Design Calculations For Irrigation Maintenance Intake Gate

EMPLOYERDOC.NO.
:
UOIIIDYDIMGHRP001
DYRAABADAM FARABDOC.NO.:H30PEG46M0143001
DESIGNCALCULATIONOFIRRIGATIONMAINTENANCE
GMWDOC.NO.:GMWJ.1114DDIMGDOC001
INTAKEGATE
REV:02
Page
DESIGNCALCULATIONSFORIRRIGATIONMAINTENANCEINTAKEGATE
PROJECT:UmaOyaMultipurposeDevelopmentProject
OWNER:MinistryofIrrigationandWaterResourcesManagementofSriLanka
CLIENT:FARABCO.
GENERALDESCRIPTION
Oneintakemaintenancegatewillbeinstalledforopeningof(1)1.0m(w)x1.0m(h)forMaintenanceofDownstreamequipments
suchasValvesandSteelLining.
Thegateswillbeoperatedunderbalancedwaterheadcondition.Thepressurebalancingwillbeattainedbycrackingthegateusing
theropedrumhoist.
ThegateisofFixedWheelTypeMediumheadgateanddesignedasperguidelineofIndianstandardIS:46222003.
Thegateswillbeofweldedsteelconstructionandconsistofastructuralsteelframeformedbytwoverticalboxgirderssupporting
thewheelsandbetweenwhichhorizontalloadcarryingmembersandverticalstiffenersareproperlyspacedaccordingtotheir
capacityanddesignwaterpressure.Theendboxgirderswilltransmitthedesignloadstothewheelswithoutwarpingorundue
deflection.Theentirefacewillbecoveredwithasteelskinplate.Theskinplate&SealwillbeonDownstreamside.Alifting
connectionwillbeprovidedonthetophorizontalmemberatthecenterofgravityofthegate.
Thegatewillbeprovidedwithrubberseals.ThetopandthesidesealswillbedoublestemJtype.Thebottomsealwillbeoftheflat
type.Theprecompressionforthetopandsidessealswillbe5mm.Allsealswillbesecuredtothegateleafwithstainlesssteel
fastenerstofacilitatetheirreplacement.
TheGateisequippedwithFourwheels.WheelswillbemadeofForgedSteelmaterialandwillrunonstainlesssteeltrackwith
hardnesshigherthanwheels.Atleasthardnessdifferentbetweenwheelsandstainlesssteeltrackwillbemiimum20HB.Wheelaxles
willbemadeofstainlesssteelmaterial.Thewheelbearingsshouldbeofselfalingningtype.
Theembeddedpartsforgateswillbeconsistofsillbeam,lintelbeams,casingconsistsofverticalsideguides,wheeltracksandload
carryingbeamssupporting,sealpaths,upperembeddedpartsmembersandanchoragesystemforembedmentinsecondary
concreteandairpipe.
Thegatewillbeprovidedwithnormal(local)control.Thegateoperationwillbelocalfromthelocalcontrolboardinstalledat985
m.a.s.l.adjacenttothepowerunit.
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
INTAKEGATE
GENERALARRANGEMENT:
DESIGNDATA:
1.1
Clearwidthoftheopening
1000
mm
1.2
Clearheightoftheopening
1000
mm
1.3
NormalWaterLevel
976.00
m.a.s.l
1.4
MaximumWaterLevel
985.3
m.a.s.l
1.5
SillLevel
963
m.a.s.l
1.6
Designhead(Normal)
13.00
0.128MPa
1.6
Designhead(Maximum)
22.30
0.219MPa
1.7
Rollerdistancefromedge(Re)
325
mm
1.8
SideSealDistanceFromEdge(Se)
100
mm
mm
1.9
StiffenerSpacing(a)
460
1.10
DesignCode
IS4622:2003
1.11
Heightofunit
1210
mm
1.12
No.ofunits/Gate
No.
2
2.1
(Inclinedheightofgate)
MATERIALSPECIFICATION:
Skinplate,stiffeners,girders,boxgirders
HotRolledSteelPlate(MildSteel),IS2062E250Gr.B
2.2
Wheel
Stainlesssteel,AISI420
2.3
Wheelpin
2.4
Wheeltrack
2.5
SealSeat
PERMISSIBLESTRESSES:
ThepermissiblestressesshallbeapplicableaccordingtoannexureBofIS4622:2003,accordinglypermissiblestressesunderNormal
Condition areasbelow,
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INTAKEGATE
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MaterialhavingYP
250
MPa
MaterialhavingYP
240
MPa
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Page
(Forplatethickness,<=20)
(Forplatethickness,20<t<40)
Conditionapplicableforgatecomponents:Wet&Inaccessible
CaseI:Forplatethickness,<=20mm
ForMWLcondition
a.
Direct/BendingtensionorCompr.
0.40
250
100
MPa
1.33
X100
=133
b.
Shearstress
0.30
250
75
MPa
1.33
X75
=100
MPa
MPa
c.
Combinedstress
0.50
250
125
MPa
1.33
X125
=166
MPa
CaseII:Forplatethickness,20mm<t<40mm
ForMWLcondition
a.
Direct/BendingtensionorCompr.
0.40
240
96
MPa
1.33
X96
=128
MPa
b.
Shearstress
0.30
240
72
MPa
1.33
X72
=96
MPa
c.
