 35175cm3 = 35849cm3 = 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 = 632kg/ cm2 < 1020kg/cm2
2 7 iii) Bending stress on D/S of flange = 22850713 / 24747 = 923kg/ cm2 < 1020kg/cm2
iv) Shear stress = 47482 / (74.3 X 1.2) = 533kg/cm2 < 765kg/cm2 Check for deflection : Permissible deflection = L / 800 = 1870 / 800 = 2.337cms. Actual deflection = [94964 / (384 X 2047000 X 2705560)] [8 X 18703 4X1870 X 18152 X 18153] = 1.550cm < 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 76.175) / (2 X 2705560) = 105kg/cm length Proposed 6mm fillet having strength of 0.7 X 0.6 X 765 = 321kg/cm length
ADO CONMAT INDIA

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 107.73] / (2 X 2705560) = 86kg/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 108.53) / (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
RA = RB = 47977kg
2 7 .5
l = L =
1 8 1 5 1 8 7 0
2 7 .5
BM = (94954 / 8) (2 X 1870 1815) = 22848306kgcms. 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 L / B1 = 1870 / 118 = 15.84 L / B2 = 1870 / 170 = 11 B1 = 236 / 2 = 118cm V1 = 0.955 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.
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Co-acting width = 40t + B = 40 X 1.45 + 30 = 88cm Sectional properties are as follows:

8 8 3 0
Area = 482.8cm2
7 6 .9 2
IXX Z1 Z2 Z3
= 2705560cm4 = 35175cm3
= 24747cm3
1 . 2 1 0 9 .3 3
i) Bending stress on U/S of skin plate = 22848306 / 35175 = 650kg/cm2 < 1020kg/cm2 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 iv) Shear stress = 47977 / (74.3 X 1.2) = 538kg/cm2 < 765kg/cm2 2 7
3 0 1 .6 1 .6
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 : F1 = S A y / 2 I = (47977 X 88 X 1.45 X 76.175) / (2 X 2705560) = 86kg/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 = [47977 X (88 X 1.45 + 30 X 1.6) X 75.45] / (2 X 2705560) = 117kg/cm length Proposed 6mm fillet having strength 321kg/cm length Weld strength required between Web and D/S flange :
180
= 35849cm3
7 5 .4 7
1 .6
1 .4 5
ADO CONMAT INDIA

F3 = [47977 X (30 X 1.6 + 27 X 1.6) X 107.73] / (2 X 2705560) = 87kg/cm length Proposed 6mm fillet having strength 321kg/cm length Weld strength required between D/S flanges : 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 : RA = 94.162t RB = 94.598t

9 4 2 3 8 k g 1 8 A 6 7 1 0 3 B 9 4 5 2 2 k g 1 8
Max. Roller load = 94.162 / 2 = 47.299t 47.3t Bending Moment = 94522 X 18 = 1701396kgcm
ii)
HFL condition : RA = 108.756t RB = 116.304t

1 1 0 0 7 5 k g 1 8 A 6 7 1 0 3 B 1 1 4 9 8 5 k g 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 :
9 4 9 6 4 k g 6 5 1 1 9 k g C 2 0 0 2 3 6 D 1 8
RA = 97.650t RB = 62.433t
1 8
Max. Roller load = 97.650 / 3 = 48.825t 48.9t say 50t Bending Moment = 94964 X 18 = 1709352kgcm
ADO CONMAT INDIA

