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PT.

Malea Energy
Head Offices : Bukaka Industrial Estate
Jl. Raya Bekasi Cibinong Km 19.5, Cileungsi, Bogor 16820, Indonesia
Phone : (62-21) 823 2323
Branch Offices : Makassar
Jl. HOS Cokroaminoto No.27, Sulawesi Selatan, Indonesia
Phone : (62-411) 311 111

DESIGN CALCULATION

PROJECT NAME : PLTA MALEA STAGE-1 (2x45 MW)

PROJECT CODE : LH16

PROJECT OWNER : PT. MALEA ENERGY

DEPART/AREA : INTAKE

DOCUMENT NO. : CAL LH16-M04-D03-CA-001

DESCRIPTION / TITLE : CALCULATION OF EMERGENCY GATE AT INTAKE

WRITTEN BY : IKI DATE : 9/1/2017

APPROVED BY : YSS DATE: :

TITLE OF REVIEWER : ENGINEERING COORDINATOR

PT. Bukaka Teknik Utama


HYDROPOWER ENGINEERING DIVISION
Jl. Raya Bekasi Cibinong Km 19.5, Cileungsi, Bogor 16820, Indonesia
Phone : (62-21) 823 2323
No.Ref :
LH16-C16-G03-DE-001 ENGINEERING CALCULATION SHEET
Date : 9/1/2017 PT.Bukaka Teknik Utama

PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
LOCATION : MAKALE, TANA TORAJA TITLE : CALCULATION OF EMERGENCY GATE AT INTAKE REV : A PAGE : i OF i

CONTENTS

1. GENERAL ................................................................................................................................. 1
1.1 Project overview ................................................................................................................................. 1
1.2 Basic Information of the Gate ................................................................................................................................. 1
1.2.1 Design information ................................................................................................................................. 1
1.2.2 Structure specification ................................................................................................................................. 1
1.2.3 References ................................................................................................................................. 1
1.2.4 Design standards ................................................................................................................................. 1

2. CALCULATION OF HYDRAULIC PRESSURE ......................................................................................................................... 2


2.1 Calculation of Hydraulic Pressure ......................................................................................................................... 2
2.2 Calculation Effec at Earthquake ......................................................................................................................... 2

3. PRELIMINARY ESTIMATE OF SKINPLATE THICKNESS ......................................................................................................................... 2

4. SECONDARY GIRDER CALCULATION ................................................................................................................................. 3


4.1 Load Calculation Of Secondary Girder ................................................................................................................................. 3
4.2 Check For Secondary Girder ................................................................................................................................. 4

5. MAIN GIRDER CALCULATION ...................................................................................... 6


5.1 Calculation Of Main Girder Load ...................................................................................... 6
5.2 Check The Top Main Girder Of The Gate Leaf At Bottom Section ...................................................................................... 6

6. CHECKING CALCULATION FOR REDUCED STRESS OF SKINPLATE ...................................................................................... 8

7. DESIGN CALCULATION OF SLIDE TRACK AND RAIL ............................................................................................................ 8


7.1 Calculation For Slide Track Selection ............................................................................................................ 8
7.2 Design Calculation Of Rail ............................................................................................................ 8

8. CALCULATION OF SPRING OPPOSED WHEEL ............................................................................................................. 9


8.1 Spring Load Bearing Calculation ............................................................................................................. 9
8.2 Calculation Of Spring Travel Distance ............................................................................................................. 10
8.3 Design Calculation Of Spring ............................................................................................................. 10

9. CALCULATION OF HOISTING FORCE ............................................................................................................. 10


9.1 Calculation Of Lifting Force For The Gate Leaf ............................................................................................................. 10
9.2 Calculation Of Closing Force ............................................................................................................. 11