Combinedstress
0.50
240
120
MPa
1.33
X120
=160
MPa
SPACINGOFGIRDER:
l1
180
mm
l2
400
mm
l3
440
mm
l4
190
mm
TotalHeightofPanel
1210
mm
THRUSTCALCULATIONONPANELOFIRRIGATIONGATE:
Thearrangementofthegateisshowninthefigureonfollowingpages,
TotalHydrostatichead(WH)duringNWL
13.00
t/m2
TotalHydrostatichead(WH)duringMWL
22.30
t/m2
C/CofRollerTrack(L1)
1000
325
1650
mm
C/CofSideSeals(L2)
1000
100
1200
mm
ClearopeningofGate(H1)
1035
mm
HeightofPanel(H2)
1210
mm
INTAKEGATE
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UOIIIDYDIMGHRP001
TotalloadonGateduringNWL
L2xH2
1000x1000
TotalloadonGateduringMWL
18.00
WHNWL
WHMWL
H2
2x1000
Page
L2xH2
1000x1000
IncreaseinthrustatMax.waterlevel
REV:02
31.60
75.56
H2
2x1000
IncreaseInThrustatMWLismorethan33%.Hence,DesignofgatewillbeonNWLconditionandCheckingofsameonMWLconditionbyIncreasing
allowableStressby33.33%asperIS4622:2003Clause9.0
CHAPTER1:DesigncalculationforNormalwaterlavel:
6
PRESSUREDISTRIBUTIONONGATE:
P1
0.1275MPa
P2
0.1258MPa
P3
0.1238MPa
P4
0.1218MPa
P5
0.1197MPa
P6
0.1175MPa
P7
0.1157MPa
CantileverMoment,D
CantileverMoment,B
Cantilevermoments,
P7.l42
2
P1.l12
2
+
+
(P6P7)l42
6
(P1P2)l12
3
2098.9
Nmm
2056.5
Nmm
1923.9
Nmm
1937.8
Nmm
Fixedendmoments,
MDC
MCD
P6.l32
12
P6.l32
12
+
+
(P4P6)l32
30
(P6P4)l32
20
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MCB
MBC
P4.l2
12
P4.l22
12
(P2P4)l2
REV:02
Page
30
(P2P4)l22
20
1645.5
Nmm
1655.9
Nmm
Disctributionfactor:
Joint
Member
Distribution
factors
RelativeStiffness
I
DC
0.476
440.0
CB
0.524
400.0
Table1:Momentdistributiononhorizontalgirders
C
Joints
Distributionfactors
0.476
0.524
FixedEndMoments
2099
1924
1937.8
1645.5
1655.9
2056.5
175
87.5
200.3
400.5
2099
1850.3
1445.2
2056.5
2056.5
192.8
212.3
2098.9
1657.5
1657.5
2056.5
2056.5
1.0
1.0
1.0
1.0
2099
MomentDistribution
2098.9
FinalMoments(N.mm/mm)
Reactionduetomoment
SimplysupportedReactions(N/mm)
22.2
26.0
24.1
26.5
24.9
22.8
FinalReactions(N/mm)
22.2
27.0
23.1
25.5
25.9
22.8
49.2
7
7.1
48.6
DESIGNOFSKINPLATE:
PanelAB
ThicknessoftheSkinPlate
16
mm
Allowingacorrosionallowance
mm
Hence,teffective
14
mm
AverageheadonpanelAB(Pa)
0.1266MPa
180
mm
460
mm
(FromFig.8&Table3ofIS4622)b/a
2.56
BendingStress14x
14x
k
x
100
123.1
100
Pa
123.1
s .
0.127
14
x
2
180
48.7
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14y=0.314x
26.0
MPa
8.0
MPa
<
100.0
2.56
BendingStress12y
12y
MPa
k
x
100
141.2
100
30.0
MPa
2.56
BendingStress12x
100
42.8
12x
SAFE
=
Pa
9.0
MPa
s .
0.127
x
2
14
100
141.2
180
Pa
42.8
s 2.
0.127
14
x
2
180
<
100.0
7.2
MPa
SAFE
PanelBC
16
mm
mm
Hence,teffective
14
mm
AverageheadonpanelBC(P3)
0.1238MPa
400
mm
460
mm
1.15
Bendingstress3x
3x
3y=0.33x
36.5
P3
400
100
36.5
0.124
100
37.0
MPa
12.0
MPa
14
.
x
<
100.0
1.15
Bendingstress4y
K
100
SAFE
MPa
x
x
32.7
P3
REV:02
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4y
4x=0.34y
32.7
100
34.0
MPa
11.0
MPa
0.124
14
x
2
400
<
100.0
7.3
MPa
SAFE
PanelCD
16
mm
mm
Hence,teffective
14
mm
AverageheadonpanelCD(P5)
0.1197MPa
440
mm
460
mm
(FromFig5&Table2ofIS4622)b/a
1.05
Bendingstress3x
3x
3y=0.33x
k
x
P3
100
32.6
0.12
100
39.0
MPa
12.0
MPa
14
32.6
440
.
x
<
100.0
1.05
Bendingstress4y
4y
4x=0.34y
SAFE
MPa
31.4
P3
440
100
31.4
0.120
100
38.0
MPa
12.0
MPa
14
.
x
<
100.0
7.4
MPa
PanelDE
16
mm
mm
SAFE
REV:02
Page
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UOIIIDYDIMGHRP001
Hence,teffective
14
AverageheadonpanelDE(Pb)
0.1166MPa
190
mm
460
mm
2.42
BendingStress14x
14x
14y=0.314x
mm
127.2
Pa
190
100
127.2
0.117
100
28.0
MPa
9.0
MPa
.
x
14
<
100.0
2.42
BendingStress12y
12y
12x=0.312y
SAFE
MPa
k
x
100
138.6
100
30.0
MPa
9.0
MPa
Pa
138.6
s .