ii)
HFL condition :
1 1 4 5 5 3 k g 1 2 6 3 8 9 k g C 2 0 0 2 3 6 D 1 8
RA = 113488kg RB = 127454kg
1 8
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 542) / 6 = 3110cm3 Bending stress FRL = 1709352 / 3100 = 551kg/cm2 < 1020kg/cm2 HFL = 2275002 / 3100 = 734kg/cm2 < 1527kg/cm2 Max. Roller load = 50,000kg Shear stress FRL = 50000 / (2 X 54 X 1.6) = 289kg/cm2 < 765kg/cm2 Bearing stress FRL = 50000 / (2 X 8 X 2.8) = 1116kg/cm2 < 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/cm2 Proposed 450 X 130mm tread width roller. C = 0.418 4.6 (50.00 X 2047) / (22.5 X 13) = 7.82t/cm2 < 9.30t/cm2
8 4 54 P L 1 6 T + H 1K 2 . m 7 8 .5 2 0 .5 m
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
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4.7
Design of Roller Axle : Material proposed Stainless steel : 20Cr13 IS:1570 part-V Yp = 490MPa Permissible stress : UTS = 690MPa Bending = 2000kg/cm2 Shear RA = RB = 25000kg = 1500kg/cm2
5 0 0 0 0 k g A B
7 .6
6 .4 2 1 .6
7 .6
BM = (50000 / 8) (2 X 19.2 6.4) = 230000kgcm Proposed 130 at bearing and 80 at end box. ZXX = 216cm3 Area = 50cm2 Bending stress = 230000 / 216 = 1065kg/cm2 < 2000kg/cm2 Shear stress = 25000 / 50 = 500kg/cm2 < 1500kg/cm2
4.8
Design of girder at curtailment :
1 8 7 0 0 A 7 4 3 3 0 0 1 8 9 A
1
B 5 7 0 2 5 S P C S @ 3 5 0 = 8 7 5 0 1 6 1 6
L if it n g
C /C
= 1 2 6 0 0
1 6 3 0
W E B S T IF F N E R
1 0
1 0 B 1 4 6 0 0 1 4 7 0 0
4 5 0
1 5 5 0
1 5 5 0
Max. horizontal girder reaction = 94.964t RA = RB = 47482kg

7 5 4 5 A 2 7 .5 A B l = L = 1 8 1 5 1 8 7 0 2 7 .5 B A B 9 4 9 6 4 k g
1 8 1 6
1 0 5 7
ADO CONMAT INDIA

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 : Area = 312.76cm IXX Z1 Z2 Z3 = 29703cm4 = 12327cm3 = 13120cm3 = 5415cm3
3 0 5 4 .8 6
2
3 0 2 4 .0 9 1 . 2 2 2 .6 4
8 8
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 : Area = 419.2cm2
5 9 .0 3 3 0 1 .6 1 0 8 .6 2 1 .6 1 6 3 .0 5 7 .5 8 1 . 2 1 .4 5
IXX Z1 Z2 Z3
= 1707036cm4 = 28915cm3 = 29646cm3 = 15716cm3
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 iii) Bending stress on D/S of flange = 7740187 / 15716 = 492kg/0 cm2 < 1020kg/cm2 3
1 .6
7 4 .3
1 .6
1 .4 5
8 8
ADO CONMAT INDIA

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 0 5 7
1 5 5 0
1 5 5 0
8 7 6
1 4 7 0 0 1 4 6 0 0 1 0 1 8 1 6
W E B S T IF F N E R
5 7 0
1 8 9 3 0 0
2 5
S P C S
3 5 0
8 7 5 0
1 8 7 0 0
1 6 1 6
1 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 5
1 2 y
4 2
s
a = 2 7
1 3 y
1 2 x
1 1 x
1 3 x
s
b =
1 1 y
3 5
3 5
b/a = 35 / 27 = 1.296 11X = 22.68 12X = 16.44 13X = 50.16
K value for b/a = 1.296 is 11Y = 13.23 12Y = 55.44 13Y = 15.44
2 4 .5
1 7 .5
ADO CONMAT INDIA

Bending stress in skin plate : b = [(K / 100) X ((p X a2) / s2)] = [(K / 100) X (0.599 X 272) / 1.452] = 2.077K kg/cm2 11X = 47kg/cm < 1020kg/cm 12X = 34kg/cm < 1020kg/cm
2 2 2 2
11Y = 27kg/cm < 1020kg/cm

