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DESIGN CALUCULATIONS OF

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


RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST
LTD. HOSPET FOR THANGARABALU SMALL
BANGALORE H.E. PROJECT(2X12.375MW) REV. 1
DRAFT TUBE GATE
DESIGN OF SUPPORTING STRUCTURE FOR MONO RAIL HOIST /CHAIN PULLEY BLOCK
1 DESIGN DATA
sl DESCRIPTION VALUES
no.
1 Type of Gate Fixed wheeltypevertical gate
2 Size of vent 4350mmx3550mm
3 NO.vents 4
4 Clear width of opening 4.35 M
5 Clear height of opening 3.55 M
6 No. of gates 4 SET
7 Sill level RL 386.412 M
8 Top of pier level RL 410.00 M
9 Thickness of Abutment Top side/middle 1.5/0.85 M
10 Thickness of pier[inter] 1.30 M
2 PERMISSIBLE STRESSES
sl Type of stress Factor Stresses in kg/cm
no.
1.0 Sturctural Steel Thk : 0 20 mm
Structural Steel - IS : 2062 2006 Yp : 2550 kg/cm2
Grade E250 -A Factor UTS 4180 kg/cm2
a Direct compression &
compression in bending 0.66 YP 1683
b Direct tension and tension
in bending 0.66 YP 1683
c Shear stress 0.45YP 1148
d direct stress in compression 0.60YP 1530
e Bearing stress 0.75 YP 1912
Stresses in kg/cm
5 Bearing stress in concrete M25 50
6 Shear stress in concrete M25 8
7 Allowable deflection = span/750 <50mt cap.
span/500 manual operation
DESIGN CALUCULATIONS OF
KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-2
RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST
LTD. HOSPET FOR THANGARABALU SMALL
BANGALORE H.E. PROJECT(2X12.375MW) REV. 1
3 Height of column
Top of pier level RL 410.00 M
Sill level RL 386.412 M
LIFT = 23.588 M
height of Lifting point in gate = 3.9 M
Hoist Hook to Rail girder flange= 2 M
clearance above pier level= 0.3 M
Height of mono-rail beam = 0.6 M
Height of column = 6.8 M
Proposed 7.0 M Height columns
4 Load on column while operating
Max. lifting capacity of Monorail = 17.5 MT
Load on column with impact factor of 10%= 19.25 MT
weight of monorail plus Girder 1.5 MT
TOTAL = 20.75 MT
Total Load on columns= say 21 MT
The arrangement of column & girder is shown below
NIY SA NIY SA
DESIGN CALUCULATIONS OF
KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-3
RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST
LTD. HOSPET FOR THANGARABALU SMALL
BANGALORE H.E. PROJECT(2X12.375MW) REV. 1
5 Design of main mono rail beam on vent
Stop log gate elements are to be lifted one by one in each unit induidially
Hence load on succussive girder / column is not considered for design.
21000 kg
A B RA=RB= 10500kg
435+65+65=565cm
Max. B.M = 10500X565/2=2966250kgcm
a Proposed ISMB 500X180with ad.flange of 200x14 at bottom and ISMC250X80 at top
SL SECTIONS AREA
NO. W T
1 Flange[1] 25.0 0.71 17.75
2 Flange[2] 18 1.72 30.96
3 web 46.56 1.27 59.1312
4 Flange[3] 18 1.72 30.96
5 Flange[4] 20 1.4 28
166.80
A = 166.8 cm
Y1 = 27.3 cm
Y2 = 26.6 cm
Y3 = 24.8 cm
Ixx = 76255.2
Z1 = 2790.6
Z2 = 2865.0
Z3 = 3076.8
Iyy = 1369.8+2bd^3/12= (1369.8+(1*1.4*20^3/12)+3828.4)
6131.5
2966250
Max. bending stress = = 1063 kg/cm
2790.6 <1380kg/sqcm hence safe
5 xwl 5x21000 x 540
Max. deflection in girder = =
384 x EI 384x20.70 x 10^5 x 76255.2
= 0.27 cm
L 540
Allowable Deflection= = = 0.72 cms
750 750
Sear stress=fs= 21000/2/46.56/1.02= 221 kg/sqcm
DIMENSIONS
DESIGN CALUCULATIONS OF
KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-4
RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST
LTD. HOSPET FOR THANGARABALU SMALL
BANGALORE H.E. PROJECT(2X12.375MW) REV. 1
b Calculating the Max. Permissble bending stress as IS800-1984 Cl 6.2.3
fbc= 0.66 fcbxfy
[(fcb)^n +(fy)^n]1/n
fy=y.p=2550kg/sqcm
n=1.4
ryy= SQ,RT.of [Iyy/A]=SQ RT of [6131.5/166.8]=6.06
fcb= k1[X+k2Y]c2/c1
l/ry=565/6.06=93 X=464 k1=1 c2/c1=1
[Table-6.5] [Table 6.4&6.3]
D/T= 52.11/3.12=16.7 Y=327 k2=0.5
fcb= 1*(464+0.5*327)*1
= 627.5
As per table 6.2 for fcb =627 the allowable permissible stress
is=
fbc= 1380 kg/sqcm [table 6.2]
DESIGN CALUCULATIONS OF
KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-5
RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST
LTD. HOSPET FOR THANGARABALU SMALL
BANGALORE H.E. PROJECT(2X12.375MW) REV. 1
c Check for local bending of flange due to monorail long travel hoist wheel load
The stress resulting from local bending is given an empherical formula[xyplane]
x= KaxxP/t^2(root)
where kax=2
Flange thickness=t=1.72+1.4=3.12 for value of
c/a =62.5/85=0.735
p= Hoist load xImpact factor+self wt.
