HYDRO MECHANICAL



HYDRO MECHANICAL

GUIDE LINES FOR  HYDRO MECHANICAL EQUIPMENTS OF IRRIGATION PROJECTS 

For this general guidelines are prepared which may be followed. The guide lines indicated are suggestive and may be followed along with relevant IS codes and best engineering practices in vogue. 

Designs shall reflect the codal references adopted and allowable stresses considered duly quoting the authority.

The drawings shall include all details with materials used along with properties like Ultimate Tensile Stress, Yield Point and hardness etc. with the authority duly quoted. 

In the first instance, the type of gate may be selected based on the recommendation indicated vide latest IS code No: 13623:1993. (RA 1998), IS codes to be followed for preparation of designs and drawings for the gates. The latest IS codes, with all the amendments updated, may be followed.

Radial Gates

1)Approved Civil Drawings showing the Cross-Section of Spillway and plan and shall include the all important details along with the following.

  1. U/S and D/S equation of profile of ogee of Spillway and the coordinates.
  2. Sill level of Radial and Stop log gates and its location with reference to crest.
  3. Top of the gate.
  4. Radius of the gate.
  5. Trunnion level.
  6. Hoist level and its location.
  7. Road bridge level and all other important details.The above may be adopted duly following the guidelines indicated in IS: 4623.The thickness of piers proposed may be to suit the type of anchorages as per codal provisions.
  1. Designs and drawings furnished for checking must be self explanatory, with detailed calculations duly indicating the formulae used and authority for its usage. Latest techniques using latest codes may be followed while designing.
  2. For all the bought out items manufactures catalogues may be furnished.
  3. The materials shall conform to those indicated in IS: 4623. The designs and drawings may be submitted in the following sequence with details indicated below and shall generally conform to the norms.
  4. The welding shall conform to IS: 816 and other relevant IS codes.

A)Design Of Embedded Metal Parts:-

The design of embedded metal parts may be done for either Independent   UnBonded type anchorages or combined bonded type anchorages. The former may be choosen for large size gates. The following are to be designed for Independent UnBonded type anchorages (As per IS: 4623 latest code & other IS codes)

  1. Calculations of water thrust and working of inclination of resultant thrust and consequently inclination of anchor flats which shall be horizontal as far as possible.
  2. Calculation of sill reaction.
  3. Designs of anchor flats.
  4. Design of trunnion girder. (Left hand & Right hand).
  5. Design of anchor girder.
  6. Design of Rest chair.
  7. Design of vertical anchorages.
  8. Design of welds for the above.
  9. Details of sill beam, wall plate assembly etc:.

The drawings should contain the above designed Components and the assemblies wherever required. Drawings showing the details of Block out and anchorages are to be shown primary and secondary concrete stages.

In case of combined bonded type anchorages the following are to be designed (As per IS: 4623 latest code and other IS codes.)

  1. Calculations of water thrust and finalisation of inclination of resultant  thrust and consequently inclination of anchor rods, which shall be horizontal as possible.
  2. Calculations of sill reaction.
  3. Design of anchor rods.
  4. Design of trunnion girder (Abutment pier, Intermediate pier).
  5. Design of rest chair (Abutment pier, Intermediate pier).
  6. Design of vertical anchorages.
  7. Details of sill beam, wall plate assembly and others.
  8. Design of welds for the above

The drawings are to be issued duly showing the above designed components and the assemblies where ever required.

Drawings showing the details of Block out and anchorages are to be issued duly showing primary and secondary stages.

Design of Gates:

(As per IS: 4623 latest code and other relevant IS codes) Detailed design of the following components may be furnished

  1. Skin plate.
  2. Verticals
  3. Horizontal girders
  4. Arms and Arms assembly. (including Bracings)
  5. Horizontal girder bracings
  6. Design of prop (above top horizontal girder if required)
  7. Design of trunnion, pin, Bush.
  8. Design of trunnion Bracket.
  9. Design of Guide Rollers and other Components.
  10. Design of welds and other Joints.
  11. Design of Tie beam/ Thrust Block and others.
  12. Seals may be provided as per IS: 11855.

