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GREY HOUND ENGINEERS (INDIA) Private Limited

Page No: 1
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

Design of Draft Tube Gates


Rampur HEP (H.P) Package II

1.0 Technical Details :

Ref : Technical specification and Drawing No.: GHE/SJVNL/RHEP/DTC 210 Rev 0

No of vents : 6Nos.

Clear width of opening : 7814mm

Clear height of opening : 3591mm

No. of EM parts : 6 sets

No. gates : 6 sets (Each having 2 elements. with flexible

joint and operated by independent rope drum

hoist under balanced head condition. The

balancing is achieved by 2Nos. filling

valves fitted in top element)

Sill level : EL 849.19M

Max. flood level : EL 873.000M

Deck slab level : EL 878.000M

Design Head Normal condition : 873.000- 849.19= 23.810M

Skin Plate : On downstream side (Turbine side)

Seals : On downstream side (Turbine side)

C/C of side Seals : 7914mm

C/C of tracks : 8314mm

Sill to top seal C/L : 3566mm

End to end of groove : 8950mm

Type of gate : Vertical type roller gate

Designed as per : IS 4622 -2003.


GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 2
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

Operated by : Individual rope drum hoist.

2.0 Material :

S No. Components Proposed Remarks


All structural members like skin
plate, end box, vertical stiffeners, IS : 2062 2006
1 Structural Steel
horizontal girders, Roller track Grade E250A /B
girder, Sill beam seal Crest etc.,
2 Rollers Cast Steel / Forged steel IS 1030
20Cr13
3 Roller pins Stainless Steel
IS : 1570 (Part V)
20Cr13
4 Roller Track Stainless Steel
IS : 1570 (Part V)
04 Cr19 Ni 9
5 Seal Seats Stainless Steel
IS : 1570 (Part V)
6 Seals Rubber Tefflon cladded IS : 11855
7 Bearings Anti Friction Bearings SKF / NSK / ZKL

3.0 Permissible Stresses: As per IS:4622 - 2003

I. Embedded Parts As per IS 4622 - Wet and Inaccessible condition


1. Structural steel IS 2062 2006 Grade E 250B
Stresses in kg/cm2
S.No Type of stresses Factor Thk < 20mm Thk 20 40mm
YP :2550kg/cm2 YP : 2448kg/cm2
UTS:4180kg/cm2 UTS:4180kg/cm2
1 Direct compression and 0.40YP 1020 979
compression in bending
2 Direct tension and 0.40YP 1020 979
tension in bending
3 Shear Stress 0.30YP 765 734
4 Combined stress 0.50YP 1275 1224
5 Bearing stress 0.45YP 1147 1102
II. Gate Leaf As per IS 4622 Dry and Accessible condition
1. Structural steel IS 2062
Stresses in kg/cm2
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 3
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

S.No Type of stresses Factor Thk < 20mm Thk 20 40mm


YP:2550kg/cm2 YP:2448kg/cm2
UTS :4180 kg/cm2 UTS :4180kg/cm2
1 Direct compression and 0.55YP 1402 1346
compression in bending
2 Direct tension and tension 0.55YP 1402 1346
in bending
3 Shear Stress 0.40YP 1020 979
4 Combined stress 0.75YP 1910 1836
5 Bearing stress 0.75YP 1910 1836

C. Bearing stress in concrete = M 200 52kg/cm 2


4.0 Groove Details :
700
200 250 250

C /C O F T R A C K 8 3 1 4
110
30

190
20
400
550

C /C O F S ID E S E A L 7 9 1 4
350

VENT 7814
300
40
25
150

12
26 55
325

2 3 25 7 2
430

65 51
750

585
135

3 8 35 5 0

25
185

20 230 20
50

5.0 Design of Gate leaf :


200 FLO W
It is proposed to design the gate in two elements i.e., top and bottom and connected
with flexible joint of roller gate, the top is fitted with two Nos. of filling valves to get
balancing of pressure before lifting.
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 4
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

C/C of seals: 7914mm


C/C of roller tracks: 8314mm
Sill to top seal centre: 3566mm
Design head: 23.812M
Thrust on gate = 7.914 X 3.566 [23.810-(3.566/2)] = 621.631t

