Study Material for Gates and Hoists Introduction

For optimum benefit controlled releases of water is of immense importance. Thus hydraulic gates form the most vital component. Though forms a very small component of the total project cost most crucial parameter in determining the success of the project. With the increase in size, head & discharge the complexities associated with gate structures have increased manifold.Major causes of failure & malfunctioning attributed to faulty hydraulic design / improper operation. Phenomenon of cavitation and vibration threatens the very safety of the hydraulic structure. Thus the precise need for careful design.

NEED:
i. ii. iii. Gates are subjected to high static water loads & dynamic loading condition. Gates have to cater to complex flow conditions. Variation in flow conditions develops sub atmospheric pressures in the gate body & its surroundings. Thus causing cavitations, vibration, down pull & uplift forces. iv. Hence the need for proper inlet shapes of the conduit, its alignment, smoothness of fluid path, profile of conduit down stream of gate slot ( fig below)

FACTORS GOVERNING THE HYDRAULIC DESIGN OF GATES:

i. Flow of water past various components streamlined such that eddies or vortices are avoided. ii. iii. Pressure shall be positive to avoid leakage. Vibrations kept minimum.

Classification of gates
i. ii. iii. High head Medium head Low head 30 m and above head 15 m to 30 m less than 15 m

Types of Gates

1. Vertical Lift Gate a. Fixed Wheel Gate b. Slide Gate 2. Radial Gate

Design of Fixed Wheel Gate

Materials for the Components of Fixed Wheel Gates

Sl. No

Component Part

Recommended Materials

Ref to, IS No

Cast steel Cast iron 1 Wheel Wrought steel Forged steel Bearing / Bushing 2 Anti-friction bearing / bronze, phosphor bronze, aluminum bronze, self lubricating bushing of high strength brass castings Wheel pins or axles Chrome nickel steel or corrosion 3 resistance steel, mild steel with nickel or hard chromium plating

1030:1998 210 : 1993

2004 : 1991 318 : 1981 305 : 1981

2004 : 1991 2062 : 1999 1068 : 1993 1337 : 1993

Structural parts of 4 gate leaf, track base, etc 5 6 Seal Wheel track

Carbon steel, structural steel

1875 : 1992 2062 : 1999 8500 : 1991

Rubber a) Stainless steel b) Corrosion resistance steel

11855 : 1986 1570 (Part 5) : 1985

7 8

Seal seat Seal base, seal seat base sill beam.

Stainless steel plate Structural steel of convenient shape

1570 (Part 5) : 1985 2062 : 1999 8500 : 1991

Seal clamp 9

Structural steel

2062 : 1999 8500 : 1991

Stainless steel Guide 10 Structural steel or corrosion resistance steel or stainless steel

6603 : 2001 2062 : 1999 8500 : 1991 6603 : 2001

11 12

Springs

Springs steel Stainless steel

6527 : 1995 2062 : 1999 6527 : 1995 2062 : 1999 8500 : 1991 210 : 1993 1030 : 1998 2004 : 1991

Anchor bolts Guide rollers and guide shoes

Structural steel Structural steel or corrosion resistance steel, cast iron, cast steel or forged steel

13

PERMISSIBLE MONOAXIAL STRESSES FOR STRUCTURAL COMPONENTS OF HYDRAULIC GATES Wet Condition Sl.No Material and Type Accessible Inaccessible
a) Structural Steel 1 2 3 4 5 6 Direct compression Compression / Tension in bending Direct tension Shear stress Combined stress Bearing stress 0.45 0.45 0.45 0.35 0.60 0.65 0.40 0.40 0.40 0.30 0.50 0.45 0.55 0.55 0.55 0.40 0.75 0.75 0.45 0.45 0.45 0.35 0.60 0.65

Dry Condition Accessible Inaccessi ble

b) Bronze or Brass

Bearing stress

0.035 UTS

0.030 UTS 0.040 UTS 0.035 UTS

Gate shall satisfy following requirements

a. Water light, leakage not more than 5 to 10 lit / m length of seal b. Capable of being raised or lowered at specified speed c. Partial open position regulation to pars required discharge.

Shall be designed for

a. Hydrostatic b. Hydrodynamic c. Wave effects d. Seismic load e. Ice formation. In addition to water load designed (if required)

Head to account sub-atmospheric pressures down stream of Gates in conducts / sluices

Operating Condition
i. ii. Under its own weight with ballast Under its own weight without ballast

HYDRAULIC DESIGN FEATURES OF GATES LAYOUT

1 2

Gate slot Gate lip

3 Aeration 4 Hydro-dynamic forces 5 Seal design

1.
i.

