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 DETAIL DESIGN REPORT OCTOBER 2011 in association with Water Works Design and Spervision Enterprise (WWDSE) Intercontinental Consultants and Technocarts PVT.LTD.(ICT)Ministry of Water and Energy - Federal Democratic Republic of Ethiopia LIST OF VOLUM ES Section -1, Volume - V Design of Hydro Mechanical Gates SECTION I - DESIGN REPORTS VOLUME I 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 WWDSE, Addis Ababa in Association with -I- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October, 2011Ministry of Water and Energy - Federal Democratic Republic of Ethiopia TABLE OF CONTENTS LIST OF VOLUMES1 TABLE OF CONTENTS11 ABBREVIATIONSV 1. UNDERSLUICES GATES AND HOISTS 1.1 General 1.2 Arrangement of Service Gate 1.3 Service Gate Operation Section -1, Volume - V Dosign of Hydro Mechanical Gates 1.4 Emergency Gate...................................................... ’•.................................................................. 1 1.5 Design of Undersluices Gates2 1.5.1 Design Data2 1.5.2 Allowoble 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 1.5.10 Design of Plate7 1.5.11 Design of End Girders10 1.5.12 Design of Wheels10 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 capocity23 2. HEAD REGULATOR GATES24 2.1 General24 2.2 Arrangement of Service Gate24 2.3 Service Gate Operation24 2.4 Emergency Gate24 WWDSE. Addis Ababa in Association with -II- Detail Design of Bale Gadula Irngation & Drainage Project ICT Pvt Ltd and A9CE PLC October. 2011Ministry of Water and Energy - Federal Democratic Republic of Ethiopia Section - /, Volume - V Design of Hydro Mechanical Gates 2.5 Design of vertical Lift Gate of Head Regulator on left Bank25 2.5.1 Design Dot25 2.5.2 Allowable Design Stresses-25 2.5.3 Stresses Allowable in Various Gate Components 2.5.4 Stresses allowable in Embedded parts..................................................-...............................26 2.5.5 Design codes26 2 2.5.6 Design Considerations & 2.5.7 Design Calculation.................................................................................................................. 2& 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 2.5 7 5.7.7 8 Track Track girder ISMB Plate—--28 -25028 2.5.7.9Gate body.................................................................................................. -—- ------------------------------------- 32 2.5.7.10 Stiffeners33 2.5.7.11 Revised Sill Beam section35 2.5.7.12 Weight of Gate36 3. GATES FOR REGULATING STRUCTURES BALE GADULA CANAL SYSTEM37 3.1 Introduction37 3.2 Selection of Gate Type37 3.3 Maintenance Bulkheads / Stoplogs38 3.4 Operating Mechanisms39 3.5 Gate Construction39 3.6 Installation & Constructional Specifications for Stan daro Sluice Gates39 3.7 Installation & Construction Specifications for the Selection of Standard Sluice Gates39 3.7.1 A: Selection39 3.7.2 Type of mounting~................40 3.7.3 Water Head 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 3.7.4.1 Conventional bottom / rebate invert type closure40 3.7.4.2 Flush bottom / Flush invert closure................................................ ......................................................41 3.7.5 Type of Spindle Movement 3 7.5.1 Rising Spindle Gates 3.7.5.2 .Non-rising spindle gates 3.7.6 Location of Hoisting Mechanism & Thrust Reaction42 WWDSE. Addis Ababa in Association with -III- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October, 2011Ministry of Water and Energy - Federal Democratic Republic of Ethiopia Section -1, Volume - V Design of Hydro Mechanical Gates 3.7.6.1 Mounted separately on platform away from gate frame / Thrust platform:.......................................... 42 3.8.6.2 Mounted directly on the frame of sluice gate / Thrust on gate frame............................................................ 42 3.7.7 Method of Gote Operation......................................................................................................... 42 3.7.7.1 ................................................................................................................................................................ ‘ 3.8.7.2 Mechanized operation............................................................................................................................1 3.7.8 Types of gates considered spigot back frame wall mounted cast iron sluice gates................. 43 3.7Al Specification........................................................................................................................................................ 43 3.7.8.2 Application...................................................................................................................................................... 43 3.7.8.3 Salient Features.....................................................................................................................................43 3.7.8.4 Materials of Construction................................................................................................................................43 3.7.8.5 Shop Testing........................................................................................................................................... 44 3.7.9 Open Channel Cast Iron Sluice Gates..................................................................................... 44 3.7.9.1 Specification:........................................................................................................................................... 44 3.7.9.2 Application...............................................................................................................................................44 3.7.9.3 Salient Features......................................................................................................................................44 7.10 Materials of Construction................................................................................................................. 44 3.7.11 Shop Testing....................................................................................................................... 45 3.7.12 Optional Features................................................................................................................45 3.7.13 Materials for Fabrication of Gates....................................................................................... 46 3.7.14 Material specifications for the gates and hoists for standard gates..................................... 