SCOPE OF HYDRO MECHANICAL WORKS - 330 MW SHEP

Detail description about selection of Gates, Design and Operational Features of all types of gates i.e. Fixed wheel Gates, Radial Gates, Bypass Gates, Slide Gates etc.
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SachinJain,India,Professional
Published Date:02-04-2018
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SCOPE OF HYDRO MECHANICAL WORKS Prepared By:- Sachin Jain Certified Energy Manager Shift In charge, DAM PROJECT-General Description BACKGROUND PROJECT PARTICIPANTS  Conceived by UPPCL in 1980.  Civil Works L&T (Major)  Started under PPP by Duncans in 1996.  Electro Mechanical BHEL  Taken over by Tata in 2003 as AHPCL.  Hydro Mechanical Precision  Taken over by GVK group in 2005  Penstocks P&R  Land acquisition 2006  Construction Start 2007  Commissioned 2015 MAJOR COMPONENTS SALIENT FEATURES  Diversion Dam 90m high  Design Capacity 330MW  Water Conductor 6 Km long  Energy Generation 1397 MU  Power House 4 x 82.5 MW  Project ownership UPPCL  Machine Vertical Francis  Concessionaire AHPCL (GVK)  Concession Period 30 Years  Project Cost 5,182 Crs  Power Purchase UPPCL(88%)  Free Power UK (12%) PROJECT LAYOUT De-siliting Basin HRT/ Intake Power Channel Power House Dam Forebay / Intake HYDRO MECHANICAL -OVERVIEW Sl.No. Location Item Description Unit Quantity Remark 1 SPILLWAY STOPLOG GATE Set 2 2 SPILLWAY STOPLOG GANTRY CRANE No. 1 3 SPILLWAY RADIAL GATE Nos. 8 Dam 4 Power Pack Nos. 8 5 Hydraulic Cylinder Nos. 16 6 Local Control Panel Nos. 8 7 Trash Rack Panels Nos. 60 INTAKE- TRASH RACK 8 TRC Machine No. 1 9 HRT INTAKE STOPLOG GATES Set 3 10 HRT INTAKE HRT GANTRY CRANE No. 1 11 HRT INTAKE SERVICE GATES Nos. 6 HYDRO MECHANICAL -OVERVIEW Sl.No. Location Item Description Unit Quantity Remark 12 Power Pack Nos. 6 13 HRT INTAKE Hydraulic Cylinder Nos. 6 14 Local Control Panel Nos. 6 15 UNDER SLUICE EMERGENCY GATES Nos. 4 16 UNDER SLUICE SERVICE GATES Nos. 4 17 Bulck Head Gate No 1 Dam- Under 18 EOT Crane Nos. 1 Sluice 19 Power Pack Nos. 4 20 Hydraulic Cylinder Nos. 8 21 Local Control Panel Nos. 4 22 Power House DRAFT TUBE GATE Nos. 12 HYDRO MECHANICAL -OVERVIEW Sl.No. Location Item Description Unit Quantity Remark 23 Power House DRAFT TUBE GANTRY CRANE No. 1 24 FOREBAY INTAKE STOPLOG GATE Set 1 25 FOREBAY INTAKE GANTRY CRANE No. 1 26 FOREBAY INTAKE GATE Nos. 4 Power House 27 Power Pack Nos. 4 28 Hydraulic Cylinder Nos. 4 29 Local Control Panel Nos. 4 30 DESILING BASIN ISOLATING STOPLOG GATE Set 1 31 DESILITING BASIN STOPLOG GANTRY CRANE No. 1 DSB 32 DESILING BASIN FLUSHING GATE Nos. 2 33 Power Pack Nos. 2 HYDRO MECHANICAL -OVERVIEW Sl.No. Location Item Description Unit Quantity Remark 34 Hydraulic Cylinder Nos. 2 35 Local Control Panel Nos. 2 36 BYPASS STOPLOG GATE No. 1 37 BYPASS STOPLOG GANTRY CRANE No. 1 POWER 38 HOUSE- BY BYPASS AUTOMATIC REGULATING GATE Nos. 3 PASS 39 Power Pack No. 1 40 Hydraulic Cylinder Nos. 3 A Remote Control Panel No. 1 B Common LT Panel No. 1 Control Room D Dam DC Battery Charging Panel Nos. 2 E Relay Panel Nos. 4 HYDRO MECHANICAL -EQUIPMENTS The main hydro-mechanical equipments required to manage and control the flow of water are:-  Radial gates of size 14.5m x 22.067 m provided on the spillway for controlling flood discharge - 08 Nos.  Spillway Stoplogs of size 14.5m x 22m consisting of 11 nos. of units each of 2.0m height on the spillway for inspection and maintenance of the spillway radial gates- 02 Nos.  Service & Emergency slide type under sluice gates of size 3m x 4m- 4 & 4 Nos.  Fixed wheel type bulkhead gate of size 5.0m x 5.32m provided for maintenance of Service & Emergency under sluice gates- 01 No.  Slide type silt flushing gates of size 2.15m x 2.6m provided for extraction of Silt/sand/gravels from the desilting basin- 02 Nos.  