FEDERAL    DEMOCRATIC    REPUBLIC    OF    ETHIOPIA MINISTRY OF WATER AND ENERGY
FEASIBILITY STUDY AND DETAIL DESIGN OF BALE GADULA IRRIGATION PROJECT
SECTION I - DESIGN REPORTS
VOLUME V- DESIGN OF HYDROMECHANICAL GATES
Spervision Enterprise fWWDSE)
and Technocarts
PVT.LTD.(ICT)Ministry of Water and Energy -
Federal Democratic Republic of Ethiopia
LIST OFVOLUM ES
Section - /, Volume - V Design of Hydro Mechanical Gates
SECTION 1 - DESIGN REPORTS
VOLUME 1
EXECUTIVE SUMMARY
VOLUME II
DESIGN OF WEIR AND HEAD REGULATOR
VOLUME III
DESIGN OF IRRIGATION AND DRAINAGE SYSTEM
VOLUME IV
DESIGN OF STRUCTURES ON CANAL AND DRAINAGE SYSTEM
VOLUME V
DESIGN OF HYDRO MECHANICAL GATES
VOLUME VI
INFRASTRUCTURE DESIGN
VOLUME VII
OPERATION AND MAINTENANCE MANUAL
SECTION II - DRAWING ALBUM
PARTI
DIVERSION WEIR AND HEAD REGULATOR
PART II
IRRIGATION AND DRAINAGE SYSTEM
PART III
CANAL AND DRAINAGE STRUCTURES
PART IV
HYDRO MECHANICAL GATES
PARTV
INFRA STRUCTURE DESIGNS
SECTION III - TENDER DOCUMENTS
VOLUME VIII
BID DOCUMENTS
VOLUME IX
TECHNICAL SPECIFICATIONS
VOLUME X
BILL OF QUANTITIES
WWOSf Addis Ababa in Association with -I- Detail Design of Bale Gadula Irrigation & Drainage Project
ICT Pvt L td and ABCE PLC
October. 2011Ministry of Water and Energy -
Federal Democratic Republic of Ethiopia
TABLE OF CONTENTS
LIST OF VOLUM 1
TABLE OF CONTENTSII
ABBREVIATIONSV
1.   UNDERSLUICES GATES AND HOISTS1
1.1     General1
1.2     Arrangement of Service Gate1
1.3     Service Gate Operation1
1.4     Emergency Gate1
1.5     Design of Undersluices Gates2
1.5.1       Design Data
1.5.2       Allowable Design Stresses2
1.5.3       Stresses allowable in various gate components2
1.5.4       Stresses allowable in Embedded Parts3
1.5.5       Design Codes3
1.5.6       Design Considerations3
1.5.6       Basic Data4
1.5.7        Hydro Dynamic Forces4
1.5.8       Water Thrust Diagram4
1.5.9       Horizontal Girder5
Section -1, Volume - V Design of Hydro Mechanical Gates
1.5.10
Design of Plate7
1.5.11
Design of End Girders10
1.5.12
Design of Wh eels10
1.5.13
Design of Pin for Wheel13
1.5.14
Track Plate14
1.5.15
Track Girder15
1.5.16
Gate Body19
1.5.17
Sill Beam21
1.5.18
Check for sealing pressure22
1.5.19
Calculation for Hoist capacity23
2.   HEAD REGULATOR GATES24
2.1     General24
2.2     Arrangement of Service Gate24
2.3     Service Gate Operation24
2.4     Emergency Gate24
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October, 2011Ministry of Water and Energy -
Federal Democratic Republic of Ethiopia
Section -1, Volume - V Design of Hydro Mechanical Gates
2.5   Design of Vertical Lift Gate of Head Regulator on  Left Bank............................................................25
2.5.1      Design Data.......................................................................................................................... 25
2.5.2      Allowable Design Stresses....................................................................................................25
2.5.3      Stresses Allowable in Various Gate Components................................................................ 25
2.5.4      Stresses allowable in Embedded parts.................................................................................26
2.5.5      Design codes........................................................................................................................ 26
2.5.6      Design Considerations..........................................................................................................26
2.5.7    Design Calculation................................................................................................................. 26
2.5.7.1          General..........................................................................................................................................................................26
2.5.7.3   Checking of plate.................................................................................................................................................................. 27
2.5.7.4   Checking the skin plate in panel.......................................................................................................................................... 27
2.5.7.5   Design of EndGirder............................................................................................................................................................ 28
2.5.7.6   Design of wheel................................................................................................................................................................... 28
2.5.7.7  Track Plate........................................................................................................................................................................... 28
2.5.7.8  Track girder ISMB -250........................................................................................................................................................ 28
2.5.7.96ate body................................................................................................................................................................................ 32
2.5.7.10   Stiffeners........................................................................................................................................................................... 33
2.5.7.11   Revised Sill Beam section................................................................................................................................................ 35
2.5.7.12    Weight of Gate................................................................................................................................................................. 36
3.        GATES FOR REGULATING STRUCTURES BALE GADULA CANAL SYSTEM.......37
3.1    Introduction.................................................................................................................................. 37
3.2    Selection of Gate Type.................................................................................................................. 37
3.3    Maintenance Bulkheads / Stoplogs.................................................................................................38
3.4    Operating Mechanisms................................................................................................................... 39
3.5    Gate Construction........................................................................................................................ 39
3.6    Installation & Constructional Specifications for Standard Sluice Gates...................................... 39
3.7    Installation & Construction Specifications for the Selection of Standard Sluice Gates............... 39
3.7.1     A: Selection........................................................................................................................ 39
3.7.2      Type of mounting............................................................................................................... 40
3.7.3      Water Head........................................................................................................................40
3.7.3.1  Seating I on-seating water head....................................................................................................................................... 40
3.7.3.2            Unseating /off-seating water head.......................................................................................................................... 40
3.7.4   Type of Bottom Closure.......................................................................................................40
3.7.4.1             Conventional bottom / rebate invert type closure..................................................................................................40
3.7.4.2             Flush bottom / Flush invert closure.......................................................................................................................41
3.7.5     Type of Spindle Movement.............................................................................................. 41
3.7.5.1           Rising Spindle Gates.............................................................................................................................................. 41
3.7.5.2  .Non-rising spindle gates................................................................................................................................................. 41
3.7.6     Location of Hoisting Mechanism & Thrust Reaction......................................................... 42
WWDSE, Addis Ababa in Association with -///- Detail Design of Bale Gadula Irrigation & Drainage Project
ICT Pvt. Ltd. and ABCE PLC
October, 2011arately on platform aW3V ,,UI"
,,O,”C'
P 'atf°rm
I.W.l
(iluire,.te/Thrunonot. fume
J16! «—«•’""" ...........................
JZ7 ...............................................................................................■"........................................................
377 1                        Manualoperation
. 0                 Mechanized operation
“ we! °lgMS “st ™ '“«*
s
3.7K1 Specification
37,8.2 Application
3 7.8.3 Salient Features
3 7.8.4 Materidu of Construction.
37.8.5           Shop Testing................
3.7.9 Open Chonnel Cast Iron Sluice Gates....
37.9.1       Specification:.................................
37.9.2             Application................................
.............. ..
...........
.........
............
........... .
...................................
3.7.11
3.7.12
3.7.13
Shop Testing
Optional Features
Materials for Fabrication of Gates
3.7.14
Material specifications for the gates and hoists for standard gates
3.7.14.1 Painting Specifications:
37.14.2  Standard Accessories
3.7.15           Optional Accessories.
3.7.15.1 Pipe hood I Stem cover:
3.8.15.2 Gate opening indicator:
3.7.15.3 Foot plate wall bracket:
3.7.15.4 Offset centre pillar:
3 7.15.5 Electrically operated lift mechanism with manual override facility:
3.7.15.6 Pneumatically operated lift mechanism with manual override facility:
3 7.15./ Portable electric / hydraulic operator for manually operated gates:
3 7.16           shop Inspection Tests
3 7.16.1 Seat Clearance Check
3.7.16.2 Movement Test:
3.7.16.3  Shop Leakage Test Under Atmospheric Pressure:
3 7.16.4. Shop Leakage Tests under Maximum Operating Head:
Shop Hydrostatic Pressure Body Test under 1.5 Times Maximum Operating Head: 3.7.16.6 OperatingToroue Test at Maximum
3.7.16.7 Dimensional Verification Check
3 7.16.8 Review of Material Test Certificates
REFERENCES
Z4WSE   AMs   Ababa
ICT Prf L>d and ABCE PLC
■IV- Detail Design of Bale Gadula Irrigation & Drained6 October.Ministry of Water and Energy -
Federal Democratic Republic of Ethiopia
ABBREVIATIONS
As                  Area of steel
B                    width
BS                 British Standard
c/c                  centre to centre
cm                  centimeters
C25                Concrete grade acceding to EBCS Cr                  Chromium
d                    depth
EBCS Ethiopian Building Code Standard
Section - /, Volume - V Design of Hydro Mechanical Gates
IS
Indian Standard
Kg
Kg/m
Kilogram
Kilogram per sq m
m
meter
mt
metric tone
mm
millimeters
m/sec
m2
m3
meters per second
Sq Meters 
cubic meters
USACE
United States
MPa N/mm2
Mega Pascal
Newton per sq mm
Ni
Nickel
W
Load
YP
Yield Point
Z
Section Modulus
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October. 2011Ministry of Water and Energy-
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Section - I, Volume - V Design of Hydro Mechanical Gates
UNDERSLUICES GATES AND HOISTS
1.1       General
Two opening of size 3.0 m wide x 2.65 m high are provided on left bank separated by a pier of 1.5 m and will be provided with two serviceJ gates> (vertica
lift wheel type ), and one emergency gate for opening 3.0 m x 2.65 m higk 
required embedded parts, hoists and mono rail arrangement will also be
provided. Sen/ice Gate shall be operated by screw hoists.
The sill of the gate is at elevation 2073.5 and the pond level is 2076.0 m.
The gates  have been designed for water head corresponding to High flood Level conditions  El 2078.10 and the hydrodynamic  extra head for taking care of the hydrodynamic  forces  downstream of the gate. Sometime the gate may  by  mistake or because of any defect, is closed in high flood conditions, the design is carried out considering this situation also. In this emergency condition, earthquake forces
will not be considered.
When  the  emergency  gate  is  not  in  use,  the  gate  will  be  stored  in  the  top  of  its guides using dogging devices.
1.2       Arrangement of Service Gate
This gate would b> subjected to a water head of 6.60 m corresponding to high flood level and would be required to regulate the flow. Since this  gate is  a low-head gate as  per the international classification, wheel mounted type arrangement is provided as  per USACE publication No. 2701. Gate will have upstream skin plate and upstream sealing and as  such will be suitable for the regulation purposes. The sealing will be of rubber seal coated with fluro-carbon so that friction is minimum. Gate lip is proposed at 45 deg. as per the general practice for minimizing hydrodynamic forces at gate bottom. Since the size of the gate is small, it would be fabricated in single unit.
1.3       Service Gate Operation
The gate shall be of regulating type. If required, suitable ballast shall also be provided for this  purpose. Since the gates  are wheel mounted and the seals  are fluro-carbon coated, friction forces would be minimum. Screw hoist is provided.
1.4       Emergency Gate
One Emergency  head Gate of same size as  service gate will also be provided. This  gate will also be of fixed wheel type and is  designed for higher water level of 2080.1 as  at some time, the canal may  have to be closed under high flood condition.
