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Kurzfassung
The main intention of [1] is to provide a uni-
Aktuelle Änderungen der VGB- Motivation for revising the guideline form standard for the safe and reliable design
Richtlinie über Auslegung und Bau and verification of cooling towers. Thus, it
von Kühltürmen in Kraftwerken specifies in detail actions, structural analysis
Since 45 years, all German cooling towers
methods, safety concept and construction re-
have been designed according to the recently
Im Hinblick auf die bevorstehende bauauf- quirements. The present paper will not cover
sichtliche Einführung europäischer Normen valid 2005-edition and earlier editions of the
all those aspects, but will mainly explain the
wurde eine Anpassung der VGB-Richtlinie für guideline VGB-R 610e “Structural Design of
background for the modifications of the treat-
den bautechnischen Entwurf, die Berechnung, Cooling Towers” – 2010 [1].
die Konstruktion und die Ausführung von Kühl- ment of wind-load and of thermal effects in
türmen notwendig. Die neue Fassung 2010 They have successfully resisted the mechani- the design concept and its consequences for
der VGB-R 610 greift – wie auch alle Fassun- cal, chemical and thermal stresses, as can be the structural safety and reliability of cooling
gen zuvor – die Erfahrungen von Anlagen- und seen from the actual photograph of the Herne towers.
Bauplanern, von Bauausführenden, Prüfinge- IV cooling tower, built in 1989 ( F i g u r e 1 ).
nieuren, Wissenschaftlern und Bauherren auf
und stellt den aktuellen Stand von Wissen- Further, this guideline has been adopted for
numerous cooling tower projects worldwide, Revision of the partial safety factor
schaft und Technik dar.
and thus represents the internationally accept- for wind loading
Neben der Weiterentwicklung betontechnolo-
gischer Konzepte werden in der VGB-Richt ed state of the art of cooling tower design and
linie erstmals Angaben zur Anwendung eines construction. Wi n d l o a d m o d e l
Betons mit hohem Widerstand gegen Säure-
angriff gemacht, bei dem auf die Verwendung Forced by the compulsory transposition of the The design of cooling tower shells for wind
einer Beschichtung der Kühlturminnenfläche European Directive EUROCODES by mid- loading is based on the concept of equivalent
verzichtet werden kann. 2012, a revision of the guideline on the struc- static pressures. The pressures are derived
Ein weiterer Schwerpunkt der Überarbeitung tural design of cooling towers [2] became nec-
stellt die Aktualisierung von Einwirkungswerten
from temporal mean values adequately ampli-
essary. This revised 2010-edition has already fied to account for the effects of the spatio-
sowie des Sicherheitskonzeptes für Wind und
Temperaturen dar. Neu gewonnene Erkennt- been published in German, an English version temporal stochastic loading process of the
nisse bei der Anwendung extremwertstatisti- is being printed. Besides fulfilling EUROCO- pressure fluctuations. The load amplification
scher Auswerteverfahren für Extremwinde auf DES, the new edition includes further im- has been derived from the gust response factor
Basis der PROGUMBEL-Software lassen eine provements with respect to safe and reliable
Reduzierung des bislang erhöhten Teilsicher- of those structural effects which are leading in
heitsbeiwertes zu. Dies wird vor dem Hinter- structural design: the design. The gust response factors were cal-
grund der historischen Entwicklung der in der −− Continuous improvements of concrete tech- culated based on a linear bending theory ap-
VGB-Richtlinie geregelten Windeinwirkung im nology concepts, plying the co-variance method for the quasi-
vorliegenden Beitrag detailliert erläutert.
