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GREY HOUND ENGINEERS (INDIA) Private Limited

PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 1
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Design of 40T Rope Drum Hoist


for operation of Draft Tube Gates
Rampur HEP (H.P) Package II

1. Technical details :
No. of hoists : 6Nos
Capacity of hoist : 40t
Speed : 1.0M / min 10%
Type : Rope drum Hoist
Lift : (EL878.00 EL849.18)+1.188 = 30.0M
Designed : As per IS 6938 2005

2. Materials :

S.No Description Material Reference


1 Hoist bridge, Hoist supporting IS 2062 2006
Structural Steel
Structures, Platform walkway etc., Grade : E250 -B
2 Rope drum and Gear wheels Cast Steel IS1030
3 Pinions Forged Steel IS2004 / En steel
4 Shafts Forged Steel IS 2004
5 Bush bearings Al Bronze IS 305/Grade AB1
6 Antifriction bearings SKF / NTN / NSK / ZKL

3. Permissible stress : As per IS : 6938 2005 and technical specification

A. Normal Working Condition :


a) Rope drum : Cast steel IS 1030 Grade 280 520W
Yp : 2854kg/cm2 UTS : 5300kg/cm2
Compressive stress = 5300 X 0.2 = 1060 kg/cm2

b) Gear wheels : Cast steel IS 1030 Grade 280 520W


Yp : 2854kg/cm2 UTS : 5300kg/cm2
Root stress = 5300 X 0.2 = 1060 kg/cm2

c) Pinions : Forged steel 55C8 IS 2004 / En9


Yp : 3570kg/cm2 UTS : 7200kg/cm2
Root stress = 7200 X 0.2 = 1440 kg/cm2.

d) Shafts :
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PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 2
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

i i) Forged steel 45C8 IS 2004 YP : 3264kg/cm 2 UTS :


6300kg/cm2

Bending stress without key way = 0.2UTS = 1260kg/cm2

Bending stress with key way = 0.75 X 1260 = 945kg/cm2

Shear stress without keyway = 0.3 X YP = 980kg/cm2

Shear stress with keyway = 0.75 X 980 = 735kg/cm2

Combined stress with keyway = 1.2 X 0.75 X 0.2 UTS = 1134kg/cm2

Eqt. Bending stress with keyway = 1.2 X 945 = 1134kg/cm2

Eqt. twisting stress with keyway = 1.2 X 735 = 882kg/cm2

Combined stress for bending and torsion


0.60Yp or 0.24 UTS which ever is less = 1512kg/cm2

e) Bush bearings : Al Bronze IS 305 Grade AB1 UTS = 5100kg/cm2


Permissible stress = 0.04 X 5100 = 204kg/cm2

f) Structural Steel : IS 2062 2006 Grade : E250 -B


0 20mm Yp : 2550kg/cm2 UTS : 4180kg/cm2

1. Direct compression, tension (0.66/ 1.1) X Yp = 1530kg/cm2


Bending stress in compression / tension

2. Average Shear stress (0.40 / 1.1) X Yp = 927kg/cm2

B. Under Breakdown torque condition :


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PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 3
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

i) Rope drum : Crushing stress 0.8Y.P = 0.8 X 2854 = 2283kg/cm 2.

ii) Gear wheels : Root stress 0.8Y.P = 0.8 X 2854 = 2283kg/cm 2.

iii) Pinions : Root stress 0.8Y.P = 0.8 X 3570 = 2856kg/cm 2


.
iv) Shafts : Forged steel IS 2004, 45C8
YP = 3264kg/cm2, UTS = 6300kg/cm2
Bending stress without keyway 0.8Y.P 2612kg/cm2
Bending stress with Keyway 0.75 X 2612 1959kg/cm2
Shear stress without Keyway 0.8YP 2612kg/cm2
Shear stress with Keyway 0.75 X 2612 1959kg/cm2
Eqt. Bending / Torsional stress with keyway 2351kg/cm2

v) Structural steel : 0.8 Yp 2040kg/cm2

4.0 Design of the Hoist Mechanism :


Hoist capacity : 40t
Lifting Speed : 1.0M/min
No. of drums 2 and No. of falls on each drum : 2
Total lift : 30.0M

4.1 Design of Wire Rope :


Max. Rope tension = P1= w/2 (1- / 1-n)
P1 = (40000 / 2) (1 0.95 / 1 0.952) = 10256kg
P2 = 10256 X 0.95 = 9744kg

Proposed 32 wire rope, 6 / 36 construction, Right hand lay, ungalvanised,


main fiber core, UTS 200kg/mm 2 having braking load capacity of 67482kg.
Conforming to IS 2266 - 1989.

Factor of safety = 67482 / 10256 = 6.58 > 6.0

4.2 Motor :
H.P required = MV / 4.5E
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PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 4
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Where M = 40t + 0.739 t (wt. of rope) = 40.739 t


V = 1.0M/min
E = Efficiency : Starting Running
Rope drum : 0.93 0.95
Open gears : 0.932 0.952
Pulleys : 0.93 0.95
Worm reducer : 0.43 0.73 .
0.322 0.594
H.P = (40.739 X 1.0) / (4.5 X 0.594) = 15.24 H.P or 11.37 KW
Proposed 15KW (20H.P) 965rpm Squirrel cage, S4 duty/50Starts / hour, Class
B insulation, Foot mounted, working on 400 / 440V A.C 3 phase, 50
Cycles/sec. output shaft extension on either sides confirming to IS 325. Frame
size : ND 180L 1No. Static Tq to rated torque : 230%
POT to FLT = 275% Make: Bharat Bijlee

4.3 Brake :
Braking torque required = [{(71620 X 20) / 965} X 1.5] = 2227kgcm.
Proposed 300 A.C Electromagnetic, solenoid operated, single phase
brake 100% coil rating, class B insulation, working on 400/440 V A.C
having braking capacity 38.80kg.m 1 No.
Make: Sterling controls or equivalent.

