OODBODHAN 2024, VOL.

07

STRUCTURAL ANALYSIS OF HYDROPOWER

STOPLOG: A CASE STUDY OF SETI
HYDROPOWER PROJECT
Sagar Timilsina1*, Paras Katuwal1
Department of Mechanical Engineering, Pashchimanchal Campus, IOE, Tribhuvan University,
1

Pokhara, Nepal
2
Department of Civil Engineering, Pashchimanchal Campus, IOE
Tribhuvan University, Pokhara, Nepal
*sgrtml2057@[Link]
(Manuscript Received 30th August, 2024; Revised 29th September, 2024; Accepted 30th September, 2024)
Abstract
Hydropower stoplogs are essential components in managing water flow within hydropower
facilities, playing a critical role in ensuring safe operations and maintenance. Despite advancements
in technology, existing designs face persistent challenges related to efficiency, environmental
impact, and maintenance needs, highlighting a significant research gap in optimizing stoplog
design. This study aims to address these issues by employing Finite Element Analysis (FEA) to
evaluate stress distributions and material behavior in stoplog design, thereby enhancing overall
performance. The methodology involved a comprehensive literature review, analytical design
calculations, and the development of a detailed Computer-Aided Design (CAD) model, followed
by iterative static structural analysis using ANSYS Mechanical. Key findings revealed that the
integration of stiffeners and support systems significantly improved the stoplog's performance,
achieving a maximum central deflection of 11.226 mm—just within the allowable limit of 11.25
mm—and a maximum stress of 241.18 MPa, well below permissible limits. These results confirm
that the optimized stoplog design is both safe and efficient, illustrating the effectiveness of FEA in
advancing hydropower infrastructure.
Keywords: ANSYS Mechanical, CAD, FEA, MIT, Structural analysis
1. Introduction the hydropower project. The features of the
Hydropower stoplogs are large, undersluice area openings are tabulated below
removable barriers used to control water flow in Table 1.
in hydropower facilities (Bureau of Indian Table 1 : Site Parameter
Standards, 2003). They help manage water Clear Opening 9m x7.553m
levels, facilitate maintenance, and ensure safety Designed Water Level 588.5 masl
by isolating sections of the system. Generally, Gate Invert Level 573.3 masl
a stoplog consists of a structural steel frame Surge Head 0 % taken
with vertical end girders and horizontal girders Design Head 15.20 m
placed between them. The stoplog's dimensions Despite significant advancements in
and the design water pressure determine the hydropower technology, existing hydropower
spacing. Secure riveting or welding holds the stoplogs often face critical challenges related
frame together in one piece. to efficiency, environmental impact, and
The concerned stoplog of this research maintenance. These challenges include
study is located in the undersluice area of optimizing stoplog design for varying water

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flow conditions, minimizing ecological analytical methods may ignore or oversimplify.
disruption, and ensuring long-term durability. 2. Methodology
Current research lacks comprehensive solutions Firstly, previous research on hydropower
that address these issues holistically. The need gates and stoplogs was reviewed, focusing on
exists to develop innovative hydropower analytical design methods and computational
stoplog systems that enhance operational analyses. With adequate site data and
efficiency, reduce environmental impacts, and information, we identified and defined the
lower maintenance costs while integrating necessary design variables. Following this,
seamlessly with existing infrastructure. preliminary calculations were performed
The research regarding stoplogs are not through analytical design. A CAD model
carried out efficiently and the designation was developed, incorporating appropriate
of stoplogs are executed only on paper. constraints and boundary conditions for
In conventional method the stoplogs are structural analysis. The results of the static
generally designed on the basic of hydrostatic structural analysis were evaluated, and if
load bearing ability considered a stoplog as an satisfactory, conclusions were drawn. In
integrated body. But in fact, the stress on body cases where the results were not adequate, we
varies from point to point so the implementation revisited the computational model or analytical
of finite elemental study method is essential for calculations for refinement. This iterative
both safety and for less material consumption approach ensured a robust and effective design
(Bendsoe & Kikuchi, 1988). process.
Finite element analysis offers significant The research methodology used for the
advantages in modeling complex geometries following study is shown in figure 1.
and evaluating stress distributions, which are
crucial for the optimized design of structures
such as hydropower stoplogs (Chen & Liu,
2015). Finite Element Analysis (FEA) is
frequently preferred over traditional analytical
methodologies for designing hydropower
structures due to many major benefits. FEA
is more successful at modelling complex
geometries and sophisticated boundary
conditions, which is critical for the thorough
design of hydropower stoplog. It provides a
detailed view of stress and strain distributions,
allowing for precise characterization of
material behavior and load responses, including
nonlinearities. Furthermore, FEA may conduct
dynamic calculations to evaluate the influence
of changing load circumstances and optimize
design parameters. This comprehensive
methodology aids in detecting important stress
spots and maintaining structural integrity that Figure 1 : Methodology