S.No. Element Element Size Head in M Thrust in t


1 Bottom element 7.914 X 1.720 28.810 312.397
2 Top element 7.914 X 1.846 22.090 309.2345

5.1 Design of Interchangeable element :


The disposition of horizontal girders are as shown :
1 1 .7 0 6 t

6 4 .6 6 7
C/C of seals = 7914mm
Design head = 23.810M
2 3 .8 1 2 M

3 0 0 .6 9 1 t

2 2 .0 9 0 M
RA = 156.512t 36

A B
RB = 155.885t 48 74 50
172

5.2 Design of Top element :


The disposition of horizontal girders are as shown :
1 3 .4 8 4 t
C/C of seals = 7914mm 7 3 .0 6 7

Design head = 22.090M


2 2 .0 9 0 M

2 9 5 .7 5 0 t
2 0 .2 4 4 M

RC = 155.120t 4 2 .3

RD = 154.114t C D
4 7 .6 87 50
5.3 Design of Horizontal girders : 1 8 4 .6

RA = 156.512t RB = 155.885t
RC = 155.120t RD = 154.114t
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 5
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

It is proposed to design girder A for a load of 156.512t and adopt the same section
for all the remaining girders.

5.3.1 Design of Horizontal Girder A :


The load on the girder = 156512kg 1 5 6 5 1 2 k g

A 2 0 l = 7 9 1 .4 2 0 B

RA = RB = 78256kg L = 8 3 1 .4

BM = (W / 8) (2L l) = (156512 / 8) (2 X 831.4 791.4) = 17048070kgcm.

Proposed Skin plate out of 25mm plate effective thickness after allowing corrosion
allowance of 1.5 mm is 23.5mm.

The Co-acting width of Skin plate :


L = 831.4cm B1 = 74 / 2 = 37cm B2 = 50cm
L / B1 = 831.4 / 37 = 22.47 V1 = 0.98
L / B2 = 831.4 / 50 = 16.628 V2 = 0.83

V1 B1 + V2 B2 = 0.98 X 37 + 0.83 X 50 = 77.76cm 77

2 .3 5
The sectional properties are as follows :

Area = 479.95cm2
4 5 .2 7

1 .6
4 2 .9 2

IXX = 830460cm4

Z1 = 18345cm3
90

Z2 = 19349cm3

Z3 = 15945cm3
5 1 .6 8

Bending stress on D/S of skin plate = 17048070 / 18345 = 929kg/cm 2 < 1346kg/cm2
Bending stress on U/S of skin plate = 17048070 / 19349 = 881kg/cm 2 < 1346kg/cm2
2 .5

2 2
Bending stress on U/S of flange = 17048070 / 15945 = 1069kg/cm
3 0 < 1346kg/cm
2 .5

32
Shear stress = 78256 / (58.8 X 1.6) = 831kg/cm2 < 856kg/cm2
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 6
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

Check for deflection :


Permissible deflection : L / 800 = 831.4 / 800 = 1.039cm
Actual deflection = (W /384 EI) (8L3 4Ll2 + l3)
= [(156512) / (384 X 2047000 X 830460] X [8 X 831.43 4 X 831.4 X 791.42+ 791.43]
= 0.722cm < 1.039cm

Design of Welds :
SF = 78256kg IXX = 830460cm4

a) F1 : Weld between skin plate and web :


F1 = SAY / 2I = [(78256 X 77 X 2.35 X 44.095) / (2 X 830460)] = 376kg/cm length
Proposed 10mm fillet weld having strength of 0.7 X 1.0 X 856 = 599kg/cm length

b) F2 : Weld between web and 1st U/S flange :


F2 = [78256 (32 X 2.5 + 30 X 2.5) 49.18] / (2 X 830460)] = 359kg/cm length
Proposed 10mm fillet weld having strength of 599kg/cm length

c) F3 : Weld between U/S flanges :


F3 = [78256 X 30 X 2.5 X 50.43] / (2 X 830460)] = 178kg/cm length
Proposed 6mm fillet weld having strength of 479kg/cm length

5.4 Design of End Box :


Bottom element :
The disposition of rollers and horizontal girders are as shown.