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
APPROVED BY : YSS SIGNATURE : DATE :
No.Ref :
LH16-C16-G03-DE-001 ENGINEERING CALCULATION SHEET
Date : 9/1/2017 PT.Bukaka Teknik Utama
PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
LOCATION : MAKALE, TANA TORAJA TITLE : CALCULATION OF EMERGENCY GATE AT INTAKE REV : A PAGE : 1 OF 12

1. GENERAL
1.1 Project overview
The Malea Hydropower Station is located on the Saddang River, at Central Sulawesi Province, in the east part
of the Republic of Indonesia, which is the first cascade hydropower station under the Cascade Hydropower
Planning of Saddang River. This station is constructed in low-weir and diversion type, with an installed capacity
of 2 45 MW for Phase I and planned 3 75 MW for Phase II.
The main hydroproject buildings of the head junction in the left right order are left-bank
gravity dam, fishway, release sluice, scouring sluice, water intake and right-bank gravity dam.
Headrace steel pipes, steel surge tank, penstock and ground powerhouse are connected to the water intake
downstream the Saddang River

1.2 Basic Information of the Gate


1.2.1 Design information

Description = Emergency Gate at Intake


Type = Fixed Wheel Gate
Equipment No. = M04-GTE-01A/B
Quantity of Gate = 2 set
Clear span = 5.50 m
Effective span = 6.10 m
Clear height = 3.50 m
Normal head = 7.00 m
Abnormal head = 9.48 m
Design head
Elevation T.O.C = 737.50 m
Elevation M.W.L = 734.48 m
Elevation F.S.L = 732.00 m
Elevation B.O.C = 725.00 m
Type of hois = Fixed wire rope hoist is used, one gantry for one gate
Seismic Coefficient = 0.15 g

1.2.2 Structure Specification

The gate consists of a cover plate , main beam , the main wheel , vertical beam end , vertical stringers , rubber seals ,
steering roller side , lifting lugs and all the necessary components . To be considered in order threaded rod and lifting
equipment gate to make it straight and was able to lift weights , no changes due to the flow of water , so that no
vibration occurs or Other forms of phenomena . On the horizontal main beams must be provided holes to drain the
water . Sealing with welding can be performed when needed to the density of the water leak .

1.2.3 References
(1) General Layout of head complex, (MHP-BD-HC-1-01-01) ;
(2) Upstream view of dam, (MHP-BD-HC-1-01-02) ;
(3) Typecal section of , (MHP-BD-HC-1-01-03).

1.2.4 Design standards


(1) Specification for Design of Steel Gate in Hydraulic and Hydroelectric Engineering (DL/T5039)
(2) Indian Standards (IS : 4622-2003)
(3) Japanese Industrial Standards (JIS)
(4) Code for Seismic Design of Hydraulic Structure of Hydropower Project (NB 35047-2015)

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
APPROVED BY : YSS SIGNATURE : DATE :
No.Ref :
LH16-C16-G03-DE-001 ENGINEERING CALCULATION SHEET
Date : 9/1/2017 PT.Bukaka Teknik Utama
PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
LOCATION : MAKALE, TANA TORAJA TITLE : CALCULATION OF EMERGENCY GATE AT INTAKE REV : A PAGE : 2 OF 12

2. CALCULATION OF HYDRAULIC PRESSURE


2.1 Calculation of Hydraulic Pressure

Fig 2.1 Gate and water elevation

= Water density 1.00 tf/m3


Hs = Design head 9.48 m
h = Sealing height 3.50 m
Bzs = span of side seals 5.62 m
g = Seismic Acceleration 0.15

Total hydraulic pressure


Pw = 0.5 x x (2Hs - h) x h x Bzs 152.05 tf

2.2 Calculation Effec at Earthquake


Static Water Pressure at Eartquake (Ps)
P0 = P x 1.13 171.82 tf

3. PRELIMINARY ESTIMATE OF SKINPLATE THICKNESS


The thickness of the preliminarily selected skinplate is calculated accroding to the following :