GATE SLOT:
Gate slot size kept to a minimum to avoid low pressure zone causing cavitation. ii. For fixed wheel gates slots are wider & deeper. Slots by virtue of discontinuity produce vortices Expansion of jet causes

iii. iv.

a) b) v.

vortices and eddies Creates zone of negative pressure on the side walls of the conduit

Modern trend to have tamper 1/10 to 1/12 & rounded corners d/s up to 30 m head and 1/24 or flatter beyond

vi. vii. viii. ix.

Optimum ratio w/d 1.4 to 1.8 Type 3 & 4 for heads > 25 m or velocity > 25 m/s R = 0.1 D (R = 3 to 5 cm) Provision of liberal ventilation on the d/s

Gate Slot
i. It is extremely important to provide smooth continuous surface downstream of gates (smoothness 250 microns or better). Abrupt into-the- flow offsets and irregularities in flow surfaces should be avoided or must be grounded to a smooth slope 1:40 to 1:60 for flow velocities up to 12m/sec and over 24m/sec respectively. ii. It is recommended to provide securely anchored and stiffened steel liners in the conduits immediately upstream and downstream of the gate slots and

including the gate slots for all high head installations. In general, the liner should extend at least 1 m upstream of emergency gate and 3m downstream of the service gate slot (See Fig I). At heads above 50rn, it is recommended to protect the fluid way surfaces with stainless steel linings. In boulder flows, hardened material even with BHN as high as 400 have been employed as lining material. iii. Provide minimum Centre to Centre spacing in between the two gate slots (i.e. Service & Emergency gates) about 4 times the upstream slot width (W) from hydraulic considerations, subject to a maximum of 1.5 times the conduit diameter. iv. Provision of "Slot flow deflector" with deflection angle upto 45 on the side walls of the conduit to reduce the vortex action in the slots for gates with upstream skin plate and sealing can be considered as a remedial measure. ( Refer v. under hydrodynamic forces also)

Tapering of downstream face of gate slot up to an angle of 45 or flatter to a height of (Urn from the gate sill can be considered for upstream sealing gates to prevent accumulation of debris within the gate slot.

vi.

Provision of "slot fillers" can be made for spillway stop logs / bulkhead slots upstream of spillway gates to bridge the slot and smoothen the pathway.

vii. Rectangular gate slots should not be provided except for very low head gates. viii. Width (W) of gate slot should be kept as small as practicable. Depth (D) of slot has little effect on cavitation hazard. The optimum WID ratio falls in the range of 1.4 to 1.8. In practice, higher values can be adopted as per physical requirements. ix. For gates operating under a head of say 10m or more, the downstream edge of the gate slot should be off-set to reduce the cavitation hazard. A downstream offset (If 0.075 to 0.10 of the slot width (W) with gradient of 1/1 0 to 1/12 for heads up to 30 m & 1/24 or flatter beyond 30m head, downstream of the gate slot and a rounded point of intersection with Radius 'R' as 0.10 times the D (say R=3 cm to 5 cm) is recommended. Upstream slot face should have a sharp and not rounded corner.

2.

GATE LIP:

i.

Designed such that pressures are positive always.

ii.

Flat lip for full gate thickness causes pockets of high negative pressures, vibrations, and cavitation & down pull.

iii.

Design of bottom lip has to meet the following requirements a) b) c) d) e) f) g) Minimum cavitations hazard Minimum vibration of the gate Minimum up thrust forces Minimum down pull forces Minimum rate of change of down pull force during openings Minimum air demand Sound structure at the bottom portion of the gate

GATE LIP:
i. ii. Gate leaf with flat bottom must be avoided. Gate bottom lip sloping at 45 to the downstrea m with sharp bottom and proper negotiating curve should be adopted for gates with downstream sealing and downstream (or upstream) skin plates. It may be noted that lip angles up to 60 have also been used. It is advisable to provide drain holes in the curved lip plate of the gate and also in webs of the horizontal beams covered by the curved plate. iii. Avoid extended vertical lip type design at bottom for gates with downstream sealing and downstream skin plate particularly for such gates which are meant for operation at small gate openings. iv. Locate the downstream flange of the bottom most girder at least at 0.6 times the girder depth (i.e. 30 angle) to prevent the jet fr om hitting the gate bottom For gates with upstream skin plate and upstream sealing, CWPRS recommends an angle of 45 between the imaginary line joining the controlling edge of the gate and downstream edge of the girder in such cases. However, location of bottom most girders should be done judiciously as higher angles for ensuring clearance of jet can sometimes cause development of uplift forces. v. The minimum gate opening for regulating gates should not be less than one half of the seating bottom lip of the gate or 75rnrn, whichever is more. vi. Provide a stainless steel overlay along the gate leaf sloping bottom to resist corrosion and cavitation damage.