0.117
14
x
2
190
<
100.0
DESIGNOFSTIFFENERS:
MPa
SAFE
REV:02
Page
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8.1
REV:02
Page
PanelAB
Bendingmomentonstiffner,M1
M1
MabXa
2056.5
945967
Nmm
460
Where,
MomentonstiffnerAB,Mab
2056.5
Stiffnerspacing,a
460
CoactingWidthofSkinPlate(We)
2VB
l1
300
mm
Nmm/mm
(Max.momentatPoint"B"isconsideredforstiffnerdesign,
referTable1)
mm
(FromAnnexureDofIS4622)
a
460
mm
a/2
230.00
l1/B
300.0
1.30
mm
230
NowFromFig11ofIS4622,V
0.22
2VB
101.2
mm
Thickness(t)
14
mm
StiffenerPlate
60
(CoactingWidthofSkinPlate)
10
NowPropertiesofCompositeSectionofStifferPlatewithSkinPlate,
Dw
Tw
y1
y2
y3
Ixx
Z1
cm cm
cm
cm
cm2
cm
cm
cm
cm4
cm
cm
cm
10.1 1.4
6.0
1.0
20.2
1.8
5.6
0.4
78.0
43.3
13.9
194.7
2VB
Z2
3
Z3
3
Where,
Dw
DepthofStiffenerPlate
Tw
ThicknessofStiffenerPlate
TotalArea
y1
CentreofGravity(C.G.)
DetailworkoutofC.G.
(VBxtxt/2)+[DwxTwx(t+Dw/2)]
Totalarea(A)
y2
t+Dwy1
y3
y1t
Detailworkoutof(Ixx)
MomentofInertia
VBxt3
12
r1
y1t/2
r2
y1(t+Dw/2)
Zxx
ModulusofSection
Max.B.M.inDiaphragm,M1
945967.0
BendingStress
twxDw
12
Nmm
f1s
f2s
f3s
MPa
MPa
MPa
21.8
67.9
4.9
<
<
<
100.0
100.0
100.0
SAFE
SAFE
SAFE
VBxtxr12
twxDwxr22
INTAKEGATE
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8.2
REV:02
Page
PanelBC
Bendingmomentinstiffener,M2
M2
MbcXa
2056.5
945967.0
Nmm
460
Where,
MomentonstiffnerBC,Mbc
2056.5
Stiffnerspacing,a
460
2VB
l2
300.0
mm
460
mm
a/2
230.0
l2/B
300.0
1.30
Nmm/mm
(Max.momentatPoint"B"isconsideredforstiffnerdesign,
referTable1)
mm
(FromAnnexureDofIS4622)
mm
230
0.22
2VB
101.2
mm
Thickness(t)
14
mm
StiffenerPlate
60
10
Dw
Tw
y1
y2
y3
Ixx
Z1
cm cm
cm
cm
cm2
cm
cm
cm
cm4
cm
cm
cm
10.12 1.4
6.0
1.0
20.2
1.8
5.6
0.4
78.0
43.3
13.9
194.7
2VB
Z2
3
Z3
3
Where,
Dw
Tw
TotalArea
y1
DetailworkoutofC.G.
Totalarea(A)
y2
t+Dwy1
y3
y1t
MomentofInertia
VBxt3
12
r1
y1t/2
r2
y1(t+Dw/2)
945967.0
twxDw3
12
Nmm
VBxtxr12
twxDwxr22
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BendingStress
8.3
f1s
f2s
f3s
MPa
MPa
MPa
21.8
67.9
4.9
<
<
<
100.0
100.0
100.0
SAFE
SAFE
SAFE
REV:02
Page
PanelCD
Bendingmomentonstiffner,M3
M3
McdXa
2098.9
965484.8
Nmm
460
Where,
MomentonstiffnerCD,Mcd
2098.9
Stiffnerspacing,a
460
EffectivewidthofSkinPlate(We)
2VB
l3
168
mm
460
mm
a/2
230
168.0
Nmm/mm
(Max.momentatPoint"D"isconsideredforstiffnerdesign,
referTable1)
mm
(FromannexureDofIS4622)
l3/B
mm
230
=
0.73
0.17
2VB
78.2
mm
Thickness(t)
14
mm
StiffenerPlate
60
10
2VB
Dw
Tw
y1
A
2
y2
y3
Ixx
Z1
4
Z2
3
Z3
3
cm cm
cm
cm
cm
cm
cm
cm
cm
cm
cm
cm3
7.82 1.4
6.0
1.0
16.9
2.0
5.4
0.6
72.8
36.2
13.5
119.4
Where,
Dw
Tw
TotalArea
y1
DetailworkoutofC.G.
