NAME OF WORK; REPAIRS AND OVERHAULING OF SPILLY CREST GATE

AND SCOURING SLUICE GATE OF BHADRA DAM

1 CONTRACTOR:
M/S. NARAYAN ENGINERS .
HOSAPETE -583203 .KARNATAKA
2 CLIENT
EXECUTIVE ENGINEER
K.N.N.L.
BHADRA DAM
KARNATAKA
3 PROJECT
BHADRA DAM -ROPE DRUM HOIST FOR SLUICE GATES
KARNATAKA

4 Design NO. AMN/NE/BP/DGN/RDH-30-01

Design calculation of
Rope Drum hoist

Total Sheets = 14Nos.

A.M.NAGABHUSHANA
CONSULTANT
 CLIENT DESIGNED BY DESIGN CALCULATIONS OF
EE NARAYAN ROPE DRUM HOIST FOR PAGE-01
KNNL ENGINEERS SLUICE GATE [6'x15']
BHADRA DAM HOSAPETE FOR BHADRA DAM, KARNATAKA
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DESIGN CALCULATIONS OF 30 MT ROPE DRUM HOIST FOR SLUICE GATE

1 DESCRIPTION

The hoisting arrangement is consisted of two drum with 4 falls on each drum
Two pulleys on each side are mounted on gate with lifting arrangement at C.G. and
two pulleys on each side are fixed to hoist bridge at ends
The drum is mounted on bush bearings and connected to out- put shaft
to worm reducer and set of open reduction . The input shaft is connected to Motor
through D.C.Electro-magnetic Brake

2 REFERENCES

1 Technical specification.and dept.drawings

2 IS 6938 - Recomandation for Design of rope drum hoist

3 IS 800 - Code of practice for general construction steel.

3 DESIGN DATA

1 SILL Level EL 14.760 M (45')

2 gate dogging level EL 37.40 M (114')
3 Rope drum Hoist level EL 56.43 M (172')
4 lifting arrangement ht 11.50 M
pulley c/c
5 top of dam EL 62.992 M[192']
6 Vent Size 1.968MX4.921 M 6'x15'
7 Capacity of hoist 30 MT
8 Type of suspension on C.G. of gate
9 Speed of hoist 0.5to 0.75 M/MIN.
10 Max. lift of gate 37.4-14.76-11.5=11.14M say 15 M
 CLIENT DESIGNED BY DESIGN CALCULATIONS OF
EE NARAYAN ROPE DRUM HOIST FOR PAGE-02
KNNL ENGINEERS SLUICE GATE [6'x15']
BHADRA DAM HOSAPETE FOR BHADRA DAM, KARNATAKA
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4 MATERIAL SPECIFICATION
SL. COMPONENT PART RECOMMENDED IS CODE
No MATERIAL
1 Structural parts including IS:2062
main girder, trestles, cross girders Structural steel
chq. Plates, hand rails ,covers
2 Drum wheels/pulleys/gears IS1030 gr. 340-570w
brake drum cast steel IS1030 gr. 280-520
3 shafts/pinions carbon steel IS 1570 part-II
Gr. 45c8/Gr.55C8
4 Pins corrosion resistant steel IS 1570 part-V
20cr13
5 Bearing /housing std. Make SKF OR Eqt.

6 Motor std. Make KEC, GEC etc.

7 Flange coupling std. Make GEB, HI-CLIFF

WMI ETC.
8 Wire rope std. Make Usha martin /
Southern wire rope
9 Brake D.C. Electro-magnetic BCH
5 MATERIAL AND STRENGTH
SL.
no Material & Strength
1 Structural Steel Gr. IS 2062
Y.P.= 250 N/mm for thickness upto 20mm
Y.P.= 240 N/mm for thickness > 20mm and < 40mm
Y.P. = 230 N/mm for thickness > 40mm
U.T.S= 410 N/mm for all thickness
2 Corrosion Resistant steel Gr. 20Cr13
IS 1570-PART-V
Y.P= 490 N/mm
U.T.S= 690 N/mm
3 CAST STEEL IS 1030 Gr. 280-520 N IS 1030 Gr. 340-570 N
Y.P= 280 N/mm 340 N/mm
U.T.S= 520 N/mm 570 N/mm
4 FORGED STEEL IS2004-En8 IS2004-En9
Gr. 45c8 Gr. 55c8
Y.P= 3200kg/cm 3700kg/cm
U.T.S= 6324kg/cm 7242kg/cm