CLASSIFICATION OF LIP SHAPES

i. ii. iii. iv. v. vi. vii. Flat lip Vertical or extended lip Vertical or extended lip Sloping lip 45dg to 60dg In some cases even 29dg to 35dg To minimize differential pressures a few drain holes are drilled in curved bottom lip and web of lowest horizontal girder (figure below)

3.
i.

AERATION:
Air supply prevents dropping down of the pressure to vapor pressure reducing chances of cavitation.

ii.

Factors affecting air demand

a) b) c) d) e) f)

Percentage of gate opening Type of flow Velocity Conduit profile Bottom shape of the gate Head loss in the air vent

Aeration
i. The location and sizing of air vents is critical for minimizing cavitation and vibration problems associated with regulating services of gated outlets. Such installations should be provided with adequate air supply downstream of the gate. The air vent should be located as near as possible to the gate. ii. In the absence of model studies, volume of air required can be estimated from the following expression for purposes of preliminary sizing of air vents for regulating gates.

Qa / Qw = 0.03 (Fr - 1)1.06. Where, Qa Qw Fr = Volume of air required in m3/s; = Outlet discharge in m3/s; = Froude No. at vena contract i.e. just downstream of the gate;

iii.

The air requirement for widely expanding sluices may be lesser than that derived from above formula.

iv.

For determining air vent size, the air velocity inside the pipe can be assumed up to 50 m/s and the pressure drop inside the conduit pipe should be limited to 0.15 kgf/cm2. For non regulating type gates, higher air velocities and pressure drops can be permitted.

v.

The Froude Number is estimated based on the velocity and depth at the venacontract. Velocity is estimated based on the head corresponding' to maximum reservoir level neglecting losses. The depth is estimated based on gate contraction coefficient of 0.80 for 45o lip and 0.60 for a sharp-edged gate lip.

vi.

The maximum air demand may be assumed to occur at a gate opening of 80%.

vii.

Head loss considered in the design of air vents consists of those caused by notches, bends, cross-sectional area changes, and friction and exit conditions. Loss coefficients identical to those for water flow may be used for air flow in vents.

viii.

It is recommended that air vent pipe should have minimum bends and the angle of bend (if at all provided) should be as obtuse as possible.

ix.

The air vent pipe should be taken sufficiently above the maximum reservoir level preferably on the downstream face of the structure so that there is no interference with the airflow and no risk to the personnel by the strong inflow of air during gate operation. If the air vent pipe opens into a gallery at a lower level, an air valve should be provided at its end for air to pass through.

x.

The air vent pipes of the adjoining sluices should not be joined into a common header.

xi.

The space between the downstream side of the gate and the sh8ft wall should not substitute for an air vent for meeting air demand requirements except when the sealing is effective for full travel of the gate.' However, it is desirable to provide a separate air vent.

xii.

It is recommended to make a nominal provision of air vent downstream of emergency gate of conduits to supply/dispel air.

xiii.

Provision of air ducts of depth of 300 mm to 500 mm can be considered fur air circulation at such locations where negative pressures can occur to prevent cavitation at flow separation points around the gate.

Design involves the following components

a. Skin plate b. Vertical and horizontal stiffeners and main girders c. Wheels and wheel tracks d. Seals and accessories e. Guide rollers / guide shoes f. Wheel track and track base

g. Guides h. Bearing Pad i. j. Seal seat, seal base and sill beam and Anchorages

Skin plate
i.In bending across stiffeners, horizontal girders or as panels and ii.In bending, co acting with stiffeners and or horizontal girders

Horizontal and vertical stiffeners and main girders

i. ii. iii. Designed as simply supported or continuous beam Main horizontal girders carry almost equal loads End vertical girders as continuous beams resting on wheel centre points with concentrated loads coming from horizontal girders at points of meeting end vertical girders.

HYDRO-DYNAMIC FORCES DETERMINED BY

i. ii. iii. Kings & Petricat curves Model studies. Magnitude of down pull is a function of a) b) c) d) e) f) g) Location of the gate Shape of the gate bottom Flow passages around the gate top Location of gate seals Initial discharge Air venting Speed of gate travel

BASIC EQUATION: P = W + A (d - u) w WHERE: P W A d = = = = HYDRAULIC AND GRAVITY FORCES. DRY WEIGHT OF GATE CROSS SECTIONAL AREA OF GATE AVERAGE DOWN THRUST PER UNIT OF AREA ON TOP OF GATE

