Appendix II

Appendix II
S.No. Document Title Document No.

1 Design calculation of Barrage gate 4410-301B-PVH-U-001
2 Design calculation of Mechanical 4410-301B-PVH-U-002
Components of Rope drum hoist
3 Design calculation of Hoist supporting 4410-301B-PVH-U-003
structure
NTPC LTD
NORTH KARANPURA
SUPER THERMAL POWER PROJECT
(3 X 660 MW)
CONSTRUCTION OF BARRAGE ACROSS GARHI RIVER
BARRAGE GATE DESIGN CALCULATION
DOC.NO.4410-301B-PVH-U-001
NorthKaranpura STPP
Barrage Gate design
DESIGN DATA
I) Clear width of opening 9.5 m

ii) Clear height of opening 5 m
iii) c/c seal 9.65 m
iv) c/c wheel track 10 m
v) Sill elevation EL 432.00 m
vi) FRL EL 437.00 m
vii) Design head 5.00 m
viii) No.of gates 10 Nos.
ix) Hoist arrangement By Rope drum hoist
Materials
I) Skin plate,girders,stiffeners,track base, IS:2062

seal clamps & bases,sill beam, side guides,etc.,
ii) Track plate IS:1570 PART V 20Cr 13
iii)seal seats IS:1570 PART V 04Cr19Ni9
iv) wheel pin IS:1570 PART V 20Cr 13
v) seals Rubber seals as per IS:11855

vi) wheel IS:2004 Cl.4
Permissible stresses & deflection As per IS:4622-1992
Permissible stresses for skinplate, vertical stiffener , horizontal girder & end vertical girder
yield stress ( Yp ) bending stress shear stress combined stress Bearing stress
0.45 Yp 0.35 Yp 0.6 Yp 0.65 Yp
2 2 2 2 2
t =< 20mm 2550.00 kg/cm 1147.50 kg/cm 892.50 kg/cm 1530.00 kg/cm 1657.50 kg/cm
20mm < t <
2 2 2 2 2
40mm 2448.00 kg/cm 1101.60 kg/cm 856.80 kg/cm 1468.80 kg/cm 1591.20 kg/cm
2 2 2 2 2
t => 40mm 2346.00 kg/cm 1055.70 kg/cm 821.10 kg/cm 1407.60 kg/cm 1524.90 kg/cm
Grade of concrete M25

characteristic compressive strength of concrete ( fck) = 25.00 Mpa
2
Bearing stress in concrete = 0.25*fck = 63.75 kg/cm
The gate shall be made in two parts.

Bottom unit 10 m X 2.0 m
Top unit 10 m X 3.0 m
2
0.00 T/m EL 437.0
LOADING DIAGRAM FOR GATE & UNITS top unit
5.0 m
Total load 3.00 T/m2
bottom unit
Sill EL 432.00 5.00 T/m2
Total load on gate = = 120.625 T

Load on bottom unit = = 77.20 T
Load on top unit = = 43.425 T
Barrage Gate - Bottom Unit design
0.4850 0.4375 0.3700 0.31750
LOADING DIAGRAM
5.00 4.70 4.05

3.35 3.00
0.3 0.65 0.7 0.35

A1 A B C C1
Panel
D
Panel
A
0.5
0.5
Panel B
0.300
Panel A (Four edges fixed)

0.65
(3 edges fixed & 1 long edge free)

Spacing of stiffeners 0.5 m
Design of skin plate
Thickness of skin plate 0.012 m

Corrosion allowance 0.0015 m
Effective thickness of skinplate 0.0105 m
Bending stress in skinplate = k/100*p*a2/s2
Panel type A B B D
Panel size 0.5 x 0.3 0.65 x 0.5 0.7 x 0.5 0.5 x 0.35
Boundary 3 edges fixed & 1 3 edges fixed & 1
conditions long edge free all four edges fixed all four edges fixed long edge free
L/B ratio 1.6670 1.300 1.40 1.4290
Pressure at
centre of panel
(kg/cm2) 0.485 0.4375 0.3700 0.318
Bending Bending stress Bending Bending
stress factor stress stress factor stress coeffic stress factor stress
coefficients k (kg/cm2) coefficients k (kg/cm2) ients factor k (kg/cm2) k (kg/cm2)
11x 23.00 91.06 3x 45.5 451.39 3x 45.5 381.7 23.50 82.90
11y 14.00 55.43 3y 13.65 135.42 3y 13.65 114.52 14.20 50.09
12x 25.80 102.15 4x 10.29 102.08 4x 10.29 86.33 20.50 72.32
12y 87.00 344.4 4y 34.3 340.28 4y 34.3 287.78 72.50 255.76
13x 67.50 267.24 59.50 209.90
13y 20.80 82.35 18.20 64.21
14x 112.00 443.4 82.00 289.28
14y 34.80 137.78 22.70 80.08
15x 61.00 241.51 48.00 169.33
The actual stress are less than permissible stress .Hence safe.
HORIZONTAL GIRDER DESIGN
Loading diagram Total load on unit 77.20 T
0.3175
5.00 0.49 4.70 0.4375 4.05
0.3700 3.35 3.00
0.300 0.650 0.700 0.350 2.000 m

A1 A B C C1
Calculation of distribution factors
stiffness Distribution factor

member (k) = 3* E*I / L =k/Sk
BA 1.54 0.52
BC 1.43 0.48
Sk = 2.97
Calculation of Fixed end moments

For uniformly distributed For FEM
Member load triangular load ( T.m )
1
A A 0.2115 0.0090 0.2205
AB -0.1426 -0.0137 -0.1563
BA 0.1426 0.0092 0.1517
BC -0.1368 -0.0172 -0.1539
CB 0.1368 0.0114 0.1482
CC1 -0.1838 -0.0071 -0.1908
Moment Distribution
A1 A AB BA BC CB CC1
D.F. 0.00 1.00 0.5185 0.4815 1.00 0.00
FEM 0.2205 -0.1563 0.1517 -0.1539 0.1482 -0.1908
Bal A&C -0.0642 0.0426
c.o -0.0321 0.0213
total 0.2205 -0.2205 0.1196 -0.1326 0.1908 -0.1908
bal 0.0067 0.0063
0.2205 -0.2205 0.1264 -0.1264 0.1908 -0.1908
direct shear 1.4550 1.4578 1.3860 1.3367 1.2534 1.1113
elastic shear 0.1449 -0.1449 -0.0921 0.0921
1.4550 1.6027 1.2411 1.2446 1.3454 1.1113
reactions 3.0577 2.4857 2.4567
3.0577 2.4857 2.4567
Coacting width of girders

y B L/B V1 V1*B
0.30 0.30 33.33 0.95 0.29 0.584 0.58
0.65 0.325 30.77 0.92 0.30 0.62
0.70 0.350 28.57 0.92 0.32 0.65
0.35 0.35 28.57 0.93 0.33
Consider coacting width for girder 0.58 m
DESIGN OF GIRDER
3.06 T/m
Load on girder 3.06 T/m
c/c of seal 9.65 m
c/c of track 10.00 m 9.65
Max.B M = 38.17 T.m 10.00
Max.S F = 14.75 T
Area = 170.90 cm2 58 X 1.05

Yt = 33.74 cm
Yb = 48.51 cm 1.0 X 80.0
Ixx = 182999 cm4
Zt = 5424.45 cm3
Zb = 3772.08 cm3 25.0 X 1.2
Zj = 5598.01 cm3
Bending stress at
2
i) top of skin plate = 703.74 kg/cm
2 2
ii ) bottom flange of girder = 1012.01 kg/cm < 1147.50 kg/cm (permissible stress)
2
iii ) junction of web and skin plate = 681.92 kg/cm
2 2
Shear stress = 184.41 kg/cm < 892.50 kg/cm (permissible stress)
Combined stress =( su ) = sx2+sy2 - sx*sy

girder combined
skin plate stress stress stress
( kg/cm2) (kg/cm2) ( kg/cm2)
sx sy sx su
at top of skinplate 102.08 340.28 703.74 700.67
at bottom of skin plate -102.08 -340.28 681.92 805.79

w
L = 10.00 m B
B = 9.65 m
w = 3.06 T/m L
Permissible deflection = L/800 = 1.25 cm

Actual deflection = w*B*(8*L3-4*L*B2+B3)/(384*E*I) = 1.034 cm < 1.25 cm
Weld details
SF(V)= 14.75 T
Ixx 182999 cm4
Between skinplate and web

3
Ay` = 58 * 1.05 * ( 33.74 - 0.5 *1.05 ) 2022.79 cm
b = 2 * 0.6 * 0.707 0.85 cm ( 6 mm fillet weld on both sides)
2
V Ay' / I b = 14.75*1000*2022.7935/182998.88*0.85 = 191.81 kg/cm Safe.
Between web and bottom flange = V Ay' / I b =

3
Ay` = 25 * 1.2 * ( 48.51 - 0.5 *1.2 ) 1437.30 cm
b = 2 * 0.6 * 0.707 0.85 cm (6 mm fillet weld on both sides)
2
V Ay' / I b = 14.75*1000*1437.3/182998.88*0.85 = 136.29 kg/cm Safe
Provide 6mm fillet weld on both sides.
VERTICAL STIFFENER DESIGN

2.50 T/m
stiffener spacing 0.50 m
Panel A
Max.load on stiffener = 5 * 0.5 = 2.50 T/m
Max Bending moment = 0.5 * 2.5 * 0.3^2 = 0.11 T.m 0.30 m
Maximum shear force = 2.5 * 0.5 = 0.75 T
Panel B 2.19 T/m

Max.BM = 2.5 * 0.65^2 / 8 = 0.5896 T.m
Max.SF = 2.5 * 0.65 / 2 = 2.75 T
0.65
Design Bending Moment 0.59 T.m
Design Shear force 2.75 T
Section properties
Ytop 6.98 cm
Ybottom 14.07 cm 12 X 1.05 12.60
Ixx 1524.13 cm4
Ztop 218.29 cm3 1.0 X 20 20.00
Zbottom 108.34 cm3
Zjunction 256.93 cm3
Bending stress at
i) top of skin plate = 270.10 kg/cm2
ii ) the bottom of web = 544.22 kg/cm2
iii ) junction of web and skin plate = 229.48 kg/cm2
Shear stress = 137.28 kg/cm2

girder combined
sx sy sy su
reaction Total load on

on each end of
girders c/c seal girder
END VERTICAL GIRDER DESIGN
3.06 9.65 14.75
2.49 9.65 11.99
14.75 T 11.99 T 11.85 T 2.46 9.65 11.85
0.300 0.650 0.700 0.350
0.450 1.05 0.500

A B
2.40
11.85
S F diagram
14.75 9.60
2.21 T.m 1.78 T.m

B M diagram
1.01 T.m
Reactions 0 X 0 0
Ra 17.15 T
Rb 21.45 T
Max.reaction 21.45 T
Max.BM 2.21 T.m 13
1.6 X 48 154
Section properties
Yt 24.00 cm
Yb 24.00 cm
4
Ixx 29491.2 cm
3
Zt 1228.80 cm Area = 154
3
Zb 1228.80 cm Igg Ax
0.00 0.0
29491 0.0
4
29491 0.0 29491.2 cm
Bending stress at
ii ) bottom of girder = 180.09 kg/cm2 Safe.
Shear stress = 139.65 kg/cm2 Safe
Provide 6mm fillet weld between skin plate and end vertical plates.
ROLLER DESIGN
Material IS:2004 Cl.4
UTS 6324 kg/cm2
Permisible contact stress 10118 kg/cm2
Max.wheel load (P ) 21.45 T

Assume tread width ( l ) 8.00 cm
Assume Radius of wheel ( r ) 15.00 cm
Young's Modulus ( E ) 2100000.00 kg/cm2
contact stress 8098.53 kg/cm2
536.24 T/m
WHEEL PIN
Shear force 10.72 T
BM 0.57 T.m 0.040
0.126
Material IS:1570 PART V 20Cr 13
2
U.T.S. 6600 kg/cm
2
Allowable bending stress = 0.2*UTS 1320 kg/cm
2
Allowable shear stress = 871.20 kg/cm
Provide 170mm dia pin d= 9.00 cm dia at ends 6.00 cm
3
Section modulus z= 71.57 cm
2
area a= 28.27 cm
2
Bending stress 794.24 kg/cm
2
Shear stress 379.31 kg/cm
ROLLER BEARING
Provide spherical roller bearing SKF 22218E
Internal dia 90 mm
External dia 160 mm
breadth 40 mm
Static capacity of bearing = 375.00 KN > 1.5 times wheel load = 315.63 KN
Design of wheel track
Max.wheel load(P) 21.45 T
radius of wheel ( r ) 15.0 cm
tread width ( l ) 8.0 cm
2
Young's modulus ( E ) 2100000 kg/cm
Min thickness of wheel track for line contact = 1.55*0.786*6*(P*r/l*E)0.5
1.012 cm
Provide 15cm X 1.2cm size track plate.
15 X 1.2 18
Check for bending stress
20 X 1.2 24
Area 122 cm2
Ytop 16.00 cm
Ybot 18.00 cm 1.6 X 30 48
Ixx 22281.07 cm4
Ztop 1392.85 cm3
Zbot 1237.61 cm3 20 X 1.6 32
33
Area 122
1/3
fb=0.5*(P/Z)*((Es/Ec)*(I/w))
P 21.45 T Grade of 2nd stage concrete = M25
3 2
Z 1392.852005 cm scbc = 10 N/mm
Es/Ec 6.761234038 fck = 25 N/mm2
4 2
I 22281.06536 cm m = Es/Ec Ec 301720.1 kg/cm
2
w 20 cm m= 6.76 Es 2040000 kg/cm
w = width of track base in contact with concrete
2
bearing stress concrete = 0.25 * fck = 63.75 kg/cm
fb = 150.8925725 kg/cm2
Check for bearing stress in concrete

p = 0.2813 * P * [(Ec)/(Es*I*w2)] 0.3333 = 2
15.40 kg/cm O.K.
Check for shear stress in web

2
area of web = 48 cm
2
fs = P / area of web = 446.869 kg/cm
Check for over lapping of bearing pressure on concrete

Length of influence of bearing pressure L = 1.5*P/(w*p)
p = bearing pressure in concrete
Length of influlence (L) = 104.47 cm
wheel spacing ( c ) = 105 cm > 104.47 cm
No overplapping occurs.
21.45 T
Check for web compression
dispersion width = 8.31 cm 1.732051
o
fc = 21.45 *1000 / 8.31*1.6 30 1.2 cm 8.313844
2
= 1613.267148 kg/cm 1.2 cm
2
permissible stress = 0.85*fy = 2081 kg/cm
Shear stress in concrete
shear stress in concrete = p*w / 2*l b
l = a+b
a = center of track to edge of concrete + half of track width
b = half width of bottom flange of track base
a= 35 cm
b= 10 cm
l= 45 cm
a
shear stress = 3.42 kg/cm2
permissible shear stress of concrete = 0.16*(fck)0.5 = 8.16 kg/cm2

Barrage Gate - Top Unit design
2
0.00 T/m
LOADING DIAGRAM FOR TOP UNIT
Top unit
3.0 m
3.00 T/m2
DESIGN OF TOP UNIT

0.2775 0.1825 0.0550
LOADING DIAGRAM
3.00 2.55 1.10

0.00
0.45 1.45 1.1 0

A1 A B C C1
Panel
C
Panel
B
Panel
A
0.5
0.5
Panel B
0.450
Panel A (Four edges fixed)

1.45
(3 edges fixed & 1 long edge free)

Spacing of stiffeners 0.5 m
Design of skin plate
Thickness of skin plate 0.012 m

Corrosion allowance 0.0015 m
Effective thickness of skinplate 0.0105 m
Bending stress in skinplate = k/100*p*a2/s2
Panel type A B D
Panel size 0.5 x 0.45 1.45 x 0.5 1.1 x 0.5
Boundary 3 edges fixed & 1 3 edges fixed & 1
conditions long edge free all four edges fixed short edge free
L/B ratio 1.1110 2.900 2.2000
Pressure at
centre of panel
(kg/cm2) 0.2775 0.1825 0.055
Bending Bending Bending stress
stress factor stress stress factor stress factor stress coeffici
coefficients k (kg/cm2) coefficients k (kg/cm2) k (kg/cm2) ents
11x 22.50 114.68 3x 50 206.92 28.07 35.01 16x
11y 13.00 66.26 3y 15 62.07 9.13 11.39 16y
12x 15.50 79.00 4x 10.29 42.58 8.51 10.61 17x
12y 51.50 262.5 4y 34.3 141.94 28.38 35.39 17y
13x 48.00 244.65 46.66 58.19 18x
13y 14.80 75.43 14.00 17.46 18y
14x 53.00 270.1 50.80 63.36 19x
14y 16.20 82.57 15.24 19.01 19y
15x 37.00 188.59 28.78 35.89 20x
The actual stress are less than permissible stress .Hence safe.
HORIZONTAL GIRDER DESIGN
Loading diagram Total load on unit 43.43 T
3.00 0.28 2.55 0.1825 1.10

