Gdansk University of Technology Civil and Environmental Engineering Faculty
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Gdansk University of Technology Civil and Environmental Engineering Faculty PROBLEMY KONTAKTOWE WRÓT ŚLUZ I INNYCH ZAMKNI ĘĆ WODNYCH W ŚWIETLE BADA Ń I DO ŚWIADCZE Ń TERENOWYCH praca doktorska CONTACT PROBLEMS IN LOCK GATES EN OTHER HYDRAULIC CLOSURES IN VIEW OF INVESTIGATIONS AND FIELD EXPERIENCES doctoral thesis CONTACTPROBLEMEN IN SLUISDEUREN EN ANDERE KEERMIDELEN IN HET LICHT VAN ONDERZOEK EN ERVARING proefschrift Author: Ryszard Daniel, M.Sc. Eng. Supervisor: Eugeniusz Dembicki, Prof. Sc.D. Eng. Gdansk, October 26, 2005. Contact Problems in Lock Gates and Other Hydraulic Closures This page is deliberately left blank. 2 Gdansk University of Technology Civil and Environmental Engineering Faculty PROBLEMY KONTAKTOWE WRÓT ŚLUZ I INNYCH ZAMKNI ĘĆ WODNYCH W ŚWIETLE BADA Ń I DO ŚWIADCZE Ń TERENOWYCH praca doktorska CONTACT PROBLEMS IN LOCK GATES AND OTHER HYDRAULIC CLOSURES IN VIEW OF INVESTIGATIONS AND FIELD EXPERIENCES doctoral thesis CONTACTPROBLEMEN IN SLUISDEUREN EN ANDERE KEERMIDDELEN IN HET LICHT VAN ONDERZOEK EN ERVARING proefschrift Author: Ryszard Daniel, M.Sc. Eng. Address: Ministry of Transport, Public Works and Water management of the Netherlands, Civil Engineering Division, P.O. Box 59, 2700AB Zoetermeer, The Netherlands Supervisor: Eugeniusz Dembicki, Prof. D.Sc. Eng. Politechnika Gda ńska, Wydział In żynierii L ądowej i Środowiska, ul. G. Narutowicza 11/12, 80-952 Gdansk, Poland Place, date: Gdansk, October 26, 2005. 3 Contact Problems in Lock Gates and Other Hydraulic Closures This doctoral thesis has been completed at the Gdansk University of Technology, Faculty of Civil and Environmental Engineering, on the authority of: • Janusz Racho ń, Prof. PhD. Eng., rector of the Gdansk University of Technology; • Krzysztof Wilde, Prof. PhD. Eng., dean of the Civil and Environmental Engineering Faculty. The thesis was publically defended by the author on October 26, 2005 in the auditorium of the Civil and Environmental Engineering Faculty of the Gdansk University of Technology, Narutowicza 11/12, 80-952 Gdansk, Poland. The defence covered a number of propositions which can be summarized by the following statement: “In the design and execution of hydraulic structures, contact issues ought to be: • dealt with starting from the very early stage of the project; • considered broadly, in an interdisciplinary manner.” The statutory opposition to this thesis was delivered by: • Władysław Buchholz, Prof. PhD. Eng., of the Szczecin (Stettin) University of Technology; • Bolesław Mazurkiewicz, Prof. PhD. Eng., of the Gdansk (Danzig) University of Technology; and answered by the author along with the questions that were forwarded by the audience. 4 CONTENTS ACKNOWLEDGEMENTS 7 STRESZCZENIE 8 SUMMARY 10 SAMENVATTING 12 1. SUBJECT, SCOPE AND THESIS OF THIS WORK 15 1.1. Contact areas in lock gates and other hydraulic closures 15 1.2. Recommended significance and place of contact analysis 17 1.3. Practical use and target group of this study 18 2. CONTACT REQUIREMENTS IN DESIGN OF HYDRAULIC GATES 19 2.1. General classification of requirements 19 2.2. From performance requirements to gate type selection 20 2.3. Choice of gate support system 22 2.3.1. Support systems of mitre gates 22 2.3.2. Support systems of vertical lift gates 25 2.3.3. Support systems of rolling and sliding gates 27 2.4. Sample case: Contact requirements for mitre gates 30 2.4.1. Functional reliability and dimensional requirements 30 2.4.2. Mechanical requirements 31 2.4.3. Dimensional precision requirements 32 2.4.4. Assembly and maintenance requirements 33 2.4.5. Aesthetical and environmental requirements 34 2.5. Some other contact requirements and requirements for other gates 36 2.5.1. General notes on slide and roller contacts 36 2.5.2. Some requirements concerning calamity engineering 37 3. SELECTION OF STRUCTURAL SYSTEMS AND FIXITIES 39 3.1. Variable systems and fixities 39 3.2. Contact levels, selection of pointed, linear or surface supports 41 3.3. Fixities of gates under bidirectional hydraulic loads 44 3.3.1. Bidirectional loads on different gate types 44 3.3.2. Locking single-leaf gates – systems and performances 45 3.3.3. Locking mitre gates – systems and performances 47 3.3.4. New tendencies, new challenges 50 3.3.5. Concluding remarks on gate locking 52 3.4. Gate tightness – linings and seals 54 3.5. Guiding and maintaining gate contacts 57 3.6. Time, temperature and otherwise determined phenomena 62 4. LOADS ON GATES IN CONTACT AREAS 67 4.1. Gate load assumptions – general 67 4.2. Stochastic model of hydraulic loads 70 4.3. Load analysis and loading combinations 73 4.4. Character and distribution forms of contact loads 71 4.4.1. Some theoretical background 75 4.4.2. Elastic contacts – examples 79 4.4.3. Inelastic contacts – examples 82 4.4.4. Load modeling at contact levels 85 4.5. Static and dynamic contact loads, fatigue 86 4.6. Stationary and moving contact loads 88 5 Contact Problems in Lock Gates and Other