AVERAGE UP THRUST PER UNIT OF AREA ON SLOPING BOTTOM OF GATE

SPECIFIC WEIGHT OF WATER

Hydrodynamic Forces
i. Broadly speaking, the magnitude of down pulI can be controlled in two ways; through KB (coefficient of pressure' on bottom) by the design of geometry of the gate bottom i.e. design of gate lip, and through KT (coefficient of pressure on top) by the dimensioning of the flow passages around the upper portion of the gate. ii. Down pulI reduces with an increase in angle of inclination of bottom Consideration for structural adequacy should also be kept in view while deciding the angle of inclination of bottom iii. Extremely flat lips cause the flow to separate completely from the gate lip and hence cause a substantial increase in the downpulI and should not be provided. iv. Both the field observations and model tests have shown that 450 sloping lip is the best suited from hydrodynamic and structural considerations. v. vi. Supply of air to the downstream of gate reduces downpull force. Gates with upstream skin plate and upstream sealing produce nominal downpull forces. It may be noted here that in spite of reduction in downpull in case of gates with upstream sealing, these have only been used for relatively low heads for the regulating service because of a number of problems resulting from extensive vortex action in the gate slot. vii. Incase of gates which are used for filling-up by crack-opening (such as Intake gates for Power Houses used for filling Penstocks), care should be taken to ensure that area of crack opening is smaller than area between the downstream edge of the gate and the gate shaft, normally designated as 'Back of the gate orifice' which otherwise could cause catapulting of gate. Such gates should advisably be equipped with hydraulic hoist to absorb any uplift forces which may develop because of the over-shooting of crack opened position. viii. Downstream sealing quick shut-off ( or emergency gates) can be configured in such a manner that the bottom seal is offset towards upstream side with respect to top seal so as to generate dependable down pull to ensure self-closure of gate.

ix.

Incorporation of "Slot Flow Arrestors" in the gate slots can considerably reduce the down pull force for gates with upstream skin plate and upstream seal, by controlling the slot flow circulation vis--vis vertical upward flow, as a remedial measure.

x.

Incorporation of "Slot Flow Deflectors upstream of gate slots to control slot vortex flow can also considerably reduce the magnitude of downpull force for gates with upstream skin plate and upstream seal, as a remedial measure. It should be noted that such measures also cause reduction of flow passages.

SEAL DESIGN:
i. ii. Selection of sealing arrangement d/s or u/s Items affecting sealing method (fig below) a) b) c) d) Hydraulic down pull & uplift forces on the gate Gate operating equipment Gate structural design Seal performance

e) f)

Aeration Access for inspection.

Seal Design
i. Upstream sealing gates have more chances of leakage as compared to downstream sealing. ii. A seal guard is usually provided for those installations, where presence of debris is likely to damage the gate seals, particularly in case of bottom seals. iii. Solid bulb music note seals are recommended at sides & top of gates operated under medium head (i.e. at a head of water >15m but less than 30m). These seals are also recommended for high head installations' (i.e. water head > 30m) as side seals. However, double stem seals are recommended for application as top seals because music note type seals at this location particularly for upstream sealing gates suffer from rolling action, when the gate is moved

iv. v.

Double stem seals should be clamped only on the extreme edges of seals. Projection of gate bottom seal should be restricted to the minimum possible as per design requirements as it can become one of the sources of gate vibration.

vi.

Metal to metal seals are used for such high head installation, where access for maintenance of sealing arrangements is difficult.

vii.

Deflection of top and bottom cantilever portions of gates, particularly in case of upstream sealing gates should be suitably restricted to ensure that sealing is maintained.

viii.

For gates with upstream skin plate and upstream sealing, the provision of contact plate (i.e. seal seat) with height equal to gate height should be provided for improving the flow conditions and elimination of curtain flow from top of gate. Such provision also helps in reducing the magnitude of downpull force.

ix.

The top seal radial gates are provided with two top seals, one fixed to the gate and the other fixed to the embedded frame to minimize water spray in the gate chamber during partial operation of gate.

x.

It should be noted that substantial leakage past high head gates can lead to silt cavitation (abrasive action of silt laden water) and vibrations of the structure.

xi.

The high head Fixed-wheel gates with upstream sealing arrangement should desirably be provided with two rows of top seals fixed on the skin plate to mitigate occurrence of vibration.

xii.

Fluoro-carbon (Teflon) Cladded seals should not be used for those gates which are to be operated under silt laden conditions.

xiii.

Upstream seal gates with upstream skin plate are preferable for silt sluices or bottom outlets. Downstream sealing gates should not be used in such situation unless provided with seals on upstream side also to prevent entry of silt into the gate slots.

Design Aspects of Radial Gate 1 Design aspects of the Radial gate involves
i) ii) Layout i.e. overall planning of the radial gate. Detailed design of component parts

2
i) ii)

Overall Planning Covers

Location of the Trunnion Radius of the gate Location of the sill Location of type of the hoist

iii) iv)

3
i)

Location of the trunnion (Clause 6.2 of 4633)

Standard practice 1500 mm clearance between the upper nappe and trunnion pin

ii)

Economical design of trunnion girder and anchorages 1/3H Resultant hydraulic thrust is close to horizontal.

iii)

For smooth operation, proper maintenance 0.5 H to 0.75 H.