Where,
Ky : is the bending stress coefficient at the middle point of the long edge of thin elasto-plastic
bearing skinplate, which is selected as per Table G1 in Appendix G of the gate design specification
q : the hydraulic pressure intensity at the center of skinplate calculation grid (MPa)
, b : the lengths of the short edge and the long edge of skinplate calculation grid, which is counting from
the attachment weld between the skinplate and the main (secondary) girder (mm).
: elastoplasticity adjustment coefficient
( when b/a > 3 1.4 b/a 3 = 1.5 )
[] : the bending allowable stress of steel.
Used Material : Q235 = 230 MPa

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
APPROVED BY : YSS SIGNATURE : DATE :
No.Ref :
No.Ref : ENGINEERING CALCULATION SHEET
Date : 9/1/2017 PT.Bukaka Teknik Utama
PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
LOCATION : MAKALE, TANA TORAJA TITLE : CALCULATION OF EMERGENCY GATE AT INTAKE REV : A PAGE : 3 OF 12

Computation sheet for the preliminarily estimated and reduced stresses of the skinplate
(No. from bottom to top):

Long edge Short edge Hydraulic pressure Skin Plate thickness


S/N b/a Ky
b (mm) a (mm) q (MPa) (mm)
1 1100 474 2.321 0.500 0.0612 4.464
2 1100 539 2.041 0.499 0.0668 5.298
3 1100 614 1.792 0.486 0.0745 6.295
4 1100 664 1.657 0.473 0.0815 7.019
5 1100 829 1.327 0.419 0.0879 8.564

Considering certain corrosion thickness, the thickness of the skinplate is selected as


11 mm and 1 mm corrosion allowance will be considered for all follow-up calculations,
and the skinplate thickness is taken as = 10 mm

4. SECONDARY GIRDER CALCULATION


4.1 Load Calculation Of Secondary Girder
Refer to the diagram above for details of arrangement of secondary girder. Load intensity:
q : Load intensity
H : the hydraulic pressure in the load width center of secondary girder ( N / mm 2 )
B : load width of secondary girder ( mm )
load calculation of secondary girder (No. from bottom to top, seismic load is considered):

Hydraulic pressure Load width Load intensity


S/N
H ( N / mm2 ) B (mm) q (N/mm)
1 0.0598 143.33 8.571
2 0.0627 411.67 25.798
3 0.0709 363.33 25.760
4 0.0782 331.67 25.925
5 0.0848 306.67 26.005
6 0.0909 203.33 18.490

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
APPROVED BY : YSS SIGNATURE : DATE :
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Date : 9/1/2017 PT.Bukaka Teknik Utama
PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
LOCATION : MAKALE, TANA TORAJA TITLE : CALCULATION OF EMERGENCY GATE AT INTAKE REV : A PAGE : 4 OF 12

4.2 Check For Secondary Girder


(1) Internal force calculation
The gate is designed as per 6-span continuous girder, with secondary girder load
q1 : secondary girder load = 18.490 N/mm
l : maximum span = 1100 mm
: Bending moment coefficient = 0.105
: shear force coefficient = 0.606
: deflection coefficient = 0.644

The diagram below is the force diagram of the secondary girder:

26.01 N/mm

l
A B C D E F G

Fig4.2 diagram below is the force diagram of the secondary girder

Maximum bending moment:


Mmax = x q1 x l 2 = 2349126.27 N.mm

Maximum shear force:


Qmax = x q1 x l = 12325.29 N

(2) Section characteristics


Section detail of secondary girder is shown as the figure on the right.
l 0 : Zero bending moment distance = 440.00 mm
B : 24 x t = 464.00 mm
2
A1 : sectional area = 2196.20 mm
4
I : cross sectional moment of inertia = 8660000.00 mm
h : section height = 160.00 mm
b : section width = 63.00 mm
d : web thickness = 6.50 mm
t : flange plate thickness = 11.50 mm
: calculat thickness of the skinplate = 10.13 mm
A2 : The action area with skinplate = 4701.63 mm2
A : Total area = 6897.83 mm

