Erbisti D e s i g n o f H y Revised and updated, this second edition of Design of Hydraulic Gates d maintains the same goal as the original: to be used as a textbook and a manual r a of design of gates, presenting the main aspects of design, manufacture, installation and operation of hydraulic gates, while introducing new products, u technologies and calculation procedures. This edition included new chapters l i on intake gates and trashrack design, highlighting the aspects of safety, c operational and maintenance procedures. To improve the strength against structural failure of intake trashracks, the author proposes a series of rigid G calculation assumptions, design parameters and manufacturing procedures, a which will certainly result in safer trashracks. Some 340 drawings and t photographs, 82 tables, 107 references and 23 worked examples help the e reader to understand the basic concepts and calculation methods presented. s Brazilian engineer Paulo Erbisti graduated in mechanical engineering and has amassed considerable experience working on numerous hydromechanical projects, contributing greatly to hydropower/dam engineering over the last few decades in South America, Africa and Asia. He has worked on many important projects including Itaipu, Belo Monte, Tucurui, Gotvand, Tarbela, Capanda, Design of Guri and Tocoma. Erbisti is a visiting professor on the topic of hydraulic gate design for the post-graduate course of hydraulic engineering at the University Hydraulic Gates of Paraná, Brazil. He is a member of the consulting board of the International Journal on Hydropower and Dams, UK. In 2011, he was elected by International Water Power & Dam Construction magazine as one of twenty people believed to have made the biggest difference to the sector over the last decade. Paulo C.F. Erbisti 2nd Edition 2nd Edition an informa business ERBISTI final.indd 1 01-05-14 13:37 Design of Hydraulic Gates, 2nd Edition TThhiiss ppaaggee iinntteennttiioonnaallllyy lleefftt bbllaannkk Design of Hydraulic Gates, 2nd Edition Paulo C.F. Erbisti Consulting Engineer CRCPress/BalkemaisanimprintoftheTaylor&FrancisGroup,aninformabusiness ©2014Taylor&FrancisGroup,London,UK TypesetbyMPSLimited,Chennai,India PrintedandBoundbyCPIGroup(UK)Ltd,Croydon,CR04YY Allrightsreserved.Nopartofthispublicationortheinformationcontained hereinmaybereproduced,storedinaretrievalsystem,ortransmittedinany formorbyanymeans,electronic,mechanical,byphotocopying,recordingor otherwise,withoutwrittenpriorpermissionfromthepublisher. Althoughallcareistakentoensureintegrityandthequalityofthispublication andtheinformationherein,noresponsibilityisassumedbythepublishersnor theauthorforanydamagetothepropertyorpersonsasaresultofoperation oruseofthispublicationand/ortheinformationcontainedherein. LibraryofCongressCataloging-in-PublicationData Erbisti,PauloC.F. Designofhydraulicgates/PauloC.F.Erbisti,consultingengineer.—Secondedition. pagescm Includesbibliographicalreferencesandindex. ISBN978-0-415-65939-0(hardback) 1. Hydraulicgates–Designandconstruction. I.Title. TC169.E72 2014 627’.882—dc23 2014008511 Publishedby: CRCPress/Balkema P.O.Box11320,2301EHLeiden,TheNetherlands e-mail:[email protected] www.crcpress.com–www.taylorandfrancis.com ISBN:978-0-415-65939-0(Hbk) ISBN:978-0-203-39624-7(eBookPDF) Table of contents Preface xi Acknowledgements xiii 1 Introduction 1 1.1 Historyanddevelopment 1 1.2 Gatecomponents 10 1.3 Mainapplications 11 1.4 Typesandclassifications 12 1.4.1 Purpose 12 1.4.2 Movement 13 1.4.3 Waterpassage 13 1.4.4 Gateleafcomposition 14 1.4.5 Location 14 1.4.6 Skinplateshape 14 2 Typesofgates 17 2.1 Flapgate 17 2.2 Cylindergate 24 2.3 Stoplogs 25 2.4 Slidegate 30 2.5 Caterpillargate 35 2.6 Mitergate 38 2.7 Rollergate 43 2.8 Segmentgate 45 2.9 Sectorgate 63 2.10 Stoneygate 66 2.11 Drumgate 68 2.12 Bear-trapgate 70 2.13 Fixed-wheelgate 71 2.14 Visorgate 82 3 Basisforselectionofgatetype 85 3.1 Introduction 85 3.2 Mostcommontypes 85 vi Table of contents 3.3 Operationalrequirements 86 3.4 Presentlimitsofgatesizesandheads 88 4 Hydrostatics 103 4.1 Introduction 103 4.2 Verticalliftgates 103 4.2.1 Weirgates 103 4.2.2 Submergedgates 105 4.2.3 Spacingofhorizontalbeams 107 4.3 Radialgates 110 5 Structuraldesign 117 5.1 Loadcases 117 5.2 Allowablestresses 119 5.3 Skinplate 121 5.3.1 Thickness 121 5.3.2 Platestresses 