CHAPTER 1 INTRODUCTION 1.

1 KERALA ELECTRICAL AND ALLIED ENGINEERING COMPANY LIMITED (KEL)

The Kerala Electrical and allied engineering company Limited, popularly known as KEL was established in 1964 in the state of Kerala, India and fully owned by the state government. As a company engaged in multiple activities, they have broadened their manufacturing base strategically to reach wider domestic and overseas market. With man power base of 1000 which include more than 150 qualified and well trained engineers, they are one of the biggest public sector companies in the state. The company has four manufacturing units located in various districts of the state.

1.2

LITERATURE REVIEW
In this conceptual project, we are designing a vertical dam gate with greater life

period than the ordinary dam gates. In this project, a study has been made on the existing vertical dam gates. In the existing system, the skin plate and associated parts of the dam gate are made with mild steel only. Then the surface is thoroughly cleaned. After that, zinc rich epoxy primer (85%zinc) is coated over it. And then a coating of coal tar epoxy primer is applied. The life of the dam gate is about 60 years. These gates are affected by corrosion due to continuous contact with water and require greater maintenance. We then thought of improving life of the dam gate. We suggested that by replacing mild steel skin plate with stainless steel skin plate, we can improve the life of the dam gate from 60 years to 80 years, since stainless steel has more life period than mild steel. Mr.K.H.Shaji (deputy manager-planning, production and subcontract) suggested that in order to reduce cost it is better to weld a thin stainless steel plate to a thick mild steel plate. Mrs.Snehalatha T.V (manager- planning and subcontract) approved our suggestion by stating that the concept is applicable in wet and inaccessible condition.

1.3 DAM
Almost every water resources project has a reservoir or diversion work for the control of floods or to store water for irrigation or power generation, domestic or industrial water supply. A spillway with control mechanism is almost invariably provided for release of waters during excess flood inflows. Releases of water may also be carried out by control devices provided in conduits in the body of the dam and tunnels. In order to achieve flow control, a gate or a shutter is provided in which a leaf or a closure member is placed across the waterway from an external position to control the flow of water. Control of flow in closed pipes such as penstocks conveying water for hydropower is also done by valves, which are different from gates in the sense that they come together with the driving equipment, whereas gates require a separate drive or hoisting equipment. Right selection of gates and their hoisting arrangement is very important to ensure safety of the structure and effective control. A designer has to plan a gate and its hoisting arrangement together. Separate planning of gates or hoists, sometimes results in unsatisfactory installation. Though the choice for the gates and hoists depends on several factors, primarily safety, ease in operation as well as maintenance and economy are the governing requirements in the same order. It is essential for the water resources engineer to be aware of the different factors, which would largely affect the choice of gates and hoists and would help in selection of the same. The past thirty-first to forty years has been a period of unprecedented water in our country. Besides a large number of small irrigation and hydro-electric scheme, more than 3000 dams have been constructed. All structures or projects harnessing water needs gates for controlling the flow as such large number of gates of different types had to be designed and manufactured. The design of gates consequently undergone considerable development, since the use of wooden (gates) needles or curries used in ancient time and has enable us to fabricate gate for high heads and situations.

Whatever may be the type of dam, it is absolutely necessary to provide a safe passage for the flood water, so as to avoid the danger of the dam being overtopped. The part of dam which discharges the flood flow to the downstream side is called as spillway. The spillway is an important part of dam complex and is located either as a part of main dam or separately at suitable place near to the dam.

1.4 GATE
The crest control for a spillway may be achieved either through automatic devices or through manually operated devices known as gate. In view of various considerations such as operational maintenance, manufacturing etc. gate can be classified into three types. The Bureau of Indian Standards code IS 13623: 1993 Criteria for choice of gates and hoists provides the basic classification of gates. Flap gate Radial gate Vertical dam gate

1.4.1 Flap Gates

The flap gate are located of the basin side of the caisson, which would lessen the downward component of the water load carried which may cause sliding and overturning under differential heads. To overcome this, flap gates have to be kept particular angle to vertical to downward components of water forces on the gates.

1.4.2 Radial Gates

The radial gates are structurally more efficient than flap gates. The radial gates could be appropriate cost for shallow waters, in deeper part of the estuary. The hinge pins will be located below the normal tidal making the maintenance more difficult. It can be operated under differential heads. They are easily accessible for minor maintenance and painting but for major maintenance, a floating crane or a barrage is needed. The operating costs are less. They can be again reduced by counter weights.

1.4.3 Vertical Dam Gates

Vertical dam gates can be operated to suite overall barrage requirements including flood control. The gates can be maintenance above high water and if necessary, they can be removed and replaced through the top of the caisson by floating crane. A vertical dam gate mounted in venture passage would give a relatively large discharge capacity. The discharge coefficient is about 1.5 for vertical dam gate and is shown in Figure 1.1. The wheels are mounted on the end girders. The bottom of gate should be so shaped that satisfactory performance and freedom from harmful vibrations are attained under all conditions of operation apart from minimizing down pull. A sectional view with a typical arrangement of various components of gate is shown in Figure 1.2.

Figure 1.1 Arrangement of Vertical Dam Gate with Hoist According to IS 4622:1992 fixed wheel gates can be classified on the basic of water heat above sill level as follows. High head gate: Gate which operates under a head of 30m and above, but less than 30m. Medium head gate: Gate which operates under a head of 15m and above, but less than 30m. Low head gate: Gate which operates under a head less than 15m.