46 3.7.14.1 Painting Specifications:.................................................................................................................................. 46 3.7.14.2 Standard Accessories.................................................................................................................................. 46 3.7.15 Optional Accessories...........................................................................................................48 3.7.15.1 Pipe hood I Stem cover:............................................................................................................................... 48 3.8.15.2 Gate opening indicator................................................................................................................................. 48 3.7.15.3 Foot plate wall bracket:................................................................................................................................ 48 3.7.15.4 Offset centre pillar:........................................................................................................................................48 3.7.15.5 Electrically operated lift mechanism with manual override facility:...............................................................48 3.7.15.6 Pneumatically operated lift mechanism with manual override facility:..........................................................48 3.7.15.7 Portable electric / hydraulic operator for manually operated gates:............................................................. 49 3.7.16 Shop Inspection Tests.............................................................................................................. 49 3.7.16.1 Seat Clearance Check. ................................................................................................................................49 3.7.16.2 Movement Test:............................................................................................................................................ 49 3.7.16. 3 Shop Leakage Test Under Atmospheric Pressure:......................................................................................49 3.7.16.4. Shop Leakage Tests under Maximum Operating Head:............................................................................ 49 3.7.16.5. Shop Hydrostatic Pressure Body Test under 1.5 Times Maximum Operating Head:................................ 50 3.7.16.6 Operating Torque Test at Maximum.............................................................................................................. 50 3.7.16.7 Dimensional Verification Check.................................................................................................................... 50 3.7.16.8 Review of Material Test Certificates............................................................................................................. 50 REFERENCES....................................................................................................................................... 51 WWDSE, Addis Ababa in Association with -IV- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October, 2011Ministry of Water and Energy - Federal Democratic Republic of Ethiopia ABBREVIATIONS Section -1, Volume - V Design of Hydro Mechanical Gates 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 IS Indian Standard Kg Kilogram Kg/m Kilogram per sq m m meter mt metric tone mm millimeters -/ m/sec m2 meters per second SqMeters m3 cubic meters USACE United States MPa Mega Pascal N/mm2 Newton per sq mm Ni Nickel W Load YP Yield Point Z Section Modulus WWDSE. Addis Ababa in Association with -V- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October 2011IB IB kn mi mMinistry of Water and Energy- Federal Democratic Republic of Ethiopia 1. UNDERSLUICES GATES AND HOISTS 1.1 General Section -1, Volume - V Design of Hydro Mechanical Gates 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 service gates (vertical lift wheel type ), and one emergency gate for opening 3.0 m x 2.65 m high The required embedded parts, hoists and mono rail arrangement will also be provided. Service 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 bfe 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 shall not be used for the regulating WWDSE, Addis Ababa in Association with -1- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCS PLC 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 a) Yield point of structural steel b) UT.S of steel = 4200kg/cm2 = 6.60 meters, it is the design head =2.80 m = 2400kg/cmz 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 0.40. yp (235 MPa) 960 kg/cm2 0.30y.p 0.50y.p 0.45y.p 2.41 x BHN 720 kg/ cm2 1200 kg/cm2 1080 kg/cm2 2.41x255=614.55N/mm2 WWDSE, Addis Ababa in Association with -2- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt Ltd. and ABCE PLC Oc ber 2011 *Ministry 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 lOOAj/bd = 9kg/cm2 Wet inaccessible conditions Direct tension/ Bending 0.40y.p 960kg/cm2 Compression Shear stress 0.30y.p 720kg/cm2 Combined stress Bearing stress 0.5y.p 0.45y.p 1200kg/cm 1080kg/cm 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 1 r IS 4622:2003 4 For concrete stresses I.S 456 (civil code) 5 For Rubber seals l.S 11855- 1986 1.5.6 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, seal base and sill beam 9. Anchorages. WWDSE, Addis Ababa in Association with -3- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section -1, Volume - V Design of Hydro Mechanical Gates LOAD TRANSFER SYSTEM ■ The static water load transferred from upstream side of gate to R.C.C pier on the downstream side as shown:- 1.5.6 Basic Data Width of c/c of seals c/c of wheels =3.0 m=3000 mm =3150 mm = c/c of seals +250 = 3150+250 =3400mm 1.5.7 Hydro Dynamic Forces In order to account for the sub atmospheric j—tl. W«.X> EL we.oo j—rLJon^O pressure at downstream of gate in sluice, an extra head of 2m of water has been added as per IS codes 4622/2003 and 5620-1978. •••Changed Design Level Height of gate 1.5.8 Water Thrust Diagram Trapezoidal ABCD = (4.0+6.50)/2x2.8x3.15 = 46.30 Tons = 2080.1 (2078.1 +2) (M.F.L) = 2076.00-2073.5 +0.3 = 2.50 +0.3 = 2.80 m l/VWDSE. Addis Ababa in Association with -4- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt Ltd. and ABCE PLC *' Oc ber 2 011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia (Say) = 50.00 T 1.5.9 Horizontal Girder B .M =— (where "L” is the span c/c of wheel) Section -1, Volume - V Design of Hydro Mechanical Gates 8 50 X 3.4 =---------- 8 c = 21.25 T-m = 21.25 x 10 5 kg-cm B.m 21,25 X 10s Z required =--------- =---------------- stress 960 Z required = 2213.54 