As  stated above, the service gate shall be of regulating type operating type and shall have to sustain unbalanced operation and are designed to provide these features. However, emergency  gates  shall be lowered under flowing water conditions and shall be lifted under balanced water head conditions created with the help of crack opening of about 150 mm. it shal! not be used for the regulatmg
I
WWDSE, Addis Ababa in Association with -7
ICT Pvt Ltd. and ABCE PLC
Detail Dss^°^ Gaduia Irrigation & Drainage Proj^i October, 2011Ministry of Water and Energy-
Federal Democratic Republic of Ethiopia
Section -1, Volume - V Design of Hydro Mechanical Gates
purposes. Provision of Galvanised iron air escape pipe of dia 100mm has also been made in between emergency gate and service gate for achieving the balanced head conditions
1.5      Design of Undersluices Gates
1.5.1   Design Data
a)   Type of gate: Vertical lift, Low Head
b)  Width of opening
c) Height of opening
d) High flood level (H.F.L) (m)
e) Up-stream pond level (m)
f) Sill/crest level (m)
g) c/c of side seals
h) C/c of wheels
i) Number of units
j) Design Head (m) =
=3.0 m
=2.50 m
=2078.10 m
=2076m
=2073.5 m
=3.15 m
=3.4 m
=2 on each bank
= 2078.1-2073.5=4.6 m
(To account for hydrodynamic forces as per I.S code 4622 /5620, take design head as 6.6 m
k) Total Head
l) Height of gate
1.5.2 Allowable Design Stresses
= 6.60 meters, it is the design head =2.80 m
a) Yield point of structural steel = 2400kg/cm2
b) UT.S of steel = 4200kg/cm2
c) U.T.S of wheel material = 8830kg /cm2
d)  Rim hardened to B.H.N =255
1.5.3    Stresses allowable in various gate components Wet inaccessible Conditions
Direct Compression/Tension in
Bending Stress
Shear stress
Combined stress
Bearing stress
Wheel shear Stress
= 61.4 N/mm2
WWDSE, Addis Ababa in Association with ICT Pvt Ltd. and ABCE PLC
0.40. yp (235 MPa) 960 kg/cm2
0.30y.p
0.50y.p
0.45y.p
2.41 xBHN
720 kg/cm2
1200 kg/cm2
1080 kg/cm2
2.41x255=614 55N/mm2
-2- Detail Design of Bale Gadula Irrigation & Drainago Project October, 2011Ministry of Water and Energy-
Federal Democratic Republic of Ethiopia
Wheel contact stress
Bearing stress in concrete for C25
Shear stress in concrete mix C 25
Bond stress in concrete mix C 25
1.5.4 Stresses allowable in Embedded Parts
Section - 1, Volume - V Design of Hydro Mechanical Gates
2.4xU.T.S = 2.4x883 =2119.2N/mm2
= 60kg/cm2
= as per table in IS 456.2000
depending on 100A /bd
s
= 9kg/cm2
Wet inaccessible conditions
Direct tension/
Bending
0.40y.p
960kg/cm2
Compression                     Shear stress Combined stress Bearing stress
1.5.5   Design Codes
1 Structural steel
2 Wheel pin material 15cr 16Ni having Y.P = 6400kg/cm2
3 Fixed wheel design -
i
4 For concrete stresses
5 For Rubber seals
1.5.6   Design Considerations
0.30y.p
720kg/cm2
0.5y.p
1200kg/cm
0.45y.p
1080kg/cm:
IS-2062 - 2006
I.S 1570 parts 5-1985 I.S 4622:2003
I.S 456 (civil code) I.S 11855- 1986
The Design of gate involves design of the following components:
1.  Skin plate;
2. Horizontal girders, vertical stiffeners and end vertical girders;
3.   Wheels and wheel tracks;
4.   Seals and accessories;
5.   Guide/guide shoes
6.   Wheel track and track base
7.   Guides
8.   Seat, seal base and sill beam
9.  Anchorages.
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V-------------------------------------------------------------------------
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•3- Detail Design of Bale Gadula Irrigation & Drainage Project
October. 2011Ministry of Water and Eneryy-
Ministry or vvmw w
Federal Democratic Republic of Ethiopia____________
s ection~ l, Volume i,
Design of Hydro Mechanicals'^
I PAD TRANSFER SYSTEM
• The static water load transferred from upstream side of gate to R.C.C pier on the downstream side as shown:-
pressure at downstream: o* gate in sluice, an extra head of 2m of water has been added as per IS codes 4622/2003 and 5620-1978.
■•Changed Design Leve Height of gate
15.8 Water Thrust Diagram
Trapezoidal ABCD
= (4 0*6 50)/2x2.8x3 15 = 46 30 Tons
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(Say) = 50.00 T
1.5.9   Horizontal Girder
B ,M =y (where “L” is the span c/c of wheel)
Section -1, Volume - V Design of Hydro Mechanical Gates
= 50X3 4 = 21.25 T-m = 21.25 x 10 5
8
kg-cm
B.m 21,25 X105 Z required =----------  =-----------------
stress                960 Z required = 2213.54 cm3
2125000 960
= 2213.54 cm3
3
Provide there Nos. ISMB 350 having Z„ 778.9 cm3  each
(i.e 778.9 x 3 ) cm =2336,7 cm3
Z required =2213.54 cm3
Z provided = 2336.7 cm3
The horizontal girders will checked for deflection which will be limited to —-
(where L is the span c/c of wheels) as per clause 5.35 of IS 4622 - 2003) (Water thrust diagram)
800
B = 0.5x(5.85+5.0) x0.85 =
4.611 m*
C = 0.5x(5.0+3.95) x 1 05 =                   4 698 m* Areas of A.B.C are almost equal
Load  in  portion  A  =  4  67X3  4  =  15.88  T
B = 4 611 x 3.4= 15.67 T
C = 4 698 x 3 4 = 15 97 T
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'
Detail Design at flate Dacula Irrigation i Drainage Pro/ect Oc'ober 201 ’Ministry nf Water end Energy-
t-vdvral F^ernot mt* Republx 0? f ,»»».•/*••’
Section - I. Volume V Design of Hydro Mechanical Gales
J
505
P59
804
382
6CT
(Load diagram of wafer thrust will be as above)
Maximum I oad-15 88> W00’34?~4E 5< kc
Sa\ loac  - 5C kg'err cConaioe^nc  the offer4 o* fixed end moments  though a detatfec  analva* i? reoumec  bir r has  hee^ found as  per experience that only *0^ tncneaae tn th* *oact»o^ w»* he sufherent
S wf*
Actua oefiectior- r Grde* f ■             > “
*a< r x / ,
r
... wii bt calculator tn cons»oe^n; me oo-actng widt** o* skin plate
A? pm clause 5 7 < o' !S 4622     2X3 co-ecfrnp widt* shall be least of following r) 40 < F
7
• 40 * 16 *126 « 64( - 126 «  65m~
Where
t « * the fhionest o' skk pwu tr the *** r a « 16mm
8* w»d?’ o' groe fw'ipt r corner we* »>* put*
a)  0 11 o' span «C 11 x 3 .4(m * C ' laMOOmm * 374 mm « 37 4cm
Mi C/< distance berfwee pirn - ttt Wi Therefore cc-sebne w*df> - 3/4 me
Gc  acting  widu  •  37  cn t tlc^^r thu>riotoe
O    Oktf    piatee    -    1t    L allowance- 14 t nwi
a
;*
;a
a
■
taJ
W
W
M
w
1 1
r
4 T“
y ft nr
f
-151w
4! cr»
M/W7 St AUtl>. Ahul>. h Aajmj.
• •     . I. tn,. At> : *-.
^Ill t
Ifeiai 1
w
w
wMinistry nf Wntnr find f nnrqy
f ndnrnl Dnmnc.rafir. FtofMihli' of f fhinpia
fAking moments of ataa About x / 37x1 45 (0.725) *66.71 (17.5-1 425/2) 37x1 45*66 71
1R RR94 t 121S 6         1254 4R
Section - z, Volume - V 0^ /7/ of I • Mn'-hnnirtil C, itv;
---------------------------- ----------- 10 422 cm
71             120 ?6
M o I of com bin Ad section
- 37x1 45 (10 422 - 0 725/ *-66 71 H 7 5*0 725 - 10 422/ *'3630 -J-'
4
- 37x1 45794 03)*65 71 x 50 886)* *3630 cm = 5044* 4G6’*’363C
-  22735 cm4
Max Reaction of E - 50 0 *g/cm
Actual deflection m girder -------------------- -- — t 50x340*4/2 */*G*5/2Z '36
?
5
r
y
1R«t p t
1R4
= 0 182 cm Allowable deflection -
Will -Win
-
175 ~r
Since Actual    deflection is ess ’b* vHcwMM Hence safe
Total panels
4M
48*
4«r              4M
AM
——
Pwir! PSM* 1! P«W! ill tad !V
«»—
-*•
e a
• >♦»
X
•e» 1
UM
a
♦
4
1 5 W D**iyn of Ptate
CnecMtny the *
* aiMs n
j/ovoo
iUT’&hn* >f 2mm 4 a
spacing of 4db
nm
0 -oOo
'"McancMMb
of eun
- 1dmm
4 - 4dc
1
- o nm
\m»i rujy 
-1oi
i
j
lub 4OC
/H
14 i
nm
• 
f Jity kod li nJ 
a/tu-l juiyo jhh> 4: f
• iat«
j Jumx                               Hh^hua % J'Whi|RMinistry of Water and Energy-
Federal Democratic Republic of Ethiopia
Section -1, Volume - v Design of Hydro Mechanical Gates
(Load diagram of water thrust will be as above)
Maximum Load=15.88x1000/340=46.52 kg
Say load = 50 kg/cm,cConsidering the effect of fixed end moments, though a detailed analysis is required, but it has been found as per experience that only 10% increase in the reaction will be sufficient.
5           w?4 Actual deflection in Girder E = — X —
384 E X-/xx
L will be calculated by considering the co-acting width of skin plate
As per clause 5.2.4 of IS 4622 - 2003, co-acting width shall be least of following:-
i)   40t + B
= 40 x 16 +125 = 640 + 125 = 765mm
Where :-
t = is the thickness of skin plate in this case it is = 16mm
B= width of girder flange in contact with skin plate
ii)   0.11 of span =0.11 x 3.4(m) =0.11 x3400mm = 374 mm = 37.4cm
iii)   c/c distance between given = 895 mm
Therefore co-acting width = 374 mm
Co-acting width = 37 cm
Effective thickness
Of   skin   plates   =   16.0   -   1.5   (crossing allowance^ 14.5 mm
= 1.45 cm
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Detail Design of Bale Gadula Irrigation & Drainage Project* October, 2011Ministry of Water and Energy-
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Section - I, Volume - I
Design of Hydro Mechanical Gates
Taking moments of area about x - x
37 X1.45 (0.725)4-66.71 (17.5+1.425/2)
37x1.45+66.71
38.8896+1215.6           1254.48
=---------------------- =------------- = 10.422 cm
53.65+66.71             120.36
M.o.l of combined section
=  37x1.45  (10.422  -  0.725)2   +66.71  (17.5+0.725  -  10.422)2   +13630  cm4 = 37x1.45(94.03)+66.71x 60.886)+13630 cm  = 5044+ 4061+13630
= 22735 cm4
Max Reaction of E = 50.0 kg/cm
4
5
Actual deflection in girder = — 
384 E X Ixx 384
5
= — x 50x340A4/2.1/10A6/22735
= 0.182 cm
Allowable deflection = — = = 0.425 cm
800 800
Since actual deflection is less than the allowable
Hence safe
Total panels 7 of 486 mm
Water load in meter
Panel I
A
0.505
y           4.4.455
Panel II
0.1)59
1           5.414
Panel III
0.896
T
1 6.218
Panel IV
0.416
1 6.60
t
1.5.10   Design of Plate
Checking  the  skin  plate  in  panels,  provide  vertical  stiffeners  of  12mm  ata spacing of 486 mm
b =505
a = 486
- =505/486 = 1.04
a
Thickness of skin plate = 16mm corrosion allowance = 1.5 mm
Net thickness = 16-1.5
= 14.5 mm
Two  long  edges  and  one  short  edge  rigidity  fixed  and  short  edge  similarly supported
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October. 2011Ministry of Water and Energy-
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Section -1, Volume - V Design of Hydro Mechanical Gates
k ax= 30
/c a 2 Bending stress = —p—
Fig 7 of IS 4622-2003
*
locr s2
= 0.3 x 0.42 x 48.6x48.6/1.45/1.45=141 Kg/cm2,960 kg/cm2 Hence safe
Panel II
b= 1080
a = 486
- =959/486=1.973
a
In this case all the edges are rigidly fixed /c3x =60
fig 5 of IS-4622 -200
Bending °
stress  =  —p—  =0.60x0.49x959x959/1.45/1.45=330
100 s2
2
kg/cm <
960  kg/cm2
Hence safe
Panel III
b=804, a = 486, - = 804/486=1.675
i
2
a
In this case, also all the edges are rigidly fixed
^3x = 53
Zc CL2
(Bending stress) oc3x = -^—= 345 kg/cm2< 960 kg/cm  Hence safe
Panel IV
Two short and one long edges rigidly fixed and one long edge similarly supported it will have lesser stress.