Figure 1.2 Vertical Dam Gate with Fixed Wheel-Sectional View Some of the important features are: It can operate at differential heads. It can be easily inspected. They can be easily accessible for minor maintenance and painting. They are not easily accessible for major maintenance; a floating crane is needed. Operating cost is less. They can be further reduced by counter weights. Vertical dam gates are not affected by wave damage, since they are protected by wave breakers and closure panel. Some of the important terminologies associated with gates are given below, which would help one to understand the operation of gates more closely. Skin plate Vertical stiffeners and horizontal girders Wheels and wheel tracks Seals and accessories Guide and guide shoes

Track base Seals seat, seal base and sill beam Anchorages

1.4.3.1 Skin Plate

A membrane which transfers the water load on a gate to the other components.

1.4.3.2 Horizontal and Vertical Stiffeners

Horizontal girders are the main structural members of a gate, spanning horizontally to transfer the water pressure from the skin plate and vertical stiffeners (if any) to the end girders or end arms of the gate. Vertical girders (also called vertical stiffeners) are the structural members spanning vertically across horizontal girders to support the skin plate.

1.4.3.3 Wheels and Wheel Tracks

Wheels provided on the sides of a gate to restrict its lateral and/or transverse movements. A structural member on which the wheels of a gate move.

1.4.3.4 Seals and Accessories

A seal is a device for preventing the leakage of water around the periphery of a gate. A bottom seal is one that is provided at the bottom of the gate leaf. Side seals are those that are fixed to the vertical ends of gate leaf. A top seal is one that is provided at the top of a gate leaf or gate frame.

1.4.3.5 Guide and Guide Shoes

That portion of a gate frame which restricts the movement of a gate in the direction normal to the water thrust. A device mounted on a gate to restrict its movement in a direction normal to the water thrust.

1.4.3.6 Track Base

A structural member on which the wheels of a gate move.

1.4.3.7 Seal Seat, Base and Sill Beam

This is the top of an embedded structural member on which a gate rests when in closed position.

1.4.3.8 Anchorages
An embedded structural member, transferring load from gate to its surrounding structure.

1.5 Material Used in Fabrication of Gates

Steel gates Wooden gates Reinforced concrete gates Aluminium gates Fabric (plastic) gates/Rubber gate Cast iron gates.

1.6 HOISTS FOR VERTICAL DAM GATE

The mechanical arrangements used for operating the gates are called Hoists. The Bureau of Indian Standards code IS 6938 1989 Design of rope drum and chain hoists for hydraulic gates code of practice lays down the guiding principles for design of rope drum and chain hoists. The general principle of a rope drum and chain hoist for vertical dam gates is shown in Figure 1.3.

Figure 1.3 Rope Drum Hoist Arrangements for Vertical Dam Gate

1.7

DIFFERENT EFFECTS ON VERTICAL DAM GATE

Where the project lies in a seismic zone earthquake forces shall be considered in

1.7.1 Earthquake Effect

accordance with IS11893:1984, and the gate designed accordingly The allowable stress as given in table-5 shall be increased by 33.5 percent in case of earthquake conditions subject to an upper limit of 85 percent of the yield point. In case of nuts and bolts increase in stress shall not be more than 25 percent of allowable stress. The permissible value of stresses in welded connections shall be the same as permitted for parent material.

1.7.2 Wave Effect

For every wide big reservoir, the effect of wave height of wave height due Increased stress in various parts of the gate, as described in the earthquake The earthquake forces and the wave effect shell not be considered to act to storms, act. In causing increase loading on the gate, shell also be considered. forces shall be allowed for the wave effect. together while computing the increased stress in the gate.

1.7.3 Ice Loading

Ice impact and pressure: Provided local conditions do not impose other values, ice impact and ice pressure shall be taken in to account in such a way that the water pressure triangle shall be replaced as given below: In water with ice thickness greater than 300mm, by an even surface pressure of 30000 N/m up to 3 depth, and In water with ice thickness up to 300mm, by an even surface of 2000 N/m up to 2 depth.

1.7.4 MWL Condition

In case the gate is to be checked for MWL condition, the allowable stress shall be increase by 33.5 percent of the values specified in annex subject to the upper limit of yield point.

1.8

OPERATION AND MAINTENANCE OF VERTICAL DAM GATES

The proper operation and maintenance of vertical gates and hoists is important

for satisfactory operation of the project. The proper operation of the gate is important for the safety of the works of the projects. For safe and systematic operation and maintenance of the gates and operation equipment, it is very important that a comprehensive operation and maintenance manual is prepared for the vertical dam gate installation on the project. The operation manual for the gate installation should contain operating instruction, necessary precaution and sequence of operation for working any equipment and accessories on the work. It should also include instruction for adjustment, which is required to be carried out during operation of any equipment. Operating personnel should be properly trained and experienced. It is desirable that graphs and charts are maintained for various characteristics or individual equipment. Experience on operation and difficulties, if any encountered should be recorded in the log book of each equipment so as to be available for studying the behavior of various structures and equipments.

1.8.1 Inspection and Maintenance

Detailed instruction for inspection and normal maintenance and repairs for gate installations should be given in the operation and maintenance manual. However for carrying out special repairs for any equipment, reference to manufacturers drawing and manuals is necessary for deciding the mode of special repairs and maintenance. In order that the inspection and maintenance experiences are complied in the form of history of any installation so as to be useful for future designs or better investigations of any failure improper to unusual operation of any equipment, all such observations can be recorded in the equipment history registers maintained for this purpose. The operation and maintenance personnel shall be familiar with general design and a construction features of the works and equipments so that they can carry out proper maintenance. Safety instructions and specific precautions for any particular operation should be given in inspection, operation and maintenance manual. Such precautions and instructions shall be followed prior to, during and after the completion of the inspection and maintenance operation. Periodic inspection and maintenance schedules for various equipments shall be included in the manual. Operation and maintenance also includes charts in respect of particulars including manufacture of all brought-out items, lubrication schedule and painting schedule. The operation and maintenance manual should also contain details of rubber seals or items which require periodic replacement and requirement of lubricants, spares and tools which should be kept in stock at any time.

