Daram Khola Hydropower Project

(9.6 MW)

Detail Design Report

Structural Design of Surge Tank

I
CONTENTS

1 Description of Surge Tank 1

1.1 Typical section of Surge Tank 1

1.2 Structural design 2

1.2.1 Load Cases 2

1.2.2 Load Combination 2

1.2.3 Structural analysis and design 2

2 DESIGN OF surface (13.3 m height) surge tank by FEM on SAP2000 V20) 4

2.1 3D model of surge tank 4

2.2 Design data 5

2.2.1 Design of concrete lining of Surge tank (RL 939.5-944.5m) 5

2.2.2 Design of concrete lining of Surge tank (RL 944.5-950.3 m) 8

2.2.3 Design of concrete lining of Surge tank (RL 939.5-944.5m) 10

2.2.4 Design of Bottom Slab 12

2.3 Crack width calculation (As per IS 456 - ANNEX F) 15

3 Design Summery 16

ANNEX I: OUTPUT OBTAIN FROM SAP 17

LIST OF TABLES

Table 1: Design Summery ................................................................................................................... 16

LIST OF FIGURES

Figure 1: Typical cross section of surge tank 1

Figure 2: Shell model for Surge tank (13.3 m surface) 4
Figure 3: Hoop tension in concrete due to internal pressure 17
Figure 4: Tensile stress due to internal pressure 17
Figure 5: Compressive Stress due to externa pressure 18
Figure 6: Axial force F22 18
Figure 7: Bending Moment (M22) 18

II
1 DESCRIPTION OF SURGE TANK

Project: Daram khola Hydropower Project

Dimension of Surge Tank
Internal diameter : 8m
Height of Surge Tank: 13.3 m (Surface)
Maximum upsurge level/maximum design head: 10.8m
Thickness of lining: 70 cm for (939.5-944.5m)
50 cm for (944.5-950.3m)
30 cm for (950.3-952.8m)

1.1 Typical section of Surge Tank

Figure 1: Typical cross section of surge tank

1
1.2 Structural design

1.2.1 Load Cases

Load cases that are defined in SAP2000 are as per IS: 7357-1974and IS-456-
200. The load cases are as follows:
 Internal pressure due to maximum upsurge water level
 External pressure due to ground water level
 External earth pressure
 Seismic load (As per IS 1893-2002)
 Hydrodynamic water pressure
 Self wt of Structure

1.2.2 Load Combination

The load combinations taken into consideration are as per IS 7357:1974 are
as follows:

 Structural self weight + internal hydrostatic pressure

 Structural self weight + internal hydrodynamic pressure
 Structural self weight + internal hydrostatic pressure + internal
hydrodynamic pressure+seismic force
 Structural self weight + external soil pressure+external water pressure
 Structural self weight + external soil pressure+external water
pressure+ seismic force

1.2.3 Structural analysis and design

The structure is designed by using working state method in which the

permissible stress for concrete and steel are not exceeded anywhere in the
structure when it is subjected to the worst combination of working loads.
 Then the 3D model of the surge tank has been prepared in the
SAP2000. The model contains 13.3m high surge tank
 The hinge support has been assigned for the model.

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 Then the model has been applied with the above-mentioned load
cases resembling the real load conditions
 Earthquake load is consider as per IS 1893-2002, Design horizanta
earthquake coffecient is calculated by assuming the Zonal factor (Z) =
0.36 Response reduction factor(R) =4, Impotrance Factor (I) =1.5 and
(Sa/g)=2.5.Hoop reinforcement has been provided to withstand the
hoop tension excerted as a result of net hydrostatic internal pressure,
hydrodynamic pressure and earthquake load. Longitudinal
reinforcement has been provided as per moment obtain from analysis.
cylindrical wall of surge tank is desined as the flexural member since
the axial force (F22) obtain from the analysis is less than (.04 fck Ag).
The vertical reinforcement are provided to withstand the seismic force.
 Thickness of concrete lining has been decided keeping the tensile
stress in concrete within the permissible limit due to internal pressure
and earthquake loadand the compressive stress in concrete with in the
permissible limit due to external pressure and earthquake load.The
reinforcement for the concrete lining is checked for crack width in
cases the concrete cracks and temperature variation of ±15ºC. The
crack width is limited to 0.2mm. The surge tank has been designed as
per the following design sheet and SAP2000 result