VERTICAL STIFFENER
Taking panel II
AB = 2 (24.3 x 95.9) x 0.490 = 2283 kg
Take panel III also
2(24.3x80.4) x 0.58 = 2266 kg
Panel IV = 2 (25x41.5)x0.6522 = 1353 kg
So take Panel II stiffener load, which is maxi.e = 2626 kg maxB.m = ^ = 2283x80.4/6=30592 kg-cm
shear force = - =3059/2 = 1529 kg
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-8- Detail Design of Bale Gadula Irrigation & Drainage Project October, 2011Ministry of Water and Energy-
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Section - I, Volume - V Design of Hydro Mechanical Gates
supported length L = | x 804 - 322
B = Half of span = 804/2 = 402
— =372/402=0.92
B
Value of V2 w.r.t above value for IS 4622 - 2003 = 0.14 Co-acting width = 2V B = 2x0.14 x 402 = 112.6 mm
2
= 113 mm (Say)
Section
a
cm
Y
Cm
^3
cm
Cm
y cm
av2
Cm44
Self
Cm4
113x14.5
16.38
0.725
13.14
Y,=3.70
2.975
18.125 = (2.975)z
159.31
-
120x12
14.40
7.45
107.25
Y2=9.75
-3.75
14.4 x (3.75)2
= 202.50
bdJ
1.2
1.2x12x12x12
12
Total
30.78
120.42
Total
361.81
172.8
Total = 361.81 +172.8 = 534.61 cm 4
,
Zz=-^r
534.61
=54 8cm
-
Bending stress f, = 30592/144.5= -211.7 kg/cm2
f 2 = 30592/54.8=558.25 kg/cm2
Hence safe < 960 kg/cm2
Shear stress in stiffener
shear area        = 1529.5/1.2/12=106.2 kg/cm2 < 720 kg/cm2
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Hence safe
Combined stress oc  = skin plate stress - 345 kg
x
Section -1, Volume - v
Design of Hydro Mechanical Gates
an
■u
A
= stiffener plate stress = -212kg/cm
Combined stress = V(« x)2
= (345x345+212x212+345x212) 2 = 486.9 kgW< 1200 kg/cm Hence safe
1.5.11  Design of End Girders
Load on one end= 50x340/2=8500 kg
*
Adding further 20%, load will be 1.2x8.5
=10.2 tons
say 11 tons
11 11 11
*
*
0.382
0.804
Of wheels 11 tons
Iereo4 0.402
.959     t of wheels
0|4795
3
1.5.12  Design of Wheels
Total water thrust coming on gate when fully Closed = 50 m.T
B.m = Load x Length
B.M. =11.0x0.4795 = 5,27 t-m
Z„ =5.27x100000/1080 = 548.9. Cm3
Provide ISMC 400           = 754.1 cm3
(More over ISMB 350 will be get fited into II
Horizontal girder each ISMB-350 t = c/c for wheel) as per IS-4622 - 2003 (w) x t
Load = 11x3.4/2=4.675 t-m
Z reqd = 4.675x100000/960=488 cm3 Z provided = 778.9 cm  Hence safe
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< n —77----------------------------------------------------- 77
Design of Bale Gadula Irrigation & Drainage Project
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M
* * M
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v
iMinistry of Water and Energy-
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Section - I, Volume - V Design of Hydro Mechanical Gates
Taking two wheels on each side
Total No. of wheels = 4 Nos
50
Load on each wheel = — = 12.51
4
(Say) The design load for wheel = 15 m.T
a)  wheel load Normal = 15 m.T = 15,000 kg
=150000N
Max = 15,0000 N (Say with one wheel not touching)
b)  wheel dia 350 mm (max)
c)  wheel material steel with U.T.S = 883 N/mm2
Rim hardened to B.H.N =255
Design Procedure
a)  Critical stress =( 0.169 x B.H.N) - 15.174 = (0.169 x 255)- 15.174
2
= 27.92 N/mm  of the projected area
27 92
2
b) Allowable stress = —-— = 9.307 N/mm of the projected area for normal
r
load r
(F.O.S) = 3 or
3
<
r
27.92
2
—:— = 13.96 N/mm  of the projected area for maximum ioad
2
(F.O.S = 2)
c) Projected area required = —-
QQ
9.307
= 16116.9 mm2 for normal load
Qr
~
_ ZZ5000 
= 16117 mm for maximum load
4^4 4-7 2x 
II
13.70
d)  Net thread width required =              = 46.4mm Provide (say) = 50 mm e)  Check for maximum shear stress
P = wheel load = 225.000N Ri = Radius of wheel crown (assumed)
= 700m
R2 = Radius of wheel = ^ =175 mm ft = Poisson ration = - = 0.25
4
B _ 1                1 _ Rx A      2R, 2RX " R,
B+A=4^+i)=|
+
+ (0.00142 + 0.00571)
October. 2011Ministry of Water and Energy-
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= 0.00356 mm.
B
From the fig 12 for — = 4,we get
Section -1, Volume - V Design of Hydro Mechanical Gates
A
i)
ii)          = 0.30
iii)         = 0.27
iv) (1Z -1y ) = 0.24
2y
Substituting these values in equation given in E 1.4 of IS -4622 -2003
2
Z(l-g )
2 (1-0.0625)
2(0.9375)
= _________________
1.875
A = E(A+B~)          = 0.206 X 1O6X 0.00356 " 0.206 xlO6X 0.00356 A 2.556
From ii) we get
0.206 xl03x3.56
a=
—31    Ap ” J 0.30
'I
2 556
225000
= 3/2.556x^|= Vl9l7
J 103                    0.30
-X
y]
0.30
a = 12.42 mm From iv) we get -
(1Z -y )= —
2y
0.24 a
024 *12-^ x 103 = 0 24X1Z -2- =1166 N/mm2
2.556
2.556
= Maximum differential of stress component Maximum shear stress = | (1Z,- y,) - |(1166) - 583
2
2
(Say) = 585 N/mm < 614 N/mm
Hence safe
(Allowable shear stress
= 2.41 x B.H.N = 2.41 x 255 = 614.55 N/mm2
Or
0.7 x U.T.S = 0.7 X 883 = 618 N/mm  Whichever is less) Check for Contact Stress
Substituting in iii)
=0.27
a
Z1 = 0.27 x a = 0.27 x 12.42 or Z1 = 3353 mm
Semi-major and semi minors axis of ellipse of contact are:- a = 12.42 mm
b = k.a =0.41 x 12.42 = 5.09 mm
2
Contact stress = 3~x^=
2 Aao                               2          3.14x12.42x5.09
| x -22™°°"
= 1700 N/mm2
(Say) 1484 N/mm2
which is less than the allowable stress
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2
2119.2 N/mm  (2.4 x U.T.S)
2.4 x 883 = 2119.2 N/mm2
Hence safe
Minimum depth of penetration of Hardness required = 2 x Zt = 2 x 2.93 = 5.86 mm (Say) 6 m.m
Section - I, Volume - V Design of Hydro Mechanical Gates
Therefore adopt Dia of wheel = 350 mm, Net tread width = 50mm
1.5.13   Design of Pin for Wheel
Design load of wheel =15m.T
For Design of pin F.O.S is taken as 5
And material of pin 15 or 16 Ni
Having Y.P = 6400 kg/cm2
(where there is no definite y.p; the same may be taken as 0.2% of proof stress)
Allowable stress = 6400
B.m = — 4
F.OS
15 x 1000 x 30 4
= 1280 kg/cm2 = 11250 kg-cm
B.M Stress
112500 
--------- —  87.89  cm on ______
1280
3
Z for circular section = — d 3 32
Now — d3 =87.89
32
87.89X32
12mm                 15 mcJOO
= 96.36 mm (Say) 100mm SF = - = 7 5 m T
2
= 7500 kg Shear stress = Hence safe
7500                        7500
0.785X10X10             = 95.54 kg/cm <840 kg/cm
2
2
Bearing stress at ends= Hence safe
vv/’>
3750
= 493 kg/cnr< 1560 kg/cm2
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Wt of gate and embedded parts
G = 0.8888 (w hH)
for w2hH< 2000 m4
where
w = span
h = height of gate
H = Head of water in the sill
Section -1, Volume - V Design of Hydro Mechanical Gates
2        0659
W = 3.80 m
h = 2.95m
H = 6.60m
w2hH
(3.8)2 x 2.80 x 6.60 = 266.85 m4
G = 0.8888 (266.85) 0659 =35.3KN = 3.53 M.T
Wt. of embedded parts is approx 0.3 of gate wt.
= 0.3x3.53 = 1.06 M.T
Total wt. of gate and embedded parts = 3.53m.T
.     +1.06m.T
Total          4.59m.T
(Say) 4.60m.T
1.5.14    Track Plate
Thickness of track plate (wheel track with point contact) t = -^- as per IS 4622 - 2003
2c X ft
where p = wheel load in N
2c = track width in mm
ft = allowable track handing stress, in N/mm2
0.4 of y.p of track material use stainless steel as per IS -1570 part 5 =0.4 x 6400
2
= 2560 kg/cm = 256 N/mm
2
Use ISMB - 300 x 140 (width of flage;
t=
1.27 x 15,000 x 10 140 x256
= 5 315 mm
But as per IS code 4522, the minimum thickness of under plate should not be less 10 mm
However provide 20 mm thick track plate of stainless steel with B H N of 300 Bearing stress in concrete -
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1.5.15   Track Girder
£S    1/3
P = 0.2813 xp (—  ^)
p = 0.2813 x 15,000 (---------------- ----------- -)1/3 \ 1 lx 8603.6 X 14x14/
=0.2813 x 15,000 (-------------- ----------------- r)1/3 \(11 X 8603.6x14x14)7
Section -1, Volume - V Design of Hydro Mechanical Gates
—  =m = 11 (modular ratio)
ec
= 0.2813 x 15,000 (——) '264.7l'
= 15.939 kg/cm2
2
~ 16 kg/cm < 60 kg/cm
2
where p = kg = wheel load
I = m.o.l of ISMB 300 in cm4
w  =  width  a  flage  =140  mm =14 cm
Hence safe
track plate 150 x
•___________
J
“e” and 150mm keep 200mm edge distance e'
The track base shall be checked for bending and shear also ab = 0.5 — X
Z \€C W/
= 0.5 x kg/cm2
15,000
573.6
8603.6 i -> (11 x-^) 3 =0.5
14
15.000 X------------
573.6
(18.91) = 247.25 kg/cm2< 960
= 165 kg/cm2
Hence
The  length  of  influence  of  the  parabolic  distribution  under  the  base  may  be  found from the following formula -
<p
-x
2. iv i p
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Where L = length of influence under the track base in mm P = wheel load in; N
W= width of track in contact with the concrete in mm
Section -1, Volume - V Design of Hydro Mechanical Gates
2
2
p = concrete stress in N/mm  which is 11 kg/cm = 1.1 N/mm2
15,000 x io 
140X1.1
= 1461 mm
? of whell________ ? of whell
■--------- 487---------- i------ 487 I |
-967
Max bending stress directly below the wheel
= 11 +2(11)(l-^g|) = 11 +22[l- g£lj = 11 + 22 (1-3.9) = 11 +22 (-2.9)
2
11-S3.8 = -52.8kg/m < 60 kg/cm Hence safe
2
Max shear force -
wheel load.