0.0550 0.00
0.450 1.450 1.100 3.000 m

A1 A B C C1
Coacting width of girders

y B L/B V1 V1*B
0.45 0.45 22.22 0.95 0.43 1.095 0.51
1.45 0.725 13.79 0.92 0.67 1.17
1.10 0.550 18.18 0.92 0.51 0.51
Consider coacting width for girder 0.51 m

DESIGN OF GIRDER
2.79 T/m
Load on girder 2.79 T/m
c/c of seal 9.65 m
c/c of track 10.00 m 9.65
Max.B M = 34.83 T.m 10.00
Max.S F = 13.46 T
Area = 163.55 cm2 51 X 1.05

Yt = 35.23 cm
Yb = 47.02 cm 1.0 X 80.0
Ixx = 174527 cm4
Zt = 4954.15 cm3
Zb = 3711.64 cm3 25.0 X 1.2
Zj = 5106.12 cm3
Bending stress at
2
i) top of skin plate = 703.09 kg/cm
2 2
ii ) bottom flange of girder = 938.46 kg/cm 1147.50 kg/cm
2
iii ) junction of web and skin plate = 682.17 kg/cm
2
Shear stress = 168.27 kg/cm

girder combined
sx sy sx su
L = 10.00 m B
B = 9.65 m
w = 2.79 T/m L
Actual deflection = w*B*(8*L3-4*L*B2+B3)/(384*E*I) = 0.990 cm 1.25 cm safe
Weld details
SF(V)= 13.46 T
4
Ixx 174527 cm
Between skinplate and web

3
Ay` = 51 * 1.05 * ( 35.23 - 0.5 *1.05 ) 1858.45 cm
2
V Ay' / I b = 13.46*1000*1858.45275/174527.07*0.85 = 168.62 kg/cm Safe.
Between web and bottom flange = V Ay' / I b =

3
Ay` = 25 * 1.2 * ( 47.02 - 0.5 *1.2 ) 1392.60 cm
2
V Ay' / I b = 13.46*1000*1392.6/174527.07*0.85 = 126.35 kg/cm Safe
Provide 10mm fillet weld on both sides.
VERTICAL STIFFENER DESIGN

1.50 T/m
stiffener spacing 0.50 m
Panel A
Max.load on stiffener = 3 * 0.5 = 1.50 T/m
Max Bending moment = 0.5 * 1.5 * 0.45^2 = 0.15 T.m 0.45 m
Maximum shear force = 1.5 * 0.5 = 0.68 T
Panel B 0.91 T/m

Max.BM = 1.5 * 1.45^2 / 8 = 0.5896 T.m
Max.SF = 1.5 * 1.45 / 2 = 2.75 T
1.45
Design Bending Moment 0.59 T.m
Design Shear force 2.75 T
Section properties
Ytop 6.98 cm
Ybottom 14.07 cm 12 X 1.05 12.60
Ixx 1524.13 cm4
Ztop 218.29 cm3 1.0 X 20 20.00
Zbottom 108.34 cm3
Zjunction 256.93 cm3
Bending stress at
ii ) the bottom of web = 544.22 kg/cm2
iii ) junction of web and skin plate = 229.48 kg/cm2
Shear stress = 137.28 kg/cm2

girder combined
sx sy sy su
at top of skinplate 244.65 75.43 270.10 307.76 345.54
at bottom of skin plate -244.65 -75.43 229.48 348.24 154.05

reaction Total load on
on each end of
girders c/c seal girder
END VERTICAL GIRDER DESIGN
2.79 9.65 13.46
1.71 9.65 8.25
13.46 T 8.25 T
0.450 1.450 1.100
0.600 1.15 1.250

A B
-5.89
8.25
S F diagram
13.46 5.89 SF on track
2.02 T.m 1.24 T.m

B M diagram
9.68 T.m
Reactions
Rb 7.57 T
Ra 14.14 T
Max.reaction 14.14 T
Max.BM 2.02 T.m 13
1.6 X 48 154
Section properties
Yt 24.00 cm
Yb 24.00 cm
Ixx 29491.2 cm4
Zt 1228.80 cm3 Area = 154
Zb 1228.80 cm3 Igg Ax
0.00 0.0
29491 0.0
4
29491 0.0 29491.2 cm
Bending stress at
ii ) bottom of girder = 164.33 kg/cm2 Safe.
Shear stress = 92.07 kg/cm2 Safe
Provide 6mm fillet weld between skin plate and end vertical plates.
ROLLER DESIGN
Material IS:2004 Cl.4
UTS 6324 kg/cm2
Permisible contact stress 10118 kg/cm2
Max.wheel load (P ) 14.14 T

Assume tread width ( l ) 8.00 cm
Assume Radius of wheel ( r ) 15.00 cm
Young's Modulus ( E ) 2100000.00 kg/cm2
contact stress 6575.70 kg/cm2
353.54 T/m
WHEEL PIN
Shear force 7.07 T
BM 0.37 T.m 0.040
0.126
2
U.T.S. 6600 kg/cm
2
Allowable bending stress =0.2*UTS 1320 kg/cm
2
Allowable shear stress = 871.20 kg/cm
Provide 170mm dia pin d= 9.00 cm dia at ends 6.00 cm
3
Section modulus z= 71.57 cm
2
area a= 28.27 cm
2
Bending stress 523.63 kg/cm
2
Shear stress 250.08 kg/cm
ROLLER BEARING
Provide spherical roller bearing SKF 22218E
Internal dia 90 mm
External dia 160 mm
breadth 40 mm
Static capacity = 375.00 KN > 1.5 times wheel load = 208.09 KN

BOM and CG Calculation of Barrage Gate
Unit Weight
S.No. Item No. Length(m) Width(m) Depth(m) weight(Ton) x w*x Material
( t/m3)
1 Skinplate ( bottom unit) 1 10.200 2.000 0.012 7.850 1.92 0.006 0.012 IS:2062
2 Skin plate ( top unit) 1 10.200 3.200 0.012 7.850 3.07 0.006 0.018 IS:2062
3 Web for all Horizontal girders 5 9.840 0.010 0.800 7.850 3.09 0.412 1.273 IS:2062
4 Flange for all Horizontal girders 5 10.000 0.012 0.250 7.850 1.18 0.818 0.963 IS:2062
5 Stiffener - web - upto top H girder 20 3.900 0.010 0.200 7.850 1.22 0.112 0.137 IS:2062
6 Full depth stiffener upto top H girder 3 3.900 0.010 0.800 7.850 0.73 0.412 0.303 IS:2062
7 Stiffener above top H girder 20 1.300 0.010 0.200 7.850 0.41 0.112 0.046 IS:2062
8 End girder web 4 5.200 0.016 0.500 7.850 1.31 0.262 0.342 IS:2062
9 Wheels Assembly 8 0.150 T/Wheel 1.20 0.400 0.480 IS:2062
Wheel pin 8 90 mm dia with 250mm Length IS:1570 part V / AISI 420
Wheel bearing 8 160/90 (OD/ID) with 40mm width MAKE SKF 22218E
Wheel body 8 300mm Dia with 80mm tread IS:1030 Gr.340-270 W

10 Guide shoe Assembly 6 0.025 0.15 0.350 0.053 IS:2062
Guide shoe vertical plates 12 0.054 0.020 0.150
Guide shoe block 6 0.072 0.020 0.150
Guide shoe base plate 6 0.150 0.150 0.010
11 Lifting bracket 4 1.300 0.500 0.016 7.850 0.33 0.275 0.090 IS:2062
12 Lifting pin 2 0.350 0.008 7.850 0.04 0.275 0.012 IS:1570 part V
13 Bush for Lifting pin 4 0.080 128/100 (OD/ID) mm bronze bush 0.275 IS:305 Gr.AB-2
14 Gate sheave 4 0.080 0.266 7.850 0.67 0.275 0.183 IS:2004 Gr.IV
15 Lifing bracket stiffener 4 1.300 0.500 0.010 7.850 0.20 0.275 0.056 IS:2062
16 Bottom seal ( cut to shape ) 1 9.700 0.020 0.100 IS:11855
17 Bottom seal clamp ( cut to shape ) 1 9.700 0.016 0.085 7.850 0.10 -0.028 -0.003 IS:2062
18 Bottom seal Retainer ( cut to shape ) 1 9.7 0.036 0.012 7.85 0.03 -0.018 -0.001 IS:2062
19 Side seal 2 5.200 0.100 0.014 0.000 IS:11855
20 Side seal clamp 2 5.200 0.050 0.016 7.850 0.07 -0.034 -0.002 IS:2062
21 side seal base 2 5.200 0.050 0.012 7.850 0.05 -0.006 0.000 IS:2062
22 Splice plate for skin plate 2 10.200 0.200 0.010 7.850 0.32 0.000 0.000 IS:2062
23 bracings plates 1 38.000 0.018 1.000 1.000 0.67 0.762 0.513 IS:2062
16.10 t 4.474 t-m
Total weight of one gate including ballast 16.10 t
Center of Gravity of gate 0.2779146 m

Hoist Capacity of Barrage Gate
Symbol
Span of Gate w 9.5 m
Height of Gate h 5 m
Design Head H 5 m
Estimated Weight G
FRL 437 m
Sill Level 432 m
Gate Weight = 16 T
Hoist Capacity
Gate Details
Specific weight of Steel 7.85 T/m3
Gate Inside the Groove in Width Side 0.075 m
Gate Inside the Groove in Top 0 m
Gate width from Centre Line of Seal 9.65 m
Gate Height from Centre Line of Seal 5 m
Precompression Force 0.1 T/m
Type of Seal
Fluro Carbon Claded Rubber Seal 0.2 0
Rubber Seal 1.5
Gate Wheel
Diameter of Wheel 300 mm
Width of Wheel 80 mm
Coefficient of Friction for Wheel Bearing
Ball/Roller Bearing 0.015 1
Bush Bearing 0.5
Coefficient of Rolling Friction for Wheel 1
Bearing/Bush for Wheel Axle
ID of Bearing 90 mm
OD of Bearing 160 mm
Width of Bearing 40 mm
2
Water Load on Gate 0 T/m
Total Water Load on Gate(P) = 120.625 T
5
2
5 T/m
Wheel Friction
Wheel Friction = P/R(f axr+f r)
Wheel Friction = 1.558 T
Side Seal Friction

Contact Width of Side Seal= 0.03
(Average pressureon side seal X Effective Area X Coefficient of
Side seal friction=
Friction)+(Precompression force X Coefficient of Friction)
Side seal friction= 2.63 T

Guide shoe Friction
Guide Shoe Friction = 0.16 T
Buoyancy Force
Buoyancy Force = 1.78 T
Uplift Force
Uplift Force = 2.03 T
Opposing forces while lowering the gate
Total force = 8.15 T
Revised Opposing forces while lowering the gate

Total Force = 8.150
Taking 25% higher = 10.1877
Seating force required

0.25
2.4125 T
Seating force available 5.81 T
Effort required for raising the gate
Total frictional force 4.343 T
Hoist Capacity 24.41169
Propose Hoist Capacity 25 T

DESIGN OF MECHANICLA
COMPONENTS OF 25T ROPE
DRUM HOIST
BARRAGE GATE
North Karanpura(660MWx3)
(JHARKHAND)
DOCUMENT No.- 4410-301B-PVH-U-002

DESIGN OF MECHANICAL COMPONENTS OF
25T ROPE DRUM HOIST FOR BARRAGE GATE Doc. No.-
North Karanpura(660MWx3) 4410-301B-PVH-U-002
(JHARKHAND) Rev.:R0
1. DESCRIPTION
The proposed Electrically Operated Rope Drum Hoist shall be designed for 25 tonnes capacity
for the operation of 9.5 M x 5 M size Barrage Gate as per the provisions contained in IS: 6938-
2005.
The Barrage Gate shall be lift and lowered by means of proposed rope drum hoist under flowing
water conditions. The rope drum hoist shall be installed on the hoist bridge duly supported on
concrete column of adequate height so as to bring out the gate out of gate groove above deck
level i.e. EL 438.0 M.
2.TECHNICAL REFERENCES
a. Technical Specifications
b. IS: 6938 2005 Code Practice for Design of Rope Drum Hoist & Chain Hoist for
Hydraulic Gates.
c. IS: 800 Code of Practice for General Construction in Steel.
d. IS: 807 2007 Code of Practice for design, manufacture, erection and testing of cranes
and hoists.
e. Tender Drawing No. NTPC Drg. No. TNVD-720-S1507 & TNVD-720-S-1508
3.TECHNICAL DATA :-
a. Capacity of Hoist - 25 MT
b. Type - Electrically Operated Rope Drum Hoist
c. Lifting speed - 0.7 5% m / min.
d. Lift - EL 432.0 438.0 +0.5 = 6.5Mts.
e. No. of Hoists required - 10
1 of 38
(JHARKHAND) Rev.:R0
4. MATERIAL SPECIFICATIONS
1. Structure Structural Steel : IS 2062

2a. Rope drum Cast Steel IS:1030 Gr.340-570 W
2b. Sheaves & Pulleys Cast Steel IS: 1030 Gr: 280-520 W
IS: 2004 Class 4 and
3. Shafts Forged Steel
Class 5
4. Bushes for rope drum Al. Bronze IS: 305 Gr: AB2
5. Wire rope Steel IS: 2266
6. Gear Wheel Cast Steel IS:1030 Gr.340-570 W
7. Pinions Forged Steel IS: 2004 Class 5
8. Threaded Fasteners Mild Steel IS: 1363 / IS: 1367
9. Gate pulley pin SS IS: 1570 30Cr13 / AISI420
5. MECHANICAL STRENGTH
SL.No. Material & Strength
1. Structural Steel IS2062
Y.P. = 250 N/mm2 for thickness < 20mm
Y.P. = 240 N/mm2 for thickness > 20mm and <40mm
Y.P. = 230 N/mm2 for thickness > 40mm
U.T.S = 410 N/mm2
Structural Steel IS: 2062 E250 BR
Y.P. = 230 N/mm2 for thickness > 40mm
U.T.S = 410 N/mm2
2. Forged Steel-
IS:2004 Class 4 IS:2004, Class5 IS:1570, 55C8
Y.P. = 320 N/mm2 Y.P. = 350 N/mm2 Y.P.= 540 N/mm2
U.T.S = 620 N/mm 2 U.T.S = 710 N/mm2 U.T.S = 800 N/mm2
3. Cast Steel
IS:1030 IS:1030 Gr.340- GR-3 AS PER IS: 2707-1996
Gr. 280-520 W 570 W
Y.P. = 280 N/mm2 Y.P. = 340 N/mm2 Y.P.= 370 N/mm2
U.T.S = 520 N/mm 2 U.T.S = 570 N/mm2 U.T.S = 700 N/mm2
4. Aluminium Bronze
IS: 305 Gr. AB2
U.T.S = 640 N/mm2
5 Stainless Steel
AISI420
Y.P. = 2
490 N/mm
U.T.S = 2
690 N/mm
2 of 38
(JHARKHAND) Rev.:R0
6.ALLOWABLE STRESSES
A. Rope drum :
IS:1030 Gr.340-570 W
Compressive stress:
2
a. Normal Condition = 0.17x5810.4 = 987.77 kg/cm
b. Break down condition:-
2
80% of YP = 0.8x3465.85 = 2772.68 kg/cm
Bending Stress
2
a). Normal Condition = 0.2 UTS = 0.17x5810.4 = 987.77 kg/cm
b). Brake Down Condition
80% of YP = 0.8x3465.85 = 2772.68 kg/cm2
Combined stress
a). Normal Condition - 0.24 UTS = 0.24x5300.71 = 1431.19 kg/cm2
b). Brake Down Condition:-
2
80% of YP = 0.8x2854.23 = 2283.38 kg/cm
B.Type-1 & 2 Gears : IS:1030 Gr.340-570 W