RA = 156566kg 1 5 6 5 1 2 k g

a
1 5 6 8 8 5 k g

b
A B
1 5 7 4 1 5

RB = 156831kg 1 0 4

Max. Roller load = 156.566 / 2 = 78.416t 78.5t


Max. Bending moment = 15 X 156566 = 2348490kgcm
Top element :
The disposition of rollers and horizontal girders are as shown.

RC = 154991kg 1 5 5 1 2 0 k g

c
1 5 4 1 1 4 k g
d
C D
1 5 8 7 1 5
1 1 7
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 7
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

RD = 154243kg

Max. Roller load = 154.991 / 2 = 77.495t 78t


Max. Bending moment = 14 X 207745 = 2324865kgcm
Proposed 620 X 20mm End box with 12mm padding
PL 20 + 12m m THK.

3 2 .5
ZXX = 4 X 2.0 X 622 / 6 = 5125cm3

62
Bending stress = 2348490 / 5125

6
= 458kg/cm2 < 1346kg/cm2

2 3 .5
Shear stress = 78500 / (2 X 32.5 X 2.0)
12
2 2
= 604kg/cm < 855kg/cm
Bearing stress = 78500 / (2 X 12 X 2.0) = 1635kg/cm 2 < 1836kg/cm2
How ever 12mm padding is proposed

5.5 Design of Roller, Bearing and Pin :


Max. Roller load = 78.5t

a) Roller :
Material : Carbon Cast Steel IS 1030 Grade 340 - 570
Permissible stress = 1.4 X 570 X 10.2 / 1000 = 8.14t/cm2
Proposed 600 with 160 tread width.
C = 0.418 (78.5 X 2046) / (30 X 16) = 7.65t/cm2 < 8.14t/cm2

b) Bearing :
As per IS 4622 2003 the static capacity of bearing is 1.5 times of roller load
= 1.5 X 78500 X 9.81 = 1155125N

Proposed Spherical roller bearing No. 24130CC/ W33 having ID : 150, OD : 250 and
thickness 100 with static capacity 1530KN with pressed steel cage.
c) Design of Pin :
Material : Corrosion resistance steel 20Cr13 IS 1570 part V
Yp 490MPa, UTS : 690MPa, Hardness : 250 270 BHN
Permissible stress : Bending = 0.40 X 490 X 10.2 = 1999kg/cm 2
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 8
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

Shear stress = 0.30 X 490 X 10.2 = 1499kg/cm 2

78500 kg

RA = RB = 39250kg A 8 .1 10 8 .1 B
2 6 .2

Bending moment = (78500 / 8) (2 X 26.10 10) = 416050kgcm

Proposed 150 at Bearing and 120 at end box.


ZXX = 331cm3
Area = 113cm2
Bending stress = 416050 / 331 = 1257kg/cm2 < 1999kg/cm2
Shear stress = 39250 / 113 = 347kg/cm2 < 1499kg/cm2
Bearing stress = 39250 / (12 X 3.2) = 1022kg/cm 2 < 1836kg/cm2

6.0 Design of Skin plate and Vertical stiffeners :


6.1 Design of Skin plate and Vertical stiffeners for Interchangeable element :
The disposition of skin plate and vertical stiffeners are as shown:

C /C O F R O L L E R T R A C K = 8314
L IF T IN G C /C = 4 9 0 0
850

56
265

6
50 0 6000
400 500 6514

FLO W

6.1.1 Design of Skin plate


1 7 y and vertical stiffeners below Girder A :

Head to the centre of the panel : 23.812 (0.48 / 2) = 23.572M


17x
p = 2.357kg/cm2
1 7 .5

18y
16x
b = 48

18x
3 0 .5

16y

b = 35 b = 35
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 9
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

b / a = 48 / 35 = 1.371 K value for b/a = 1.371 is

16X = 23.33 16Y = 11.39

17X = 8.70 17Y = 29.01

18X = 28.56 18Y = 7.28

Bending stress in skin plate :