4.4 Rope Drum :


Wire rope : 32mm
Proposed 2 drums with each 2 falls
Material : Cast steel IS 1030 Grade 280 520 W
Min. drum : 20 X 32 = 640mm
Proposed 650mm PCD. Circumference = 2.042M
Lift : 30M
No. of grooves required/drum = (32 X 2 / 2.042) + 3 = 32.38grooves33 grooves
Pitch of the grooves = 32 + 3 = 35mm
Depth of grooves = 0.35d = 0.35 X 32 = 11.2mm 11.00mm
Radius of the groove = 0.53d = 0.53 X 32 = 16.96 3 517mm
70 100
Length of the drum = 170 + 33 X 35 + 55 = 1380mm 100

Groove Details :
R 17

28
1
5 29 11

0
R2

M 24
640 PC D

640 PCD
560 PCD

66 67
30
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PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 5
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Design of Shell :
Proposed shell thickness = 30mm
Compressive stress = C = (K X P) / (p X t)
150
Where K = Coefficient for single layer wind = 1
P = Max. Rope tension = 10256kg
5 90 25 30
p = pitch = 3.5cm
1400
1380
55 t = Thickness
3 3 S P C S of
@ 3 5 Cshell
/C = 1 1 5 5 = 3.0cm 70 100 20
100
C= (1 X 10256) / (3.5 X 3.0) = 977kg/cm < 1060kg/cm2 2

66
Check for bending :
730 PC D

375 P C D
200
800

90
112

150
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PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 6
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Self weight of drum = 1000kg


Wire rope tension Max. P1 = 10256kg
1 0 2 5 6 k g 1 0 0 0 k g

A B
RA = RB = 5628kg 1 3 8

Bending moment = 371082kgcm


ZXX = / 32D (D4 d4)

= ( / 32 X 61.8) (61.84 55.84) = 7771cm3

Bending stress = 371082 / 7771 = 48kg/cm2 < 1060 kg/cm2

Combined stress = 9772 + 482 = 978kg/cm2 < 1060 kg/cm2

4.5 Design of Gear Wheel W1 and Drum connection bolts :

Proposed 20mm (as per drawing) - 6Nos. of fit bolts to IS 3640 having
Shank 21mm.
30 55
Max. Load on each bolt = 10256 + 500 + 620 = 11376kg 35

32
R 17
Load on each bolts = (11376 X 65) / (73 X 6) = 1688kg

Shank Area of bolts = ( / 4) X 2.12 = 3.46cm2


800
730 P C D

650 PC D
Shear stress = 1688 / 3.46 = 487kg/cm2 < 900kg/cm2

Material of bolts : class 4.8 of IS 1367 560

Yp = 320Mpa UTS = 420Mpa

4.6 Design of Reduction Unit :


The reduction unit consists of 2 end gear boxes of open gear with 2 train
each and on central drive unit consists of worm reducer, brake and motor.
Hoist speed 1.0M/min, Drum 650 PCD, circumference = 2.042
Drum speed : (1.0 X 2) / 2.042 = 0.9794rpm.
Motor speed = 965rpm.
Total Reduction ratio required = 965 / 0.9794 = 985.3
Proposed worm reducer ratio 60 : 1
Open reduction required = 985.3 / 60 = 16.42
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PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 7
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Proposed the following open gears


12M 8M
(114 / 22) X (76 / 24) = 16.409
Actual hoisting speed : (925 X X 0.65) / (60 X 16.409 X 2) = 0.959M/min
Total load on W1 P1 = (10256 X 0.65) / (1.368 X 0.95) = 5130kg
Total load on W2 P2 = (5130 X 0.264) / (0.608 X 0.95) = 2345kg

Load Face Permissible


No. of Module PCD root=Pq/fm
Design P width q stress Material
teeth PA cm kg/cm2 2
kg cm kg/cm
C.S IS 1030
W1 114 12 / 20 136.8 5130 15 2.50 713 1060
Gr280-520W
Forged steel
P1 22 12 / 20 26.4 5130 15 3.27 932 1440
55C8 / En9
C.S IS 030
W2 76 8 / 20 60.8 2345 10 2.73 800 1060
Gr280-520W
Forged steel
P2 24 8 / 20 19.2 2345 10 3.2 938 1440
55C8 / En9

Torque transmitted by P2 shaft = (2 X 2345 X 8) = 45024kg cm


Torque required by worm reducer output shaft = 45024 / 0.95 = 47394kgcm
Torque developed by the motor shaft = 47394 / (60 X 0.73) = 1082kg cm
H.P of motor required = (1082 X 925) / 71620 = 13.974H.P
Proposed 20HP is in order.

Worm reducer:
Proposed worm reducer 60 : 1, Type U, size 9, input H.P 14.9, input speed
1000rpm, output torque 498kgm, output shaft extended on either side with self
locking reversible gear box 1 No.
Starting efficiency = 0.43 and
Running efficiency = 0.73

Make: Elecon / DAVID BROWN


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PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 8
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

4.7 Checking up of Wire Rope, drum and Gears for Motor Break down torque
condition of motor i.e. 275 % of Motor Torque :
Motor HP provided 20HP, 965rpm POT / FLT =275%
= ((71620 X 20) / 965) X 2.75 = 4082kg cm
Starting efficiency of system up to drum = 0.93 3 X 0.43 = 0.346
Torque on each drum = X 4082 X 0.346 X 60 X 16.409 = 695268kgcm
Rope tension = 695268 / 32.5 = 21393kg

4.7.1 Wire rope


F.O.S = 67482 / 21393 = 3.15 > 3.0

4.7.2 Rope drum


c = (1 X 21393) / (3.5 X 3.0) = 2037kg/cm2 < 2283kg/cm2

Note : No check is required for bending stress since the crushing stress is on
very much on lower side than permissible

4.7.3 Checking the Gear wheels and Pinion under BDT condition :
Tooth load on W1P1 = (21393 X 0.65) / (1.368 X 0.93) = 10930kg
Tooth load on W2P2 = (7941X 0.264) / (0.608 X 0.93) = 5103kg

Desc No of teeth Module / PA P kg q f root = pq / fm Allowable


stress
W1 114 12 / 20 10930 2.50 15 1518 2283
P1 22 12 / 20 10930 3.37 15 2046 2856
W2 76 8 / 20 5103 2.73 10 1741 2283
P2 24 8 / 20 5103 3.2 10 2041 2856

5.0 Design of Shafts : Gear Box Assembly


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PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 9
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

R 3 25 8
16

300
112

95
720

120
320 260
380 320

420
300
90 700 759 400 221 90
2260

1890
100 90 1610 90
90

90
700

700
1280
400
2260
759

90
400
311

P tH W 1
8 1 61 0 0 9 0 3 4 0 9 0 1 0 0
W1
P t P 720
P tV W 1

1
P tW

5.1 Tooth load on Gear Wheel W1 and P1 :


1

P rW
1
P rV W 1

q P1 q P rH P 1
300
P rV P 1

P rH W 1
P rP 1
P rP
P rW 1 1
P tV P 1
P tP
1

Rt

P tW
1 P tH P 1
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PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 10
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Sign Conversion
Rope load horizontal = 0 (+) (-)
Rope load Vertical = Normal = 10256kg
BDT = 21393kg

q = sin-1 (300 / 816) = 21.5705783

Ptw1 = (-) 5130 PtP1 = (+) 5130


Prw1 = 5130 X tan 20 = (+) 1867 PrP1 = (-) 1867
PtHw1 = 5130 sin 21.5705783 = (-) 1886kg
PtHP1 = 5130 sin 21.5705783 = (+) 1886kg
PtVw1 = 5130 cos 21.5705783 = (-) 4771kg
PtVP1 = 5130 cos 21.5705783 = (+) 4771kg
PrHw1 = 1867 cos 21.5705783 = (+) 1736kg
PrHP1 = 1867 cos 21.5705783 = (-) 1736kg
PrVw1 = 1867 sin 21.5705783 = (-) 686kg
PrVP1 = 1867 sin 21.5705783 = (+) 686kg

