Dt Gate-support Structure

DESIGN CALUCULATIONS OF

KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-1

RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST

LTD. HOSPET FOR THANGARABALU SMALL

BANGALORE H.E. PROJECT(2X12.375MW) REV. 1

DRAFT TUBE GATE

DESIGN OF SUPPORTING STRUCTURE FOR MONO RAIL HOIST /CHAIN PULLEY BLOCK

1 DESIGN DATA

sl DESCRIPTION VALUES

no.

1 Type of Gate Fixed wheeltypevertical gate

2 Size of vent 4350mmx3550mm

3 NO.vents 4

4 Clear width of opening 4.35 M

5 Clear height of opening 3.55 M

6 No. of gates 4 SET

7 Sill level RL 386.412 M

8 Top of pier level RL 410.00 M

9 Thickness of Abutment Top side/middle 1.5/0.85 M

10 Thickness of pier[inter] 1.30 M

2 PERMISSIBLE STRESSES

sl Type of stress Factor Stresses in kg/cm²

no.

1.0 Sturctural Steel Thk : 0 ≤ 20 mm

Structural Steel - IS : 2062 – 2006 Yp : 2550 kg/cm2

Grade E250 -A Factor UTS 4180 kg/cm2

a Direct compression &

compression in bending 0.66 YP 1683

b Direct tension and tension

in bending 0.66 YP 1683

c Shear stress 0.45YP 1148

d direct stress in compression 0.60YP 1530

e Bearing stress 0.75 YP 1912

Stresses in kg/cm²

5 Bearing stress in concrete M25 50

6 Shear stress in concrete M25 8

7 Allowable deflection = span/750 <50mt cap.

span/500 manual operation






3 Height of column

Top of pier level RL 410.00 M

Sill level RL 386.412 M

LIFT = 23.588 M

height of Lifting point in gate = 3.9 M

Hoist Hook to Rail girder flange= 2 M

clearance above pier level= 0.3 M

Height of mono-rail beam = 0.6 M

Height of column = 6.8 M

Proposed 7.0 M Height columns

4 Load on column while operating

Max. lifting capacity of Monorail = 17.5 MT

Load on column with impact factor of 10%= 19.25 MT

weight of monorail plus Girder 1.5 MT

TOTAL = 20.75 MT

Total Load on columns= say 21 MT

The arrangement of column & girder is shown below

NIYSANIYSA






5 Design of main mono rail beam on vent

Stop log gate elements are to be lifted one by one in each unit induidially

Hence load on succussive girder / column is not considered for design.

21000 kg

A B RA=RB= 10500kg

435+65+65=565cm

Max. B.M = 10500X565/2=2966250kgcm

a Proposed ISMB 500X180with ad.flange of 200x14 at bottom and ISMC250X80 at top

SL SECTIONS AREA

NO. W T

1 Flange[1] 25.0 0.71 17.75

2 Flange[2] 18 1.72 30.96

3 web 46.56 1.27 59.1312

4 Flange[3] 18 1.72 30.96

5 Flange[4] 20 1.4 28

166.80

A = 166.8 cm²

Y1 = 27.3 cm

Y2 = 26.6 cm

Y3 = 24.8 cm

Ixx = 76255.2

Z1 = 2790.6

Z2 = 2865.0

Z3 = 3076.8

Iyy = 1369.8+2bd^3/12= (1369.8+(1*1.4*20^3/12)+3828.4)

6131.5

2966250

Max. bending stress = = 1063 kg/cm²

2790.6 <1380kg/sqcm hence safe

5 xwl³ 5x21000 x 540³

Max. deflection in girder = =

384 x EI 384x20.70 x 10^5 x 76255.2

= 0.27 cm

L 540

Allowable Deflection= = = 0.72 cms

750 750

Sear stress=fs= 21000/2/46.56/1.02= 221 kg/sqcm

DIMENSIONS






b Calculating the Max. Permissble bending stress as IS800-1984 Cl 6.2.3

fbc= 0.66 fcbxfy

[(fcb)^n +(fy)^n]1/n

fy=y.p=2550kg/sqcm

n=1.4

ryy= SQ,RT.of [Iyy/A]=SQ RT of [6131.5/166.8]=6.06

fcb= k1[X+k2Y]c2/c1

l/ry=565/6.06=93 X=464 k1=1 c2/c1=1

[Table-6.5] [Table 6.4&6.3]

