KUNDAH PSP CONSORTIUM

DESIGNED BY:

OM INFRA LIMITED
NBCC PLAZA, TOWER- III,
4TH FLOOR, SECTOR-5, PUSHP VIHAR,
SAKET, NEW DELHI-110017

PROJECT:
KUNDAH PUMPED STORAGE H.E. PROJECT

CLIENT:

TAMILNADU GENERATION AND DISTRIBUTION

CORPORATION LIMITED

CONSULTANT:

WAPCOS LIMITED
 Tamilnadu Generation and Distribution Corporation Ltd.
CHKD: RECM: APPVD:
WAPCOS Ltd.

Contractor KUNDAH PSP CONSORTIUM

KUNDAH PUMPED STORAGE H. E. PROJECT,

Project :
PHASE – 1, (1 X 125MW), PACKAGE-II
“DESIGN CALCULATION OF HOISTING ARRANGEMENT”
Title FOR 65T ROPE DRUM HOIST
FOR SURGE SHAFT GATES
Phase Rev. Revision CHKD. SUB. DATE
Pre – feasibility Study
Feasibility Study
Concept & Basic Design
Tender Design
Construction Design
As Built Design

Document No. Revision

Design
memo
OMIL/KPS-HEP/PKG-II/DGN/SURG/450 0
Prepared By. Checked By. Submitted By. Date of Submission

MOHIT MANISH JAIN HC JAIN 11.07.2023

 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

1 Description
The Propsed electrically operated Rope Drum Hoist is designed of capacity 65 Tonnes
for the operation of HRT Surge Shaft Gates (size - 4.55m X 8.5m) as per the provision contained
in the IS:6938. The Gate shall be operated by proposed Hoist under balance water head condition
achieved by Filling Valve.
The Hoist shall be installed on the hoist bridge duly supported of fixed legs & girder on adequate
height so as to Bring out the gate out of the groove above Deck Level = 2235.0 m

2 Mechanical Strength of proposed Materials

Y.P UTS
Material Material Specification
(Kg/cm²) (Kg/ cm^2)
Structure Steel
Upto 20 th 2600
IS:2062, Gr-B
over 20 upto 40th 2400 4200
Over 40th 2300
IS:1570 C40 3190 5800
Carbon Steel IS:2004 CL.4 3300 6340
IS:2004 CL.5 3600 7200
IS:1030
Cast Steel 2850 5300
Gr.280-520N
Aluminium Bronze IS:305 Gr.AB-2 6000
AISI:420 AISI:420 4990 7033

3 Allowable Stress
A. Rope Drum IS:1030 Gr-280-520N
Compressive Stress Under Normal Condtion : 5300x0.2= 1060 Kg/cm²
Compressive Stress Under BDT Condtion : 2850X0.8= 2280 Kg/cm²

B. Gear IS:1030 Gr-280-520N

i Compressive Stress Under Normal Condtion : 5300x0.2= 1060 Kg/cm²
ii Compressive Stress Under BDT Condtion : 2850X0.8= 2280 Kg/cm²

C. Pinions IS:2004 CL.5 (55C8)

i Compressive Stress Under Normal Condtion : 7200x0.2= 1440 Kg/cm²
ii Compressive Stress Under BDT Condtion : 3600x0.8= 2880 Kg/cm²

D. Shafts IS:2004 CL.5

Normal Condition
i Bending Stress without Keyway : 7200x0.2= 1440 Kg/cm²
ii Bending Stress with Keyway : 7200x0.2x0.75= 1080 Kg/cm²
iii Shear Stress without Keyway : 3600x0.3= 1080 Kg/cm²
iv Shear Stress with Keyway : 3600x0.3x0.75 810 Kg/cm²
v Equ.Bending Stress without Keyway : 1440x1.2= 1728 Kg/cm²
vi Equ.Bending Stress with Keyway : 1440x1.2x0.75= 1296 Kg/cm²
vii Equ .Shear Stress without Keyway : 1080x1.2= 1296 Kg/cm²
viii Equ .Shear Stress with Keyway : 1080x1.2x0.75= 972 Kg/cm²
ix Combined Stress without Keyway : 7200x0.24= 1728 Kg/cm²
x Combined Stress with Keyway : 7200x0.24x0.75= 1296 Kg/cm²

PAGE : 1 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

BDT Condition
i Bending & shear Stress Without Key Way : 3600x0.8= 2880 Kg/cm²
ii Bending & shear Stress With Key Way : 3600X0.8X0.75= 2160 Kg/cm²
iii Equ Bending & shear Stress Without Key Way : 2880X1.2= 3456 Kg/cm²
iv Equ Bending & shear Stress With Key Way : 2880X1.2X0.75= 2592 Kg/cm²
v Combined stress without keyway: 3600X0.8= 2880 Kg/cm²
vi Combined stress with keyway: 3600X0.8X0.75 2160 Kg/cm²

E. Bush for Sheaves IS:305 Gr.AB-2

i Bearing stress under normal Condition : 6000X0.35= 210 Kg/cm²
ii Bearing stress under BDT Condition : 6000X0.035X1.2= 252 Kg/cm²

F. Key for Shaft IS:2004 CL.4

i Shear Stress : 3300x0.3= 990 Kg/cm²
ii Crushing stress : 6340x0.2= 1268 Kg/cm²
iii Shear Stress under BDT Condition : 3300x0.8= 2640 Kg/cm²
iv Crushing Stress under BDT Condition : 3600x0.8= 2880 Kg/cm²

G. Pin for Gate sheaves AISI420

i Bending Stress Under Normal Condition : 7033X0.2= 1406.6 Kg/cm²
ii Shear Stress Under Normal Condition : 4990X0.3= 1497 Kg/cm²
iii Bending Stress Under BDT Condition : 4990X0.8= 3992 Kg/cm²
iv Shear Stress Under BDT Condition : 4990X0.8= 3992 Kg/cm²

H. Pin for Balancing sheaves IS:2004 CL.4

i Bending Stress Under Normal Condition : 6340X0.2= 1268 Kg/cm²
ii Shear Stress Under Normal Condition : 3300X0.3= 990 Kg/cm²
iii Bending Stress Under BDT Condition : 6340X0.8= 5072 Kg/cm²
iv Shear Stress Under BDT Condition : 3300X0.8= 2640 Kg/cm²

I. Structure steel IS:2062, Gr. -Br

Normal Condition
(upto 20mm thk)
i Bending Stress : 2600x0.66= 1716 Kg/cm²
iii Shear Stress : 2600x0.4= 1040 Kg/cm²
iii Direct Tension/Compression : 4200x0.17= 714 Kg/cm²
iv Crushing Stress : 2600x0.75= 1950 Kg/cm²
over 20 upto 40thk
i Bending Stress : 2400x0.66= 1584 Kg/cm²
iii Shear Stress : 2400x0.4= 960 Kg/cm²
iii Direct Tension/Compression : 4200x0.17= 714 Kg/cm²
iv Crushing Stress : 2400x0.75= 1800 Kg/cm²
BDT Condition
v Stresses (over 20 upto 40thk) : 2400x0.8= 1920 Kg/cm²
vi Stresses (upto 20thk) : 2600x0.8= 2080 Kg/cm²

J. Material of wheel axles IS:2004 CL.4

Yield Stress = 3264 Kg/cm²
UTS = 6324 Kg/cm²

PAGE : 2 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

Normal Condition
i Bending Stress without Keyway : 6324x0.2= 1264.8 Kg/cm²
ii Bending Stress with Keyway : 6324x0.2x0.75= 948.6 Kg/cm²
iii Shear Stress without Keyway : 3264x0.3= 979.2 Kg/cm²
iv Shear Stress with Keyway : 3264x0.3x0.75= 734.4 Kg/cm²
v Equ.Bending Stress without Keyway : 1264.8x1.2= 1517.76 Kg/cm²
vi Equ.Bending Stress with Keyway : 1264.8x1.2x0.75= 1138.32 Kg/cm²
vii Equ .Shear Stress without Keyway : 979.2x1.2= 1175.04 Kg/cm²
viii Equ .Shear Stress with Keyway : 979.2x1.2x0.75= 881.28 Kg/cm²
ix Combined Stress without Keyway : 6324x0.24= 1517.76 Kg/cm²
x Combined Stress with Keyway : 6324x0.24x0.75= 1138.32 Kg/cm²