15,000 
,
2
= —= 7500 kg
Shear area of web = 30 x 0.75 = 22.5 cm2
(tw = 7.5 mm)
Therefore the shear stress
ftw)
USE ISMB - 300
2
Developed = ^77 = 333 kg/cm < 740 kg/cm Hence safe
2
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Section - I, Volume - V Design of Hydro Mechanical Gates
Check for shear stress
Second stage concrete m25
Modular ratio m = 11
Wheel load = 15 m.T =15.000kg
Shear stress in concrete 4 kg/crrr
Load on shear plane = 15.000 x cos 45° = 15,000 x 0.707 = 10605 kg Length of shear plane = (250+140 -14+11x14)V2
= (376 +154)x1.414 = 749.42 mm = 74.94 cm
Length of concrete in longitudinal direction:-
It is mimi of following :-
i)    c to c of wheels = 967 mm
ii)   Length of influence = 1461 mm
Shear capacity of concrete = 4 x 96.7 x 74 94 = 28986 kg It is greater than 10605 kg
Hence safe
No reinforcing bars are reqd
(However minimum shear reinforcement shall be provided.) Check for bending of bottom flange
Use ISMB - 300
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Section -1, Volume - V
Design of Hydro Mechanical Gates
Concrete stress = 11 kg/cm2 Bending stress in bottom flange
b =70
12.3           35x35
=--------- X 11 x-----------------------
100 
1.25x 1.25
a = 400'
b           79 a 350
=0.179
Take min value of
K = 12.3
2
= 1060 kg/cm > 960 kg/cm
2
It is unsafe
Therefore weld 10mm m.s extra (plate at Bottom)
_k 
-— X 11 X ------------------------------- x 11 x----------------- = 327.4
35x35 
12.3           „„              35x35 
,
2
kg/um < 960 kg/cm
2
100 Hence safe
Note:-
2.25x2.25             100 
2.25x2.25
Therefore for wheel track  girder (ISMB -300) an extra plate of m.s  of 10mm thick  must be welded to safe guard against bending of bottom flange. Suitable Welding method may be adopted for the same.
X
\ s
/
/
/
/
/
/
/
/
/
/
J
0
L
•I®-
J
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1.5.16    Gate Body
Thickness = 16 mm
Corrosion allowance = 1.5mm
Effective thickness = 16.0 mm
1.5         mm
14.5       mm
Flat plate with all edges rigid andfixed
b _450
a 450
K 3x = 30.9
Section -1, Volume - V Design of Hydro Mechanical Gates
Bending stress =
^3X
100
=------ X 0.7 X----------------
30.9 
45x45
100 
1.45x1.45
2
= 208 kg/cm < 960 kg/cm
2
Hence safe
A
7
Loading  on  each  stiffener  =  2  (|  x  45  x  22.5)x  0.7 = 708.75 kg
Say 710 kg = w
.M =— =—-— = 5325 kg -cms
6 6
S.F = ^ = 355k5
(u</2)
Stiffener provide and 120 x 12 x 450 Co-acting width of liner plate:- Support length Ln = j x 450 = 180mm
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B = Half of span = ~ = 225 m
= — =o.8 from the curve IS 4622 B 225
Coating width = 2V xB = 2xO.14x225
2
= 63 mm (say) = 60mm
Section -1, Volume - V Design of Hydro Mechanical Gates
V2 = 0.14
Section
a
cm2
Y
cm
^3
cm
Cm
y cm
ay
Cm
l4
Self
Cm4
60x14.5
6x(1.45)
=8.7
0.725
6.307
Y!=4.917
4.192
8.7(4.192)2
=210.00
-
120x12
12x1.2
=14.4
7.45
107.280
Y2=8.533
-2.533
14.4 x (-2.533)2
= 92.39
bdJ
12
1.2x12x12x12
12
Total
23.1
113.587
Total
302.39 +
= 172.8
Total = 302.39 + 172.8 = 475.19 cm4
475.19
4.917
= 96.64 cm3
-7        475 19 Cr ™                      3  3
Z 2 =--------- = 55.69 cm
8..533
Bending stress f,= — = -55.10 kg/cm < 960 kg/cm
2
f 2 =-------- = 95.6 kg/cm2
. 
5325
nr
/
2
55.69 
y
2
Shear stress = SF =— =25kg/cm < 720 kg Hence safe
Combines Stress
oc  = Lining and stress = 208 kg/cm
x
2
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oc4 = Stiffener stress = -55.10 kg/cm2
Section - I, Volume - V Design of Hydro Mechanical Gates
••• Combines stress = x/(a x)2 + (” y)
a
2 “ (ax)
= V(208)2 + (—55.11)2 - (208)(—55.10) = V43264 + 3036 + 11460.8
2
=757760.8 = 240 kg/cm < 1200 kg/cm Bond capacity of stiffener
Max load on the stiffener = 710 kg Stiffener section = 120 x 12 x 450 Bond area = 2 (12 x45) = 1080 cm2
2
Bond stress = Hence safe
1.5.17    Sill Beam
ISMB -300
2
2
1080 = 0.657 kg/cm < 9 kg/cm
Total wt of gate = 3.53m.T
Wtof stem = 1.0 m.T
Total1' 4.5 m.T
Length of sill = c/c of seal + 250
= 2150 +250
= 2400 =240cm Bearing width = 140 mm = 14 cm
Bearing area = 14 x 240 = 3360 cm2
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2. HEAD REGULATOR GATES
2.1         General
Section -1, Volume - V Design of Hydro Mechanical Gates
/ ■ y           -**"
One span of size 2.0m wide x  1.70m high on left bank  is  provided for regulation of the Primary  canal and include one service gate( vertical lift wheel type ), and one emergency  gate of opening 2.0 m wide x  1.70 m including embedded parts, screw hoists for service gate and monorail for emergency gate.
The  sill  of  the  gate  is  at  elevation  2074.3  and  the  pond  level/  Full  supply  level  is 2076.00.
The  gates  have  been  designed  for  water  head  corresponding  to  high  flood  level condition. High flood level is 2078.03 m.
When  the  emergency  gate  is  not  in  use,  the  gate  will  be  stored  in  the  top  of  its guides using dogging devices.
2.2        Arrangement of Service Gate
This  gate would be subjected to a water head of 3.73 m corresponding to high flood level and would be required to regulate the flow. Since this  gate is  a lowhead gate as  per the international classification, wheel mounted type arrangement is provided as  per USACE publication No. 2701. Gate will have upstream skin plate and upstream sealing and as  such will be suitable for the regulation purposes. The sealing will be of rubber seal coated with fluro-carbon rso that friction is  minimum. Gate lip is  proposed at 45 deg. as  per the general practice for minimizing hydrodynamic  forces  at gate bottom. Since the size of the gate is  small, it would be fabricated in single unit.
'2.3       Service Gate Operation
'
/ e.
The gate shall be of regulating type. If required, suitable ballast shall also be
provided for this purpose. Since the gates are wheel mounted and the seals are
fluro-carbon coated, friction forces would be minimum. In view of this rope drum
hoists are provided at this stage for simplicity of operation and manufacture.
However, if at detailing stage, if considered necessary, any other hoisting
. arrangement like screw hoist or hydraulic hoist is found essential it can be
provided. In both these cases, suitable block-outs and embedment for hoist stem
will be needed. Arrangement of dismantling and supporting the gate and hoist will
also be provided in that case.
2.4 Emergency Gate
In addition to regulating gate, one Emergency  head Gate of same size as  service gate will also be provided. This  gate will also be of fixed wheel type and is generally  subjected to El. 2076.00 m. However, this  gate is  also designed for higher water level of 2078.03 as  some time the repair of service gate is  delayed and higher levels than pond level are there on the upstream
As stated above, the service gate shall be of regulating type and shall have to
sustain unbalanced operation and are designed to provide these features 
However, emergency gates shall be lowered under flowing water conditions and
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Section -1, Volume - V Design of Hydro Mechanical Gates
shall be lifted under balanced water head conditions  created with the help of crack opening of about 150 mm. It shall not be used for the regulating purposes. Provision of Galvanised Iron air escape pipe of dia 100mm has  also been made in between emergency gate and service gate for achieving the balanced head conditions.
2.5       Design of Vertical Lift Gate of Head Regulator on Left Bank
2.5.1 Design Data
S.no
Item
Left bank data
1
Type of gate
Vertical lift wheel type
2
Width of opening
2.0 m
3
Height of opening
1.50 m,
4
u/s Pond Level
2076.00
5
Sill Level
2074.5
6
Max Flood level
2078.103
7
c/c to seals
1.8m
8
c/c of track
2.40 m
9
No of units'
One
10
Design head
5.6 m
11
Height of gate
1.80 m
2.5.2     Allowable Design Stresses
Yield point of structural steel = 2400kg/cm2
UT.S of structural steel = 4200kg/cm2
U.T.S of wheel material = 8830kg /cm2
Rim hardened to BHN = 255
2.5.3     Stresses Allowable in Various Gate Components
Wet Inaccessible Conditions Direct Compression/Tension in
Bending Stress
0.40.p
960 kg/cm2
Shear stress
0.30y.p
720 kg/ cm2
Combined stress
0.50y p
1200 kg/ cm2
Bearing stress
0.45y.p
1080 kg/ cm2
Wheel shear Stress
2 41 x BHN
2.41x255= 614 55N/mm2
= 61 4 N/mnr
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Wheel contact stress
Bearing stress in concrete for M25
Shear stress in concrete mix
Bond stress in concrete mix
2.5.4 Stresses allowable in Embedded parts
Section -1, Volume - V Design of Hydro Mechanical Gates
2.4xU.T.S = 2.4x883 =2119.2N/mm2
= 60kg/cm2
= 4.0kg/cm2
= 9kg/cm2
Wet Inaccessible Conditions
Direct tension/
Bending
0.40y.p
960kg/cm2
Compression
Shear stress
0.30y.p
720kg/cm2
Combined stress
0.5y.p
1200kg/cm
Bearing stress
0.45y.p
1080kg/cm
2.5.5 Design codes
1. Structural steel
IS-2062 - 2006
2. Wheel pin material 15cr 16Ni having Y.P
= 6400kg/cm2
I.S     1570 parts 5-1985
3. Fixed wheel design
I.S 4622:2003
4. For concrete stresses " r
I.S    456 (civil code)
5. For Rubber seals
I.S     11855- 1986
2.5.6 Design Considerations
The Design of gate involves design of the following components:
1.   Skin plate;
2.    Horizontal girders, vertical stiffeners and end vertical girders;
3.   Wheels and wheel tracks;
4.    Seals and accessories;
5.   Guide/guide shoes
6.   Wheel track and track base
7.   guides
8.   seat seat, seal base and sill beam
9.   Anchorages.
Bale Gadula (Left Bank)
2.5.7 Design Calculation
2.5.7.1 General
One unit only on Left Bank (Head Regulator)
Width of span = 2.0 m
h - 1 50 m
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m.F.L = 2078.10
FSL = 2076
Gate H = F.S.L - crest level + freeboard = 2076,00 -2074.5+.3= 1.8 m
2.5.7.2  Water Load
=(3.8+5.6)x1.8x2.15 =18.443m.T Water= 18.5 T
B.m = — = 18.5x2.4/8=5.55 t-m 8
Section -1. Volume - V Design of Hydro Mechanical Gates
Z
reqd
=5.55x100000/960 = 578 cm3
Provide 3 Nos ISMB 200 Zxx = 223.5 cm3, i.e. provided is 670.5 cm3 Horizontal girder ISMB 200 will be provided i.e. same as in case of Yadot Left Bank Head Regulator
2.5.7.3  Checking of plate
Thickness of skin plate = 12mm
K = 58
2.5.7.4    Checking the skin plate in panel
600 600 600 600
P-1
0.342
R2
0.675
R3
0.54
0.243
4--------------------------------  2.40 
Panel I
------------------------------------ ►
k a2
Bending stress = — p — 
°                 100 r s2
2
=55.8/100x0.397x 34.2x34.2/1.05/1.05=234 kg/cm < 960 kg/cm Panel 3
b = 600, a = 540, - =600/540=1.11, K = 29 a
2
2
Bending stress = p jJ= 29/100x0.5x54x54/1.05/1.05=383 kg /cm  <960 kg/cm2
Hence Safe
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2.5.7.5 Design of EndGirder
Load=5.357 tons
Say 6.0 tons
B.m=6.00(0.27+0.243/2)=2.349 t-m Zreqd = 2.349x10000/1080=217.5 cm3 Size of ISMC - 250
Zxxprovided = 305 cm3
As ISMB 200 to be fixed in ISMC - 250 2.5.7.6  Design of wheel
Dia of wheel = 250mm
Tread width = 30 mm
Dia of pin = 70mm
2.5.7.7  Track Plate
Section -1, Volume - V Design of Hydro Mechanical Gates
Thickness of track plate 16 mm (Stainless steel IS - 1570 part 5 Section of track plate 150 x 16mm
B.H.N of track plate = 300 2.5.7.8  Track girder ISMB -250
2
Bearing stress = 5.4 kg/cm < 60kg/cm Bending stress in Track girder
2
2
80kg/cm < 960 kg/cm
2
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Section -1, Volume - V Design of Hydro Mechanical Gates
e               /3
The track base shall be checked for bending and shear also:- Bending stress
oc^ = o.5 (^x-Y
z\Ec wJ
Where:-
oc & =bending stress in N/mm2
P= Load on roller, in N
Z= modules of section of the track base about the N.A, in mm3
Ec= modules of elasticity in concrete, in N/mm2
Es= modules of elasticity in steel, in N/mm2
1= M.O.I of track base about the N.A in mm4
W= width of track base
cc-fr = 0.5x
4000X10 (llx5131.6X10 )
4
410.5x10s                                        125 2
„  4000X10 
=0.5x------------------ - 410.5xl03
(4515800)173
=0.5X—X165.29=8.053 N/mm =80.53kg/cm <960kg/cm
2
2
Hence safe
<
The length of influence of the parabolic distribution under the base may be found from the following formula:
L=
3_ P
2wXp
Where
P = Total wheel load, in N
L =Length of influence under track base in mm
W=width of track in contact with the contact in mm & p= stress in concrete N/mm2
Length of influence
L _ 3XP
~2XwXp
use ISMB 250                  width of flenge = 125mm
= |x6000x10/125/54= 1333.3(Say) 1334mm Half of influence length -1334/2=667 mm
Max bending pressure directly below the wheel = 5 4+2 (5 4) ( 1 - —
X <44.5)- 7
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Section -1, Volume - v Design of Hydro Mechanical Gates
387 = 637 mm
c/c of wheels = 637 mm
Max bending pressure directly below the wheel = 5.4+2 (5.4) (l - ^)=5.4+10.8(l -SS)=5.4+10.8(l - 2.45)
2
=5.4+10.8(1.45)=5.4=15.66=-10.26kg/cm < 60kg/cm Hence safe.
Max shear force = 6000/2=3000 kg
Shear area of web = 25x0.69cm = 17.25cm2 (tw=6.9mm)
Therefore the shear stress
Developed =3000/17.25=258 kg/cm2<720kg/cm2
2
Hence safe
i.e .3 of yp
(.3x2400)=       x2400=720kg/cm2 Hence safe
CHECK FOR SHEAR STRESS IN CONCRETE
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SecfKY? - I V ‘oiume k Des/gn of Hm’.v Me-.•'M •
CHECK FOR SHEAR STRESS IN CONCRETE:- Use ISMB = 250
Width of flange =125
Second Stage concrete M:5
Modular ratio m=11
Wheel load = 6000kg
Shear stress in concrete= 1.9 kg /cm"
Load on the shear plane = 6000xcos 45°=6000x0.707=4242 kg
Length of shear plane = (250+62.5+62.5-10+11x10)V2
Clear cover ‘e’ has been kept 250mm = (375-10+110)x1.414
(Against minimum 150mm as per code .4622 -2003) = (475) x1.414
Length of shear plane = 671.65mm = 67.165cm (say ) 67cm Length of concrete in longitudinal direction:
it is minimum of following:-
i)    C to C Of wheels = 637.5mm
ii)   Length of influence = 890mm
Shear capacity of concrete = 1.9X63.75x67 = 8109kg >4242kg
No reinforcing bar are required
(However mini shear reinforcement shall be provided) CHECK FOR BENDING OF BOTTOM FLENGE
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Design ofHydiv Mochnnicnl Gatos
Check for bending of bottom FLG
Use I SMB 250
Bending stress in bottom plane and concrete pressure = 5.4kg /cm" ex. = —p-=          12 3x5 4x *^266 ka/cm?<960ka/cnv Hence safe
100 V 100 
7X7
2 5 7 PGate hod\
Gate  P-xJy  and  liner  shall  be  cheeked  to  withstand  full  external  pressure  with  the permissible stress of 80% of the yield point stress and the material
Design Head =3 6m
Say (4m)
Thickness provided - 10mm
Hat plate with al edges
ngidlv fixer
’ - M kv * 30 F
<; <Sc
t fleet ive thionesr *~l0mm. ' Sm**- « f 5mm
< 0 85cn
bending stress r He* & max th* oetrnmnec from the following formula as per IS AC*''
45<
I».             **'
j.    •    ~~    I    yvi    •©>    < KM           X’
► - No* fll'iltJHAW/m let U, y •
I * *«lc piotfruu ■ •
• «>u. I - tla WhJtl -
:
VVW/ /‘xZ
A'M*. 
I. 
will
r ; /. 
Af’ r r .Ministry of Wafer nod I nerqy
I adorn! Democratic fdipuhlic of f Ihiopia
S= effective thicknew of plate - 0 85cm
Section - I, Volume - V qn of Hydro Mechanical Gates
- Bending qfrese in kg
?
- 34 7kg/cm '960kg/cm;
5 MO ,
/cm- / 0 4
100
Hence ^afe
45X45
Z 0 #5/0 35
450
4*50
a
400
2 5 7 10 Stiffener*
Loading or •act* tftfferer:
W* 2f; JT45X22 5) XO 4* 4C5*g
Max sending mt s m ? — *------------  •? JC3 5 <q or
MJ5X *S __ ,
H
Max SF - - - 202 5Mq
SflfHtnerj provided rd 90*0x430 Co-acting w»dts of inar state Support langtr • L* * w4SC
- 'WmrMinistry of Water and Energy-
Federal Democratic Republic of Ethiopia
(From the curve as per I.S 4622-2003) V  = 0.14
2
Co-acting width = 2 V B =2x0.14x225=63mm
2
(Say) = 60mm
Section -1, Volume - V Design of Hydro Mechanical Gates
Section
Acm2
y
ay
cm3
cm
Y
Cm
Ay-2
Cm4
I self
Cm4
60 x 8.5 mm
6x(0.85)2
= 6x0.7225
=4.335
0.425
1.8423
Y,-
2.034
Y y 
r
=1.609
4.335x(1.609)2 =4.335x2.589
11.223cm2
60x8mm
6x(0.8)2
=6x0.64
3.84
3.85
14.784
y2-
4.816
Y2=
-1.816
3.84x(-1.8769)2 3.84x3.3
12.664cm2
= 8x3
Total
8.175
16.626
=14.4
Total
38.3cm4
38.3 ^1—
2.034 38.3
z  =--
2
4.816
.. 
= 18.823cm3 =7.953cm'-
Bending, stress f- = ---------- = (-)161,4kg/cm
.         3037.5                                       2  -
18.823
f 2 =           = 382kg/cm2 < 960kg/cm2 Hence Safe
Shear stress =S - = 202.5kg Shear area = 6X0.8 = 4.8cm2
Shear stress =             = 42.2kg/cm2<720kg/cm2
Hence Safe
Combined stress -
oc x = lining plate stress = 347kg/cm2
oc y = stiffeners piate stress = -161.4 kg/cm*
Combined stress a v = x) * 4- (a y)* - (-a x) - (-a y)
V(347;2 + (-161.42;             - <347;(-161.4)=
7(120409)  +  (26050;  -»  (560067;  =  ^202465  =450kg/cm2<  1200kg/cm2 Hence safe
Bond Capacity of stiffeners
May Bonding stress in concrete (allowable)- 9kg/cnrr
•     Load of stiffeners = 405kg
•     Stiffeners section =60x8/450
202 5
III
n
»
B
B
B
B
B
B
B
Bl
B
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BMinistry of Water and Energy-
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Section -1, Volume - V Design of Hydro Mechanical Gates
•     Bonding area = 2(6x45)
= 540cm2
•     Bonding stress = —- = 0.75l<g/cm2
540
•     (say) = approx 1 Okg/cm2
•     < 9kg/m2
Hence safe
2.5.7.17 Revised Sill Beam section
Since the mini width of seal seat for sill Beam As per I.S-4622 =80mm
So take bigger section of ISMB 250 Wt. of gate = 1.80t
Miscellaneous, lugs if required = 0.50t Total weight =2.3t = 2300kg
to = S9
3th stiffener @ 400 tic
Note - length of sill = c/c of side seals +250
=2150+250mm=2400mm = 240cm
Bearing width = 125mm
Bearing area = 12 5x240=3000cm-’
Bearing     stress     developed     in     concrete     =     0.67kg/cm2<60kg/cm-Herce     Safe (So adopt section ISMB - 250 For sill Beam'
wheel frictional - t 40t
0 side seal leaction = 0 970 t
fop seal reaction - 0 40 t
fotal seal leaction <R) = 1 37 t
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Section - /, Volume - V Design of Hydro Mechanical Gates
Use Flu carbon cladded seals to reduce friction
F = pR = 0.2x1.37 t= 0.274 t
wt of gate = 1.8t
Buoyancy  effect  =1.8/7.85  =  0.223.  Net  wt  of  gate  in  water  =  1.8-  0.223  =  1.577 t
Length of sea (Bottom) = 2.6m
Seating pressure =1.577/2.6=0.606t/meter
It is greater than =0.25 +1m
Hence the gate will lower itself.
2.5.7.12 Weight of Gate
Span = W = 2.6m
Height of gate = h = 2m
Head on sill = H = 5.6
2                        2 x 1.8 x 5.6= 68.1m4
The factor w hH = (2.6)
G = 0.8888(68.1)°!5S= 14.35kN = 1.435 T (say) = 1.5 Wt of embedded parts
1.5         x 0.3 = 0.45 t
Total wt = 1.50 t + 0.45 t= 1.95 mT (Say) 2.00 mT Head Regulator (width = 2.0m. ht = 1.5m
Hoist capacity
wt of gate 1.800 m T
|
seal friction 0.277 m T
j.
pre compression C.060 mT
j
wheel friction 1.400 m.T
I
Guide friction 0.100 mT Down thrust 0.020
*
Sum = 3657 t , precompression= 0 692 t Add 20% =4 351
There for provide 6 T screw Hoist Capacity
n "h 36' De,a" DbS,°n °fBale Gaduld l,IUJd,IU11 & p'^ct
October 2011Ministry of Water and Energy-
Federal Democratic Republic of Ethiopia
Section - /, Volume - V Design of Hydro Mechanical Gates
3.
3.1
GATES FOR REGULATING STRUCTURES BALE GADULA CANAL SYSTEM
Introduction
Different types of control gates are provided for the canal system of Welmel
Irrigation Project so as to enable the delivery of water in desired operation
pattern throughout the command area. Annexure-I (Part 1 &2) provides the
details of all the gated installations along with discharges through each offtake,
wherever gates are provided.
As   seen   from   the   layout   of   the   civil   structures,   the   gates   provided   at   different
locations  are  low  head  gates  having  heads  less  than  15  m  as  per  the  universal
classifications   provided   under   different   international   standards   like   IS:   5620,   DIN
19704  and  USBR  guidelines.  It  can  also  be  seen  that  gates  are  having  sealing
only  on  three  sides  i.e.  two  sides  and  bottom.  Top  sealing  is  not  envisaged.  In
view   of   this   background,   all   the   gates   are   designed   and   provided   with   features 
commensurate with low head gates.