4
i) ii)

Radius of the Gate (Clause 6.3 )

Recommended radius H to 1.25 H Larger radius increases the pier dimensions.

5
i)

Location of the sill (Clause 6.4)

Slightly down stream of crest to avoid cavitations of the down stream glacis. ii) General guidelines 0.30 to 0.80 m below the crest

6
a) i) ii)

Location of the hoist (Clause 6.5)

Down stream Hoist force is at the largest possible lever arm. Hoisting angle does not change considerably during the hoisting operation. iii) b) i) Involves larger pier sizes Up stream Larger hoisting capacities.

7
i) ii)

Design of structural parts (Clause 6.1 (b)

Skin plate and stiffeners Horizontal girders Arms Trunnion hub Trunnion pin Trunnion bush or bearing Trunnion brackets Trunnion girder or yoke girder Load carrying anchors Anchorage girder Thrust block Trunnion tie Seals Seal seat, seal base and sill beam Guide roller

iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv)

xvi)

Anchor bolt

Materials for Parts of Radial Gates

Sl. No
1.

Component part
Skin plate, stiffeners, horizontal girders, arms, bracings, tie members, anchorage girder, yoke girder,

Recommended Materials
Structural Steel

Ref to IS No.
808 2062

embedded girder, rest girder, load carrying anchors.

8500

Cast Steel Guide rollers 2. Structural Steel Forged Steel

1030 2062 1875 2004

Wrought steel Cast iron 3. Trunnion, hub and bracket Cast steel Structural Steel Pin Structural Steel

1570 210 1030 2062 2062 8500

Cast steel 4. Forged Steel

1030 1875 2004

Corrosion resisting Steel

6603

Materials for Parts of Radial Gates Bushing 5. Bronze / self Lubricating Bushing 305 306 318

6.

Seal Seat Seal base, seal-seat

Stainless steel plate Structural steel

6911 2062 8500

7. base and sill beam 8. Pre stressed anchor rods Pre stressed anchor 9. cables, rods, HDPE sheath and Corrosion resistant grease

PERMISSIBLE MONOAXIAL STRESSES FOR STRUCTURAL COMPONENTS OF HYDRAULIC GATES Material and type of Stress Structural Steel Direct compression 1 and compression bending 2 3 4 5 11. Direct tension and tension bending Shear Stress Combined stress Bearing Stress Bronze Direct bearing stress 0.035 0.030 0.040 0.035 0.45 0.35 0.60 0.65 0.40 0.30 0.50 0.45 0.55 0.40 0.75 0.75 0.45 0.35 0.60 0.65 0.45 0.40 0.55 0.45 Wet Condition Dry Condition

S.No

Accessible Inaccessible Accessible Inaccessible (YP) (YP) (YP) (YP)

10.

8
a)

Design of skin plate and stiffeners (Clause 6.6)

As per clause 6.6.2 the skin plate shall be designed for either of the following conditions unless more precise methods are available. i) ii) In bending across the stiffeners or horizontal girders as applicable or As panels in accordance with the procedure and support conditions given in Annexure C of code 4623. iii) Minimum thickness of stain plate excluding corrosion allowance may be 8 mm

iv)

For large size crest gates it is economical to use two or more sizes of the plates at different sections.

b)

The skin plate while designing the stiffeners and horizontal girders can be considered as [8 (i) (a)] i) i. Co-acting width of skin plate is taken as the least of the following. 40t t B ii. iii. + B where = Thickness of skin plate = Width of stiffener flange in contact with the skin plate

0.11 span and Centre-to-Centre of stiffeners and girders width of the skin plate acting with beam or stiffeners in panel fabrication [ as per point 8 (b)] shall be worked out as per Annexure D of 4623.

iv.

The stresses shall be combined as per formula (6.6.6) x 2 + y2 x y +3 T2xy

Where v x y Txy = Combined stress = Sum of stresses along X axis = Sum of stresses along y axis = Sum of shear stresses in x y plane.

duly considering appropriate signs x & y i. Designed skin plate thickness to be increased by at least 1.5 mm for corrosion (6.6.8)

9
a) i) ii)

Design of Horizontal girders

Number of Horizontal girders and arms (6.7.1) For height of gate upto 8.5 m 2 No For height of gate upto 8.5 m and 12 m 3 Nos. For height of gate upto above 12 m 4 or more

iii)

b)

In the case of the vertical stiffeners designed as continuous beam the girders may be so spaced that bending moment in the vertical stiffeners at the horizontal girders are about equal.

c)

Girders shall be designed taking fixity at arms support. For inclined arms the girders shall also be designed for the compressive stress induced

d)

Girders shall be checked for shear at the point of support by the arms for values not exceeding Annexure B of 4623 (6.7.5)

10

Stiffeners and Bracings for Horizontal girders (6.7.6) Design of the bearing and intermediate stiffeners shall be as indicated in IS800.