Gleichfalls wird der neue Ansatz für betriebs- −− Highly resistant concrete against acid at- static response, and the spectral method for
bedingte Temperatureinwirkungen ausführlich tack, the resonant response. However, in the shell
dargestellt und abschließend werden die Aus- −− Probabilistic-based partial safety factor for design multiple responses are leading, e.g.
wirkungen auf die Bewehrung einer repräsen- tension or bending for the reinforcement, or
tativen Kühlturmschale untersucht. wind load,
compression for buckling safety. Each of them
−− Realistic consideration of thermal effects,
will attain its peak values at different wind
−− Requirements for increased durability. load distributions. Therefore, two wind load
Authors cases are considered in the VGB Guideline
To guarantee high quality standards and safe
Professor Dr.-Ing. Hans-Jürgen Niemann reliability of the cooling tower components
Ingenieurgesellschaft Niemann & Partner during power plants’ lifetime, this new edition
Bochum/Germany for the structural design of cooling towers [1]
VGB PowerTech - Autorenexemplar - © 2011
[1]. The first one, We is derived from the ex- Compressive failure of concrete yield strength anywhere in the shell under the
ternal wind pressures and given by E{1.00 G + 1.5 W} ≤ fc28/1.5 actions of G and W alone:
We: we (z,θ) = cpe(θ) φ FI qb(z) (1) (G – dead load; W – wind load) Asfyk
n(γwWk) ≤ ––––– – n(γGGm) (3)
γs
where z – height above ground; θ – horizontal A return period of 200 years is attributed to
angle with θ = 0° at stagnation; cpe – external the design wind load. Internal pressure is not Introducing the code values for the partial fac-
pressure coefficient; φ - dynamic factor ac- considered. No detailed provisions are given tors of steel and dead load, the limit state func-
counting for resonance to turbulence; FI – in- for the buckling safety. The partial wind load tion becomes:
terference factor accounting for an increase of factor was chosen as γW = 1.50; however, the Asfyk
the shell response by neighbouring buildings; value to be adopted in a project was often ne- n(γwWk) ≤ ––––– – n(1.00 · Gm) (4)
1.15
qb – gust wind velocity pressure. The gust gotiated with the owner.
wind velocity pressure qb accounts for the ef- (ii) The probability of extreme wind loads is
fects of the pressure fluctuations on the struc- 1 9 7 9 : VG B G u i d e l i n e [ 4 ] derived from the probability of the annual
tural response. wind speed maxima. Typically, a cumulative
Tensile failure of reinforcement Gumbel type I distribution is fitted to ob-
The internal pressures are determined by the E{1.00 G + 1.75 We}≤ fyk served data. A threshold velocity v is not ex-
flow at the top of the tower, namely by qb(H). Buckling safety ceeded with probability F(v) which is given by
Their mean is distributed uniformly over the E{1.00 G + 1.00 (We + Wi)} ≤ Ecrit/5 the Gumbel I expression as
circumference and the tower height. The inter-
nal pressure fluctuations are band-limited with In 1979, γW = 1.75 was recommended, again P (≤ v) = F (v)
a cut-off frequency in the order of the ratio of to be considered with a partial factor of γM = πv–µ
1 for the yield strength. An operational failure = exp ∙– exp ∙– ∙– –––– +E∙∙∙ (5)
the mean wind speed to the diameter at the ∙6 σ
tower top. Therefore, the effect of resonance to probability of ≤ 5 · 10-4 was attributed to this
turbulence is small and φ = 1 for the loading value. It was confirmed in the editions of 1980 where µ – mean, σ – standard deviation of the
by internal pressures. External and internal [5], 1990 and 1997. yearly extremes; E = 0.577 is the Euler number.
pressure fluctuations are uncorrelated. Based Given the non-exceedence probability F(v),
In 2001, the code DIN 1055-100: “Basis of the threshold velocity (e.g. the characteristic
on these observations, the second wind load design, safety concepts and design rules” was
case is given by value or the design value) can be calculated:
introduced in Germany which specified the
We + Wi: w(z,θ) = procedures and target values in the partial fac- ∙6
v = µ ∙1 + –– V ∙– In∙– In(F(v))∙ – E∙∙ (6)
= cpe(θ) φ FI qb(z) – cpi FI qb(H) (2) tor method. The code assesses a wind load fac- π
tor of 1.50 when the wind load is leading, and
The wind load case W is either W = We or W = a partial factor of γM = 1.15 for the yield Here, V = σ/µ – coefficient of variation. An
We + Wi whichever is more unfavourable. strength. Nominally, this ensures a safety in- average value of V = 0.12 is typical for a mid-
dex of β = 3.8 (failure probability 7 · 10-5) in latitudes wind climate. The square root of the
a service life of 50 years, or β = 4.7 and Pf = partial factor γw equals the ratio of design and
Partial factors for wind 1.3 · 10-6 in a reference period of 1 year. The characteristic wind speeds:
loading in the past safety concept of cooling towers was adapted vd
∙γw = ––
v
to this new framework in the 2005-edition. For k
The real level of reliability depends on para the specific needs of cooling towers, the wind ∙6 ∙ ∙
π V – In∙– In(F(vd))∙ – E
1 + –– (7)
meters such as the workmanship in the con- load factor was recalculated and γW = 1.6 was –––––––––––––––––––––––––
=
struction work, the material quality and the obtained. This decrease from 1.75 was in part ∙6 ∙ ∙
π V – In∙– In(F(vk)∙ – E
1 + ––
designer’s expertise. On the other hand, the op- due to the increase of γM from 1 to 1.15.