5 AL-BRONZE -IS 305 GR.AB1

U.T.S= 630 N/mm

 CLIENT DESIGNED BY DESIGN CALCULATIONS OF
EE NARAYAN ROPE DRUM HOIST FOR PAGE-03
KNNL ENGINEERS SLUICE GATE [6'x15']
BHADRA DAM HOSAPETE FOR BHADRA DAM, KARNATAKA
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6 PERMISSIBLE STRESSES

1 Structural Steel IS 2062 yp=2550kg/cm^2 UTS =4200kg/cm^2

a Bending and compression 0.55 YP
(0.55X2550) = 1402 Kg/Sq.cm

b Shear 0.4 YP
(0.4X2550) = 1020Kg/Sq.cm

2 Cast Steel IS : 1030 Gr. 280-520N

Bending &compression 0.2XUTS = 1060 Kg/Sq.cm
(0.2X520X10.2)
CS-340-570 IS-1030
0.2XUTS = 1163 Kg/Sq.cm
3 Shafts /Pinions (0.2X570X10.2)
45c8 55c8
IS : 1570 (Part-II) IS : 1570 (Part-II)
YP = 3200kg/cm^2 3700kg/cm
UTS = 6324kg/cm^2 7242kg/cm
0.2UTS = 1265kg/cm^2
0.2XUTS = 1448 Kg/Sq.cm
a) Bending without keyway[ 0.2 UTS]
1248 Kg/sq.cm
[0.2x6324]
Bending with keyway
b) 765 Kg/sq.cm
[0.75X1248]
c) Shear without keyway
[0.3XYP] 1160 Kg/sq.cm
Shear with Keyway
d) (0.75X1160) 720 Kg/sq.cm

e) Combined stress with key

[0.6YP/0.24UTS] 1468 Kg/sq.cm
f) Allowable stress B.D.T. Condition
[2/3xYP] 2584kg/sqcm

4 Al. Bronze Bearing stress 0.03UTS 261kg/sqcm

[0.04x640x10.2]
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EE NARAYAN ROPE DRUM HOIST FOR PAGE-04
KNNL ENGINEERS SLUICE GATE [6'x15']
BHADRA DAM HOSAPETE BHADRA DAM, KARNATAKA
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7 DESIGN OF WIRE ROPE

No. of drums 2
No.of falls = 4
No.of pulleys on bridge = 4
Efficiencies starting running
Drum with bronze h 0.93 0.95
each pulley with bronze bush 0.93 0.95
2 sets of spur gears 0.93 0.95
worm reducer 0.36 0.78
overall efficiency = 0.93*0.93*0.93^4*0.36 0.95*0.95*0.95^4*0.78
= 0.233 = 0.573

30 [1-0.95]= = 4.043 MT
Max.Rope tension = 2 [1-0.95^4]

Selected 24mm dia 6/37 construction, right hand lay improved plough, fibre core,
UTS=180kg/cm^2 having breaking strength of 34251 kg conforming to IS 2266
34251
F.O.S in rope = = 8.47 >6
4043