D/T= 52.11/3.12=16.7 Y=327 k2=0.5

fcb= 1*(464+0.5*327)*1

= 627.5

As per table 6.2 for fcb =627 the allowable permissible stress

is=

fbc= 1380 kg/sqcm [table 6.2]






c Check for local bending of flange due to monorail long travel hoist wheel load

The stress resulting from local bending is given an empherical formula[xyplane]

σx= ± KaxxP/t^2(root)

where kax=2

Flange thickness=t=1.72+1.4=3.12 for value of

c/a =62.5/85=0.735

p= Hoist load xImpact factor+self wt.

4 [nos. of wheel]

= 21000x2

= 10500 kg

4

10500

σx= = 1079 kg/sqcm

3.12^2

The stress resulting from load bending y-z plane

σy= ± KazxP/t^2 where kaz=0.6

for value of

c/a =62.5/85=0.735

σy= ± 5250X0.6 /3.12^2 = 324 kg/sqcm

combined stress at inside of the flange

σc= σx ²+ σy ²+ σx x σy

=

= 2107 kg/sqcm <0.85x2550=2167kg/sqcm






7 Design of columns [END/INTERM-PIER]

Max. reaction of girder on column = 21000 kg

Height of column= 800 cms

Proposed 2- ISMC300X90 BACK TO BACK

A=45.74x2= 91.48 cm^2

Ixx=2xIyy+2xAx[D/2]^2

Ixx=2x311.5+2x45.74x20^2 = 37215 cm^4

Iyy=2xIxx+2xwx[D/2-t of web]^2/12

Iyy=2x6384.2+2x9x[40/2-7.6]^2/12 = 13281 cm^4

Zxx= 37215/[D/2+FLW/2]= = 2482 cm^3

Zyy== 13281/[D/2] = 885.4 cm^3

rxx= SQ,RT.of [Ixx/A]=SQ RT of [37215/91.48]=20.2 cm

ryy= SQ,RT.of [Iyy/A]=SQ RT of [13281/91.48]=12.05 cm

Effective Ht. of column

Lxx=1.5*700= 1050 cm

Lyy=0.5*700= 350 cm

LXX/rxx= 1050/20.25= 51.9 <200

Lyy/ryy= 350/15.6= 22 <200

permissible compressive stress for l/r =52 is 1164 kg/sqcm

actual compressive stress in column= 21000/91.48= 230 kg/sqcm

max.load on colomn= 21000 kg

self wt.of column+beam= 1000 kg

total load 22000

Max. compressive stress in column= 22000/91.48= 240 kg/sqcm






WIND LOADS

A]Wind in the direction of flow

wind pressure= 160 kg/m^2

width of column= 0.3 m

form factor 1.6

wind load per mtr ht of column=

0.3x160x1.6= 77 kg

B]Wind from main girder


width of column= 0.62 m

form factor 1.6

effective length of girder on each colomn=

7.8/2= 3.9 m

wind load on column=

0.55*3.15x160x1.6= 619 kg

C]Wind form mono-rail hoist


width of hoist= 0.6 m

ht of hoist 1

form factor 1.6

effective load on each colomn= 50%

wind load from hoist on column= 0.6*1.5x160x1.6x1/2=

77 kg

total wind load on top of column= 619+77 696 kg






Moment at -A

a]due to wind load on wind ward column

MA1= 77x[700/100]x700

2

188650 kgcm

a]due to concentrated load at B

MA2= 696*700

487200 kgcm

Total moment at A

MA= MA1+MA2= 675850 kgcm

For Int/end column

Stress in column at A due to moments

fa= MA/Zxx= 763 kg/sqcm

<1683 kg/sqcm

check for unity formula (240/1164+763/1683) 0.7 <1






8 BATTENS

Battens are proposed for columns

Heght of column= 700cm

r min. Of column= 12.05cm

L/r min. = 58.1

spacing of battens shall be minimum of following

1] L/r min. < 40

2] 0.6XL/rmin. = 0.6x58.1= 35 <40

l= 35x12.05 = 422 cm

Proposed battens at 1000mm c/c =d

Depth of intermediate batten =300mm

Thickness of batten =10mm

Adopt battens of size 300x10 mm at 1000mm c/c.