erational level of reliability is a matter of the The characteristic wind velocity vk is exceed-
2 0 0 5 : VG B G u i d e l i n e [ 2 ]
provisions in the design code, in particular: ed by definition with probability 0.02, or not
−− The return period of the characteristic wind Tensile failure of reinforcement exceeded with probability P(≤ vk) = 0.98. The
speed in connection with the wind load E{1.00 G + 1.60 W + 1.50 · B + 1.50 · S} requirement for the design wind speed vd is
safety factor, ≤ fyk/1.15 specified in EN 1990, section B.5:
−− The nominal value of the dead load in con- Compressive failure of concrete
junction with the partial factors for unfa- {1.35 G + 1.60 W + 1.50 · B + 1.50 · S} P (≤ vd) = Φ (–αE · β) (8)
vourable or favourable action effects, ≤ fc/1.5
where Φ designates the Gaussian probability
−− The structural resistance, mainly the yield Buckling safety
distribution; αE is a weighting factor for the
VGB PowerTech - Autorenexemplar - © 2011
strength of the steel reinforcement and the E{1.00 G + 1.00 (We + Wi)} ≤ Ecrit/5
action effect. A value of αE = –0.7 is recom-
buckling capacity combined with their re- (B – soil settlement; S – shrinkage) mended in DIN 1055-100 in accordance with
lated partial factors.
EN 1990 in the case that an action is leading.
A brief retrospect may highlight the develop- Considering one year as the proper reference
ment in the past. In the following equations period, the safety index is β = 4.7 (reliability
E{X} designates the action effect due to a load Current level of reliability based class RC 2 for standard risk). With this target,
combination X. on conventional storm statistics the partial factor from equation (7) is calcu-
lated as
1970: VIK guideline [3]
The reliability is calculated applying the level
Design in the so-called critical state which βw = 1.62 ≅1.6,
I method. The basic conditions are as fol-
corresponds to the failure limit state: lows: as has been specified in the 2005-edition [2].
Tensile failure of the reinforcement (i) Tensile failure of the reinforcement occurs
E{1.00 G + 1.5 W} ≤ fyk when the tensile membrane force n reaches the
vmax – µ f1 (τ)
––––––– = –––– (12)
σ f2 (τ)
Probability of non-exceedance
0.995
The data from Figure 2 were analysed apply-
0.99
ing the ProGumbel software [7]. The mean in a
sample of n = 44 annual maxima is 38.08 m/s
and the observed sample maximum 50.0 m/s.
0.95 They are amongst the highest values in Ger-
0.9 many. The curvature parameter has a mean of
τm = 0.132 with confidence interval – 0.009 <
τ < 0.238. Monte-Carlo simulations show that
the reliability in predicting the mean µ and the
0.5 standard deviation σ is satisfactory for wind
data samples covering 30 or more years. Cal-
0.1 culation of the upper limit or the curvature
parameter is not straightforward even for large
0.01
0.001 samples. Data from weather stations with high
0 10 20 30 40 50 60 70 exposure and a high mean of the yearly ex-
tremes show a clear upper limit. 169 weather
Wind speed in m/s
stations in Germany have been analysed and
Figure 2. O
bserved extreme wind speeds at the Brocken mountain in Germany, 1142 m above
the corresponding curvature was obtained be-
sea level. Parameters of fitted Gumbel type III cumulative probability distribution: tween τ = 0.07…0.15. The partial factor for
mean µ = 38.08 m/s; standard deviation σ = 4.60 m/s; coefficient of variation V = the Gumbel type III distribution becomes
0,121; curvature τ = 0.132; upper limit vmax = 67.65 m/s.
