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ICS 93.160
.
Q BIS 2005
BUREAU
OF
INDIAN
STANDARDS
SHAH ZAFAR MARG
Price Group 7
FOREWORD
This Indian Standard ( Second Revision) was adopted by the Bureau of Indian Standards, afier the draft finalized
by the Hydraulic Gates and Valves Sectional Committee had been approved by the Water Resources Division
Council.
Controlled release of water from reservoirs is made by the use of spillway gates provided on crests, control gates
in conduits or in the body of the dam and tunnels. For the operation of these gates, various types of mechanisms
are provided. The rope drum and chain hoists are used for gates which close by their own weight and where no
positive thrust is required to close them.
in the formulation of this standard, due weightage has been given to international co-ordination among the
standards and practices prevailing in different countries in addition to relating it to the practices in the field
in this country.
This standard was first published in 1973 and subsequently revised in 1989. In this revision the requirements
of motors, hoist limit switch, control panel and figures have been modified in the light of experience gained over
the years,
The composition of the Committee responsible for the formulation ofthis standard is given in Annex B.
For the purpose of deciding whether a particular requirement of this standard is complied with, the final
value, observed or calculated expressing the result of a test or analysis, shall be rounded off in accordance with
IS 2:1960 Rules for rounding off numerical values ( revised ). The number of significant places retarned in the
rounded off value should be the same as that of the specified value in this standard.
.
.
1S 6938:2005
Indian Standard
DESIGN OF ROPE DRUM AND CHAIN HOISTS FOR
HYDRAULIC GATES CODE OF PRACTICE
(Second
Revision )
same ) and the downward forces closing the. gate
while lowering shail be at least 20 percent higher
than the frictional and other forces opposing the
downward motion. The necessary closing/seating
load shall be calculated considering the net crosssectional area of the bottom seal and maximum water
pressure acting on it such that the lowering force is
more than the seating load. However, the values of
closingkeating load shall be greater than those given
below:
1 SCOPE
Type of Gate
3 GENERAL
Minimum Seating
Load
a)
b)
4 DESIGN
4.1.1
1) Wheel friction,
2)
3)
c)
d)
specific
PARTS
e)
OF MECHANICAL
to a
+3$
J(71~+c+71f32
where
cc
Cr,C* = tensile/compressive
and
stresses, in N/mz;
IS 6938:2005
LEfe=+-------*
5
c!)
h----l-i-t
!1
II
2
i?
a
%
&
Ix
.,
,I 1 11
I
I
1,
II
II
I
I
t,
I/
vh
-----
----
IS 6938:2005
FLANGE
(J
UPLtNG
+
PROCK
FOR
DRIVE
<fMANNUA
~
END
REDUCTION
ROPE
)YJIRM
-~ /REDuCER
I
1ti
UNIT
DRUM
r
z .-.
I
GEAR BOX
WI
OIST
BASE
FRAME
SUPPORT
ELEVATION
MACHINERY ASSEMBLY
HAND
Ru~
cOvER~RUM
DRIVE
GEAR
%
FLOATING
\C/L
.
OF
SH
ROPE
SECTK)N B-B
SECTION A-A
IB
Machine Asserrtbly
SPROCKET
SPROCKET FOR
MANUAL DRIVE
FLANGE COUPLING r
R=4Fl
/41kb---(!llHml-M
1I
I I
ii
. ~l!.J,
,
l!~
!.
~HOIST
Ii
!i:
------
11~~
1
BRIDGE+
g
n
-----------
----
- ----
Ill \\
,TOP SHEAVE
------
------
.-.
II
. .
I
i
SHEAVE
i~
I
I
ELEVATION
i!
f
~i
i
GATE SHEAVE
;;
i
i
!!
!!
i.
MACHINERY ASSEMBLY
!!
i
i
t.
i
.
w
G
1C
Gate Attachment
FIG.
with Balancing
Sheave Assembly
1 TYPICALHOISTINGARRANGEMENTS
OFGATES
GATE SHEAVE
IS 6938:2005
3
n
IS 6938:2005
4.3.1.3 The drum may be flanged at ends. The flanges
4.2.1 General
The wire rope shall bemade from improved plough
steel, galvanized ( if required ), Langs lay and fibre
core or normally of 6 x 36 or 6 x 37 construction and
shall conform to 1S2266.