Root Stress
a. Normal Condition = 0.2x5810.4 = 1162.08 kg/cm2
b. Break down condition = 0.8x3465.85 = 2772.68 kg/cm2
C. Pinion : IS:1570, 55C8
Root Stress:
a. Normal Condition = 0.2x8154.94 = 1630.99 kg/cm2
b. Break down condition
80% of YP = 0.8x5504.59 = 4403.67 kg/cm2
D. Bushes : IS 305Gr.AB2
Bearing stress:
a. Bearing Stress under normal condition : 6523.96x0.04 = 261 kg/cm2
b. Bearing Stress under BDT condition : 6523.96x0.04x1.2 = 313.1 kg/cm2
133% of Allowable Stress = 1.33x260.958205912334
= 347.07 kg/cm2
E. Pin for Gate Sheave : AISI420
a. Bending Stress under Normal Condt.= 7033.64x0.2 = 1406.73 kg/cm2
b. Shear Stress under Normal Condition = 4994.9x0.3 = 1498.47 kg/cm2
c. Bending Stress under BDT condition= 4994.9x0.8 = 3995.92 kg/cm2
d. Shear Stress under BDT condition = 4994.9x0.8 = 3995.92 kg/cm2
F. Key for Shafts : IS:2004 Class 4
a. Shear Stress : 3261.98x0.3 = 978.59 kg/cm2
b. Crushing Stress : 6320.08x0.3 = 1896.02 kg/cm2
b. Shear Stress under BDT Condition : 6320.08x0.8 = 5056.07 kg/cm2
b. Crushing Stress under BDT Condition : 6320.08x0.8 = 5056.07 kg/cm2
3 of 38
(JHARKHAND) Rev.:R0
F. Cheek Plate / Structural Steel : IS 2062

i). Direct Compression and Compression in Bending
Direct Tension and Tension in Bending
Normal conditions
2
Plate < 20 mm = 0.55x2548.42 = 1401.63 kg/cm
Plate < 20 mm < 40 mm = 0.55x2446.48 = 1345.57 kg/cm2
2
Plate < 40 mm = 0.55x2344.55 = 1289.5 kg/cm
Break down condition:-
80% of Y.S or 1.33% of allowable stress, which is = 1.33x0.55of YS = 0.73 OF YS
2
Plate < 20 mm = 0.73x2548.42 = 1860.35 kg/cm
Plate < 20 mm < 40 mm = 0.73x2446.48 = 1785.93 kg/cm2
Plate < 40 mm = 0.73x2344.55 = 1711.52 kg/cm2
ii). Shear Stress
Normal condition = 0.4 XYS
Plate < 20 mm = 0.4x2548.42 = 1019.37 kg/cm2
Plate < 20 mm < 40 mm = 0.4x2446.48 = 978.59 kg/cm2
2
Plate < 40 mm = 0.4x2344.55 = 937.82 kg/cm
Break down condition = 1.33 X Allowable stress
Plate < 20 mm = 1.33x1019.37 = 1355.76 kg/cm2
Plate < 20 mm < 40 mm = 1.33x978.59 = 1301.52 kg/cm2
Plate < 40 mm = 1.33x937.82 = 1247.3 kg/cm2
iii). Bearing Stress
Normal condition = 0.4 x UTS = 0.4x4179.41 = 1671.76 kg/cm2
B D T condition= 1.33 X Allowable stress = 1.33x1671.76 = 2223.44 kg/cm2
iv). Combined Stress

Normal condition = 0.75 x YS
Plate < 20 mm = 0.75x2548.42 = 1911.31 kg/cm2
Plate < 20 mm < 40 mm = 0.75x2446.48 = 1834.86 kg/cm2
Plate < 40 mm = 0.75x2344.55 = 1758.41 kg/cm2
v) Bending stress
Normal conditions = 0.5 X YS = 0.5x2548.42 = 1274.21 kg/cm2
B D T condition= 1.33 X Allowable stress = 1.33x1274.21 = 1694.7 kg/cm2
4 of 38
(JHARKHAND) Rev.:R0
F. Shafts : IS 2004 CLASS 4
a. Normal Condition
2
Bending stress without keys = 0.2x6320.08 = 1264.02 kg/cm
2
Bending stress with keys = 0.75x1264.02 = 948.02 kg/cm
2
Torsional stress without keys = 0.3x3261.98 = 978.59 kg/cm
Torsional stress with keys = 0.75x978.59 = 733.94 kg/cm2

2
Combined stress without keys = 0.24x6320.08 = 1516.82 kg/cm
Combined stress with keys = 0.75x1516.82 = 1137.62 kg/cm2
Equivalent bending stress without keys = 1.2x1264.02 = 1516.82 kg/cm2
Equivalent bending stress with keys = 1.2x948.02 = 1137.62 kg/cm2
Equivalent Torsional stress without keys = 1.2x978.59 = 1174.31 kg/cm2
Equivalent Torsional stress with keys = 1.2x733.94 = 880.73 kg/cm2
b. Break Down Condition
80% of YP
Bending stress without keys = 0.8x3261.98 = 2609.58 kg/cm2
Bending stress with keys = 0.75x2609.58 = 1957.19 kg/cm2
Torsional stress without keys = 0.375x3261.98 = 1223.24 kg/cm2
Combined stress without keys = 0.8x3261.98 = 2609.58 kg/cm2
5 of 38
(JHARKHAND) Rev.:R0
G. Shafts : IS 2004 CLASS-5
a. Normal Condition
2
Bending stress without keys = 0.2x7237.51 = 1447.5 kg/cm
2
Bending stress with keys = 0.75x1447.5 = 1085.63 kg/cm
2
Torsional stress without keys = 0.3x3567.79 = 1070.34 kg/cm

2
Combined stress without keys = 0.24x7237.51 = 1737 kg/cm
Combined stress with keys = 0.75x1737 = 1302.75 kg/cm2
Equivalent bending stress without keys = 1.2x1447.5 = 1737 kg/cm2
b. Break Down Condition
80% of Allowable Stress in normal condition
Bending stress without keys = 0.8x3567.79 = 2854.23 kg/cm2
Bending stress with keys = 0.75x2854.23 = 2140.67 kg/cm2
Torsional stress without keys = 0.375x3567.79 = 1337.92 kg/cm2
Combined stress without keys = 0.8x3567.79 = 2854.23 kg/cm2
6 of 38
(JHARKHAND) Rev.:R0
7.0 DESIGN OF HOIST MECHANISM
Hoist Capacity = 25 MT
Lifting lowering speed = 0.7 m /min. 5%
No. of falls of wire rope = 2 falls / drum (side)
No. of drums = 2 (TWO)
Total lift provided = 6.5 meters
7.1 MOTOR
Total load on Rope = M= 25 0 (Weight of wire rope)
= 25 T
Lifting Speed = V= 0.7 M/min
Rope Drum Running effy. = 0.95 as per IS:6938-2005 for Bronze Bearing
Pulley running efficiency (A.F.
0.98 as per IS: 6938-2005
Bearing) =
(Total 1No. of Pulley per side) Pulley efficiency = 0.98^1 = 0.98
Worm reduction efficiency = 0.7348
Gear Running efficiency = 0.95 per stage. As per IS: 6938-2005
Number of pair of open spur gears used = 2
Total open gear running efficiency = 0.95^2 = 0.9
Overall running efficiency = Rope drum efficiency x Open gear Efficiency x Pulley
efficiency x Worm gear box efficiency.
E = overall running efficiency = 0.95x0.98x0.7348x0.9 = 0.62
MVS 25x0.7
Motor KW Required = = = 4.61 kW
6.12 E 6.12x0.62
Motor selected 5.5 kW ( 7.5 HP), 925 r.p.m, sq, cage, 40% CDF,
150 Starts / hr., TEFC, Fr. Size 132S Make: Bharat Bijlee. POT 2.75
Rope Drum Starting effy. = 0.93 as per IS:6938-2005 for bronze bearing
Pulley starting efficiency (A.F. Bearing) = 0.95 as per IS: 6938-2005
Worm reduction Starting efficiency = 0.46
Gear starting efficiency = 0.93 per stage. As per IS: 6938-2005
Number of pair of open spur gears used = 2
Total open gear starting efficiency = 0.93^2 = 0.86
(Total 1No. of Pulley per side) Pulley efficiency = 0.95^1 = 0.95
Overall starting efficiency = Rope drum efficiency x Open gear Efficiency x Worm gear
box efficiency.
Es = overall starting efficiency = 0.93x0.46x0.86x0.86 = 0.35
Overall running eff. Starting torque
Ratio = <
Overall starting eff. Running torque
0.62 Starting torque
Ratio = <
0.35 Running torque
Ratio = 1.77 < 2.75
7 of 38
(JHARKHAND) Rev.:R0
7.2 HOIST BRAKE

1.5x7.5x716.2 1.5x7.5x716.2
Required Torque rating of brake = =
r.p.m 925
= 8.71 kg-m
BRAKES SELECTED -
a). Electro hydraulic thrustor operated Brake Model EBTM 150 C- 18 kg
Having braking torque 9 Kgm. Make: Electromag
b). D.C. Electro magnetic Brake , Model No. IPB- 200 , 100% CDF
Having Torque Rating- 15 Kgm. Make: Electromag
7.3 Brake Drum Coupling

a. Between Motor & worm gear box
1.5xHPx100 1.5x7.5x100
H.P. /100 r.p.m. = = = 1.22
r.p.m 925
Coupling selected Model N7P6O8 200 Dia. Brake drum.
Allowable HP/100rpm : 6.5 Make MARK-ACE IND/MECO.
b. At worm gear box
Coupling selected Model N53P3D6 150 Dia. Brake drum.
Allowable HP/100rpm : 1.5 Make MARK-ACE IND/MECO.
7.4 Flexible Coupling (B/w G.B O/P Shaft & line Shaft & b/w line shaft & pinion shaft)
1.5xHPx100x70x0.7348 1.5x7.5x100x70x0.7348
H.P. /100 r.p.m. = = = 31.28
2xr.p.m 925x2
Required Torque rating of 1.5x7.5x716.2x70x0.7348 1.5x7.5x716.2x70x0.7348
= =
coupling 2xr.p.m 2x925
= 224.02 kg-m
Coupling selected Flexible Geared coupling-size 103
H.P. /100 r.p.m. 61.5 Max. Torque rating 440 kgm
Make: - New Allenberry
7.5 DESIGN OF WIRE ROPE
WIRE ROPE:-
Total Load on Ropes = Capacity + wt. of wire rope = 25 + 0= 25 T
No. of falls on each drum = 2 Nos
Pulley efficiency, = 0.95 per Pulley with A.F. Bearing
Wire rope tension = W/2 {(1- )/ (1- n)}
= 25000x(1-0.95)/2x(1-0.95^2) = 6410.26 kg
= 62.88 kN
Min breaking strength required, = FOS XRope Tension = 6x62.88
= 377.28 kN
8 of 38
(JHARKHAND) Rev.:R0
Proposed 28 mm dia. wire rope, 6X36 construction, right hand lay,
2 2
fiber core, Improved Plow steel, UTS= 1960N/mm or 200kg/mm ,galvanized
, having breaking Load of 507 KN/ 51681.96 kg
MAKE: USHA MARTIN/FORT WILLIAM INDUSTRIES LTD.
Galvanization Factor- 0.9
Factory of safety = 51681.96x0.9/6410.26 = 7.26 > 6 Hence safe.

7.6 DESIGN OF ROPE DRUM
MATERIAL : IS:1030 Gr.340-570 W

Proposed 2 drums with each 4 falls
Minimum Drum Dia: 20d = 20x28 = 560 mm
Proposed Drum Dia = 750 mm PCD
Circumference = 3.14x0.75 = 2.36 M
Total Lift = 6.5 M
No. of Grooves required = 6.5x2/2.36+3 = 5.5+3 = 8.51 @ 14
Shell thickness below groove (t) = 3.5 cm (assumed)
Pitch of Groove = 28 + 2.5 = 30.5 mm= 3.05 cm
1. DESIGN OF SHELL
Proposed shell thickness = 3.5 cm
Compressive stress, sc = KXT/PXT
Where,
K = 1
T = 6410.26 kg
P = 3.05 cm
t = 3.5 cm
sc = 1x6410.26/(3.05x3.5)
= 600.49 kg/cm2 < 987.77 kg/cm2
1
20
13
35
750
652
748
9 of 38
(JHARKHAND) Rev.:R0
2. GROOVES DETAILS
Wire rope dia = 28 mm

Depth of groove = 0.35x28 = 9.8 mm(min) Take 13 mm
Radius of groove = 0.53x28 = 14.84 mm(min) Take 20 mm
Inside Dia of drum = 750-2x(14+35) = 652 mm
Turned dia of drum = 750-2x(14)= 722 mm
Overall length of drum= 20 + 167.5 + 30.5x14 + 66.5 + 25
= 706 mm
CHECKING OF BENDING STRESS OF THE DRUM :-
6410.26 kg 17.28 kg/cm

A B
706
Wt. of drum = 1220 kg. = w1
Wt. of drum/LG. = 1220/70.6 = 17.28 kg/cm =W1
Wire rope tension = 6410.26 kg. = w2
Bending moment due to self wt. of drum = w1 x L/2 x L/2 = 17.28x70.6^2/4
= 21532.4 kgcm
Bending moment due to wire rope tension = w2 x L/4 = 6410.26x70.6/4
= 113141 kgcm
Total B.M.= = 21532.44+113141.09 = 134673.53 kgcm
Z for drum = (D4 d4) / 32D = 3.14(72.2^4-65.2^4)/(32x72.2)
= 12377.04 cm
Bending stress = 134673.53/12377.04 = 10.88 kg/cm2
Combined stress = (600.49^2+10.88^2)^0.5 = 600.59 kg/cm2
< 1431.19 kg/cm2
10 of 38
(JHARKHAND) Rev.:R0
7.7 SELECTION WORM REDUCER
4XV where,
Motor r.p.m = 925 Drum R.P.M. = PXD V - is Velocity in m/min,
D - is Rope drum P.C.D.
Drum r.p.m. = 0.7x2/3.14x0.75 = 0.59
Speed of the motor proposed = 925.00 rpm
Total reduction required = 925/0.59 = 1567.8
Service Factor for 12 hours/day Operation and Medium Impulsive load= 1.25 for NAV gears
Equivalent Power = Actual power x Service factor = 5.5x1.25= 6.875 kW
Selected central worm reducer: - Single reduction 70 :1 ratio,

Type SUM SM Series, Size-8, I/p & O/p kW 8.5 & 6.25@1000 r.p.m., O/p Torque-4175Nm,
with input & output shaft extended on both sides
Make:NAW/Shanthi Gear.
Reduction required for end gearing (open gearing) = 1567.8/70 = 22.4

7.8 DESIGN OF END GEARING (SPUR TYPE- DOUBLE STAGE):-
Description No. of teeth Module in P.C.D. P.A. in Material

mm In mm Deg.
W1 87 12 1044 20 IS:1030 Gr.340-570 W
P1 21 12 252 20 IS:1570, 55C8
W2 99 8 792 20 IS:1030 Gr.340-570 W
P2 19 8 152 20 IS:1570, 55C8
Actual lifting speed = 925x19x21x3.14x0.75/(70x87x99x2) = 0.7 M/min

Drum effy. = 0.95
Effy. Of W1 gear & P1 pinion set = 0.95
6410.26x37.5
Tooth load W1&P1 = = 5102.57 kg
52.2x0.95x0.95
11 of 38
(JHARKHAND) Rev.:R0
Effy. Of W2 gear & P2 pinion set = 0.95

5102.57x12.6
Tooth load W2&P2 = = 1708.99 kg
39.6x0.95
PxQ
Root Stress =
FxM
Where,
P = Tooth Load
Q = Strength factor
F = Face width
M = Module
Description Tooth Load Strength Face Width Module Root Stress Allowable
(in kg) Factor Q F in cm M in Kg/cm2 Stress
W1 5102.57 2.6 12 1.2 921.3 1162.08
P1 5102.57 3.3 13 1.2 1169.34 1630.99
W2 1708.99 2.6 6 0.8 925.7 1162.08
P2 1708.99 3.5 7 0.8 1246.14 1630.99
7.9 Design of Connection Bolts for Wheel W1 and Rope Drum