Drawings furnished shall comprise of above items in detail. Each drawing shall indicate the key plan and critical dimensions. The Assembly drawings for the above components may be furnished in detail where ever necessary.

A)Design of Hoist Mechanism:

(As per latest IS: 6938 codes and other codes) Hoist capacity may be calculated.

Type and location of the Hoist may be choosen.It is preferable to have U/S suspension of hoist mechanism so that hoist capacity gets reduced.

 In case of Rope Drum Hoist the following components are to be designer

  1. Design of Wire Rope.
  2. Design of Rope Drum.
  3. Design of Gear reduction mechanism Motor and Brake.
  4. Design of Shafts.
  5. Selection of Bearings and plumber Blocks.
  6. Dail indicator, Limit switch and turn buckle, lifting bracket etc.All the above components are to be checked for Break Down Torque condition. (B.D.T) also
  7. Design of manual operation.  

The Drawings shall indicate the above components in detail with all assemblies duly detailing the individual items. The exposed components may be covered suitably.

 For high head gates and for higher capacity hoists hydraulic hoist may be adopted. The hoist may be designed as per IS: 10210 and other relevant IS codes. The detailed designs and drawings may be furnished.

D. Design of Hoist Bridge.

(As per latest IS: 800 and other relevant latest IS codes)

The layout of the Hoist Bridge may be finalised and location of main bridge girders and cross girders for supporting motor, gear box, drum etc may be indicated in the design. All the cross girders and main girders may be designed for the loads coming over them. The detail design of welds may be furnished.

The drawings showing the details of Hoist bridge girders and cross girders may be furnished with all full details including welding and other joining methods. The Hoist bridge may covered by not less than 6mm chequered plate and suitable railings may be provided.

The ladders may be provided for approach from sill to Hoist Bridge covering all the components walk Way Bridge may be provided at trunnion level connecting all the vents for inspection and maintenance.

All hydro mechanical components may be painted as per IS code 14177.

The location of grooves, gates, hoist mechanism and Hoist Bridge may be furnished with reference to the axis of dam/cut water edge.

STOP LOG GATES:

The size of the stop logs may be finalised duly considering the Hoist capacity and storing arrangement. The numbers of sets of stop logs are to be proposed as per standard practice of 1 set per 10Nos of vents, subject to a maximum of 3 sets. The Bottom piece may be provided with suitable legs for resting over ogee of spill way.

The following items are to be designed as per IS: 4622 latest code and other relevant IS codes.

  •  Calculation of Thrust over the stoplog element.
  •  Design of skin plate, Horizontal girders, verticals.
  • Design of Rollers, pin and selection of Bearings.
  • Design of Roller supporting plate.
  • Design of Roller Track, seal track.
  • Finalisations of Groove.
  • Design of Centre of Gravity and Hoist capacity.
  • Design of lifting pin and Brackets.
  • Seals may be provided as per IS: 1185

The drawings showing the details of sill beam, Guide Track, Roller Track, seal track and its anchorages (primary & secondary) are to be furnished.

The drawing showing the details of components and its assemblies in detail are to be furnished

The drawings showing the details of storing arrangement for stop logs may have to be furnished.

Hydraulic model studies may have to be conducted to ascertain the uplift and down pull forces on stop log gates and report shall be furnished.

LIFTING BEAM:

Lifting beam shall be designed and drawings prepared to suit the gantry and stop logs. IS: 13591 (Latest along with amendments) and relevant IS codes may be followed while designing the lifting beam.

Design of Gantry/ Electrically Operated Traveling Crane(E.O.T). for the operation of stop logs.

The capacity of gantry/EOT required may be calculated duly considering all the forces including hydro dynamic forces that it has to encounter.

The type of lifting arrangement (Gantry/ E.O.T.) is to be selected suitably as per provisions available in civil structure.