4.3.2 A4aterialfor
Drums
a)
b)
c)
Operating
(2)
(1)
i)
ii)
iii)
Condition
Normal
Minimum
Fxctor
of Safety
(3)
operation condition
Kx T
pxt
f.
where
c, = compressive stress, in N/mm2;
K=
coefficient which depends upon the
number of layers of rope over the drum
and may be taken from Table 2;
T=
tension on one wire rope in N;
P=
4.3 Drums
4.3.1
General
Table 2 Value Qf K
4.3.1.1
S1 No.
Number of Layers of
Rope Over the Drum
Value of K
(1)
(2)
(3)
ii)
1.75
iii)
2.0
iv)
2.25
IS 6938:2005
4.3.3.1
Table 3
the various
materials
be taken
as follows:
Material
Indian
Standard
(1)
(2)
Cast iron
IS 210
from which
Ratio for
( Clause 4.4.l )
Normal Torque
Conditions
(3)
Breakdown
Conditions
0.4 UTS
0.2 UTS
80 percent of YP
Mild
0.17
1S 2062
UTS
sl
No.
(4)
0.2 UTS
steel
Type of Pulley/
i)
12
ii)
20
c)
4.4.3 Grooves
Sheaves or pulleys shall be machine-grooved to a
depth of not less than 1.5 times the diameter of the
rope. Grooves shall be finished smooth and shall be
free from surface defects likely to injure rope. The
contour at the bottom of the grooves shall be circuiar
over an angle of approximately 130 * 5. The radius
of the groove shall be 0.53 times the diameter of a
rope. The included angle which is-the angle between
the straight slopes at the sides of the grooves shall
.
be approximately 52.
b)
-D
NOTE
80 percentof YP
a)
Sheave
Diameter
b)
a)
of Pulley.v/Sheaves
4.5.2 Design
IS 6938:2005
Table 4 q Value for Calculation of Stress in Tooth
at Root ( External Tooth) for 20 Full Depth
-Involute System and 20 Stub Tooth Systems
pinion
and lower
strength
grade
( Clause 4.5.l )
Number of Teeth
on Gear/Pinion
(1)
(2)
q Value for
q -value
for 20 20 Stub Tooth
(3)
(4)
4.60
3.215
i)
12
ii)
13
4.35
3.086
iii)
14
4.10
2.941
iv)
15
3.90
2.865
v)
16
3.75
2.770
vi)
17
3.60
2.717
4.5.6.1
vii)
18
3.50
2.652
viii)
21
3.30
2.506
ix)
24
3.20
2.424
x)
28
3.10
2.325
4.6 Chain
xi)
34
3.00
2.242
xii)
40
2.90
2.179
xiii)
50
2.80
2.110
xiv)
65
2.70
2.040
xv)
80
2.60
2.008
xvi)
I 00
2.50
1.976
2.50
1.976
xvii)
Above
100
NOTE Intermediate
a)
90 N/mm*, and
b)
70 Nhnrn2.
0 root
a)
Pxq
Fxrn
4.6.2 Maintenance
shall also be given due
consideration in arriving at the selection of the size
of the chains. Materials for various~arts of the chain
shall be as follows:
where
0 root
4.5.3
= tooth load, in N;
= module in mm.
Allowable
a)
Straps
Stress
c)
Rollers
d) Pins
4.7 Shafts
4.5.4 Material
4.7.1
General
appropriate load/
Shafis shall have
adequate bearing
smoothly and, if
IS 6938:2005
shouldered,
shall
be provided
with
fillets
2)
of large
Twisting:
radius.