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CHAPTER 2 DESIGN OF VERTICAL DAM GATE 2.1 DESIGN DATA

L Hc FSL SL RE =400 cm =500 cm =588.24 cm =578 m =27.5 cm SE Ht a =5 cm =505 cm Clear width of opening Clear height of opening Full supply level Maximum water level Sill level Roller distance from edge Side seal distance from edge Sill to C.I of top seal Spacing of stiffener Total hydrostatic head

MWL =589.2 cm

=Hc+5=500+5 =32 cm =588.24-578 =10.24 m

(WH) = FSL-SL

2.2

DESIGN STANDARDS
(i) (ii) (iii) I.S 4622 Fixed wheel gates structural design-Recommendations. I.S 800 Code of practice for general construction in steel. I.S 456 Code of practice for plain and reinforced concrete.

2.2.1 Material Standards

11

(i) (ii) (iii) (iv)

I.S 2062 Hot rolled low, medium and high tensile structural steel I.S 1570 (part 2)Schedule of wrought steels(carbon steels-unalloyed) I.S 1570(part 5)Schedule of wrought steels(stainless and heat resisting steels) I.S 1030Carbon steel castings for general engineering purposesspecification

2.3

MATERIAL SPECIFICATIONS
- IS 2062 - IS 1030, Gr 280-520 -Stainless steel 12Cr12, IS 1570 -Stainless steel 20Cr13, IS 1570

Skin plate, Stiffeners, Girders etc. Wheels Wheels pin Wheels track

2.3.1 The permissible conditions shall be applicable to wet and inaccessible condition
Yield Stress Direct/Bending stress Shear stress Combined stress yp b c c =25010.2 =0.4 yp =0.32.55103 =0.5 yp = 0.5 2.55 x 103= 1.27 103 kg/cm2 =2.55103 kg/cm2 =0.42.55103=1.02103 kg/cm2 =765 kg/cm2

Bending stress on concrete con = 50kg/cm2

2.4

DESIGN FOR SKIN PLATE

WH L1 L2 H1 H2 Pt = FSL-SL = 588.24-578.0 =10.24 m = 455 cm = 410 cm = L+2RE = 400 +2 27.5 = L+2SE = 400+2 5 = 220 cm = Ht-H1 = 505-220 = 285 cm = L2 Ht/(100 100) (WH-Ht/(2 100)) = 410 505/10000(10.24-505/(2 100)) =159.74 t 12

Total hydrostatic head c/c tracks c/c side seals Height of the bottom unit Height of the top unit Total load on gate

Total load on bottom unit

p1

= L2 H1/10000(WH-(H1/200)) = 410 220/10000(10.24-(220/200)) = 82.44 Ton

Thickness of skin plate With corrosion allowance Effective thickness Spacing of girders

S1 S l1 l2 l3 l4

= 1cm =1.5mm = S1-0.15 = 0.15 m = 0.9 m = 0.9 m = H1/100-(l1+l2+l3) = 220/100-(0.15+0.9+0.9) = 0.25 m = 0.85 cm

Pressures (in m of water)

P1 P2 P3 P4 P5 P6 P7 = WH = 10.24m = P1-l1 =10.24-0.15 = P2-0.5l2 = P3-0.59l2 = P4-0.5l3 = P5-0.5l3 = P6-l4 =10.09-0.5 0.9 = 9.64-0.5 0.9 = 9.19-0.5 0.9 =8.74-0.5 0.9 = 8.29-0.25 =10.09 m = 9.64 m = 9.19 m = 8.74 m = 8.29 m = 8.04 m

Figure 2.1 Diagram for Skin Plate, Stiffener Along With Panels

2.4.1 Panel A-B

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a1= a b1= l2 100 For b/a = 2, for 3x1, 3x1

= 32 cm = 0.90 100 =90 cm

k1=50 (from table 2, I.S 4622) = k1/100 P3 (a1 2/s 2) 1/10 = 50/100 9.64 32 2/0.85 2 1/10 = 683.14 kg/cm 2 3y1 = 0.3 3x1 = 0.3 683.14 =204.94kg/cm 2

Figure 2.2 Diagram for Panel A-B

2.4.2 Panel B-C

a2= a; b2 = l3 100 b 2/a 2 = 2.81 For b/a = 2, k 2 = 50 3x2 = (k2/100) P5 (a2 2/s 2) (1/10) = 50/100 8.74 (32 2/0.85 2) (1/10) = 619.36 kg/cm 2 3y2 = 0.3 3x2 = 0.3 619.36 = 185.81kg/cm 2 = 90 cm

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Figure 2.3 Diagram for Panel B-C

2.5

DESIGN FOR STIFFENER

Ra = P4 (l2/2) 100 +0.5(P2-P4)/10 (l2/100) 2/3 = 9.19 (0.9/20) 100+0.5(10.09-9.19)/10 0.9 100 0.667 = 44.06 kg/cm Rb = 0.5 l2 100 (P2-P4)/10+(P4/10) l2 100 Ra = 0.5 0.9 100 ((10.09-9.19)/10)+(9.19/10) 0.9 100 44.06 = 42.7 kg/cm