8 MOTOR
KMV Where K = 1
HP of motor required = M = 30
4.5 E V = 0.6
E = 0.78 x 0.95x0.95 x 0.95^4 = 0.573
1 x 30 x 0.6
= 8.144 HP
4.5 x 0.573
Selected 7.5 KW ,10 HP , 965 rpm 40% CDF class B insulation, TEFC, squirel cage induction
motor having min. breaking torque of 250%,with shaft extended both sides.
Make -GEC / ABB./ KIRLOSKAR
9 BRAKE
Rated HP= 10
Rated speed= 965 rpm
Full load torque= 63000xhpx2.54 7.537 kg-m
rpmx2.2x100
Brake down torque= 7.537x2.5= 18.8425 kg-m
71620 x 10 x 1.5
Breaking torque required = = 1113.26 kgcm
at 150% 965
Selected 200MM drum dia , AC Electro magnetic solenoid operated
single phase brake , coils working on 400/440 AC 50 cycles
class- B insulation having braking torque capacity 1387 kg.m at 100% coil rating. - 1 NO.
Make - Electro- Mag, Strom craft, WMI.
 CLIENT DESIGNED BY DESIGN CALCULATIONS OF
EE NARAYAN ROPE DRUM HOIST FOR PAGE-05
KNNL ENGINEERS SLUICE GATE [6'x15']
BHADRA DAM HOSAPETE FOR BHADRA DAM, KARNATAKA
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10 ROPE DRUM
material cast steel IS 1030 GR-280-520N 24dia All in mm
26.5
Wire rope dia =d = 24mm
Total lift 15 M = 8.4
Nos. of falls 4x4 =
Total lifting capacity 30 MT
= 20
Material : Cast steel IS 1030 - Gr-280 - 520 W
Min drum dia = 20 xd = 20 x 24 = 480 mm pcd 520mm
Proposed 520mm PCD with shell thickness of 20mm
Pitch of groove =[d+2.5]= 24 + 2.5 = 26.5mm
K x T Where,
Crushing stress in shell =C= c = compressive stress in kg/cm^2
P x t K= co-efficient which depend on no.
of layers on drum.= 1
T=Tension on one wire rope in kg.=4043
1 x 4043 p = pitch of groove in cm=2.65
= t = thickness of shell in cm=2
2.65 x 2
= 763 kg/sqcm < 1060kg/cm^2
[0.2*uts=.2*520*10.2=1060]
15 x 4
No. of winding required on each drum = 3
pxd
= 15*4/3.1416/0.48+3 = 39.728
Say 43nos
Drum Length= 30+16+55+70+[43x 26.5]+70+113 = 1493.5 mm
Min radius of groove = 0.53 x d = 12.72 mm
Radius groove adopted = 13.0 mm
Depth of groove = 0.35 x 24 = 8.4 mm Length of rope= 178.432 M
wt.of drum= 503
 CLIENT DESIGNED BY DESIGN CALCULATIONS OF
EE NARAYAN ROPE DRUM HOIST FOR PAGE-06
KNNL ENGINEERS SLUICE GATE [6'x15']
BHADRA DAM HOSAPETE FOR BHADRA DAM, KARNATAKA
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11 WORM REDUCER
Hosting Speed = 0.5 to 0.75 M / min.
Motor speed = 965 rpm
Rope drum 520 dia. = p*d = 1.634 M
Drum speed = 0.6x2 0.734 RPM
1.634
Total reduction required = 965 1315
0.734
Proposed worm reducer ratio = 60 : 1

Select worm reducer 60:1 ratiO size 600 having Input HP 7.5,out put torque kg.m
both input & output shaft extended on both sides.
*
Make - Shanthi/ Elecon/Greaves.

