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
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
1.4.3.8 Anchorages
An embedded structural member, transferring load from gate to its surrounding structure.
Figure 1.3 Rope Drum Hoist Arrangements for Vertical Dam Gate
1.7
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.
1.8
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.
10
MWL =589.2 cm
(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.
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
2.4
Total hydrostatic head c/c tracks c/c side seals Height of the bottom unit Height of the top unit Total load on gate
p1
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
Figure 2.1 Diagram for Skin Plate, Stiffener Along With Panels
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
14
2.5
For maximum bending moment, equating shear to zero: 0.5 (P2-P4)/(10 l2 100) X 2+(P4/10) X= Rb 0.5 (10.09-9.19)/(10 0.9 100) X2+9.19/10 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 = 42.7
15
Figure 2.4 Bending Moment Diagram for Stiffener Panel A-B 2.6
2.7
22.512 Y2=5.77
bs2
2.8
17
2.9
18
Vi a
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
23.54 22706.58
= 17.16 cm
= 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
Sgb1 L1/
Modulus of elasticity E
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,
= [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
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 Area 56.523 0.4 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
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
Bending stresses in girders fgc1 fgc2 fgc3 = bmgc/Zgc1 = 953.3 kg/cm2 = 630.58 kg/cm2 =662.28 kg/cm2
21
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
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
Check
PC = 2 (RA+RB+RC)/1000 = 2 (1.22 104+1.7 104+1.21 104)/1000 = 82.6 t
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
23
Effective width of skin plate li = 0.6 Y2, b =a/2, li/b=5.44, a5 = 3.25+13+0.85 16 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 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
24
feg1 feg2
= M3/Zeg1 = M3/Zeg2
Zp
= db3/32
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
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P5 P6 P7
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
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Figure 2.16 Bending Moment Diagram for Stiffener Effective width of skin plate, (We) l2 = 1.2 m, From IS 4622,Vi = 0.83 l2 100/(0.5 a) We T1= 0.8 cm = 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
Sectional properties
Section Area Y 0.5 4.35 8.1 Ay Y1,Y2 Y AY2 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
1.75 81.34 1.9 19.35 5.6 188.16 = 2.25 cm = 6.25 cm =146.83cm3 = 52.86 cm3
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
RB RC
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
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
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
31
Length of side seal Length of top seal Head on top seal Effective leaded with of seal Ws Frictional co-efficient F2
Ht L2 Ht
= [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
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 b Shear stress Combined stress Calculated values : Direct/bending stress h Shear stress of girder Combined stress = = c 683.14 kg/cm2 557.75 kg/cm2 = 1.2 103 kg/cm2 33 = c 1.02 103 kg/cm2 = = 765 kg/cm2 1.27 103 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.
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PHOTOGRAPHY
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