2.5.1 Panel A-B

For maximum bending moment, equating shear to zero: 0.5 (P2-P4)/(10 l2 100) X 2+(P4/10) X 0.0005X2 +0.919X 42.7 = 0 X M1 M1 bms1 = -0.919 + (0.9192+4 0.0005x42.7)/2 0.0005 = Rb XP4/10 X X/2 = 976.05 kg.cm = M1 a = 976.05 32 = 3.12 104 kg.cm = 43.35cm Maximum bending moment at X = Rb 0.5 (10.09-9.19)/(10 0.9 100) X2+9.19/10 X = 42.7

Bending moment in each stiffener

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Figure 2.4 Bending Moment Diagram for Stiffener Panel A-B 2.6

EFFECTIVE WIDTH OF SKIN PLATE (We)

L2= 0.91m, L2 100/(0.5 a) From IS 4622; We = 2 (a/2) Vi = 2 (32/2) 0.7 = 22.4 cm a = 32 cm = 0.91 100/0.5 32 = 5.63

2.7

DESIGN OF BENDING STRESS FOR STIFFENER

Section Area 19.04 5.36 Y 0.425 4.2 Ay 8.092 47.7 78.304 Y1,Y2, Y Y1=2.58 2.155 5.37 Y Ay-2 88.422 13.212 173.0124 Isdf 0.83 20.058 0.32 295.35 Total

22.4 0.85 6.7 0.8 25 2

22.512 Y2=5.77 1.57

6 7.95 30.4 Y1 = AY/A I self Zs11 Zs12 = bd3/12

= 78.304/30.4 Y2 = (0.85+6.7+0.8)-2.58 = 295.35/2.58 = 295.35/5.77 = 3.12 104/114.47

= 2.58 cm = 5.77 cm = 114.477 cm3 = 51.1872 cm3 = 272.5438 kg/cm2 16

Bending stress, bs1 = Mbs1/Z s11

bs2

= Mbs2/Zs12 = 3.12 10/51.1872 = 609.527 kg/cm2

Figure 2.5 Conventional Diagram for Stiffener

2.7.1 Panel B-C

Rb1 = P6 l3/20 100+0.5(P4-P6)/10 l2 100 2/3 = 8.29 0.9/20 100+0.5 (9.19 8.29)/10 0.9 100 2/3 = 40.01 kg/cm Rc = 0.5 l3 100 (P4 P6)/10 + P6/10 l3 100 Rb1 = 0.5 0.9 100 (9.198.29)/10+8.29/10 0.9 100 40.01 = 38.65 kg/cm Rc 0 X1 M2 = 0.5 (P4-P6)/(10 l3 100) X12+(P6/10) X1 = 0.0005X12+0.829X138.65 = -0.829+ (0.8292 + 4 0.0005 38.65)/2 0.0005 = 45.38 cm = Rc X1P6/10 X12/20.5(P4-P6)/10 l3 100 X13 0.5 1/3 = 38.65 45.38-8.29/10 45.382/20.5(9.19-8.29)/(10 0.9 100) 45.383 0.5 1/3 = 892.55 kg cm 38.65 = 0.45/900 X12 + 0.829X1

2.8

BENDING MOMENT OF STIFFENER

bms2 = M2 a = 892.73 3.2 = 2.86 104 kg cm

2.8.1 Bending stress

fs21 = bms2/Zs1 = 2.86 10/114.477 fs22 = bms2 /Zs2 = 2.86 10/51.187 = 558.73 kg/cm2 < b = 249.83 kg/cm2

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Figure 2.6 Bending Moment Diagram for Stiffener Panel B-C

2.9

DESIGN FOR HORIZONTAL GIRDER

WA = P1 l1 10 + 0.5 l1 (P1-P2)10 + Ra = 10.09 0.15 10 + 0.5 0.15 0.15 10 + 44.06 = 59.3 kg/cm WB WC = ( Rb+ Rb1) = 84.71 kg/cm = P7 l4 10+0.5(P6-P7)l4 10+Rc = 8.04 0.25 10+0.5(8.29 8.04) 0.25 10+Rc = 59.06 kg/cm RA RB RC = WA 0.5 l2 = WB 0.5 l2 = WC 0.5 l2 = 59.3 0.5 410 = 84.71 0.5 410 = 59.06 0.5 410 = 1.22 10 4 kg = 1.7 10 4 kg = 1.21 10 4 kg = 44.7+40.01

Figure 2.7 Diagram for Horizontal Girder

2.9.1 Bending moment for Horizontal Girder

bmgb = RB(L1/2 L2/4) = 2.12 10 6 kgcm = 1.7 10 4(455/2 410/4)

2.10 EFFECTIVE WIDTH OF SKIN PLATE

L = 4550 mm B = 450 L/B =10.11

18

Vi a

= 0.95 (From IS 4622 graph) = 2 0.95 450 = 85.5 cm

Sectional properties:
a = 85.5 cm, Section 85 0.8 38 0.8 25 2 T1= 0.85 cm, b1 = 38 cm, a2 = 25 cm, Y 0.425 19.85 Ay 30.886 603.44 1992.5 2626.826 Y1,Y2,Y Y1 =17.16 Y2 =23.69 Y3 =16.31 T2= 2 cm, t = 0.8 cm Y 17.1 3.84 Ay-2 20365.54 448.26 Isdf 4.376 104 3.66 103 Total 4.7 104 Area 72.625 30.40

50 39.85 153.075 Y1 = Ay/A Y2 Y3 Iself Zgb1 Zgb2 Zgb3

23.54 22706.58

= 2626.826/153.075 = 17.16 cm = (T1 + b1 + T2)Y1 = 0.85+38+ 217.16 = 23.69 cm = Y1-T1 = 17.16 0.85 = 4.4 104 = Igb/ygb1 = 4.7 10 4/17.16 = Igb/ygb2 = 4.7 /23.69 = Igb/ygb3 = 47 /16.31 = 2.9 103 cm = 2 103 cm = 2.7 103 cm = 16.31 cm