f1 – ∙–ln(1 – Φ(αEβ)∙τ
1+V––––––––––––––––––
value, µ, and standard deviation, σ, the addi- f2
∙γw = ––––––––––––––––––––––– (13)
Partial wind load factor with a tional curvature parameter, τ, has been intro- f1 – –ln(0.98)∙τ
∙
statistical model having an upper limit 1+V –––––––––––––
duced. It determines the boundary: For type II f2
1.87
indicate clearly a positive curvature of the dis-
tribution and consequently an upper limit.
VGB PowerTech - Autorenexemplar - © 2011
Γ designates the gamma-function. In equation Figure 3. Partial safety factor for wind load as a function of the safety index β obtained for the
(11), the positive sign applies to positive τ generalised Gumbel cumulative probability distribution types I and III; with participati-
and vice-versa. Besides the parameters mean on factor αE = – 0.7, variation coefficient V = 0.125, curvature τ = 0.15.
0.35
0.30
1.20
dT
0.25 H
z
1.15
0.20
1.10
2
(—RB )
w
0.15
1.05
0.10
1.00
0.05 0 2 4 6 8 10
qb (H)
· 104
(dT · nmin)2
0.00
0.0 0.1 0.2 0.3 0.4 0.5
Vm, 10
dT · nmin
esonant response of cooling tower shells to wind gustiness; (a) experimental results for (R/B)2, the ratio of resonant to quasi-static
Figure 4. R
response variance, as a function of normalised wind speed; (b) dynamic factor of the VGB Guideline based on (a).
In the two equations (7) and (13), the coeffi- effect as an amplification factor for wind forc- −− Both, the mean and the background mem-
cient of variation, V, and the curvature, τ, are es. The dynamic factor is defined in the Ger- brane force increase proportionate to the
the only distribution parameters required. A man national annex DIN EN 1991-1-4/NA: wind velocity pressure.
typical value is V = 0.125 and τ = 0.15. In Annex NA.C.2, by −− Unlike linear structures, several modes (ap-
F i g u r e 3 , the partial factor is shown as a proximately the first 10) contribute to the
function of the reliability index β. 1 + 2 kp · Iv(zs) ∙B² + R² resonant response.
φ = cd = –––––––––––––––––––– (14)
As was to be expected, the type III distribution 1 + 2 kpQ· Iv(zs) · B −− Resonance σR increases moderatly dispro-
leads to a much lower wind load factor of portionate to the velocity pressure qm, the
1.3 as compared to the traditional approach where: B², R² – factors of the quasi-static (back- exponent being 1.68.
type I with the parameters considered. The ground) response variance and resonant re- −− For the ratio of the variances of the resonant
code value of γw = 1.5 is already attained by sponse variance, σ2Q and σ2R respectively; Iv(zs) and the background response the following
assuming a rather small curvature of τ = 0.05 – turbulence intensity at a reference height zs, expression applies:
which may be considered as a safe lower limit. kp, kpQ – peak factors for the total and quasi-
It can be shown that the ratio of the predicted static response fluctuations. The code proce- σ2R/σ2B = R²/B²
maximum to the mean for τ = 0.05 would be dure is applicable to structures where the first π2
(vmax/µ) ≅ 3.0. For the Brocken Mountain, mode of vibration dominates the response, and = factor · –– (dm/L)2/3 (vm,10/(dm . nmin))2.7
2δ
this would mean a maximum 10 min average provided the modal shape has the same sign
VGB PowerTech - Autorenexemplar - © 2011
wind speed of 115 m/s which is far beyond everywhere. Obviously, the method cannot be
recorded values. In conclusion the partial where δ – damping decrement; L – Daven-
utilised for cooling towers considering that the
safety factor is introduced in the 2010-edition port’s integral turbulence length scale, L =
lowest natural frequencies are associated with
[1] with a value of 1.5 which – as could been 1200 m; vm,10 – mean wind speed at 10 m
ovalling modes having 3 to 5 circumferential
shown – is on the safe side. above ground; dm – mean shell diameter; nmin
waves. The particular features of the random
– lowest natural frequency.