BDT Condition
i Bending & shear Stress without Keyway : 3264x0.8= 2611.2 Kg/cm²
ii Bending & shear Stress with Keyway : 3264x0.8x0.75= 1958.4 Kg/cm²
iii Equ Bending & shear Stress without Keyway : 2611.2x1.2= 3133.44 Kg/cm²
iv Equ Bending & shear Stress with Keyway : 2611.2x1.2x0.75= 2350.08 Kg/cm²
v Combined stress without keyway : 3264x0.8= 2611.2 Kg/cm²
vi Combined stress with keyway : 3264x0.8x0.75= 1958.4 Kg/cm²

4 Technical specification
i) Designed as per = IS:6938
ii) Lifting Capacity including wt. of wire rope = ( 65 + 2) = 67 T
iii) Deck Level = 2235.00 M
iv) Sill Level = 2157.45 M
v) Lift for Dogging Beam proposed = 0.50 M
vi) Min. Lift required = 2235-2157.45+0.5 = 78.05 M
vii) Lift Proposed = 78.50 M
vii) Hoist operating speed = 0.70 M/MIN

5 Design/selection of Components for Hoist

Efficiency
Components
Running Starting
Worm Gear Box 0.8135 0.44
Gate Sheave 0.98 0.95
Spur Gear-1 0.95 0.93
Spur Gear-2 0.95 0.93
Rope Drum 0.95 0.93
Total = 0.68 0.34

No of Pair of Spur Gear = 2 each side

No of Roating Sheave = 1 each side
No. of Fall on Each Drum = 2

Overall Running to starting effieciency ratio = (0.68/0.34) = 2.00

Starting Torque to Rated Torque Ratio of Motor = 2.25 Safe

PAGE : 3 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

5.1 Motor
Motor K.W= (Wx V X S)/(6.12 x Er)
where,
W (Lifting capacity) V (Hoist Speed) Ser.Fact.(S)
67 T 0.7 M/MIN 1

K.W = (67x0.7x1)/(6.12x0.68) = 11.27 K.W

= 15.11 HP
Propsed TEFC Squirrel Cage Induction motor, with "F" CLASS Insulation and 3ph, 50c/s, 415v, 40% CDF, S3/S4 Duty, 150
starts/Hr, 6 Pole

K.W HP RPM POT Qty. Frame size Make

15 20 935 2.75 1 160L BBL

5.2 Design/Selection of Brakes-

Torque on motor Shaft = (20x4500)/(2x3.14x935) = 15.32 Kg-m
150% Breaking Load,Torque= 15.32x1.5 = 22.98 Kg-m

Proposed :
a Type Dia (mm) Braking Torque Qty. Make
AC EM 300 45.7 Kg-m 1 Elektromag/Sterling Control
100% coil rating on 400/415V, 50cylce/sec.

b Type Dia (mm) Braking Torque Qty. Make

EBTM
250 35 Kg-m 1 Electromag/Sterling Control
Thruster

18kg Thruster, 100% coil rating on 400/415V, 50cylce/sec.

5.3 Brake Drum Coupling-

Required H.P AT 100 rpm = (20x100)/935 = 2.14

a For EM Brake
Dia (mm) Size HP at 100RPM Pilot Bore Type Qty.
300 N92PBD12 18 25.4 Brake Drum Type flexible 1

b For Thruster Brake

Dia (mm) Size HP at 100RPM Pilot Bore Type Qty.
250 NBPBD10 9.5 25.4 Brake Drum Type flexible 1
Make : Electomag/Mark-AEC

5.4 Wire Rope

S.W.L = 67 T
Total no. of Fall = 4
No. of Rope Drum = 2
No. of Fall per side 4/2= 2
Sheave Efficiency = 0.98
Rope Tension= = (67/2)x(1-0.98)/(1-0.98^2) = 16.92 T
= 165.99 Kn
Factor of Saftey = 6 (Normal Condition )
Min. Breaking Strength required = 165.99x6 = 995.91 Kn

PAGE : 4 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

Proposed :
Dia (mm) Type Construction Breaking Load Wire Strength
40 Fibre core 6x36 1035 Kn 1960 N/MM2
Make : Usha Martin/Bharat Wire Rope

Factor of Saftey= (1035/165.9852) 6.24 > 6 safe

5.5 Rope Drum : Material:- IS:1030 Gr-280-520N

Total Drum = 2 nos.

Min PCD OF Drum = (20x40) = 800 mm
Proposed PCD of 1st layer = 1120 mm = 1.12 m
Circumfrence of 1st layer = 3518.58 mm = 3.52 m
PCD of 2nd layer = 1200 mm 1.2 m
Circumfrence of 2nd layer 3769.91 mm = 3.77 m
Groove Depth = (0.35x40)= 14.0 ≈ 14 mm
Radius of Groove = (0.53x40)= 21.2 ≈ 21.5 mm
Pitch of Groove = (1.1x40)= 44 ≈ 44 mm

Effective Groove Required (considering 1st layer PCD)= (78.5x1000x2)/(3.14x1120) = 44.64 nos.
Effective Groove Required (considering 2nd layer PCD)= (78.5x1000x2)/(3.14x1200) = 41.67 nos.

Effective Groove Required (considering both layers)= (44.64+41.67)/2 = 43.16 nos.

say 44 nos.
Proposed,
Effective grooves proposed on 1st layer = 24 nos.
Effective grooves proposed on 2nd layer = 20 nos.
Idle grooves proposed on 1st layer (when gate at sill beam) = 2 nos.
Idle grooves proposed on 2nd layer (when gate above Deck) = 1 no.
Groove proposed on 1st layer for wire rope clamp = 2 nos.

Total Grooves required at 1st layer = (24+2+2) = 28 nos.

Total Grooves required at 2nd layer = (20+1) = 21 nos.

Gate lifted by 1st layer = = (24x3.52)/2) = 42.24 M

Gate lifted by 2nd layer = = (20x3.77)/2) = 37.70 M
Total lift achieved = 79.94 M

Groove Length per Drum= (28x44)= 1232 mm

Drum Length proposed = 1525 mm (refer detail drg.)

Thickness of Rope Drum

K  W
t 
P  C
Where
k = 1.75 Co-efficient depend upon no. of Layer
W = 16920 Kg Rope Tension
P = 4.4 cm Pitch of Groove
Permissible Compressive stress = 1060 Kg/cm²
Thickness of rope drum (t) = (1.75x16920)/(4.4x1060)= 6.35 ≈ 6.5 cm
Actual compressive stress of Drum = (1.75x16920)/(4.4x6.5)= 1035.31 Kg/cm² safe

PAGE : 5 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

Checking Bending stress of Rope Drum

Self weight of Rope Drum = 3700 Kg
Appx. Weight of Wire rope per Drum = 1000 Kg
Total Weight of Drum including wire rope = 4700 Kg
Bending Moment due to self weight = (4700x152.5)/4= 179187.5 Kg-cm
Bending moment due to Rope Tension = (16920x152.5)/4= 645075 Kg-cm
Total Bending Moment = (179187.5+645075)= 824262.5 Kg-cm

Section Modulus ( Z ) 

  D4  d 4 
32  D

Where
D= 108 cm Min. Outside Diameter of rope drum
d= 95 cm Inside Diameter of rope drum
Z= (3.14(108^4-95^4)/32X108 = 49606.07 cm3

Bending Stress= 824262.5/49606.07 = 16.62 Kg/cm²

Combined Stress ( combined )   c2   b2

= (1035.31^2+16.62^2)^0.5= 1035.44 Kg/cm² < 1060 Kg/cm² safe

5.6 Bolts for connecting Gear with rope drum

Rope Tension= 16920 Kg

PCD of Bolts= 1400 mm
Proposed no. of Bolts= 6 nos.
Load on Bolts= (16920x1400)/1120 = 21150.00 Kg
Load on each Bolts= 21150/6 = 3525 Kg

Proposed 21 mm dia Fit Bolts

Grade of Bolts 8.8
Ultimate Tensile Load= 122000 N
UTS = 500 Kg/cm²
Y.P = 3000 Kg/cm²
Min. cross Section Area= 11.78 cm2
Allowable shear stress= (3000x0.3)= 900 Kg/cm²
Shear Stress in bolts= (3525/11.78)= 299.24 Kg/cm²