2.11

BENDING STRESS IN GIRDER

fgb1 fgb2 = bmgb/Zgb1 = 2.12 106/2.7 103 = 785.19 kg/cm2 = bmgb/Zgb2 = 2.12 106/2 103 = 1 103 kg/cm2 fgb3 = bmgb/Zgb3 = 2.12 106/2.9 103 = 731.03 kg/cm2 < 1.02 103kg/cm2

2.11.1Shear stress in the web

Depth of the web at the end Thickness of the web at the end d1= b1 = 38 cm t1e = t1 = 0.8 cm 19

Sgb1 L1/

= RB/d1e t1e = 5 WB L14/384 E Igb = 1.01 10 3

= 1.7 104/38 0.8 = 2047000 kg/cm2 = 0.45 < L1/800

= 557.75 kg/cm2 < 765 = 0.57

Modulus of elasticity E

Figure 2.8 Conventional Diagram for Horizontal Girder

2.11.2Girder A
bmga = RA (L1/2 L2/4) = 1.52 106 kg cm a3 =v1g (l1+0.5 l2) 100, b3=32.33, T4=2.0 t3=t2,

Effective width of skin plate

= /6, a3=57, T3=s, x1=b3 cos(), yGA1 yGA1 yGA2 yGA3 IGA1 IGA2 IGA Zga1 Zga2 Zga3 fga1 fga2 fga3 b2 = 10 cm, x1=28, t2 = 1 cm, b3=(b1-b2)/cos (), a4=18,

= [a3 T3 T3/2+b2 t2 (T3+b2/2)+b3 t3 (T3+b2+b3/2 cos()) +a4 T4 (T3+b2+x1+T4/2)] /(a3 T3+b2 t2+b3 t3+a4 T4) = 18.28 cm = T3+b2+x1+T4-yGA1 = yGA1-T3 yGA2 yGA3 = 22.57 cm =17.43 cm

=a3 T3 (yGA1-T3/2)2+b2 t2(yGA1-b2/2-T3)2+b3 t3(T2+b2+b3/ 2 cos()-yGA1)2 = a4 T4 (T3+b2+b3 cos()+T4/2-yGA1)2+t3 b33/l2 cos()2 = IGA1+IGA2 = IGA/yGA1 = IGA/yGA2 = IGA/yGA3 =bmga/Zga1 = bmga/Zga2 = bmga/Zga3 IGA= 3.74 104 cm4 Zga1= 2.04 103 Zga2= 1.65 103 cm3 Zga3= 2.14 103 cm3 fga1= 745.65 kg/cm2 fga2= 920.95 kg/cm2 fga3= 710.97 kg/cm2 IGA1= 1.84 104 cm4 IGA2= 1.89 104 cm3

20

Shear stress

= RA/(d1 e t2)

= 319.93 kg/cm2

Figure 2.9 Conventional Diagram for Horizontal Girder A

2.11.3Girder C
Bending moment in girder bmgc = RC (L1/2 L2/2) = 1.21 10 (4550/2 4100/2) = 1.51 106 kg cm Effective width of skin plate (a1) a1 Y1 Y2 Y3 y Section 66.5 0.85 38 0.8 18 2 = 2062.06/122.92 = 16.77 0.85 = 16.77 0.425 y 0.425 19.85 Ay 24.02 603.44 = L1/0.5 l3 100=10.11 = Vi (0.5 0.9 + 0.25)100 = 16.77 cm = 15.92 cm = 16.345 cm Y1,Y2,Y Y1=16.77 Y2=24.08 Y 16.345 4.23 Ay-2 15099.83 543.94 20615.22 Isdf 3.4 104 3.66 104 Total 3.82 104 Vi = 0.95 =66.5 cm

= (0.85+38+2)16.77 = 24.08 cm

Area 56.523 0.4

36 39.85 1434.6 Y3=15.92 23.93 122.92 2062.06 Ay-2 = 56.52 16.345 = 15099.83 cm2 Zgc1 Zgc2 Zgc3 = Igc/Ygc1 = Igc/Ygc2 = 2.9 103 cm3 = 1.51 106/2.28 103 = 3.82 104/16.77 = 3.82 104 / 24.08

= 2.88 103 cm3 = 1.59 103 cm3

Bending stresses in girders fgc1 fgc2 fgc3 = bmgc/Zgc1 = 953.3 kg/cm2 = 630.58 kg/cm2 =662.28 kg/cm2

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Figure 2.10 Conventional Diagram for Horizontal Girder C Shear stress in web Sgc 11 31 c1 = Rc/d1e t1 = - 3x1+fgb1 = - 3y1+fs11 = 1.21 104/38 0.8 = -683.14+727.8 = -204.99+272.2 = 398.02 kg/cm2 = 44.66 kg/cm2 = 67.26 kg/cm2 = 59.24 kg/cm2 Combined stress in the skin plate at X on the outer face of skin plate

= ( 112 + 312 11 31) = (44.44+67.26(44.66-67.26)

On the inner face of skin plate 12 32 = 3x1+fgb3 = 3y1+fs11 = 1.37 103 kg/cm2 = 204.94+272.2 = 477.14 kg/cm2