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2 DESIGN OF SURFACE (13.3 M HEIGHT) SURGE TANK BY FEM ON
SAP2000 V20)

2.1 3D model of surge tank

Analysis of the structure was done by finite element analysis using SAP2000
version 20

Figure 2: Shell model for Surge tank (13.3 m surface)

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2.2 Design data

2.2.1 Design of concrete lining of Surge tank (RL 939.5-944.5m)

Height of saft 13.3 m

Elevation at top of the surge tank 952.8 m
Elevation at the bottom of surge tank 939.5 m
Total height of tank 1330 cm
Upsurge elevation 950.3 m
Downsurge elevation 935.5 m
Design head for surface surge saft 1080 cm
Temperature difference 15 ⁰C

Allowable stresses
a. For Cement concrete grade 250 Kg/cm2
1. Permissible tensile stress 13 Kg/cm2

b. Reinforcement bar
1. Type of steel: high strength deformed bars
Yeild stress 5000 Kg/cm2
permissible tensile stress 1300 Kg/cm2
Modulus of elasticity 2.00E+06 Kg/cm2
Internal radius tank, a 400 cm
External radius, b 425 cm
Ratio of r/t 5.71

Possion's ratio of concrete, νc 0.2

Permissible compressive stress due to bending

8.5 N/mm2
in concrete, σcbc

Modular ratio M250 conc 10.98 N/mm2

Modulus of elasticity of concrete, EC 2.50E+05 Kg/cm2

Permissible crack width 0.02 cm

Unit weight of water 1.00E-03 Kg/cm3

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Thickness of lining based on hoop tension (Manual calculation)
Hoop tension 505.00 KN
Thickness of lining based on hoop tension 345.80846 mm
Assumed thickness, t 70 cm
Area of steel for hoop tension 0.3884615 cm2/cm
Required reinforcement 3884.6154 mm2/m
Number of layer 2
Diameter of bar 20
area of a steel bar 314.15927 mm2
Spacing required 161.74536
Provided spacing 150 mm
mm2/m
Provided Ast 4188.7902
OK

Total hoop Steel required for lining based on SAP result:From SAP2000 - F11
Hoop tension 505 KN/m
1. Hoop Reinforcement
Required reinforcement 3884.6154 mm2/m
Diameter of bar 20
No of layer 2
Area of a steel bar 314.15927 mm2
Spacing required 161.74536
Provided spacing 150 mm
Provided Ast 4188.7902 mm2/m O

For Longitudinal Bars

Based on axial force and moment
Compressive strength of concrete, fck 25 Mpa

Tensile stress in steel, fy 500 Mpa

6
Basis for steel Design (Combined compression and Bending)
Section moment, M22 411 kN-m/m
Design axial load (Compression), F22 475 kN/m
Clause 32.3.2, Check, .04 fck Ag 700 kN

Since the axial load do not exceeds the permissible limit, wall can be designed as
Flexural Member

Based on bending moment obtain from SAP From SAP2000 - M22

Moment at critical section 411 kN-m/m

Depth rwquired to resist the bending moment 351.58075 mm
Depth provided 700 mm
Effective depth 625
Area of vertical reinforcement 1592.9208
Minimum area of reinforcement(.85bd/Fy) 1062.5
Area required (Ast) (Limit State) 1592.9208
Area Required (working Stress) 2611.878
Diameter of bar provided 20
Area of one bar 314
number of layers 2
Spacing required 120.22001
spacing privided 100
Area provided 3140 Ok
Check for Concrete thickness:(From SAP result)
1. for internal pressure
permissible tensile stress in concrete 13 Kg/cm2
Actual tensile stress 10.41 Kg/cm2
OK
2. for external pressure
Actual compressive stress 19.86 Kg/cm2
permissible stress in direct compression 60 Kg/cm2