5.7 Gear Box

Proposed K.W of Motor= 15 K.W
Service Factor as per Gearbox catalogue= 1.25
Minimun Rating of Gear Box= 15x1.25 = 18.75 K.W

Proposed Worm Reducer having:

Reduction Ratio Size Type Input k.w Input RPM O/p k.w O/P Torq
60 12 U 20.1 1000 16.35 9350 Nm

Running Efficiency = 81.35 %

Starting efficiency = 44 %
Make - NAW

PAGE : 6 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

5.8 Open gear & Pinion

Module
Description Teeth PCD (mm) Pressure Angle Material
(mm)
W1 110 20 2200 20 IS:1030 Gr280-520N
P1 16 20 320 20 IS:2004 Gr-55c8
W2 116 10 1160 20 IS:1030 Gr280-520N
P2 19 10 190 20 IS:2004 Gr-55c8

Speed of the Hoist (during 1st layer)= (935x16x19x3.142x11.2)/(60x110x116x2) = 0.65 m/min

Speed of the Hoist (during 2nd layer)= (935x16x19x3.142x12)/(60x110x116x2) = 0.70 m/min

Tooth load for W1P1= (16920x1120)/(2200x0.95x0.95) = 9544.4 Kg

Tooth load for W2P2= {9544.4x(320/2)} / {(1160/2)x0.95} = 2771.51 Kg

Root Stress= (PxQ / FxM)

Where,
P = Tooth Pressure F = Face Width
Q = Strength Factor M = Module

Des. P (kg) Q F (cm) M (cm) Root Stress Allowable stress

W1 9544.4 2.5 16 2 745.66 1060 Kg/cm² safe
P1 9544.4 3.47 17 2 1034.97 1440 Kg/cm² safe
W2 2771.51 2.5 10 1 692.88 1060 Kg/cm² safe
P2 2771.51 3.75 11 1 1039.32 1440 Kg/cm² safe

Torque on drum/W1 Gear = (16920x116)/2= 981360 Kg-cm

Torque on P2 shaft = (981360x16)/(110x0.95x0.95)= 158164.29 Kg-cm
RPM of P2 shaft = 935/60= 15.58 RPM
RPM of P1W2 Shaft = 15.58x16/116= 2.15 RPM
Rpm of W1/Rope Drum = (2.15x16)/110= 0.31 RPM

5.9 Rope Drum Shaft

Self Weight of Gear = 2200 Kg
Self weight of Rope Drum = 4700 Kg (including wire rope)

Case-1 When Gate is at Deck Level (full open) & Rope is on middle of drum

W1 C.L of Wire rope C.L of Drum Bush

A B C D E

27.9 55.5 92.5 12.1

C.L of support
188.00

Vertical Load at different location on the rope drum shaft

Total vertical load at loaction B = Self load of gear (W1)+Half load of drum+Load due to Rope Tension at
C+Tooth load of Gear W1
= (2200+2350+(16920x92.5)/148)+9544.4= 24669.4 Kg
Total vertical load at loaction D = (Self wt. of drum/2)+Load due to Rope Tension at C
= (2350+(16920X55.5)/148 = 8695 Kg

PAGE : 7 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

Vertical Load at A = (24669.4X160.1+8695X12.1)/188= 21567.98 Kg

Vertical Load at E = 24669.4+8695-21567.98 = 11796.42 Kg

Horizontal Load at different location on the rope drum shaft from Gear (W1)
Hor. Load at "B" due to Gear W1 = = 9544.4xTan20 = 3473.88 kg
Hor. Load at "A" due to Gear W1 = =(3473.88X160.1/188 = 2958.34 Kg
Hor. Load at "D" due to Gear W1 = =(3473.88X27.9)/175.9 = 551 Kg
Hor. Load at "E" due to Gear W1 = =(3473.88-2958.34) = 515.54 Kg

Resultant Load at Different Locations

Resultant Load at A = (21567.98^2+2958.34^2)^0.5 = 21769.92 Kg
Resultant Load at B = (24669.4^2+3473.88^2)^0.5 = 24912.79 Kg
Resultant Load at D = (8695^2+551^2)^0.5 = 8712.44 Kg
Resultant Load at E = (11796.42^2+515.54^2)^0.5 = 11807.68 Kg
Maximum Resultant Load = 24912.79 Kg

Bending Moment at Different Locations

Bending Moment at B = (24912.79X2.79) = 69506.68 Kg-cm
Bending Moment at D = (8712.44X1.21) = 10542.05 Kg-cm
Maximum Bending Moment = 69506.68 Kg-cm

Case-2 When Gate is at Sill beam (Full close) & Rope is on Gear side

W1 C.L of Wire rope C.L of Drum Bush

A B C D E

27.9 38 110 12.1

C.L of support
188

Vertical Loads at different location on the rope drum shaft

Ver. load at B = Wt. of Gear (W1) + Half wt. of drum + Load due to Rope Tension at C+Tooth load of Gear W1
= (2200+2350+(16920X110)/148)+9544.4= 26670.08 Kg

Total vertical load at loaction D = (Self load of drum/2) +Load due to Rope Tension at C
= (2350+(16920X38)/148 = 6694.32 Kg
Vertical Load at A = (26670.08X160.1+6694.32X12.1)/188 = 23142.98 Kg
Vertical Load at E = 26670.08+6694.32-23142.98 = 10221.42 Kg

Horizontal Loads at different location on the rope drum shaft from Gear (W1)
Hor. Load at "B" due to Gear W1 = 9544.4XTAN20 = 3473.88 kg
Hor. Load at "A" due to Gear W1 = (3473.88X160.1/188 = 2958.34 Kg
Hor. Load at "D" due to Gear W1 = (3473.88X27.9)/175.9 = 551.00 Kg
Hor. Load at "E" due to Gear W1 = (3473.88-2958.34) = 515.54 Kg

Resultant Load at Different Locations

Resultant Load at A = (23142.98^2+2958.34^2)^0.5 23331.29 Kg
Resultant Load at B = (26670.08^2+3473.88^2)^0.5 26895.37 Kg
Resultant Load at D = (6694.32^2+551^2)^0.5 6716.96 Kg
Resultant Load at E = (10221.42^2+515.54^2)^0.5 10234.41 Kg
Maximum Resultant Load = 26895.37 Kg

PAGE : 8 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

Bending Moment at Different Locations

Bending Moment at B (26895.37X2.79) = 75038.08 Kg-cm
Bending Moment at D (6716.96X1.21) = 8127.52 Kg-cm
Maximum Bending Moment = 75038.08 Kg-cm

Case-3 When Rope is on Drum Bush side

W1 C.L of Wire rope C.L of Drum Bush

A B C D E

27.9 143.4 4.6 12.1

C.L of support
188.00

Vertical Load at different location on the rope drum shaft

Total vertical load at loaction B = Self load of gear (W1)+Half load of drum+Load due to Rope Tension at
C+Tooth load of Gear W1
= (2200+2350+(16920x4.6)/148)+9544.4= 14620.29 Kg

Total vertical load at loaction D = (Self wt. of drum/2)+Load due to Rope Tension at C
= (2350+(16920X143.4)/148 = 18744.11 Kg
Vertical Load at A = (14620.29X160.1+18744.11X12.1)/188= 13656.98 Kg
Vertical Load at E = 14620.29+18744.11-13656.98 = 19707.42 Kg

Horizontal Load at different location on the rope drum shaft from Gear (W1)
Hor. Load at B due to Gear (W1) tooth load = 9544.4xTan20 = 3473.88 kg
Reaction at A due to Horizontal load =(3473.88X160.1/188 = 2958.34 Kg
Reaction at D due to Horizontal load =(3473.88X27.9)/175.9 = 551 Kg
Reaction at E due to Horizontal load =(3473.88-2958.34) = 515.54 Kg

Resultant Load at Different Locations

Resultant Load at A = (13656.98^2+2958.34^2)^0.5 = 13973.72 Kg
Resultant Load at B = (14620.29^2+3473.88^2)^0.5 = 15027.33 Kg
Resultant Load at D = (18744.11^2+551^2)^0.5 = 18752.21 Kg
Resultant Load at E = (19707.42^2+515.54^2)^0.5 = 19714.16 Kg
Maximum Resultant Load = 19714.16 Kg