4.7.2
Dimensioning
of Shafts
where
Me =
4.8 Bearings
4.7.3 Material
4.8.1
4.7.4 Allowable
Stress
b)
moment,
in
M=
T=
Types of Bearing
bending
equiva-lent
Nm;
c)
t=O:08 d+3 mm
crb*+ 31J
where
where
combined stress, in N/mm* and shall
not exceed 0.24 UTS or 0.60 YP,
whichever
.,
is less;
4.9 Couplings
4.9.1
Material
1) Bending
Me = 0.5( Iu+Jm
9
IS 6938:2005
the gears can be easily removed or replaced and shall
be such that the gears are suitably lubricated. Facilities
for oil tilling and draining, connection for oil level
indication
and adequate
breathing
shall be provided
Structure
5 ELECTRICAL
5.1 Efficiency
5.3.1
EQUIPMENT
of System
5.1.1
5.2 Motors
5.2.1 The motor shall be totally enclosed fancooled,
high starting torque, squirrel cage, three phase
induction motor of rated capacity conforming to
Table 5 Efficiencies
Brake
of Various Components
of Hoisting Mechanism
( Clause 5.1.1)
S1 No.
Particular of Elements
Starting Efficiency
Percent
Rwnning Efficiency
Percent
(1)
(2)
(3)
(4)
93
95
93
95
95
98
95
98
i)
Drum/sheave/pulley:
a) Bronze bushing
b) Anti-friction
ii)
bearing
iii)
iv)
v)
Electrical
As per manufacturers
recommendations
do
motor
10
As per
manufacturers
recommendations
do
IS 6938:2005
5.4.1
General
6.6.3.1
5.4.2.1
INDICATOR
6.2 The indicator dial shall be made from nonrustingmetal or~namelled plate or thick plastic sheet.
It shall generally-be of circular shape. If agreed to,
other shapes may also be adopted.
if
required for emergency operation in.the event of electric
supply failure.
6.7.2 Electrical interlocks shall be provided to prevent
operation by electrical power when the manual drive
is engaged.
IS 6938:2005
ANNEX
(Clause
2)
LIST OF REFERRED
IS No.
INDIAN
325:1996
513:1994
800:1984
2062:1999
2004:1991
12
2266:2002
2485:1979
Specification
for drop forged
sockets for wire ropes for general
engineering
purposes
( first
revision
revision _)
1030:1998
Title
IS No.
Title
210:1993
STANDARDS
3445:1992
4622:2003
IS 6938:2005
ANNEX
( Foreword)
COMMITTEE
Hydraulic
COMPOSITION
Sectional
Committee,
Kunj,
New Delhi
( 2047,
2, Sector
D,
Vasant
Authority,
SHIU R. K. RUSTACiI
New Delhi
SHRI R. M. SINNARKAR
SHRI S, L. PATIL( Alternate
DIRECTORGATES( E &NE)
DIRECTOR( GATES-NW&
National Hydroelectric
Government of Maharashtra,
Research Institute,
Nasik
Roorkee
S)(
Alternate)
)
SUPERINTENDING
ENGINEER( GATES)
EXECUTIVE ENGINEER( Alternate
Alternate )
SHRIG. S. SHAFtMA
SHRI A. K. Rov ( Alternate
DIRECTOR( MECHANICAL)
SENIORMANAGER( DESIGN ) ( Alternate
SHRI S. R. SINHA
SHRI UDAYANBANEREJEE(
SHRI J. P. MISHRA
SHRI B. P. SINGH( Alternate
Ltd, Allahabad
.
)
Alternate )
)
Triveni Structural
Alternate )
DGM ( HTE )
Ltd, Bhopal
Irrigation
Chairman )
Irrigation
SHRI N. VISHWANATHAN(
110 070)
Central Electricity
12
Representative(s)
Organization
In Personal Capacity
WRD
PROFGOPALCHAU~AN
Member
Secretary
SHRIMATIROSY DHAWAN
Joint Director ( WRD ), BIS
13
Member
) ]
statutory
harmonious
attending
institution
development
to connected
established
of the activities
matters
under
the
of Indian
Bureau
of standardization,
marking
,Vlandards
and quality
a et,
1986
certification
to promote
of goods and
in the country.
Copyright
BI-S has the.copyright of all its publications. NO part of these publications may be reproduced in any form
without the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing
the standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating
to copyright be addressed to the Director (Publications), BIS.
Review of Indian Standards
Amendments are iss-ued to standar-ds as the need ariseson the basis of comments. Standards are also reviewed
periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
needed; if the review indicates that changes are needed, it is taken, up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue
of BIS Catalogue and Standards : Monthly Additions.
This Indian Standard has been developed from Doc : No WRD 12( 339).
Amendments
Amend No.
Date of Issue
Text Affected
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