2
12Y = 115kg/cm < 1020kg/cm

2
13X = 104kg/cm < 1020kg/cm
13Y = 32kg/cm < 1020kg/cm
Check for combined stress : Max on D/S of skin plate x = 637 + 34 = 671kg/cm < 1020kg/cm y = - 115kg/cm < 1020kg/cm
2 2 2 2 2 2
C = 671 + 115 + 671 X 115 = 735kg/cm < 1910kg/cm Design of vertical stiffener : Head to the center of the panel = 0.599kg/cm2 W1 = 2 X X 17.52 X 0.599 = 183kg W2 = 2 X 24.5 X 17.5 X 0.599 = 514kg RA = 697kg Point of application
A w
1
1 7 . 5 4 2
2 4 . 5
= ( X 17.53 X ) + (24.5 X 17.5 X 33) / [(17.52 / 2) + (24.5 X 17.5)] = 27.386cm BM = 697 X 27.386 [183 (27.386 17.5 X ) + (514 / 19.5) X (9.8862 / 2)] = 14923kgcm The co-acting width of skin plate : L = 42 L/B = 2.4 B = 17.5 V = 0.348
2VB = 2 X 0.348 X 17.5 = 12.18cm 12cm
1 7 .5
ADO CONMAT INDIA

It is proposed 200 X 10mm plate as stiffeners.

1 .4 5 6 .4 6 1 . 0 1 4 .9 9
2 2 2
Area = 37.40cm2 IXX = 1740cm4 Z1 = 269cm3 Z2 = 116cm3
1 2
Bending stress in compression = 14923 / 269 = - 55kg/cm2 < 1020kg/cm2 Bending stress in tension = 14923 / 116 = 129kg/cm2 < 1020kg/cm2 Check for combined stress : x = - 32 55 = - 87kg/cm < 1020kg/cm y = 104kg/cm < 1020kg/cm
2
C = 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/cm2
15 1 7 .5
s4
s4 s2
b = 103 b = 88
y x
s3 s3
y x
s2
3 5
3 5
b/a = 88 / 35 = 2.514
K value for b/a = 2.514 is
1 7 .5
68
20
ADO CONMAT INDIA

2X = 25.00 3X = 50.00 4X = 10.29
2Y = 7.91 3Y = 15.00 4Y = 34.30
Bending stress in skin plate : b = [(K / 100) X ((p X a2) / s2)] = [(K / 100) X (0.527 X 352) / 1.452] = 3.071K kg/cm2 2X = 77kg/cm < 1020kg/cm
2 2 2
2Y = 24kg/cm < 1020kg/cm

2
3X = 154kg/cm < 1020kg/cm 4X = 32kg/cm < 1020kg/cm

2 2
2Y = 46kg/cm < 1020kg/cm

2
2Y = 105kg/cm < 1020kg/cm
Check for combined stress : Max. of D/S of skin plate x = 637 + 32 = 669kg/cm < 1020kg/cm y = - 105kg/cm < 1020kg/cm
2 2 2 2 2 2
C = 669 + 105 + 669 X 105 = 727kg/cm < 1275kg/cm Design of vertical stiffeners : Head to the centre of the panel = 0.527kg/cm2 W3 = 2 X X 17.52 X 0.527 = 161kg W4 = 2 X 68 X 17.5 X 0.527 = 1254kg
B W
3
RB = RC = 788kg
1 7 . 5
6 8 1 0 3
1 7 . 5
BM = 788 X 51.5 (161 X 39.833 + (1254 / 2) (68 / 4) = 23510kgcm The co-acting width of skin plate :
1 7 .5
ADO CONMAT INDIA

L = 103 L/B = 103 / 17.5 = 5.886
B = 17.5 V = 0.834
2VB = 2 X 0.834 X 17.5 = 29.19cm 29cm It is proposed 200 X 10mm plate as stiffeners.
2 9 4 .1 8 1 .4 5
2 2 2 2 2
Area = 62.05cm2 IXX = 2233cm4 Z1 = 534cm3 Z2 = 129cm3
1 7 .2 7
Bending stress in compression = 23510 / 534 = - 44kg/cm2 < 1020kg/cm2 Bending stress in tension = 23510 / 129 = 182kg/cm2 < 1020kg/cm2 Check for combined stress : x = - 46 - 44 = - 90kg/cm < 1020kg/cm y = + 154kg/cm < 1020kg/cm
2 2 2
C = 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
b = 40
s s
1 6 y
1 6 x
s
1 7 x
1 8 y
55
s
15
1 7 y
= 3 5
3 5
1 7 .5
3 7 .5
1 8 x
20
1 . 0
ADO CONMAT INDIA