Normal condition :
Fw1 (V) = - 4771 686 = - 5457kg Fw1 (H) = + 1736 1886 = - 150kg
FP1 (V) = + 4771 + 686 = + 5457kg FP1 (H) = - 1736 + 1886 = + 150kg

BDT Condition :Pt =10930 Pr=3978


Fw1 (V) = - 11628kg Fw1 (H) = - 319kg
P tP
FP1 (V) = +11628kg FP1 (H) = +319kg W 2
2

5.2 Tooth load of Gear Wheel W2 and P2 :


Normal condition : P 2

PtP2 (V) = - 2345kg


P rP 2

P rW 2

P tW 2
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PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 11
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

PrP2 (H) = - 836kg


PtW2 (V) = + 2345kg
PrW2 (H) = + 836kg
BDT Condition :
PtP2 (V) = - 5103kg PrP2 (H) = - 1857kg
PtW2 (V) = +5103kg PrW2 (H) = +1857kg

5.3 Design of Drum shaft:


Material of shaft Forged steel IS2004 55C8/ En9
A. Normal loads:
a) Vertical load in kgs: At a At b (W1)
Rope tension + 10256 ----
Weight of drum + 500 + 500
Rope weight + 370 + 370
Shaft weight + 83 + 83
Tooth load of W1 ---- - 5457
Weight of gear wheel ------ + 620
+ 11209 - 3884
b) Horizontal load in kgs:
Tooth load of W1 --- - 150
Vertical reaction : (Taking moment about B)
RVA = + 10589kg
1 0 7 5 6 k g - 4 4 1 7 k g

RVB = - 3264kg a b
- 1 5 0 k g

A 5 .5 B
1 4 4 9 .5
Horizontal reaction : 1 5 9

RHA = - 9kg
RHB = + 141kg
RA = 105892 + 92 = 10589kg
RB = - 32642 + 1412 = - 3267kg
BM @ a = 10589 X 5.5 = 58240kgcm
BM @ b = 3267 X 9.5 = 31037kgcm
Proposed : 90mm shaft
ZXX = 72cm3
Area = 64cm2
Bending stress = 58240 / 72 = 809kg/cm2 < 1000kg/cm2
Shear stress = 10589 / 64 = 165kg/cm2 < 826kg/cm2
Bearing :
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PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 12
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Gear wheel W1 side:


Proposed bush bearing Al. Bronze IS 305 grade AB 1
Size ID : 90 OD : 120 150 long
Bearing Stress = 3267 / (9 X 15) = 24kg/cm2 < 204kg/cm2
Non gear wheel side (Drum Hub side) :
Proposed bush bearing Al. Bronze IS 305 grade AB 1
Size ID : 90 OD : 120 70 long
Bearing stress = 11209 / (9 X 7) = 178kg/cm2 < 204kg/cm2

B. Checking for BDT condition:


a) Vertical load in kgs: At a At b(W1)
Rope tension + 21393 ----
Weight of drum + 500 + 500
Rope weight + 370 + 370
Shaft weight + 83 + 83
Tooth load of W1 --- - 11628
Weight of gear wheel --- + 620
+ 22346 - 10055
b) Horizontal load in kgs:
Tooth load of W1 --- - 232
Vertical reaction :
RVA = + 20972kg
RVB = - 8681kg 1 6 0 4 3 k g - 7 4 0 7 k g
- 2 3 2 k g
a
Horizontal reaction :
b
A 5 .5 B
1 4 4 9 .5
1 5 9

RHA = - 19kg
RHB = - 300kg
RA = 209722 + 192 = 20972kg
RB = - 86812 + 3002 = -8686kg
BM @ a = 20972 X 5.5 = 115346kgcm
BM @ b = 8686 X 9.5 = 82517kgcm
Proposed : 90mm shaft
ZXX = 72cm3
Area = 64cm2
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PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 13
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Bending stress = 115346 / 72 = 1602kg/cm2 < 1872kg/cm2


Shear stress = 20972 / 64 = 328kg/cm2 < 1959kg/cm2
5.4 Design of shaft P1W2 : Material : Forged steel 55C8 IS 2004/ En9
A. Normal Condition:
a) Vertical load in kgs:
At c (W2) At d (P1)
Tooth load of P1 ---- + 5457
Tooth load of W2 + 2345 ---
Shaft weight + 48 + 48
Self weight of P1 ---- + 70
Self weight of W2 + 110 -------
+ 2483 + 5575
b) Horizontal load in kgs:
Tooth load of P1 ------ + 150kg
Tooth load of W2 + 836 -------

Vertical reaction :
RVC = + 3753kg 2 3 4 5 k g 5 5 2 7 k g
8 3 6 k g P 1 1 5 0 k g

RVD = + 4305kg
c W 2 d
C 1 5 1 5 1 7 .5 D
4 7 .5

Horizontal reaction :
RHC = + 627kg
RHD = + 359kg
RC = 37532 + 6272 = 3805kg
RD = 43052 + 3592 = 4320kg

BM @d = 4320 X 17.5 = 75600kgcm


Torque transmitted = 5130 X 13.2 = 67716kgcm
Eqt. Twisting moment = 677162 + 756002 = 10143kgcm
Eqt bending = (101493 + 75600) = 88546kgcm

Proposed : 11cm shaft at key way & 9cm at bearing.


ZXX = 131cm3
ZPP = 262cm3
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Eqt. Bending stress = 88546 / 131 = 676g/cm2 < 945kg/cm2


Eqt. Twisting stress = 101493 / 262 = 387kg/cm2 < 735kg/cm2
Bearing :
Proposed plummer block SKF Make to suit 90 shaft at bearing with
22220K bearing and H 320 sleeve. Static capacity 490KN
Dynamic capacity 425KN
Make SKF

B. Check for BDT Condition:


a) Vertical load in kgs:
At c At d
Tooth load of P1 ---- + 11628
Tooth load of W2 + 5103 ---
Shaft weight + 48 + 48
Self weight of P1 ---- + 56
Self weight of W2 + 110 --------
+ 5261 + 11746

b) Horizontal load in kgs:


Tooth load of P1 ---- + 319
Tooth load of W2 + 1857 ------
Vertical reaction :
RVC = + 7927kg 3 7 9 8 k g 8 5 1 7 k g
1 3 5 0 k g P 1 2 3 2 k g

RVD = + 9080kg c W 2 d
C 1 5 1 5 1 7 .5 D
4 7 .5

Horizontal reaction :
RHC = + 1388kg
RHD = + 788kg
RC = 79272 + 13882 = 8048kg
RD = 65792 + 5732 = 9114kg
BM = 9114 X 17.5 = 159495kgcm
Torque transmitted = 10930 X 12 = 131160kgcm
Eqt. Twisting moment = 1311602 + 1594952 = 206498kgcm
Eqt Bending = (206498 + 159495) = 182997kgcm
Proposed : 11cm shaft at keyway & 9cm at bearing.
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