Hydraulic Closures 5. ANALYSIS OF SELECTED CONTACT PROBLEMS 91 5.1. Contact phenomena on segment and asperity level 91 5.2. Problems of pointed contacts in mitre gate hinges 94 5.2.1. Wear in collar rings – problems and solutions 94 5.2.2. Wear in bottom pivots – problems and solutions 92 5.3. Linear contact through gate post lining (case Naviduct) 96 5.4. Examples of surface contact problems 98 5.4.1. Wear in a gate ball hinge (case Orange Locks) 101 5.4.2. Ball hinge Φ 10,0 m of the New Waterway Barrier 104 5.4.3. Drive arm connection of the Orange Locks gates 106 5.5. Dealing with some complex and special contact cases 110 6. LABORATORY INVESTIGATIONS OF GATE HINGE MATERIALS 113 6.1. Some historical background, “thread” forming 113 6.2. Purpose and scope of investigations 116 6.3. Model description and research parameters 118 6.4. Why to refrain from lubrication, general material preferences 122 6.5. Research results, summary 124 6.5.1. Specific wear factors 124 6.5.2. Friction coefficients 127 6.5.3. Changes to material structure 130 6.6. Discussion, conclusions and recommendations 134 6.6.1. General, classification of tested materials 134 6.6.2. Metallic versus non-metallic materials 134 6.6.3. Steels and non-iron alloys 136 6.6.4. Homogeneous synthetics versus composites 137 7. THE SUSPENSION GATE IDEA 139 7.1. Disadvantages of pivot supported gates 139 7.2. Genesis and mechanism of a suspension gate 141 7.3. Possible sub-types and arrangements 144 7.4. Short feasibility study 148 7.4.1. Torsional suspension – cable 148 7.4.2. Torsional suspension – chain or packed flats 151 7.4.3. Gate bearings 153 7.4.4. Assembly, installation and maintenance 155 7.5. Gate costs and concluding remarks 158 8. CONCLUSIONS AND RECOMMENDATIONS 161 8.1. Concluding remarks on the significance of contact engineering 161 8.2. Some technological conclusions and recommendations 162 8.3. Areas of further research, anticipation of developments 164 BIBLIOGRAPHY 167 ENCLOSURES 171 6 ACKNOWLEDGEMENTS The author would like to thank all individuals who raised the idea of this thesis, managed to incite his enthusiasm for it and helped to realize this idea by supervising, commenting and setting up propitious conditions for this work. This includes in particular Prof. E. Dembicki, the supervisor of this thesis, and Dr. K.Wilde, the dean of the Civil and Environmental Engineering Faculty of the Gda ńsk University of Technology, Prof. Bolesław Mazurkiewicz of the Gda ńsk University of Technology and Prof. Władysław Buchholz of the Szczecin University of Technology, the opponents, Prof. J. Głomb of the Polish Academy of Sciences, Prof. H. Huis in ‘t Veld of the TNO Institute in Eindhoven and Dr. S. Rienstra of the Eindhoven University of Technology. Although the work on this thesis did not make part of any subsidized project, nor was it financially supported in another way, the majority of the used material was collected from the author’s research, design and other activities in the Civil Engineering Department of the Dutch Ministry of Transport, Public Works and Water Management. The employment in this department gave the author a unique opportunity to participate in a number of fascinating hydraulic projects. The thanks for that opportunity are extended to Mr. W. Seinen, Mr. H. van der Weijde and Mr. J.C.F. Hendriks – as well as to all colleagues of the Civil Engineering Department (Bouwdienst Rijkswaterstaat). Special thanks are addressed to Mrs. J.N. Stelling, the author’s wife, who took diverse family tasks over, tolerating her husband’s long evenings behind the PC during the work on this thesis. This thesis would not be possible without her encouraging support. 7 Contact Problems in Lock Gates and Other Hydraulic Closures STRESZCZENIE Niniejsza praca doktorska jest prób ą zebrania do świadcze ń i rezultatów bada ń autora w problematyce podpar ć i innych elementów kontaktowych zamkni ęć hydraulicznych, takich jak wrota śluz, jazów i ruchomych zapór. Uj ęcie tematu ma charakter interdyscyplinarny. Praca zawiera zarówno przegl ąd obci ąż eń, zjawisk trybologicznych i innych istotnych do projektowania i utrzymania elementów kontaktowych, jak i przadstawienie wpływu szeroko poj ętego zachowania si ę tych elementów na proces wyboru i projektowania całych ustrojów zamkni ęć hydraulicznych. Zebrany materiał oraz przedstawione rozwi ązania pochodz ą głównie z 20-letniej praktyki autora w zakresie projektowania, bada ń, i organizacji budów obiektów hydrotechnicznych – przede wszystkim zamkni ęć wodnych. Przewa żaj ącą cz ęść tej praktyki autor zdobył pracuj ąc jako in żynier prowadz ący projekty infrastrukturalne w Wydziale In żynierii (Bouwdienst Rijkswaterstaat) holenderskiego Ministerstwa Transportu, Gospodarki Wodnej i Robót Publicznych. Obok opracowa ń i rozwi ąza ń własnych w pracy wykorzystano tak że szereg do świadcze ń kolegów autora, dost ępn ą literatur ę oraz wiedz ę uzyskan ą drog ą kontaktów mi ędzynarodowych, w tym poprzez Stałe Mi ędzynarodowe Stowarzyszenie Kongresów Żeglugi (PIANC), którego autor jest czynnym współpracownikiem.