The   gate   openings   vary   from   very   small   opening   sizes   such   as   300   mm   to
moderate widths of 3100 mm.
Provision of Gates in Canal System are detailed in Appendix I
3.2
Selection of Gate Type
In  view  of  such  large-and  multidimensional  openings,  it  would  be  uneconomical  as 
well  as  cumbersome  to  design  individual  gated  installations.  As  such  it  is  proposed
to group the gates as under
Group A Gates having opening and height up to 1000 mm
Group B : Gates having opening and height from 1000 mm to 1500 mm
Group C : Gates larger than 1500 mm width and height
For  gates  under  Groups  A  and  B  it  is  proposed  to  provide  cast  iron  gates  which
are  suitable  for  low  heads  and  are  generally  available  off  the  shelves  at  reputed
vendors.  However,  the  vendors  supply  cast  gates  as  per  the  standard  sizes  and
patterns   available   with   them.   In   view   of   this,   the   gates   of   available   sizes   are
required  to  be  provided  only  It  may  be  possible  that  a  particular  gate  may  seem  to
be  somewhat  bigger  than  the  openings,  but  it  cannot  be  avoided  due  to  feasibility 
and  economy  considerations.  It  may  be  necessary  to  change  the  gate  groove  etc.
for  accommodating  these  gates.  However,  opening  sizes  are  retained  as  per  civil
structure
Considering above factors  and the availability  of standard gates  with the vendors,
gates at various locations are provided as below
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Section -1, Volume - V Design of Hydro Mechanical Gates
S.No.
Gate of openingWidth x
Height
IS CODE NO
1 to 6 (6 Nos)
,2.0m x 1.2 m
As per IS 13349:1992
7 (1 No)
2.0 mx 0.90 m Type C2
IS 13349:1992
8 to 10 (3 Nos)
1.8 mx 0.9 m Typed
IS 13349:1992
11 to 14 (4 Nos)
1.8 m x0.8m Type C1
IS 13349:1992
15 to 19 (5 Nos)
1.5 mx 0.70 m TypeBI
IS 13349:1992
20 to 25 (6 Nos)
1.5mx0.50m TypeBI
IS 13349:1992
26 to 30 (5 Nos)
1.0m x 0.40 m TypeA5
IS 3042:1965
1 to 2 (2 Nos)
0.50x1.05 TypeAl
As per IS 3042:1965
3 to 4 (2 Nos)
0.80x1.05 TypeA3
As per IS 3042:1965
5 to 6 (2 Nos)
0.70x1.05 TypeA2
As per IS 3042:1965
7(1 No)
0.70x0.75 TypeA2
As per IS 3042:1965
8(1 NoO
0.80 x 0.75 type A3
As per IS 3042:1965
9 (1 No)
0.70x0.75 TypeA2
As per IS 3042:1965
10(1 No)
0.80x0.75 Type A3
As per IS 3042:1965
11 to 13 (3 Nos)
0.70x0.65 TypeA2
As per IS 3042:1965
14 (1 Nos)
0.90x0.65 TypeA4
As per IS 3042:1965
15 to 16 (2 Nos)
0.80x0.55 Type A3
As per IS 3042:1965
17(1 Nos)
0.70x0.55 TypeA2
As per IS 3042:1965
18 to 19 (2 Nos)
0.50x0.55 TypeAl
As per IS 3042:1965
20 (1 No)
0.50x0.35 TypeAl
As per IS 3042:1965
21 (1 No)
0.70x0.35 TypeA2
As per IS 3042:1965
22 (1 No)
0.90x0.35 TypeA4
As per IS 3042:1965
23 (1 No)
0.70x0.35 TypeA2
As per IS 3042:1965
24 (1 No)
0.50x0.35 TypeAl
As perlS 3042:1965
25 (1 No)
0.80x0.35 Type A3
As per IS 3042:1965
26 1 No)
0 70x0.25 TypeA2
As per IS 3042:1965
27 (1 No)
0 80 x 0.25 type A3
As per IS 3042:1965
28 (1 No)
0.70x0.25 TypeA2
As per IS 3042:1965
29 (1 No)
0.50x0.25 TypeAl
As per IS 3042:1965
30 (1 No)
0 70x025 TypeA2
As per IS 3042:1965
3.3       Maintenance Bulkheads / Stoplogs
All   the   head   regulators   and   cross   regulators   are   provided   with   maintenance gates upstream of the main gates so that they can be maintained whenever
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Section -1. Volume - Design ofHyd^ Mec^a' ze
necessary. For standard gates  stop logs  shall be provided for repa.r. For gates  a various  off takes, provision of the maintenance bulkhead is  not cons  cere: necessary. However they  can be selectively  provided in case the need anse^ at later stage while detailing..
3.4       Operating Mechanisms
Since the gates  and the imminent water heads  are essentially  low. the resulting hoisting capacities  are also small. In view of this  consideration, it is  proposed to provide operation of all the gates  with the help of hand operated screw hoists  of standard capacities for simplicity.
3.5       Gate Construction
Gates under groups A & B are fabricated out of cast iron of grade IS.210 and
different materials described under technical specifications. Arrangement of the structural members shall be as per the design and layout in line with the
calculations.
3.6       Installation & Constructional Specifications for Standard Sluice Gates
Detailed write up covering the criteria of the choice of gates  and related specifications  including the material specifications, test procedures, acceptance
criteria and painting requirements are in the subsequent paragraphs
3.7
Installation & Construction Specifications for the Selection of Standard
Sluice Gates
3.7.1
A: Selection
Various  factors  guiding  selection  of  a  sluice  gate  are  adopted  as  under  Type  of
Application
Various  types  of sluice gates  are available to suit specific  application. Various 
applications and the most suitable type of sluice gate that should be used for that
application is given hereunder.
A)     For isolation of flow in and out of a closed conduit.
B)      For  isolation  of  flow  in  and  out  of  an  open  channel.  Channel  side  wall
mounting gates as perAWWAC513.
C)      For  weir  application  for  controlling  level  of  liquid.  Downward  opening  weir
gates.
D)     For drainage from outfall structures and plants to: Flap gates / tide gates I
automatic
drainage gates
E)     For modulation of flow in and out of a closed conduit.
The above stated applications cover most of the general applications for which
gates are used and the selection for gates is based on the above criteria and
standards
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Section-I, Volume -y Design of Hydro Mechanical Gate*
Face wall mounting sluice gates are as per IS13349/ AWWAC560/BS7775/
IS3042.
3.7.2   Type of mounting
3.7.2.1 Mounting on face of wall (to isolate flow in and out of conduit)
3.7.2.2 Mounted on face of wall through C.l. wall thimble
These gates  are mounted on to the flange of C.l. wall thimble with the help of studs. A wall thimble is a separate accessory which is first embedded in the wall with its  flange flush with the face of wall. Since no portion of the gate frame is embedded in the wall, the installed gate can be easily removed from its position for repairs, if necessary, without breaking concrete and can be remounted again with equal ease. The thimble can be made and supplied earlier than the gate, and can be installed in position. The gate can be mounted on thimble later. This helps to advance construction schedule. These gates  are flange/flat back  frame gates made generally as per A WW A C5601/ BS 7775/ IS13349 and are suitable for seating as well as high unseating / off seating head applications.
3.7.3 Water Head
3.7.3.1   Seating I on-seating water head
When the water pressure tends to press the door/shutter on to the gate frame then the type of water head is called seating /on-seating water head. Sluice gates as per AWW A C560 I BS 7775/ ISI3349 / 1S3042 are suitable for seating water head application. Gates suitable for seating water head application are provided with side wedges only.
3.7.3.2   Unseating /off-seating water head
When the water pressure tends to push the door/shutter away i.e. unseat from the gate frame then the type of water head is called unseating /off-seating water head.
3.7.4      Type of Bottom Closure
3.7.4.1   Conventional bottom / rebate invert type closure
In case of conventional bottom / rebate invert type closing gates, water sealing at the invert is achieved by providing metallic sealing strips / faces along the edges of the gate. To enable mounting of such gates ample vertical clearance between the invert of gate and invert of chamber/channel is required, This vertical clearance in form of a wall below the gate invert does not allow complete flushing of chamber, if needed. If this is acceptable then conventional bottom closing gates can be used, If gate with conventional bottom closing is installed at a situation, where the bottom of gate opening is to be at the same level as the invert of the chamber/channel or where ample vertical clearance between invert of gate and invert of chamber/ channel is not available, then a recess or a cut out is required. Debris, silt and foreign material may then collect in the cut out/recess and this may prevent the gate from closing fully thereby giving rise to heavy leakage, In such locations only Flush bottom closure gates should be used.
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3.7.4.2 Flush bottom / Flush invert closure
Section - I, Volume - V Design of Hydro Mechanical Gates
In the locations  where there is  no scope of providing ample vertical clearance between the invert of the gate and the chamber floor or especially  in case of channels  where the invert of the gate and the channel floor are to be at the same GATE level, or when complete drainage of the chamber is  required, gates  with flush INVERT bottom I flush invert closing are adopted. In case of flush bottom closing gates, water sealing at the bottom of gate is  achieved by  providing a resilient rubber seal pressing against a machined cast iron face, the contacting faces  between the two being at the same level as  that of the gate invert and chamber/channel floor. This  avoids  the need to provide a permanent slot or cut out or box out in the channel floor. Since there is no slot or cutout at the gate invert there is  no chance of accumulation of foreign material and of impediment to flow and interference with proper closing of gate. Whatever foreign materials  like debris, gravel, silt etc. that might settle at the gate invert get flushed out with the flow as  soon as  the gate is  opened, with flush bottom closing gates, bottom wedges  are not provided since such gates  are free from problems  inherent with deflection of bottom of shutter.
After the gate is erected in position, the temporary recess or cut out required to be
provided in the invert/floor to accommodate bottom portion of sluice gate frame
should be filled up with easily removable materials like asphalt surfacing material
or concrete containing saw dust to ensure unobstructed invert surface.
In   view   of   specific   requirements   of   this   project,   gates   under   B   are   generally considered suitable and are adopted.
3.7.5    Type of Spindle Movement
3.7.5.1  Rising Spindle Gates
The sluice gates  in which the spindle rises  and lowers  during upward and downward movement of shutter while opening and closing of sluice gate are I called rising spindle gates. These gates  have non-rotating spindle and rotating lift nut housed in lift mechanism which remains  well above water level. Since the rotating lift-nut and engaging threaded stem are above the platform, these can be regularly  cleaned and lubricated Moreover, the spindle extending above the lift mechanism also gives an indication of the extent of closure/opening of gate.
3.7.5.2. Non-rising spindle gates
The sluice gates  in which the spindle remains  at the same position during upward and downward movement of shutter while opening and closing of sluice gate are called non- rising spindle gates. These gates  have rotating stem and non rotating lift nut housed in a pocket at the top of shutter which remains submerged
Since the threaded portion of stem and lift nut remain submerged, they  remain exposed to damage and corrosion Regular cleaning and lubrication of such submerged parts  is  impossible Moreover, debris  or rubbish jamming in the spindle threads may create difficulty in gate operation
Since we have ample clearance, raising spindles are provided for the hoists
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3.7.6 Location of Hoisting Mechanism & Thrust Reaction
Section -1, Volume - v Design of Hydro Mechanical Gates
3.7.6.1   Mounted separately on platform away from gate frame / Thrust platform:
When the distance between centreline of gate opening to top of operating platform is  more than 2 times  the height of gate opening then the operating headstock  is  generally  mounted on a civil platform or a fabricated platform located above the gate frame. For such cases  the gate frame can have short length extension guides  to retain at least one half the vertical height of the shutter when the shutter is  in the open position. When the lift mechanism is  mounted on a platform away  from gate frame it is  essential to specify  sill and platform levels  or distance from centre line of waterway  opening to the top of platform for every  gate required.