= ( 122+ 322 12 32 ) = (1.37 103) 2+477.142 (1.37 103 477.14) = 1.2 103 kg/cm2

Figure 2.11 Conventional Diagram for Combined Stresses in the Skin Plate

Total load on bottom unit

P = L2 /100 H1/100 (P1+P2)/2 = 410/100 220/100 (10.24+8.04)/2 = 82.44 t 22

Check
PC = 2 (RA+RB+RC)/1000 = 2 (1.22 104+1.7 104+1.21 104)/1000 = 82.6 t

Location of centre of pressure

hr = H1/3 2 P7+P1/(P7+P1) = 220/3 2 8.04+10.24/(8.04+10.24) = 105.59 cm

Figure 2.12 Diagram for Load on Bottom Unit Distance of the bottom wheel from the bottom of the gate y1 = 33.5 cm y2 Wheel load W1 W2 = 145 cm = P/2 (y1+y2-hr)/145 = 82.44/2 33.5+145105.59 = P/2-W1 = 82.44/2-20.73 = 20.73 t = 20.49 t Distance between the wheels

2.12 DESIGN OF END GIRDER

Bending moment at W1 M3 M4 = RA(Y1-l1 100) =1.22 104(33.5-0.15 100) =2.25 105kg-cm Bending moment at B = W1 1000[(l1+l2)100-Y1]-RA l2 100 =20.73 1000[(0.15+0.9)100-33.5]-1.22 104 0.9 100 =1482195-1098000 =3.84 105kg-cm

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Figure 2.13 Conventional Diagram for End Girder

Effective width of skin plate li = 0.6 Y2, b =a/2,li/b=5.44, Vi=0.85 Effective width Sectional properties Section 29.85 0.85 40 1.2 40 1.2 Yeg1 Yeg2 Zeg1 Zeg2 Area 25.374 8 Y 0.425 20.85 Ay 10.78 1000.8 1000.8 2012.38 =16.58 cm = 0.85+40-16.58 = 2.16 104/16.58 = 2.16 104/24.27 = 24.27 cm =1.3 103cm3 = 889.98 cm3 Y1,Y2,Y Y1=16.58 Y2=24.27 Y 16.155 3.42 Ay-2 6621.16 561.43 Iself 1.52 0.64 104 Total 2.16 104 a5 = 3.25+13+0.85 16

48 20.85 121.37 = 2012.38/121.37 = T5+b3-Yeg1 = Ieg/Yeg1 = Ieg/Yeg2

24

feg1 feg2

= M3/Zeg1 = M3/Zeg2

= 2.25 105/1.3 103 = 2.25 105/889.98

=173.07 kg/cm2 = 252.81 kg/cm2

Figure 2.14 Conventional Diagram for Horizontal Girder Section at B

2.13 DESIGN OF WHEEL

Maximum wheel load W1 Ut Modulus of elasticity Wheel diameter Length Actual contact stress E Dw Lw c = 20.73 t = 5.3 103 kg/cm2 = 2047000 kg/cm2 = 30 cm = 7 cm = 0.418 ((W1 1000 E)/(0.5 Dw Lw)) = 0.418 (20.73 1000 2047000)/(0.5 30 7) = 8.4 103 kg/cm2 Material of the wheel cast steel Gr 280-520, IS1030

2.14 SELECTION OF BEARING

Provide a spherical roller bearing no.21316cc Db = 8, Db = 17, B = 3.9, Static capacity = 335 k

2.15 DESIGN OF WHEEL PIN

Maximum BM in pin lp bmp = 14+2.4 = 16.4 B = 3.9 = 7.49 104kg-cm 25 = 0.5 W1 1000(lp/2-B/4) = 0.5 20.73 1000(16.4/2-3.9/4)

Zp

= db3/32

= 83/32 = bmp/Zp = 7.49 104/50.27

= 50.27 cm3 = 1.49 103

Bending stress, fbsp

Material stainless steel 30Cr13 BHN in the annealed condition, BHN = 220 uts = 490 BHN/14.19 = 490 220/14.19 Permissible stress, a1 = 0.2uts uts = 7.6 103kg/cm2 = 1.52 103kg/cm2

Figure 2.15 Diagram for Wheel Pin Shear stress Minimum diameter of pin at one end Area Ap = 3.14 d12/4 = 0.5 W2 1000/Ap = 308.95 kg/cm2 d1 = 6.5 cm = 3.14 6.52/4 = 33.17 cm2 = 0.5 20.49 1000/33.17

2.16 DESIGN OF TOP UNIT

Height of top unit H2 l4 = Ht-H1 l2 = 1.2 m, = H2/100-(l1+l2+l3) = 285 cm l3 = 1.2 m, = 0.2 m Spacing of girders l1 = 0.25 m,

2.16.1Design of Skin Plate

Thickness P1 P2 P3 P4 s = P1-l1 = P2-0.5l2 = P3-0.5l3 =10 mm, Pressure (in m of water) = 10.24-(220/100) = 8.04-0.25 = 7.79-0.5 1.2 = 7.19-0.5 1.2 = 8.04 m = 7.79 m = 7.19 m = 6.59 m = WH-(H1/100)

26

P5 P6 P7

= P4-0.5l3 = P5-0.5l3 = P6-l4 a = 32 cm,

= 6.59-0.5 1.2 = 5.99-0.5 1.2 = 5.39-0.2 b = 120 cm, k = 509 from table2, IS4622)

= 5.99 m = 5.39 m = 5.19 m

b/a = 120/32 = 3.75

for b/a = 2.86,for 3x,

Panel A-B
3x1 3y1 = k/100 P3 a2/s2 1/10 =3 68.13 kg/cm2 = 0.3 3x1 = 110.44 kg/cm2 = 0.3 368.13 =50/100 7.19 322/102 1/10