11
i)

Arms : (6.8)
As many pairs of arms as the number of horizontal girders shall be used unless vertical end girders are provided. ii) iii) Inclined arms used to economize on the horizontal girders. Designed as columns for the axial load and bending moment transmitted by horizontal girders and shall be as per IS 800. iv) The inclined arms fixed to horizontal girders at about one-fifth of the width of the gate span from each end of girder. v) The joints between the arms and the horizontal girders shall be designed against the side thrust due to the inclination of the arms. vi) Bracings connecting the arms spaced to satisfy equal l/r ratio of the arms in both longitudinal and transverse directions is nearly equal.

12
i)

Trunnion Hubs (6.9)

Minimum thickness of steel hub t= = 0.3 d upto 450 mm dia. shaft 0.25 d subject to a minimum of 135 mm for shafts above 450 mm dia. where, t= d= Hub thickness and diameter of the pin.

For large size gates hub may be designed as thick cylinder

13
i)

Trunnion pins (6.10)

May be solid or hollow and designed against bending for the total load transferred through the trunnion hub ii) Check for shear and bearing also due to the same load.

iii)

The bending, bearing and shear stress shall not exceed 0.33 YP, 0.35 UTS and 0.25 YP respectively.

iv) v)

The pin shall be a medium fit in the bearing lugs and locked. The trunnion pin shall be subjected to ultrasonic / radiographic tests to ensure soundness against manufacturing defects.

vi)

For materials other than corrosion resistant steel pin shall be coated with hard chromium plating to a minimum thickness of 50 microns.

14
a) i) ii)

Trunnion Bush / Bearing (6.11)

Material Slide type bronze bushing or self lubricating bush bearings. Antifriction roller bearings. Spherical plain bearings. Minimum thickness of bushing in mm = 0.08d + 3 not less than 12mm

iii) b)

Whered is the pin diameter in mm

15
i)

Trunnion Bracket (6.12)

Bracket shall be rigidly fixed to yoke girder by bolts or welding. Arms of the Bracket shall be designed to bearing act bending.

ii)

16

Anchorage system (6.13)

a)

The anchorage system shall be designed to with stand the total water load either.

i) ii)

In bond as a bond stress between the anchors and concrete (fig) or In bearing as a bearing stress between the concrete and the embedded girder at the upstream end of the anchors duly insulated (fig 2) or.

iii)

Through a pre-stressed anchorage system using either steel rounds or steel cables.

b)

The maximum horizontal and vertical force on the trunnion pin shall be calculated for i) ii) Gate resting on sill and head varying from Zero to maximum. Gate position varying from fully closed to fully open at maximum constant water level. iii) iv) Worst of the two is chosen. For combined anchorage the loading shall be determined with one gate closed and the adjacent gate fully open. v) For inclined anchors at angle m to the horizontal, the horizontal force determined shall be multiplied by sec m. vi) The length of embedment of anchors for bonded type shall be such that the bond stress shall not exceed the permissible values of concrete used subject to a minimum of two-thirds of radius of gate leaf. Anchors may be hooked at end or provided with anchor plates. The bonded anchors shall be insulated for a minimum of 500 mm length from the concrete face to avoid cracking of face concrete. vii) Normally bonded anchorages are selected upto 12m X 12m size gates

17
i)

Radial gates with common anchorages

The hydraulic thrust on the gate is transmitted to the trunnion girder through brackets. ii) iii) iv) Load is transmitted through the anchor bars as bonded anchorages. The rods are used as load carrying anchorages. Anchors are not welded to trunnior girder but are fixed with nuts and pre-tensioning can be carried out v) Additional flats can also be welded after pre-tensioning.

Limitations:

i)

Advantageous for construction of piers since no accurate pier shape is required.

ii) iii)

Economical upto gate size 12 m width X 10 m height. Due to common trunnion girder for adjacent gates failure of anchorage of one gate may trigger failure of all gates.

18

Radial gates with independent anchorage system.

i) Hydraulic thrust transmitted from trunnion bracket to yoke girder and to anchor girder through un-bonded tie flats. ii) Anchor girder embedded in concrete transmits to pier.

Advantages: i) Gates can be made to suit the vent width even when there is variation in civil construction. ii) iii) No successive failure of gates when anchorage of one fails. Suitable for large size of gates.

Disadvantages: i) ii) iii) Need for shaping of pier for movement of arms. Thorough checking of weld between anchor girder and tie flats. Large width of piers compared to common anchorages

19

Anchorages with post-Tensioned anchor rods

i) The hydraulic thrust is transmitted from trunnion girder to anchor plate through high-tensile anchor bars. ii) iii) Anchor rods are horsed in galvanized steel tubes After installation there rods are to be post-tensioned on down stream of trunnion girder to share the equal load. iv) Used for the larger gates.