3.8.6.2Mounted directly on the frame of sluice gate / Thrust on gate frame
When the distance between the centre line of water way  opening and top of operating platform is  not sufficient to accommodate a platform, or when there is  no suitable concrete structure available for mounting the headstock  above the gate, or when making a platform to take the operating load is  impractical or unnecessarily costly, then the operating headstock  is  mounted on the top of gate frame. In this case the thrust reaction comes  on the gate frame and not on the platform. For
-   such   cases   the   gate   frame   is   provided   with   full   length   extension   guides   to   retain the   vertical   height   of   the   shutter   when   the   shutter   is   in   the   open   position.   The extension   guides   are   then   connected   through   a   bridge   I   yoke   which   transfers   the thrust coming from operating headstock on to the gate frame.
We shall adopt any of the mountings described above depending on the condition of
each installation.
3.7.7     Method of Gate Operation
3.7.7.1   ManualOperation
Manual operation of sluice gates is recommended when frequency of gate
operation is low and when there is no constraint in time required for opening and
closing of a gate. Manual operation can be effected by means of either ungeared
or geared type lift- mechanism. Selection of the type of lift mechanism depends 
on the hoisting capacity required for each gate. It should enable gate operation by 
a single person with an effort not more than 20 Kgs. Manually operated gates can
be provided with electric I hydraulic portable operator for faster operation of gates.
3.8.7.2   Mechanized operation
Mechanized operation of sluice gate is  recommended when frequency  of operation of gate is  high and where faster gate operation is  required. Mechanized operation can be effected by  means  of electric  I pneumatic  / hydraulic  actuation. Manual override facility  is  recommended for operation of electric  operated gate in case of electric  failure and for operation of pneumatic  operated gate in case of electric  I pneumatic failure.
o,
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Section - /, Volume - V
Design of Hydro Mechanical Gates
3.7.8    Types of gates considered spigot back frame wall mounted cast iron sluice
gates
3.7.81 Specification
These gates conform to IS: 3042 in general.
3.7.8.2  Application
These gates  are mounted on the face of a wall and are used to isolate flow in and out of a conduit and are manufactured for seating heads  upto 15 meters. These gates are not suitable for unseating head application.
3.7.8.3  Salient Features
•       Spigot  back  frame  designed  for  mounting  on  wall  through  grouting  of  spigot in wallopening and anchoring of frame face on face of wall using anchor bolts.
•       Closed  top  frame  upto  gates  size  1000x1000  mm  and  open  top  frame  for gates bigger than this size.
•     Suitable for seating head application only.
•        Fixed   taper   wedges   on   shutter   to   match   with   adjustable   taper   wedges provided on frame.
•       Non  corroding  metal  to  metal  sealing  faces/strip's  on  the  periphery  of  gate aperture  for  conventional  bottom  closure  gates.  Sealing  faces  fitted  by  counter sunk head machine screws on plain machined faces of frame and shutter.
•     Offered with conventional bottom closing.
•        Provided    with    pin    and    knuckle    type    stem    connecting    arrangement    to connect the shutter with the spindle.
•        Rising   spindle   gate   with   lift   mechanism   mounted   on   separate   platform above gate frame to transfer thrust reaction on platform.
•       Single   piece   or   multi-piece   spindle   as   required   to   connect   the   shutter   to the gate operating arrangement.
•     Couplings as required to connect the multi-piece spindles.
•     Fixed type stem guide brackets as required to guide the spindle.
•     Manual lift mechanism to enable a single person to operate gate with effort <
20 Kgs.
•     Anchor bolts with nuts and washers as required for frame, stem guide brackets 
and pillar of lift mechanism.
•     Offered with painting as required by the client or as stated on page no. 41.
3.7.8 4 Materials of Construction
Depending on application and requirement, we may  select and specify  the material of construction for various  components  from the alternatives  stated elsewhere under these specifications at the detailing stage.
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37.8.5    Shop Testing
•    Leakage test at atmospheric pressure
Section -1, Volume - V Design of Hydro Mechanical Gates
• 
Designed for channel application, breast wall not required.
,
I
•     Movement  test  for  checking  interference  free  movement  of  complete gateassembly
•    Seat clearance check for checking clearance between mating sealing faces 3.7.9   Open Channel Cast Iron Sluice Gates
3.7.9.1   Specification:
These gates are generally made as per standard designs available with the vendors.
37.9.2 Application
These gates are mounted I fixed in between two parallel side walls of an open channel and are used to isolate flow within as well as in and out of an open channel. These are suitable for seating as well as unseating water head but the height of water in both cases should be less than height of shutter.
3.7.9.3   Salient Features
•  r Self contained frame suitable for grouting within the side walls of the channel on two sides and grouting within the floor of channel on bottom. Frame to remain flush with channel walls as well as channel floor after grouting.
•    Suitable for flow from either direction.
•    Metal sealing faces secured in grooves on frame sides to offer non-corroding sealing faces remaining in forced contact with rubber sealing arrangement.
•    Flush bottom closure arrangement.
•    Provided with pin and knuckle type stem connecting arrangement to connect the shutter with the spindle.
•    Single piece rising spindle to connect the shutter to the gate operating arrangement mounted directly on gate frame.
•     Manual lift mechanism to enable a single person to operate gate with effort<20Kgs.
7.10 Materials of Construction
Component
Material
Specification
Gate frame, wall,
Cast Iron
ASTMA126
mounting, head stock,
i-------------------------------------- —------------------------------------------ f
stem guide bracket
I
and wedging devices                     |
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JMinistry of Water and Energy-
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Section - /. Volume - V Design of Hydro Mechanical Gates
Component
Material
Specification
Wedges sealing faces
Ph. Bronze
ASTM B21
LTB
BS:1400
Bronze
ASTM A 240/276
Gunmetal
Stainless Steel
Rubber Seal
Natural or
IS:11855
synthetic rubber
ASTM D 2000
Seal Clamp
Structural Steel
Standard
Connecting
Cast Iron
Standard
block/stem
LTB
Standard
block/Thrust nut
Bronze
Standard
Gunmetal
Standard
Stem/Spindle
Mild Steel
Standard
Coupling'
Mild Steel
Standard
Cast Iron
Standard
Operating Nut
Ph. Bronze
Standard
LTB
Standard
Bronze
Standard
Fasteners
Mild Steel
Standard
Stainless Steel
Standard
Anchor bolts
Mild Steel
Standard
Depending on application and requirement, we may  select and specify  the material of construction for various  components  from the alternatives  stated under G below.
3.7.11 Shop Testing
•   Movement   test   for   checking   interference   free   movement   of   complete   gate assembly.
• Seat clearance check for checking clearance between mating sealing faces.
3.7.12 Optional Features
•      Self  contained  gate  with  lift  mechanism  mounted  directly  on  gate  frame.  Stem cover is made of galvanized steel or transparent tube
•     Gate opening indicating arrangement
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■ Piectricaliy operated « mechanism with manual override faculty 
’ pneumatically operated lift mechanism with manual overnde facility ’ portable electnc / hydraulic operator for manually operated gates
3.7.13 Materials for Fabrication of Gates
adopted if necessary.
3.7.14 Material specifications for the gates and hoists for standard gates
3.7.14.1   Painting Specifications:
Painting of sluice gates is carried out generally as per the requirements of the paint schedule approved by  the purchaser. However when specific  painting specification
or schedule is not provided, then following painting procedure is adopted.
•    Surface preparation: Blast clean or ground to near with metal finish.
•      Priming:  1  coat  of  red  oxide  primer  before  and  after  shop  testing.  Total pnmingthfckness 75 microns.
•      Finish  painting  for  gate  assembly:  2  coats  of  black  bitumen  paint  for  gate assembly.
Total paint thickness inclusive of priming 200 microns.
•    Finish painting for headstock: Grey enamel paint. Total paint thickness 150
microns.
3.7.14.2Standard Accessories
All water control gates shall be supplied with following standard accessories, wher
required.
a)           Lift mechanism I Screw hoist:
Manually   operating   floor   mounting   cast   iron   un   geared   or   geared   headstock   J with floor stand / pillar capable of operating the gate with an effort not more
P'"ars are provided with elliptical window opening
□earpyfh 6 t0 ena^le c,ean|ng and greasing of spindle threads. The un
ea oc^s are Provided wh^n the lifting inoric or® inw and enable easy
I
J
IMinistry of Water and Energy-
Federal pemocratic^epublicofEthiopia^
Section - I, Volume - V Design of Hydro Mechanical Gates
to a bevel or spiral bevel gear arrangement which when operated through a
crank handle, operates the gate. Geared headstocks are provided w
machined gears completely encased in housing to protect from i , u ,
and other atmospheric effects. Geared headstocks are provi e wi
arrangement for lubrication as well as for locking of removable cran
with the pillar after it is removed from the driving shaft.
When the gear ratio required to operate the gate is  higher than 1.7 a two speed geared headstock  is  to be furnished. The slower speed with high gear ratio is  provided for initial crack  opening of gate needing maximum torque. The faster speed with low gear ratio is provided for further opening after the gate is
initially crack opened.
Bench type lift mechanism are pillar less  and are generally  provided for mounting on yoke of self contained frame gate. These can be ungeared or geared depending upon requirement.
Twin lifting headstocks  or tandem operating mechanism is  provided for gates having width of opening greater than twice the height of opening. Twin lifting headstocks  are connected by  tandem shaft for simultaneous  operation of gates.
b)  Stem Spindle:
Single piece or multiple piece spindles  as  required shall be provided to connect the shutter with the lift mechanism. The spindles  are generally  provided with square threads.
c)   Stem Guides:
Adequate number of stem guides  with machine bored split journals, to limit unsupported length of stem within fifty  times  its  diameter. Fixed centre stem guides  are provided when the distance of the centre line of spindle from the face of wall is  less  than 175 mm. These are directly  mounted on face of wall using anchor bolts. The stem guides  have machined bore split journal to facilitate erection. Adjustable type Stem guides  are provided when the distance of the centre line of spindle from the face of wall is  more than 200 mm. These comprise of a right angled bracket to be secured on the face of wall with anchor bolts  and an adjustable guide which can be secured on the horizontal face of the right angles  bracket. The stem guide is  adjustable in a direction perpendicular to face of wall and have machine bored split journal to facilitate erection.
d)   Couplings:
Internally threaded couplings to couple I connect small lengths of stem when stems are to be longer than four to five meters. The couplings are provided with pins passing through engaging spindles for locking. For mild steel stems, couplings are of cast iron and have hexagonal shape For stainless steel stems, couplings are of stainless steel and have round shape.
e)
Stop nut:
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October, 2011Ministry of Water and Energy-
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.          u^Ct'°^~ L Volume ~ V
Cast iron stop nut with set screw on threaded rising stems  of manually operated gates  to prevent chances  of over closing of gate and thus  to avoid chances  of damage to wedge blocks, stem and the operating platform. The safety stop nut is furnished with a set screw for setting it in a fixed position after the gate is installed.
f) Anchor belts
L-shaped   anchor   bolts   for   gate   frame,   stem   guide   brackets   i   and   operating headstock, as necessary.
3.7.15 Optional Accessories
Wherever      necessary,      following      optional      accessories      and      variations      in construction of accessories are offered upon specific request.
3.7.15.I.Pipe hood I Stem cover.
Steel or transparent plastic  (polycarbonate /acrylic) pipe hood I stem cover is provided on headstock  of rising spindle gates  to protect spindle threads  from dirt, dust and weather.
3.8.15.2Gate opening indicator:
Pipe hood type gate opening indication; arrangement is  provided on rising spindle gates; to indicate "OPEN” or "CLOSE" position of gate and if required the extent of gate opening by providing a scale with I cm graduation.
3.7.15.3Foot plate wall bracket:
Foot plate wall bracket is  provided to support headstock  pillar in cases  where civil platform is  not available for mounting of headstock. The bracket is  secured to the vertical face of the wall using anchor bolts  and the pillar is  then secured on the horizontal face of bracket using bolts and nuts.