12 Reduction unit :
Proposed worm reducer ratio = 60 : 1
Open reduction required = 1315 21.92
60

Proposed following open

spur gear 85x 82 = 19.5238
21 17
Actual Hoisting speed= 965*3.1416*0.52/19.524/60/2 0.673 m/min
No.
of Module/ PCD F.W. f Strength
Description Teeth in cm-M cms cms-F factor Q
W2 85 1/20 0 85 14 2.6
[IS : 1030 Gr. 340-570N]
P2 21 1/20 0 21 14 3.4
[IS : 1570 (Part-II)55c8]
W1 82 0.8/20 0 65.6 10 2.6
[IS : 1030 Gr. 340-570N]
0
P1 17 0.8/20 13.6 10 3.6
[IS : 1570 (Part-II)55c8]
CLIENT DESIGNED BY DESIGN CALCULATIONS OF
EE NARAYAN ROPE DRUM HOIST FOR PAGE-07
KNNL ENGINEERS SLUICE GATE [6'x15']
BHADRA DAM HOSAPETE FOR BHADRA DAM, KARNATAKA
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CHECK FOR GEAR WHEELS FOR LOADS TQ=[HPX5252]RPM 54.425
Normal condition 10 HP 5.442
TORQUE ON MOTOR SHAFT= 5.442 kgm
on worm reducer output shaft/ist pinion=
tp1= 5.442*60*0.78 = 254.686 kgm
on ist gear /2nd pinion
tp2= 254.686*82/17*0.95 = 1167.06 kgm
on drum and drum gear= 1167.1*85/21*0.95 = 4487.78 kgm
Break down condition 250%
TORQUE ON MOTOR SHAFT= 5.442*2.5 = 13.605 kgm
on worm reducer output shaft/ist pinion=
tp1= 13.605*60*0.36 = 293.868 kgm
on ist gear /2nd pinion
tp2= 293.87*82/17*0.93 = 1318.27 kgm
on drum and drum gear= 1318*85/21*0.93 = 4961.33 kgm
stresses in gears and pinions
normal condition
tooth load ist reduction 254.686*1000/0.5/150 3395.81 kg
tooth load on 2nd reduction= 1167.1*1000/0.5/164*0.5 7116.46 kg
break down condition
tooth load ist reduction 293.87*1000/0.5/150 3918.27 kg
tooth load on 2nd reduction= 1318.3*1000/0.5/164*0.5 8038.41 kg
normal condition Stress= PXQ/FXM
CS-340-570 IS-1030
W1 3395.8*2.6/10/0.8 = 1104 kg/sq.cm
55C8-IS2004-EN9 < 1448Kg/cm 2
P1 3395.8*3.6/10/0.8 = 1528 kg/sq.cm
CS-340-570 IS-1030 < 1854Kg/cm 2
W2 7116.5*2.6/14/1 = 1322 kg/sq.cm
55C8-IS2004-EN9 < 1448Kg/cm 2
P2 7116.5*3.4/14/1 = 1728 kg/sq.cm
break down condition < 1854Kg/cm 2
W1 3918.3*2.6/10/0.8 = 1273 kg/sq.cm
< 2076Kg/cm 2
P1 3918.3*3.6/10/0.8 = 1763 kg/sq.cm
< 2586Kg/cm 2
W2 8038.4*2.6/14/1 = 1493 kg/sq.cm
< 2076Kg/cm 2
P2 8038.4*3.4/14/1 = 1952 kg/sq.cm
< 2586Kg/cm 2
checking wire rope and drum at break down condition
torque on drum = 1167.1*85/21*0.93 = 4393.3 kgm
rope tension under bdc of motar= 4393.3/0.5/0.52/2 8448.65 kg
torque on drum =
0.5xpcd of drum breaking strenth of rope = 34251 4.054 >3
factor of safety on rope = rope tension under bdc 8448.65
 CLIENT DESIGNED BY DESIGN CALCULATIONS OF
EE NARAYAN ROPE DRUM HOIST FOR PAGE-08
KNNL ENGINEERS SLUICE GATE [6'x15']
BHADRA DAM HOSAPETE FOR BHADRA DAM, KARNATAKA
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13 SHAFTS
A DRUM SHAFT

4243kg 8777kg

B
A a b
6.5cm 8cm
150cm
RA RB

Load acting at point b = Tooth load of W2 + 1/2 wt. Of drum

=+ Wt. Of gear wheel

= 7116 + 125 + 100 = 8776.51 kgs

cos20
Load acting at point a = 1/2 wt of drum+rope tension = 200+4043= kgs.
= 4243 kgs
Taking moment @ A
RB X 150 =8777 X142 + 4243 X 6.5
RB = 8493 Kgs. RA = 4527kgs.

Max.B.M =Ma= 4280*6.5 = 27579.5 kgcm

Max.B.M =Mb= 4104*8 = 70216 kgcm

Proposed 110 mm dia shaft

Material 45C8 IS:1570(part2)
Zxx II d3 = II X 11^3 = 130.6 cm^3
32 32

Bending stress 27580 = 211 kg/sq.cm < 1248 kg/sq.cm

130.6

shear stress= 4280 4280 45 kg/sq.cm < 720 kg/sq.cm

II d2 95
4
 CLIENT DESIGNED BY DESIGN CALCULATIONS OF
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KNNL ENGINEERS SLUICE GATE [6'x15']
BHADRA DAM HOSAPETE FOR BHADRA DAM, KARNATAKA
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B 2ND PINION SHAFT

3633kg 7590kg 3633kg

16cm 38cm 38cm 16cm

C c d D

33cm 44cm 33cm

RC RA RB RD
VETICAL LOADS
Load acting at point - c = Tooth load of p1
=+ Wt. Of gear pinion
3396 + 20 = 3633 kgs
= cos20
Load acting at point - d = Tooth load of p2
=+ Wt. Of gear wheel =
7116 + 100 7590 kgs
cos20
Load acting at point - c = Tooth load of p1
=+ Wt. Of gear pinion
3396 + 20 = 3633 kgs
= cos20