121 5.3.3 Effectivewidth 125 5.4 Horizontalbeams 126 5.4.1 Numberofbeams 126 5.4.2 Girderdimensions 127 5.4.2.1 Webthickness 127 5.4.2.2 Webdepth 128 5.4.2.3 Flanges 128 5.4.3 Elasticstability 129 5.4.3.1 Compressionflanges 129 5.4.3.2 Webstability 130 5.4.3.3 Stiffeners 136 5.4.4 Simplebendingofbeams 136 5.5 Segmentgate 139 5.5.1 Skinplate 139 5.5.2 Gateframing 140 5.5.2.1 Girderarrangement 140 5.5.2.2 Horizontalbeams 140 5.5.2.3 Verticalbeams 141 5.5.3 Radialarms 149 5.5.3.1 Axialloadsonthearms 149 5.5.3.2 Bearingloads 150 5.5.3.3 Bucklingcheck 152 5.6 Siltpressureongates 155 5.7 Gateseismicloads 156 6 Embeddedparts,guidesandsupports 159 6.1 Slotsandniches 159 6.2 Wheeltrack 161 6.2.1 Beamonanelasticfoundation 161 6.2.2 DimensioningbytheAndree-Fricketheory 165 Table of contents vii 6.3 Slidetracks 170 6.4 Concretebearingpressure 174 6.5 Lateralguidance 175 6.6 Wheelsandpins 177 6.6.1 Designfeatures 177 6.6.2 Contactpressurebetweenwheelandtrack 180 6.6.3 Permissiblecontactstresses 186 6.6.4 Surfacehardness 188 6.7 Gatehingesandbearings 188 6.7.1 Typesofbearings 188 6.7.2 Cylindricalbushings 188 6.7.3 Sphericalplainbearing 190 6.7.4 Rollerbearings 192 7 Estimatinggateweights 195 7.1 Introduction 195 7.2 Segmentgates 196 7.3 Fixed-wheelgates 197 7.4 Double-leaffixed-wheelgates 197 7.5 Stoplogs 199 7.6 Flapgates 200 7.7 Caterpillargates 201 7.8 Embeddedparts 201 8 Hydrodynamicforces 211 8.1 Introduction 211 8.2 Modeltests 214 8.3 Factorsinfluencingdownpull 217 8.4 Formulaeforthepredictionofdownpull 220 8.5 MethodofKnapp 231 9 Gateoperatingforces 237 9.1 Introduction 237 9.2 Gateweight 237 9.3 Frictiononsupportsandhinges 238 9.4 Sealdeflection 240 9.5 Sealfriction 241 10 Aeration 251 10.1 Introduction 251 10.2 Airvents–functionsandfeatures 251 10.3 Airvents–empiricalcalculation 253 10.4 Air-demandratio 254 10.5 Airventdimensioning 258 11 Gatehoists 265 11.1 Introduction 265 11.2 Screwlifts 265 viii Table of contents 11.3 Wireropes 267 11.4 Rollerchains 271 11.5 Oilhydraulicdrives 274 11.6 Gatehoistarrangement 283 11.7 Handoperation 286 11.8 Designcriteria 288 11.8.1 Loadcapacity 288 11.8.2 Operatingspeed 288 11.8.3 Safetyfactors 288 11.9 Gatepositionmeasurement 289 12 Materials 295 12.1 Introduction 295 12.2 Heattreatment 295 12.3 Rolledsteels 296 12.4 Steelsformachineelements 296 12.5 Stainlesssteels 297 12.6 Caststeels 297 12.7 Forgedsteels 297 12.8 Graycastirons 298 12.9 Bronzes 298 12.10 Bolts 298 13 Gateseals 307 13.1 Introduction 307 13.2 Woodseals 307 13.3 Metallicseals 307 13.4 Rubberseals 307 13.5 Materialforrubberseals 311 13.6 Cladseals 313 13.7 Rubbersealhardness 314 13.8 Rubberspecifications 314 13.9 Sealleakage 314 13.10 Manufactureandassemblyofseals 315 13.11 High-headsegmentgates–designconsiderations 317 13.12 Double-sealinggates 321 14 Manufacture,transportationanderection 335 14.1 Manufacture 335 14.1.1 Manufacturingsteps 335 14.1.2 Full-sizelayoutdrawings 335 14.1.3 Storingofrawmaterial 335 14.1.4 Marking 336 14.1.5 Cutting 336 14.1.6 Curving 336 14.1.7 Structurewelding 336 14.1.8 Finishing 337 Table of contents ix 14.1.9 Pre-assembly 337 14.1.10 Machining 339 14.1.11 Mechanicalfit-up 341 14.1.12 Anticorrosiveprotection 342 14.1.13 Inspection 345 14.1.14 Manufacturingtolerances 347 14.2 Transportation 349 14.3 Fielderection 350 14.3.1 Erectioninstructions 350 14.3.2 Erectionofembeddedparts 350 14.3.3 Erectiontolerancesofembeddedparts 352 14.3.4 Gateassembly 353 14.4 Acceptancetests 354 15 Trendsandinnovationingatedesign 357 15.1 Long-spangates 357 15.2 High-headgates 362 15.3 Refurbishmentandmodernizationofgatesanddams 364 15.3.1 Heighteningofexistinggates 365 15.3.2 Installationofnewgatesonthetopofthedam 369 16 Intakegates 377 16.1 Intakegatesandaccessories 377 16.2 Typesofemergencygates 378 16.3 Gatehoists 380 16.3.1 Typesofhoists 380 16.3.2 Hydraulichoists 381 16.3.3 Cablehoists 382 16.3.4 Gantrycranes 384 16.4 Fillingthepenstock 385 16.5 Aeration 388 16.6 GuardgatesforKaplanturbines 389 16.7 Guardgatesforbulbturbines 390 16.8 DrafttubestoplogsforbulbandKaplanturbines 391 17 Intaketrashracks 395 17.1 Introduction 395 17.2 Rackbarspacing 396 17.3 Designconsiderations 397 17.4 Flowvelocity 401 17.5 Headloss 402 17.6 Flow-inducedvibrations 402 17.7 Rack-cleaningmachines 410 17.8 Safedesigncriteriafortrashracks 413 Nameindex 419 Subjectindex 421