cm3 2125000 960 = 2213.54 cm3 Provide there Nos. ISMB 350 having Z„ 778.9 cm each 3 (i.e 778.9 x 3 ) cm =2336,7 cm3 a Z required = 2213.54 cm3 Z provided = 2336.7 cm3 L The horizontal girders will checked for deflection which will be limited to — 800 (where L is the span c/c of wheels) as per clause 5.35 of IS 4622 - 2003) (Water thrust diagram) B = 0.5x(5.85+5.0) x 0.85 = 4.611 m2 C = 0.5x(5.0+3.95) x 1.05 = 4.698 m2 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 WWDSE, Addis Ababa in Association with -5- Detail Design of Sale Gadula Irrigation & Drainage Project ICT Pvt. Ltd and ABCE PLC October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section — I, 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 wZ4 Actual deflection in Girder E =-------- X ——— 3 84 E X"lxx 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 'east 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 WWDSE, Addis Ababa in Association with -6- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October. 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section -1, Volume - V Design of Hydro Mechanical Gates Taking moments of area about x - x 37 x1.45 (0.725) + 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.I 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)+66.71x60.886)+13630 cm = 5044+ 4061+13630 = 22735 cm4 Max Reaction of E = 50.0 kg/cm 4 Actual deflection in girder =--------------- = — x 50x340 4/2.1/10 6/22735 5 w-e* 5 AA * 384 E X Ixx 384 = 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 .486 Wafer load in meter Panel I 4 Panel II 0.505 y 4.4.455 ojs9 1 5.414 Panel III QJM T X 6.218 Panel IV 0.416 | 6.60 f 3.4 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 WWDSE, Addis Ababa in Association with -7- Detail Design of Bale Gadula Irrigation & Drainage Froject ICT Pvt. Ltd. and ABCE PLC October. 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia k ax= 30 Bending stress = Section -1, Volume - V Design of Hydro Mechanical Gates Fig 7 of IS 4622-2003 = 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 k 3x =60 fig 5 of IS-4622 -200 2 2 Bending stress = =0.60x0.49x959x959/1.45/1.45=330 kg/cm2< 960 kg/cm2 Hence safe Panel III b=804, a = 486, - = 804/486=1.675 a In this case, also all the edges are rigidly fixed ^3x ” 53 (Bending stress) oc3x = 7^—= 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 = y =3059/2 = 1529 kg WWUSE. Addis Ababa in Association with -8- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section -1, 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) SEFFINER 120 X 12 Section a cm2 Y Cm Ay cm Cm y cm Cm Self Cm4 113x14.5 16 38 0.725 13.14 Y,=3.70 2 975 18.125 = (2.975)' 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 4 534.61 3.70 „ 534.61 = 144.5 cm3 = — =54.8 cm Bending stress (, = 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 : = 1529.5/1.2/12=106.2 kg/cm2 -- ----- -------- shear area < 720 kg/cm2 . WWDSE, Addis Ababa in Association with -9- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Hence safe Combined stress oc = skin plate stress = 345 kg/cm Section -1, Volume - V Design of Hydro Mechanical Gates x 2 oc.y = stiffener plate stress = -212kg/cm2 Combined stress = x/( ax2 ) + (“ y) a 2 ~ (ax)(-ay) = (345x345+212x212+345x212) 2 = 486.9 kg/cm < 1200 kg/cm A 2 2 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 I 11 tons |asQ4_____ lo59__ I of wheels A ff 0.402 | 0.4024^95 0 4795 B.m = Load x Length B.M. =11.0x0.4795 = 5,27 t-m Zxx =5.27x100000/1080 = 548.9. Cm3 Provide ISMC 400 Z„ = 754.1 cm3 (More over ISMB 350 will be get fited into I! Horizontal girder each ISMB — 350 t = c/c for wheel) as per IS — 4622 — 2003 (w) x 4 Load = 11x3.4/2=4.675 t-m Z reqd = 4.675x100000/960=488 cm3 Z provided = 778.9 cm Hence safe 1.5.12 Design of Wheels Total water thrust coming on gate when fully Closed = 50 m.T WWDSE, Addis Ababatin Association with -10- Detail Design of Bale Gadula Irrigation & Drainage Project 3 ICT Pvt. Ltd. and ABCE PLC October, 2011Ministry of Water and Energy- FederalDemocratic Republic ofEthiopia Section -1, Volume - V Design of Hydro Mechanical Gates Taking two wheels on each side Total No. of wheels = 4 Nos 50 Load on each wheel = — = 12.5 t 4 (Say) The design load for wheel = 15 m.T a) wheel load Normal = 15 m T = 15,000 kg =150000 N 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 = 27.92 N/mm of the projected area 2 b) Allowable stress = —:— = 9.307 N/mm of the projected area for normal 27.92 2 •e 3 load r (F.O.S) = 3 or i " —-— = 13.96 N/mm of the projected area for maximum load (F.O.S = 2) c) Projected area required = = 16116.9 mm2 for normal load Or - — 96 =16117 mm for maximum load d) Net thread width required = = 46.4mm Provide (say) = 50 mm e) Check for maximum shear stress P = wheel load = 225.000N Rt = Radius of wheel crown (assumed) = 700m R2 = Radius of wheel = =175 mm H = Poisson ration = - = 0.25 27.92 - B_1 1_ 4 _ 700_ A 2R 2R ~ R ~ 175 2l2 = + *<° 00142 + 0.00571) WWDSE, Addis Ababa in Association with -11- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia = 0.00356 mm. $ Section - I, Volume - V Design of Hydro Mechanical Gates From the fig 12 for - = 4,we get A i) K = 0.41 ii) =0.30 a3 iii) - =0.27 iv) ; (1Z -1y ) = 0.24 zy Substituting these values in equation given in E of IS -4622 -2003 Z(l-/z ) 2 2 (1-0.0625) 2(0.9375) 1-875 A = E(4+B) ~ 0 206 x 106x 0.00356 “ 0.206 x 106x 0.00356 * 2S56 0.206 X1O3X3.56 From ii) we get J io3 x 0.30 l 2-556 __ 225000 = " yj 12.556 x —0.=30 VT9T7 a = 12 42 mm From iv) we get ~ (1Z -y )=— = . 0.24 a 0.24x12.42 2y 2 _5S6 x 103 = 0.24 X 12.42 2.556 = 1166 N/mm2 = Maximum differential of stress component Maximum shear stress = | (1Z y,) = |(1166) = 583 r (Say) = 585 N/mm < 614 N/mm 2 2 2 Hence safe (Allowable shear stress = 2.41 x B.H.N = 2.41 x 255 = 614.55 N/mm2 Or 0.7 x U. ES = 0.7 X 883 = 618 N/mm Whichever is less) Check for Contact Stress Substituting in iii) =0.27 a Z, = 0.27 xa = 0.27x12.42 orZ, = 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 Contact stress = - x -— = 3P 2 Aab 3 2 x 225,000/V 3.14x12.42x5.09 = 1700 N/mm2 (Say) 1484 N/mm2 which is less than the allowable stress WWDSE, Addis Ababa in Association with -12- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia 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 Zi = 2 x 2.93 = 5.86 mm (Say) 6 m.m Section -1, 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 =-------- F.OS 15x 1000x 30 = 1280 kg/cm2 4 Stress 4 = 11250 kg-cm Z for circular section = — d 3 32 Now ~ d3 = 87.89 d 3 _ 87,89X32 7t d _ 3 187,89X 32 _ 3V87 89X32 \ 3.14 = 9.636 cm = 96.36 mm (Say) 100mm S.F=y = 7.5m.T = 7500 kg 2 = 95.54 kg/cm <840 kg/cm 2 Hence safe Hence safe ZWDSE, Addis Ababa in Association with -13- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October. 