2 2 2 2 2
b = [(K / 100) X ((p X a ) / s )] = [(K / 100) X ((2.357 X 35 ) / 2.35 )] = 5.228K kg/cm

2 2 2 2
16X = 122kg/cm < 1346cm 16Y = 60kg/cm < 1346kg/cm

2 2 2 2
17X = 45kg/cm < 1346kg/cm 17Y = 152kg/cm < 1346kg/cm

2 2 2 2
18X = 149kg/cm < 1346kg/cm 18Y = 39kg/cm < 1346kg/cm

Check for combined stress :


2 2
x = 929 + 45 = 974kg/cm < 1346kg/cm
2 2
y = - 152kg/cm < 1346kg/cm
2 2 2 2
C = 974 + 152 + 974 X 152 = 1058kg/cm < 1836kg/cm
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 10
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

Design of vertical stiffener :


Head to the center of the panel = 2.357kg/cm 2 W 1 W 2
2
W1 = 2 X X 17.5 X 2.357 = 722kg
W2 = 2 X 17.5 X 30.5 X 2.357 = 2516kg

1 7 .5
RA = 3238kg A
1 7 .5 3 0 .5
48
Point of application
= ( X 17.53 X + 30.5 X 17.5 X 32.75) / [(17.52 / 2) + (30.5 X 17.5)] = 28.05cm
BM = 3238 X 28.05 [722 (28.05 17.5 X ) + (2516 / 30.5) X (10.55 2 / 2)
= 74406kgcm

Co-acting width of skin plate :


L = 48 B = 17.5
L/B = 2.74 V = 0.390

2VB = 2 X 0.390 X 17.5 = 13.65cm 14cm

It is proposed to provide 200 X 12mm vertical stiffener.


14
2
Area = 56.90cm
2 .3 5
5 .8 9

IXX = 2548cm4
20

Z1 = 433cm3 1 .2
1 6 .4 6

Z2 = 155cm3

Bending stress in tension = 74406 / 433 = - 172kg/cm 2 < 1346kg/cm2


Bending stress in compression = 74406 / 155 = 480kg/cm 2 < 1346kg/cm2

Check for combined stress :


2 2
x = - 39 - 172 = 211kg/cm < 1346kg/cm
2 2
y = 149kg/cm < 1346kg/cm
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 11
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

2 2 2 2
C = 211 + 149 + 211 X 149 = 313kg/cm < 1836kg/cm
6.1.2 Design of Skin plate and vertical stiffeners between Girder A & B :
Head to the centre of the panel : 23.810 (0.48 + 0.74 / 2) = 22.962M
p = 2.296kg/cm2
s 4y
s 4x

1 7 .5
s 2y s 3y
b = 74

s 2x

39
s 3x

a = 35 a = 35 1 7 .5

b / a = 74 / 35 = 2.114 K value for b/a = 2.114 is

2X = 24.93 2Y = 9.158

3X = 49.96 3Y = 14.99

4X = 10.29 4Y = 34.30

Bending stress in skin plate :

2 2 2 2 2
b = [(K / 100) X ((p X a ) / s )] = [(K / 100) X ((2.296 X 35 ) / 2.65 )] = 5.093kg/cm

2 2 2 2
2X = 127kg/cm < 1346kg/cm 2Y = 47kg/cm < 1346kg/cm

2 2 2 2
3X = 254kg/cm < 1346kg/cm 3Y = 77kg/cm < 1346kg/cm

2 2 2 2
4X = 52kg/cm < 1346kg/cm 4Y = 175kg/cm < 1346kg/cm
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 12
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

Check for combined stress : Max. on D/S of skin plate


2 2
x = 929 + 52 = 981kg/cm < 1346kg/cm
2 2
y = - 175kg/cm < 1346kg/cm
2 2 2 2
C = 981 + 175 + 981 X 175 = 1079kg/cm < 1836kg/cm
Design of vertical stiffeners :
Head to the center of the panel = 2.296kg/cm 2
W3 = 2 X X 17.52 X 2.296 = 703kg W 3 W 4 W 3

W4 = 2 X 39 X 17.5 X 2.296 = 3134kg

1 7 .5
B C
RB = RC = 2270kg 1 7 .5 39 1 7 .5
74

BM = 2270 X 37 (703 X 25.333 + (3134 / 2) (39 / 4)) = 50903kgcm

Co-acting width of skin plate :


L = 74 B = 17.5
L/B = 4.229 V = 0.72

2VB = 2 X 0.72 X 17.5 = 25.2cm

It is proposed to provide 200 X 12mm as vertical stiffener.