b/a = 40 / 35 = 1.143 16X = 19.46 17X = 9.17 18X = 32.13
K value for b/a = 1.143 is 16Y = 11.95 17Y = 30.57 18Y = 9.64
Bending stress in skin plate : b = [(K / 100) X ((p X a2) / s2)] = [(K / 100) X (0.448 X 352) / 1.452] = 2.610K kg/cm2 16X = 51kg/cm < 1020kg/cm 17X = 24kg/cm < 1020kg/cm 18X = 84kg/cm < 1020kg/cm
2 2 2 2
16Y = 31kg/cm < 1020kg/cm 17Y = 80kg/cm < 1020kg/cm 18Y = 25kg/cm < 1020kg/cm
2 2
Check for combined stress : Max. on D/S of skin plate. x = 634 + 25 = 659kg/cm < 1020kg/cm y = - 84kg/cm < 1020kg/cm
2 2 2 2 2 25
c = 659 + 84 + 659 X 84 = 705kg/cm < 1275kg/cm Design of vertical stiffeners : Head to the centre of the panel = 0.448kg/cm2 W5 = 2 X X 17.52 X 0.448 = 307kg W6 = 2 X 37.5 X 17.5 X 0.448 = 588kg RD = 895kg Point of application
D
1 7 .5
3 7 . 5 5 5
1 7 .5
ADO CONMAT INDIA

= ( X 17.53 X + 37.5 X 17.5 X 36.25) / [(17.52 / 2) + (37.5 X 17.5)] = 31.599cm BM = 895 X 31.599 [307 (31.599 17.5 X ) + (588 / 37.5) X (14.0992 / 2)] = 20603kgcm The co-acting width of skin plate : L = 55 L/B = 3.142 B = 17.5 V = 0.432
2VB = 2 X 0.432 X 17.5 = 15.12cm 15cm It is proposed 200 X 10mm plate as stiffeners. Area = 41.75cm2 IXX = 1869cm4 Z1 = 319cm3 Z2 = 120cm3
1 5 .5 9 5 .8 6 1 5 1 .4 5 1 . 0
Bending stress in compression = 20603 / 319 = - 65kg/cm2 < 1020kg/cm2 Bending stress in tension = 20603 / 120 = 172kg/cm2 < 1020kg/cm2
Check for combined stress : x = - 25 - 65 = - 90kg/cm < 1020kg/cm y = + 84kg/cm < 1020kg/cm
2 2 2 2 2 2
C = 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
20
ADO CONMAT INDIA

P = Wheel load in N = 490500N r = radius of the wheel = 225mm E = Modulus of elasticity = 200810.7N/mm2 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 :
2 .0 2 .0 2 5 35 3 .2 3 . 2 2 4 .7 2
The section proposed is as follows

1 7 .4 8
2 0
Area = 282cm2 IXX = 68991cm4 Z1 = 3946cm3 Z2 = 2791cm3 6.2.1
Checking the Bearing stress in concrete : b = 0.2813 X P[EC / (ES X I X w2)] 1/3 P =Roller load = 50000kg EC = Youngs modulus of concrete (M200) ES = Youngs modulus of steel I = Moment of Inertia = 68991cm4 w = width of plate contact with concrete = 25cm b = 0.2813 X 50000 [(1/8.98) X (1 / 68991) X (1 / 252)] 1/3 = 19.297kg/cm2 < 52kg/cm2 (Ec / Es = 1/8.98)
6.2.2 Check for Bending stress : b = 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/cm2 < 893 kg/cm2
ADO CONMAT INDIA