4 [nos. of wheel]
= 21000x2
= 10500 kg
4
10500
x= = 1079 kg/sqcm
3.12^2
The stress resulting from load bending y-z plane
y= KazxP/t^2 where kaz=0.6
for value of
c/a =62.5/85=0.735
y= 5250X0.6 /3.12^2 = 324 kg/sqcm
combined stress at inside of the flange
c=

x + y + x x y
=
= 2107 kg/sqcm <0.85x2550=2167kg/sqcm
DESIGN CALUCULATIONS OF
KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-6
RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST
LTD. HOSPET FOR THANGARABALU SMALL
BANGALORE H.E. PROJECT(2X12.375MW) REV. 1
7 Design of columns [END/INTERM-PIER]
Max. reaction of girder on column = 21000 kg
Height of column= 800 cms
Proposed 2- ISMC300X90 BACK TO BACK
A=45.74x2= 91.48 cm^2
Ixx=2xIyy+2xAx[D/2]^2
Ixx=2x311.5+2x45.74x20^2 = 37215 cm^4
Iyy=2xIxx+2xwx[D/2-t of web]^2/12
Iyy=2x6384.2+2x9x[40/2-7.6]^2/12 = 13281 cm^4
Zxx= 37215/[D/2+FLW/2]= = 2482 cm^3
Zyy== 13281/[D/2] = 885.4 cm^3
rxx= SQ,RT.of [Ixx/A]=SQ RT of [37215/91.48]=20.2 cm
ryy= SQ,RT.of [Iyy/A]=SQ RT of [13281/91.48]=12.05 cm
Effective Ht. of column
Lxx=1.5*700= 1050 cm
Lyy=0.5*700= 350 cm
LXX/rxx= 1050/20.25= 51.9 <200
Lyy/ryy= 350/15.6= 22 <200
permissible compressive stress for l/r =52 is 1164 kg/sqcm
actual compressive stress in column= 21000/91.48= 230 kg/sqcm
max.load on colomn= 21000 kg
self wt.of column+beam= 1000 kg
total load 22000
Max. compressive stress in column= 22000/91.48= 240 kg/sqcm
BASE PLATE
FLOW
DESIGN CALUCULATIONS OF
KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-7
RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST
LTD. HOSPET FOR THANGARABALU SMALL
BANGALORE H.E. PROJECT(2X12.375MW) REV. 1
WIND LOADS
A]Wind in the direction of flow
wind pressure= 160 kg/m^2
width of column= 0.3 m
form factor 1.6
wind load per mtr ht of column=
0.3x160x1.6= 77 kg
B]Wind from main girder
wind pressure= 160 kg/m^2
width of column= 0.62 m
form factor 1.6
effective length of girder on each colomn=
7.8/2= 3.9 m
wind load on column=
0.55*3.15x160x1.6= 619 kg
C]Wind form mono-rail hoist
wind pressure= 160 kg/m^2
width of hoist= 0.6 m
ht of hoist 1
form factor 1.6
effective load on each colomn= 50%
wind load from hoist on column= 0.6*1.5x160x1.6x1/2=
77 kg
total wind load on top of column= 619+77 696 kg
A
B
WIND LOAD
A WIND LOAD
WIND LOAD
WIND LOAD
MA
AXIAL
LOAD-P
A
B B
A
AXIAL
LOAD-P
AXIAL
LOAD-P
FLOW
DESIGN CALUCULATIONS OF
KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-8
RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST
LTD. HOSPET FOR THANGARABALU SMALL
BANGALORE H.E. PROJECT(2X12.375MW) REV. 1
Moment at -A
a]due to wind load on wind ward column
MA1= 77x[700/100]x700
2
188650 kgcm
a]due to concentrated load at B
MA2= 696*700
487200 kgcm
Total moment at A
MA= MA1+MA2= 675850 kgcm
For Int/end column
Stress in column at A due to moments
fa= MA/Zxx= 763 kg/sqcm
<1683 kg/sqcm
check for unity formula (240/1164+763/1683) 0.7 <1
DESIGN CALUCULATIONS OF
KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-9
RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST
LTD. HOSPET FOR THANGARABALU SMALL
BANGALORE H.E. PROJECT(2X12.375MW) REV. 1
8 BATTENS
Battens are proposed for columns
Heght of column= 700cm
r min. Of column= 12.05cm
L/r min. = 58.1
spacing of battens shall be minimum of following
1] L/r min. < 40
2] 0.6XL/rmin. = 0.6x58.1= 35 <40
l= 35x12.05 = 422 cm
Proposed battens at 1000mm c/c =d
Depth of intermediate batten =300mm
Thickness of batten =10mm
Adopt battens of size 300x10 mm at 1000mm c/c.