25
Area = 82.75cm2
2 .3 5
4 .4 2

IXX = 2955cm4

Z1 = 669cm3
20

1 .2
1 7 .9 3

3
Z2 = 165cm

Bending stress in tension = 50903 / 669 = - 76kg/cm 2 < 1346kg/cm2kg/cm2


Bending stress in compression = 50903 / 165 = + 309kg/cm 2 < 1346kg/cm2
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 13
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

Check for combined stress : Max. on D/S of skin plate


2 2
x = -77 - 76 = -153kg/cm < 1346kg/cm
2 2
y = 254kg/cm < 1346kg/cm
2 2 2 2
C = 153 + 254 + 153 X 254 = 356kg/cm < 1836kg/cm
6.1.3 Design of Skin plate above Girder B :
Head to the centre of the panel : 23.810 (0.48 + 0.74 + 0.5 / 2) = 22.342M
a = 35 p = 2.234kg/cm2

s 16y

3 2 .5
s 18x
b = 50

s 16x
s 18y

1 7 .5
s 17x

s 17y
a = 35
b/a ratio = 50 / 35 = 1.429 K value for b/a = 1.429 is

16X = 24.17 16Y = 11.28

17X = 8.61 17Y = 28.73

18X = 23.02 18Y = 6.90

Bending stress in skin plate :


2 2 2 2 2
b = [(K / 100) X ((p X a ) / s )] = [(K / 100) X ((2.234 X 35 ) / 2.65 )] = 4.955K kg/cm
2 2 2 2
16X = 120kg/cm < 1346kg/cm 16Y = 56kg/cm < 1346kg/cm
2 2 2 2
17X = 43kg/cm < 1346kg/cm 17Y = 142kg/cm < 1346kg/cm
2 2 2 2
18X = 114kg/cm < 1346kg/cm 18Y = 34kg/cm < 1346kg/cm

Check for combined stress : Max. on D/S of skin plate


GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 14
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

2 2
x = 929 + 43 = 972kg/cm < 1346kg/cm
2 2
y = - 142kg/cm < 1346kg/cm
2 2 2 2
C = 972 + 142 + 972 X 142 = 1050kg/cm < 1836kg/cm

Design of vertical stiffeners : w 5 w 6

Head to the centre of the panel = 2.234kg/cm 2

1 7 .5
W7 = 2 X X 17.52 X 2.234 = 684kg
W8 = 2 X 32.5 X 17.5 X 2.234 = 2541kg D
1 7 .5 3 2 .5
RF = 3225kg 50
Point of application
= [( X 17.53 X ) + 32.5 X 17.5 X 33.75] / ( X 17.52 + 32.5 X 17.5) = 29.066cm

BM = 3225 X 29.066 [(684 X (29.066 - X 17.5) + (2541 X 11.566 2 / (32.5 X 2))]


= 76607kgcm

Co-acting width of skin plate :


L = 50 B = 17.5
L/B = 2.86 V = 0.403
2VB = 2 X 0.403 X 17.5 = 14cm

It is proposed to provide 200 X 12mm vertical stiffener.