Totalarea(A)
t+Dwy1
y2
y3
y1t
MomentofInertia
VBxt3
12
r1
y1t/2
r2
y1(t+Dw/2)
Zxx
ModulusofSection
twxDw3
12
VBxtxr12
twxDwx r22
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BendingStress
8.4
965484.8
REV:02
Page
Nmm
f1s
f 2s
f 3s
MPa
MPa
MPa
26.6
71.4
8.1
<
<
<
100.0
100
100
SAFE
SAFE
SAFE
PanelDE
Bendingmomentinstiffener,M4
M4
MdeXa
2098.9
965484.8
Nmm
460
Where,
MomentonstiffnerDE,Mde
2098.9
Stiffnerspacing,a
460
2VB
l4
278
mm
460
mm
a/2
230.0
l4/B
278
1.21
Nmm/mm
(Max.momentatPoint"D"isconsideredforstiffnerdesign,
referTable1)
mm
(FromannexureDofIS4622)
mm
230
0.22
2VB
101.2
mm
Thickness(t)
14
mm
StiffenerPlate
60
10
Dw
Tw
y1
y2
y3
Ixx
Z1
Z2
Z3
cm cm
cm
cm
cm2
cm
cm
cm
cm4
cm3
cm3
cm3
10.12 1.4
6.0
1.0
20.2
1.8
5.6
0.4
78.0
43.3
13.9
194.7
2VB
Where,
Dw
Tw
TotalArea
y1
DetailworkoutofC.G.
Totalarea(A)
y2
t+Dwy1
y3
y1t
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=
=
Page
MomentofInertia
VBxt3
12
twxDw3
r1
y1t/2
r2
y1(t+Dw/2)
Zxx
ModulusofSection
965484.8
BendingStress
REV:02
VBxtxr12
twxDw x r2
12
Nmm
f1s
f2s
f3s
MPa
MPa
MPa
22.3
69.3
5.0
<
<
<
100.0
100.0
100.0
SAFE
SAFE
SAFE
DESIGNOFHORIZONTALGIRDERS:
ReactiononeithersideofGirders,
RB
WBL2
29211
(ForvalueofWBreferTableNo.1)
29141
(ForvalueofWCreferTableNo.1)
29501
(ForvalueofWDreferTableNo.1)
2
RC
WCL2
2
RD
WDL2
2
DESIGNOFGIRDERD:
NowMax.BendingmomentisactingonGirderD,wedesigngirderDandusesamesectionforgirderB&C
BMGB
=
=
RB
15335807
L1
2
L2
Nmm
V1B1+V1B2
EffectiveWidthofSkinPlate
B1
l1
180
mm
&
L=L1=
1650
mm
B2
l2
200
mm
&
L=L1=
1650
mm
2
Where,l1
cantileverportionofskinplate
Where,l2
Distancebetweengirder
L/B1
9.17
L/B2
8.25
NowFromFig11ofIS4622,V1
0.93
V2
0.91
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V1B1
167.40
mm
V2B2
182.00
mm
V1B1+V2B2
349.40
mm
Thickness(t)
14
mm
REV:02
Page
NowadoptBuiltup'I'sectionforhorizontalGirder,
Flangeplate
160
16
Webplate
350
10
Dw
Tw
Wf
NowpropertiesofComposite'I'section
VB1+VB2
Tf
A
2
y1
y2
y3
Ixx
cm
cm cm
cm
cm
cm
cm
cm
cm
cm
cm
34.94 1.4
35.0
0.8
16.0
1.6
102.5
14.8
23.2
13.4
Dw
DepthofWebPlate
Tw
ThicknessofWebPlate
Wf1
WidthofFlangePlate1
Tf1
ThicknessofFlangePlate1
Wf2
WidthofFlangePlate2
Tf2
ThicknessofFlangePlate2
Totalarea
y1
DetailworkoutofC.G.
y2
t+Dw+Tfy1
y3
y1t
=
=
MomentofInertia
((VBxt3)/12)+((TwxDw3)/12)+((WfxTf3/12)+(VBxtxr12)
+(TwxDwxr22)+(WfxTfxr22)
r1
y1t/2
r2
y1(t+Dw/2)
r3
y1(t+Dw+Tf/2)
Zxx
ModulusofSection
Max.BendingmomentinGirder
15335807
Nmm
Z3
3
cm
cm
cm
1752.5
1116.2
1935.8
(VBxtxt/2)+(DwxTwx(t+Dw/2))+(WfxTfx(t+Dw+Tf/2))
Totalarea(A)
25912.5
Z2
Z1
Where,
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BendingStress
Shearstress
f1s
f2s
f3s
MPa
MPa
MPa
8
14
<
<
<
100
100
100
SAFE
SAFE
SAFE
29501
=
350.0
=
10.0
8.43
MPa
<
75
MPa
SAFE
CheckofwebofgirderforStability:
Dw
Tw
43.75
<
SAFE
45
Checkofflangeofgirderundercompression:
AsperDIN4114,Majorradius(iy)shouldbemorethatC/40.
Propertiesofgirderundercompression:
Tw
Dw/5
Wf1 Tf1
cm cm
cm
cm
16.00 1.60
7.00 0.80
Supportofgirder,C
1650
mm
(iy
42
A
cm
31.2
Iyy
cm4
546.1
>
iy
cm
4.18
Now,
C/40
41
AstheaboverelationfulfillstheconditionofDIN4114,thesectionissafeundercompression.