Slide type desilting basin stoplog provided for vent size opening of 12m x 10m to isolate the desilting basin- 01 No. HYDRO MECHANICAL -EQUIPMENTS The main hydro-mechanical equipments required to manage and control the flow of water are:-  HRT Intake slide type stoplog are provided for opening of 5m x 6.2m to isolate the HRT tunnel for carrying out repairs/maintenance- 03 Nos.  Fixed wheel type HRT Intake Service Gates of size: 5m x 6.2m- 06 Nos.  Slide type Forebay Intake stoplog provided for opening of vent size of 4.7 x 5.6m to isolate Forebay intake to permit maintenance of structure/equipment d/s of the stoplog- 01 No.  Fixed Wheel type Forbay vertical gates of size: 4.4m x 5.6m- 04 Nos.  Draft tube gates of size 4.772m x 5.08m are provided to enable the isolation of the draft tube from the tail water for inspection and maintenance work on the draft tube and turbine runner- 12 Nos.  Trash racks of size 4.20m x 4.05 m (height 19.7m) in front of HRT intake structure to prevent debris entering the HRT- (5 x 12) 60 Nos. HYDRO MECHANICAL -EQUIPMENTS The main hydro-mechanical equipments required to manage and control the flow of water are:-  Trash racks of size 4.40m x 4.16 m (height 16.10m) in front of Forebay intake structure to prevent debris entering the Forebay- (8 x 4) 32 Nos.  50T capacity Gantry Crane travelling on rails at Dam Top with the respective detachable type semi automatic lifting beams for operation of Spillway Stoplog Gates and Fixed Wheel Under sluice Bulk Head Gates- 01 No.  25T capacity Gantry Crane with requisite lifting beam is provided on deck on out let side of two desilting basin chambers for operation of desiliting basin isolating stoplogs- 01 No.  20T capacity gantry crane with requisite lifting beam is provided at deck level of HRT Intake structure to operate its stoplog elements- 01 No.  20T moving gantry crane is provided at deck level of Forebay Intake Structure to operate stoplog elements of the Forebay Intake- 01 No. HYDRO MECHANICAL -EQUIPMENTS The main hydro-mechanical equipments required to manage and control the flow of water are:-  20T capacity Gantry Crane travel on rails at deck level of structure with respective detachable type semi automatic lifting beam for operation of draft tube gates- 01 No  400T capacity twin cylinder (2x200 MT) Hydraulic Hoists are provided for operation of the Spillway gates under unbalanced head condition.  600t capacity double acting hydraulic hoist cylinders installed in gate operation chamber for operation of service & emergency gates provided in the body of dam.  170T capacity double acting hydraulic hoist cylinder installed in Silt flushing gate operation chamber provided in the gate shaft.  45T capacity Hydraulic Hoist for operation of HRT Service gates.  40T capacity Hydraulic Hoist for operation of Forbay Service gates. GATES A Gate is a closure device in which a leaf is moved across the fluid way from an external position to control flow of water.  Depending upon the head the gates are also further classified as:-  a) Low Head ( Less than 15 meters)  b) Medium head ( Between 15 to 30 meters)  c) High head ( Above 30 meters) Common Type of Gates in INDIA Vertical Lift Radial Gate Gates Fixed Wheel Type Slide Type Spillway Crest Orifice Spillway Gates Basic IS Codes  IS 13623 - Criteria for choice of gates and hoist.  IS 4622 - Recommendation for structural design of fixed wheel gates.  IS 4623 - Recommendation for structural design of radial gate.  IS 5620 - Recommendation for structural design of low head slide gate.  IS 9349 - Recommendation for structural design of medium and high slide gate.  IS 6938 - Design of Rope drum and chain hoist for hydraulic gates.  IS 10210 - Criteria for design of hydraulic hoist for gates.  IS 11288 - Recommendation for design of screw hoist and hydraulic gates.  IS 807 - Design, erection and testing (structural portion) of cranes and hoist- code of practice.  IS 3177 - Code of practice for electric overhead travelling cranes and gantry cranes other than steel work crane.  IS 13591 - Criteria for design of lifting beam.  IS 11855 - Guidelines for design and use of different types of rubber seals for hydraulic gates. CONTINUED…..  