shell vibrations have been investigated as early
as 1975 applying theoretical and experimental The factor reflects the influence of the tower
Adjustment of the dynamic factor
methods. The experiments were performed in shape, in particular the aspect ratio and the
accounting for gust wind effects
two wind tunnels using aeroelastic models and position of the throat. For aspects ratios rang-
measuring the shell strains. The tensile meridi- ing from 2 to 2.5, an average value of 0.16 is
The dynamic factor reflects the effect of reso- onal membrane forces were considered as criti- valid. The throat is positioned between 0.7 · H
nance on the peak response of a structure. In cal, leading wind effect. The theoretical part and 0.8 · H. F i g u r e 4 ( a ) compares the
2005, the latest EN 1991-1-4 appeared which utilised the spectral method. Details are given theoretical curve with the experimental results
introduced a method to calculate the gust in [8]. The findings were and a good agreement is found. F i g u r e 4 ( b )
50 50
40 40
30 30
Air temperature inside in °C
Temperature gradient in K
20 20
Tinside - Toutside
Tinside
10 10
0 0
-10 -10
-20 -20
-25 -25
a) Measured temperatures in one year (526,000 values) b) Thermal actions derived from the measured
approx. 15 m above fill system (vapour zone) temperatures shown in a)
(both states: operation and outage)
Figure 5. Measurements of inner and outer air temperatures in the vapour zone.
shows the diagram of the dynamic factor φ −− Operational temperature, decisive in winter When leaving the piping system and mixed
derived from (a). It was introduced to the VGB season, with the natural air draft, the temperature will
Guideline in 1980 [5]. The diagram was re- −− Summer outage. be reduced to about + 35 °C in the spray zone
fined in 1990 by including on the abscissa an on the level of the trickling system and to
Whereas the temperature gradient for summer about + 25 °C in the vapour zone above the
additional geometry parameter, namely the
outage keeps constant since that time, a conse- trickling system, depending on the respective
ratio of the throat diameter to the distance of
quent detailing and adjustment of the other fill system. In the transition zone a linear de-
the throat from the tower top, dT/(2zT). In this
temperature values has continuously improved crease of temperature should be applied. These
manner, it became possible to account for very
the cooling tower design. Beyond that, a re- assumptions have been partly confirmed by
slender tower shapes or those having a lower
valuation of considering the thermal impacts numerical CFD simulations [9] and measure-
aspect ratio. Today, new tower shapes are be-
in the safety and design concept has to be ad- ments [10, 11] and have been agreed with the
ing designed with the throat at the tower top.
justed to the related valid standards. VGB Working Group “Cooling Technology in
In such a case, the abscissa becomes infinity
and the resonance factor as well. This is obvi- Power Plants”.