Bending Moment at Different Locations

Bending Moment at B = (15027.33X2.79) = 41926.25 Kg-cm
Bending Moment at D = (18752.21X1.21) = 22690.17 Kg-cm
Maximum Bending Moment = 41926.25 Kg-cm

Maximum Bending Moment in all Cases = 75038.08 Kg-cm

Maximum Resultant Load in all Cases = 26895.37 Kg-cm

Proposed Rope Drum Shaft Dia= 150 mm = 15 cm

Zxx = (3.14x15^3)/32 = 331.17 cm3
Area = (3.14x15^2)/4 = 176.63 cm2
Material = IS:2004 Cl.-V

Bending Stress= (75038.08/331.17)= 226.58 Kg/cm² 1440 Kg/cm² safe

Direc Shear Stress= (26895.37/176.63)= 152.27 Kg/cm² 1080 Kg/cm² safe

PAGE : 9 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

5.10 Bush for rope drum shaft Material: IS:305 Gr.AB-2

Shaft Diameter = 150 mm = 15 cm
Minimum Thickness of Bush = (0.08x150+3) = 15 mm
Proposed Thickness of Bush = 15 mm = 1.5 cm
OD of Bush = 180 mm = 18 cm
ID OF Bush = 150 mm = 15 cm
Length of Bush on Gear Side = 260 mm = 26 cm
Length of Bush on flange Side = 180 mm = 18 cm

Max. Load on Bush on Gear (W1) Side= 26895.37 Kg

Max. Load on Bush on Flange Side= 18752.21 Kg

Bearing Pressure at the Bush on

Gear side = 26895.37/(15x26)= 68.96 Kg/cm² < 70 Kg/cm² safe
Flange side = 18752.21/(15x18)= 69.45 Kg/cm² < 70 Kg/cm² safe

5.11 Design of Supporting Bracket (Cheek plate) for Rope Drum

Thickness of plate = 32 mm
Maximum Load on Bracket= 23331.29 Kg-cm
Bearing Stress = 23331.2944097836/(3.2x15)= 486.07 Kg/cm² < 1800 Kg/cm² safe

5.12 Shaft for Pinion-P1 & Gear-W2 Material = IS:2004 CL.5

Weight of Gear Wheel-W2 = 455 Kg
Weight of Pinion P1 = 90 Kg

Vertical Load
W2 P1
3404.38 Kg 10246.94 Kg

A1 C1 D1 B1
18 18 20

RVA1 56 RVB1

Load Acting at C1= Tooth Load of W2+ wt of W2

2771.51 + 455
=
COS 20
= 2949.38 + 455 = 3404.38 Kg

Load Acting at D1= Tooth Load of P1+ wt of P2

9544.4 + 90
=
COS 20
= 10156.9 + 90 = 10246.938 Kg

RVB1 = 3404.38X18+10246.94X36/56 7681.58 Kg

RVA1 = 3404.38+10246.94-7681.58 = 5969.74 Kg
Maximun Vertical Load = 7681.58 Kg

PAGE : 10 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

Horizontal Load W2 P1
1008.75 3473.88

A2 C2 D2 B2
18 18 20

RHA2 56 RHB2

Horizontal Load at C2 due to load on Gear-W2 = 2771.51xtan20 = 1008.75 Kg

Horizontal Load at D2 due to load on Pinion-P1= 9544.4Xtan20 = 3473.88 Kg

RHB2 = 1008.75X18+3473.88X36/56 = 2557.45 Kg

RHA2 = 1008.75+3473.88-2557.45 = 1925.18 Kg
Maximiun Horizontal Load = 2557.45 Kg

Resultant load at C1/C2 = (1008.75^2+3404.38^2)^0.5 = 3550.6872 Kg

Resultant load at D1/D2 = (10246.94^2+3473.88^2)^0.5 = 10819.779 Kg

Resultant Load RVA1/RHA2 = (5969.74^2+1925.18^2)^0.5 = 6272.49 Kg

Resultant Load RVB1/RHB2 = (7681.58^2+2557.45^2)^0.5 = 8096.12 Kg
Max Resultant Load at support = 8096.12 Kg

Resultant B.M at C1/C2 = 6272.49x18 = 112904.82 Kg-cm

Resultant B.M at D1/D2 = 8096.12X20 = 161922.4 Kg-cm
Maximun Resultant B.M = 161922.4 Kg-cm

Torque transmit by P1W2 shafts= 9544.4x16 = 152710.4 Kg-cm

Equivalent Toqrue = (161922.4^2+152710.4^2)^0.5 = 222574.3 Kg-cm
Equivalent Bending Moment = 0.5x(161922.4+222574.32) = 192248.36 Kg-cm

Proposed shaft dia= 130 mm Shaft Dia at Bearing= 100 mm

Material = IS:2004 Cl.-V
Zxx of Shaft= (3.14x13^3)/32= 215.69 cm3
Zpp of Shaft= (3.14x13^3)/16= 431.38 cm3
C.S area= (3.14x10^2)/4= 78.5 cm2

Equivalent Bending Stress = 192248.36/215.69

= 891.32 < 1296 Kg/cm² safe
Equivalent Torsional Stress = 222574.32/431.38
= 515.96 < 972 Kg/cm² safe
Direct Shear Stress = 8096.12/78.5
= 103.14 < 810 Kg/cm² safe
Bending stress = 161922.4/215.69)
= 750.72 < 1080 Kg/cm² safe
Torsional shear stress = 152710.4/431.38
= 354 < 810 Kg/cm² safe
Combined stress = (750.72^2+3x354^2)^0.5
= 969.29 < 1296 Kg/cm² safe

PAGE : 11 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

5.13 Shaft for Pinion-P2 Material = IS:2004 CL.5

Weigh of Pinion-P2= 18 Kg
Vertical Load
C.L OF P2
2967.38 Kg

A3 D3 B3

18 38
RVA2 56 RVB3

Load Acting at D3= Tooth Load of W2+ wt. of P2

2771.51 + 18
=
COS 20
= 2949.38 + 18 = 2967.3793 Kg

RVA3 = 2967.38X38/56 = 2013.58 Kg

RVB3 = 2967.38-2013.58 = 953.8 Kg
Maximun Vertical Load = 2013.58 Kg

Horizontal Load

1008.75 Kg

A4 D4 B4
18 38

RHA4 56 RHB4

Horizontal Load at C2 due to W2 Gear= 2771.51xtan20 = 1008.75 Kg

RHB4 = 1008.75X18/56 = 324.24 Kg

RHA4 = 1008.75-324.24 = 684.51 Kg
Maximun Horizontal Load at RHB4 / RHA4 = 684.51 Kg

Resultant load at D3/D4 = (2013.58^2+684.51^2)^0.5 = 2126.7483 Kg

Resultant Load RVA3/RHA4 = (953.8^2+684.51^2)^0.5 = 1174.01 Kg

Resultant Load RVB3/RHB4 = (953.8^2+324.24^2)^0.5 = 1007.41 Kg
Max Resultant Load at support = = 1174.01 Kg

Resultant B.M at D3/D4 = 1174.01x38 = 44612.38 Kg-cm

Torque transmit by P1W2shafts = 2771.51x9.5 = 26329.345 Kg-cm
Equivalent Toqrue = (44612.38^2+26329.345^2)^0.5 = 51802.5 Kg-cm
Equivalent Bending Moment = 0.5x(44612.38+51802.5) = 48207.44 Kg-cm

Proposed shaft dia= 100 mm Shaft Dia at Bearing= 80 mm

Zxx of Shaft= (3.14x10^3)/32= 98.17 cm3
Zpp of Shaft= (3.14x10^3)/16= 196.35 cm3
C.S area= (3.14x8^2)/4= 50.24 cm2

PAGE : 12 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

Equivalent Bending Stress = 48207.44/98.17

= 491.06 < 1296 Kg/cm² safe
Equivalent Torsional Stress = 51802.5/196.35
= 263.83 < 972 Kg/cm² safe
Direct Shear Stress = 1174.01/50.24
= 23.37 < 810 Kg/cm² safe
Bending stress = 44612.38/98.17)
= 454.44 < 1080 Kg/cm² safe
Torsional shear stress = 26329.345/196.35
= 134.09 < 810 Kg/cm² safe
Combine stress = (454.44^2+3x134.09^2))^0.5
= 510.35 < 1296 Kg/cm² safe