2011Ministry of Water and tnergy- Federal Democratic Republic of Ethiopia Section -1, Volume - V Design of Hydro Mechanical Gates Wt of gate and embedded parts G = 0.8888 (v/hH)0 659 for w2hH< 2000 m4 where w = span h = height of gate H = Head of water in the sill W = 3.80 m 'J w2hH h = 2.95m I (3.8)2 x 2.80 x 6.60 H = 6.60m J = 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 2 = 2560 kg/cm = 256 N/mm Use ISMB - 300 x 140 (width of flage) t= 1.27x15,000x10 140X256 = 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: - WWDSE, Addis Ababa in Association with -14- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October, 2011/ *■ Ministry of Water and Energy- Federal Democratic Republic of Ethiopia 1.5.15 Track Girder Section -1, Volume - V Design of Hydro Mechanical Gates P = 0.2813 \sxlxw* xp (—?)1'3 — m = 11 (modular ratio) = ec pH = 0.2813 x 15,000 f-------- ———-) \llx 8603.6 x 14x14/ 1'3 =0.2813 x 15,000 (------------ ---------------- -)in \(11 X 8603.6 x 14 x 14)/ = 0.2813 x 15,000 (-^—) '264.71 = 15.939 kg/cm2 2 2 = 16 kg/cm < 60 kg/cm Hence safe where p = kg = wheel load I = m.o.l of ISMB 300 in cm4 w = width a flage =140 mm =14 cm track plate 150 x “e" and 150mm keep 200mm edge distance 'e' The track base shall be checked for bending and shear also ab = 0.5 - f—x-)1/3 Z \€C wj . 15,000 = 0.5 x--------- 573.6 kg/cm2 = 165 kg/cm2 Hence (Hx^^O.5 x 1^000 14 573.6 (18.91) = 247.25 kg/cm2< 960 The length of influence of the parabolic distribution under the base may be found from the following formula:- - 3 p 2 w xp WWDSE. Addis Ababa in Association with -15- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. and ABCE PLC October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section -1, Volume - V Design of Hydro Mechanical Gates 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 2 2 p = concrete stress in N/mm which is 11 kg/cm = 1.1 N/mm2 3 15,000x 10 - X--------------------- 2 140X1.1 = 1461 mm 967.0 415 Max bending stress directly below the wheel = 11+2(11)(l-gg£) = 11+22 [l- §§] = 11 +22 (1-3.9) = 11 +22 (-2.9) 11-63.8 = -52.8kg/m < 60 kg/cm z 2 Hence safe Max shear force =--------------- =---------- = 7500 kg wheel load 15,000 . 2 2 Shear area of web = 30 x 0.75 = 22.5 cm2 (tw = 7.5 mm) Therefore the shear stress (tw) USE ISMB - 300 Developed = = 333 kg/cm2< 740 kg/cm2 Hence safe WWDSE, Addis Ababa in Association with -16- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd. andABCE PLC October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia^ Section -1, 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,OOOkg Shear stress in concrete 4 kg/cm2 Load on shear plane = 15,000 x cos 45°= 15,000 x 0.707 = 10605 kg Length of shear plane = (250+140 -14+11x14)72 = (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 WWDSE, Addis Ababa in Association with -17- Detail Design of Balo Gadula Irrigation & Drainage Project ICT Pvt. Ltd. andABCE PLC October. 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section - I, Volume - V Design of Hydro Mechanical Gates Concrete stress = 11 kg/cm2 Bending stress in bottom flange 12.3 35x35 =--------- X 1 1 X-------------------- 100 1.25x 1.25 a = 400 ’ £ = — =0.179 a 350 100 Hence safe Note:- Take min value of K = 12.3 2 2 = 1060 kg/cm > 960 kg/cm It is unsafe Therefore weld 10mm m.s extra (plate at Bottom) = JL x 11 X 35x35_ = — x 11 x 35x35 = 327.4 kg/cm2< 960 kg/cm2 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 XT x S X X x X X >777777777777777 IJ / ■ WWDSE, Addis Ababa in Association with ICT Pvt. Ltd. and ABCE PLC -18- Detail Design of Bale Gadula Inigajjon & Drainage Project October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia 1.5.16 Gate Body Thickness = 16 mm Corrosion allowance = 1.5mm Effective thickness = 16.0 mm Section -1, Volume - V Design of Hydro Mechanical Gates 1.5 mm 14.5 mm Flat plate with all edges rigid andfixed - -1 a 450 K = 30.9 3x Bending stress = 100 2 2 = 208 kg/cm < 960 kg/cm Hence safe 30.9 ----- X 0.7 X----------------- 45x45 100 1.45 x 1.45 BM Loading on each stiffener = 2 (| x 45 x 22.5)x 0.7 = 708.75 kg Say 710 kg = w ii —WL _ 710x45 r-oor- i —------------ -— = 5325 kg -cms S.F=^2 = 355 kg (w/2) Stiffener provide and 120 x 12 x 450 Co-acting width of liner plate;- Support length L,, = | x 450 = 180mm WWDSE. Addis Ababa in Association with -19- /CT Pvt. Ltd. and ABCE PLC Detail Design of Bale Gadula Irrigation & Drainage Project October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section -1, Volume - V Design of Hydro Mechanical Gates B = Half of span = — = 225 m = S = 0 8 frOm the CUrVe 'S 4622 Coating width = 2V xB = 2xO.14x 225 2 = 63 mm (say) = 60mm V2 = 0.14 ■ ■ ■ III III In Section a_ cm2 Y cm ^3 cm Cm y cm Self Cm4 4 11 1 60x14.5 6x(1.45) =8.7 0.725 6.307 Y,=4.917 4.192 8 7(4.192)2 =210.00 Cm J ■ III 120x12 12x1.2 =14.4 7.45 107.280 Y2=8.533 -2.533 14.4 x (-2.533)2 = 92.39 bd 12 1.2x12x12x12 12 * Total 23.1 113.587 Total 302.39 + = 172.8 T Total = 302.39 + 172.8 = 475.19 cm4 14.4 Hence safe Combines Stress <x = Lining and stress = 208 kg/cm 2 Shear stress = SF =— =25kg/cm < 720 kg 2 H M M M M x W/VDSE, Addis Ababa in Association with -20- Detail Desian of Bale Gadula Irrigation & Drainage Project ICT Pvt Ltd. and ABCE PLC ~ Oc^er, 2011 *Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section -1, Volume - V Design of Hydro Mechanical Gates = Stiffener stress = -55.10 kg/cm2 Combines stress = V(« *)2 + (-ay)2 - (ax) (-ay) = V(208)z + (—55.11)2 - (208)(-55.10) = a/43264 + 3036 + 11460.8 2 2 =V57760.8 = 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 Bond stress = Hence safe 1.5.17 Sill Beam ISMB -300 710 = 0.657 kg/cm < 9 kg/cm o Total wt of gate = 3.53m.T Wtof stem = 1.0 m.T 1 — - Total' 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 WWDSE, Addis Ababa in Association with -21- Detail Design of Bale Gadula Irrigation & Drainaqe Project ICT Pvt. Ltd. and ABCE PLC Oclober. 