ZXX = 131cm3
ZPP = 262cm3
Eqt. Bending stress = 182997 / 131 = 1397kg/cm2 < 1982kg/cm2
Eqt. Twisting stress = 206498 / 262 = 788kg/cm2 < 1982kg/cm2

5.5 Design of P2 Shaft : Material : Forged steel 55 C8 IS 2004/En9.


A. Normal Condition :
Vertical load in kgs:
Tooth load of P2 - 2345
Weight of P2 + 30
- 2315
Horizontal load in kgs:
Tooth load of P2 - 836kg

Vertical reaction :
RE = - 1584kg
RF = - 731kg - 2 3 3 0 k g
- 8 3 6 k g

F
Horizontal reaction : E
1 5
4 7 .5
3 2 .5

RE = - 572 kg
RF = - 264kg
Resultant reaction :
RE = - 15842 + 5722 = -1684kg
RF = - 7312 + 2642 = - 777kg
Max. BM = 1684 x 15 = 25260 kgcm
Torque transmitted = 2345 X 9.6 = 22512kgcm
Eqt. Twisting moment = 252602 + 225122 = 33836kgcm
Eqt. Bending = X (33836 + 25260) = 29548kgcm
Proposed : shaft 8cm at key way and 7.5cm at bearing
ZXX = 50cm3
ZPP = 100cm3
Eqt. Bending stress = 29548/ 50 = 591kg/cm2 < 900kg/cm2
Eqt. Twisting stress = 33836 / 100 = 338kg/cm2 < 744kg/cm2

Bearing:
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Proposed Plummer block SKF Make to suit 75 shaft with 2217K


bearing and H317 adopter sleeve having dynamic capacity 58.5KN,
static capacity 23.6KN, Make SKF.

B. BDT Condition :
Vertical load in kgs:
Tooth load of P2 - 5103
Weight of P2 + 30
- 5073

Horizontal load in kgs:


Tooth load of P2 - 1857

Vertical reaction :
- 3 6 9 3 k g
RE = - 3471kg - 1 3 5 0 k g

E F
RF = - 1602kg
1 5 3 2 .5
4 7 .5

Horizontal reaction :
RE = - 1271kg
RF = - 586kg

Resultant reaction :
RE = - 34712 + 12712 = - 3696kg
RF = - 16022 + 5862 = - 1706kg
Max. BM @ d = 3696 x 15 =55440 kgcm
Torque transmitted = 5103 X 9.6 = 48989kgcm
Eqt. Twisting moment = 554402 + 489892 = 73983kgcm
Eqt. Bending = (73983 + 55440) = 64712kgcm

Proposed Shaft : 8cm at middle 7.5cm at key way


ZXX = 50cm3
ZPP = 100cm3
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Eqt. Bending stress = 64712 / 50 = 1294kg/cm2 < 1982kg/cm2


Eqt. Twisting stress = 73983 / 100 = 740kg/cm2 < 1982kg/cm2

5.6 Design of Line shaft : Material 45C8/ En8


Torque transmitted = 2345 X 8 = 18760kgcm
Proposed 8.0cm shaft at bearing 85
ZXX = 50cm3
Torsional stress = 18760 / 50 = 375kg/cm2 < 702kg/cm2
Angle of twist = 584TL / Nd4
Where T = 18760kgcm
L = 100cm
N = 8.168 X 105kg/cm2
D = 8.5cm
= (584 X 22512 X 100) / (8.168 X 105 X 8.54) = 0.308 < 0.33

5.7 Design of Manual operation:


H.P of the motor provided in the hoist = 20 H.P 965rpm
Torque of the motor = (71620 X 20) / 965 = 1484kgcm
S P 1

C lu tc h

S P 2
M o to r

Sprocket No. of teeth Pitch PCD cm


SP1 20 121.78cm
SP2 38 121.5cm

Torque at hand operation shaft = 1484 X 20 / 38 = 781kgcm


Crank radius 40cm
Effort required = 781 / 40 = 19.52kg
Proposed 2 people for operation of manual operation.
Effort required by each person = 19.52 / 2 = 9.76kg < 10.0kg
Actual Hoisting speed for manual operation
= (24 X X 0.65) / (60 X 16.409 X 1.5 X 2)
= 0.01659M/min = 1.65cm/Min
Chain : Single strand roller chain
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Pitch: 19.05mm (3/4)


Breaking load = 3300kg
Weight = 1.25kg/m
6.0 Design of Lifting Arrangement : (Provided in gate drawing)
6.1 Design of Pulley Shaft :
Load on pulley shaft = Rope tension P1 + P2 + Self weight of pulley
= 10256 + 9744 + 145 = 20150kg

2 0 1 5 0 k g

RA = RB = 10075kg A
2 .5 5 1 2 .5
1 7 .6
2 .5 5
B

Max. BM = (20150 / 8) (2 X 17.6 12.5) = 57176kgcm

Proposed 125 shaft : Material IS 1570 (Gr 431)


Area = 123cm2
ZXX = 192cm3

Bending stress = 57176 / 192 = 298kg/cm2 < 840kg/cm2


Shear stress = 10075 / 123 = 82kg/cm2 < 816kg/cm2

Design of Bush Bearing :


Load on pulley = 20150kg
Material of Bush : Al. Bronze IS 305 Grade AB 1
Permissible stress = 204kg/cm2

Proposed Bush bearing ID : 125, OD : 155 & 125 long


Bearing pressure : 20150 / (12.5 X 12.5) = 129kg/cm 2 < 204kg/cm2

6.2 Design of Lifting Bracket :


D
= 20150 / (2 X 14.5 X 2) = 347kg/cm2 C
1 6 .0

A B

Tensile stress along AA = 20150 / ((34 14.5) X 2) 1 4 .5


2 0 th ic k

= 517kg/cm2 < 840kg/cm2


6 0 .0
Max. Tearing stress () = X ((2R)2 + d2) / ((2R)2 - d2)
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

= 347 X ((2 X 16)2 + 14.52) / ((2 X 16)2 14.52)

= 347 X (1234.25 / 813.75) = 526kg/cm2 < 1408kg/cm2

7.0 Dial & Dial Assembly Calculations :


Dial Calculations :
110
Total lift : 32M

Gate lift up to FRL : 4.65M

41
1m = 11

8
61
25 60 100
Dial reading : 32 X 11 = 330

50
150
185
Dial rotation : 330 / 360 = 0.9167 revolutions
50
No. of revolutions made by drum for 32M lift