RC=RD= 3633/2= 1817 kg

RA=RB= [3633+7590]/2= 5612 kg
bending moment under -c

BM=RcX16= 1011*16 = 29072 kgcm

BM UNDER -d
BM=RAX22= 5724*22 = 125928 kgcm

PR0POSED SHAFT 110MM DIA

Material 45C8 IS:1570(part2)
ZXX= II d3 130.67 cm^3
32
polar modulus
zpp=2xzxx = 261 cm^3

bending stress=fb= BM UNDER P1 /ZXX= 125928/130.67=

963 kg/cm
< 1248 kg/sq.cm
TORSIONAL SHEAR=ts= torque on 1st gear /2pinion /Zpp= 116706.1/261=
= 447 kg/cm < 720 kg/sq.cm
combined stress=fc=fb+3xts= 1236 kg/cm <1468 kg/cm
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EE NARAYAN ROPE DRUM HOIST FOR PAGE-10
KNNL ENGINEERS SLUICE GATE [6'x15']
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C FIRST PINION SHAFT

3633 kg

22cm 22cm

E 44cm F

LOAD P= TOOTH LOAD ON 1ST REDUCTION 3396 ,+20

0.9396
cos20
= 3633 kg

RF=RE= 1816 kg

Bending moment in shaft

B.M= 1365*22 39952 kgcm

torque on shaft=torque on wormed reducer output shaft/1 pinon = 25469 kgcm

PRAPOSED SHAFT 75MM DIA

Material 45C8 IS:1570(part2)
ZXX= II d3 =
32
= 41.42 cm^3
polar modulus

zpp=2xzxx 82.83 cm^3

bending stress=fb= BM UNDER P/ZXX= 39952/41.42= 964 kg/cm

TORSIONAL SHEAR=ts= torque on 1st gear /Zpp=

25469/82.83 = 307 kg/cm

combined stress=fc=fb+3xts=

SQRT(964*964+3*307*307) = 1101 kg/cm

<1468 kg/cm
 CLIENT DESIGNED BY DESIGN CALCULATIONS OF
EE NARAYAN ROPE DRUM HOIST FOR PAGE-11
KNNL ENGINEERS SLUICE GATE [6'x15']
BHADRA DAM HOSAPETE FOR BHADRA DAM, KARNATAKA
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14 BEARINGS

For drum shaft

Provide bronze bush of alminium bronze-IS305 Grade AB1
on gear side
ID=110mm
OD= 110+2*(.08*110+3) = 133.6 mm
Provide OD=14cm
Length=14cm

Bearing stress bush=fb=11546/[11/9]= 117 kg/cm

on non gear side RB = 8493 Kgs.

ID=11cm
OD=14cm
length =10cm
Bearing stress bush= 5853/(8x9) = 81 kg/cm

For the second pinon shaft

max. reaction on bearing is RC= 4725 kg

RD= 3021 kg
Provide std. plumber block SNA520+2220K+H320
Static cap. Of Bearing =5000kg

For the first pinon shaft

max. reaction on bearing is RE= 524 kg
RF= 1418 kg
Provide std. plumber block SNA515+2215K+H315
STATIC CAP, Bearing =2000kg
 CLIENT DESIGNED BY DESIGN CALCULATIONS OF
EE NARAYAN ROPE DRUM HOIST FOR PAGE-12
KNNL ENGINEERS SLUICE GATE [6'x15']
BHADRA DAM HOSAPETE FOR BHADRA DAM, KARNATAKA
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16 MANUAL OPERATION
Torque on motar= 5.442 kgm
considering that 2 persons will be operating the hoist ,each applying a force of
10kg at lever arm of 400mm
force applied = 2x10 kg
lever arm = 40 cm
applied torque = 20x40= 800 kg-cm