Advantages: i) ii) Less steel is required for the bars which results in a more compact beam. Anchorage movements due to extension of the anchor bars are virtually eliminated. iii) Piers may be narrower

Disadvantages: i) Compilers joining the rods are susceptible for failure

20

Post-Tensioned pre-stressed concrete anchorages

i) Water thrust is transmitted to the common trunnion girder.

ii)

Trunnion girder shall be anchored to the spillway pier by a posttensioned anchor system.

iii)

Tested in un-bonded condition

Advantages: i) ii) iii) iv) Narrow spillway piers Frictional forces due to movement of trunnion brackets are eliminated. The pre-stressed anchorages puts pier concrete in compression. The anchorage are less bulky

Disadvantages: i) ii) iii) iv) v) vi) Loss of pre-stress due to creep in concrete. Loss of pre-stress due to shrinkage of concrete. Loss of pre-stress due to relaxation of steel. Loss of pre-stress due to elastic shortening of concrete. Loss of pre-stress due to slip in anchorages Loss of pre-stress due to friction along the cable and the anchorages

21

Trunnion Girder or yoke Girder

i) ii) Designed to be safe in bending, shear and torsion May or may not be embedded in concrete. If embedded wrapped with cork mastic or thermo Cole. iii) The concrete immediately is contact with the trunnion girder which takes the thrust in bearing from it should be non-shrinkage quality for a minimum thickness of 300 mm iv) To-allow for the elongation of the insulated load carrying anchors and trunnion tie, the trunnion bracket shall be fixed to slide on the rest chair using bronze or steel pads.

22 23

Thrust block and Trunnion Tie (6.15)

i) Required when inclined arms are used.

Seals, seal interference (6.16)

i) ii) For reducing seal friction, clad seals are used. Cladding may be of brass, bronze, stainless steel, fluorocarbon or Teflon iii) Seal interference shall vary from 2 to 5mm.

24

Seal Seat, Seal Seat base and sill beam (6.17)

i)

Minimum thickness of stainless steel seal seat plate 6mm for low head gates and 8 mm for others after machining.

ii)

The minimum thickness of stainless steel flat provided on sill beam shall be 6 mm after machining.

25

Guide Roller (6.18)

i) ii) Limits the lateral motion to not more than 6 mm in either direction. Designed to 5 % of gate weight.

26

Sizing of components
i) ii) iii) iv) As derived from design Minimum 10 mm for structural components of the gate. For webs of bracing members 8 mm is permissible. Fillet welds minimum 6 mm leg size, continuous and water tight. Satisfy IS 9595 regarding thickness of members being welded.

27
i)

General Features of Design

Considerations for choice of radial gate. i. v) Most economical, most suitable for spillways and out lets.

Simplicity of operation and smooth flow pattern past the gate in spillways.

vi) vii)

For out lets, high co-efficient of discharges favours of choice. For heads over 8 m over the spillway proves economical than other types.

28
i) ii)

Requirements to be satisfied
Water tight Capable of being operated by the hoist at required speed. Amenable to manual operation Should be capable of regulation at required discharge without cavitations and undue vibration.

iii)

iv) 29
i) ii) iii) iv) v)

Loads acting on the gate

Hydrostatic Hydrodynamic Wave action Dead weight Silt load

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i) ii)

Advantages of Radial Gates

Grooves are not necessary hence no cavitation Gates curved bottom acts as a bell mouth, thus the flow is smooth Outfall slope can be steeper, thus saving in concrete and no cavitation. Vibrations are less for partial opening due to bell mouth shape. Simple in construction, hence less cost. Hoist capacity is low due to additional leverage vi) vii) viii) ix) x) Less hoist capacity as no rollers are used Wearing of parts is less in radial gates Maintenance is easy in closed position also Erection is easy once the Trunnion is fixed. Weight of the gate is less

iii) iv) v)

HYDRAULIC HOIST

1. Need.
1) This type of hoist is used in the gates which are not self closing. This type of hoist is capable to produce thrust both in opening and closing of gate. ii) This type of hoist has given more precise and easy control in operation of gate. iii) It requires less space. iv) This are mainly used to operate bonnet gate and radial gate.

2. General
A hydraulic hoist consists of a cylinder with upper and lower cylinder head, piston and stem passing through a packing in the lower cylinder head. The hoist is operated by a motor and oil pump arrangement with the directional control by valves which are actuated by electric contact from any desired position.

3. Factor governing the choice of hydraulic hoist:

1. High capacity and low travel. 2. Larger range of hoisting / lowering speed, 3. Limited space availability, 4. Dampening of vibrations of gates, 5. Requirement of positive thrust.