14
2 .3 5

2
Area = 56.90cm
5 .8 9

IXX = 2548cm4
20

1 .2
Z1 = 433cm3
1 6 .4 6

Z2 = 155cm3

Bending stress in tension = 76607 / 433 = - 177kg/cm 2 < 1346kg/cm2


Bending stress in compression = 76607 / 155 = + 494kg/cm 2 < 1346kg/cm2
Check for combined stress :
2 2
x = -34 -177 = -211kg/cm < 1346kg/cm
2 2
y = 114kg/cm < 1346kg/cm
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Page No: 15
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

2 2 2 2
C = 211 + 114 + 211 X 114 = 286kg/cm < 1836kg/cm

6.2 Design of Skin plate and Vertical stiffeners for Top element :
The disposition of skin plate and vertical stiffeners are as shown:

C /C O F R O L L E R T R A C K = 8314
L IF T IN G C /C = 4 9 0 0

850
8

56
265

6
5 0 0 6000
400 500 6514

6.2.1 Design of Skin plate and vertical stiffeners below Girder D : FLO W

Head to the centre of the panel : 22.090 (0.476 / 2) = 21.852M


p = 2.185kg/cm2
17y

17x

18y 1 7 .5
b = 4 7 .6

16x
18x
3 0 .1

16y

b = 35 b = 35

b / a = 47.6 / 35 = 1.36 K value for b/a = 1.36 is

16X = 22.87 16Y = 11.44

17X = 8.75 17Y = 29.17

18X = 28.46 18Y = 7.48

Bending stress in skin plate :


GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 16
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

2 2 2 2 2
b = [(K / 100) X ((p X a ) / s )] = [(K / 100) X ((2.185 X 35 ) / 2.35 )] = 4.85K kg/cm

2 2 2 2
16X = 111kg/cm < 1346cm 16Y = 55kg/cm < 1346kg/cm

2 2 2 2
17X = 42kg/cm < 1346kg/cm 17Y = 141kg/cm < 1346kg/cm

2 2 2 2
18X = 138kg/cm < 1346kg/cm 18Y = 36kg/cm < 1346kg/cm

Check for combined stress :


2 2
x = 929 + 42 = 971kg/cm < 1346kg/cm
2 2
y = - 141kg/cm < 1346kg/cm
2 2 2 2
C = 971 + 141 + 971 X 141 = 1049kg/cm < 1836kg/cm

Design of vertical stiffener :


Head to the center of the panel = 2.185kg/cm 2
W 1 W 2
W1 = 2 X X 17.52 X 2.185 = 669.0kg
W2 = 2 X 30.1 X 17.5 X 2.185 = 2302kg

RA = 2971kg 1 7 .5
A
1 7 .5 3 0 .1
Point of application 4 7 .6
= [( X 17.53 X ) + 30.1 X 17.5 X 32.5] / ( X 17.52 + 30.1 X 17.5)
= 27.847cm
BM = 2971 X 27.847 [(669 X (27.847 - X 17.5) + (2302 X 10.34 2 / (30.1 X 2))]
= 67820kgcm

Co-acting width of skin plate :


L = 47.6 B = 17.5
L/B = 2.72 V = 0.38
2VB = 2 X 0.38 X 17.5 = 13.3cm 13cm
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 17
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

It is proposed to provide 200 X 12mm vertical stiffener.


13

2 .3 5
Area = 54.55cm2

6 .0 9
IXX = 2493cm4

20
1 .2
Z1 = 409cm3

1 6 .2 6
Z2 = 153cm3

Bending stress in tension = 67820 / 409 = - 666kg/cm 2 < 1346kg/cm2


Bending stress in compression = 67820 / 153 = + 443kg/cm 2 < 1346kg/cm2

Check for combined stress :


2 2
x = -55 -166 = -221kg/cm < 1346kg/cm
2 2
y = 111kg/cm < 1346kg/cm
2 2 2 2
C = 221 + 111 + 221 X 111 = 293kg/cm < 1836kg/cm
6.2.2 Design of Skin plate and vertical stiffeners between Girders C & D :
Head to the centre of the panel : 22.090 (0.476 + 0.87 / 2) = 21.179M
p = 2.118kg/cm2
s 4y
a = 35
s 4x
1 7 .5

s 2y s 3y
b = 87

s 2x s 3x
52
1 7 .5

a = 35

b / a = 87 / 35 = 2.485 K value for b/a = 2.485 is

2X = 25.00 2Y = 8.00
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 18
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