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Material Selection and Allowable Stress and the installation process more manageable.
Deformation Calculation The first design iteration was conducted using
The material used for the fabrication of Ansys
the stoplog is E350B0 and its properties are Mechanical for Finite Element Analysis
tabulated in the Table 2. (FEA) to identify areas with high stress
concentrations, significant stress gradients,
Table 2 : Material Properties
and large deformations. Based on these
Steel Grade E350B0 findings, we incorporated additional supports
Density 7850 kg/m3 and stiffening elements, such as stiffeners and
Young’s Modulus 210 GPa back cover plates. Several subsequent design
Poisson’s Ratio 0.3 iterations were performed to assess how these
Ultimate Tensile Strength (fu) 490 MPa modifications improved the structural behavior
Yeild Strength (fy) 350 MPa
of the stoplog under the intended design
conditions. Additionally, two vertical beams
For the computation of allowable stress and
were added with a 4-meter span to facilitate
deflection, IS 4622 (2003): Recommendations
the hoisting process and reduce deflection in
for Structural Design of Fixed-Wheel Gates is
the center.
followed.
As per the table at Annex B of the code
the permissible stress differs depending on
wet/dry/accessible/inaccessible condition.
For stoplogs stresses given under dry and
accessible conditions is applied since they
are stored above water level and are only
occasionally used i.e.
Figure 2 : Stoplog CAD Model
Permissible Stress (S)=0.75xfy x e
The bottom stage of the three-stage
= 0.75 x 350 MPa x 1 stoplog model, which experiences the highest
= 262.5 MPa hydrostatic forces, was analyzed using Ansys.
Where, e= Welding Efficiency= 1 for shop As a result, the two upper stages are expected
weld [ cl-[Link]] to remain within safe limits for allowable stress
And according to cl-5.3.5 of the code, and total deformation.
maximum deflection of the gate under normal All geometries were meshed using
conditions of the loading shall be limited to ANSYS Mechanical tools. The precision
1/800 of the span (clear opening span). i.e. of computational analysis relies heavily on
Maximum Deflection= (1/800) x L mesh size and boundary conditions (Chen &
Liu, 2015). Generally, a finer mesh leads to
= (1/800) x 9000 mm
more accurate results, while precise boundary
= 11.25 mm conditions are essential for relevant outcomes.
2.2 Model Preparation and Meshing However, there is a point where further mesh
For the mechanical design, firstly, the refinement does not significantly alter the
CAD model was prepared in Solid works results. To establish a mesh-independent
software using the geometrical data from site solution, a Mesh Independence Test was
observation. performed to identify a mesh size that produces
Due to the large height of the stoplog, the stable and consistent results. For the selection
of appropriate mesh size, Mesh Independence
design was divided into three stages to make
Test (MIT) was performed taking size of mesh
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as independent parameter and the maximum 3.2 Structural Analysis
deflection at skin plate as dependent variable.
The mesh size was reduced till a convergence
was seen on the output deflection result.