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 OK

2.2.2 Design of concrete lining of Surge tank (RL 944.5-950.3 m)

Thickness of lining based on hoop tension (Manual calculation)

Hoop tension 292.00 KN
Thickness of lining based on hoop tension 199.9526154 mm
Assumed thickness, t 50 cm
Area of steel for hoop tension 0.224615385 cm2/cm
required reinforcement 2246.153846 mm2/m
Number of layer 2
Diameter of bar 16
area of a steel bar 201.0619298 mm2
Spacing required 179.0277457
Provided spacing 150 mm
Provided Ast 2680.825731 mm2/m OK

Total hoop Steel required for lining based on SAP result:From SAP2000 - F11
Hoop tension 292 KN/m
1. Hoop Reinforcement
Required reinforcement 2246.153846 mm2/m
Diameter of bar 16
No of layer 2
Area of a steel bar 201.0619298 mm2
Spacing required 179.0277457
Provided spacing 150 mm
Provided Ast 2680.825731 mm2/m OK

For Longitudinal Bars

Based on axial force and moment
Compressive strength of concrete, fck 25 Mpa
Tensile stress in steel, fy 500 Mpa

Basis for steel Design (Combined compression and Bending)

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Section moment, M22 10.98 kN-m/m
Design axial load (Compression), F22 175.06 kN/m
Clause 32.3.2, Check, .04 fck Ag 500 kN
Since the axial load do not exceeds the permissible limit, wall can be designed as
Flexural Member
Based on bending moment obtain from SAP From SAP2000 - M22
Moment at critical section 10.98 kN-m/m
Depth rwquired to resist the bending moment 57.46525593 mm
Depth provided 500 mm
effective depth 425
Area of vertical reinforcement 59.55840798
Minimum area of reinforcement(.85bd/Fy) 722.5
Area required (Ast) 722.5
Area Required 722.5
Diameter of bar provided 16
Area of one bar 200.96
number of layers 2
Spacing required 278.1453287
spacing privided 100
Area provided 2009.6 Ok

Check for Concrete thickness:(From SAP result)

1. for internal pressure
permissible tensile stress in concrete 13 Kg/cm2
actual tensile stress 7.45 Kg/cm2
OK
2. for external pressure
actual compressive stress 6.05 Kg/cm2
permissible stress in direct compression 60 Kg/cm2

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2.2.3 Design of concrete lining of Surge tank (RL 939.5-944.5m)

Thickness of lining based on hoop tension (Manual calculation)

Hoop tension 83.50 KN
Thickness of lining based on hoop tension 57.17823077 mm
Assumed thickness, t 70 cm
Area of steel for hoop tension 0.064230769 cm2/cm
required reinforcement 642.3076923 mm2/m
Number of layers 2
Diameter of bar 20
area of a steel bar 314.1592654 mm2
Spacing required 978.220467
Provided spacing 150 mm
Provided Ast 4188.790205 mm2/m OK

Total hoop Steel required for lining based on SAP result:From SAP2000 - F11
Hoop tension 83.5 KN/m
1. Hoop Reinforcement
Required reinforcement 642.3076923 mm2/m
Diameter of bar 12
No of layer 2
Area of a steel bar 113.0973355 mm2
Spacing required 352.1593681
Provided spacing 150 mm
Provided Ast 1507.964474 mm2/m OK

For Longitudinal Bars

Based on axial force and moment
Compressive strength of concrete, fck 25 Mpa
Tensile stress in steel, fy 500 Mpa
Basis for steel Design (Combined compression and Bending)