Panel B-C
3x2 3y2 = k/100 P5 a2/s2 1/10 = 306.69 kg/cm2 = 0.3 3x2 = 92.01 kg/cm2 = 0.3 306.69 = 50/100 5.99 322/12 1/10

2.17 DESIGN OF STIFFENER Panel A-B

Ra = P4 l2/20 100+0.5(P2-P4)/10 l2 100 2/3 = 6.59 1.2/20 100+0.5(7.79-6.59)/10 1.2 100 2/3 = 43.98 kg/cm Rb = 0.5l2 100 (P2-P4)/10+P4/10 l2 100-Ra = 0.5 1.2 100 (7.79-6.59)/10+6.59/10 1.2 100-43.98) =42.3 kg/cm For maximum bending moment, equating shear to zero 0.5 (P2-P4)/(10 l2 100)X2+P4/10 X 0.5 (7.79-6.59)/(10 1.2 100)X2+ 6.59/10 X 0.0005X2+0.659X X = (-bb2-4ac)/2a = (-0.659(0.6592+4 0.0005 41.94))/(2 0.0005) = 60.83cm M1 = Rbx-P4/10 X/2-(P2-P4)/(10 l2 100) X3 0.5 1/3 = Rb = 41.94 = 41.94

27

= 1.29 103 kg/cm Ms1 = M1 a = 4.14 104 kg/cm

Figure 2.16 Bending Moment Diagram for Stiffener Effective width of skin plate, (We) l2 = 1.2 m, From IS 4622, l2 100/(0.5 a) We T1= 0.8 cm Vi = 0.83 = 1.2 100/(0.5 32) = 7.5 = 2 a/2 7.5 = 2 32/2 7.5 = 26.56 cm b0 = 6.7 cm, t0 = 0.8 cm, a1 = 7.5 cm, a = 32 cm

a0 = 26.56 cm, T0 = s = 10 mm,

Sectional properties
Section Area Y 0.5 4.35 8.1 Ay Y1,Y2 Y 1.75 1.9 5.6 AY2 81.34 19.35 188.16 = 2.25 cm = 6.25 cm =146.83cm3 = 52.86 cm3 Iself 105.2 20.05 205.335 Itotal

26.56 1 26.56 6.7 0.8 5.36 7.5 0.8 6 Y1 = Ay/A Y2 Zs1 Zs2 = (T0+b0+T1)-Y1 =I total/Y1 = Itotal/Y2

13.28 2.25 23.316 6.25 48.6 = 85.196/37.92 = 1+6.7+0.8-2.25 = 330.36/2.25 = 330.36/6.25

330.36

Bending stresses
fs11 fs12 = Ms1/Zs1 = Ms1/Zs2 = 4.14 104/146.83 = 4.14 104/52.86 = 281.958 kg/cm2 = 783.20 kg/cm2

Panel B-C
28

Rb Rc

= P6 l3/20 100+0.5 P4-P6/10 l3 10 2/3 = 5.39 1.2/20 10+0.5 (6.59 5.9)/10 1.2 100 2/3 = 0.5 l3 100 (P4-P6)/10+P6/10 l3 100 Rb = 0.5 1.2 100 6.595.39/100+5.39/10 1.2 10037.14 = 34.74 kg/cm = 37.14 kg/cm

For maximum bending moment 0.5 P4-P6/10 l3 100 X12+P6/10 X1 0.5 (6.595.39)/10 1.2 100 X12+5.39/10 X1 0.0005 X12+0.539X134.74 X = -b b2-4ac/2a = -0.53 0.5392+ 4 0.0005x34.74/2 0.0005 M2 Ms2 fs21 fs22 = 1.1 103 kg/cm = M2a = M2a/Zs11 = M2a/Zs12 = 3.51 104 kg/cm = 238.79 kg/cm2 = 664.63 kg/cm2 <1020 kg/cm2 = 61cm. = RcX1P6/10X12/20.5 (P4-P6)/(10 l3 100) 13 0.5 1/3 =0 = Rc = 34.74

Figure 2.17Conventional Diagram for Stiffener

2.18 HORIZONTAL GIRDER

WA WB WC RA = [P2 l1 10+0.5 l1 (P1P2) 10+Ra] = [79 0.25 10+ 0.5 0.25 (8.047.79) 10 +44.34] = (Rb+Rb1) = 79.08 kg/cm = 45.32 kg/cm = [P7 l4 10+0.5 (P6P7) l4 10]+Rc = WA 0.5 L2 = 1.32 104 kg 29 = 64.13 kg/cm

RB RC

= WB 0.5 L2 = 1.62 104 kg = WC 0.5 L2 = 9.29 103 kg = 2.03 106 kgcm

Bending moment
bmgb = RB(L1/2L 2/4)

Bending stress
fgB1 fgB2 fgB3 = bmgb/ZgB1 = bmgb/ZgB2 = bmgb/ZgB3 = 695.86 kg/cm2 = 960.62 kg/cm2 = 661.39 kg/cm2

Shear stress in web

Depth of web at the end of d1e Thickness of web at the end t1e SgB1 = RB/d1e t1e = 1.62 104/35 0.8 = 35 = 0.8 = 578.57 < 765 kg/cm2

Combined stress in the skin plate at X On the other face of skin plate
11 31 c1 = - 3x1+fgB1 = - 3y1+fs11 = 112+31211 31 = 327.732+171.232 327.73 171.23 On the inner face of skin plate 12 32 12 = 3x1+fgB3 = 3x1+fg11 = 122+322 12 32 = (1.03 103)2+392.1121.03 103 392.11 = 899.98 kg/cm2 = 368.13+661.39 = 110.4+281.67 = 1.03 103kg/cm2 = 392.11 kg/cm2 = 283.92 kg/cm2 = -368.13+695.86 = -110.44+281.67 = 327.73 kg/cm2 = 171.23 kg/cm2