= (32 X 2) / ( X 0.65) = 31.34


95 130
No. of revolutions made by P1w2 shaft

= 31.34 X (114 / 20) = 178.645

Worm reducer ratio : 60: 1 24 40

P 1 W 2 SHAFT
Utilized ratio = 60 X 0.9167 = 55
40

Open reduction required


125

25
75

= 178.645 / 55

= 3.248 25
50
52 / 16 = 3.25

PCD in
Sprocket No. of Teeth Pitch
mm
SP1 52 210.34
SP2 16 65.10
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Chain : Single strand roller chain


Pitch: 12.7mm (1/2)
Guaranteed breaking load = 2000kg
Weight = 0.7kg/m
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

8.0 Design of Hoist Supporting structure :


The arrangement is shown in the sketch. The hoist supporting structure is
designed considering Normal Load. The allowable stresses for normal load are de
rated considering the impact factor of 1.1 .
3100

310200
475
365
B4 B3 A4

475

475
525 C 7004 400 1475C 3

C2

1270
1610

C5 B2 A2
FLO W

B5 A1 A5
340
A3
640
1200

1200

C6 C1
A6
560

B6
B1
2450

C7
900

900

B7 A7
1250
350

350
104209800
350

350

B7 A7
C7
1250
900

900

B1
B6 A6
2450

C6 C1
560

1225 325 434 400 716


1200

1200

S H A FT
W 2
640

A3
B5 A1 A5
340

C5 B2 A2
525 1100 1475
C2
325
1610

1270

C 4 DRUM
C3

B4 B3 A4
P U LLE Y
475

475
365

475
310
200

1550 1550
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

8.0.1 Technical Details :


Type of Hoist Rope Drum
Capacity 40t
Nos required 2nos

8.0.2 Material :
Structural Steel IS 2062 2006 Grade E 250 A/B

8.0.3 Permissible Stress :


The permissible stresses for normal load condition is de-rated considering
impact factor of 1.1 since structure is proposed for design of loads without impact.

A. Normal Condition :
Bending stress in tension or compression
= 0.66 Yp = 0.66 X 2448 = 1615 / 1.1 = 1468kg/cm2
Average shear stress = 0.4 X 2448 = 979 / 1.1 = 890kg/cm2
Bearing stress = 0.75 Yp = 0.75 X 2448 = 1836 / 1.1 = 1669kg/cm2

B. BDT Condition :
Permissible stress under BDT condition 0.8 Yp shall be 1.33 times of normal condition
ie Bending stress = 1.33 X 1615 = 2153kg/cm2
Average Shear stress = 1.33 X 979 = 1305kg/cm2
Bearing stress = 0.75 Yp = 1.33 X 1836 = 2447kg/cm2

C. The loads of various points are as follows :

Normal BDT Normal BDT


Rope
Point Loads loads Loads loads
Tension
in kg In kg in kg In kg
A +10120 +15045 P1 10256 21393
B -3784 -6413 P2 9744 19896
C -3782 +5824
D +4247 +6604
E -1694 -2691
F -781 -1017
8.1 Design of Cross Member : C1
Normal Condition :
9744kg

13
78
0k
9744kg

g
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Load at a = Resultant of Rope tensions of P 2 + Self wt. of pulley, pin etc


= 13780 + 145 = 13925kg
UDL = self wt. = 250kg

RA1 = 6623kg 1 3 9 2 5 k g
2 5 0 k g
a
A 1 B 1
6 4 5 6
1 2 0

RB1 = 7552kg

Max. BM = (13925 X 64 X 56)/120 + (250 X 120 / 8)) = 419643kgcm


Proposed 800mm X 20mm plate 2nos.
ZXX = 2 X 2.0 X (802 / 6) = 4267cm3
Bending stress = 419643 / 4267 = 98kg/cm2 < 1468kg/cm2
Shear stress = 7552 / (2 X 40 X 2.0) = 47kg/cm 2 < 890kg/cm2

Design of Weld :
25

The length of weld provided

= 35 X 4 = 140cm length.
350

Weld strength required

= 7552 / 140 = 54kg/cm length.


25

Proposed 6mm fillet weld having strength of : 0.7 X 0.6 X 890 = 373kg/cm length.

6 9 6 2 .5 k g
Design of Cheek Plate :

P = Load acting on Cheek Plate = 13925 / 2 = 6962.5kg/cm2


d = 1 2 .5
= 6962.5 / (12.5 X 2) = 278.5kg/cm2
R = 15

Max. Tearing stress () = X ((2R)2 + d2) / ((2R)2 - d2)


C
= 278.5 (1756 / 1444)
t = 2 .0
2 2
= 339kg/cm < 1468kg/cm

BDT Condition : 14455kg

Load at a = 28137 + 145 = 28282kg 20


44
2k
14455kg

g
2 0 5 8 7 k g
2 5 0 k g
a
A 1 B 1
6 4 5 6
1 2 0
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

RA1 = 13323kg
RB1 = 15209kg

Max. BM = (28282 X 64 X 56) / 120 + (250 X 120 / 8) = 848439kgcm


ZXX = 4267cm3
Bending stress = 848439 / 4267 = 199kg/cm2 < 2153kg/cm2
Shear stress = 15209 / (2 X 40 X 2.0) = 95kg/cm2 < 1305kg/cm2
8.2 Cross channel C2 :
Normal Load :
Load at a = Reaction of shaft P1W2 = RC = 3805kg
Load at b = Reaction of shaft P2 shaft = RE = - 1684kg

3 7 8 2 k g - 1 6 9 4 k g 5 0 k g
a b
B 2 A 2
3 5 .9 4 0 7 1 .6
1 4 7 .5

RB2 = [(3782 X 111.6 1694 X 71.6) / 147.5] + 25 = 2087kg


RA2 = + 84kg
Max. BM at a = 2087 X 35.9 ((50 / 147.5) X (35.92 / 2)) = 74705kgcm

1 .1 4
Proposed ISMC 200mm X 75mm plate

Area = 28.5cm2 0 .6 2

IXX = 1830cm4
20

1 7 .7 2

ZXX = 181cm3

f bending = 74705 / 181 = 413kg/cm2 < 1468kg/cm2


7 .5 0
f shear =2087 / (20 X 0.62) = 168kg/cm2 < 890kg/cm2

BDT Condition :
RB2 = 4320kg 5 8 2 4 k g - 2 6 9 1 k g 5 0 k g
a b
B 2 A 2
3 5 .9 4 0 7 1 .6
RA2 =+ 82kg 1 4 7 .5

Max. BM at b = 4320 X 35.9 ((50 / 147.5) X (35.92 / 2)) = 154870kgcm


fbending = 154870 / 181 = 856kg/cm2 < 2153kg/cm2
fshear = 4320 / (20 X 0.62) = 348kg/cm2 < 1305kg/cm2
8.3 Cross channel C3 :
Normal Load :
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Load at a = RB2 of C2 = 2087kg


UDL = self wt. including platform
2 0 6 4 k g
5 0 0 k g
RA3 = 1896kg A 3 B 3
3 4 1 2 7
1 6 1
RB3 = 691kg

