KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-1
RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST LTD. HOSPET FOR THANGARABALU SMALL BANGALORE H.E. PROJECT(2X12.375MW) REV. 1 DRAFT TUBE GATE DESIGN OF SUPPORTING STRUCTURE FOR MONO RAIL HOIST /CHAIN PULLEY BLOCK 1 DESIGN DATA sl DESCRIPTION VALUES no. 1 Type of Gate Fixed wheeltypevertical gate 2 Size of vent 4350mmx3550mm 3 NO.vents 4 4 Clear width of opening 4.35 M 5 Clear height of opening 3.55 M 6 No. of gates 4 SET 7 Sill level RL 386.412 M 8 Top of pier level RL 410.00 M 9 Thickness of Abutment Top side/middle 1.5/0.85 M 10 Thickness of pier[inter] 1.30 M 2 PERMISSIBLE STRESSES sl Type of stress Factor Stresses in kg/cm no. 1.0 Sturctural Steel Thk : 0 20 mm Structural Steel - IS : 2062 2006 Yp : 2550 kg/cm2 Grade E250 -A Factor UTS 4180 kg/cm2 a Direct compression & compression in bending 0.66 YP 1683 b Direct tension and tension in bending 0.66 YP 1683 c Shear stress 0.45YP 1148 d direct stress in compression 0.60YP 1530 e Bearing stress 0.75 YP 1912 Stresses in kg/cm 5 Bearing stress in concrete M25 50 6 Shear stress in concrete M25 8 7 Allowable deflection = span/750 <50mt cap. span/500 manual operation DESIGN CALUCULATIONS OF KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-2 RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST LTD. HOSPET FOR THANGARABALU SMALL BANGALORE H.E. PROJECT(2X12.375MW) REV. 1 3 Height of column Top of pier level RL 410.00 M Sill level RL 386.412 M LIFT = 23.588 M height of Lifting point in gate = 3.9 M Hoist Hook to Rail girder flange= 2 M clearance above pier level= 0.3 M Height of mono-rail beam = 0.6 M Height of column = 6.8 M Proposed 7.0 M Height columns 4 Load on column while operating Max. lifting capacity of Monorail = 17.5 MT Load on column with impact factor of 10%= 19.25 MT weight of monorail plus Girder 1.5 MT TOTAL = 20.75 MT Total Load on columns= say 21 MT The arrangement of column & girder is shown below NIY SA NIY SA DESIGN CALUCULATIONS OF KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-3 RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST LTD. HOSPET FOR THANGARABALU SMALL BANGALORE H.E. PROJECT(2X12.375MW) REV. 1 5 Design of main mono rail beam on vent Stop log gate elements are to be lifted one by one in each unit induidially Hence load on succussive girder / column is not considered for design. 21000 kg A B RA=RB= 10500kg 435+65+65=565cm Max. B.M = 10500X565/2=2966250kgcm a Proposed ISMB 500X180with ad.flange of 200x14 at bottom and ISMC250X80 at top SL SECTIONS AREA NO. W T 1 Flange[1] 25.0 0.71 17.75 2 Flange[2] 18 1.72 30.96 3 web 46.56 1.27 59.1312 4 Flange[3] 18 1.72 30.96 5 Flange[4] 20 1.4 28 166.80 A = 166.8 cm Y1 = 27.3 cm Y2 = 26.6 cm Y3 = 24.8 cm Ixx = 76255.2 Z1 = 2790.6 Z2 = 2865.0 Z3 = 3076.8 Iyy = 1369.8+2bd^3/12= (1369.8+(1*1.4*20^3/12)+3828.4) 6131.5 2966250 Max. bending stress = = 1063 kg/cm 2790.6 <1380kg/sqcm hence safe 5 xwl 5x21000 x 540 Max. deflection in girder = = 384 x EI 384x20.70 x 10^5 x 76255.2 = 0.27 cm L 540 Allowable Deflection= = = 0.72 cms 750 750 Sear stress=fs= 21000/2/46.56/1.02= 221 kg/sqcm DIMENSIONS DESIGN CALUCULATIONS OF KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-4 RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST LTD. HOSPET FOR THANGARABALU SMALL BANGALORE H.E. PROJECT(2X12.375MW) REV. 1 b Calculating the Max. Permissble bending stress as IS800-1984 Cl 6.2.3 fbc= 0.66 fcbxfy [(fcb)^n +(fy)^n]1/n fy=y.p=2550kg/sqcm n=1.4 ryy= SQ,RT.of [Iyy/A]=SQ RT of [6131.5/166.8]=6.06 fcb= k1[X+k2Y]c2/c1 l/ry=565/6.06=93 X=464 k1=1 c2/c1=1 [Table-6.5] [Table 