2011Ministry of Water and Eneryy- Federal Democratic Republic of Ethiopia Section -1, Volume - V Design of Hydro Mechanical Gates 2 2 Bearing stress developed in concrete =4500/3360 = 1 14 kg/cm < 60 kg/cm Hence safe For wheel friction forces for Bush and Roller Bearing F = ^ (fa x r + fr) F = Total friction force, in N P = Total hydrostatic load in N R = Radius of wheel, in mm fa = co-efficient of axle friction , in mm r = effective radious of bearing in mm a) Co-efficient of axle friction (fa = 0.2) b) Co-efficient of rolling friction (fr = 10) P = 50 t =50x 1000 kg = 50,000 x 10N R= 175 mm fa = 0.2 for bronze bush bearing fr= 1.0 ' r = 59 50,000 x 10 175 (0 2x59+1.0) 50,0000 175 ( 11.8 +1) = 175 50000 (12.8) = 36570 N = 3.657 tg Therefore total friction = 3.657 T Seal friction Average head =6.6+3.8= 5.255 m Side seals = ( 5.255 X 0.76x 2.95) x2= 2(1.178)t = 2.356 t Top seal = 3.78 x 0.076 x 2.15 = 0.617 t Total friction = 2.356 t +0.617 = 2.973 t Use fluorocarbon cladded seals for reducing the friction /z = 0.2 for fluorocarbon seal. F = /zR = 0.2 X2.973 = 0.5946 t = 0.6t 1.5.18 Check for sealing pressure Wt of gate = 3.53m.T Vol = density =3.53/7.85 = 4497 T Net wt. of gate in water = 3.53 -0.449 = 3.08 t Length of seal Bottom = 3.4 meter mVOSE) Addis Ababa in Association with -22- Detail Design of Bale Gadula Irrigation & Drainaqe Project ICT Pvt. Ltd. and ABCE PLC *' Oc ber 2 011Ministry of Water and Energy- Federal DemocraticRepublicofEthiopia^ Seating pressure /meter = 3.081/3.8=0.81 t/m Hence safe It is greater than (0.25 t/m) (mini seating pressure for low Head gates) 1.5.19 Calculation for Hoist capacity 1. Wt. of gate = 3.53 T 2. Seal friction = 0.60 T 3. Pre compression = 0.060 T 4. Wheel friction = 2.973 T 5. Guide friction = 0.165 Total friction = 3.798 t Hoist capacity Section -1, Volume - V Design of Hydro Mechanical Gates Rising . Gate weight 2.5t 3.530 | . Friction force 3.385 t 3.7978 | . Down thrust > 0.040j Sum' = 7.361 As per relevant IS = 1.472 t code add 20% more ----------------- ‘ 8.832 t Therefore provide 101 Hoist capacity Weld sizes Taken 8mm fillet weld size Lowering 2.500 | 3.385 j 0.000 I For welding horizontal girder with skin plate Strength of 800 weld size per cm = 0.8 x1 x 0.707x 720 = 407 kg Taking efficiency as 80% = 0.8 x 407 = 325 kg 1 cm of felet weld can take load = 325 kg (240 +240) = 480 cm can take the load = 325 x 400 = 156000 kg =156 T Therefore provide 8mm fillet weld size for welding of all the components of gate. WWDSE, Addis Ababa in Association with -23- Detail Design of Bale Gadula tmgation & Drainage Project ICT Pvt. Ltd and ABCE PLC October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia 2. HEAD REGULATOR GATES 2.1 General Section - /, Volume — V Design of Hydro Mechanical Gates 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 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 ICT Pvt. Ltd and AB^Ce'plc500'31'0" 24 Detail Design of Bale Gadula Irrigation & Drainage Project October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia 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 1.8 m 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 Shear stress Combined stress Bearing stress Wheel shear Stress = 61.4 N/mm2 0.40.p 0.30y.p 0.50y.p 0.45y.p 2.41 x BHN 960 kg/cm2 720 kg/ cm2 1200 kg/ cm2 1080 kg/ cm2 2.41x255= 614.55N/mm2 ^Abr^Sr>SOCiatiOn WHh ~25' Detail Design Of Ba,e Gadu,a lm'^ticn & Drainage Project rvi. ua. and AuCE FLC October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia 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 — I, Volume - V Design of Hydro Mechanical Gates 7 4xll 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 O.5y.p 1200kg/cm' Bearing stress 2.5.5 Design codes 1 Structural steel 2. Wheel pin material 15cr 16Ni having Y.P = 6400kg/cm2 3 Fixed wheel design 4. For concrete stresses 5. For Rubber seals 2.5.6 Design Considerations 0.45y.p 1080kg/cm: IS-2062 - 2006 I.S 1570 parts 5-1985 IS 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 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 WWDSE, --------------------------------------- ----------------------------------------------------------------------- -------- ICT Pvt Ltd. and ABCE PLC-------------------------------------------------------------------------------------------------- October. * -^project Addis Ababa in Association with -26- Detail Design of Bale Gadula Irrigation & Drat nag ?o11Ministry of Water and Energy- Federal Democratic Republic of Ethiopia 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 Wate^ 18.5 T Section -1, Volume - V Design of Hydro Mechanical Gates B.m = — = 18.5x2.4/8=5.55 t-m 8 =5.55x100000/960 = 578 cm3 Provide 3 Nos ISMB 200 Z„ = 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 w/ -=—=1.57 a 380 r K = 58 2.5.7.4 Checking the skin plate in panel 600___________600 ___________ 600 _ 600 * PP_-11 A- 0.342 ' R2 0.675 R3 0.54 0.243 ◄---------------------------- 2.40 ---------------------------------- ► Panel I Bending stress = — p — 100 H s2 =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 2 2 Bending stress = P §= 29/100x0.5x54x54/1.05/1.05=383 kg /cm 2<960 kg/cm2 Hence Safe WWDSE. Addis Ababa in Association with ICT Pvt. Ltd. andABCE PLC 27- Detail Design of Bale Gadula Irrigation & Drainage Project October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia 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 re Size of ISMC - 250 Zxxprovided = 305 cm3 Section - I, Volume - V Design of Hydro Mechanical Gates Z qd ~ 2.349x10000/1080=217.5 cm 3 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 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 2 Bearing stress = 5.4 kg/cm < 60kg/cm Bending stress in Track girder 2 2 80kg/cm < 960 kg/cm /C7 Pvt. Ltd and ABCE pL ^ sociation w,th Detail Design of Bale Gadula Irrigation & Drainage Project October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section - /, Volume - V Design of Hydro Mechanical Gates The track base shall be checked for bending and shear also:- Bending stress or A = 05^x-) z \£c w/ ,/3 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.l of track base about the N.A in mm4 W= width of track base =0.5X^-^X165.29=8.053 N/mm =80.53kg/cm <960kg/cm 2 2 2 Hence safe •• l The length of influence of the parabolic distribution under the base may be found from the following formula: L=ix— 2 IvXp 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 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) (l - 2^ V (44.S)2 JMinistry of Water and Energy- Federal Democratic Republic of Ethiopia Section - I, Volume - V Design of Hydro Mechanical Gates c/c of wheels = 637 mm Max bending pressure directly below the wheel = 5.4+2 (5.4) (l - g^)=5.4+10.8(l - ^)=5.4+10.8(1 - 2.45) =5.4+10.8(1.45)=5.4=15.66=-10.26kg/cm < 60kg/cm ? 