4. Parameters in the design of hydraulic hoist

1. Capacity of hoist 2. speed of lifting and lowering 3. Position of Oil Tank. In case of gate that are lowered by gravity, the oil tank should preferably be kept at the level higher than the cylinder top. 4. Number of hoist and their method of operation. Whether from separate hydraulic system or from a centralized system. In latter case whether the gate are to be lowered selective or simultaneously. 5. Stroke of hoist. This will determine the capacity of oil tank. 6. Frequency of operation. 7. Space limitations if any

5. Hoisting capacity:
Weight of the Gate along with all its component including the weight of wire rope and its attachments

All Frictional Forces Wheel Friction Guide Friction Seal Friction Trunnion friction in case of radial gate Friction of moving parts of hoist.

Any Hydrodynamic Load, like down pull force / uplift. Silt and ice load, wherever encountered

The worst combination of these forces either lowering or rising cycle should consider and these should increase to 20% as reserve.

6. Design Involve following component

1. Cylinder 2. Cylinder head 3. Piston stem. 4. Couplings 5. Piston

6. Piston rings and packing 7. Seals and packing. 8. Hanger stud 9. Gate position indicator

7. Design of hoist component :i) Cylinder Operating pressure: - Maximum operating oil pressure should be 20N/mm2 for design of hydraulic cylinder. ii) Cylinder head The cylinder head should be designed as a thick flat plate, held down at outer perimeter in accordance to IS 2825:1969. When bonnet cover is providing to work as one of the cylinder head than it should be design accordance with IS 9349: 1979. iii) Stems Piston stem should be solid or hollow construction and if made of forged steel should be hard chromium plated to at least 0.05 mm thickness with stress limited to 0.4 of yield point at pressure setting of pump relief valve. iv) Couplings Couplings for connecting the stems between the gate and hoist are:a) Clevis coupling: - The male and female parts of clevis should be connected by steel pin. The pin should be designed against shear, bending, and bearing. b) Split collar coupling: - This type of coupling is more convient to assemble and disassemble can be used generally for vertical stem gate. c) Hook and eye type coupling: - this type of coupling is suitable for gate on slope of about 15 deg. with vertical. This is similar to clevis type of coupling except the addition of skid pads on the loop of hook to provide an easy method of holding the stem for alignment on the slope. v) Piston Piston should be designed for operating pressure. The steel piston should be provided with suitable protection so that the finish piston may not affect the smooth cylinder wall. vi) Piston rings and packings:-

The piston should be fitted with hydraulic type piston rings and also with a stuffing box having V- packing rings. These packing rings should eliminate leakage past the piston and permit holding of piston in any position for long period of time when outflow of oil from below the piston is blocked. vii) Gate position indicator An indicator to show the position of gate in its full travel should provided. viii) Test pressure:-

The hoist cylinder, cylinder heads, piston appurtenant, piping, valve other parts and control subjected to oil pressure should be tested at 150% of the operating pressure for period not less than 30 min.

8. Fabrication:The hoist cylinder should be composed of flanges of weldable forged steel forges steel; shell of pierced, rolled steel forging or flat steel formed to cylindrical shape; joined to each other with not more than two longitudinal welds. If the cylinder is forged, the flange should be forged as integral part of cylinder, otherwise the flange of the cylinder should be butt welded to cylinder shell. In either case cylinder should be annealed and stressed / relived before machining. All butt weld in the cylinder and cylinder head should be tested for full strength by 100% radiographic examination. The cylinder bore should be honed to finish of 1.6 micron.

9. Hydraulic operating system

The hydraulic- electric operating system consists of:1. oil tank 2. Filter and strainers 3. Pumps with motors and starting equipment 4. control valve 5. Pressure relief 6. Piping 7. Pressure gauge 8. pressure switches 9. push buttons, relay, and other electrical equipment for actuating and controlling the system 10. Stand by pump and driving device as necessary.

10. Hoist support frame

It should be designed to withstand the maximum load occurring at the time of operation of the gates.

11. Oil
The oil should be suited to the viscosity and temperature range of operation.

12. Advantage of hydraulic hoist:

1. Hoist capacity: - Hydraulic hoist of higher capacities are economical and operationally better suited. 2. Space: - Layout of work and space being smaller in case of hydraulic hoist. 3. Speed: - They are lowered at almost any desired speed. Moreover the speed can be easily adjusted within the limits of system. 4. Economy of installation: - The oil tank and the cylinder are paced at any desired location and it is only necessary to interconnect these unit, the various units are installed at most economical location. 5. Minimum maintenance: - parts are self lubricated and also they are totally enclosed and protected against outside contaminants, these required minimum maintenance.

13. Disadvantage of hydraulic hoist:

The hydraulic hoist required a good honed cylinder of sufficient length depending on the lift of gates. Sometimes the availability of these cylinders is a problem.