6.2.4 Check for Web Compression : wheel load = 50000kg Web thickness = 32mm Under 45 dispersion of load Web Compressive Stress = 50000 / (10.4 X 3.2) = 1502kg/cm2 < 1958kg/cm2 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/cm2 < 62kg/cm2 6.2.6 Check for Shear stress in concrete : Roller load = 50000kg Bearing stress in concrete 17.07kg/cm2 Length of shear = 2 X (10.9 + 47.5) = 82.59cm Shear stress = Bearing stress in concrete X width of track 2 X Length of Shear = (17.07 X 25) / (2 X 82.59) = 2.6kg/cm2 < 5.0kg/cm2 Permissible punching shear as per IS800 clause
v2X 4 7 .5 v 2X 1 0 .9
50000kg
10.4cm
3 5
3.2
1 2 .5 3 . 2 2 5
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
2.0
45
ADO CONMAT INDIA

b.
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).
ADO CONMAT INDIA

P = CSnWh Where P = Hydrodynamic pressure in kg/cm2 at a depth y. n = Design horizontal seismic co-efficient = Io (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/m3 h = Depth of reservoir = 6.5M. P = 0.73 X 0.06 X 1000 X 6.5 = 284.7kg/cm = 0.2847t/M2 Hence percentage of increase in pressure = (0.2847 / 6.5) X 100 = 4.42% Permissible increase in stresses = 33.33% > 4.42% As earthquake forces are not critical and do not govern theO Cdesign, 7 .5 H O L E for L K IN G & 1 check S stresses shall not be made for this condition. 1860
10 380 7 5 .57 5 .5 50 550 10 300 550 380 IN -L O C K P L A T E (T Y P ) 10 L IF T IN G C /C = 1 2 6 0 0 M 16 H EX S CR E W FO R
12
90
240
90
280
25 1
250
440
12 280 300 155 200

12
R3 80
Hoist capacity = 55t

1 DRA HO LE Load on 0eachINlifting side = 27.5t
100
12
100
180
280
12
1 200 00
20
200
280 400 345
494 12 10 5
20
10 600 800
500
500
100
8.0
Design of lifting arrangement :
50
400
150
12
ADO CONMAT INDIA

8.1
Design of pulley pin : Load on pulley shaft = SWL + self weight of pulley = 13750 + 105 = 13855kg
185g 35k
RA = RB = 6927.5kg
23 .
1 3 1. 76
23 .
Bending moment = (13855 / 8) (2 X 17.6 13) = 38448kgcm Proposed shaft 125mm. Material IS 2062 ZXX = 192cm3 A = 123cm2 Bending stress = 38448 / 192 = 200kg/cm2 < 836kg/cm2 Shear stress = 6927.5 / 123 = 56kg/cm2 < 765kg/cm2 8.2 Design of cheek plate : p = 13855 / (12.5 X 2.6) = 426kg/cm2 Max. tearing stress T = p {[(2R) + d ] / [(2R) - d ]}
2 2 2 2
13855kg
1 01 6
= 426 [(302 + 12.52) / (302 12.52)] = 605kg/cm2 < 0.66 X 2550 X 0.95 / 0.11
155
150
ADO CONMAT INDIA

= 1453kg/cm2 8.3 Design of Pin 2 : RC = RD = 13855kg

C
2
185g 35k a
1. 76 2. 1 6
185g 35k b
2
Bending moment = 13855 X 2 = 27710kgcm Proposed 125mm Pin Material IS 2062 ZXX = 192cm3 Area = 123cm2 Bending stress = 27710 / 192 = 144kg/cm2 < 836kg/cm2 Shear stress = 13855 / 123 = 113kg/cm2 < 765kg/cm2
200R
8.4
Design of Bracket welded to girder : p = 13855 / (12.5 X 2) = 554.2kg/cm2 Max. tearing stress along AB T = p {[(2R)2 + d2] / [(2R)2 - d2]} = 554.2 [(302 + 12.52) / (302 12.52)] = 674kg/cm2 < 1453kg/cm2
125
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 :
35 5g 02 k A B
3 5
8 0 10 5
3 5
ADO CONMAT INDIA