Operational temperature
ously not realistic, the amended abscissa is not Thus the following operational temperatures
Operation conditions in winter season with
appropriate for such tower shapes. Calcula- TOP for the design of the cooling tower shell
minimum atmospheric temperatures outside
tions of the mode shapes show that the lowest are relevant:
the shell and increased vapour temperatures
natural is associated with lower wave num- −− Uniform temperature change
inside are relevant for the maximum bending
bers. This would indicate a limited increase of in vapour zone
R². However, the effect on the resonance fac- constraints in the shell wall. According to Ger-
man standards, in winter a minimum atmos- ∆TNOP = – 15 K
tor is less pronounced in view of equation
pheric temperature of –24 °C is to be assumed. −− Temperature gradient in vapour zone
(14): an increase of R2/B2 from 0.3 to 0.6 in-
This is a standard value for Germany, which ∆TMOP = + 49 K
creases φ only by about 10 %. Therefore, the
VGB Working Group decided to withdraw the might be precised by a meteorological exper- −− Uniform temperature change
VGB PowerTech - Autorenexemplar - © 2011
refinement for unusual tower shapes and to tise. The atmospheric temperature during con- in spray zone
delete the additional geometry parameter. Of struction of the cooling tower is assumed to be ∆TNOP = – 10 K
course, it may be substituted by results of constant +15 °C. If the climatic conditions dif- −− Temperature gradient in spray zone
more detailed calculations. fer decisively, realistic values again need to be ∆TMOP = + 59 K
evaluated by a meteorological expertise. The
new edition [1] details the regard of differing Then the effective temperature gradient
atmospheric temperatures by setting parame- ∆TMOPeff across the cross-section of the shell
Revision regarding thermal actions wall can be determined using the heat resist-
on cooling towers ters and using formulas to determine the rele-
vant thermal impact. ance values for both internal and external shell
surface Rsi = Rse = 0.04 (m2K)/W and a me-
Initiating with the first German guideline for In the water distribution pipes in general a dium heat conductivity for concrete according
cooling towers in 1970 [3] mainly two relevant maximum water temperature of about + 50 °C to DIN EN ISO 10456. In case of the spray
situations for thermal impacts on cooling tow- can be expected. Higher temperatures have to zone the heat resistance value for internal shell
er shells have been identified as relevant: be looked upon as an accidental situation. surface has to be set to Rsi = 0 (m2K)/W.
+25 °C 25 +35 °C 25
20 20
15 15 2h
10 10 4h
6h
Temperature in °C
Temperature in °C
5 5 8h
0 0 12 h
-5 -5
-10 -10
-15 -15
-20 -20
-24 °C -24 °C
-25 -25
Initial state Initial state
-30 -30
0.00 0.10 0.20 0.30 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80
12 12
10 10
8 Steady state acc. [1] 8 Steady state acc. [1]
6 6
4 4
Meridional stress in N/mm2
2 2
0 0
-2 -2
-4 -4
-6 -6
-8 -8
-10 -10
-12 -12
-14 -14
0.00 0.10 0.20 0.30 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80
Figure 6. Time-dependent temperature change in the wall’s cross-section and resulting thermal stresses.
Measurements of the inner and outer air tem- strength. The more relevant stresses are the σ = E/[2(1-v)] · αT · ∆TMOPeff
perature in the vapour zone [10, 11], converted maximum tensile stresses of 5.2 N/mm2 in the = 0.2125 · 29.9 K = 6.4 N/mm2
into thermal actions as shown in F i g u r e 5 , vapour zone and 6.2 N/mm2 in the spray zone > 6.2 N/mm2 = σ12 h
are covered by the characteristic values ac- (F i g u r e 6 ). These tensile stresses will be
cording to [1]. Anyway, all temperature de- lower than the analysed linear stress state and Spray zone:
faults have to be confirmed or adjusted by the thus will have been already considered in the d = 80 cm and ∆TMOP = + 59 K
cooling plant designer, especially if deviating design concept: ⇒ ∆TMOPeff = + 47.6 K
from normal operation conditions or in case of R
∆TMOPeff = ––––––––––– ∆TMOP σ = E/[2(1-v)] · αT · ∆TMOPeff
dry and hybrid cooling towers. Rsi + R + Rse
= 0.2125 · 47.6 K = 10.1 N/mm2
In general, temperature effects due to opera- d/λ > 5.2 N/mm2= σ12 h
= –––––––––––– ∆TMOP (15)
tion can be assumed to act axisymmetrically. Rsi + d/λ + Rse
Non-axisymmetric temperature distributions M11 = M22 It is obvious that the thick lower ring beam
might occur, if the fill system is operated sec- d2
VGB PowerTech - Autorenexemplar - © 2011
es due to rotationally changing sectorwise or alternatively an ultimate load analysis may An equivalent uniform temperature
operation of the fill system. be performed. change of ∆TN = – 15 K shall be as-
To verify the serviceability limit state, the sumed.