Proposed M- 20 Fit bolts @ 820 PCD 8 Nos., As per IS:3640, 1367-3/
IS1363, Gr. 5.8
Rope Tension = 6410.26 kg
Total load on bolts = 6410.26x750/820 = 5863.04 kg
Load on each bolt = 5863.04/8 = 732.88 kg
Cross Sectional Area of one bolt = 3.14x2^2x0.85/4= 2.67 cm2
Shear stress in bolt = 732.88/2.67 = 274.49 kg/cm2
0.3XY.S 1019.37 kg/cm2
Allowable Shear Stress = = 0.3x400X100/(1.2 x9.81)=
1.2 Hence safe.
Grade of Bolt is 5.8 YS of bolt is 400 N/mm2. Material of Bolt will be as per
IS-1367, Bolt size M 20 x 95 mm Long.
12 of 38
(JHARKHAND) Rev.:R0
8. DESIGN OF SHAFT
8.1. Design of Drum Shaft- Shaft 1
A) When Rope Tension Is On Gear Wheel Side
Vertical loads
12590.3 kg 300 kg
A1 C1 D1 B1
19.2 69.5 6.5

95.2 cm
RVA1 RVB1
Weight of drum = 600 kg
Weight of gear wheel W 1= 450 kg
Weight of gear wheel W 2 = 100 kg
Weight of pinion P1= 55 kg
= Vertical component of tooth load of W1+Wt. of W1+ Wt of

Load acting at C1
drum+ rope tension
5102.57 600
= + 450 + + 6410.26
Cos 20 2
= 5430.04 + 450 + 300 + 6410.26
= 12590.3 kg
Load acting at D1 = Weight of drum

600
=
2
= 300 kg
12590.3x76+300x6.5
RVA1 =
95.2
= 10071.56 kg
RVB1 = 12590.3+300-10071.56 = 2818.74 kg
13 of 38
(JHARKHAND) Rev.:R0
Horizontal loads:-
1857.18 kg
A2 C2 B2
19.2
95.2 cm
RHB1
RHA1
0
Horizontal load at C2 due to load on w1 gear = 5102.57 x tan 20
= 1857.18 kg
1857.18x76
RHA1 = = 1482.62 kg
95.2
RHB1 = 1857.18-1482.62 = 374.56 kg

Resultant load at A1 / A2 = (10071.56^2+1482.62^2)^0.5 = 10180.1 kg
Resultant load at B1 / B2 = (2818.74^2+374.56^2)^0.5 = 2843.52 kg
Resultant B.M. at C1 / C2 = (10071.56^2+1482.62^2)^0.5x19.2
= 195457.96 kgcm
Resultant B.M. at D1 = (2818.74^2+374.56^2)^0.5x6.5
= 18482.86 kgcm
Proposed 130 shaft confirming to IS:2004 Class 4 having UTS
6320.08 kg./cm & YP = 3261.98 kg./cm
x 13^3
Zxx of shaft = = 215.69 cm3
32
x 13^2
C.S. area = = 132.73 cm2
4
Bending stress in shaft = M / Z = 195457.96/215.69 = 906.2 kg/cm2

< 1264.02 kg/cm2
Resultant Load at C1 / C2 = (12590.3^2+1857.18^2)^0.5
= 12726.54 kg
Resultant Load at D1 = (300^2+374.56^2)^0.5
= 479.89 kg
Shear stress = 12726.54/132.73 = 95.88 kg/cm2
< 978.59 kg/cm2
14 of 38
(JHARKHAND) Rev.:R0
When the Rope Tension Is On Non-Gear Wheel Side
Vertical loads
6180.04 kg 6710.26 kg
A3 C3 D2 B3
19.2 69.5 6.5

95.2 cm
RVA2 RVB2
Vertical component of Tooth load of W1 + Wt. of gear wheel +
Load acting at C3 =
Weight of drum
5102.57 600
= + 450 +
Cos 20 2
= 5430.04 + 450 + 300
= 6180.04 kg
Load acting at D2 = Weight of drum + Rope tension
600
= + 6410.26
2
= 6710.26 kg
RVA2 = (6180.04x76+6710.26x6.5)/95.2
= 5391.8 kg
RVB2 = 6180.04+6710.26-5391.8
= 7498.5 kg
Horizontal loads:-
1857.18 kg
A4 C4 B4
19.2
95.2 cm
RHB2
RHA2
Horizontal load at C4 due to load on w1 gear = 5102.57 x tan 20 0
= 1857.18 kg
1857.18x76
RHA2 = = 1482.62 kg
95.2
RHB2 = 1857.18-1482.62 = 374.56 kg
15 of 38
(JHARKHAND) Rev.:R0
Resultant B.M. at C3 & C4 = (5391.8^2+1482.62^2)^0.5x19.2
= 107365.04 kgcm
= 48801.02 kgcm
2
< 1264.02 kg/cm
= 6453.06 kg
Resultant Load at D2 = (6710.26^2+374.56^2)^0.5
= 6720.71 kg
< 978.59 kg/cm2
8.2. Design of Bush
A)At Gear Wheel W1
Resultant load at C1 & C2 and C3 & C4= 12726.54 kg
Shaft Dia. = 130 mm
Min. thickness of bush = 0.08x130+3 mm
= 13.4 mm
Provided thickness = 15 mm
Proposed to provide Al. bronze Gr. AB-2, IS: 305 with ID = 130 mm OD = 160 mm
Length = 120 mm
Bearing stress in bush = 12726.54/(13X12) = 81.58 < 260.958 kg/ cm2
B) At Non-Gear Wheel End
Resultant load at D1 & D2 = 6720.71 kg
Shaft Dia. = 130 mm
= 13.4 mm
Length = 60 mm
16 of 38
(JHARKHAND) Rev.:R0
8.3. Design of Shaft- P1W2
Vertical loads
1918.67 kg 5485.04 kg
A5 C5 D4 B5
17.4 12.2 15.4

45 cm
RVA3 RVB3
Load acting at C5 = Tooth load of W2 + Wt. of W2
1708.99
= + 100
Cos 20
= 1818.67 + 100
= 1918.67 kg
Load acting at D4 =Vertical component of tooth load of P1+ Weight of P1
5102.57
= + 55
Cos 20
= 5430.04 + 55
= 5485.04 kg
RVB3 = (1918.67x17.4+5485.04x29.6)/45
= 4349.82 kg
RVA3 = 1918.67+5485.04-4349.82
= 3053.89 kg
Horizontal load:-
622.02 kg 1857.18 kg
A6 C6 D5 B6
17.4 12.2 15.4

45 cm
RHA3 RHB3
Horizontal load at C6 due to load on W2 gear = 1708.99 x tan 20 0

= 622.02 kg
Horizontal load at D5 due to load on P1 = 5102.57 x tan 20 0
= 1857.18 kg
17 of 38
(JHARKHAND) Rev.:R0
RHA3 = (622.02x27.6+1857.18x15.4)/45
= 1017.07 kg
RHB3 = 622.02+1857.18-1017.07
= 1462.13 kg
= 2016.98 kg
Resultant Load at D4/ D5 = (5485.04^2+1857.18^2)^0.5
= 5790.92 kg
Resultant Load at RVA3/RHA3 = (3053.89^2+1017.07^2)^0.5
= 3218.8 kg
Resultant Load at RVB3/RHB3 = (4349.82^2+1462.13^2)^0.5
= 4588.98 kg
Resultant B.M. at C5/C6 = 3218.8x17.4
= 56007.12 kgcm
Resultant B.M. at D4/D5 = 4588.98x15.4
= 70670.29 kgcm
Torque transmitted by P1W2 shaft = 1708.99x39.6
= 67676 kgcm
2 2
Equivalent Torque = (M + T ) = (70670.29^2+67676^2)^0.5
= 97848.51 kgcm
Equivalent Bending moment = 0.5x(70670.29+97848.51)
= 84259.4 kgcm
6320.08 kg./cm & YP = 3262 kg./cm
Shaft diameter at bearing 90 mm
x 11^3
32
x 11^3
Zpp of shaft = = 261.34 cm3
16
x 9^2
C.S. area = = 63.62 cm2
4
18 of 38
(JHARKHAND) Rev.:R0
Equivalent Bending stress = 84259.4/130.67

= 644.83 kg./cm < 1957.19 kg./cm
Equivalent Torsional stress = 97848.51/261.34
= 374.41 kg./cm < 880.73 kg./cm
Direct Shear Stress = 4588.98/63.62
= 72.13 kg./cm < 733.94 kg./cm
Bending Stress = 70670.29/130.67
= 540.83 kg./cm < 948.02 kg./cm
Torsional Shear Stress = 67676/261.34
= 258.96 kg./cm < 733.94 kg./cm
Combined Stress = (540.83^2+3x258.96^2)^0.5
= 702.62 kg./cm < 1957.19 kg./cm
8.4.Design of Shaft P2
Vertical loads
1828.67 kg
A7 D6 B7
15.4 29.6
45 cm
RVA5 RVB5
Load acting at D6 = Tooth load of P2 + Weight. Of P2
1708.99
= + 10
Cos 20
= 1818.67 + 10 = 1828.67 kg
1828.67x29.6
RVA5 = = 1202.86 kg
45
RVB5 = 1828.67-1202.86 = 625.81 kg
19 of 38
(JHARKHAND) Rev.:R0
Horizontal loads
622.02 kg
A8 D7 B8
15.4 29.6
45 cm
RHA5 RHB5
0
Horizontal load at D7 due to tooth load on P2= 1708.99 x tan 20
622.02 kg
622.02x29.6
RHA6 = = 409.15 kg
45
RHB6 = 622.02-409.15 = 212.87 kg
Resultant Load at D6 / D7 = (1828.67^2+622.02^2)^0.5
= 1931.56 kg
= 1270.54 kg
= 661.02 kg
= 19566.19 kgcm
Torque transmitted by P2 shaft = 1708.99x7.6
= 12988.32 kgcm
Equivalent Torque = (M2 + T2) = (19566.19^2+12988.32^2)^0.5
= 23484.72 kgcm
= 21525.46 kgcm
6320.08 kg./cm & YP = 3262 kg./cm
Shaft diameter at bearing 60 mm
x 7^3
32
20 of 38
(JHARKHAND) Rev.:R0
x 7^3
16
x 6^2
C.S. area = = 28.27 cm2
4
= 639.31 kg./cm < 1137.62 kg./cm
= 348.7 kg./cm < 880.73 kg./cm
= 44.94 kg./cm < 733.94 kg./cm
= 581.12 kg./cm < 948.02 kg./cm
Torsional Shear Stress = 12988.32/67.35
= 192.85 kg./cm < 733.94 kg./cm
= 670.28 kg./cm < 1957.19 kg./cm
8.5. BEARINGS
(i)For Shaft P1W2
Max load on Plummer block brg. = 4588.98 kg.
Min. capacity of bearing = 1.5X4588.98 = 6883.47 kg.
= 67526.84 N
Proposed Plummer Block SNL520 ,MAKE FAG/SKF with 22220 EK
bearing and H320 adaptor sleeve having dynamic capacity 433000 N
and static capacity 490000 N
Both static & dynamic capacity is much more than 67526.84 N
Max. Horizontal Load on Plummer Block = 1462.13 kg.
Max. Vertical Load on Plummer Block = 4349.82 kg.
Proposed M 24 bolts as per IS:1367-3/ IS1363, Gr. 5.8
Number Bolt per Plummer Block = 2
Cross Sectional Area of one bolt = 3.4x2.4^2x0.85/4= 3.85 cm
Shear stress in bolt = 1462.13/(3.85x2) = 189.89 kg./cm
0.3XY.S
Allowable Shear Stress = = 0.3x400x100/(1.2x9.81)
1.2
= 1019.4 kg./cm Hence safe
Tensile stress in bolt = 4349.82/(3.85x2) = 564.91 kg./cm
100X400X120
Allowable tensile Stress =
235X9.81
21 of 38
(JHARKHAND) Rev.:R0
Grade of Bolt is 5.8 YS of bolt is 400 N/mm2 . Material of Bolt will be as per
IS-1367-3/IS:3640, Bolt size M 24 x 150 mm Long.
(ii)For Shaft P2
= 18696 N

Both static & dynamic capacity is much more than 18696 N
Cross Sectional Area of one bolt = 3.4x1.6^2x0.85/4= 1.71 cm
0.3XY.S
Allowable Shear Stress = = 0.3x400x100/(1.2x9.81)
1.2
100X400X120
Allowable tensile Stress =
235X9.81
Grade of Bolt is 5.8 YS of bolt is 400 N/mm2 . Material of Bolt will be as per
IS-1367-3/IS:3640, Bolt size M 20 x 120 mm Long.
8.6. DESIGN OF HOIST LINE SHAFT (DRIVING SHAFT)
Material: IS 2004 CLASS 4
Torque transmitted by P-2 shaft= 12988.32 kgcm
Min. Shaft diameter = 60 mm
x 6^3
16

= 306.26 kg./cm < 733.94 kg./cm
1700
Length of shaft / Dia. of shaft = = 28.33 < 50
60
So angle of twist need not be checked.
22 of 38
(JHARKHAND) Rev.:R0
9 DESIGN KEY
PINION P1 & GEAR W2
Shaft Diameter(d) = 110 mm

Torque on P1W2 Shaft = 67676 kg-cm
Length of Key for Gear: 90 mm & for pinion : 130 mm
Width: 28 mm, Thickness: 16 mm Material of the Key : IS:2004 Class 4
Note: Design of key done based on shortes length
Shear Stress of Key=2T/(bdl)
= 2X67676/(2.8X11X9)
= 488.28 kg/cm2 < 978.59 kg/cm2
Crushing Stress of Key=4T/(tdl)
= 4X67676/(1.6X11X9)
= 1708.99 kg/cm2 < 1896.02 kg/cm2
PINION P2
Shaft Diameter(d) at Pinion = 70 mm

Shaft Diameter(d) at Coupling = 65 mm
Torque on P2 Shaft = 12988.32 kg-cm
Length of Key for Pinion: 90 mm Width: 20 mm,
Thickness: 12 mm Material of the Key : IS:2004 Class 4

= 2X12988.32/(2X7X9)
= 206.16 kg/cm2 < 978.59 kg/cm2
= 4X12988.32/(1.2X7X9)
= 687.21 kg/cm2 < 1896.02 kg/cm2
Length of Key for Coupling: 85 mm Width: 18 mm,
Thickness: 11 mm Material of the Key : IS:2004 Class 4
= 2X12988.32/(1.8X6.5X8.5)
= 261.2 kg/cm2 < 978.59 kg/cm2
= 4X12988.32/(1.1X6.5X8.5)
= 854.85 kg/cm2 < 1896.02 kg/cm2
23 of 38
(JHARKHAND) Rev.:R0
10. CHECKING OF HOIST MECHANISM UNDER BRAKE DOWN TORQUE CONDITION

OF MOTOR
Break down torque of motor = 275% of full load torque
Motor torque at break-down condition, T= 2.75x7.5x71620/(N)
= 2.75x7.5x71620)/(925) = 1596.93 kgcm
a)Transmission/driving Shaft:-
Torque transmitted to driving shaft i.e. output torque of worm reducer
Tx Starting effy. Of worm reducer x reduction ratio of worm reduce
=1596.93x0.46x70 = 51421.15 kgcm
Torque transmitted to driving shaft/side = 51421.15/2 = 25710.575 kgcm
b) END GEARS
Drum gear & Pinion (W1 & P1)
Tooth Load on W1 & P1 = 25710.575x99x0.93/(19x12.6) = 9887.94 kg
Stress at the root of Pinion P1, = P x Q / (F x M)
= 9887.94x3.3/(12x1.2)
= 2265.99 kg./cm < 4403.67 kg./cm
Stress at root of Gear W1, = P x q/ (F x m)
= 9887.94x2.6/(12x1.2)
= 1785.32 kg./cm < 2772.68 kg./cm
W2 gear & P2 Pinion
Tooth load on W2 & P2 = Torque on transmission shaft/P.C.R. of P2
= 25710.575/7.6 = 3382.97 kg
Now stress at root of pinion P2, = PXq/ (FXm)
= 3382.97x3.5/(6x0.8)
= 2466.75 kg./cm < 4403.67 kg./cm
Now , stress at the root of Gear W2, = P x q/ (Fxm)
= 3382.97x2.6/(6x0.8)
= 1832.44 kg./cm < 2773 kg./cm
c) Drum
Load on drum i.e. Rope tension = tooth load on drum gear x starting effy. Of Drum gear & pinion
x starting effy. Of drum x (P.C.D. of gear w1/P.C.D. of drum)
= 9887.94x0.93x1044/750 = 12800.53 kg
Now Cr = Kt/Pt = 1x12800.53/(3.05x3.5)= 1199.11 kg./cm < 2772.68 kg./cm
d) ROPE
Maximum pull per rope = 12800.53 kg
Now breaking strength of rope = 51681.96 kg
So Factor of safety = Breaking strength/Pull = 51681.96/12800.53 = 4.04 > 3
24 of 38
(JHARKHAND) Rev.:R0
e) Drum shaft
i) When the rope tension is on gear wheel side.
Vertical loads
24073.06 kg 300 kg
A11 C11 D11 B11
19.2 69.5 6.5