Max. BM = 1896 X 34 ((500 / 161) X (342 / 2)) = 62669kgcm

1 .1 4
Proposed ISMC 200mm X 75mm channel
Area = 28.5cm2
0 .6 2
IXX = 1830cm4
ZXX = 181cm3

20

1 7 .7 2
fbending = 62669 / 181 = 346kg/cm2 < 1468kg/cm2
fshear = 1896 / (20 X 0.62) = 153kg/cm2 < 890kg/cm2
7 .5 0

BDT Condition :
3 1 0 5 k g
5 0 0 k g

RA3 = 3658kg A 3
3 4 1 2 7
B 3

1 6 1

RB3 = 1162kg

Max. BM = 3658 X 34 ((500 / 161) X (342 / 2)) = 122577kgcm


fbending = 122577 / 181 = 677kg/cm2 < 2153 kg/cm2
fshear = 3658 / (20 X 0.62) = 295kg/cm2 < 1305kg/cm2

8.4 Cross Girder C4 :


Normal Load :
Load at a = RA1 of drum shaft = 10589kg
Load at b= RB3 of C3 = 691kg
UDL = self wt. + live load = 160 + 0.80 X 3.545 X 500 = 1578kg

1 0 1 2 0 k g 6 8 6 k g
RB4 = 6677kg
1 4 0 0 k g

B 4 A 4
1 2 2 .5 4 0 1 4 7 .5

RA4 = 6181kg 3 1 0

15
1 .7 4

2
Max. BM = 6677 X 167 ((1578 / 354.5) X (167 / 2)) = 1052987kgcm
Proposed ISMB 450 X 150
0 .9 4

Area = 92.2cm2
45
4 1 .5 2
1 .7 4
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

IXX = 30400cm4

IYY = 834cm4

ZXX = 1354cm3

fbending = 1052987 / 1354 = 777.7kg/cm2 < 1468kg/cm2


fshear = 6677 / (45X 0.94) = 157.84kg/cm2 < 890kg/cm2
Check for Deflection :
Permissible deflection : 354.5 / 800 = 0.44cm
Actual deflection ()
= [(10589 X 354.53) / (48 X 2047000 X 30400)] [(3 x 167 / 354.5) 4(167 /354.5)3]
+ [(691 X 354.53) / (48 X 2047000 X 30400)] [(3 X 147.5 / 354.5) - 4(147.5 /354.5)3]
+ [(5 X 150 X 354.53) / (48 X 2047000 X 30400)]
= 0.157 + 0.010 + 0.011 = 0.178cm < 0.44cm

BDT Condition :

RB4 = 12365kg 1 5 0 4 5 k g 9 0 6 k g
1 4 0 0 k g

B 4 A 4
1 2 2 .5 4 0 1 4 7 .5
3 1 0
RA4 = 11347kg

Max. BM = 12365 X 167 ((1578 /354.5) (1672 / 2)) = 2002883kgcm


fbending = 1219246 / 1354 = 900.5kg/cm2 < 2153kg/cm2
fshear = 12365 / (45 X 0.94) = 292.32kg/cm2 < 1305kg/cm2

8.5 Design of Cross Girder C5 :


Normal Load :
Load at a = RB of Drum shaft =- 3267kg
Load at b = RA1 of C1 = 6623kg
Load at c = RA3 of C3 = 1896kg
Load at d = RD of P1 W2= 4320kg
Load at e = RF of shaft P2= -777kg
UDL = self wt. = 200 + 0.45 X 3.545 X 500 = 998kg 1000kg
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

6 6 2 3 k g
- 3 7 8 4 k g 1 8 7 8 k g 4 2 4 7 k g - 7 8 1 k g
9 0 0 k g
a b c d e e
B 5
7 .5 A 5
1 2 2 .5 3 2 .5 3 5 .9 4 0 .0 7 1 .6
3 1 0 .0

RB5=[(-777 X 71.6 + 4320 X 111.6 + 1896 X 147.5 + 6623 X 155 3267 X 187.5) / 310]
+ 500 = 3659kg
RA5 = 9795 3659 = 6136kg
Max. BM at c = 3659 X 200 [-3267 X 32.5 + (500 X 177.25 / 2)]
= 749530kgcm

Section Proposed is as follows : Proposed ISMB 450 X 150


15

1 .7 4
Area = 92.2cm2

IXX = 30400cm4
0 .9 4
4
IYY = 834cm
45
4 1 .5 2

ZXX = 1354cm3

fbending = 749530 / 1354 = 554kg/cm2 < 1468kg/cm2


1 .7 4

fshear = 6134 / (45 X 0.94) = 145kg/cm2 < 890kg/cm2


Check for Deflection :
Permissible deflection as per IS 6938 2005 = span /800 = 354.5/800 = 0.44cm

Actual deflection :
1 = ((-3267 X 354.53) / (48 X 2047000 X 30400)) [(3 X (167 / 354.5)) (4X (167 /
354.5)3] = - 0.0485cm
2 = ((6623 X 354.53)/(48 X 2047000 X 30400))[(3 X (155/ 354.5)) (4X (155 /354.5)3]
= 0.096cm
3 = ((1896 X 354.53) / (48 X 2047000 X 30400)) [(3 X (147.5 / 354.5)) (4(147.5/
354.5)3] = 0.027cm
4 = ((4320 X 354.53) / (48 X 2047000 X 30400)) [(3 X (111.6 / 354.5)) 4 (111.6 /
354.5)3] = 0.053cm
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

5 = ((-781 X 354.53)/(48 X 2047000 X 30400))[(3 X (71.6/354.5)) 4(71.6 / 354.5)3]


= -0.007cm
6 = ((5 x 200 X 354.53) / (384 X 2047000 X 30400)) = 0.002cm

= 1 + 2 + 3 + 4 + 5 + 6 = 0.1225 < 0.44cm

BDT Condition :

9 7 3 2 k g
- 6 4 1 3 k g 2 6 9 9 k g 6 6 0 4 k g - 1 0 1 7 k g
9 0 0 k g
a b c d e e
B 5
7 .5 A 5
1 2 2 .5 3 2 .5 3 5 .9 4 0 .0 7 1 .6
3 1 0 .0

RB5 = [(-1706 X 71.6 + 9114 X 111.6 + 3658 X 147.5 +13323 X 155 - 8686 X 187.5) /
354.5] + 500 = 5777kg
RA5 = 16203 - 5777 = 10426kg

BM at d = 5777 X 200 [-8686 X 32.5 + (450 X 200 / 2)]