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
APPROVED BY : YSS SIGNATURE : DATE :
No.Ref :
LH16-C16-G03-DE-001 ENGINEERING CALCULATION SHEET
Date : 9/1/2017 PT.Bukaka Teknik Utama
PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
LOCATION : MAKALE, TANA TORAJA TITLE : CALCULATION OF EMERGENCY GATE AT INTAKE REV : A PAGE : 5 OF 12

Position of the neutral axis (to the leading edge of the skinplate):

Y1 = = 32.15 mm

Y2 = + h - y1 = 137.98 mm

Cross sectional moment of inertia to Axis X :

4
Ix = = 19532607.86 mm

Modulus of bending section:


3
W1 = Ix / y 1 = 607532.57 mm
3
W2 = Ix / y 2 = 141559.00 mm

Static moment of neutral surface:

S0 = = 147794.75 mm3

(3) Checking calculation of strength


Used material is : Q235B
[] = 160.00 MPa [] = 95 MPa
Positive stress:
1 = Mmax / W1 = 3.87 MPa safe
2 = Mmax / W2 = 16.59 MPa safe
Shear stress:
= Qmax . S0 / Ix . d = 14.35 MPa safe

Reduced stress:
2 2 safe
zh = 2 + 3 = 29.88 MPa
[ ] = 1.1 x = 176.00 MPa

(4) Deflection check

f max = = 0.04 mm

f max / l = 0.0000394 mm

Allowable deflection ; [f] = l / 250 = 4.40 mm OK

The deflection meets requirements

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
APPROVED BY : YSS SIGNATURE : DATE :
No.Ref :
LH16-C16-G03-DE-001 ENGINEERING CALCULATION SHEET
Date : 9/1/2017 PT.Bukaka Teknik Utama
PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
LOCATION : MAKALE, TANA TORAJA TITLE : CALCULATION OF EMERGENCY GATE AT INTAKE REV : A PAGE : 6 OF 12

5. MAIN GIRDER CALCULATION


5.1 Calculation Of Main Girder Load
- Flat Submerged gates

No. Girder yk (m) hk (m) Where : b1 = 0.287 m


A 0 5.980 b2 = 0.823 m
B 1 6.267 5.277 b3 = 0.727 m
C 2 7.090 6.591 b4 = 0.663 m
D 3 7.817 7.684 b5 = 0.613 m
E 4 8.480 8.640 b6 = 0.407 m
9.093 5.98 2
F 5 9.500 P1 = tf/m
P2 = 6.27 tf/m2
P3 = 7.09 tf/m2
W = Design Load = 34.74 tf P4 = 7.82 tf/m2
lo = Effective span = 6.06 m P5 = 8.48 tf/m2
lh = Sealing width = 5.62 m P6 = 9.09 tf/m2
P7 = 9.50 tf/m2

Top Beam = b1 x (2P1 + P2)/ 6 x B ( 5.53 ) tf


Beam B = {b1 x (P1 + 2P2)/ 6 + b2 x (2P2 + P3)/ 6} x B ( 22.72 ) tf
Beam C = {b2 x (P2 + 2P3)/ 6 + b3 x (2P3 + P4)/ 6} x B ( 34.74 ) tf
Beam D = {b3 x (P3 + 2P4)/ 6 + b4x (2P4 + P5)/ 6} x B ( 34.41 ) tf
Beam E = {b4 x (P4 + 2P5)/ 6 + b5 x (2P5 + P6)/ 6} x B ( 34.31 ) tf
Beam F = {b5 x (P5 + 2P6)/ 6 + b6x (2P6 + P7)/ 6} x B ( 29.23 ) tf
Bottom = {b6 x (2P6 + P7)/ 6} x B ( 11.92 ) tf
172.85
Note : Because the maximum design load work at point C , then
bending moments and shear forces calculated only Beam C