95.2 cm
RVA11 RVB11
Weight of drum = 600 kg
Weight of gear wheel W 1= 450 kg
Weight of gear wheel W 2 = 100 kg
= Vertical component of tooth load of W1+Wt. of W1+ Wt of
Load acting at C11
drum+ rope tension
9887.94 600
= + 450 + + 12800.53
Cos 20 2
= 10522.53 + 450 + 300 + 12800.53
= 24073.06 kg
Load acting at D11 = Weight of drum
600
=
2
= 300 kg
RVA11 = 24073.06x76+300x6.5
95.2
= 19238.47 kg
RVB11 = 24073.06+300-19238.47 = 5134.59 kg
Horizontal loads:-
3598.92 kg
A21 C21 B21
19.2
95.2 cm
RHB11
RHA11
0
= 3598.92 kg
25 of 38
(JHARKHAND) Rev.:R0
3598.92x76
RHA11 = = 2873.09 kg
95.2
RHB11 = 3598.92-2873.09 = 725.83 kg
Resultant B.M. at C11 / C21 = (19238.47^2+2873.09^2)^0.5x19.2
= 373474.98 kg
= 33706.65 kg
3
Zxx of shaft = 215.69 cm
C.S. area = 132.73 cm2

2
< 2609.58 kg/cm
= 24340.59 kg
Resultant Load at D11 = (300^2+725.83^2)^0.5
= 785.38 kg
Shear stress = 24340.59/132.73
= 183.38 kg/cm2
2
< 1223.2 kg/cm
When the Rope Tension Is On Non-Gear Wheel Side
Vertical loads
11272.53 kg 13100.53 kg
A31 C31 D21 B31
19.2 69.5 6.5

95.2 cm
RVA21 RVB21
Vertical component of Tooth load of W1 + Wt. of gear wheel +
Load acting at C31 =
Weight of drum
9887.94 600
= + 450 +
Cos 20 2
= 10522.53 + 450 + 300
= 11272.53 kg
Load acting at D21 = Weight of drum + Rope tension
600
= + 12800.53
2
= 13100.53 kg
RVA21 = (11272.53x76+13100.53x6.5)/95.2
= 9893.55 kg
26 of 38
(JHARKHAND) Rev.:R0
RVB21 = 11272.53+13100.53-9893.55
= 14479.51 kg
Horizontal loads:-
3598.92 kg
A41 C41 B41
19.2
95.2 cm
RHB21
RHA21
0
= 3598.92 kg
3598.92x76
RHA21 = = 2873.09 kg
95.2
RHB21 = 3598.92-2873.09 = 725.83 kg

Resultant B.M. at C31 & C41 = (9893.55^2+2873.09^2)^0.5x19.2
= 197803.78 kgcm
= 94234.99 kgcm
< 2609.58 kg/cm2
= 11833.1 kg
Resultant Load at D21 = (13100.53^2+725.83^2)^0.5
= 13120.62 kg
< 1223.2 kg/cm2
f) Design of Bush
i)At Gear Wheel W1
Resultant load at C11 & C21 and C31 & C41= 24340.59 kg
Bearing stress in bush = 24340.59/(13X12) = 156.03 < 2223.44 kg/cm2
ii) At Non-Gear Wheel End
Resultant load at D11 & D21 = 13120.62 kg
Bearing stress in bush = 13120.62/(13X6) = 168.21 < 2223.44 kg/cm2
27 of 38
(JHARKHAND) Rev.:R0
g) Design of Shaft- P1W2

Vertical loads
3700.08 kg 10577.53 kg
A51 C51 D41 B51
17.4 12.2 15.4

45 cm
RVA31 RVB31
Load acting at C51 = Tooth load of W2 + Wt. of W2
3382.97
= + 100
Cos 20
= 3600.08 + 100
= 3700.08 kg
Load acting at D41 =Vertical component of tooth load of P1+ Weight of P1
9887.94
= + 55
Cos 20
= 10522.53 + 55
= 10577.53 kg
RVB31 = (3700.08x17.4+10577.53x29.6)/45
= 8388.36 kg
RVA31 = 3700.08+10577.53-8388.36
= 5889.25 kg
Horizontal load:-
1231.3 kg 3598.92 kg
A61 C61 D51 B61
17.4 12.2 15.4

45 cm
RHA31 RHB31
Horizontal load at C61 due to load on W2 gear = 3382.97 x tan 20 0
= 1231.3 kg
Horizontal load at D51 due to load on P1 = 9887.94 x tan 20 0
= 3598.92 kg
RHA31 = (1231.3x27.6+3598.92x15.4)/45
= 1986.83 kg
RHB31 = 1231.3+3598.92-1986.83
= 2843.39 kg
28 of 38
(JHARKHAND) Rev.:R0
= 3899.58 kg
Resultant Load at D41/ D51 = (10577.53^2+3598.92^2)^0.5
= 11173.02 kg
= 6215.36 kg
= 8857.17 kg
Resultant B.M. at C51/C61 = 6215.36x17.4
= 108147.26 kgcm
= 136400.42 kgcm
Torque transmitted by P1W2 shaft = 3382.97x39.6
= 133965.61 kgcm
2 2
Equivalent Torque = (M + T ) = (136400.42^2+133965.61^2)^0.5
= 191185.41 kgcm
= 163792.92 kgcm
Zxx of shaft = 130.67 cm3
Zpp of shaft = 261.34 cm3
C.S. area = 63.62 cm2
= 1253.49 kg./cm < 1957.19 kg./cm
= 731.56 kg./cm < 1957.19 kg./cm
= 139.22 kg./cm < 917.43 kg./cm
Bending Stress = 136400.42/130.67
= 1043.85 kg./cm < 1957.19 kg./cm
= 512.61 kg./cm < 917.43 kg./cm
= 1370.4 kg./cm < 1957.19 kg./cm
29 of 38
(JHARKHAND) Rev.:R0
h)Design of Shaft P2
Vertical loads
3610.08 kg
A71 D61 B71
15.4 29.6
45 cm
RVA51 RVB51
Load acting at D61 = Tooth load of P2 + Weight. Of P2
3382.97
= + 10
Cos 20
= 3600.08 + 10 = 3610.08 kg
3610.08x29.6
RVA51 = = 2374.63 kg
45
RVB51 = 3610.08-2374.63 = 1235.45 kg
Horizontal loads
1231.3 kg
A81 D71 B81
15.4 29.6
45 cm
RHA51 RHB51
0
Horizontal load at D71 due to tooth load on P2= 3382.97 x tan 20
1231.3 kg
1231.3x29.6
RHA61 = = 809.92 kg
45
RHB61 = 1231.3-809.92 = 421.38 kg
Resultant Load at D61 / D71 = (3610.08^2+1231.3^2)^0.5
= 3814.29 kg
= 2508.95 kg
= 1305.3 kg
= 38637.77 kgcm
30 of 38
(JHARKHAND) Rev.:R0
Torque transmitted by P2 shaft = 3382.97x7.6

= 25710.57 kgcm
2 2
Equivalent Torque = (M + T ) = (38637.77^2+25710.57^2)^0.5
= 46410.24 kgcm
= 42524.01 kgcm
Zxx of shaft = 33.67 cm3
Zpp of shaft = 67.35 cm3
C.S. area = 28.27 cm2
= 1262.96 kg/cm < 1957.19 kg./cm
= 689.09 kg./cm < 1957.19 kg./cm
= 88.75 kg./cm < 917.43 kg./cm
= 1147.54 kg./cm < 1957.19 kg./cm
= 381.75 kg./cm < 917.43 kg./cm
= 1324.4 kg./cm < 1957.19 kg./cm
i) BEARINGS
(i)For Shaft P1W2
= 130333.26 N
Hence safe
Hence safe
31 of 38
(JHARKHAND) Rev.:R0
(ii)For Shaft P2
= 56127.28 N

Cross Sectional Area of one bolt = 3.4x2^2x0.85/4= 2.67 cm
Hence safe
Hence safe
i) DESIGN KEY
PINION P1 & GEAR W2
Torque on P1W2 Shaft = 133965.61 kg-cm
Note: Design of key done based on shortes length
= 2X133965.61/(2.8X11X9)
= 966.56 kg/cm2 < 5056.07 kg/cm2
= 4X133965.61/(1.6X11X9)
= 3382.97 kg/cm2 < 5056.07 kg/cm2
PINION P2
Torque on P2 Shaft = 25710.57 kg-cm

= 2X25710.57/(2X7X9)
= 408.1 kg/cm2 < 5056.07 kg/cm2
= 4X25710.57/(1.2X7X9)
= 1360.35 kg/cm2 < 5056.07 kg/cm2
32 of 38
(JHARKHAND) Rev.:R0
Key for Coupling:

= 2X25710.57/(1.8X6.5X8.5)
= 517.06 kg/cm2 < 5056.07 kg/cm2
= 4X25710.57/(1.1X6.5X8.5)
= 1692.18 kg/cm2 < 5056.07 kg/cm2
j) Design of Connection Bolts for Wheel W1 and Rope Drum
Rope tension = 12800.53 kg
Total load on bolts = 12800.53x750/820 = 11707.8 kg
Load on each bolt = 11707.8/8 = 1463.48 kg
Shear stress in bolt = 1463.48/2.67 = 548.12 kg/cm2
0.3XY.S 0.3x400X100/(1.2 x9.81)= 1019.37 kg/cm2
Allowable Shear Stress = =
1.2 Hence safe.
11. DIAL CALCULATION:-
Total lift= 6.5 m
Drum circumference= 3.14x75 = 235.62 cm
Length of the rope winding = 6.5x2 = 13 m
No. of turn of drum for full lift = 13x100/235.62 = 5.52
No. of Rev. of P1W2 Shaft = 5.52x87/21 = 22.87
Provide 3 sets of pinions & gears as follows:-
Material of gears IS-2062
Material of pinions IS-2062
No. of Module/ PCD

teeth Pitch 50
st 59 3 177
1 Gearbox
1st Pinion 19 3 57
2nd Gearbox 73 3 219
2nd Pinion 19 3 57
3rd Gear 73 3 219

rd 19 3 57
3 Pinion
Sprocket 1 25 9.525 75.997
Sprocket 2 25 9.525 75.997
33 of 38
(JHARKHAND) Rev.:R0
Total reduction of Gear/Pinion/Sprocket = 59x73x73x25/(19x19x19x25) = 45.84
0
Total angle of movement of dial = 22.87x360/45.84 = 179.61
0
Movement of Dial needle for one meter lift = 179.61/6.5 = 27.6
MAKE: - Sprocket - Rol-kobo/SKF
Chain Rol-kobo/SKF
12. GATE PULLEY & BALANCING PULLEY:-
PULLEYS IS: 1030 Gr: 280-520 W
i)Gate Pulley (2 Nos. per side)

P.C.D. of pulley= 20 x rope dia. = 20x28 = 560 mm
Load / Pulley = 2x6410.26 = 12820.52 kg
Gate Pulley Pin IS: 1570 30Cr13 / AISI420
12820.52 kg
70 70
140 cm R2
R1
R1 = R2 = 6410.26 kg
Pin dia.= 100 mm
x 10^3
32
x 10^2
C.S. area = = 78.54 cm2
4
Max. B.M. = 6410.26x7 = 44871.82 kgcm

= 457.08 kg./cm < 1406.73 kg./cm
= 81.62 kg./cm < 1498.47 kg./cm
At B.D.T. Condition:-
Load / Pulley = 2x12800.53 = 25601.06 kg
R1 = R2 = 12800.53 kg
Max. B.M. = 12800.53x7 = 100535.36 kgcm
34 of 38
(JHARKHAND) Rev.:R0

= 1024.09 kg./cm < 3995.92 kg./cm
= 162.98 kg./cm < 3995.92 kg./cm
Design of Bush
Load on Sheave = 12820.52 kg
Shaft Dia. = 100 mm
= 11 mm
Length = 100 mm
Bearing stress in bush 12820.52/(10X10)
= = 128.21 < 260.958 kg/ cm2
Load on Sheave under BDT = 25601.06 kg
ii) Balancing Sheave IS: 1030 Gr: 280-520 W
P.C.D. of sheave= 20 x rope dia. = 20x28 = 560 mm
Wt. of Sheave = 175 kg. (Max.)

Vertical Load on Sheave= 175+6410.26
= 6585.26 kg
Horizontal load on sheave= 6410.26 kg
Resultant Load on Sheave= (6585.26^2+6410.26^2)^0.5
= 9190.05 kg
Sheave Pin IS:2004 Class 4
9190.05 kg
70 70
140 cm
R2
R1
R1 = R2 = 9190.05/2 = 4595.03 kg
Pin dia.= 100 mm
35 of 38
(JHARKHAND) Rev.:R0
x 10^3
32
x 10^2
C.S. area = = 78.54 cm2
4
Max. B.M. = 4595.03x7 = 32165.21 kgcm

= 327.65 kg./cm < 1264.02 kg./cm
= 58.51 kg./cm < 978.59 kg./cm
At B.D.T. Condition:-
Vertical Load on Sheave= 175+12800.53
= 12975.53 kg
Horizontal load on sheave= 12800.53 kg
Resultant Load on Sheave= (12975.53^2+12800.53^2)^0.5
= 18226.85 kg
R1 = R2 = 18226.85/2 = 9113.43 kg
Max. B.M. = 9113.43x7 = 63794.01 kgcm

= 649.83 kg./cm < 2609.58 kg./cm
= 232.07 kg./cm < 1223.24 kg./cm
Design of Bush
Load on Sheave = 9190.05 kg
Shaft Dia. = 100 mm
= 11 mm
Length = 100 mm
Load on Sheave under BDT = 0 kg
13. Design of cheek plate (Drum Shaft Supports)
Plate thickness = 25 mm
Shaft dia. at drum support = 160 mm
Bearing Stress = 10180.1/(16x2.5) = 254.5 kg./cm < 1671.76 kg./cm
At B.D.T. condition, bearing stress = 19451.82/(16x2.5) = 486.3 kg./cm
< 2223.44 kg./cm
36 of 38
(JHARKHAND) Rev.:R0
Design of weld of cheek plate with cross beam:-
Length of weld provided = 2x 40 + 40 = 120 cm
8 mm fillet weld
Weld Strength of 12 mm fillet weld in normal condition = 0.707x 1.2x (0.3 x 2550)
= 649.026 kg/cm
Weld Strength of 12 mm fillet weld in B.D.T. condition = 0.707 x 1.2 x (0.375 x 2550)
= 811.283 kg/cm
i) Load per unit length in Normal condition = 10180.1/120= 84.8342 kg/cm
< 649.026 kg/cm
ii) Load per unit length in B.D.T.condition = 19451.82/120= 162.1 kg/cm
< 811.283 kg/cm
14. Rotary Type Double acting Limit Switch:-
Mounted on P1 & W2
Total number of turns of rope drum for entire lift of operation is = 5.52
(87x5.52)
Rotation of P1 & W2 shaft for gear = = 22.87
21
No. of Pitch PCD
teeth
Sprocket 1 21 9.525 63.91
Sprocket 2 25 9.525 75.997
(22.87x21)
Rotation of rotary limit switch = = 19.2
25
Used Rotary Geared limit switch having Gear Ratio 40: 1,
Chain Rol-kobo/SKF
Limit Switch - Speed-O-Control/BCH
15. Manual Drive Mechanism:-
Load / Rope = 6410.26 kg
Torque on each drum = 6410.26x37.5 = 240384.75 kgcm
Torque on each cross shaft = 467555
240384.75x21x19/(87x99xeffy.
x (23/117) (21/98)/effy. Of
Ofdrum
drum&&end
endgears
gears)
= 240384.75x21x19/(87x99x0.95^3) = 12988.4 kgcm
Torque on output shaft of worm reducer = 12988.37x2 = 25976.74 kgcm
Torque on input shaft of worm reducer = 25976.74/(70xeff. Of worm reducer)
= 25976.74/(70x0.7348) = 505.03 kgcm
37 of 38
(JHARKHAND) Rev.:R0
No. of Pitch PCD
teeth
Sprocket 1 27 12.7 109.4
Sprocket 2 57 12.7 230.54
Radius of arm of hand lever = 400 mm = 40 cm