5.14 Bearing
a For Shaft P1W2
Max load on plummer Block = 8096.12 Kg
Min. capacity of plummer block = 8096.12x1.5 = 12144.18 Kg
= 119134.41 N
Dia of shaft at support = 100 mm
Proposed ,
Plummer Block = SNL522 Adopt. Sleeve = H322
A.F. Bearing = 22222EK (Size: 110x200x53)
Dynamic Capacity = 572000 N
Static capacity = 640000 N (Both static & Dynamic capacity more than)
Make = SKF/FAG

Max Horizontal Load on Plummer Block = 2557.45 Kg

Max Vertical Load on Plummer Block = 7681.58 Kg
Proposed Dia 24 Bolts as per IS:1367 Gr.-8.8
Y.P = 640
No. of Bolts = 2
Cross section area = 3.14x2.4^2*0.85 = 3.84 cm2
Shear Stress in Bolts = 2557.45/3.84x2 = 333.00 Kg/cm²
Tensile stress in bolts = 7681.58/3.84x2 = 1000.21 Kg/cm²
Allowable Shear stress = 0.3x Y.S/1.2 = 1630.99 Kg/cm² safe
Allowable Tensile stress= 100x640x120/235x9.81 = 3331.38 Kg/cm² safe

b For Shaft P2
Max load on plummer Block = 1174.01 Kg
Max capacity of plummer block = 1.5x1174.01 = 1761.015 Kg
= 17275.56 N
Dia of shaft at support= 80 mm
Proposed,
Plummer Block = SNL518 Adopt. Sleeve = H318
A.F. Bearing = 22218EK (Size: 90x160x40)
Dynamic Capacity = 331000 N
Static capacity = 375000 N
Make = SKF/FAG
Max Horizontal Load on Plummer Block = 684.51 Kg
Max Vertical Load on Plummer Block = 2013.58 Kg

PAGE : 13 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

Proposed M 20 Bolts as per IS:1367, Gr-8.8

Y.P = 640
No. of Bolts = 2
Cross section area = 3.14x2^2*0.85 = 2.67 cm2
Shear Stress in Bolts = 684.51/2.67x2 = 128.19 Kg/cm²
Tensile stress in bolts = 2013.58/2.67x2 = 377.07 Kg/cm²
Allowable Shear stress = 0.3x Y.S/1.2 = 1630.99 Kg/cm² safe
Allowable Tensile Stress= 100x640x120/235x9.81 = 3331.38 Kg/cm² safe

5.15 DESIGN OF KEY

a For PINION -P1

Shaft Diameter (d) = 13 cm
Torque on P1-W2 shaft = 152710.4 Kg-cm

LG. (cm) B (cm) Thickness (cm) Nos. Material

17 3.2 1.8 2 IS:2004 CL.4

Shear Stress =2T/(bdl) = 2x152710.4/(3.2x13x17x2)

= 215.94 Kg/cm² < 990 Kg/cm² safe
Crushing Stress = 4T/(tdl) = 4 x152710.4/(1.8x13x17)
1535.55 /2
= 767.77 Kg/cm² < 1268 Kg/cm² safe

b For Gear -W2

Shaft Diameter (d) = 13 cm
Torque on P1-W2 shaft = 152710.4 Kg-cm

LG. (cm) B (cm) Thickness (cm) Nos. Material

10 3.2 1.8 2 IS:2004 CL.4

Shear Stress =2T/(bdl) = 2x152710.4/(3.2x13x10x2)

= 367.09 Kg/cm² < 990 Kg/cm² safe
Crushing Stress = 4T/(tdl) = 4 x152710.4/(1.8x13x10)= 2610.43 Kg/cm²
= 2610.43/2
= 1305.22 Kg/cm² < 1268 Kg/cm² Fail

c For Pinion -P2

Shaft Diameter (d) = 10 cm
Torque on P2 shaft = 26329.345 Kg-cm

LG. (cm) B (cm) Thickness (cm) Nos. Material

11 2.8 1.6 1 IS:2004 CL.4

Shear Stress =2T/(bdl) = 2x26329.345/(2.8x10x11)= 170.97 Kg/cm²

< 990 Kg/cm² safe
Crushing Stress = 4T/(tdl) = 4 x26329.345/(1.6x10x11)= 598.39 Kg/cm²
< 1268 Kg/cm² safe

PAGE : 14 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

d For Coupling on P2/Floating shaft

Shaft Diameter (d) = 7.5 cm
Torque on P2 shaft = 26329.35 Kg-cm

LG. (cm) B (cm) Thickness (cm) Nos. Material

8 2 1.2 2 IS:2004 CL.4

Shear Stress =2T/(bdl) = 2x26329.35/(2x7.5x8x2) = 219.41 Kg/cm²

< 990 Kg/cm² safe
Crushing Stress = 4T/(tdl) = 4 x26329.35/(1.2x7.5x8x2) = 731.37 Kg/cm²
< 1268 Kg/cm² safe

5.16 Design of Floating Shaft

Modules of Rigidity = 79 GN/m2
Shaft Diameter = 8 cm Ø at End = 7.5 cm
Length of shaft = 500 mm
Material = IS:2004 CL.5
j = 8^3x3.14/16= 100.48 cm3 = 0.10048 m3
Torque on normal condition = 1527.1 Kgm
Angular defelection = 1527.1x9.81/(0.00001x79x10^9)
= 0.019 < 0.33 safe

5.17 Coupling for connecting reducer & pinion (p2) shaft with floating shaft
Shaft Dia at coupling location = 7.5 cm
RPM of floating shaft = 15.58
Torque on motor shaft = 15.32 kg-m
Torque on reducer output/floating shaft = 15.32x60x0.8135/2 = 373.88 kg-m
150% Breaking Load Torque = 373.88x1.5 = 560.82 kg-m
HP on floating shaft = 2x3.14x15.58x373.88)/4500= 8.1
Coupling Rating (Normal Rating at 100 RPM) = (8.1X100)/15.58 = 52 HP

Proposed
Size Nos. req. Breaking torque HP/100RPM Type P. Bore Max. Bore
104 2 840 117 Half Rigid & Half Flexible 50mm 110mm

Make -NAW, Lovejoy, MECO

6 Checking of Hoist compenents Under Breakdown Condition

Torque of the motor = 15.32 Kg-m

BDT torque of motor (T) = 15.32x2.75 = 42.13 Kg-m
Starting eff upto drum = 0.44x0.93^2x0.93 0.35
Torque at O/P of the Reducer/P2 shaft = (42.13x60x0.44x100)/2= 55611.6 Kg-cm
Torque at the p1w2 shaft = 55611.6x116x0.93/19= 315756.8 Kg-cm
Torque at the W1 shaft/rope drum = 315756.81x110x0.93x0.93/16= 1877549.2 kg-cm

Motor Torque -BDT (T) X Worm reduction X ɳ0 X

Rope Tension = [( W1xW2 Teeth )/ (P1xP2 teeth )]
Drum Radius X 2
= [4213x60x0.35x(110/16)x(116/19)] / (56x2)
= 33156.59 Kg = 325.1 Kn

PAGE : 15 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

6.1 Factor of safety of Wire Rope Under BDT Condition

Factor of Safety = 1035/325.1= 3.18 > 3 safe

6.2 Rope Drum

Compressive Stress= = 2028.81 Kg/cm² < 2280 Kg/cm² safe

Checking Bending stress of Rope Drum

Approximate Weight of Drum (W1)= 4700 Kg
Bending Moment due to self weight= (4700x152.5)/4 179187.5 Kg-cm
Bending moment due to Rope Tension= (33156.59x152.5)/4= 1264095 Kg-cm
Total Bending Moment= (179187.5+1264094.99)= 1443282.5 Kg-cm