2 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 Hence safe (.3x2400)= ^x2400=720kg/cm Hence safe i.e .3 of yp 2 CHECK FOR SHEAR STRESS IN CONCRETE (m.s) liner plate * 15 MB - 250 width of flenge *WWDSE, Addis Ababa in Association with ICT Pvt. Ltd and ABCE PLC -30- Detail Design of Bale Gadula Irrigation & Drainage Project October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section — I, Volume — V Design of Hydro Mechanical Gates CHECK FOR SHEAR STRESS IN CONCRETE:- Use ISMB = 250 Width of flange =125 Second Stage concrete M 5 2 Modular ratio m~11 Wheel load = 6000kg L2 Shear stress in concrete= 1.9 g /cm Load on the shear plane = SOOOxcos 45°=6000x0.707=4242 kg Length of shear plane = (250+62.5+62.5-10+11x10)72 Clear cover ‘e’ has been kept 250mm = (375-10+110)x1.414 (Against minimum 150mm as per code .4622 -2003) = (475) xl.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 = 8 109kg >4242kg No reinforcing bar are required (However mini shear reinforcement shall be provided) CHECK FOR BENDING OF BOTTOM FLENGE ^PW Li S^Sc/pT° £d C,8,/0n GadU'° ,m9a,ion & Dmngc p^ciMinistry of Water and Energy- Federal Democratic Republic of Ethiopia_________ Check for bending of bottom FLG Use ISMB 250 Section-I, Volume-v Design of Hydro Mechanical Gales Bending stress in bottom plane and concrete pressure = 5.4kg /cm2 «« = iooPs^ioo12 3x5 4x ^T266 kg/cm <960kg/cm Hence safe 2 2 2.5.7.9Gate body Gate Body and liner shall be cheeked to withstand full externa! pressure with the permissible stress of 80% of the yield point stress and the material Design Head =3 6m Say (4m) Thickness provided = 10mm Flat plate with all edges rigidly fixed b 450 - = —= 1,K3x = 30.9 a 450 , Effective thickness =10mm-1.5mm = 8.5mm = 0.85cm Bending stress in flat & may the determined from the following formula as per IS 4622-2003 450 «3X=— p ^-Where ioo r s2 k 3x = Non dimensional factor = 30 9 p = water pressure = 0.4kg/cm2 a and b = Bay width = 45cms d ICTPvU. ?d ^ndAlcE'pLC OC:ia'IOn ' 32' De'ail DeS,gn of Bale Gadula & ^octobef^01'Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section -1, Volume - V Design of Hydro Mechanical Gates S= effective thickness of plate = 0.85cm , 30.9 . 45X45 oc3x = Bending stress in kg /cm - — x 0.4 x 085x085 =347kg/cm <960kg/cm Hence safe 2 2 B A 2.57.10 Stiffeners Loading on each stiffeners W= 2(|X45X22.5) X0.4= 405kg Max bending mt = m = — =------------------ = 3037.5 kg.cm “ wL 405X 45 66 Max SF = = 202.5kg Stiffeners provided:- and 60x8x450 Co-acting width of liner plate 2 Support length = LN = -x450 = 180mm B= half of span i.e = — =225m 2 WWDSE. Addis Ababa in Association with -33- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd and ABCE PLC Ocl*ber ,Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section (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 I I I Section Acm2 y ay cm3 cm Y Cm Ay-2 Cm4 1 self , Cm4 60 x 8.5 mm 6x(0.85)2 "6x0.7225 =4.335 0.425 1.8423 Yr 2.034 Yy r =1.609 4.335x(1.609)2 =4.335x2.589 11.223cm2 i 60x8mm 6x(0.8)2 =6x0.64 3.84 3.85 14.784 Yr 4.816 Y2= -1.816 2 3.84x(-1.8769) ~ 3.84x3.3 12.664cm2 = 8x3 Total 8.175 16.626 =14.4 Total 38.3 Zi=------ - 18.823cm 2.034 38.3 n Z 2 =----- =7.953cm3 3 4.816 Bending, stress f! = 2 18.823 4kg/ m C i r f2 = = 382Rg/cm2 < 960kg/cm2 Hence Safe Shear stress =S F = 202.5kg Shear area = 6X0 8 = 4 8cm" Shear stress = ^7 = 42.2kg/cm <720kg/cm Hence Safe Combined stress:- « x = lining plate stress = 347kg/cm2 «y = stiffeners plate stress = -161.4 kg/cm2 Combi^ stress « „ = V(347)2 + (-161.42) 2 - _(347)(-161.4)= 2 2 L __') I 2 7(120409) + (26050) + (560067) = V202465 =450kg/cm < 1200kg/cm Hence safe Bond Capacity of stiffeners Max Bonding stress in concrete (allowable^ 9kg/cm2 • Load of stiffeners = 405kg • Stiffeners section =60x8x450 October.Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section -1, Volume - V Design of Hydro Mechanical Gates • Bonding area = 2(6x45) = 540cm2 • Bonding stress = 777 = ft.75kg/cm2 540 • (say) = approx 1 .Okg/cm2 • < 9kg/m2 Hence safe 2.5.7. H 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 stainless still plate 90 x 8 mm Note length of sill = c/c of side seals +250 =2150+250mm=2400mm = 240cm Bearing width = 125mm Bearing area = 12.5x240=3000cm2 Bearing stress developed in concrete « 0.67/c /cm <60kg/cm Hence Safe 5 2 2 (So adopt section ISMB - 250 For sill Beam) wheel frictional = 1.40t 0 side seal reaction = 0.970 t Top seal reaction = 0.40 t Total seal reaction (R) = 1.37 t WWOSt. Addis Ababa in Association with ICT Pvt Ltd. and ABCE PLC -35- Detail Design of Bate Gadula Irrigation & Drainage Project Octobei, 2011Use Flu carton Cladded seals <0 reduce (notion wFt=of gate==0.12.x18t .371= 0.274 t Buoyancy effect =1.8/7.85 = 0.223. Nel wt of gate In water = 1.8-0.20.^ Length of sea (Bottom) = 2.6m Seating pressure =1.577/2.6=0.606t/meter It is greater than = 0.25 + 1 m 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 The factor w^hH = (2.6)2 x 1.8 x 5.6= 68.1m4 G = 0.8888(68.1) 0 65B . = 14.35kN = 1.435 T (say) = 1.5 Wt of embedded parts 1.5 x 0.3 = 0.451 Total wt = 1.501 + 045t= 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 0.060 mT | wheel friction 1.400 m.T j Guide friction 0.100 mT 4 Down thrust 0.020 Sum = 36571, precompression= 0.6921 Add 20% =4.35t There for provide 6 T screw Hoist Capacity IMinistry of Water and Energy- Federal Democratic Republic of Ethiopia Section - I, Volume - V Design of Hydro Mechanical Gates 3. GATES FOR REGULATING STRUCTURES BALE GADULA CANAL SYSTEM 3.1 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 destred operation pattern throughout the command area. Annexure-I (Part 1 &2) provides the details of all the gated installations along with discharges through each offta e, 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 LISBR 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 aenpraliv <... . October, 2011Ministry of V/ater and Energy- Federal Democratic Republic of Ethiopia Section-I, Volume ~y Design of Hydro Mechanical a,tf . 