Transverse shear=S = 2.5%Xof axial load
Transverse shear=S = 2.5%X22000 = 550 kg
Longitudinal shear =Sd/na s= transeverse shear
Moment=Sd/2n d=c/c distance of battens longitudinally
n=no of parallel planes of battens
a=min. distanace across welds
(450-2*15)=420mm
Moment=Sd/2n = 550x100/(2x2) = 9625 kgcm
Longitudinal shear =Sd/na= 550X100/(2X42) = 458 kg
distance between centroids of member=400mm =c
min. effective depth reqdd=75% of c = 300mm provide 300mm
Longitudinal shear stress = 458/[30x1] = 54kg/sqcm
Bending stress = 22000/2
= 212 kg/sqcm
1/6 x1x30 < 1530 kg/sqcm
DESIGN CALUCULATIONS OF
KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-10
RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST
LTD. HOSPET FOR THANGARABALU SMALL
BANGALORE H.E. PROJECT(2X12.375MW) REV. 1
9 Design of Column base plate
Proposed base plate= 600x400x20mm
moment on each column base = MA= 676850 kgcm
Total load on column= 22 mt
a]The thickness of base plate requiored as per cl.6.4.3 of IS800 is
t= 3w[a^2-b^2/4]fb
t= thickness of base plate
w=the pressure of loading
under base plate=22000/[60x40]= 9.2 kg/sqcm
a= the greater projection of plate beyond column= 10cm
b= the lesser projection of plate beyond column= 10cm
fb=1530 kg/sqcm
t= 1.3 cm Providded 20mm thickness of plate
b]checking the unit width of cantilever portion
bending moment = 9.2x10x10/2= 460 kgcm
0.666
bending stress= 460/0.66= 697 kg/sqcm
<1530kg/sqcm
BASE PLATE
FLOW
DESIGN CALUCULATIONS OF
KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-11
RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST
LTD. HOSPET FOR THANGARABALU SMALL
BANGALORE H.E. PROJECT(2X12.375MW) REV. 1
10 Design of Foundation Bolts
Proposed 6nos. of Bolts/column
Distance between holes c/c= 50cm
No. of effective bolt= 3
Max. B.M. in column= 676850 kgcm
Tensile load on each Bolt/ column = 50cm
676850 =
Proposed 20 mm bolts
50x3 5355 kg
A in Tensile = 9.425cm^2
A in Shear = 8.01cm^2
Tensile stress in Bolt= 5355/9.425=568kg/sqcm <945kg/sqcm
Shear stress = 22000*10%/(2x8.04)=131kg/sqcm
Length of bolt =l= 5093 = 90cm
px2x9 [M-250 Shear stress=9kg/sqcm]
Adopted 1200 mm long bolt with 50 mm thread length..
10a Check for compressive stresses in concrete
MA= = 676850 kgcm
Ecentricity=e= mc/pc= 676850/2200= 30.76 cm
size of column base= b=40cm h=60cm
e/h= 11.75/60= 0.512667
Area of tensile steel = 9.425 [2xpie/4xd^2]
AREA OF COM. STEEL = 0
EFFECTIVE DEPTH=h-d1=60-5=55cm
[b*h^2/6]+[2(ac-1)Asc/h] x[0.5h-d1]^2
modulus section =J= (40*55^2/6)+((2*13-1)*16.08)/55*(0.5*55-5)^2
= 22335.488
Atr=b*d+(m-1)Asc= 40*55+(13-1)*16.08 m=13
= 2313.1
Max comp stress= PC*1000/Atr+Mc/j
(22000/2313.1)+(803200/222335.5)
13 kg/sqcm <50kg/sqcm
Min comp stress= PC*1000/Atr-Mc/j
(22000/2313.1)-(803200/222335.5)
6 kg/sqcm <50kg/sqcm
11 CONNECTION DETAILS BETWEEN MONO RAIL GIRDER &COLUMN GIRDER.
Max. load occurs when pulley block is at cross girder
MAX. designed load = 22000 kg
Proposed 6 nos. of M20 Bolts
A in Tensile = 2.45 cm^2
A in Shear = 3.14 cm^2
Shear stress in bolt= 22000/(6x3.14X2)= 583 kg/sqcm
[double shear] <865 kg/sqcm
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V