10
Section moment, M22 9.97 kN-m/m
Design axial load (Compression), F22 475 kN/m
Clause 32.3.2, Check, .04 fck Ag 700 kN
Since the axial load do not exceeds the permissible limit, wall can be designed as
Flexural Member

Based on bending moment obtain from SAP

Moment at critical section 9.97 kN-m/m
Depth rwquired to resist the bending moment 54.75852665 mm
Depth provided 300 mm
effective depth 225 mm
Area of vertical reinforcement 102.804061
Minimum area of reinforcement(.85bd/Fy) 382.5
Area required (Ast) 382.5
Area Required 382.5
Diameter of bar provided 12
Area of one bar 113.04
number of layers 2
Spacing required 295.5294118
spacing privided 200
Area provided 565.2 Ok

Check for Concrete thickness:(From SAP result)

1. for internal pressure
permissible tensile stress in concrete 13 Kg/cm2
actual tensile stress 1.86 Kg/cm2
OK
2. for external pressure
actual compressive stress 0.41 Kg/cm2
permissible stress in direct compression 60 Kg/cm2
OK

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2.2.4 Design of Bottom Slab

Output From Sap 2000 V20

KN-
Moment at critical Section (M11) 468
m
Shear Force at critical section (V23) 483.405 KN
Rebar calculation:(Along X-X axis)
Compressive strength of concrete (fck ) 25 MPa
Yield Stress of Steel (fy ) 500 MPa
Width of wall (b ) 1000 mm
Effective depth (d ) 1115 mm
Provide clear cover 75 mm
Overall depth (D ) 1200 mm

Tensile bars(Top face)

Rebar dia. 20 mm
Area of rebar 314 mm2
Ast 982.20 mm2
Minimum area of reinforcement(.12bd/100) 1440.00 mm2
Minimum area required(Max of Ast and Ast min) 1440.00 mm2
Spacing required 218.06 mm
Spacing Provided 150.00 mm
Area Provided 2093.33 mm2
Tensile Rebar provided % 0.17 %
(Check for reinforcement) Ok
Tensile bars(Bottom face)
Rebar dia. 20 mm
Area of rebar 314.00 mm2
Ast 982.20 mm2
Minimum area of reinforcement(.12bd/100) 1440.00 mm2

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Minimum area required(Max of Ast and Ast min) 1440.00 mm2
Spacing required 218.06 mm
Spacing Provided 150.00 mm
Area Provided 2093.33 mm2
Tensile Rebar provided % 0.17 %
(Check for reinforcement) Ok
Check for Section and Neutral axis Depth
Limiting neutral axis depth (Xu,lim) 512.90 mm
Neutral Axis depth (xu ) 101.18 mm
Under reinforced
Moment of resistance (MOR) 976.623
limiting moment is less than resisting moment Ok
Check For Shear
Shear force at critical section 483.405 KN
Width of section 1000 mm
Depth of section 1200 mm
Percentage of tensile reinforced provide in section 0.35 %
Shear strength of concrete(IS 456:2000 Table 19) 0.41 MPa
Shear strength of critical section 493.707 KN
Check OK

Calculation of reinforcement (Along Y-Y axis)

Output From Sap 2000 V20
KN-
Moment at critical Section (M22) 475.5
m
Shear Force at critical section (V13) 458.925 KN
Rebar calculation:
Compressive strength of concrete (fck ) 25 MPa
Yield Stress of Steel (fy ) 500 MPa
Width of wall (b ) 1000 mm