1 S.No. Gate of openingWidth x Height IS CODE NO 1t()6 (6 Nos) 1No) 7( 8Ito 10 (3 Nos) VI to 14 (4 Nos) 1 5 to 19 (5 Nos) 2 Oto 25 (6 Nos) ,2.0m x 1.2 m As per IS 13349:1992 2.0 mx 0.90 m Type C2 1.8 mx 0.9 m TypeCI 1.8mx0.8m TypeCI 1.5 mx 0.70 m TypeBI 1.5mx0.50m TypeBI IS 13349:1992 IS 13349:1992 IS 13349:1992 IS 13349:1992 IS 13349:1992 r >6 to 30 (5 Nos) 1.0m x 0.40 m TypeA5 IS 3042:1965 Ito 2 (2 Nos) As per IS 3042:1965 r 3 to 4 (2 Nos) 5 to 6 (2 Nos) 0.50x1.05 TypeAl 0.80x1.05 TypeA3 0.70x1.05 TypeA2 7(1 No) 0.70x0.75 TypeA2 [ 8(1 NoO 0.80x0.75 type A3 9 (1 No) 10 (1 No) 11 to 13 (3 Nos) 14(1 Nos) 15 to 15 (2 Nos) 17 (1 Nos) 18 to 19 (2 Nos) 20 (1 No) 0.70x0.75 TypeA2 0.80x0.75 Type A3 0.70x0.65 TypeA2 0.90 x 0.65 TypeA4 0.80x0.55 Type A3 0.70x0.55 TypeA2 0.50x0.55 TypeAl 0.50x0.35 TypeAl 21 (1 No) 0.70x0.35 TypeA2 22 (1 No) 23 (1 No) 24 (1 No) 25 (1 No) 261 No) 0.90 x 0.35 Type A4 0.70x0.35 TypeA2 0.50 x 0.35 TypeAl 0.80x0.35 Type A3 As per IS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 As perlS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 As per IS 3042:1965 0.70x0.25 TypeA2 As per IS 3042:1965 27 (1 No) 0.80x0.25 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) 0.70x0.25 TypeA2 As per IS 3042:1965 3.3 Maintenance Bulkheads I Stoplogs All the head regulators gates upstream of the and cross regulators are provided with maintenance main gates so that they can be maintained whenever ICT Pvi. Lid. and ABCEPLC°^at,On W'th '38' D&lai1 ^sign of Bale Gadula Irrigation & Drainago P'°ficl OctoM WMinistry of Water and Energy- Federal Democratic Republic of Ethiopia Secbon - /. Vofarae - V Design of Hydro Mecter&J GWes necessary. For standard gates stop logs shall be provided for repair For gates at various off takes, provision of the maintenance bulkhead is not considered necessary. However they can be selectively provided in case the need arises 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 tne 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 matenal 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 openmg we.r gates. D) For drainage from outfall structures and plants to: Flap gates / fide gates / 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 cntena and WWDSt Add s Abjo.i fMsk'Cj’c.i .. ICT P\t Ltd andABCEPLC 39- Detail Des>y> 1 ol Safe imgaiion 4Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Design of Hydro Mechanical Gates Section — I, Volume — V 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 AWWA C560 / BS 7775/ ISI3349 / IS3042 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 I 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. WWDSE, Addis Ababa in Association with -40- Detail Design of Bale Gadula Irrigation & Drainage Project ICT Pvt. Ltd and ABCE PLC Qc ber 2011 *Ministry of Water and Energy- Federal Democratic Republic of Ethiopia 37.4.2 Flush bottom / Flush invert closure Section - /, 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 / 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. 37.5 Type of Spindle Movement 3.7.5.7 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. 37.5.2.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. /?r W/(/l '41: Detail °eSign °fBale GadU,a ,rngai’On & DrBinQge PmiectMinistry of Water and Energy- Federal Democratic Republic of Ethiopia Section-I' Volum Design of Hydro Mechanio^q^ 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 t ga e 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 / 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. fl. 7.2 Mechanized operationMinistry of Water and Energy- Federal Democratic Republic of Ethiopia Section - /. Volume - V Design of Hydro Mechanical Gates 3.7.8 Types of gates considered spigot back frame wall mounted cast iron sluice gates 37.8.1 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 wail 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/stri^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. October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia —. 3.7.8.5 Shop Testing . Leakage test at atmospheric pressure Section-I, Volume Design of Hydro Mechanic^^ . 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. 3.7.9.2 Application These gates are mounted / 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 • Designed for channel application, breast wall not required. 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 weil 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 S pecification Gate frame, wall, Cast Iron ASTMA126 mounting, head stock, ______ stem guide bracket and wedging devices ‘CT ^’J^ndAB^E^S0C'dtl°^Wth'~ ^ : Detail Desi9n of Bale Gadula IrrigationFor^e^oHMinistry of Water and Energy- Federal Democratic Republic of Ethiopia Section -1, 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 material of construction for various components under G below. 3.7.11 Shop Testing • Movement test for checking interference free assembly. may select and specify the from the alternatives stated movement of complete gate 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 oisiiie « 0^ Ocfooer, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia • Non rising spindle . electrically operated lift mechanism with manual override facility Section-l . Pneumatically operated lift mechanism with manual override facility . Portable electric / hydraulic operator tor manually operated gates 3 7.13 Materials for Fabrication of Gates The client to select and specify materials of construction of various components from the following alternatives based on the application and requirement. « required, materials of construction other than those specified below may also be adopted if necessary. 3.7. f4 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 Jesting. Total primingthfckness 75 microns. . Finish painting for gate assembly: 2 coats of biack 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, required. a) Lift mechanism I Screw hoist: Manually operating floor mounting cast iron un geared or 9ea pH headsto^ more with floor stand / pillar capable of operating the gate with an e w jth than 20Kgs. The pillars are provided with elliptical window ope$ un removable cover to enable cleaning and greasing of spindle ea sy geared headstocks are provided when the lifting loads are low an en ^er gate operation without need of gearing. These are easier to ope fastest operation. These are provided with a thrust bearing eniovable ferrous threaded stem nut engaging with spindle threads. A eas y hanCj type hand wheel is then mounted on the stem nut and rotation nO n wheel results in gate operation. The headstock can be Pr0 j n- at O arrangement for locking of the hand wheel to prevent unauthorized op The geared headstocks are provided with thrust bearing mounted nconpected threaded stem nut engaging with spindle threads. The stem nut is — I WCTWPDvtS.EL, tAdd. dains dAAbBabCaEinPLACssociation with -46- Detail Design of Bale Gadula Irrigation & Dr3 Q ber, lo ’Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section - /, 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 with machined gears completely encased in housing to protect from dirt, dust, ram and other atmospheric effects. Geared headstocks are provided with arrangement for lubrication as well as for locking of removable crank handle 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 spiit 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: WWDSE, Addis Ababa in Association with ICT Pvt Ltd and ABCE PLC 47 ' De,ail Des,9" o'Bale Gadula Irrigation & Drainage Project October, 2011 ’ ““ L. . -.