10
COMBINEDSTRESSCALCULATION:
ConsideringthemaximumstressinPanelBC,combinedstressarecheckedforthesamebelow
10.1 Combinedstressesatskinplateadjusenttostiffners:
UpstreamSide
Combinedstress,
Where,
x
y
xy
(x2+y2xy+3xy2)0.5
31.4
MPa
=
=
=
=
x+f1y
11
6.1
0
+
MPa
<
34.0
125MPa
MPa
4.9
(TherewillbenoshearinplaneXY)
SAFE
REV:02
Page
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
Combinedstressfordownstream
sideofskinplate,
Where,
x
y
xy
(x2+y2xy+3xy2)0.5
33.4
4y =
=
=
=
MPa
34.0
x+f1y
11.0
+
32.8
MPa
<
125MPa
SAFE
MPa
21.8
10.2 Combinedstressesatskinplateadjusenttohorizontalgirders:
UpstreamSide
Combinedstress, = (x2+y2xy+3xy2)0.5
=
32.1
MPa
y+f1y
12.0
20.8
MPa
<
125MPa
Where,
xy
37.0
MPa
8.8
SAFE
REV:02
Page
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
Combinedstressfordownstream
sideofskinplate,
Where,
y
11
(x2+y2xy+3xy2)0.5
=
=
35.5
MPa
x =
<
37.0
125MPa
SAFE
MPa
y+f1y(Compressivestressesingirders)
12.0
+
8.8
3.2
MPa
=
=
=
xy
1650
CHECKFORDEFLECTION
Permissibledeflection
2.06
mm
800
Bendingdeflectionofgirder
5WL3
384EI
Where,
LengthofGirder(L)
1650
mm
MomentofInertia(INA)
259124890
mm
Loadongirder(W)
WDL
N
MPa
81129
ModulusofElasticity
205000
Bendingdeflectionofgirder
Sheardeflectionofhorizontal
girder,2
0.09
mm
WL2(bd2bd12+td12)
64EsIt
Where,
C/Cofrollertrack(L=L2)
1650.0
mm
Loadongirder(W1=Rd)
48.7
Nmm
160.0
mm
380.0
mm
d1
350.0
mm
mm
8.0
Es
82737.0
N/mm2
259124890
mm4
0.05
mm
REV:02
Page
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
TotalActualDeflection
0.14
mm
<
2.06
12
mm
SAFE
DESIGNOFENDGIRDER:
Thetotalloadongate(P)
LocationofC.G.ofareai.e.Y
18.0
2P1
P7
P1
P7
615.0
H1
615.0 mm
Where,H1
1210
mm
Pressureattopofunit(P7)
0.116
MPa
Pressureatbottomofunit(P1)
0.128
MPa
Now,hr
1210.3
Distanceofbottomwheelofgate(y1)
300
Distancebetweenwheels(y2)
295.29
590.6
mm
540.0
mm
P(y1+y2hr)
Wheelload(W1)
180000
t=
595.3
mm
mm
595.3
300
)X
(Adopted)
40785.1N
40785.09121
2xy2
Hence,wheelload(W2)
180000.0
2
49214.9N
REV:02
Page
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
Hence,wheelload(W2)
49214.9
Reaction(RB)
29211.1N
l1
180
mm
Reaction(RC)
29140.8N
l2
400
mm
Reaction(RD)
29501.5N
l3
440
mm
l4
190
mm
120
mm
280
mm
260
mm
180
mm
BendingmomentatRX
29211.1
3505328.0
BendingmomentatRC
BendingmomentatRY
49214.9
2095749.7
29501.5
5310262.9
Nmm
280
Nmm
x
Designofendgirderformax.Bendingmoment
180.0
Nmm
5310262.9
Nmm
NowadoptBuiltupsectionforendBoxplateGirder
CheckingEndpalteforthismoment,
Endplate
16
ZxxModulasofSection
413962.7
mm3
ZxxModulasofSection
413962.7
mm3
Max.Bendingmomentinendgirder
5310263
BendingStress
394
1150
Nmm
f 2s
f1s
MPa
Page
120
REV:02
f 3s
MPa
MPa
12.8
12.8
12.8
<
<
<
100.0
100.0
100.0
SAFE
SAFE
SAFE
29211.1
400.0
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
13
Page
DESIGNOFWHEEL:
Maximumloadonwheel(W)
49214.9
MaterialofwheelAISI420annealedhavingUTS
14
REV:02
BHNofwheels
150
BHN
WheelDia(Dw)
200
mm
WheelcontactWidthorLength(Lw)
60
mm
ContactModulusofElasticity(E)
2.05
PermissibleContactStress(p)
1.4
UTS
Actualcontactstress(c)
0.418
542
<
826
MPa
105
MPa
590
MPa
826
WxE
0.5xDwxLw
MPa
)0.5
SAFE
MPa
BEARINGSELECTION:
Equivalentstaticbearingload,P0
Where,
Radialstaticload,F0r
Axialstaticload,F0a
Maximumadjustmentangle,
Y0
Bearingcapacityrequired,P
=
=
=
F0r+Y0.F0a
49214.9
54024.1
=
=
=
49214.9
For.Sin
=
=
=
=
2.8
X1841.0
N
N
=
49214.9
XSin2o=
1717.6
2
2.8
1.5XP0
X56456.2
1.5
81,036.2 N
TheadoptedbearingissphericalRollerbearing(Doublerow).BearingNo.22212havingOD110mm,ID60mm&Width28mmandstaticloadcapacityof
16.6t.(ReferFAGcatalogueattachedherewith)
15
DESIGNOFROLLERPIN:
49214.9
Nowwheelload(P)
Max.BendingmomentwilloccuratX1
Max.BendingMoment
WheelLoadx
3395829
Nmm
3395828.7
Nmm
Max.BendingMoment
69
N
mm
X1
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
TheadoptedMaterialforPinisAISI420withhardenedandtemperedhavingUTS&YPasunder.