3.7.15.4Offset centre pillar
Offsetcentre pillar can be used in lieu of foot wall bracket in cases  where civil platform is  not available. The foot of the pillar is  secured to the horizontal face of the vertical wall usinganchor bolts. The top portion of pillar has  an offset bracket which enables  mounting of bench type operating mechanism on it for gate operation.
3.7.15.5Electrically operated lift mechanism with manual override facility:
Electrically  operated lift mechanism comprise of electric  actuators  manufactured by  Rotork  / Aumaand mounted on floor stand pillar. These actuators  enable gate operation between 250-300 mm /minute and are rated for opening or closing of a gate within 15 minute The actuators  are provided with manual override facility  to manually operate the gate in event of electric failure or malfunction.
3 7 15 6Pneumatically operated lift mechanism with manual override facility:
Pneumatically    operated    lift    mechanism    comprise    of    double    acting    pneumatic cylinder which pulls the shutter to open and pushes to close. The pneumatic
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actuating  system  is  generally  designed  for  operating  at  air  supply  pressure  of  5
bars   In   the   event   of   failure   in   air   supply   an   easily   engage   able   overnde arrangement is provided to manually operate the gate.
3.7.15.7Portable electnc / hydraulic operator for manually' operated gates
Portable electnc  I hydraulic  operator is  provided for faster opening of manually operated gates  A common portable operator can be used for operation of a number of gates  of different sizeslocated near each other. The operator is  trolley mounted for ease in transportation from one location to another and for local movement at a particular location.
3.7.16 Shop Inspection Tests
3.7.16.1   Seat Clearance Check
Clearance, if any, between the mating sealing faces  of the gate frame and shutter, in gate fully  closed position is  checked to ensure that 0.10 mm thick  feeler gauge does  not pass  through the mating sealing faces. This  check  is  carried out for each gate.
3.7.16.2Movement Test:
•      The  gate  is  mounted  horizontally  on  a  bed  plate  along  with  stem,  coupling, stem  guides  and  headstock  i.e.  complete  gate  assembly  as  shown  on  drawing and following checks are trade by fully opening / closing the gate once
•      Checking  the  distance  from  centre  line  of  gate  opening  to  base  of  headstock  to verify   that   the   spindle   length   provided   is   of   correct   length.   -   Confirming interference  free  movement  of  spindle  by  checking  that  couplings  do  riot  foul with stem guides while opening / closing of gate
•      Checking  that  adequate  threaded  length  is  provided  for  full  opening  &  closing  of gate  In  a  lot  of  gates  having  same  gate  size,  spindle  length,  s.ame  number  of couplings  &  stem  guides  and  headstock,  this  test  IS  carried  out  on  one  gate assembly selected at random
3.7.16. 3 Shop Leakage Test Under Atmospheric Pressure:
The gate, after applying one coat of primer, is  put horizontally  on the floor in upside down position and water is  filled in the spigot portion of gate frame. Fall in water level is  measured over a specific  period of time. Company  acceptance norms  require that leakage, if any, when tested as  above shall not exceed 1.25 litres  per minute per meter length of sealing perimeter. This  test is  carried out for each gate but only  in respect of those gates  which involve water sealing arrangement all along the complete periphery of gate aperture/opening.
3.7.16.4.  Shop Leakage Tests under Maximum Operating Head:
The gate, after applying one coat of primer, is  mounted on a test bench either vertically  or horizontally. A hydraulic  pressure equal to the maximum operating head above gate centreline is  applied from the back  i.e. unseating side of the gate in closed position. Water leaked through the gate under above maximum
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Federal Democratic Republic of Ethiopia____________________________________ Design of Hydro Mechanical Gates
unseating pressure is  collected and its  volume measured. Leakage acceptance norms as per IS: 13349 requires that the test shall not show leakage in excess of 2.5,3.5, and 4.5 litres per minute per meter length of sealing perimeter for Class 1 (head up to 5 Meters), Class  2 (head above 5andupto 10 meters) and Class  3 (head above 10 and uptol5 meters) Sluice Gates respectively
Leakage acceptance norms as per A WW A C560 shall be followed. After carrying out the test satisfactorily  as  above the gate is  opened slightly  and then closed. Leakage test as above is carried out once again. Thus each gate is shop tested for leakage two times  and each time leakage, if any, has  to be within the respective permissible limits stated above.
3.7.16.5.  Shop Hydrostatic Pressure Body Test under 1.5 Times Maximum Operating
Head:
After satisfactorily  carrying out the leakage test, with the gate mounted in closed position on test bench, water pressure equal to 1.5 times  the maximum operating head is  applied from the unseating side for a period of five minutes. Acceptance norm requires that under this test there shall be no leakage through the metal, nor shall any part be permanently deformed This test is carried out for each gate.
3.7 16.60peratmg Torque Test at Maximum
The gate is mounted on a test bench either vertically or horizontally and hydraulic pressure equal to the specified maximum head above gate centre line is  applied from the back i.e. unseating side of the gate in closed position. The gate is then opened and torque required to operate the gate under above maximum unseating pressure is  measured The acceptance norm requires  that the torque should not exceed 70 Newton I meter
3 7 16 7Dimensional Verification Check
Actual dimensions of gates are verified with reference to the important dimensions given in our general arrangement drawings furnished against each order Variation in dimensions, if any, shall be within the permissible limits as per class III of IS-5519 for castings and extra coarse limits as per IS-2102 for dimensions without specified tolerances
3 7 16 8Review of Material Test Certificates
Material test certificates as agreed for important components like Cast iron castings of gate frame, shutter 8 wall thimble, Ferrous and non ferrous seat facings and spindles etc are furnished for review at the time of shop inspection
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Section - I. Volume - V ____________________ Design of Hydro Mechanical Gates
REFERENCES
1.  WWDSE-Bale Gadula Irrigations drainage Project-Design of Weir and Head regulator-Draft Detailed Design Report April 2010
2.   WWDSE-Bale Gadula Irrigation & drainage Project-Design of Canal and Drainage Structures-Draft Detailed Design Report April 2010
3.   Ethiopian Building Code Standards-2 Structural Use of Concrete
4.   Ethiopian Building Code Standards-4 Design of composite Steel and Concrete Structures.
5.   Bureau of Indian Standards-IS 1570 part V
6.   Bureau of Indian Standards-IS 4622 Design of Fixed wheel gates
7.   Bureau of Indian Standards-IS 11855-1986 Rubber Seals
8.   Bureau of Indian Standards-IS 3042-1965 Cast Iron Gates
9.   Bureau of Indian Standards-IS 13349-1992 Cast Iron Gates
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l('I Ltd Aid ABCb PtC
October 2011Ministry of Water and Energy-
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Section -1, Volume - V Design of Hydro Mechanical Gates
APPENDIX I
Salient Features of Irrigation System Gates for BAGID Project
Gate Opening
Q in the
Take-off
Canal(cumcs
)
Crest Level
S.No
Width
Height
Name of Off-Take/Structure
Chainage
Q in the
Parent
Canal(cumcs
)
U/S FSL
PC
Off
taking
Canal
PC(H
R)
Off-
Taking
Canals
PC(
HR)
Off
taking
Canal
1
Off-Taking from MCs to SC-1-1
1058
3.651
0.023
2061.84
2060.64
2060.79
2.00
0.50
1.20
1.05
2
Off-Taking from MCs to SC-1-2
2789
3.651
0.067
2018.91
2017.71
2017.86
2.00
0.50
1.20
1.05
3
Off-Taking from MCs to SC-1-3
2973
3.651
0.198
2014.97
2013.77
2013.92
2.00
0.80
1.20
1.05
4
Off-Taking from MCs to SC-1-4
4022
3.651
0.084
1980.42
1979.22
1979.37
2.00
0.80
1.20
1.05
5
Off-Taking from MCs to SC-1-5
4445
3.651
0.077
1970.00
1968.80
1968.95
2.00
0.70
1.20
1.05
6
Off-Taking from MCs to SC-1-6
5396
3.651
0.074
1949.80
1948.60
1948.75
2.00
0.70
1.20
1.05
7
Off-Taking from MCs to SC-1-7
6375
3.651
0.101 ;
1938.07
1936.87
1937.02
2.00
0.70
0.90
0.75
8
Off-Taking from MCs to SC-1-8
7041
3.000
0.127
1937.40
1936.45
1936.60
1.80
0.80
0.90
0.75
9
Off-Taking from MCs to SC-1-9
9095
3.000
0.134
1907.10
1906.15
1906.30
1.80
0.70
0.90
0.75
10
Off-Taking from MCs to SC-1-10
10287
3.000
0.245
1896.90
1895.96
1896.11
1.80
0.80
0.90
0.75
11
Off-Taking from MCs to SC-1-11
11421
3.000
0.114
1885.27
1884.32
1884.47
1.80
0.70
0.80
0.65
12
Off-Taking from MCs to SC-1-12
13223
2.352
0.144
1872.22
1871.92
1872.07
1.80
0.70
0.80
0.65
13
Off-Taking from MCs to SC-1-13
14117
2.352
0.144
1860.32
1859.52
1859.67
1.80
0.70
0.80
0.65
14
Off-Taking from MCs to SC-1-14
14117
2.352
0.231
1860.32
1859.52
1859.67
1.80
0.90
0.80
0.65
15
Off-Taking from MCs to SC-1-15
16040
2.352
0.087
1835.40
1834.60
1834.75
1.50
0.80
0.70
0.55
16
Off-Taking from MCs to SC-1-16
17862
1.705
0.131
1822.07
1821.37
1821.52
1.50
0.80
0.70
0.55
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Soction - /. Volume - V Dosign of Hydro Mochnmcal Gntos
Gato Oponlng
Q in the
Q in the
Crest Lovol
Hoight
Name of Off-Take/Structure
Chainage
Parent Canalfcumcs
Take-off
Canal(cumcs
U/S FSL
Off
Oft-
taking
Taking
Canal
Canals
PC(
HR)
Off
taking
Canal
Off-Taking from MCs to SC-1-17
18931
1.705
0.144
1802.00
1801.30
1801.45
0.70
0.70
0 55
Off-Taking from MCs to SC-1-18
18931
1.705
0.060
1802.00
1801.30
1801.45
0.50
0 70
0 55
Off-Taking from MCs to SC-1-19
20038
1.705
0.070
1777.40
1776.70
1776.85
0.50
0.70
0 55
Off-Taking from MCs to SC-1-20
21250
1.705
0.067
1757.43
1756.73
1756.88
0.50
0.50
0 35
Off-Taking from MCs to SC-1-21
21250
1.096
0.111
1757.43
1756.73
1756.88
0.70
0 50
0 35
Off-Taking from MCs to SC-1-22
22087
1.096
0.184
1747.34
1746.79
1746.94
0.90
0 50
0 35
Off-Taking from MCs to SC-1-23
22734
1.096
0.090
1739.45
1738.90
1739.05
0 70
0 50
0 35
Off-Taking from MCs to SC-1-24
23809
1.096
0.111
1724.87
1724.32
1724.47
1.50
0.50
0 50
0 35
Off-Taking from MCs to SC-1-25
24400
1.096
0.131
1715.28
1714.73
1714.88
1.50
0 80
0 50
0 35
Off-Taking from MCs to SC-1-26
25949
1.096
0.131
1687.23
1686.68
1686.83
1.00
0 70
0 40
Off-Taking from MCs to SC-1-27
0 25
26710
0.420
0.194
1669.22
1668.97
1.00
0.80
Off-Taking from MCs to SC-1-28
0 40
29628
0 25
0.420
0.134
1633.90
1634.05
1.00
Off-Taking from MCs to SC-1-29
0.70
29628
0 40
0.420
0.067
1634.30
1633.90
Off-Taking from MCs to SC-1-30
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Summery

Key Project Details

Main Components

1. Undersluice Gates and Hoists

2. Head Regulator Gates

3. Canal System Gates

Design Standards

Key Technical Specifications