5.2 Check The Top Main Girder Of The Gate Leaf At Bottom Section
(1) Calculation of internal force
Diagram of the force on the main girder:

Fig 5.1 Diagram of the force on the main girder


Where,
W : Design Load = 340647.43 N
l h : Where, the seal width of gate = 5620.00 mm
lo : Bearing span of gate = 6060.00 mm
q : Load of main girder W/ l h = 60.61 N/mm

Maximum shear force:


Qmax = 1/2 x q x l h = 170323.72 N

Maximum bending moment:

Mmax = = 276776037.09 N.mm

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
APPROVED BY : YSS SIGNATURE : DATE :
No.Ref :
LH16-C16-G03-DE-001 ENGINEERING CALCULATION SHEET
Date : 9/1/2017 PT.Bukaka Teknik Utama
PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
LOCATION : MAKALE, TANA TORAJA TITLE : CALCULATION OF EMERGENCY GATE AT INTAKE REV : A PAGE : 7 OF 12

(2) Section characteristics


516
9
11 300

400 9

11 300

Detail of the cross section of main girder is shown in the figure below, and its
parameters are listed in the table below:
2
Lenght Width A y' Ay' y Ay
Item
(mm) (mm) (mm2) (mm) (mm3) (mm) (mm4)
Skin plate 516.00 9 4644 4.50 20898 -148.08 101832220.1
Leading flange 300 11 3300 14.50 47850 -138.08 62918114.59
Web 400 9 3600 220.00 792000 67.42 16363627.34
Rear flange 300 11 3300 425.50 1404150 272.92 245801518.9
14844 2264898 426915480.9

Position of the neutral axis (to the leading edge of the skinplate):
y1 = Ay' / A = 152.58 mm
y2 = t1 + t2 + h0 + t4 = 278.42 mm
Cross sectional moment of inertia to Axis x:
Ix = = 475013377.92 mm4

Modulus of bending section:


W1 = Ix / y1 = 3113208.00 mm3
W2 = Ix / y2 = 1706103.85 mm3
Static moment of neutral surface:
2
S = b1.w4.(y2-w4/2))+((tf.(y2-w4) )/2 = 1222446.37 mm3

(3) Checking calculation of strength


Used material is : Q345 B steel
[] = 220.00 MPa [] = 130 MPa
Positive stress:
1 = Mmax / W1 = 88.90 MPa safe
2 = Mmax / W2 = 162.23 MPa safe
Shear stress:
= Qmax . S0 / Ix .t = 48.70 MPa safe

Reduced stress:
2 2 safe
zh = 2 + 3 = 182.85 MPa
[ ] = 1.1 x = 242.00 MPa
The strength meets requirements

(4) Deflection check

f max = = 10.88 mm

f max / l = 0.0017950 mm
Allowable deflection ; [f] = l / 500 = 12.12 mm OK

The deflection meets requirements

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
APPROVED BY : YSS SIGNATURE : DATE :
No.Ref :
LH16-C16-G03-DE-001 ENGINEERING CALCULATION SHEET
Date : 9/1/2017 PT.Bukaka Teknik Utama
PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
LOCATION : MAKALE, TANA TORAJA TITLE : CALCULATION OF EMERGENCY GATE AT INTAKE REV : A PAGE : 8 OF 12

(5) Checking calculation of overall stability


l 1 : The maximum interval of the lateral bearing points of pressure flange = 1100.00 mm
b1 : Width of the lower flange = 300.00 mm
The girder is made of Q345 B steel , and provided with lateral support at the middle of span.
Code for Design of Steel Structure:
l 1 / b1 = 3.67 < 16.
The overall stability checking calculation of girder can be skipped.

(6) Checking calculation of local stability


ho / tw = 44.44 OK
the local stability meets the requirements.