3X = 50.00 3Y = 15.00

4X = 10.29 4Y = 34.30

Bending stress in skin plate :


2 2 2 2 2
b = [(K / 100) X ((p X a ) / s )] = [(K / 100) X ((2.118 X 35 ) / 2.35 )] = 4.698K kg/cm

2 2 2 2
2X = 117kg/cm < 1346kg/cm 2Y = 38kg/cm < 1346kg/cm

2 2 2 2
3X = 235kg/cm < 1346kg/cm 3Y = 70kg/cm < 1346kg/cm

2 2 2 2
4X = 48kg/cm < 1346kg/cm 4Y = 161kg/cm < 1346kg/cm

Check for combined stress : Max. on D/S of skin plate


2 2
x = 929 + 48 = 977kg/cm < 1346kg/cm
2 2
y = - 166kg/cm < 1346kg/cm
2 2 2 2
C = 977 + 166 + 977 X 166 = 1070kg/cm < 1836kg/cm
Design of vertical stiffeners :
Head to the center of the panel = 2.118kg/cm 2

W 3 W 4 W 3

W3 = 2 X X 17.52 X 2.118 = 649kg


1 7 .5

W4 = 2 X 52.0 X 17.5 X 2.118 = 3855kg


B C
1 7 .5 52 1 7 .5
87
RB = RC = 2576.5kg

BM = 2576.5 X 43.75 (649 X 31.833 + (3855 / 52) (52 / 4) = 90454kgcm

Co-acting width of skin plate :


L = 87.0 B = 17.5
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 19
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

L/B = 4.97 V = 0.78

2VB = 2 X 0.78 X 17.5 = 27.3cm

It is proposed to provide 200 X 12mm vertical stiffeners.


27
2
Area = 87.45cm

2 .3 5
4 .2 4
IXX = 3004cm4

20
Z1 = 708cm3 1 .2

Z2 = 166cm3 1 8 .1 1

Bending stress in tension = 90454 / 708 = - 128kg/cm 2 < 1346kg/cm2


Bending stress in compression = 90454 / 166 = + 544kg/cm 2 < 1346kg/cm2

Check for combined stress :


2 2
x = -70 - 128 = -198kg/cm < 1346kg/cm
2 2
y = 235kg/cm < 1346kg/cm
2 2 2 2
C = 198 + 235 + 198 X 235 = 375kg/cm < 1836kg/cm

6.2.3 Design of Skin plate above Girder D :


Head to the centre of the panel : 22.090 (0.476 + 0.87 + 0.5 / 2) = 20.494M
p = 2.049kg/cm2
a = 35

s 16y
3 2 .5

s 18x
b = 50

s 16x
s 18y
1 7 .5

s 17x

s 17y
a = 35
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 20
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

b/a ratio = 50 / 35 = 1.429 K value for b/a = 1.429 is

16X = 24.17 16Y = 11.28

17X = 8.61 17Y = 28.73

18X = 23.02 18Y = 6.90

Bending stress in skin plate :


2 2 2 2 2
b = [(K / 100) X ((p X a ) / s )] = [(K / 100) X ((2.049 X 35 ) / 2.35 )] = 4.545K kg/cm

2 2 2 2
16X = 110kg/cm < 1346kg/cm 16Y = 51kg/cm < 1346kg/cm

2 2 2 2
17X = 39kg/cm < 1346kg/cm 17Y = 131kg/cm < 1346kg/cm

2 2 2 2
18X = 105kg/cm < 1346kg/cm 18Y = 31kg/cm < 1346kg/cm

Check for combined stress : Max. on D/S of skin plate


2 2
x = 929 + 39 = 968kg/cm < 1346kg/cm
2 2
y = - 131kg/cm < 1346kg/cm
2 2 2 2
C = 968 + 131 + 968 X 131 = 1040kg/cm < 1836kg/cm

Design of vertical stiffeners :


Head to the centre of the panel = 2.049kg/cm 2 w 5 w 6

W7 = 2 X X 17.52 X 2.049 = 628kg


1 7 .5

W8 = 2 X 32.5 X 17.5 X 2.049 = 2331kg


D
RF = 2959kg 1 7 .5 3 2 .5
50
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 21
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