D= Outside Diameter of rope drum= 108 cm

d= Inside Diameter of rope drum= 95 cm
Z= (3.14(108^4-95^4)/32X108= 49606.07 cm3

Bending Stress= 1443282.49/49606.07= 29.09 Kg/cm²

Combined stress= (2028.81^2+29.09^2)^0.5 = 2029.02 Kg/cm²
< 2280 Kg/cm² safe
6.3 Design/selection of Bolts for connecting Gear with rope drum
PCD of Bolts= 1400
No of Bolts= 6
Load on Bolts= 33156.59x1400/1120 = 41445.74 kg
Load on each Bolts= 41445.74/6 = 6907.62 Kg
= 67763.8 N < 122000 N safe
Proposed Dia 21 fit Bolts as per IS:1363
Grade of Bolts 8.8
Ultimate Tensile Load= 122000 N
UTS= 500 Kg/cm²
y.p= 3000 Kg/cm²
Cross Section Area= 11.78 cm2
Allowable shear stress= (3000x0.8) 2400 Kg/cm²
Shear Stress in bolts= (6907.62/11.78) 586.39 Kg/cm² safe

6.4 Stress on open Gear & Pinion under BDT Condition

Tooth load for W1P1= (33156.59x1120)/(2200x0.95x0.93) 19105.51 Kg
Tooth load for W2P2= (19105.51x320)/(1160x0.93) 5667.1887 Kg

Tooth Strength Module Face Width

Item Root Stress Allowable stress
Load Factor (cm) (cm)
W1 19105.51 2.5 2 16 1492.62 2280 Kg/cm² safe
P1 19105.51 3.47 2 17 2071.75 2880 Kg/cm² safe
W2 5667.19 2.5 1 10 1416.8 2280 Kg/cm² safe
P2 5667.19 3.75 1 11 2125.2 2880 Kg/cm² safe

Torque on W1 Gear = 33156.59x112/2 = 1856769 Kg-cm

Torque on P1W1 shaft = (1856769.04x19)/(110x0.93X0.93)= 370811.25 Kg-cm
Torque on P2 Gear = 370811.25X16/(116X0.93)= 65307.88 Kg-cm

PAGE : 16 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

6.5 Rope Drum Shaft

Self Weight of Gear= 2200 Kg
Self weight of Rope Drum= 4700 Kg

Case-1 When Gate is at Deck Level (full open) & Rope is on middle of drum

W1 C.L of Wire rope C.L of Drum Bush

A B C D E
27.9 55.5 92.5 12.1

188

Vertical Load at different location on the rope drum shaft

Vertical load at loaction B = Self load of gear (W1)+Self load of drum/2+Load due to
Rope Tension at C+Tooth load of Gear W1
= (2200+2350+(33156.59X92.5)/148)+19105.51
= 44378.38 Kg

Vertical load at loaction D = Self load of drum/2+Load due to Rope Tension at C

= (2350+(33156.59X55.5)/148 = 14783.72 Kg
Vertical Load at A = (44378.38 X 160.1+14783.72 X 12.1)/188 = 38743.94 Kg
Vertical Load at E = 44378.38+14783.72-38743.94 = 20418.16 Kg

Horizontal Load at different location on the rope drum shaft from Gear (W1)
Hor. Load at "B" due to Gear W1 = = 19105.51XTAN20 = 6953.84 kg
Hor. Load at "A" due to Gear W1 = (6953.84X160.1/188 = 5921.86 Kg
Hor. Load at "D" due to Gear W1 = (6953.84X27.9)/175.9 = 1102.97 Kg
Hor. Load at "E" due to Gear W1 = (6953.84-5921.86) = 1031.98 Kg

Resultant Load at Different Locations

Resultant Load at A= (38743.94^2+5921.86^2)^0.5 = 39193.89 Kg
Resultant Load at B= (44378.38^2+6953.84^2)^0.5 = 44919.89 Kg
Resultant Load at D= (14783.72^2+1102.97^2)^0.5 = 14824.81 Kg
Resultant Load at E= (20418.16^2+1031.98^2)^0.5 = 20444.223 Kg
Maximun Resultant Load= = 44919.89 Kg

Bending Moment at Different Locations

Bending Moment at B = (44919.89X2.79) = 125326.49 Kg-cm
Bending Moment at D = (14824.81X1.21) = 17938.02 Kg-cm
Maximun Bending Moment = 125326.49 Kg-cm

Case-2 When Gate is at Sill beam (Full close) & Rope is on Gear side

W1 C.L of Wire rope C.L of Drum Bush

A B C D E
27.9 38 110 12.1

188

PAGE : 17 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

Vertical Load at different location on the rope drum shaft

Ver. load at B = Wt. of Gear (W1) + Half wt. of drum + Load due to Rope Tension at C+Tooth load of Gear W1
= (2200+2350+(33156.59X110)/148)+19105.51
= 44425.64 Kg

Total vertical load at loaction D = Self load of drum/2+Load due to Rope Tension at C
= (2350+(33156.59X38)/148 = 10863.18 Kg
Vertical Load at A = (44425.64X160.1+10863.18X12.1)/188 = 38531.86 Kg
Vertical Load at E = 44425.64+10863.18-38531.86 = 16756.96 Kg

Horizontal Load at different location on the rope drum shaft from Gear (W1)
Hor. Load at "B" due to Gear W1 = = 19105.51XTAN20 = 6953.84 kg
Hor. Load at "A" due to Gear W1 = (6953.84X160.1/188 = 5921.86 Kg
Hor. Load at "D" due to Gear W1 = (6953.84X27.9)/175.9 = 1102.97 Kg
Hor. Load at "E" due to Gear W1 = (6953.84-5921.86) = 1031.98 Kg

Resultant Load at Different Locations

Resultant Load at A = (38531.86^2+5921.86^2)^0.5 = 38984.262 Kg
Resultant Load at B = (44425.64^2+6953.84^2)^0.5 = 44966.58 Kg
Resultant Load at D = (10863.18^2+1102.97^2)^0.5 = 10919.03 Kg
Resultant Load at E = (16756.96^2+1031.98^2)^0.5 = 16788.707 Kg
Maximun Resultant Load = 44966.58 Kg

Bending Moment at Different Locations

Bending Moment at B = (44966.58X2.79) = 125456.76 Kg-cm
Bending Moment at D = (10919.03X1.21) = 13212.026 Kg-cm
Maximun Bending Moment = 125456.76 Kg-cm

Case-3 When Rope is on Drum Bush side

W1 C.L of Wire rope C.L of Drum Bush

A B C D E

27.9 143.4 4.6 12.1

C.L of support
188.00

Vertical Load at different location on the rope drum shaft

Vertical load at loaction B = Self load of gear (W1)+Half load of drum+Load due to Rope Tension at
C+Tooth load of Gear W1
= (2200+2350+(33156.59x4.6)/148)+19105.51= 24686.05 Kg

Vertical load at loaction D = (Self wt. of drum/2)+Load due to Rope Tension at C

= (2350+(33156.59X143.4)/148 = 34476.05 Kg
Vertical Load at A = (24686.05X160.1+34476.05X12.1)/188= 23241.47 Kg
Vertical Load at E = 24686.05+34476.05-23241.47 = 35920.63 Kg

Horizontal Load at different location on the rope drum shaft from Gear (W1)
Hor. Load at B due to Gear (W1) tooth load = 19105.51xTan20 = 6953.84 kg
Reaction at A due to Horizontal load =(6953.84X160.1/188 = 5921.86 Kg
Reaction at D due to Horizontal load =(6953.84X27.9)/175.9 = 1102.97 Kg
Reaction at E due to Horizontal load =(6953.84-5921.86) = 1031.98 Kg

PAGE : 18 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

Resultant Load at Different Locations

Resultant Load at A = (23241.47^2+5921.86^2)^0.5 = 23984.04 Kg
Resultant Load at B = (24686.05^2+6953.84^2)^0.5 = 25646.77 Kg
Resultant Load at D = (34476.05^2+1102.97^2)^0.5 = 34493.69 Kg
Resultant Load at E = (35920.63^2+1031.98^2)^0.5 = 35935.45 Kg
Maximum Resultant Load = 35935.45 Kg

Bending Moment at Different Locations

Bending Moment at B = (25646.77X2.79) = 71554.49 Kg-cm
Bending Moment at D = (34493.69X1.21) = 41737.36 Kg-cm
Maximum Bending Moment = 71554.49 Kg-cm

Maximun Bending Moment in all Cases = 125456.76 Kg-cm

Maximun Resultant Load in all Cases = 44966.58 Kg-cm

Parposed Rope Drum Shaft Diameter= 150 mm = 15 cm

Zxx = (3.14x15^3)/32 = 331.17 cm3
Area = (3.14x15^2)/4 = 176.63 cm2

Bending Stress = (125456.7582/331.17) = 378.83 Kg/cm²

< 2880 Kg/cm² safe
Direct Shear Stress = (44966.58/176.63) = 254.58 Kg/cm²
< 2880 Kg/cm² safe