6. CHECKING CALCULATION FOR REDUCED STRESS OF SKINPLATE


Checking calculation is carried out for the Grid 3 adjacent to the top main girder of
the gate leaf at bottom section in the preliminary estimation of skinplate thickness.
Hydraulic pressure intensity at the center of skinplate calculation grid: q = 0.0668 MPa
a : Length of the short edge of skinplate calculation grid = 539.00 mm
b : Length of the long edge of skinplate calculation grid = 1100.00 mm
b/a = 2.04 mm
Bending stress coefficient at the middle point of the long edge of thin elasto-plastic
ky : bearing skinplate obtained via look-up: = 0.50
: Elasto-plasticity adjustment coefficient = 1.50
: Skinplate thickness = 10.13 mm
Local bending stress in the center of long edge of bearing skinplate in the direction
perpendicular to the axis of main (secondary) girder:

my = = 94.31 MPa

Local bending stress of skinplate grid along the axis of main (secondary) girder:
mx = = 28.29 MPa
Overall bending stress of the upper flange of main (secondary) girder corresponding
to the skinplate checking calculation point:
ox = = 8.49 MPa
Reduced stress of skinplate:

= 86.13 MPa OK

It meets the requirements

7. DESIGN CALCULATION OF SLIDE TRACK AND RAIL


7.1 Calculation For Slide Track Selection
Each section of gate leaf shall be provided with 4 slide tracks at the support of main girder and
the effective length of each slide track is : 500 mm. The slide track is made of
high-strength steel based POM composites. The load on unit length of slide track is calculated based on
the assumption that force is born by top main girder of the gate leaf at bottom section:

= 0.34 MPa

F1 : Sliding friction coefficient is considered as = 0.15 MPa

7.2 Design Calculation Of Rail


The main rail is formed by welding and mainly made of Q345 B steel
The section of rail is shown in the figure below:

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
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PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
LOCATION : MAKALE, TANA TORAJA TITLE : CALCULATION OF EMERGENCY GATE AT INTAKE REV : A PAGE : 9 OF 12

240

90 60

40

Fig 7.2 The section of rail

Bk : In the above figure, width of base plate of rail = 240.00 mm


: Thickness of base plate = 40.00 mm
S : Width of railhead fitting with slide track = 60.00 mm
c : Length of cantilever section of base plate = 90.00 mm

(1) Bearing stress of concrete of rail base plate:


h = qh / Bk = 1.42 MPa
Concrete strength is C30 [ h ] = 11.00 MPa

(2) Bending stress of rail base plate:


2 2
= 3 h c / = 21.557 OK

To sum up, the strength of supporting rail meets requirements

8. CALCULATION OF SPRING OPPOSED WHEEL


8.1 Spring Load Bearing Calculation
Total length of water seal : L = 7000.00 mm
The P60-A rubber and plastic water seal (including PTFE) is adopted, and
when the pre-compression length of water seal is 2 mm, the precompression is: = 4.10 N
compressing force of water seal Ps = 28700.00 N

Provided with 8 120 mm spring opposed wheels and


stress of each opposed wheel is: P = 3587.50 N

Pressure of each spring:


F = P * 145 / 125 + 145 = 1926.62 N

Fig 8.1 The section of wheel

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
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PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
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8.2 Calculation Of Spring Travel Distance


The total height of spring opposed wheel before and after entering gate slot is h = 198.00 mm
h' = 188.00 mm
Wheel displacement = 10.00 mm
spring travel distance H = 18.62 mm

8.3 Design Calculation Of Spring


Spring shall be YA 16 65 240 GB / T 2089. It is known from specifications that:
Spring material: = 60Si2Mn
structural type = End tightened up and ground flush
supporting ring: n2 = 2.00
diameter d = 16.00 mm
intermediate diameter D = 65.00 mm
effective cycles n = 8.50
free height H0 = 240.00 mm
spring stiffness F' = 277.00 N/mm
maximum working load Fn = 14642.00 N
maximum working deformation fn = 53.00 mm
piece weight of spring m = 3.36 kg