The latest IS codes 6938, 807 and 3177 may be followed while designing Gantry/ E.O.T.

The Hoist mechanism, cross travel mechanism and long travel mechanism and its supporting structure, portal frame, legs Rails, Rails fixing arrangement, lifting Beam, wheel bogies and their assemblies etc are to be designed in detail and accordingly drawings are to be furnished. For all the bought out items the catalogue of the manufactures are to be furnished.

The gantry shall be designed keeping in view operation and storing of stop log elements. It shall also ensure that the civil structure takes the loads of the gantry (leg loads etc) and transmit the same without damaging the civil structure.

Design of Hoist Mechanism:

The following components may be designed as per latest IS code 6938 & IS 3177 & IS 807 and other relevant codes..

  1. Design of wire Rope.
  2. Design of Rope Drum.
  3. Design of Gear reduction, mechanism, Motor and Brake.
  4. Design of Shafts.
  5. Selection of Bearings and plumber Blocks.
  6.  Dail indicator, limit switch, Turn Buckle and lifting brackets etc.
  7. Design of manual operation.

All the above components are to be checked for Break down Torque condition (B.D.T) also.

The Drawings shall indicate the above components in detail with all assemblies duly detailing the individual items. The components may be covered suitably.

 Design Of Portal Frame

  1.Stability calculations.

  2.Loading diagrams including the loads of portal frame and hoist Mechanis

  3.Design of portals..

  1. Wind load calculations on portal frame
  2. Design of gantry rail girder.
  3. Design of Upstream Side (U/S) and down Stream Side (D/S )columns.
  4. Design of U/S & D/S girders.
  5. Design of articulated bogie.
  6. Design of wheel Bogie.
  7. Design of long travel mechanism (Motor, Brake Wheel, Reduction unit etc).
  8. Cross travel Mechanism
  9. Cabin Details

 Detailed drawing of gantry showing all the components along with assemblies. The designs & drawing shall be self explanatory with all relevant authorities indicated and supplied.

Vertical Fixed wheel/Slide Gates

The following may be considered while taking up designs and drawings.

1) Inspection chamber, if required, is to be provided duly furnishing all its details along with dogging beam details.

2) Width of the hoist platform shall be suitably fixed to suit that type of hoist Provided considering maneuverability of man and machine. Pier thickness shall   be suitably kept based on the type of gate provided to accommodate  depth of grooves primary and secondary and anchorages with suitable cover.

3)  A minimum distance of 1200mm shall be provided between grooves of emergency and service gates.

4)  For medium and high head gates model studies may be conducted to ascertain Hydrodynamic forces and same are to be taken into consideration for design of gate.

A)E.M. PARTS AND GATES

Vertical Gates are to be designed as per latest code of IS-4622/ IS: 5620/IS: 9349 (vertical fixed wheel gates/ low head slide gates/ High head slide gates respectively).

The following items are to be deigned.

  1. Calculation of Thrust coming over the gate.
  2. Design of skin plate, Horizontal girders, Verticals etc.
  3. Design of Rollers, Pin and selection of Bearing, Design of sliding bars
  4. Design of Roller supporting plates.
  5. Design of Roller Track, seal track.
  6. Finalisation of Groove.
  7. C.G. of the Gate and Hoist capacity calculations.
  8. Design of Lifting Pin and Bracket.
  9. Seals may be provided as per IS: 11855.

The drawing showing the details of above components and its assemblies in detail are to be furnished.

The drawing showing the details of sill beam,Guide Track, Roller Track and its anchorages (Primary & Secondary) are to be furnished.The location of groove with respect to the Hoist bridge level and axis of the dam/cut water edge may have to be furnished.

B)Hoist Mechanism:-

The type of Hoist mechanism may be decided as per the Hoist capacity, as per field conditions.

I.Rope drum hoist

(As per latest IS 6938 & other IS codes).The following components are to be designed.