Provide one set of sprockets driving driven

sprocket sprocket
[sp2] [sp1]
no.of teeth = 32 24
pitch = 1.905 1.905
pcd 19.4 14.5

tension in chain = 800 = 82.47 kg

0.5x19.4

with FOS of 5 ,min. breaking strenth of chain req.= 440 kg

provide a simple chain having pitch 19.05mm,having a min. breaking strength=2950kg
applied torque on the motar shaft= 800x19.4/14.5= 1070>800 kg-cm

17 CHECKING MANUAL OPERATION FOR FORCE APPLIED BY EACH PERSON

H.P. of Motor = 10 HP
Torque on motor shaft = 544 kgcm
Sprockets proposed no.of teeth PCD in cms pitch

SP1 24 14.5 3/4"

SP2 32 19.4 3/4"
Ratio of sprocket = 32/24 = 1.33
Torque developed at SP2= 544X1.33= 724 kgcm
Proposed crank shaft of 400mm long
Load on shaft = 724/40 = 18 kgs
Proposed 3/4" pitch chain having breaking strength of 2948 kgs
no. of persons required = 2
Force applied by each person = 18/2 =9kgs<10kgs
Hand operated speed is 24 rpm
Actual lifting speed = 0.65m/min
speed of motor shaft= 24x1.33 rpm
rated motor speed = 965 rpm
rate of reduction in lifting speed = 24x1.33/[965]
Actual lifting speed of during manual operation = 0.65x24x1.33/935= 0.0215 m/min
= 2.15cm/min
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KNNL ENGINEERS SLUICE GATE [6'x15']
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18 DESIGN OF CONNECTIONS
A BOLTS BETWEEN DRUM AND DRUM GEAR[provide fit bolt conform to IS3640 . cl.6.6]

Dia of bolt 2 cm
No.of bolts 6 nos
PCD of bolts 50 cm
A=Area of bolt= 3 sqcm
shear force due to torque =
SF1= torque on drum/drum gear= 2750x100 =
1/2xPCD of boltxnos of bolt 1/2x50x6 1833 kg
Shear force due to rope tension and weight of drum gear

Rope tension = 5128 kg

wt. of drum gear 140 kg

SF2=shear force in each bolt= 5128+140 = 878 kg

6[nos of bolt]

shear stress in bolt= SF1+SF2 (1833+878)/3 = 904 kg/sqcm

A <1224 kg/sqcm
[as per IS800,permissible shear stress for close tolerance bolts=1224kg/sqcm]

B KEY BETWEEN 2ND PINION AND SHAFT[material for key 40c8 IS 1570]

torque on shaft = 56277.0 kgcm

dia of shaft= 9 cm
shear in the key = 56277 = 12506 kg
0.5x9

provide key= w=2.2 cm

h=1.4 cm
l=10 cm

shear stress in key =12506 = 568 kg/sqcm

2.2x10
C KEY BETWEEN 1ST GEAR AND SHAFT[material for key 40c8 IS 1570]
Torque on shaft = 56277.0 kgcm
Dia of shaft= 9 cm
shear in the key = 56277 = 12506 kg
0.5x9
provide key= w=2.2 cm
h=1.4 cm
l=12 cm
shear stress in key = 12506 = 474 kg/sqcm
2.2x12
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KNNL ENGINEERS SLUICE GATE [6'x15']
BHADRA DAM HOSAPETE FOR BHADRA DAM, KARNATAKA
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D KEY BETWEEN 1ST PINION AND SHAFT[material for key 40c8 IS 1570]

Torque on shaft = 15171.0 kgcm

Dia of shaft= 6 cm
Shear in the key = 5171 = 5057 kg
0.5x6

Provide key= w=1.8 cm

h=1.1 cm
l=8.5 cm

Shear stress in key = 5057 = 331 kg/sqcm

1.8x8.5

17 POSITION INDICATOR [DIAL INDICATOR]

Normal lift of gate = 15.5 M

Drum dia 0.52 M
no of revelution of drum required= 2x15.5 = 19
3.1416x0.52

no of revelution on 1st pinion shaft= 19x85/21x82/17= 370.952

provide worm reducer having reduction 70; 1 and set of sprocket

no of teeth on driving sprocket = 24 [onp2shaft]

no of teeth on driven sprocket = 38 [on worm shaft]

total reduction providded = 70x88/16 = 385

total rotation= 371/385= 0.964
total rotation of indicator = = 0.964x360 347 deg

OOOOO-OOOOO