Girder C (provide same section for girder A also)

bmgc= RC (L1/2L2/4) = 9.29 103 (455/2410/2) = 1.16 106 kgcm

Bending stress in grider

fgc1 fgc2 = bmgc/Zgc1 = bmgc/Zgc2 = 1.16 106/2.28 103 = 508.7 kg/cm2 = 1.16 106/1.59 103 = 729.559 kg/cm2

30

fgc3

= bmgc/Zgc3

= 1.16 106/2.4 103 = 48.33 kg/cm2 = L2/100 H2/100 P1+P7/2 = 410/100 285/100 8.04+5.9/2 = 77.3 t = 77.2 t

Total load on top unit P Check PC

= 2 RA+RB+RC/1000 = 2 1.31 104+1.62 104+9.29 103/1000

Location of centre of pressure

Hr = H2/3 (2 P7+P1)/(P7+P1) = 285/3 (2 5.19+8.04)/(5.19+8.04) Distance bottom wheel from bottom of gate Distance between the wheel Wheel load W1 y2 = P/2 y1+y2 hr/y2 =77.2/2 43.4+171.6 132.27/171.6 = 18.63 t W2 = P/2-W1= 77.2/218.63 = 20.01 t y1 = 132.27cm = 43.4 cm = 171.6 cm

Figure 2.18 Diagram for Horizontal Girder

Hoist capacity and check for self closing intake gate

(i) Wheel friction (ii) Hav Hav P Mean radius of bearing r F1 Seal friction F2 Total load on a gate P = WH Ht/200 WH = 10.24 505/200 = 7.71 m. = Ht/100 L2/100 Hav = 505/100 410/100 7.71 = 0.25 (db + Db) 10 = 0.25 (8 + 17) 10 = 159.64/0.5 30 10 r = 62.5mm. F1 = 2.06 t = P/0.5 DW 10 (0.015 62.5 + 1) P =159.64 t = 10.24 m = 10.24 2.525 Average head on gate

31

Length of side seal Length of top seal Head on top seal Effective leaded with of seal Frictional co-efficient F2

Ht L2 Ht Ws

= 505 cm = 410 cm = WH Ht/100 = 5.19 cm. = 0.04 m = 0.2 [Teflon cladded seal] = 10.24 505/100

= [2 Ht/100 Ws hav + ht Ws L2/100] = [2 500/100 0.04 7.71 + 5.19 0.04 410/100] 0.2 = 0.7932 t

Friction in seal due to pre-compression. For 3 mm pre-compression, force per meter length Total force on scale Fs = 1 kg/cm = (2Ht + L2) = (2 505 + 410) = 1.42 103 t Friction due to pre-compressions F3 = fs/1000 = 0.2 1.42 103/1000 = 0.28 t Uplift on top seal Total projection of top seal from the face of skin plate xt = 1.0 + 4.2 Total uplift on top seal F4 = xt L2 (ht/10)/1000 = 5.2 410 (5.19/10)/1000 = 1.11 t Minimum download force required at 250 kg/m Fo Minimum weight of gate required = 0.25 L1/100 = 0.25 455/100 Wgm = 1.14 t = F1 + F2 + F3 + F4 + Fo = 2.06+0.7932+0.28+1.11+1.14 = 5.30 t Weight of bottom unit Weight of top unit Wheel assembly Weight of gate Weight of gate Down pull gate Wg1 Wg2 Wg3 Wg Wg F5 = 2.578 t = 2.634 t = 8 x 0.34 = Wg1+Wg2+Wg3 = 6.0 t =3t 32 = 0.274 t = 5.48 t = 5.2 cm.

Hoist capacity

Hc1 Hc1

= 1.2(wg + F1 + F2 + F3 + F5) =1.2(6+2.03+0.7932+0.28+1.11+1.14) = 14.57 t

Provide 15 t capacity hydraulic hoist

CONCLUSION
This conceptual project titled DESIGN OF VERTICAL DAM GATE AND HOIST MECHANISM provided an insight on improving the life of dam gate from 60 years to 80 years. This is an economical way of producing a vertical dam gate with greater life. This project also provided a chance to study about the various components of the vertical dam gate such as skin plate, stiffener, girder, wheel etc., and also the pressure acting on various points on the skin plate. Also the various design calculations like reaction forces, bending moments, bending stresses, shear stresses and combined stresses were calculated and found out that the calculated values come under the safe limit. Design values : Direct/bending stress Shear stress Combined stress Calculated values : Direct/bending stress Shear stress of girder h = = 683.14 kg/cm2 557.75 kg/cm2 33 b c = = = 1.02 103 kg/cm2 765 kg/cm2 1.27 103 kg/cm2

Combined stress

1.2 103 kg/cm2

REFERENCES
For books 1. R.K.Bansal, editor. Fluid mechanics. New Delhi: Lakshmi Publication;2007. 2. 3. S.Senthil, editor. Strength of materials. New Delhi: Lakshmi Publication; Seventh Edition 2009. I.S 4622 Fixed wheel gates structural design-Recommendations. Bureau of Indian Standards.

Website 4. http://en.wikipedia.org/wiki/Floodgate. 5. http://www.fantes.com/stainless-steel.html. 6. http://www.fanagalo.co.za/tech/tech_grade_304.html. 7. http://www.azom.com/Details.asp?ArticleID=965.

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PHOTOGRAPHY

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Vertical Dam Gate in KEL

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Vertical Dam Gate

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