6.6 Bush for rope drum

Max. Load on Bush on Gear Side= 44966.58 Kg
Max. Load on Bush on Flange Side= 34493.69 Kg

Shaft Diameter = 150 mm = 15 cm

Minimum Thickness of Bush = (0.08x150+3) = 15 mm

Proposed Thickness of Bush = 15 mm = 1.5 cm

OD of Bush = 180 mm = 18 cm
ID OF Bush = 150 mm = 15 cm
Length of Bush on Gear Side = 260 mm = 26 cm
Length of Bush on flange Side = 180 mm = 18 cm

Bearing Pressure of the Bush on

Gear side = 44966.58/(15x26)= 115.3 Kg/cm² < 252 Kg/cm² safe
Flange side = 34493.69/(15x18)= 127.75 Kg/cm² < 252 Kg/cm² safe

6.7 Design/Selection of Supporting Bracket for Rope Drum

Thickness of plate = 32 mm
Maximium Load on Bracket= 39193.89 Kg-cm
Bearing Stress = 39193.8938175732/(3.2x15)= 816.54 Kg/cm² < 1920 Kg/cm² safe

PAGE : 19 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

6.8 Shaft for P1W2

Weight of Gear Wheel-W2 = 455 Kg

Weight of Pinion P1 = 90 Kg

Vertical Load
C.L OF W2 C.L OF P1
6485.9 Kg 20421.66 Kg

A1 C1 D1 B1
18 18 20

RVA1 56 RVB1

Load Acting at C1= Tooth Load of W2+ wt of W2

5667.19 + 455
COS 20
6030.9 + 455 = 6485.8976 Kg

Load Acting at D1= Tooth Load of P1+ wt of P2

19105.5 + 90
COS 20
20331.7 + 90 = 20421.659 Kg

RVB1 = 6485.9X18+20421.66X36/56= 15212.96 Kg

RVA1 = 6485.9+20421.66-15212.96 = 11694.6 Kg
Maximun Vertical Load = 15212.96 Kg

Horizontal Load
2062.69 Kg 6953.84 Kg

A2 C2 D2 B2
18 18 20

RHA2 56 RHB2

Horizontal Load at C2 due to load on Gear-W2 = 5667.19xtan20 = 2062.69 Kg

Horizontal Load at D2 due to load on Pinion-P1= 19105.51Xtan20 = 6953.84 Kg

RHB2 = 2062.69X18+6953.84X36/56 = 5133.33 Kg

RHA2 = 2062.69+6953.84-5133.33 = 3883.2 Kg
Maximiun Horizontal Load at support = 5133.33 Kg

Resultant load at C1/C2 = (2062.69^2+6485.9^2)^0.5 = 6805.9965 Kg

Resultant load at D1/D2 = (20421.66^2+6953.84^2)^0.5 = 21573.133 Kg

Resultant Load RVA1/RHA2 = (11694.6^2+3883.2^2)^0.5 = 12322.46 Kg

Resultant Load RVB1/RHB2 = (15212.96^2+5133.33^2)^0.5 = 16055.69 Kg
Max Resultant Load at support = 16055.69 Kg

PAGE : 20 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

Resultant B.M at C1/C2 = 12322.46x18 221804.28 Kg-cm

Resultant B.M at D1/D2 = 16055.69X20 321113.8 Kg-cm
Maximun Resultant B.M = 321113.8 Kg-cm

Torque transmit by P1W2shafts= 16055.69x16 256891.04 Kg-cm

Equivalent Toqrue = (321113.8^2+256891.04^2)^0.5 411226.3 Kg-cm
Equivalent Bending Moment = 0.5x(321113.8+411226.31) 366170.06 Kg-cm

Proposed shaft dia= 130 mm Shaft Dia at Bearing= 100 mm

Zxx of Shaft= (3.14x13^3)/32= 215.69 cm3

Zpp of Shaft= (3.14x13^3)/16= 431.38 cm3
C.S area= (3.14x10^2)/4= 78.5 cm2

Equivalent Bending Stress= 366170.06/215.69 = 1697.67 Kg/cm²

< 2592.00 Kg/cm² safe
Equivalent Torsional Stress= 411226.31/431.38 = 953.28 Kg/cm²
< 2592.00 Kg/cm² safe
Direct Shear Stress= 16055.69/78.5 = 204.53 Kg/cm²
< 2160.00 Kg/cm² safe
Bending stress= 321113.8/215.69) = 1488.77 Kg/cm²
< 2160.00 Kg/cm² safe
Torsional shear stress= 256891.04/431.38 = 595.51 Kg/cm²
< 2160.00 Kg/cm² safe
Combined stress= (1488.77^2+3x595.51^2))^0.5 = 1811.17 Kg/cm²
< 2160.00 Kg/cm² safe
6.9 Design of shaft P2-
Weigh of P2= 18 Kg

Vertical Load
C.L OF P2
6048.9 Kg

A3 D3 B3
18 38

RVA2 56 RVB3

Load Acting at D3= Tooth Load of p2+ wt of p2

5667.19 + 18
COS 20
6030.9 + 18 = 6048.8976 Kg

RVA3 = 6048.9X38/56 = 4104.61 Kg

RVB3 = 6048.9-4104.61 = 1944.29 Kg
Maximun Vertical Load at support = 4104.61 Kg

PAGE : 21 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

Horizontal Load
2062.69 Kg

A4 D4 B4
18 38

RHA4 56 RHB4

Hor. Load at C2 due to load on w2 Gear= 5667.19xtan20 = 2062.69 Kg

RHB4 = 2062.69X18/56 = 663.01 Kg

RHA4 = 2062.69-663.01 = 1399.68 Kg
Maximum Horizontal Load at support = 1399.68 Kg

Resultant load at D3/D4 = (4104.61^2+1399.68^2)^0.5 = 4336.6954 Kg

Resultant Load RVA3/RHA4 = (1944.29^2+1399.68^2)^0.5 = 2395.7 Kg

Resultant Load RVB3/RHB4 (1944.29^2+663.01^2)^0.5 = 2054.23 Kg
Max Resultant Load at support = 2395.7 Kg

Resultant B.M at D3/D4 = 2395.7x38 = 91036.6 Kg-cm

Torque transmit by P2 shafts = 5667.19x9.5 = 53838.305 Kg-cm
Equivalent Toqrue = (91036.6^2+53838.305^2)^0.5 = 105765.0 Kg-cm
Equivalent Bending Moment = 0.5x(91036.6+105764.95) = 98400.78 Kg-cm

Proposed shaft dia= 100 mm Shaft Dia at Bearing= 80 mm

Zxx of Shaft= (3.14x10^3)/32= 98.17 cm3
Zpp of Shaft= (3.14x10^3)/16= 196.35 cm3
C.S area= (3.14x8^2)/4= 50.24 cm2

Equivalent Bending Stress= 98400.78/98.17 = 1002.35 Kg/cm²

< 2592 Kg/cm² safe
Equivalent Torsional Stress= 105764.95/196.35 = 538.66 Kg/cm²
< 2592 Kg/cm² safe
Direct Shear Stress= 2395.7/50.24 = 47.69 Kg/cm²
< 2160 Kg/cm² safe
Bending stress= 91036.6/98.17) = 927.34 Kg/cm²
< 2160 Kg/cm² safe
Torsional shear stress= 53838.305/196.35 = 274.20 Kg/cm²
< 2160 Kg/cm² safe
Combined stress= (927.34^2+3x274.2^2))^0.5 = 1041.88 Kg/cm²
< 2160 Kg/cm² safe

PAGE : 22 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

7 DESIGN OF KEYS
a For PINION -P1
Shaft Diameter (d)= 13 cm
Torque on P1-W2 shaft= 256891.04 Kg-cm

LG. (cm) B (cm) Thickness (cm) Nos. Material

17 3.2 1.8 2 IS:2004 CL.4

Shear Stress =2T/(bdl) = 2x256891.04/(3.2x13x17x2)