RA = RB = 15262.5kg Bending moment = (30525 / 8) (2 X 150 80) = 839438kgcm Proposed beam having following section : Area = 108.0cm2
24 2 0 .0 7 . 8 1 . 16 . 6 1 1
IXX = 7472cm4 ZXX = 623cm3
Bending stress = 839438 / 623 = 1347kg/cm2 < 1580kg/cm2 Shear stress = 15262.5 / (2 X 20 X 1.6) = 238kg/cm2 < 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 X d2 / 4) X fs X n fn = 4F / (2 X X d2 X n) = 4 X 55000 / (2 X X 1.6 X 360) = 61 < 720kg/cm2
10.0 S.No 1 2 Gate weight C.G calculations: Description Skin plate 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
2 .0
2 .0
ADO CONMAT INDIA

Horizontal girder
Vertical stiffener
5 6 7 8 9
Roller assembly Side guide Top channel Splice plate Typical joints
10
Seal assembly
280 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 roller 140 thread width with 22226E bearing and 140 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 44 X 127 6500 60 x 10 6500 90 x 14 flat seal 18100 80 x 10 18100 20 x 20 8100 1500kg/assembly 200kg
8 4 4 4 4 32 5 40 5 8 4 1 2 4 4 5 2 4 1 1 1 2 1
98.4 2785.0 12532.5 2883.3 1980.5 527.8 4633.0 4082.0 301.4 1704.0 160.0 632.0 737.9 56.3 106.8 43.3 58.5 122.5 50.0 113.7 56.8 3000.0 200.0 55271.7
59.60 2.4 93.2 184.0 185.6 102.4 92.4 11.2 184.0 59.6 38.9 13.7 ---40.85 92.8 174.3 ----------------------
5869.0 6684.0 1168029.0 530527.0 367581.0 54047.0 428089.0 45718.0 113835.0 101558.0 6224.0 8658.0 ----2298.0 9911.0 7547.0 ---------------------2991474.0
11 12
Lifting Arrangement with bottom block Fasteners
x = 2991474.0 / 52271.7 = 57.2cm Adopted 57cm.
11.0
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)
ADO CONMAT INDIA

fr = 0.1 4) F = (348843 / 22.5) (0.015 X 9 + 0.1) = 3643kg Seal friction: Side seal friction: 2 X X b X h X l = (2 X 1.5 X 4.4 X 0.31 X 620) = 2537kg Friction due to seal pre compression = 2 X 620 X 1 X 1.5 = 1860kg Guide friction = (55500 / 100) X 5 = 2775kg
5) 6)
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 Roller Friction Seal Friction Friction due to seal pre compression Guide friction Add 20% reserve capacity Less
: : : : : :
55,500.00 3,643.00 2,537.00 1,860.00 2,775.00 66,315.00 13,263.00 79,578.00 - 25,000.00 54,578.00
Proposed 55t Rope Drum hoist for operation of the same. 12.0 Design of Counter weight Box: The counter weight box including self wt. = 50000kg 1 . Designed for with impact load of 55000kg It is proposed to suspend the counter weight at 1750mm span.
500g 50k
7 5 5 7 0 1 . 0 1 . 0 1 . 5 1 .0 1 .0 130
RA = RB = 27500kg
7 0
15 70 19 80
7 0
Bending moment = 27500 X [(1750 / 2) (1890 / 4)] = 11068750kgcm
ADO CONMAT INDIA

Proposed beam having following section :
Area = 410cm2 IXX = 1009717cm4 ZXX = 15299cm3 Bending stress = 11068750 / 15299 = 723kg/cm2 < 1480kg/cm2 Shear stress = 27500 / (2 X 123 X 1) = 112kg/cm2 < 1200kg/cm2 Permissible deflection = span / 750 = 1750 / 750 = 2.333 Deflection = (5 X 50000 X 18903) / (384 X 2047000 X 1009717) = 2.13cm < 2.333cm Bearing stress = 45000 / (70 X 1800) = 0.357kg/cm2 <1680kg/cm2 However L75 X 75 X 8 stiffeners is proposed at 750mm C/C A counter weight of 45t is proposed. 45t counter weight is to be provided at 3.5t/m3 density MS scrap and concrete.

Design of Vertical Lift Service Gates of Budaun Irrigation Project

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Design of Vertical Lift Service Gates of Budaun Irrigation Project

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