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Effective depth (d ) 1140 mm
Provide clear cover 50 mm
Overall depth (D ) 1200 mm
Tensile bars(Top face)
Rebar dia. 20 mm
Area of rebar 314 mm2
Ast 975.56 mm2
Minimum area of reinforcement(.12bd/100) 1440.00 mm2
Minimum area required(Max of Ast and Ast min) 1440.00 mm2
Spacing required 218.06 mm
Spacing Provided 150.00 mm
Area Provided 2093.33 mm2
Tensile Rebar provided % 0.17 %
(Check for reinforcement) Ok
Tensile bars(Bottom face)
Rebar dia. 20 mm
Area of rebar 314.00 mm2
Ast 975.56 mm2
Minimum area of reinforcement(.12bd/100) 1440.00 mm2
Minimum area required(Max of Ast and Ast min) 1440.00 mm2
Spacing required 218.06 mm
Spacing Provided 150.00 mm
Area Provided 2093.33 mm2
Tensile Rebar provided % 0.17 %
(Check for reinforcement) Ok
Check for Section and Neutral axis Depth
Limiting neutral axis depth (Xu,lim) 524.40 mm
Neutral Axis depth (xu ) 101.18 mm
Under reinforced
Moment of resistance (MOR) 999.388
limiting moment is less than resisting moment Ok
Check For Shear

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Shear force at critical section 458.925 KN
Width of section 1000 mm
Depth of section 1200 mm
Percentage of tensile reinforced provide in section 0.35 %
Shear strength of concrete(IS 456:2000 Table 19) 0.41 MPa
Shear strength of critical section 493.707 KN
Check OK

2.3 Crack width calculation (As per IS 456 - ANNEX F)

D provided at critical section 700 mm

Ast provided at critical section 2513.3 mm^2
Factored Moment at critical section on water side 400 kN-m
Asc provided at critical section 0 mm^2
C/C spacing of Ast 125 mm c/c
Dia of bar in tension zone 20 mm
Permissible Bending Compressive Stress in Concrete 5.25 N/mm2
Since we are considering stresses due to Earthquake, the stresses specified above
Has been exceeded upto a limit of 33.333 percent.
Modular Ratio (Es/Ec) 17.778
Overakk depth(D) 700 mm
Width of member (b) 1000 mm
Effective Depth(d) 640 mm
Tensile reinforcement(Ast) 2513.27 sq.mm/m width
Compressive reinforcement Asc 0 sq.mm/m width
d' 60 mm.
Clear Cover 50 mm
Spacing 125 mm
Percentage of tensile reinforcement (pt) 0.35904 %
Percentage of compressive reinforcement(pc) 0 %
xu (From linear elastic theory) 198.604 mm
Taking moments of areas of the cracked-transformed
section about NA

15
Gross moment of inertia of section(Ig) 2.9E+10 mm4
Cracked moment of inertia of section(Icr) 1.1E+10 mm4 Ok
Moment due to service Load(Un-factored)(M) 266.667 KN.m
Strain in concrete at the level of steel(ed) 0.00092
Strain in concrete at outer most tension face(eD) 0.00105
Minimum cover to the longitudional bar(Cmin) 50
Distance from the point considered the surface of
nerest longitudional bar 86.6386
Modulus of elasticity of reinforcement(Es) 200000 N/mm2
Average steel strain at the level consider(em) 0.00067
Crack width(Wcr) 0.15252 mm
As per IS 456:2000 Clause No. 35.3.2
Permissible Limit for cracking is 0.2 mm. OK

3 DESIGN SUMMERY

Table 1: Design Summery

Hoop Reinforcement Vertical Reinforcement
Member Elevation Level Diameter No of Spacing Diameter No of Spacing
of bar layer provided of bar layer provided
939.5-944.5 m 20 2 150 20 2 100
Wall 944.5-950.3 m 16 2 150 16 2 200
950.3-952.8m 12 2 150 12 2 200
Reinforcement Along X- axis Reinforcement Along Y-axis
Bottom Slab 20 2 150 20 2 150
Top Slab 12 2 150 12 2 150

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ANNEX I: OUTPUT OBTAIN FROM SAP

Figure 3: Hoop tension in concrete due to internal pressure

17
Figure 4: Tensile stress due to internal pressure
Figure 5: Compressive Stress due to externa pressure

Figure 6: Axial force F22

18
Figure 7: Bending Moment (M22)

19