UTS
790
MPa
YP
600
MPa
Bending/CompressioninTension
0.40
600
240
MPa
ShearStress
0.30
600
180
MPa
AdoptedPindia(d)
55
mm
AreaofPin
2376
mm2
Modulusofsection(z)
16334
mm3
Bendingstress
Max.B.M.
207.9 MPa
Shearstress
<
WheelLoad
0.75xAreaatend
240
MPa
27.6
MPa
SAFE
<
180
MPa
SAFE
Checkingplateforbearingstresses
Reactionproducedatbothplates
a
69 mm
146 mm
Takingmoment@A=0
Px
Rb
49214.9X
69
Rb
146
Rb
Ra
Rb
Ra
ForthesereactionforcesRaandRbbearingstressinsupportplates,
23259.10
49214.9
72474.0
REV:02
Page
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
Bearingstress
REV:02
Page
ReactionatpointA
Area
Area
DiaofPin
55
28
1540 mm2
=
ReactionatpointA
Bearingstress
(Wheret=28mmseefigure)
72474.0
72474.0
1540
47.1
MPa
<
112.5
MPa
SAFE
(Allowablestress=0.45XYp)
ReactionatpointB
Bearingstress
Area
DiaofPinatB
30
22
660 mm2
Area
ReactionatpointB
Bearingstress
23259
(Wheret=22mmseefigure)
23259.1
660
35.2
MPa
<
112.5
MPa
SAFE
(Allowablestress=0.45XYp)
16
DESIGNOFWHEELTRACK:
HalfContactwidth(b)
1.55
P.r
l.E
0.5
Where,b
Halfcontactwidth
Wheelload
49215
Radiusofwheel
100
ModulusofElasticity
205000
MPa
Treadwidthofwheel
60
mm
HalfContactwidth(b)
Z1
=
=
BHNofwheeltrack
0.980
N
mm
mm
Depthtopointofmaximumshearingstress
0.786
xb
0.77
mm
ThicknessofWheelTrackshallbeminimum6timesthedepthtothepointof
maximumofshearingstress.
6xZ1
225275
0.77
4.6
mm
BHN (ForSS420inhardenedandtemperedcondition)
WeadoptWheeltrackplatthickness26mmwhichissafeandadequate.
17
DESIGNOFWHEELTRACKBASE:
The Track base shall be embedded in concrete. The Stress in concrete, shall be calculated by
followingformula.WehavetakencareCl.5.7.5.1ofIS4622fordesignofwheeltrackbase.
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
WheelTrackPlate
BeamFlange1
(t)
mm
26
(w)mm
60
Compressivestressinwheeltrack1
=
=
Tensilestressinwheeltrack
tf2
mm2
mm
260
12
150
10
70
16
INA
7300
Z1
69.7
mm4
33089579
mm3
474435
P
2Z1
8
Ea
Ec
I
b
MPa
0.40
0.40
96.0
x
x
MPa
Ec
=
=
=
=
=
=
=
=
=
=
)0.33
SAFE
Ea
Ec
I
b
)0.33
SAFE
Yp
240
MPa (Modulousofelasticityofthefoundation)
5940X(fck+3.5)0.5
28795.2
MPa
(Where,fckis20Mpa)
205000
MPa (Modulousofelasticityofthebeam)
70
mm (Supportlength)
33089579
mm4 (Momentofinertiaofbeam)
49215
N
474435
Sectionmodulous
246469
Sectionmodulous
540
mm
(C/Cofwheel)
3.55
Ea
I
(
)0.33
Ec
b
532
mm
P
bd
1.32
<
6
(Whered=minvaluebetweenL1andL2)
Mpa
Mpa
SAFE
Herethepressuredistributionunderadjacentwheeldonotoverlaps
TheTrackbasebeamshallbecheckedinshearstressusingfollowingformula:
LoadonTrackbasebeam
49215
Max.shearforceatpointA
49215
2
=
mm
bf2
=
=
=
C.G.2
tw
Permissiblebendingstress(b)
C.G.1
dw
MPa
Bearingpressureinconcrete,P0
tf1
BeamFlange2
Page
bf1
P
2Z2
15.0
Ea
b
I
P
Z1
Z2
L1
L2
BeamWeb
REV:02
24607.4544
134
Z2
mm3
246469
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
ShearArea
dwxtw
=
=
150
1500
10
2
mm
Where,
dw
WidthofWebBeam
150
mm
tw
Thick.ofWebBeam
10
mm
Load/Area
ActualShearStress
24607
1500
16.4
MPa
<
30
Permissibleshearstress(s)
SAFE
MPa
0.30
Yp
0.30
100
30.0
MPa
ThewebofTrackbaseshallbecheckedforcompression:
WhenloaddirectlyappliedtoTopflange,itshallbeconsideredasdisperseduniformly,atangleof450degreetotheHorizontal(ReferCl.