6.4&6.3] D/T= 52.11/3.12=16.7 Y=327 k2=0.5 fcb= 1*(464+0.5*327)*1 = 627.5 As per table 6.2 for fcb =627 the allowable permissible stress is= fbc= 1380 kg/sqcm [table 6.2] DESIGN CALUCULATIONS OF KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-5 RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST LTD. HOSPET FOR THANGARABALU SMALL BANGALORE H.E. PROJECT(2X12.375MW) REV. 1 c Check for local bending of flange due to monorail long travel hoist wheel load The stress resulting from local bending is given an empherical formula[xyplane] x= KaxxP/t^2(root) where kax=2 Flange thickness=t=1.72+1.4=3.12 for value of c/a =62.5/85=0.735 p= Hoist load xImpact factor+self wt. 4 [nos. of wheel] = 21000x2 = 10500 kg 4 10500 x= = 1079 kg/sqcm 3.12^2 The stress resulting from load bending y-z plane y= KazxP/t^2 where kaz=0.6 for value of c/a =62.5/85=0.735 y= 5250X0.6 /3.12^2 = 324 kg/sqcm combined stress at inside of the flange c=
x + y + x x y = = 2107 kg/sqcm <0.85x2550=2167kg/sqcm DESIGN CALUCULATIONS OF KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-6 RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST LTD. HOSPET FOR THANGARABALU SMALL BANGALORE H.E. PROJECT(2X12.375MW) REV. 1 7 Design of columns [END/INTERM-PIER] Max. reaction of girder on column = 21000 kg Height of column= 800 cms Proposed 2- ISMC300X90 BACK TO BACK A=45.74x2= 91.48 cm^2 Ixx=2xIyy+2xAx[D/2]^2 Ixx=2x311.5+2x45.74x20^2 = 37215 cm^4 Iyy=2xIxx+2xwx[D/2-t of web]^2/12 Iyy=2x6384.2+2x9x[40/2-7.6]^2/12 = 13281 cm^4 Zxx= 37215/[D/2+FLW/2]= = 2482 cm^3 Zyy== 13281/[D/2] = 885.4 cm^3 rxx= SQ,RT.of [Ixx/A]=SQ RT of [37215/91.48]=20.2 cm ryy= SQ,RT.of [Iyy/A]=SQ RT of [13281/91.48]=12.05 cm Effective Ht. of column Lxx=1.5*700= 1050 cm Lyy=0.5*700= 350 cm LXX/rxx= 1050/20.25= 51.9 <200 Lyy/ryy= 350/15.6= 22 <200 permissible compressive stress for l/r =52 is 1164 kg/sqcm actual compressive stress in column= 21000/91.48= 230 kg/sqcm max.load on colomn= 21000 kg self wt.of column+beam= 1000 kg total load 22000 Max. compressive stress in column= 22000/91.48= 240 kg/sqcm BASE PLATE FLOW DESIGN CALUCULATIONS OF KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-7 RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST LTD. HOSPET FOR THANGARABALU SMALL BANGALORE H.E. PROJECT(2X12.375MW) REV. 1 WIND LOADS A]Wind in the direction of flow wind pressure= 160 kg/m^2 width of column= 0.3 m form factor 1.6 wind load per mtr ht of column= 0.3x160x1.6= 77 kg B]Wind from main girder wind pressure= 160 kg/m^2 width of column= 0.62 m form factor 1.6 effective length of girder on each colomn= 7.8/2= 3.9 m wind load on column= 0.55*3.15x160x1.6= 619 kg C]Wind form mono-rail hoist wind pressure= 160 kg/m^2 width of hoist= 0.6 m ht of hoist 1 form factor 1.6 effective load on each colomn= 50% wind load from hoist on column= 0.6*1.5x160x1.6x1/2= 77 kg total wind load on top of column= 619+77 696 kg A B WIND LOAD A WIND LOAD WIND LOAD WIND LOAD MA AXIAL LOAD-P A B B A AXIAL LOAD-P AXIAL LOAD-P FLOW DESIGN CALUCULATIONS OF KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-8 RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST LTD. HOSPET FOR THANGARABALU SMALL BANGALORE H.E. PROJECT(2X12.375MW) REV. 1 Moment at -A a]due to wind load on wind ward column MA1= 77x[700/100]x700 2 188650 kgcm a]due to concentrated load at B MA2= 696*700 487200 kgcm Total moment at A MA= MA1+MA2= 675850 kgcm For Int/end column Stress in column at A due to moments fa= MA/Zxx= 763 kg/sqcm <1683 kg/sqcm check for unity formula (240/1164+763/1683) 0.7 <1 DESIGN CALUCULATIONS OF KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-9 RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST LTD. HOSPET FOR THANGARABALU SMALL BANGALORE H.E. PROJECT(2X12.375MW) REV. 1 8 BATTENS Battens are proposed for columns Heght of column= 700cm r min. Of column= 12.05cm L/r min. = 58.1 spacing of battens shall be minimum of following 1] L/r min. < 40 2] 0.6XL/rmin. = 0.6x58.1= 35 <40 l= 35x12.05 = 422 cm Proposed battens at 1000mm c/c =d Depth of intermediate batten =300mm Thickness of batten =10mm Adopt battens of size 300x10 mm at 1000mm c/c. Transverse shear=S = 2.5%Xof axial load Transverse shear=S = 2.5%X22000 = 550 kg Longitudinal shear =Sd/na s= transeverse shear Moment=Sd/2n d=c/c distance of battens longitudinally n=no of parallel planes of battens a=min. distanace across welds (450-2*15)=420mm Moment=Sd/2n = 550x100/(2x2) = 9625 kgcm Longitudinal shear =Sd/na= 550X100/(2X42) = 458 kg distance between centroids of member=400mm =c min. effective depth reqdd=75% of c = 300mm provide 300mm Longitudinal shear stress = 458/[30x1] = 54kg/sqcm Bending stress = 22000/2 = 212 kg/sqcm 1/6 x1x30 < 1530 kg/sqcm DESIGN CALUCULATIONS OF KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-10 RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST LTD. HOSPET FOR THANGARABALU SMALL BANGALORE H.E. PROJECT(2X12.375MW) REV. 1 9 Design of Column base plate Proposed base plate= 600x400x20mm moment on each column base = MA= 676850 kgcm Total load on column= 22 mt a]The thickness of base plate requiored as per cl.6.4.3 of IS800 is t= 3w[a^2-b^2/4]fb t= thickness of base plate w=the pressure of loading under base plate=22000/[60x40]= 9.2 kg/sqcm a= the greater projection of plate beyond column= 10cm b= the lesser projection of plate beyond column= 10cm fb=1530 kg/sqcm t= 1.3 cm Providded 20mm thickness of plate b]checking the unit width of cantilever portion bending moment = 9.2x10x10/2= 460 kgcm 0.666 bending stress= 460/0.66= 697 kg/sqcm <1530kg/sqcm BASE PLATE FLOW DESIGN CALUCULATIONS OF KARE POWER M/S NARAYAN SUPPORT STRUCTURE FOR PAGE-11 RESOURCES PRIVATE ENGINEERS DRAFT TUBE GATE HOIST LTD. HOSPET FOR THANGARABALU SMALL BANGALORE H.E. PROJECT(2X12.375MW) REV. 1 10 Design of Foundation Bolts Proposed 6nos. of Bolts/column Distance between holes c/c= 50cm No. of effective bolt= 3 Max. B.M. in column= 676850 kgcm Tensile load on each Bolt/ column = 50cm 676850 = Proposed 20 mm bolts 50x3 5355 kg A in Tensile = 9.425cm^2 A in Shear = 8.01cm^2 Tensile stress in Bolt= 5355/9.425=568kg/sqcm <945kg/sqcm Shear stress = 22000*10%/(2x8.04)=131kg/sqcm Length of bolt =l= 5093 = 90cm px2x9 [M-250 Shear stress=9kg/sqcm] Adopted 1200 mm long bolt with 50 mm thread length.. 10a Check for compressive stresses in concrete MA= = 676850 kgcm Ecentricity=e= mc/pc= 676850/2200= 30.76 cm size of column base= b=40cm h=60cm e/h= 11.75/60= 0.512667 Area of tensile steel = 9.425 [2xpie/4xd^2] AREA OF COM. STEEL = 0 EFFECTIVE DEPTH=h-d1=60-5=55cm [b*h^2/6]+[2(ac-1)Asc/h] x[0.5h-d1]^2 modulus section =J= (40*55^2/6)+((2*13-1)*16.08)/55*(0.5*55-5)^2 = 22335.488 Atr=b*d+(m-1)Asc= 40*55+(13-1)*16.08 m=13 = 2313.1 Max comp stress= PC*1000/Atr+Mc/j (22000/2313.1)+(803200/222335.5) 13 kg/sqcm <50kg/sqcm Min comp stress= PC*1000/Atr-Mc/j (22000/2313.1)-(803200/222335.5) 6 kg/sqcm <50kg/sqcm 11 CONNECTION DETAILS BETWEEN MONO RAIL GIRDER &COLUMN GIRDER. Max. load occurs when pulley block is at cross girder MAX. designed load = 22000 kg Proposed 6 nos. of M20 Bolts A in Tensile = 2.45 cm^2 A in Shear = 3.14 cm^2 Shear stress in bolt= 22000/(6x3.14X2)= 583 kg/sqcm [double shear] <865 kg/sqcm ooooooo oooooooo ooooooo V