----------- r - —,Ministry of Water ant Federal Democratic Cast iron stop nut w.th s t screw on threaded rising stems of manually operated gates to prevent c over closing of gate and thus to avoid ting | and the opera p atform chances of damage to we g for setting j( jn a fixed posjtjon safety stop nut is fuuiished with a sel the gate is installed. f) Anchor bolts L-shaped anchor bolts for gate frame, stem guide brackets i and operating headstock, as necessary. 3.7.15 Op tional 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 coven 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. 3.7.15.40 ftset 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 Electrically operated lift me h • by Rotork I Aumaand m ° aniSm comprise of electric actuators manufactured operation between 250-300 ^ °nfloor stand P|,,ar These actuators enable gate 9ate within 15 minute Th /minUte and are rated for opening or closing of a manually operate thp 3 Uators are Provided with manual override facility to even*o,e,e* - “■ ' mechanism with manual override facility: p S0cia,l0n w,th -48- Detail Design of Bale Gadula Irrigation & Dro tCTPvt. Ltd and ABCE ^ ^^ ^ 2011 eMinistry of Water and Energy- Federal Democratic Republic of Ethiopia Section -1, Volume - V Design of Hydro Mechanical Gates 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 ovemde arrangement is provided to manually operate the gate. 3.7.15.7Portable electric / hydraulic operator for manually operated gates. Portable electric 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 made by fully opening I 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 not 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 ICTiHandABCE pLC n S0Cial'°n49 Detai> Desl9r' of Balc Gadula Irrigation & Drainage Project" October, 2011Ministry of Water and Energy- Federal Democratic Republic of Elhiop^_ Section-I, Volume „ Design of Hydro Mechanic^rQ^ unseating pressure is collected and its volume measured. Leakage ac norms as per IS: 13349 requires that the test shall not show leakage in P 9nce 6f 25,3.5, and 4.5 litres per minute per meter length of sealing perimeter for C' ^ ° (head up to 5 Meters), Class 2 (head above 5andupto 10 meters) and 1 (head above 10 and upto!5 meters) Sluice Gates respectively. 3Ss 3 nnrm<- as D Leakage accep anc 00 , the « er A WW A C560 shall | be followed. After carrying is ed s jght)y and then c| ” Jaga,n Thus each gate is shop tested X’”" "™s a"d each ,te leaka9e' “ a"y' KaS “ be Wi,h'n reS|>eai" 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 nead 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. 3.7.16.60perating 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 7.16.7Dimensiona! Verification Check diman ■ d'mensions of 9ates are verified with reference to the important order ^°nS 9'ven 'n °Ur 9eneral arran9ement drawings furnished against each class in 1 kVc d,mensions’,f anV. shal1 be within the permissible limits as per f r CaSt'n9S and eXtra coarse “ as per iS-2102 for. dimensions without specified tolerances. 3 7.16.8Review of Material Test Certificates men LT? ° castings taiXnLX ShU,,er S Wa" a9ree<J for 'mPortant components like Cast iron "0" Sea' s e c are furnished for review al lhe time of shop inspection WWDSE, Addis Ababa in Association with ICT Pvt Ltd. and ABCE PLCMinistry of Water and Energy- Federal Democratic Republic of Ethiopia REFERENCES Section -1, Volume - V Design of Hydro Mechanical Gates 1. WWDSE-Bale Gadula Irrigations drainage Project-Design of Weir and Head regulator-Draft Detailed Design Report April 2010 2. WWDSE-Bale Gadula Irrigation S 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 WWDSE Addis Ababa in 1^1 rvi. Lio anofibLE PLC W ith -51- Detail Design of Bale Gadula Irrigation & Drainage Project October, 2011Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section -1. Volume - V Design of Hydro Mechanical Gates appendix I Salient Features of Irrigation System Gates for BAGID Project Gate Opening Crest Level Width Height S.No Name of Off-Take/Structure Chainage Q in the Parent Canal(cumcs ) Q in tho Tako-off Cana!(cumcs ) U/SFSL 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 3651 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.'i01 . 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 1.80 070 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 0.90 080 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 WWDSE, Addis Ababa in Association with ICT Pvt. Ltd. and ABCE PLC -52- Detail Design of Bale Gadula Irrigation & Drainage Project -___Octo^r~'i011 -—-Ministry of Water and Energy- Federal Democratic Republic of Ethiopia Section — I, Volume — V Design of Hydro Mechanical Gates Crest Level Gate Opening S.No Name of Off-Take/Structure Chainage Q in the Parent Canalfcumcs I Q in the Take-off Canal(cumcs ) U/S FSL Width Height PC Off taking Canal PC(H R) Off- Taking Canals PC( HR) Off taking Canal 17 Off-Taking from MCs to SC-1-17 18931 1.705 0.144 1802.00 1801.30 1801.45 1.50 0.70 0.70 0.55 18 Off-Taking from MCs to SC-1-18 18931 1.705 0.060 1802.00 1801 30 1801.45 1.50 0.50 0.70 0.55 19 Off-Taking from MCs to SC-1-19 20038 1.705 0.070 1777.40 1776.70 1776.85 1.50 0.50 070 0.55 20 Off-Taking from MCs to SC-1-20 21250 1.705 0.067 1757.43 1756.73 1756.88 1.50 0.50 0.50 0.35 21 Off-Taking from MCs to SC-1-21 21250 1.096 0.111 1757.43 1756.73 1756.88 1.50 0.70 0.50 0.35 22 Off-Taking from MCs to SC-1-22 22087 1.096 0.184 1747.34 1746.79 1746.94 1.50 0.90 0.50 0.35 23 Off-Taking from MCs to SC-1-23 22734 1.096 0.090 1739.45 1738.90 1739.05 1.50 0.70 0.50 0.35 24 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 25 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 26 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 0.25 27 Off-Taking from MCs to SC-1-27 26710 0.420 0.194 1669.22 1668.82 1668.97 1.00 0.80 0.40 0.25 28 Off-Taking from MCs to SC-1-28 29628 0.420 0.134 1634.30 1633.90 1634.05 1.00 0.70 0.40 0.25 29 Off-Taking from MCs to SC-1-29 29628 0.420 0.067 1634.30 1633.90 1634.05 1.00 0.50 0.40 0.25 30 Off-Taking from MCs to SC-1-30 30907 0.420 0.087 1608.27 1607.87 1608.02 1.00 0.70 0.40 0.25 Noto! DB stands for Division Box; PC for Parent Canats/MCs, WSL stands for Water Surface Level; also Emb L stands for Embankment Level & SCs as Off-taking Canals WWDSE, Addis Ababa in Association with ICT Pvt Ltd. and ABCEPLC -53- Detail Design of Bale Gadula Irrigation & Drainage Project October, 20111 Ministry of Water and Energy- Federal Demor.ratk' RanuhU*
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