8.7.1.3ofIS:8002007)
(t+tf1)xTan45
26
38.00
mm
Totallengthofdispersion,2X
76
mm
Totalwidthofdispersion,T'
tw
10
mm
10
mm
Area
2XxT'
12
76.0
10
Tan450
760
mm2
REV:02
Page
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
Compressionstress
REV:02
Page
WheelLoad
Area
49215
760
65
MPa
<
213
MPa
SAFE
(85%ofYP=250)
TheflangeofTrackbasebeamshallbecheckedinlateralbendingfollowingformula:
WidthofbottomFlangeofbeam(bf2)
70
mm
Permissiblebendingstress(b)
0.4
NowBearingstress()
1.32
MPa
Bendingmomentinflange
809
Thicknessofflange(tf2)
16
mm
Zf(modulusofsectionforflange)
tf2
250
bf2X
bf2
100
mm2
42.67
MPa
6
Bendingstress
B.M.
809
Zf
42.67
=
19.0
MPa
<
100
i)
SAFE
MPa
CheckofweldbetweenTopflangeandweb:
Maximumshearforceatjunction,1
RaXaXy
Ixx
49215
x(
60
X26.0
X56.7
X12.0
260
X37.7
33089579
=
Minimumweldsize,s
306.8 N/mm
306.8
X0.707
Weldsizeprovided
ii)
1.6
mm
6.0
mm
X132.3
(ForE7018electrode,132MPa=0.3
X490x0.9)
Checkofweldbetweenbottomflangeandweb:
RaXaXy
Ixx
49215
x(
16
33089579
210.3 N/mm
X70.0
X126.3
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
Minimumweldsize,s
18
18.1
Page
210.3
X0.7
2
Weldsizeprovided
REV:02
1.1
mm
mm
X132.3
(ForE7018electrode,132MPa=0.3X490x0.9)
CHECKOFWELDING
Checkofweldingandshearstrengthatconnectionofstiffnerandskinplate
(HeredesigniscarriedoutforstiffneratsectionCDduetohigherloadatthatsection)
RaXaXy
Ixx
Where,
Max.loadonstiffner,Ra
12427.7
Areaofflangeof"T"section,a
VB
t
14
Distanceofcentroidofarea"a"fromneutralaxis,y
78.2
1094.8
mm2
y1
t/2
20.1
7.0
13.1
mm
Momentofinertiaof"T"section,Ixx
Hence,1
728486
mm
12427.7
1094.8
13.1
728486.4
1
18.2
244.6
N/mm
Checkofweldingandshearstrengthatconnectionofwebplateofhorizontalgirderandskinplate
RaXaXy
Ixx
Where,
29211.1
Max.loadongirder,Ra
VB1+VB2
349.40
t
14
2
4891.6
mm
y1
t/2
147.9
7.0
140.9
mm
259124890
Hence,2
29211.1
4891.6
259124890.0
77.7
N/mm
140.9
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
18.3
REV:02
Page
Checkofweldingandshearstrengthatconnectionofflangeplateandwebplateofhorizontalgirder
RaXaXy
Ixx
Where,
29211.1
Max.loadongirder,Ra
wf
160.0
tf
16.0
2
2560.0
mm
y2
t/2
232.1
8.0
224.1
mm
259124890
Hence,3
29211.1
mm4
2560.0
224.1
259124890.0
3
18.4
64.7
N/mm
Weldsrengthbetween(i)flange&webofhorizontalgirderand(ii)skinplate&webofhorizontalgirder
StrengthofweldofSize"s"
2X0.7XsXs
Where,
Weldsize,s
mm
Allowableshearstress,s
100
MPa
Hence,Strengthofweld
840
N/mm
Here,thevaluesofweldstrengthishigherthanthemaximumshearforce(1,2&3)calculatedforabovementionedcases.So,6mm
weldingsizeissafeforconnectionof(i)Skinplate&webofhorizontalgirderand(ii)webplate&flangeplateofhorizontalgirder.
Herewehavecalculatedweldstrengthforcasewhereloadingishigherandhenceitisselfexpanatorythatweldingatdifferentsectionsis
undersafelimit.
19
CALCULATIONOFCENTREOFGRAVITY
Centreofgravityformajorpartsofgatesiscalculatedasbelow:
Sr.No.
DESCRIPTION
SkinPlate
HorizontalWebPlate
FlangePlate
Stiffener
EndPlateplate
DISTANCEFROMU/SFACE
OFSKINPLATE(mm)
WEIGHT
(Kg)
WxL
225.0
1800.0
191
101.0
19291.0
17428.4
374
46.6
64.85
26.7
1731.5
108
120.0
12960.0
Wheelassembly(Appx.)
62
120.0
7440.0
Rubbersealingassembly(Appx.)
18.2
14.2
258.4
Ballast
202
200.0
40400.0
854
TOTAL
C.G.ofgatesfromU/Sofskinplate
100792.5
854
118.1
100792.5
mm
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
173
=
20
mm
REV:02
Page
(Adopted)
HOISTCAPACITYCALCULATIONFORMWLCONDITION
WeightofGateLeaf
1.000
(Appx.)
0.965
(Appx.)
9.467
KN
(Appx.)