Transverse shear=S = 2.5%Xof axial load

Transverse shear=S = 2.5%X22000 = 550 kg

Longitudinal shear =Sd/na s= transeverse shear

Moment=Sd/2n d=c/c distance of battens longitudinally

n=no of parallel planes of battens

a=min. distanace across welds

(450-2*15)=420mm

Moment=Sd/2n = 550x100/(2x2) = 9625 kgcm

Longitudinal shear =Sd/na= 550X100/(2X42) = 458 kg

distance between centroids of member=400mm =c

min. effective depth reqdd=75% of c = 300mm provide 300mm

Longitudinal shear stress = 458/[30x1] = 54kg/sqcm

Bending stress = 22000/2

= 212 kg/sqcm

1/6 x1x30² < 1530 kg/sqcm






9 Design of Column base plate

Proposed base plate= 600x400x20mm

moment on each column base = MA= 676850 kgcm

Total load on column= 22 mt

a]The thickness of base plate requiored as per cl.6.4.3 of IS800 is

t= √3w[a^2-b^2/4]fb

t= thickness of base plate

w=the pressure of loading

under base plate=22000/[60x40]= 9.2 kg/sqcm

a= the greater projection of plate beyond column= 10cm

b= the lesser projection of plate beyond column= 10cm

fb=1530 kg/sqcm

t= 1.3 cm Providded 20mm thickness of plate

b]checking the unit width of cantilever portion

bending moment = 9.2x10x10/2= 460 kgcm

0.666

bending stress= 460/0.66= 697 kg/sqcm

<1530kg/sqcm






10 Design of Foundation Bolts

Proposed 6nos. of Bolts/column

Distance between holes c/c= 50cm

No. of effective bolt= 3

Max. B.M. in column= 676850 kgcm

Tensile load on each Bolt/ column = 50cm

676850 =Proposed 20∅ mm bolts 50x3 5355 kg

A in Tensile = 9.425cm^2

A in Shear = 8.01cm^2

Tensile stress in Bolt= 5355/9.425=568kg/sqcm <945kg/sqcm

Shear stress = 22000*10%/(2x8.04)=131kg/sqcm

Length of bolt =l= 5093 = 90cm

px2x9 [M-250 Shear stress=9kg/sqcm]

Adopted 1200 mm long bolt with 50 mm thread length..

10a Check for compressive stresses in concrete

MA= = 676850 kgcm

Ecentricity=e= mc/pc= 676850/2200= 30.76 cm

size of column base= b=40cm h=60cm

e/h= 11.75/60= 0.512667

Area of tensile steel = 9.425 [2xpie/4xd^2]

AREA OF COM. STEEL = 0

EFFECTIVE DEPTH=h-d1=60-5=55cm

[b*h^2/6]+[2(ac-1)Asc/h]x[0.5h-d1]^2

modulus section =J= (40*55^2/6)+((2*13-1)*16.08)/55*(0.5*55-5)^2

= 22335.488

Atr=b*d+(m-1)Asc= 40*55+(13-1)*16.08 m=13

= 2313.1

Max comp stress= PC*1000/Atr+Mc/j

(22000/2313.1)+(803200/222335.5)

13 kg/sqcm <50kg/sqcm

Min comp stress= PC*1000/Atr-Mc/j

(22000/2313.1)-(803200/222335.5)

6 kg/sqcm <50kg/sqcm

11 CONNECTION DETAILS BETWEEN MONO RAIL GIRDER &COLUMN GIRDER.

Max. load occurs when pulley block is at cross girder

MAX. designed load = 22000 kg

Proposed 6 nos. of M20 Bolts

A in Tensile = 2.45 cm^2

A in Shear = 3.14 cm^2

Shear stress in bolt= 22000/(6x3.14X2)= 583 kg/sqcm

[double shear] <865 kg/sqcm

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Dt Gate-support Structure