Now, force required on hand lever = 505.03x27/(40x57)
= 505.03x27/(40x57) = 5.98 kg
Two men required with total effort = 2 x100 = 200 N ( 20.38 Kg.)
Breaking load of 12.7 mm pitch chain = 2950 kg. (Ref. IS: 2403)
Lifting speed of gate = 24x27x3.14x0.75/(57x70x4.14x5.21x2)
= 0.0089 M/min
= 0.89 cm/min
Chain Rol-kobo/SKF
Limit Switch - Speed-O-Control/BCH
16. ROTARY ENCODERS: -
Arrangement of the rotary incoder to provide the signal for digital gate position indicator shall be
installed on the line shaft with the help of split type duplex sprocket. Digital gate position
indicator installed in the control panel located in the barrage control room. Digital gate position
indicator connected with transducer with the help of 4 core screened armoured cable.
ROTARY ENCODER: - ENC- 50/6-360 ABZ/8-30V
COUPLING: - AHC 14-20 6X6
DISITAL READOUTS: - CH-A
Make: Encoder India / Vidyut Industries
38 of 38
DESIGN OF HOIST SUPPORTING
STRUCTURE FOR 25T ROPE
DRUM HOIST
BARRAGE GATE
North Karanpura(660MWx3)
(JHARKHAND)
DOCUMENT No.- 4410-301B-PVH-U-003

DESIGN OF HOIST SUPPORTING STRUCTURE FOR
(JHARKHAND) Rev.:R0
1. Description
Hoist Capacity = 25 T
Crowd Load = 500 kg/m2
Weight of Chequered Plate = 47.1 kg/m2
Impact Factor = 1.32
BDT Factor = 2.75
2. Mechanical Strength of Proposed Materials
Y.P
Material Material Specification
(Kg/cm2)
Structural Steel
upto 20th. 2548
IS:2062, Gr.-A & B
Over 20 upto 40th. 2446
Over 40th. 2344
Material for Structure IS:2062 Gr.-A & B ( Reference IS: 800 / 1984 )
Allowable Bending stress = 0.66 x 2548 = 1681 Kg/cm2
2
Allowable shear stress = 0.4 x 2548 = 1146 Kg/cm
Allowable Bearing stress = 0.75 x 2548 = 1911 Kg/cm2
BDT Condition = 0.8 x 2548 = 2038 Kg/cm2
Bolts
Bolts provided as per IS-1367, Cl.-4.6
YS of bolt is 240 N/mm2.
0.3XY.S 0.3x240X100/(1.2 x9.81)= 611.62 kg/cm2
1.2
BDT Condition = 0.8x2446.48 = 1957.19 Kg/cm2
0.3XY.S 0.3x400X100/(1.2 x9.81)= 1019.37 kg/cm2
1.2
0.3XY.S 0.3x480X100/(1.2 x9.81)= 1223.24 kg/cm2
1.2
3. Loads at different locations
3.1 Loads & Self Weight for Rope Drum Hoist Arrangement
Normal Condition BDT Condition With Impact
Rope Tension = 6410.26 kg 12800.53 kg 8461.5432 kg
A = 7507.85 kg A = 14497.69 kg A = 9910.36 kg
B = 10180.1 kg B = 19451.82 kg B = 13437.73 kg
C = 4588.98 kg C = 8857.17 kg C = 6057.45 kg
D = 3218.8 kg D = 6215.36 kg D = 4248.82 kg
E = 661.02 kg E = 1305.3 kg E = 872.55 kg
F = 1270.54 kg F = 2508.95 kg F = 1677.11 kg
G = 9190.05 kg G = 18226.85 kg G = 12130.87 kg
1 of 22
(JHARKHAND) Rev.:R0
3.2 Self Weight for Rope Drum Hoist
Self weight of the Rope drum Assembly = 2000 kg
(Excluding weight of rope drum, gears, pinions, overload arrangements as the same has already
included in the reaction at various location of hoist)
Self weight per unit length of the rope drum Assembly= 2000/(6.35) = 314.96 Kg/m
(Note: 8.687m is perimeter of the base frame for the hoist supporting structure of rope drum assembly)
Self weight of Drive Unit Assembly = 1000 kg
Self weight per unit length of the Drive Unit Assembly = 1000/5.55
= 180.18 Kg/m
(Note: 8.801m is perimeter of the base frame for central drive unit assembly)
4. Layout of the Hoisting Arrangement of the Rope Drum Hoist
Hoist platform is assembly of the beams having load bearing beams number A to K. Others beams for
have also been provided in open space to support chequered plate. Details of the same same not shown
in the layout.
Location Location of
of Leg Leg
Beam :J
E2 G2 H2 I2 I2 H2 G2 E2
J1
J1
375
Balancing
Sheave
C/L of
D1 Beam :H Beam :D
D2 D2 D1
925
Beam :G Beam :E
C/L of Rope B C/L of Rope
A Drum
B Drum A
FLOW
488
2600
Beam :F
375
G C/G of F1 G
F2 F2
A1 F1 Gate A1
83 C1 C2 C2 Beam :C
C/L of P1W2 C1
C D Shaft D C
472 Beam :A
794
C/L of P2
E F Shaft Beam :I F E
B1 B1
B2 B2
132 A2 Beam :B A2
423 450
Beam :K
K1 H1 I1 I1 H1 G1 E1
E1 G1
1800 1025 750 1900 550 1900 750 1025 1800 K2
Lay of Hoist Bridge

5. Design of Beam : A
550.16 kg/m
C E
A1 A2
190 472 132 #
794
Self Weight of Beam A = 18 kg/m
Load due to self weight of chequered plate and crowd load =(500+47.1)X0.4= 217.2 kg/m
Load due to self weight of the Rope Drum Assembly & Beam = 18+314.96= 332.96 kg/m
Total UDL Load = 217.2+332.96 = 550.16 kg/m
2 of 22
(JHARKHAND) Rev.:R0
Load, Stress & Deflection in beam A under Impact loading
Reaction at A1 = (6057.45X604+872.55X132+0.55016X794^2/2)/794
= 4971.41 kg = 4.97 T
Reaction at A2 = 6057.45+872.55+0.55016X794-4971.41
= 2395.42 kg = 2.40 T 371.7
Maximum bending moment = 4971.41X19-550.16X0.19X9.5 = 93463.8 kgcm
ISMC = 300 75
Area of Beam = 28.5 cm2 11.4
2
Area of web = 10.99 cm
Ixx = 1830 cm4 6.2
4
Iyy = 141 cm
200
Zxx = 181 cm3
Zyy = 26.4 cm3
D = 200 mm 13.6
T = 11.4 mm
L = 79.4 cm
rx = 8.02 cm
ry = 2.2 cm
d1 = 20 cm
t = 0.62 cm
d1/t = 32.3 < 85.00 Hence stiffners are not required
Refer Table 6.1 B - IS :800-1984 D/T = 17.5 L/ry = 36.09
( On conservative side )
2
Permissible bending stress = 1632 kg/cm
As per IS:800 Cl. No.-6.2.3
Bending Stress on Beam A= 93463.75/181
= 516.37 kg/cm2 < 1632 kg/cm2 SAFE
Shear Stress on Beam A = 4971.41/10.99
= 452.36 kg/cm2 < 1146 kg/cm2 SAFE
Deflection of the Beam A
d= (79.4^3/(2.1X10^6X1830))X((5X550.2X0.79/384)+(6057.5/48)X(3X190/794-4X(190/794)^3)
+(872.55/48)X(3X662/794-4X(662/794)^3)
d= 0.01 cm
Permissible Deflection = L/800 = 0.1 cm SAFE
Load & Stress in beam A under BDT Condition

Reaction at A1 = (8857.17X604+1305.3X132+0.55016X794^2/2)/794
= 7173.11 kg = 7.17 T
Reaction at A2 = 8857.17+1305.3+0.55016X794-7173.11
= 3426.19 kg
= 3.43 T
Maximum bending moment = 7173.11X19-550.16X0.19X9.5
= 93692.01 kgcm
Bending Stress on Beam A= 93692.01/181
= 517.64 kg/cm2 < 2170.56 kg/cm2 SAFE
Shear Stress on Beam A = 7173.11/10.99
= 652.69 kg/cm2 < 1524.18 kg/cm2 SAFE
Thermal Expansion of the beam = 0.000012XDTXL (As per IS:800 CL. No.-3.3.4)
DT = 25
L = 794 mm
2
E = 2140672.78 kg/cm
Thermal Expansion of the beam = 0.24 mm
3 of 22
(JHARKHAND) Rev.:R0
Welding :-
Max. shear force on the Beam = 7173.11 kg
Length of the Weld = 180 mm
Fillet size is 6 mm, Shear area = 18X0.6X0.707X2 = 15.27 cm2
Stress= 7173.11/15.27
= 469.75 kg/cm2 < 2038 kg/cm2 SAFE
6. Design of Beam : BB
Load, Deflection & Stress in beam BB under Normal Condition
687.87 kg/m
A2
B1 B2
575 450
1025
Self Weight of Beam BB = 40 kg/m

Load due to self weight of chequered plate and crowd load = (500+47.1)X(0.6085)
= 332.91 kg/m
Load due to self weight of the Base Frame & Cover = 40+314.96
= 354.96 kg/m
Load & Stress in beam BB under Impact loading
Reaction at B1 = (2395.42X450+0.68787X1025^2/2)/1025
= 1404.18 kg = 1.40 T
Reaction at B2 = 2395.42+0.68787X1025-1404.18
= 1696.31 kg = 1.70 T
Section of Beam BB ISMC 300 X 90 X 7.8
Area of web = 21.28 cm2 D 300 mm
Ixx = 6420 cm4 T 13.6 mm
3
Zxx = 428 cm L 103 cm
ry 2.6 cm
D/T 22.06 L/ry 39.42
Permissible bending stress = 1621.8 kg/cm2
Bending Stress on Beam BB= 69369.27/428
= 162.08 kg/cm2 < 1621.8 kg/cm2 SAFE
Shear Stress on Beam BB = 1696.31/21.28
= 79.71 kg/cm2 < 1146 kg/cm2 SAFE
Deflection of the Beam BB
d= (102.5^3/(2.1X10^6X6420))X((5X687.9X1.025/384)+(2395.4/48)X(3X450/1025-4X(450/1025)^3))
d= 0.00 cm
As per IS :807
Permissible deflection = L/800 = 0.13 cm SAFE
Load & Stress in beam BB under BDT Condition
Reaction at B1 = (3426.19X450+0.68787X1025^2/2)/1025
= 1856.71 kg
= 1.86 T
Reaction at B2 = 3426.19+0.68787X1025-1856.71
= 2274.55 kg
= 2.27 T
4 of 22
(JHARKHAND) Rev.:R0
= 95390.07 kgcm
Bending Stress on Beam BB= 95390.07/428
= 222.87 kg/cm2 < 2156.99 kg/cm2 SAFE
Shear Stress on Beam BB = 2274.55/21.28
= 106.89 kg/cm2 < 1524.18 kg/cm2 SAFE
DT = 25
L = 1025 mm
2
E = 2140672.78 kg/cm
Welding :-
Stress= 1696.31/21.21
= 79.98 kg/cm2 < 1621.8 kg/cm2 SAFE
7. Design of Beam : CC
Load, Deflection & Stress in beam CC under Normal Condition
687.87 kg/m
A1
C1 C2
575 450
1025
Self Weight of Beam CC = 40 kg/m

Load due to self weight of chequered plate and crowd load = (500+47.1)X(0.6085)
= 332.91 kg/m
= 354.96 kg/m
Load & Stress in beam CC under Impact loading
Reaction at C1 = (4971.41X450+0.68787X1025^2/2)/1025
= 2535.1 kg = 2.54 T
Reaction at C2 = 4971.41+0.68787X1025-2535.1
= 3141.38 kg = 3.14 T
Section of Beam CC ISMC 300 X 90 X 7.8
Area of web = 21.28 cm2 D 300 mm
Ixx = 6420 cm4 T 13.6 mm
3
Zxx = 428 cm L 103 cm
ry 2.6 cm
D/T 22.06 L/ry 39.42
Bending Stress on Beam CC= 134397.42/428
= 314.01 kg/cm2 < 1621.8 kg/cm2 SAFE
Shear Stress on Beam CC = 3141.38/21.28
2 2
= 147.62 kg/cm < 1146 kg/cm SAFE
5 of 22
(JHARKHAND) Rev.:R0
Deflection of the Beam CC
d= (102.5^3/(2.1X10^6X6420))X((5X687.9X1.025/384)+(4971.4/48)X(3X450/1025-4X(450/1025)^3))
d= 0.01 cm
As per IS :807
Permissible deflection = L/800 = 0.13 cm SAFE
Load & Stress in beam CC under BDT Condition
Reaction at C1 = (7173.11X450+0.68787X1025^2/2)/1025
= 3501.7 kg = 3.50 T
Reaction at C2 = 7173.11+0.68787X1025-3501.7
= 4376.48 kg = 4.38 T
= 189976.92 kgcm
Bending Stress on Beam CC= 189976.92/428
= 443.87 kg/cm2 < 2156.99 kg/cm2 SAFE
Shear Stress on Beam CC = 4376.48/21.28
= 205.66 kg/cm2 < 1524.18 kg/cm2 SAFE
DT = 25
L = 1025 mm
E = 2140672.78 kg/cm2
Welding :-
Stress= 3141.38/21.21
2 2
= 148.11 kg/cm < 1621.8 kg/cm SAFE
8. Design of Beam : D
457.54 kg/m
D1 D2
1025
Self Weight of Beam D = 40 kg/m