Point of application
= [( X 17.53 X ) + 32.5 X 17.5 X 33.75] / ( X 17.52 + 32.5 X 17.5) = 29.066cm

BM = 2959 X 29.066 [(628 X (29.066 - X 17.5) + (2331 X 11.566 2 / (32.5 X 2))]


= 70282kgcm

Co-acting width of skin plate :


L = 50 B = 17.5
L/B = 2.86 V = 0.403

2VB = 2 X 0.403 X 17.5 = 14cm

It is proposed to provide 200 X 12mm vertical stiffener.


14
Area = 56.90cm2
2 .3 5
5 .8 9

IXX = 2548cm4

Z1 = 433cm3
20

1 .2
1 6 .4 6

Z2 = 155cm3

Bending stress in tension = 70282 / 433 = - 162kg/cm 2 < 1346kg/cm2


Bending stress in compression = 70282 / 155 = + 453kg/cm 2 < 1346kg/cm2
Check for combined stress :
2 2
x = - 31 - 162 = -193kg/cm < 1346kg/cm
2 2
y = 105kg/cm < 1346kg/cm
2 2 2 2
C = 193 + 105 + 193 X 105 = 262kg/cm < 1836kg/cm
8.0 Weight & C.G calculations of Draft tube gate :

S.No. Description Size No Weight x Wx


1720 X 25 8604 1 2904.3 1.25 3630.0
1 Skin plate
1946 X 25 8604 1 3285.9 1.25 4206.0
GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 22
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

620 X 20 - 3666 4 1427.4 33.5 47818.0


230 X 10 - 620 6 67.2 33.5 2250.0
350 X 12 270 16 142.4 26.0 3703.0
2 End Box
250 - 20mm thick 8 61.7 26.0 1602.0
140 X 12 260 8 27.4 19.0 521.0
230 X 25 3666 2 330.9 62.25 20602.0
900 X 16 - 8044 4 3637.2 47.5 172767.0
3 Horizontal girder 320 X 25 8176 4 2053.8 93.75 192545.0
300 X 25 6000 4 1413.0 96.25 136001.0
200 X 12 3666 18 1261.5 12.5 15769.0
4 Vertical stiffener 900 X 8 3666 3 621.6 47.5 29526.0
150 X 10 1500 3 53.0 93.0 4928.0
160 X 16 - 7824 2 314.4 - - - - -----
5 Splice plates 160 X 16 - 580 4 46.6 33.5 1562.0
160 X 12 - 450 3 20.3 94.1 1910.0
600 X 170 wheel with
6 Roller assembly 24130CC/W33 bearing and 8 3320.0 26.0 86320.0
SS axle - 415kg/assembly
7 Slide guide 20.2kg/assembly 4 80.8 43.2 3490.0
44 X 127 bulb seal- 15060 1 71.5 ---- ----
60 X12 15000 2 170.0 ---- ----
8 Seal assembly 90 X 14 - 7724 1 16.0 ---- ----
80 X 10 7724 1 48.5 ---- ----
20 X 20 - 7724 1 24.3 ---- ----
Lifting
9 945kg/assembly 2 1890.0 ---- ----
Arrangement
10 Fasteners 200kg 1 200.0 ---- ----
23489.7 729150.0

x = 729150.0 / 21599.7 = 33.75 adopted 33cm

Note : The element weight for CG calculation is taken without weight of lifting
arrangement.
9.0 Hoist capacity calculations:
The top element of Draft tub gate is fitted with 2 Nos. of filling valves for

balancing the pressures. The elements are lifted / operated under balanced head

condition using rope drum hoist.


GREY HOUND ENGINEERS (INDIA) Private Limited
Page No: 23
PROJECT : RAMPUR HEP ( H.P) PACKAGE II SUBJECT: DESIGN OF DRAFT TUBE GATES
Rev : 1

Wt. of gate leaf including filling valves: 24000kg

Add 20 % reserve: 4800kg

28800kg

Proposed to use 40t Rope drum hoist with 1.0M/min speed and 30M lift.