Guiderollerfrictionforce
0.947
KN(10%ofGateWeight)
ForceduetoRollerfriction(F)
Where,P
=
=
faxr+fr
AreaX(Avg.Head)+WgCos75
1650.0
3046.6
=
P
(Takinginclinedconditiongateweight=ActualGateweightXSin(75o))
1210.0
0.0000 +
3046.6
3.0 KN
Where,
C/Cofsideseal
1200
mm
Silltocloftopseal
1100
mm
Avg.headforMWLCondition
0.0
t/m
Wheelradius(R)
100
mm
AxleFriction(fa)
0.01
RollerFriction(fr)
110
Effectiveradiusofbearing22212(r)
Balanced head condition
60
42.5 mm
ForceduetoRollerfriction,F
0.043
KN
ForceduetoSealfriction,FS
(bxLxh+FxL)
Widthofcontactofseal
Where,
b
L
Slidinglengthofseal
Avg.Waterheadonseal
Initialcompressiveforceofrubberseal
Coefficientoffriction
0.2
(PTFErubbertostainlesssteel,ReferAppendixFofIS5620)
Wehaveconsidered5mmDeflectionOrCompressionofrubberseal
Doublestemtyperubbersealhaving50mmdiaofbulbx150mmlong.
Rubbersealincontactwithsealseat
b
30
mm
Forcedevelopedinsealduetoinitial
%mmcompressionF
12.0
N/mm
Fs(Side)
30
+
5853
1100
x
1100
0
)X
0.2
Fs(Side)
Fs(Top)
3193.0
3.19
KN
Fs(Top)
12.0
5.85 KN
30
SiderubbersealFriction
x
1200
12.0
1200
ToprubbersealFriction
0.2
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
TotalSealFriction
9.0
REV:02
Page
KN
UpliftduetoDifferentialpressure =
(P6
(0.00
0.00
Where,A =
P2)
0.00) X
N
540200
(GateClosingunderBalancedHeadCondition)
WidthofgirderXdepthofgirder
1480
365
540200 mm2
=
DownwardforcewhileclosingofGate,
Lowering
Rising
a)
GateLeaf
9.467
(l)
9.467
(l)
b)
RollerFriction
0.043
(l)
0.043
(j)
c)
Guidefriction
0.947
(l)
0.947
(j)
d)
SealFriction
9.046
(l)
9.046
(j)
e)
Upliftforce
0.000
(j)
0.000
(j)
19.503
(l)
0.569
(l)
SelfLoweringforce =
0.569
KN
Seatingload0KN/masGatewillbeClosedinbalancedHeadConditiononly
=
1.200
x
0
Seatingpressure =
0
KN
Hereselfloweringforcesislessthanseatingforcerequired.Henceballastisrequiredtoclosethegate.
Minimumballastrequired
Minimumballastrequired
BallastProvided
Bouancyforceactingongateduring
lowering
=
=
=
0.57
0.59
1.96
wXw
s
11.4
=
=
KN
KN
KN
o
(Takinginclinedconditionballastrequired=Ballastreq./Sin(75 ))
x
kN
1
7.85
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
Where,
w
s
w
=
=
=
ThehoistcapacityisrequiredtolifttheGate
=
Hoistcapacityincluding30%reserve
Hoistcapacityprovided
21
11.4
7.85
1
kN
t/m
t/m2
9.5
21.5
27.9
KN
2.8
tonne
3.0
ton
REV:02
Page
(weightofgateincludingBallast)
(Densityofsteel)
(Densityofwater)
0.043
0.947
9.0
1.96
KN
(AsperSTS7.3Farabdocument:H30MG02G00204)
CHECKOFGATEUNDERSEISMICLOADING
Increseinwaterpressure,P
Cxaxwxh
0.75
0.018525
0.19
0.00001
13
13000
MPa
Where,
Dimensionlesspressurecoefficient,C
0.75
Earthquakeintensity,a
0.19
(Considered)
Specificweightofwater,w
Totalreservoirdepth,h
976.00
NormalwaterheadatFRL,h
0.12753MPa
%increseinwaterthrust
0.018525
0.00001
N/mm
963
100
m=
13000
mm
15 %
0.12753
Increseinwaterthrustduetoearthquakei.e.15.1%islessthanallowableincreaseinthrust(33%)andhenceirrigationgateissafeunderearthquake
condition.
22
LIFTINGPLATEANDWELDDESIGN
Maximumshearforceatjunction,t
=
2X
Where,
Allowableshearstress,ss
0.707
Lengthofweld
545mm
Loadononeplate
30000N
Sizeofweld
6mm
540
0.3
162
MPa
Maximumshearforceatjunction,t
(AsperAWSCl.No.2.5.4.2forE7018electrode)
P
=
2X
=
XL
6.5
0.707
XL
MPa
Here,thevaluesofweldstrengthishigherthanthemaximumshearforceso6mmweldissafefortheabovegivenconnectionbetweenliftingplateandtop
girder.
INTAKEGATE
EMPLOYERDOC.NO.:
UOIIIDYDIMGHRP001
Bearingstress,s
(Thicknessofliftingplate)T
P
A
(Thicknessofpadplate)T'
16 mm
8 mm
Diaofholeinplate
40 mm
Where,
Loadonliftingplates,P
Area,A
Hence,sbearing
60000N
30000
(16
40
1280
mm2
47
(Where2isImpactfactor)
+16)
MPa
<
112.5
SAFE
MPa
Shearstressinliftingplate,
Shearstress,s
Area,A
Hence,stension
P
A
(16
4624
289)
X
2
mm
60000
4624
13.0
MPa
<
75.0
MPa
SAFE
(Allowablebearingstress=0.45xYp)
REV:02
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Design Calculations For Irrigation Maintenance Intake Gate

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Balanced head condition

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