= 1397814kgcm

fbending = 1397814 / 1354 = 1032kg/cm2 < 2153kg/cm2


fshear = 10924 / (45 X 0.94) = 258kg/cm2 < 1305kg/cm2

8.6 Design of Cross Channel C6 :


A. Normal Condition :
Load at a = RB1 of C1 = 7552kg
UDL = 150 + 0.45 X 3.545 X 500 = 947.6kg 948kg

7 5 5 2 k g 8 5 0 k g

RB6 = 3777 kg B 6 A 6
3 1 0
RA6 = 4723 kg

Max. BM = 700758kgcm

Proposed ISMC 400mm X 100mm channel

Section Proposed is as follows :


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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Area = 63.8cm2

IXX = 15200cm4

ZXX = 760cm3

Web thickness = 0.88cms

fbending = 700758/ 760 = 922kg/cm2 < 1468kg/cm2

fshear = 4723 / (40 X 0.88) = 134kg/cm2 < 890kg/cm2

Check for Deflection :


Permissible deflection as per IS 6938 2005 = span /800 = 354.5/800 = 0.44cm
Actual deflection
= ((7552X354.53)/(48 X 2047000 X 15200))+[(5 X 199.5 X 354.53)/(384 X 2047000 X
15200] = 0.229cm < 0.44cm

B. BDT Condition :
1 1 1 0 5 k g 8 5 0 k g

B 6 A 6
RB6 = 7125 kg 3 1 0

RA6 = 9032kg

BM = 1368666kgcm

fbending = 1368666 / 760 = 1801kg/cm2 < 2153kg/cm2


fshear = 9032 / (40 X 0.88) = 257kg/cm2 < 1305kg/cm2
8.7 Design of Channel C7 :
Load acting on channel = weight of drive unit = 600kg

6 0 0 k g

RB7 = RA7 = 300kg B 7 A 7


3 1 0

Max. BM = 26588kgcm
Section Proposed is as follows : Proposed ISMC 150 X 75
Area = 21.3cm2
IXX = 788cm4
ZXX = 105cm3
Web thickness = 0.57cm
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Bending stress = 26588 / 105 = 253kg/cm2 < 1468kg/cm2


Shear stress = 300 / (15 X 0.57) = 35kg/cm 2
8.8 Design of Girder AB :
A. Normal loading:
UDL = self weight of girder = 1200kg

5 0 5 9 k g 5 3 6 8 k g 4 2 0 1 k g 3 0 0 k g 3 0 0 k g 4 2 0 1 k g 5 3 6 8 k g 5 0 5 9 k g
1 2 0 0 k g
A 4 A 5 A 6 A 7 A 7 A 6 A 5 A 4

A B
8 4 1 6 1 1 2 0 9 0 3 5 3 5 9 0 1 2 0 1 6 1 8 4
9 8 0

RA = RB = 17938kg
Bending Moment = (17938 X 490) [(300 X 35) + (4723 X 125) + (6134 X 245)
+ (6181 X 406) + (600 X 490 / 2)] = 4029429kgcm

24
Proposed Section as follows :

2
Area = 192cm2

IXX = 304256cm4
1

ZXX = 6085cm 3
96

fbending = 4029429 / 6085 = 662kg/cm2 < 1468 kg/cm2


fshear = 17938 / (96 X 1.0) = 187kg/cm2 < 890kg/cm2
2

Check for Deflection :


Permissible deflection as per IS 6938 2005 = L /800 = 980 / 800 = 1.225cm

Actual deflection :

1 = ((6181 X 9803) / (6 X 2047000 X 304256)) [(3 /4) (84 / 980)) (84 / 980)3)]

= 0.10cm

2 = ((5368 X 9803) / (6 X 2047000 X 304256)) [(3 /4) (245 / 980)) (245 / 980)3)]

= 0.266cm

3 = ((4201 X 9803) / (6 X 2047000 X 304256)) [(3 /4) (365 / 980)) (365 / 980)3)]

= 0.271cm

4 = ((300 X 9803) / (6 X 2047000 X 304256)) [(3 /4) (455 / 980)) (455 / 980)3)]
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

= 0.019cm

5 =((5 X 1200 X 9803) / (384 X 2047000 X 304256)) = 0.023cm

= 1 + 2 + 3 + 4 + 5 = 0.679cm < 1.225cm

B. BDT Condition :

7 1 2 0 k g 7 6 4 1 k g 5 9 7 8 k g 3 0 0 k g 3 0 0 k g 5 9 7 8 k g 7 6 4 1 k g 7 1 2 0 k g
1 2 0 0 k g
A 4 A 5 A 6 A 7 A 7 A 6 A 5 A 4

A B
8 4 1 6 1 1 2 0 9 0 3 5 3 5 9 0 1 2 0 1 6 1 8 4
9 8 0

RA = RB = 32203kg

Bending Moment

= (32303 X 490) [300 X 35 +9032 X 125 +10904 X 245 +(11347 X 406) +(600 X 490 / 2)]

= 7209708kgcms

fbending = 7209708 / 6085 = 1185kg/cm2 < 2153kg/cm2


fshear = 32203 / (96 X 1.0) = 335kg/cm2 < 1305kg/cm2
8.9 Design of Main Girder CD :
Normal Load :
UDL = Self weight + live load = 1200 + 0.75 X 500 X 9.8 = 4875kg4900KG

7 1 4 7 k g 3 7 1 5 k g 4 2 0 1 k g 3 0 0 k g 3 0 0 k g 4 2 0 1 k g 3 7 1 5 k g 7 1 4 7 k g
4 9 0 0 k g
B 4 B 5 B 6 B 7 B 7 B 6 B 5 B 4

C D
8 4 1 6 1 1 2 0 9 0 3 5 3 5 9 0 1 2 0 1 6 1 8 4
9 8 0

RC = RD = 16863kg
BM = 16863 X 490 [300 X 35 + 3777 X 125 + 3659 X 245 + (6677 X 406) +
(2450 X 490/2)] = 3572678kgcm
24
Proposed section is as follows :
2

Area = 192cm2

IXX = 304256cm4
1
3
ZXX = 6085cm
962
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PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

fbending = 3572678 / 6085 = 587kg/cm2 < 1468kg/cm2


fshear = 16863 / (96 X 1) = 176kg/cm2 < 890kg/cm2

Check for Deflection :


Permissible deflection as per IS 6938 2005 = L /800 = 980 / 800 = 1.225cm
Actual deflection :
1 = ((6677 X 9803) / (6 X 2047000 X 304256)) [(3 /4) (84 / 980)) (84 / 980)3)]
= 0.107cm
2 = ((3659X 9803) / (6 X 2047000 X 304256)) [(3 /4) (245 / 980)) (245 / 980)3)]
= 0.158cm
3 = ((3777 X 9803) / (6 X 2047000 X 304256)) [(3 /4) (365 / 980)) (365 / 980)3)]
= 0.217cm
4 = ((300 X 9803) / (6 X 2047000 X 304256)) [(3 /4) (455 / 980)) (455 / 980)3)]
= 0.019cm
4 = ((5 X 1200 X 9803) / (384 X 2047000 X 304256)) = 0.023cm
= 1 + 2 + 3 + 4 = 0.524 < 1.225cm
BDT Condition :