IS 15466 - Rubber seals for hydraulic gates- specification.  IS 14177 - Guidelines for painting system for hydraulic gates and hoist.  IS 800 - General Construction in Steel- Code of Practice.  IS 456 - Code of practice for plain and reinforced concrete. RADIAL GATE Definition of Radial gate “A device used for controlling the flow of water over spillways or into canals by having the upstream face curved in the form of an arc the center of which is at the center of the gate hinge —called also tainter gate” Advantages • Better discharge characteristics than partial gate openings. • Low cost. • Bearings are located out of the water. • Aesthetics – Does not require an overhead supporting structure (gate tower). • Does not require gate slots which can become plugged with ice or debris and can cause cavitations. Disadvantages • Longer piers. • Relatively high concentrated loads at the trunnions. • More complex fabrication than other gate options. • More complicated dogging system to facilitate maintenance activities. RADIAL GATE RADIAL GATE Radial gate- Structural design In a radial gate, water pressure is transferred from the curved face to the radial gate arms which transfer the load to a common bearing on either side of the gate opening. Load combinations for water control gates can be complex and special care should be taken in identifying all of the important combinations. Agencies will usually provide guidance (or rigid codes) on this but here some of the most important ones: •Dead Load + Impact (during installation, dry testing, or servicing) •Dead Load + wave load •Dead Load + Hydrostatic Load corresponding to top of gate •Dead Load + Hydrostatic Load at design flow level + Ice load •Dead Load + Hydrostatic Load at spillway design flow (gates open) •Dead Load + Hydrostatic Load at design flow level + Earthquake force •Dead Load + Hydrostatic Load at Inflow Design Flow with gates open. RADIAL GATE Radial gate- PARTS Radial gates consist of the following four parts: •The gate leaf assembly, including the curved skin plate, cross bracing or struts, supporting beams and girders, and rubber seals. •Arm assembly, including the arm columns, bracing, and hub. •Trunnion assembly, including a pin, busing, thrust washers, lubrication provisions, and yoke. •Trunnion support assembly, including the trunnion beam or anchor block and anchorage system. RADIAL GATE Radial gate- Strength Calculation – Auxiliary horizontal beams – Loads acting on main frameworks – Beam arrangement and design hydraulic – Arrangement of main vertical beams and arms pressures – Section properties of horizontal connection beams – Strength of auxiliary horizontal beams – Sectional properties of arm – Skin plate – Frameworks – Bending stresses – Stresses of frameworks – Correction factor – buckling and stability of buckling – Hydraulic load acting on skin plate – Trunnion assemblies – Stresses acting on skin plate – Trunnion pins – Main vertical beams – Trunnion bearing – Loads – Bracket – Bending moment and shearing force – Hoist System – Sectional modulus and stresses – Operation load – Hydraulic cylinder RADIAL GATE Radial Gate- Bill of Quantity Total wt. per unit Sl.No. Description Sub Item Weight (KG) Remark (BOQ) in KG Sill Beam 423.62 Spillway radial Gate 2nd Total no of 1 3177.72 Stage EP vents are 8 Wall Plate 2754.1 Horizontal Girders 8204.77 Horizontal Stiffners 1775.7 Gate Leaf Bottom Element Lifting Bracket 5057.6 2 25643.4 Downstream Skin Plate & Vertical Stiffeners 7646.77 Arm Support 2958.56 BOQ for one Horizontal Stiffeners 1671.04 Gate Leaf Intermediate 3 10147.4 Gate Element 2nd Vertical Girders and Skin Platee 8476.36 Horizontal Stiffners 1671.04 Gate Leaf Intermediate 4 8965 Element 3rd Vertical Girders and Skin Platee 7293.96 Vertcal Girders 3369.84 Gate Leaf Intermediate 5 8965.89 Skin Plate and Horizontal Element 4th 5595.96 Stiffeners

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