Load due to self weight of chequered plate and crowd load = (500+47.1)X0.1875
= 102.58 kg/m
= 354.96 kg/m
Load, Stress & Deflection in beam D
Reaction at D1 = (0.45754X1025^2/2)/1025
= 234.49 kg = 0.23 T
Reaction at D2 = 0.45754X1025-234.49
= 234.49 kg = 0.23 T
6 of 22
(JHARKHAND) Rev.:R0
Maximum bending moment = 234.49X51.25-457.54X0.5125X25.625
= 6008.83 kgcm
ISMC = 300 90
2
Area of Beam = 46.3 cm 13.6
Area of web = 21.28 cm2
Ixx = 6420 cm4 7.8
4
Iyy = 313 cm
300
3
Zxx = 428 cm
Zyy = 47.1 cm3
D = 300 mm 13.6
T = 13.6 mm
L = 102.5 cm
rx = 11.8 cm
ry = 2.6 cm
d1 = 30 cm
t = 0.78 cm
Bending Stress on Beam D = 6008.83/428
= 14.04 kg/cm2 < 1621.8 kg/cm2 SAFE
Shear Stress on Beam D = 234.49/21.28
= 11.02 kg/cm2 < 1146 kg/cm2 SAFE
Deflection of the Beam D
d= (102.5^3/(2.1X10^6X6420))X((5X457.5X1.03/384)+(4971.4/48)X(3X/1025-4X(/1025)^3)
d= 0.0000 cm
2
DT = 25 L = 1025 mm E = 2140672.78 kg/cm
Welding :-
Length of Weld = 250 mm
Stress = 234.49/20.36
= 11.52 kg/cm2 < 2038 kg/cm2 SAFE
9. Design of Beam : E
1163 kg/m
B1 C1 A D1
E1 E2 500
423 794 458 550 375
2600
Self Weight of Beam E = 75 kg/m
= 772.78 kg/m
Load due to self weight of Rope Drum Assembly & Beam = = 75+314.96 = 389.96 kg/m
Load, Stress & Deflection in beam E under Impact loading
Reaction at E1 = (1404.2X2177+2535.1X1383+9910.36X925+234.49X375-1.163X2600^2/2)/2600
7 of 22
(JHARKHAND) Rev.:R0
= 4571.95 kg = 4.57 T
Reaction at E2 = 1404.18+2535.1+9910.36+234.49+1.16274X2600-4571.95
= 12535.30 kg = 12.54 T
Maximum bending moment = 12535.3X92.5-234.49X37.5-1162.74X0.925X46.25
= 1100978.4 kgcm 250
Area of Beam = 92.6 cm2 12
4
Ixx = 20030.96 cm 10
Iyy = 3127.72 cm4
326
Zxx = 1144.63 cm3
Zyy = 250.22 cm3
D = 350 mm 12
T = 12 mm
L = 260 cm
rx = 14.71 cm
ry = 5.81 cm
d1 = 32.6 cm
t = 1 cm
T/t = 1.2 < 2.00
Le= 0.85x2600/10 cm = 221 cm
Le/ry= 221/5.81
= 38.04
Y = 26.5 10 5
2
Le
r
y
= 26.5X10^5/(38.04^2)
= 1831.32 Mpa
fcb = 1831.32 Mpa
fy = 250 Mpa
Permissible bending stress
f cb f y
f bc 0.66 1.4
(f cb f y1.4 )1 1.4
= 0.66X1831.32X250/((1831.32^1.4+250^1.4)^(1/1.4))
= 158.11 Mpa
= 1611.72 kg/cm2
Bending Stress on Beam E= 1100978.4/1144.63
= 961.86 kg/cm2 < 1611.72 kg/cm2 SAFE
Shear Stress on Beam E = 12535.3/32.6
= 384.52 kg/cm2 < 1146 kg/cm2 SAFE
Deflection of the Beam E between supports
d= (260^3/(2.1X10^6X20031))X(((5X1162.7X2.6/384)+(1404.2/48)X(3X423/2600-4X(423/2600)^3)
+(2535.1/48)X(3X1217/2600-4X(1217/2600)^3)+(9910.36/48)X(3X1675/2600-4X(1675/2600)^3)
+(234.49/48)X(3X2225/2600-4X(2225/2600)^3)
d= 0.12 cm
8 of 22
(JHARKHAND) Rev.:R0
Load & Stress in beam E under BDT Condition
Reaction at E1 = (1856.7X2177+3501.7X1383+14497.69X925+234.49X375-1.163X2600^2/2)/2600
= 7097.02 kg = 7.10 T
Reaction at E2 = 1856.71+3501.7+14497.69+234.49+1.16274X2600-7097.02
= 23106.62 kg = 23.11 T
Maximum bending moment = 23106.62X92.5-234.49X37.5-1162.74X0.925X46.25
= 2078825.5 kgcm
Bending Stress on Beam E = 2078825.5/1144.63
2 2
= 1816.16 kg/cm < 2143.59 kg/cm SAFE
Shear Stress on Beam E = 23106.62/32.6
= 708.79 kg/cm2 < 2038 kg/cm2 SAFE
DT = 25
L = 2600 mm
E = 2140672.78 kg/cm2
Welding :-
2
Fillet size is 6 mm, Shear area = 32.6X0.6X0.707X2 = 27.66 cm
Stress = 23106.62/27.66
= 835.38 kg/cm2 < 2038 kg/cm2 SAFE
10. Design of Beam : F
150 kg/m
G
F1 F2
262 488
750
Self Weight of Beam F = 150 kg/m

Total UDL Load = 150 kg/m
Load, Stress & Deflection in beam FF under Impact loading
Reaction at F1 = (12130.866X488+0.15X750^2/2)/750
= 7949.4 kg = 7.95 T
Reaction at F2 = 12130.866+0.15X750-7949.4
= 4293.97 kg = 4.29 T
Maximum bending moment = 4293.97X48.8-150X0.488X24.4
= 207759.66 kgcm
316
2
Area of web = 50 cm
Ixx = 10820.99 cm4 10
Iyy = 8922.93 cm4
250
Zxx = 708.41 cm3 156

Zyy = 564.74 cm3
D = 270 mm 10 10
T = 10 mm
L = 75 cm 90
rx = 10.42 cm
ry = 9.47 cm
d1 = 25 cm
9 of 22
(JHARKHAND) Rev.:R0
t = 1 cm
Le= 0.85x750/10 cm
= 63.75 cm
Le/ry= 63.75/9.47
= 6.73
26.5 10 5
Y = 2
Le
r
y
= 26.5X10^5/(6.73^2) = 58508.07 Mpa

fcb = 58508.07 Mpa
fy = 250 Mpa
f cb f y
f bc 0.66 1.4
(f cb f y1.4 )1 1.4
= 0.66X58508.07X250/((58508.07^1.4+250^1.4)^(1/1.4))
2
= 164.94 Mpa = 1681.35 kg/cm
Bending Stress on Beam FF = 207759.66/708.41
2 2
= 293.28 kg/cm < 1681.35 kg/cm SAFE
Shear Stress on Beam FF = 7949.4/50
= 158.99 kg/cm2 < 1146 kg/cm2 SAFE
Deflection of the Beam FF
d= (75^3/(2.1X10^6X10821))X((5X150X0.75/384)+(12130.9/48)X(3X262/750-4X(262/750)^3))
d= 0 cm
Load & Stress in beam FF under BDT Condition
Reaction at FF1 = (18226.85X488+0.15X750^2/2)/750
= 11915.85 kg = 11.92 T
Reaction at FF2 = 18226.85+0.15X750-11915.85
= 6423.50 kg = 6.42 T
Maximum bending moment = 6423.5X48.8-150X0.488X24.4
= 311680.72 kgcm
Bending Stress on Beam FF= 311680.72/708.41
2 2
= 439.97 kg/cm < 2236.2 kg/cm SAFE
Shear Stress on Beam FF = 11915.85/50
= 238.32 kg/cm2 < 1527.618 kg/cm2 SAFE
DT = 25
L = 750 mm
E = 2140672.78 kg/cm2
10 of 22
(JHARKHAND) Rev.:R0
Welding :-
Stress = 11915.85/42.42
= 280.9 kg/cm2 < 2038 kg/cm2 SAFE
Supporting Bracket for Equaliser Sheave
Load on each Equalizer Sheave Bracket under Impact condition = 6065.43 kg
Proposed Sheave Bracket of Width: 300 mm

Thickness: 16 mm , Height: 500 mm
200
Pin Diameter = 100 mm
Shear Stress = 6065.43/(2X1.6X8)
500
= 236.93 kg/cm2
2
< 1146 kg/cm SAFE
130
Bearing Stress = 6065.43/(1.6X10)
= 379.09 kg/cm2
2
< 1911 kg/cm SAFE 16 300
Tensile Stress at Minimum Crosssection = 6065.43/((30-10)X1.6)
= 189.54 kg/cm2
< 1681 kg/cm2 SAFE
Load on each Equaliser Sheave Bracket under BDTcondition = 9113.43 kg
Shear Stress = 9113.43/(2X1.6X8)
= 113.92 kg/cm2 < 2038 kg/cm2 SAFE
Bearing Stress = 9113.43/(1.6X10)
2
= 569.59 kg/cm2 < 2038 kg/cm SAFE
Tensile Stress at Minimum Crosssection = 9113.43/((30-10)X1.6)
= 284.79 kg/cm2
< 2038 kg/cm2 SAFE
Welding :-
Max. shear force on the Bracket Plate= 9113.43 kg
Fillet size is 6 mm, Shear area = 20X0.6X0.707X2+30X0.6X0.707 = 29.69 cm2
Stress = 9113.43/29.69
= 306.95 kg/cm2 < 1146 kg/cm2 SAFE
11. Design of Beam :G
876 kg/m
B2 F D C2 F2 B D2
G1 G2
423 132 472 190 83 375 550 375
2600
Self Weight of Beam G = 75 kg/m
= 485.55 kg/m
Load due to self weight of Rope Drum Assembly & Beam = = 75+314.96
= 389.96 kg/m
11 of 22
(JHARKHAND) Rev.:R0
Load, Stress & Deflection in beam G under Impact loading
Reaction at G1= (1696.3X2177+1677.1X2045+4248.8X1573+3141.4X1383+4293.97X1300
+13437.73X925+234.49X375+0.87551X2600^2/2)/2600
= 15080.65 kg = 15.08 T
Reaction at G2 1696.31+1677.11+4248.82+3141.38+4293.97+13437.73+234.49+0.87551X2600-
= 15080.65
= 15925.49 kg = 15.93 T
Maximum bending moment = 15925.49X92.5-234.49X37.5-0.87551X925X46.25
= 1426859.04 kgcm
Section of Beam at Center 250
Ixx = 20030.96 cm4 10
4
Iyy = 3127.72 cm
326
3
Zxx = 1144.63 cm
Zyy = 250.22 cm3
D = 350 mm 12
T = 12 mm
L = 260 cm
rx = 14.71 cm
ry = 5.81 cm
d1 = 32.6 cm
t = 1 cm
T/t = 1.2 < 2.00
Le= 0.85x2600/10 cm
= 221 cm
Le/ry= 221/5.81
= 38.04
Y = 26.5 10 5
2
Le
r
y
= 26.5X10^5/(38.04^2)
= 1831.32 Mpa
fcb = 1831.32 Mpa
fy = 250 Mpa
f cb f y
f bc 0.66 1.4
(f cb f y1.4 )1 1.4
= 0.66X1831.32X250/((1831.32^1.4+250^1.4)^(1/1.4))
= 158.11 Mpa
= 1611.72 kg/cm2
Bending Stress on Beam G= 1426859.04/1144.63
= 1246.57 kg/cm2 < 1611.72 kg/cm2 SAFE
Shear Stress on Beam G = 15925.49/32.6
2 2
= 488.51 kg/cm < 1146 kg/cm SAFE
12 of 22
(JHARKHAND) Rev.:R0
Deflection of the Beam G
d= (260^3/(2.1X10^6X20031))X(((5X875.5X2.6/384)+(1696.3/48)X(3X423/2600-4X(423/2600)^3)
+(1677.11/48)X(3X555/2600-4X(555/2600)^3)+(4248.82/48)X(3X1027/2600-4X(1027/2600)^3)
+(3141.38/48)X(3X1217/2600-4X(1217/2600)^3)+(4293.97/48)X(3X1300/2600-4X(1300/2600)^3)
+(13437.73/48)X(3X1675/2600-4X(1675/2600)^3+(234.49/48)X(3X2225/2600-4X(2225/2600)^3)
d= 0.23 cm
Load & Stress in beam Funder BDT Condition
Reaction at G1= (2274.6X2177+2509X2045+6215.4X1573+4376.5X1383+6423.5X1300
+19451.82X925+234.49X375+0.87551X2600^2/2)/2600
= 21270.22 kg = 21.27 T
Reaction at G2 2274.55+2508.95+6215.36+4376.48+6423.5+19451.82+234.49+0.87551X2600-
= 21270.22
= 22491.26 kg = 22.49 T
Maximum bending moment = 22491.26X92.5-234.49X37.5-0.87551X925X46.25
= 2034192.76 kgcm
Bending Stress on Beam G = 2034192.76/1144.63
= 1777.16 kg/cm2 < 2143.59 kg/cm2 SAFE
Shear Stress on Beam G = 22491.26/32.6
2 2
= 689.92 kg/cm < 2038 kg/cm SAFE
DT = 25
L = 2600 mm
E = 2140672.78 kg/cm2
Welding :-
Fillet size is 6 mm, Shear area = 32.6X0.6X0.707X2 = 27.66 cm2
Stress = 22491.26/27.66
2 2
= 813.13 kg/cm < 1146 kg/cm SAFE
12. Design of Beam : H
774.91 kg/m
F1
H1 H2
1300 1300
2600
Self Weight of Beam H = 50 kg/m
= 724.91 kg/m
Total UDL Load = 50+724.91 = 774.91 kg/m
Load, Stress & Deflection in beam H under Impact loading
Reaction at H1 = (7949.4X1300+0.77491X2600^2/2)/2600
= 4982.08 kg = 4.98 T
Reaction at H2 = 7949.4+0.77491X2600-4982.08
= 4982.09 kg = 4.98 T
Maximum bending moment = 4982.08X130-774.91X1.3X65
= 582190.51 kgcm
13 of 22
(JHARKHAND) Rev.:R0
ISMC = 300 140
2
Area of Beam = 58.6 cm 13.1
Ixx = 8990 cm4 7.7
Iyy = 486 cm4
300
Zxx = 599 cm3
3
Zyy = 69.5 cm
D = 300 mm
T = 13.1 mm
L = 260 cm
rx = 12.4 cm
ry = 2.86 cm
d1 = 30 cm 13.1
t = 0.77 cm
Bending Stress on Beam HH= 582190.51/708.41
= 821.83 kg/cm2 < 1336.2 kg/cm2 SAFE
Shear Stress on Beam HH = 4982.09/50
2 2
= 99.64 kg/cm < 1146 kg/cm SAFE
Deflection of the Beam HH between supports
d= (260^3/(2.1X10^6X10821))X((5X774.9X2.6/384)+(4982.1/48)X(3X1300/2600-4X(1300/2600)^3)
d= 0.12 cm
Load & Stress in beam HH under BDT Condition
Reaction at H1 = (11915.85X1300+0.77491X2600^2/2)/2600
= 6965.31 kg = 6.97 T
Reaction at H2 = 11915.85+0.77491X2600-6965.31
= 6965.31 kg = 6.97 T
Maximum bending moment = 6965.31X130-774.91X1.3X65
= 840010.41 kgcm
Bending Stress on Beam HH = 840010.41/599
= 1402.35 kg/cm2 < 1777.15 kg/cm2 SAFE
Shear Stress on Beam HH = 6965.31/23.1
2 2
= 301.53 kg/cm < 2038 kg/cm SAFE
DT = 25
L = 2600 mm
E = 2140672.78 kg/cm2
Welding :-
Stress= 6965.31/15.27
2 2
= 456.14 kg/cm < 1146 kg/cm SAFE
14 of 22
(JHARKHAND) Rev.:R0
13. Design of Beam : I
Load, Deflection & Stress in beam II

922.78 kg/m
I1 I2
2600
Self Weight of Beam II = 72.4 kg/m

= 670.2 kg/m
Load due to self weight of the CDU = 72.4+180.18
= 252.58 kg/m
Load, Stress & Deflection in beam II under Self Weight
Total UDL Load = 670.2+252.58
= 922.78 kg/m = 9.23 kg/cm
ISMc = 300
Area of Beam = 46.3 cm2
Ixx = 6420 cm4
Iyy = 313 cm4 90
3
Zxx = 428 cm 13.6
3
Zyy = 47.1 cm
D = 300 mm 7.8
T = 13.6 mm
300
L = 260 cm
rx = 11.8 cm
ry = 2.6 cm 14
d1 = 30 cm
t = 0.78 cm
Maximum bending moment = 9.23X260^2/8 = 77993.5 kgcm
Bending Stress on Beam II= 77993.5/428
2 2
= 182.23 kg/cm < 1305.6 kg/cm SAFE
Shear Stress on Beam II = 9.23X260/21.28
= 112.77 kg/cm2 < 1146 kg/cm2 SAFE
Deflection of the Beam II
d= (260^3/(2.1X10^6X6420))X((5X922.8X2.6/384)
d= 0.040 cm
DT = 25
L = 2600 mm
E = 2140672.78 kg/cm2
15 of 22
(JHARKHAND) Rev.:R0
Welding :-
Stress= 2399.228/21.21
= 113.12 kg/cm2 < 1146 kg/cm2 SAFE
14. Design of Beam :J
322 kg/m
G2 H2 I2 I2 H2 G2 E2
E2
J1 J2
1800 1025 750 1900 550 1900 750 1025 1800