Calculation to be carried out as per above data


Total cycles of spring n1 = n + n2 = 10.50
Pitch t = H0 - 1.5 d / n1 = 20.57 mm
o
Pitch angle = Arctan t / D = 5.75
Spread length L = D n1 / cos = 2154.99 mm

(1) Spring height in limiting condition Hj = H0 - fn = 187.00 mm


Spring pressure in limiting condition Pj = Fn = 14642.00 N
(2) Spring height in working condition H2 = H0 - F / F' = 233.04 mm
Spring pressure in working condition F = 1926.62 N
(3) Spring height before opposed wheel entering slot H1 = H0 - F/F'+ H = 251.67 mm
Spring precompression before opposed wheel entering slot: P1 = F - H.F' = -3231.31 N
(4) In case of water seal to be compressed by 4 mm
after water retaining, height of spring opposed wheel: h' + 4 - n2 = 190.00 mm

9. CALCULATION OF HOISTING FORCE


9.1 Calculation Of Lifting Force For The Gate Leaf
The gate leaf is lifted in the dynamic water.
The total water pressure of the top gate leaf is: Pw = 1520.49 kN
(1) Frictional resistance of slide track
Sliding friction coefficient f1 = 0.15
Frictional resistance of slide track Tzd = f 1 P1 = 228.07 kN

(2) Frictional resistance of water seal


The P60-A rubber and plastic water seal (including PTFE) is adopted, and when the
pre-compression length of water seal is 4mm, the precompression is e = 5.80 N/mm
The friction coefficient of water seal and stainless steel f2 = 0.20
Seal height h1 = 3.80 m
Action width of water seal Bzs = 5.62 m
Design head Hs1 = 5.98 m
Action width of water seal z = 0.07 m
3
Water density = 10.00 kN/m
Water deal precompression Tzd1 = e (2h1 + Bzs) = 76.68 kN

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
APPROVED BY : YSS SIGNATURE : DATE :
No.Ref :
LH16-C16-G03-DE-001 ENGINEERING CALCULATION SHEET
Date : 9/1/2017 PT.Bukaka Teknik Utama
PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
LOCATION : MAKALE, TANA TORAJA AREA : CALCULATION OF EMERGENCY GATE AT INTAKE REV : A PAGE : 11 OF 12

Water pressure borne by water seal


= 30.28 kN

Frictional resistance of water seal


= 21.39 kN
(3) Lifting force
Weight of top gate leaf G1 = 115.00 kN (estimation)
Weight of mechanical pick-up beam G2 = 23.00 kN (estimation)
Fw = 1.2 (Tzd + Tzs ) + 1.1 (G1 +G2) = 451.16 kN

The 451 kN, Fixed wire rope hoist is used, one gantry for one gate, which meets the requirements.

9.2 Calculation Of Closing Force


The gate will be closed in static water by relying on its dead weight. Therefore, there
is no need to calculate closing force

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
APPROVED BY : YSS SIGNATURE : DATE :
No.Ref :
LH16-C16-G03-DE-001 ENGINEERING CALCULATION SHEET
Date : 9/1/2017 PT.Bukaka Teknik Utama
PROJECT : PLTA MALEA STAGE-1 (2X45MW) AREA : INTAKE DOC.NO : CAL LH16-M04-D03-CA-001
LOCATION : MAKALE, TANA TORAJA TITTLE : CALCULATION OF EMERGENCY GATE AT INTAKE REV : A PAGE : 12 OF 12

10. SKETCH OF DESIGN

DESIGNED BY : IKI SIGNATURE : DATE :


REVIEWED BY : SBR SIGNATURE : DATE :
APPROVED BY : YSS SIGNATURE : DATE :