  1. Design of Wire Rope.
  2. Design of Rope Drum.
  3. Design of Gear reduction mechanism Motor and Brake.
  4. Design of Shafts.
  5. Selection of Bearings and plumber Blocks.
  6. Dial indicator, Limit switch and turn buckle, lifting bracket etc. All the above components are to be checked for Break Down Torque condition. (B.D.T) als
  7. Design of manual operation.         

The Drawings shall indicate the above components in detail with all assemblies duly detailing the individual items. The exposed components may be covered suitably.   

II)For Screw Rod Hoist with power operation.

      The following components are to be designed following latest code of IS 11228.Design of Screw Rod.

  1. Design of Nut.
  2. Design of Worm & Worm Wheel mechanism/bevelgear mechanism
  3. Calculation of Motor Capacity & its selection.
  4. Checking for B.D.T. conditions as per IS codes.
  5. Design of Manual operation

The drawings showing the details of above components including its assemblies in detail are to be provided with longitudinal girders and cross girders duly providing chequered plate of not less than 6mm over the bridge girders. Suitable railings may be provided.

III) Screw Rod type Hoist (Manual):-

Latest IS code 11228 may be followed. Design components are as detailed below.

  1. Design of Screw Rod.
  2. Design of Nut, selection of Bearing
  3. Design of Fork etc.

The drawings showing the details of above Components including its assemblies in detail are to be furnished. The supporting structure to carry the Hoist Mechanism may have to be provided with longitudinal girders and cross girders duly providing not less than 6mm chequered plate over the bridge girders. Suitable railings may be provided.

For high head gates and for higher capacity hoists hydraulic hoist may be adopted. The hoist may be designed as per IS 10210 and other relevant IS codes. The detailed designs and drawings may be furnished.

(C)Design of Hoist Bridge.

(As per latest IS 800 and other relevant latest IS codes) The layout of the Hoist Bridge may be finalised and location of main bridge girders and cross girders for supporting motor, gear box, drum etc may be indicated in the design. All the cross girders and main girders may be designed for the loads coming over them. The detail design of welds may be furnished.

The drawings showing the details of Hoist bridge girders and cross girders may be furnished with all full details including welding and other jointing methods. The Hoist bridge may covered by not less than 6mm chequered plate and suitable railings may be provided.

The ladders may be provided for approach from sill to Hoist Bridge covering all the components.

All hydro mechanical components may be painted as per IS code 14177.

The location of grooves, gates, hoist mechanism and Hoist Bridge may be furnished with reference to the axis of dam/cut water edge

DESIGN OF TRASH RACKS:

The trash racks may be designed following recommendations detailed in IS 11388 and other relevant IS codes.

RADIAL GATES:

Design of Embedded Metal Parts:-

1. Calculation of water thrust and finalisation of unclothing of resultant and anchors.

2. Calculation of full reaction.

3. Design Horizontal anchor rods/ flats.

4. Design of trunnion girders for intermediate and Abutment piers.

5. Design of anchor girder (if provided)

6. Design of Rest Chair.

7. Design of Vertical anchorages.

Drawing to be issued:-

  1. Details of Block out.
  2. Details of Main anchor rods for intermediate and Abutment piers.
  3. Details of Trunnion girder for intermediate and Abutment piers.
  4. Details of Rest chair for intermediate and Abutment piers.

The Designs, Materials, welding and others shall confirm to the relevant IS codes indicated in the Annexure.

The Designs are to be furnished as detailed below for checking of Hydro Mechanical equipments. These are indicated for checking of deigns only.

Radial gates:

3. Embedded Metal Parts:-Design

    Design Components:-

            Calculation of Thrust on the gate for FRI condition.

            The Thrust may be calculated at one meter unlevels and water level raising.

            The thrust is to be calculated for 1mt outering (a) when the gate is rusting on sill and water level raising and (b) gate under max. Water level conductor and gate lifted by one meter successively.

            If the anchors are kept uncovered the thrust parallel to the girder may be calculated for the cases (a) and (b) to determine wax vertical upward and downward forces.  

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