Figure 5 : Deformation results across Stoplog

The results of the finite element analysis
Figure 3 : Mesh Model (FEA) of the hydropower stoplog indicate
2.3 Boundary conditions and Load that the design is both structurally sound and
Constraints efficient under specified loading conditions.
The sealing of Undersluice Stoplog is The observed central deflection of 11.226
downstream so the seal stopper acts as a fixed mm is just below the allowable maximum
support for analysis in finite element solver- of 11.25 mm, demonstrating that the stoplog
Ansys. Whereas the back of the skin plate is is operating within acceptable limits. This
subjected to hold the total hydrostatic pressure. close margin highlights the effectiveness of
All the strength calculations were performed the design, ensuring safety while maximizing
based on the maximum hydrostatic pressure in material efficiency.
the system.
Calculation for hydrostatic pressure:
Total head=15.2m
Hydrostatic Pressure
(P)=dxgxh=1000x9.81x15.2= 0.149MPa.
3. Results
3.1 Mesh Independence Test
Numbers of iteration were carried out to
optimize the model. The maximum deflection Figure 6 : Stress Distribution
obtained on mesh independent test is displayed across Stoplog
in the Table 3 and Figure 6. From Figure 6,
the circled mesh element corresponding to
mesh size of 37.5 mm was chosen for the static
structural analysis. So deflection and stress
results represented are retained from mesh size
37.5mm.

Figure 7 : Region of Maximum Stress

The stress distribution analysis reveals
a maximum stress of 241.18 MPa, localized
primarily in the boundary area, which is well
within the permissible limits. This indicates
that the design can withstand the hydrostatic
Figure 4 : Mesh Independence Test Results forces without risk of failure, confirming its
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reliability in real-world applications. increased durability and performing dynamic
The significance of these results lies in load studies to accommodate for changing water
their contribution to improving hydropower conditions and seismic impacts. Furthermore,
stoplog designs. By employing FEA, the adopting a modular design would make travel
study identifies critical stress concentrations and installation easier, while upgrading finite
and deformation patterns that traditional element analysis techniques could provide
methods might overlook. This approach not deeper insights into structural relationships,
only enhances safety and performance but also
ultimately improving the stoplog's integrity,
paves the way for future innovations, such as
efficiency, and durability.
optimized designs and material use.
4. Conclusion Acknowledgement
Authors would like to acknowledge Seti
In conclusion, the finite element analysis
Khola Hydropower Project for providing
of the hydropower stoplog indicates that the base data of Seti Khola Hydropower Project.
design is both safe and efficient under the The authors would also like to thank
specified conditions. The mesh independence Machhapuchhre Metal & Machinery (P.) Ltd.
test confirmed that a mesh size of 37.5 mm for necessary support.
provides reliable results for deflection and References
stress calculations. The central deflection Bureau of Indian Standards. (2003).
of 11.226 mm, while close to the maximum Recommendations for structural design
allowable deflection of 11.25 mm, is within of fixed-wheel gates (IS 4622:2003).
acceptable limits, demonstrating that the Bureau of Indian Standards.
stoplog's structural performance is nearly Chen, X., & Liu, Y. (2015). Finite element
optimal. The stress distribution analysis shows modeling and simulation with ANSYS
that the maximum stress of 241.18 MPa is Workbench (1st ed.). CRC Press. https://
localized in the boundary area, well within the [Link]/10.1201/b17284
permissible stress limits. The incorporation of Bendsoe, M. P., & Kikuchi, N. (1988).
stiffeners effectively reduces central deflection Generating optimal topologies in
by increasing rigidity and reducing bending structural design using a homogenization
moments. Further improvements to the method. Computer Methods in Applied
hydropower stoplog could include improving Mechanics and Engineering, 71(1), 197–
224.
materials by investigating alternatives for

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APPENDIX

Figure 8 : Shop Drawing of Stoplog

Table 3: Final Model Parameters Based on Analysis
Material Sec- Section (Thick-
S. N. Part Material Grade
tion ness in mm)
1. Skin Plate MS Plate 12
2. Side Vertical Girder MS Plate 12
3. Back Cover Plate MS Plate 20
4. Horizontal T Girder MS Plate Flange=20
(T Section) Web=12
E350 B0
5. Vertical Stiffener MS Plate 10
6.1 Sliding Base Plate MS Plate 47
6.2 Sliding Pad MS Plate 10
7. Horizontal Girder Base MS Plate 20
8. Bracing Stiffener MS Plate 16

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