= 363.25 Kg/cm² < 2640 Kg/cm² safe
Crushing Stress = 4T/(tdl) = 4 x256891.04/(1.8x13x17x2)
= 1291.56 Kg/cm² < 2880 Kg/cm² safe

b For Gear -W2

Shaft Diameter (d)= 13 cm
Torque on P1-W2 shaft= 256891.04 Kg-cm

LG. (cm) B (cm) Thickness (cm) Nos. Material

10 3.2 1.8 2 IS:2004 CL.4
Shear Stress =2T/(bdl) = 2x256891.04/(3.2x13x10)
= 1235.05 Kg/cm² = 1235.05/2
= 617.525 Kg/cm² < 2640 Kg/cm² safe
Crushing Stress = 4T/(tdl) = 4 x256891.04/(1.8x13x10)
= 4391.29983 Kg/cm² = 4391.3/2
= 2195.64991 Kg/cm² < 2880 Kg/cm² safe

c For Pinion -P2

Shaft Diameter (d)= 10 cm
Torque on P2 shaft= 53838.305 Kg-cm

LG. (cm) B (cm) Thickness (cm) Nos. Material

11 2.8 1.6 1 IS:2004 CL.4

Shear Stress =2T/(bdl) = 2x53838.305/(2.8x10x11)

= 349.6 Kg/cm² < 2640 Kg/cm² safe

Crushing Stress = 4T/(tdl) = 4 x53838.305/(1.6x10x11)

= 1223.59784 Kg/cm² < 2880 Kg/cm² safe

d For Coupling on Floating shaft

Shaft Diameter (d)= 7.5 cm
Torque on P2 shaft= 53838.305 Kg-cm

LG. (cm) B (cm) Thickness (cm) Nos. Material

8 2 1.2 2 IS:2004 CL.4

Shear Stress =2T/(bdl) = 2x53838.305/(2x2x7.5x8)

= 448.65 Kg/cm² < 2640 Kg/cm² safe

Crushing Stress = 4T/(tdl) = 4 x53838.305/(2x1.2x7.5x8)

= 1495.50847 Kg/cm² < 2880 Kg/cm² safe

PAGE : 23 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

8 Sheaves
Min. PCD for Gate Sheave= 20x wire rope diameter = 800 mm
Min. PCD for Balancing Sheave= 12x wire rope diameter = 480 mm

Material = Cast steel as per IS:1030 Gr.280-520N

8.1 Design of Pin & Bush/Bearing for sheaves.

8.1.1 Pin For Gate sheave
Self weight of sheave = 100 Kg (apprx.)

Proposed Pin Diameter = 150 mm

Material = AISI 420
Zxx = 3.14x15^3/32 = 331.17 cm3
Area = 3.14x15^2/4 = 176.63 cm2

C.L of Sheave

A B c

101 101
202 mm

Normal Condition :
Rope Tension = 16920 Kg
Total vertical load on sheave= 2x16920+100= 33940 Kg
Vertical Reaction at A or C = 16970 Kg
Bending Moment = 16970X10.1 = 171397 Kg-cm

Bending stress= 171397/331.17= 517.55 Kg/cm2 < 1406.6 Kg/cm2 safe

Direct Shear Stress= 16970/176.63= 96.08 Kg/cm2 < 1497 Kg/cm2 safe

BDT Condition :
Rope Tension = 33156.59 Kg
Total vertical load on sheave = 2x33156.59+100 = 66413.18 Kg
Vertical Reaction at A or C = 33206.59 Kg
Bending Moment = 33206.59X10.1 = 335386.56 Kg-cm

Bending stress= 335386.559/331.17= 1012.73 Kg/cm2 < 3992 Kg/cm2 safe

Direct Shear Stress= 33206.59/176.63= 188.00 Kg/cm2 < 3992 Kg/cm2 safe

8.1.2 Bearing For Gate sheave:-

Max. Load on Bearing = 33940 kg
Required capacity of bearing = 33940x1.5 = 50910 kgs
= 499.17 kN
Proposed Spherical Roller Bearing = 22230 CC/W33
ID OD Width Dyn. Cap Sta. Cap. Make
mm mm mm kN kN
SKF/FAG/NTN/INA
150 270 73 898 1080

PAGE : 24 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

8.1.3 Pin for Balancing sheave

Self weight of sheave = 75 Kg (apprx.)
Proposed Pin Diameter= 125 mm
Material = IS:2004, Cl-IV
Zxx = 3.14x12.5^3/32 = 191.65 cm3
Area = 3.14x12.5^2/4= 122.66 cm2

C.L of Sheave

A B c

87.5 87.5
175
mm

Normal Condition :
Rope Tension = 16920 Kg
Total vertical load on sheave= 16920x2 +75 = 33915 Kg

Reaction at A or C = 16957.5 Kg
Max. Bending Moment= 16957.5x8.75 = = 148378.13 Kg-cm

Bending stress= 148378.13/191.65= 774.21 Kg/cm2 < 1268 Kg/cm2 safe

Direct Shear Stress= 16957.5/122.66= 138.25 Kg/cm2 < 990 Kg/cm2 safe

BDT Condition :
Rope Tension = 33156.59 Kg
Total vertical load on sheave= 33156.59x2 +75 = 66388.18 Kg

Reaction at A or C = 33194.09 Kg
Max. Bending Moment= 33194.09X8.75= = 290448.3 Kg-cm

Bending stress= 290448.29/191.65= 1515.51 Kg/cm2 < 5072 Kg/cm2 safe

Direct Shear Stress= 33194.09/122.66= 270.62 Kg/cm2 < 2640 Kg/cm2 safe

8.1.4 Bush for Balancing sheave :-

Sheave pin dia= 125 mm= 12.5 cm
Thikness of Bush= 0.08x125+3 13 mm
Parposed thickness of Bush= 15 mm
OD of Bush= 155 mm
ID of Bush= 125 mm
Length of Bush= 130 mm

Normal Condition :
Max. Load on bush = 33915 Kg
Bearing Pressure = 33915/(12.5x13)= 209 Kg/cm2 < 210 Kg/cm2 safe
BDT Condition :
Max Load on bush = 33194.09 Kg
Bearing Pressure = 33194.09/(12.5x13)= 204 Kg/cm2 < 252 Kg/cm2 safe

PAGE : 25 OF 26
 OM INFRA LIMITED
Kundah Pumped Storage H.E. Project, (1x125MW), Package-II
65T Rope Drum Hoist for Surge SHaft Gates
Design of Hoisting Components"

8.1.5 Supporting Bracket for Balancing sheave

250

155 mm
100
20

Proposed
Min. Width of Bracket= 250 mm= 25 cm
Thickness= 20 mm= 2 cm

Normal Condition :
Load on each sheave bracket= 16957.5 Kg
Shear stress= 16957.5/(2x10)= 847.88 Kg/cm2 < 960 Kg/cm2 safe
Tensile Strengh at minimun cross section= 16957.5/((25-12.5)x2) = 678.30 Kg/cm2
< 714 Kg/cm2 safe
Bearing stress= 16957.5/(12.5x2)= 678.30 Kg/cm2 < 1584 Kg/cm2 safe

BDT Condition :
Load on each sheave bracket= 33194.09 Kg
Shear stress= 33194.09/(2x10)= 1659.7 Kg/cm2 < 2080 Kg/cm2 safe
Tensile Strengh at minimun crossection= 33194.09/((25-12.5)x2) = 1327.76 Kg/cm2
< 2080 Kg/cm2 safe
Bearing stress= 33194.09/(12.5x2) = 1327.76 Kg/cm2 < 2080 Kg/cm2 safe

9 Other items:
i) Selection of Rotary Limit Switch & Its Components
To stop the Lifting & Lowering of hoist positively when its reach extreme end, Rotary type of
limit switch provided. Rotary Limit Switch is connected to P1W2 shaft with chain & sprockets.
Revolution of the Rope drum = 44.00 nos.
Revolution of the P1W2 shaft = (44x110)/16 = 302.50 nos.
Sprockets :
Simplex, Pilot bore, Type-B, steel/cast,
Teeth Pitch PCD
Sprocket-1 20 9.525 60.89
Sprocket-2 80 9.525 60.89

Rotation of Rotary limit switch = 303x20/80= 75.63 < 84 (Effective Rotation)

Used Rotary limit switch having Gear Ratio= 96 - 1
Model no.GRLS/96/4SH (Double Acting)-1no., Make: SPEED-O-CONTROL/BCH

PAGE : 26 OF 26