1 0 2 3 1 k g 4 8 6 4 k g 5 9 7 8 k g 3 0 0 k g 3 0 0 k g 5 9 7 8 k g 4 8 6 4 k g 1 0 2 3 1 k g
4 9 0 0 k g
B 4 B 5 B 6 B 7 B 7 B 6 B 5 B 4

C D
8 4 1 6 1 1 2 0 9 0 3 5 3 5 9 0 1 2 0 1 6 1 8 4
9 8 0

RC = RD = 23823kg

BM= 23823 X 490[300 X 35 + 5978 X 125 + 4864 X 245 + 10231 X 400 + (2450 X490 / 2)]
= 5031190kgcm

fbending = 5031190 / 6085 = 827kg/cm2 < 2153kg/cm2


fshear = 23816 / (96 X 1) = 248kg/cm2 < 1305kg/cm2
GREY HOUND ENGINEERS (INDIA) Private Limited
PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 33
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

9.0 Design of Pylon :


Loading : The steel pylon is proposed to be designed for following loads :
1. Max. vertical load from the bridge bearings = 2 X 17938 = 35876kg

2. Self weight of Pylon = 1500kg

3. Vertical reaction due wind force reaction when gate is dogged


Span of pylon : 3545cm
Wind moment on gate :
Wind pressure = 65kg/cm2
Wind load on gate = (8.6 X 3.6) X 1.2 X 65 = 2415kg
CG of wind load acting = 40 + (360 / 2) = 220cm
Vertical reaction due to wind load : 2415 X 220 / 354.5 = 1499kg
Total vertical force = 35876 + 1500 + 1499 = 38875kg
38840kg

II. Wind load acting on Hoist, Hoist bridge and Pylon : 562kg

a) Wind load on Hoist = 2 X (3.0 X 1.2) X 1.2 X 65 = 562kg


1020kg
b) Wind load on Hoist bridge = (9.8 X 1.0) X 1.6 X 65 = 1020kg
c) Wind load on Pylon = (0.42 X 6.0) X 1.6 X 65 = 262kg
750

262kg
300 650
GREY HOUND ENGINEERS (INDIA) Private Limited
PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 34
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Wind load moment = 562 X 750 + 1020 X 650 + 262 X 300


= 1163100kgcm
It is proposed the following section for column.

Area = 2 X 63.8 + 2 X 40 X 1.0 = 207.6cm2


IXX = 2 X 15200 + (2 X 40 X 1.0 X 20.52)
= 64020cm4 Y
40
IYY = (2 X 1.0 X 403 / 12) + 2 X 508 + 2 X 63.8 X 15.22

1.0
= 41163.4cm4 ISMC 300 X 90

30
rXX = 17.56cm X X
18.65 18.65
rYY = 14.08cm 2.35 2.35

ZXX = 3645.78cm3

1.0
Y
ZYY = 2923.54cm3 42

Since the pylon is effectively held in position and restricted in direction at bottom

and top, it is effectively restrained in direction but not held in position (Ref IS

800 1989).

Hence effective length = Length of pylon.

However for rigidity the two column pylon is braced.

Effective length = 800cm

Slenderness ratio = 800 / 17.56 = 45.56

Permissible stress = 136MPa = 136 X 10.2 = 1387kg/M 2

Permissible bending stress = 1530kg/cm2

Bending stress = 1163100 / 2923.54 = 397.84kg/cm2 < 1530kg/cm2

Compressive stress = 38875 / 207.6 = 187.26kg/cm2 < 1387kg/cm2

Check for unity = (397.84 / 1530) + (187.26 / 1387) = 0.395 <1.0


GREY HOUND ENGINEERS (INDIA) Private Limited
PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 35
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

9.1 Design of Base Plate :


The following size plate was used which was used for similar hoist. 70cm X 70cm X 2.5cm
50

140
10
200

420
195

00
1
200

400
700

10
195
200

10
140
50

50 200 200 200 50


700
Max. vertical load
Bearing area = 70 X 70 = 4900cm2
Bearing pressure concrete = 38625 / 4900 = 7.882kg/cm2 < 52kg/cm2
Thickness of plate required as per clause 5.4.3 of IS 800 IS 1984.
t = (3w / Fb) (A2 (B2 / 4))
Where w = bearing pressure in concrete = 7.882kg/cm2
GREY HOUND ENGINEERS (INDIA) Private Limited
PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 36
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

Fb = 185 MPa = 1887kg/cm2


A = Greater projection beyond column = 14cm
B = Lesser projection of plate betyond column = 14cm
t = ((3 X7.882)/1887) ((142 (142 /4)) = 1.84cm. However it is proposed = 2.5cm

9.2 Design of anchor Bolts :


Bending moment in the column = 1163100kgcm
Lever arm = 30cm
No. of bolts provided = 12 Nos. of 30mm dia.
Force in bolt = 1163100 / 30 = 38770kg
Load on each bolt = 38770 / 12 = 3231kg
Area of the bolt = ( / 4) X 32 = 7cm2
Stress in the bolt = 3231 / 7 = 462kg/cm2 < 960kg/cm2
Length of bolt required = 3231 / ( X 3 X 12) = 29cm
Proposed 750mm length bolts.
9.3 Design of Bracings :
Total load on the column = 38875kg
2 % of the load = 972kg
Wind load on bracings = 250kg
Total load for design of bracings = 972 + 250 = 1222kg
25

I. Design of Diagonal Bracings :


500

The bracings are inclined at 51.115


950

2680

Force in the bracing = 1222 / cos 51.115


= 1947kg 400

Proposed L 75 X 75 X 8
2500

Area = 8.9cm2 3982


3982
rXX = 2.28cm
9 01 11019 0
l = 199cm
l / rXX = 199 / 2.28 = 87 < 180
6000
4050

2680

Permissible stress = 90 X 10.2


3982
= 918kg/cm2 3982
220
420
Actual compressive stress = 1947 / 8.9
2500

= 219kg/cm2 < 918kg/cm2


670

670
950
950
950

2680
500
25

3100
GREY HOUND ENGINEERS (INDIA) Private Limited
PROJECT : RAMPUR HEP ( H.P) SUBJECT : DESIGN OF 40T ROPE DRUM HOIST FOR Page No : 37
PACKAGE II OPERATION OF DRAFT TUBE GATES Rev :1

II. Design of Horizontal Bracings :


Compressive force = 1222kg
Length = 0.85 X 355 = 302cm
Proposed L 75 X 75 X 8.
Area = 8.9cm2
rXX = 2.28cm
l = 302cm
l / rXX = 302 / 2.28 = 133
Permissible stress = 68 X 10.2 = 694kg/cm2
Actual compressive stress = 1222 / 8.9 = 137kg/cm2 < 898kg/cm2
Since it is only 9.8M span it is proposed to provide a slotted hole for
expansion.

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