11500
Self Weight of Beam J = 322 kg/m

Total UDL Load = 322 kg/m = 322 kg/m
Load, Stress & Deflection in beam J under Impact loading
Reaction at J1= (12535.3X9700+15925.5X8675+4982.1X7925+1199.6X6025+1199.6X5475
+4982.09X3575+15925.49X2825+12535.3X1800+0.322X11500^2/2)/11500
= 36493.99 kg = 36.49 T
Reaction at J2= 12535.3+15925.5+4982.1+1199.6+1199.6+4982.09+15925.49+12535.3+3703-
36493.99
= 36494.00 kg = 36.49 T
Maximum bending moment = 36494X575-12535.3X395-15925.49X292.5-4982.09X217.5-
1199.614X27.5-322X5.75X287.5
= 9725500.47 kgcm 400
2
Area of Beam = 368 cm 25
Area of web = 168 cm2
Ixx = 674385.42 cm4 16
cm4
1050
Iyy = 26702.51
3
Zxx = 12261.55 cm
Zyy = 1335.13 cm3
D = 1100 mm 25
T = 25 mm
L = 1150 cm
rx = 42.81 cm
ry = 8.52 cm
d1 = 105 cm
t = 1.6 cm
D/T = 44.0 L/ry = 134.98
Le= 0.85x11500/10 cm
= 977.5 cm
Le/ry= 977.5/8.52
= 114.7
26.5 10 5
Y = 2
Le
r
y
= 26.5X10^5/(114.73^2)
= 201.32 Mpa
16 of 22
(JHARKHAND) Rev.:R0
fcb = 201.32 Mpa
fy = 250 Mpa
f cb f y
f bc 0.66
(f cb1.4 f y1.4 )1 1.4
= 0.66X201.32X250/((201.32^1.4+250^1.4)^(1/1.4))
= 89.51 Mpa
= 912.44 kg/cm2
Bending Stress on Beam J= 9725500.47/12261.55
= 793.17 kg/cm2 < 912.44 kg/cm2 SAFE
Shear Stress on Beam J = 36494/368
= 99.17 kg/cm2 < 1146 kg/cm2 SAFE
Deflection of the Beam J
d= (1150^3/(2.1X10^6X674385.4))X(((5X322X11.5/384)+(12535.3/48)X(3X1800/11500-4X(1800/11500)^3)
+(15925.49/48)X(3X2825/11500-4X(2825/11500)^3)+(4982.09/48)X(3X3575/11500-4X(3575/11500)^3)
+(1199.61/48)X(3X5475/11500-4X(5475/11500)^3)+(1199.61/48)X(3X6025/11500-4X(6025/11500)^3)
+(4982.09/48)X(3X7925/11500-4X(7925/11500)^3)+(15925.49/48)X(3X8675/11500-4X(8675/11500)^3)
+(12535.3/48)X(3X9700/11500-4X(9700/11500)^3)
d= 0.88 cm
Load & Stress in beam J under BDT Condition
Reaction at J1= (23106.6X9700+22491.3X8675+6965.3X7925+1199.6X6025+1199.6X5475
+6965.31X3575+22491.26X2825+23106.62X1800+0.322X11500^2/2)/11500
= 55614.3 kg = 55.61 T
23106.6+22491.3+6965.3+1199.6+1199.6+6965.31+22491.26+23106.62+3703-
Reaction at J2 = 55614.3
= 55614.31 kg = 55.61 T
Maximum bending moment = 55614.3X575-23106.62X395-22491.26X292.5-6965.31X217.5-
1199.614X27.5-322X5.75X287.5
= 14192169.24 kgcm
Bending Stress on Beam J = 14192169.24/12261.55
= 1157.45 kg/cm2 < 1213.55 kg/cm2 SAFE
Shear Stress on Beam J = 55614.31/168
= 331.04 kg/cm2 < 2038 kg/cm2 SAFE
DT = 25
L = 11500 mm
E = 2140672.78 kg/cm2
Welding :-
Max. shear force on the Beam= 55614.31 kg
Stress = 55614.31/78.48
2 2
= 708.64 kg/cm < 1146 kg/cm SAFE
17 of 22
(JHARKHAND) Rev.:R0
15. Design of Beam :K
322 kg/m
G1 H1 I1 I1 H1 G1 E1
E1
K1 K2
1800 1025 750 1900 550 1900 750 1025 1800
11500
Self Weight of Beam K = 322 kg/m
Total UDL Load = 322 kg/m
= 322 kg/m
Load, Stress & Deflection in beam K under Impact loading
Reaction at K1= (4572X9700+15080.7X8675+4982.1X7925+1199.6X6025+1199.6X5475
+4982.08X3575+15080.65X2825+4571.95X1800+0.322X11500^2/2)/11500
= 27685.79 kg = 27.69 T
Reaction at K2= 4572+15080.7+4982.1+1199.6+1199.6+4982.08+15080.65+4571.95+3703-27685.79
= 27685.80 kg = 27.69 T
1199.614X27.5-322X5.75X287.5
= 8053426.59 kgcm
400
2
Area of Beam = 368 cm 25
Area of web = 168 cm2
4
Ixx = 674385.42 cm 16
4
1050
Iyy = 26702.51 cm
Zxx = 12261.55 cm3
Zyy = 1335.13 cm3
D = 1100 mm 25
T = 25 mm
L = 1150 cm
rx = 42.81 cm
ry = 8.52 cm
d1 = 105 cm
t = 1.6 cm
D/T = 44.0 L/ry = 134.98
Le= 0.85x11500/10 cm
= 977.5 cm
Le/ry= 977.5/8.52
= 114.7
26.5 10 5
Y = 2
Le
r
y
= 26.5X10^5/(114.73^2)
= 201.32 Mpa
fcb = 201.32 Mpa
fy = 250 Mpa
18 of 22
(JHARKHAND) Rev.:R0
f cb f y
f bc 0.66 1.4
(f cb f y1.4 )1 1.4
= 0.66X201.32X250/((201.32^1.4+250^1.4)^(1/1.4))
= 89.51 Mpa
= 912.44 kg/cm2
Bending Stress on Beam K= 8053426.59/12261.55
= 656.8 kg/cm2 < 912.44 kg/cm2 SAFE
Shear Stress on Beam K = 27685.8/368
= 75.23 kg/cm2 < 1146 kg/cm2 SAFE
Deflection of the Beam K
d= (1150^3/(2.1X10^6X674385.4))X(((5X322X11.5/384)+(4572/48)X(3X1800/11500-4X(1800/11500)^3)
+(15080.65/48)X(3X2825/11500-4X(2825/11500)^3)+(4982.08/48)X(3X3575/11500-4X(3575/11500)^3)
+(1199.61/48)X(3X5475/11500-4X(5475/11500)^3)+(1199.61/48)X(3X6025/11500-4X(6025/11500)^3)
+(4982.08/48)X(3X7925/11500-4X(7925/11500)^3)+(15080.65/48)X(3X8675/11500-4X(8675/11500)^3)
+(4571.95/48)X(3X9700/11500-4X(9700/11500)^3)
d= 0.75 cm
Load & Stress in beam K under BDT Condition
Reaction at K1= (7097X9700+21270.2X8675+6965.3X7925+1199.6X6025+1199.6X5475
+6965.31X3575+21270.22X2825+7097.02X1800+0.322X11500^2/2)/11500
= 38383.66 kg = 38.38 T
Reaction at K2 = 7097+22491.3+6965.3+1199.6+1199.6+6965.31+21270.22+7097.02+3703-38383.66
= 38383.67 kg = 38.38 T
= 10965497.44 kgcm
Bending Stress on Beam K= 10965497.44/12261.55
= 894.3 kg/cm2 < 1213.55 kg/cm2 SAFE
Shear Stress on Beam K = 38383.67/168
= 228.47 kg/cm2 < 2038 kg/cm2 SAFE
DT = 25
L = 11500 mm
2
E = 2140672.78 kg/cm
Welding :-
Max. shear force on the Beam= 38383.67 kg
Stress = 38383.67/78.48
= 489.09 kg/cm2 < 1146 kg/cm2 SAFE
19 of 22
(JHARKHAND) Rev.:R0
16. Design of Column W3 & W4
500
4Nos. @1500 =6000
7500
W1 & W2
1500
1000
W5 2600 W5
Normal Wind Load on Structure
Wind
Form Pressu
Components L B/H Nos. Wind Load Wind Load
Factor re
2
(kg/m )
F1 Area of Gate 9.5 10.2 1.2 1 60 9.5x10.2x1.2x1x60 6976.8 kg

F2 Area of Column 0.25 7.5 1.2 2 60 0.25x7.5x1.2x2x60 270 kg
F3 Area of Horizontal Beam 11.5 1.1 1.2 1 60 11.5x1.1x1.2x1x60 910.8 kg
F4 Area of Hoist Equipment 1.3 1.2 2 3 60 1.3x1.2x2x3x60 561.6 kg
W1= Load on each pair of column applied at middle of column due to wind load on gate
= F1/2 + Fh/2 = 6976.8/2+0/2 = 3488.4 kg
W2= Load on each pair of column applied at middle of column due to wind load on Column
= F2 = 270 kg
W3= Load on each pair of column applied at top of column due to wind load on horizontal beam
= F3/2 = 455.4 kg
W4= Load on each pair of column applied at top of column due to wind load on Hoist Equipment
= F4/2 = 280.8 kg
W5= Reaction on the column due wind load
= ((3488.4+270)X3750+(455.4+280.8)X7500)/2600
= 7544.42 kg
Storm Wind Load on Structure
Wind
Form Pressu
Components L B/H Nos. Wind Load Wind Load
Factor re
2
(kg/m )
S1 Area of Gate 9.5 10.2 1.2 1 150 9.5x10.2x1.2x1x150 17442 kg

S2 Area of Column 0.25 7.5 1.2 2 150 0.25x7.5x1.2x2x150 675 kg
S3 Area of Horizontal Beam 11.5 1.1 1.2 1 150 11.5x1.1x1.2x1x150 2277 kg
S4 Area of Hoist Equipment 1.3 1.2 2 3 150 1.3x1.2x2x3x150 1404 kg
P1= Load on each pair of column applied at middle of column due to wind load on gate
= S1/2 + Fh/2
= 17442/2+0/2
= 8721 kg
20 of 22
(JHARKHAND) Rev.:R0
P2= Load on each pair of column applied at middle of column due to wind load on Column
= S2 = 675 kg
P3= Load on each pair of column applied at top of column due to wind load on horizontal beam
= S3/2
= 1138.5 kg
P4= Load on each pair of column applied at top of column due to wind load on Hoist Equipment
= S4/2
= 702 kg
P5= Reaction on the column due wind load
= ((8721+675)X3750+(1138.5+702)X7500)/2600
= 18861.06 kg
Max. Load on column ( with impact ) = 36494.00 kg
Max. Load on column ( with BDT ) = 55614.31 kg
Section of Column
C/L to C/L of Column

Y
2
Area = 236 cm 11500
4
Ixx = 31950.67 cm C/L to C/L of Column
4
2600
Iyy = 35318.67 cm
3
FLOW
Zxx = 1996.92 cm
3
Zyy = 2207.42 cm 250 X 10
210
rx = 11.64 cm 10 X 230
ry = 12.23 cm X
Ly = 150 cm Lx = 1500 cm
Ly/ry = 12.26 Lx/rx = 128.87
Refer Table 5.1 of IS 800 - 1984 sac = 57.00 Mpa
2
Permissible Compressive Stress= 581.4 kg/cm
Permissible Compressive Stress under BDT= 581.4X1.33 kg/cm2
= 773.262 kg/cm2
Load Cases
i) Gate Operating Under Normal Condition with Wind blowing across the gate
Maximum Load on end Column = 36494+7544.42
= 44038.42 kg
Axial Stress = 44038.42/(236)
= 186.6 kg/cm2 SAFE
ii) Gate Operating Under BDT Condt. with normal Wind
Maximum Load on end Column = 55614.31+7544.42 = 63158.73 kg
Axial Stress = 63158.73/(236)
2
= 267.62 kg/cm SAFE
iv) Considering Seismic Condition
Total load on hoist bridge = Dead weight of hoist+Dead weight of hoist
bridge+25% of live load
= 5000 + 11000 + 0.25 x 25000
= 22250 kg
Seismic Force= 0.38 X 22250 = 8455 kg
Assuming the seismic force acting at the top of the column
Reaction on column = 8455X7500/(2600X2) = 12194.71 kg
Maximum Load on Column = (5000+11000+6250)/4+12194.71
= 17757.21 kg
Axial Stress = 17757.21/(236)
2
= 75.24 kg/cm SAFE
21 of 22
(JHARKHAND) Rev.:R0
v) Storm Wind with Dead Weight
Load on the column due to dead weight = (5000+11000)/4 = 4000 kg
Load on the column due to Storm Wind = 18861.06 kg
Total load on the column = 4000+18861.06 = 22861.06 kg
Uplift on column = 18861.06-4000
= 14861.06 kg
2
Axial Stress = 22861.06/(236) = 96.87 kg/cm SAFE
17. Design of Base Plate
Maximum Load on Base Plate = 63158.73 kg
FLOW
450
Bearing Pressure = 63158.73/(45X45)
= 31.19 kg/cm2
= 3.06 Mpa
Permissible bearing stress of concrete = 0.25 X fck
grade of concrete = M 20 fck = 20 Mpa
Permissible bearing stress of concrete = 5 Mpa
450
From IS:800 Cl. No.-5.4.3

3w 2 b
2

t a
bs 4
where=
w = the pressure on the underside of the base,in Mpa
sbs= the Permissible bending stress in slab bases ( for all steels,shall be assumed as 185
MPa)
a= the greater projection of the plate beyond column, in mm;
b= the lesser projection of the plate beyond the column, in mm
t= the slab thickness, in mm;
a= 110 mm
b= 100 mm
t= ((3X3.06/185)X(110^2-100^2/4))^0.5 = 21.83 mm
Provided thickness of the base plate 25 mm
18. Bolt
Number of Bolt Provided = 12
Maximum Uplift load = 18861.06 kg
Load on each bolt = 18861.06/12
= 1571.76 kg
Bolt Diameter= 20 mm
500
Tensile stress on the bolt= 1571.76/((3.14X2^2)/4)

= 500.3067 kg/cm2
Check for bond stress
Bond area = 3.14X2X50
= 314.16 cm2 120 120 120
Bond Stress = (1571.76)/314.16

= 5 kg/cm2
Permissible bond stress for M20 grade concrete = 0.8 Mpa

2
= 8.15 kg/cm
22 of 22

Appendix II

Uploaded by

Copyright:

Available Formats

Appendix II

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Appendix II

Uploaded by

Copyright:

Available Formats

Appendix II

S.No. Document Title Document No.

CONSTRUCTION OF BARRAGE ACROSS GARHI RIVER

BARRAGE GATE DESIGN CALCULATION

I) Clear width of opening 9.5 m

I) Skin plate,girders,stiffeners,track base, IS:2062

iv) wheel pin IS:1570 PART V 20Cr 13

v) seals Rubber seals as per IS:11855

Permissible stresses & deflection As per IS:4622-1992

Grade of concrete M25

The gate shall be made in two parts.

LOADING DIAGRAM FOR GATE & UNITS top unit

Total load on gate = = 120.625 T

Barrage Gate - Bottom Unit design

0.4850 0.4375 0.3700 0.31750

5.00 4.70 4.05

0.3 0.65 0.7 0.35

Panel A (Four edges fixed)

(3 edges fixed & 1 long edge free)

Design of skin plate

Thickness of skin plate 0.012 m

Loading diagram Total load on unit 77.20 T

0.300 0.650 0.700 0.350 2.000 m

Calculation of distribution factors

stiffness Distribution factor

Calculation of Fixed end moments

Coacting width of girders

Area = 170.90 cm2 58 X 1.05

Combined stress =( su ) = sx2+sy2 - sx*sy

at bottom of skin plate -102.08 -340.28 681.92 805.79

Permissible deflection = L/800 = 1.25 cm

Between skinplate and web

Between web and bottom flange = V Ay' / I b =

VERTICAL STIFFENER DESIGN

Panel B 2.19 T/m

Shear stress = 137.28 kg/cm2

Combined stress =( su ) = sx2+sy2 - sx*sy

at bottom of skin plate -451.39 -135.42 229.48 505.04

reaction Total load on

0.300 0.650 0.700 0.350

0.450 1.05 0.500

2.21 T.m 1.78 T.m

Shear stress = 139.65 kg/cm2 Safe

Max.wheel load (P ) 21.45 T

Check for bearing stress in concrete

Check for shear stress in web

Check for over lapping of bearing pressure on concrete

Shear stress in concrete

shear stress in concrete = p*w / 2*l b

permissible shear stress of concrete = 0.16*(fck)0.5 = 8.16 kg/cm2

LOADING DIAGRAM FOR TOP UNIT

DESIGN OF TOP UNIT

3.00 2.55 1.10

0.45 1.45 1.1 0

Panel A (Four edges fixed)

(3 edges fixed & 1 long edge free)

Design of skin plate

Thickness of skin plate 0.012 m

Loading diagram Total load on unit 43.43 T

shear stress in concrete = pw / 2l b

Actual deflection = wB(8L3-4L*B2+B3)/(384EI) = 0.990 cm 1.25 cm safe