In the past edition [2] the temperature gradient
both in the vapour and in the spray zone was limitation of crack width, displacements and −− Indirectly induced soil settlements B
equally assumed to ∆TMOP = + 33 K only, ac- stresses is focussed. The specific variables in Soil settlements in this sense are induced by
companied by higher combination values than general will be calculated linearly. Regarding foreign effects due to underground mining
usual, both for the frequent (ψ1) and for the cooling tower design only the limitation of the or neighbouring buildings and represent in-
quasi-permanent (ψ2) value. This procedure crack width is relevant. In both VGB Guide- direct actions.
was pragmatic for civil engineers, but was lines [1, 2] the characteristic crack width wk is −− Seismic actions AE and accidental actions A
somehow misleading for the cooling plant de- limited to: Seismic actions or accidental actions may
signers. Consequently long and intensive dis- −− Shell: wk ≤ 0.20 mm be derived from design values. The damp-
cussions have been necessary for each project −− Columns and foundation: wk ≤ 0.30 mm ing coefficient can be set to D = 0.05 and
to balance the understanding of both civil and −− Basin and fill the importance factor γI is to be determined
mechanical engineers, and finally to convince support structure: wk ≤ 0.15 mm in agreement with the power company ac-
the client about the safe and reliable design of cording to DIN EN 1998-1.
the cooling tower. In order to avoid this misun- In addition to the verifications of the different
design limit states a buckling safety of γB ≥ 5 Referring to DIN EN 1990 and DIN EN
derstanding, the new edition [1] now provides
is required with respect to characteristic val- 1992-1-1 different design situations need to be
the physically realistic temperature gradient as
ues for the combination of actions G + We + analysed for the different design limit states.
a characteristic value, but offering adequate
Wi (dead load G, external wind pressure We Accordingly, appropriate safety factors and
safety and combination values. For future
and internal suction Wi). The resulting design combination values for the actions Fd = Fk/γF
projects this will help to clarify the co-opera-
procedure is appropriate to determine the wall as well as the partial safety factors for the ma-
tion between structural engineer and cooling
thickness distribution of the shell. terial capacities Rd have been defined ( Ta -
plant designer.
b l e s 1 and 2 ).
Summer and winter outage Regarding the defined design situations, char-
acteristic values Fk for the essential actions are Considering these safety factors and combina-
For summer outage a temperature state is to be to be considered: tion values the verification of ultimate limit
considered, which is composed of an axisym- −− Dead load G state results in relevant combinations of ac-
metric uniform temperature change ∆TNS in The specific weight of reinforced con- tions:
the middle surface of the shell and an effective crete is assumed to be 25 kN/m3. −− Persistent and transient design situation:
temperature gradient ∆TMS acting as a cosine-
−− Wind load W ∑ γG,j · Gk,j + γQ,1 · Qk,1
function over half the circumference. Former
The wind load W as a quasi-static load j≥1
investigations have demonstrated that the non- + ∑ γQ,i · ψ0,1 · Qk,i (18)
is separated into external pressure We
axisymmetric effect is negligible [12], so that i>1
and internal suction Wi.
the maximum values of ∆TMSeff again can be −− Accidental design situation:
assumed to act axisymmetrically and constant −− Temperature T
over tower height: The thermal actions consist of uniform ∑ Gk,j + A + ψ1,1 · Qk,1
j≥1
temperature changes ∆TN and tempera- + ∑ ψ2,i + Qk,i (19)
−− Uniform temperature change ture gradients ∆TM for different atmos- i>1
∆TNS = + 22 K pheric and operational conditions, as −− Earthquake (seismic action):
−− Effective temperature gradient already explained in detail.
∆TMSeff = – 25 K −− Shrinkage S ∑ Gk,j + AE + ∑ ψ2,i · Qk,i (20)
j≥1 i≥1
For winter outage only the temperature change
Table 1. Partial safety factors γF (γG, γQ) and combination values ψi for actions
∆TNW in the shell’s middle surface needs to be
on cooling tower shells.
regarded:
−− Uniform temperature change Partial safety factor Combination value
Action
∆TNW = – 39 K γG1 γQ1 ψ0 ψ1 ψ2
G 1.00/1.35 - - - -
Safety concept W (We,Wi) - 0/1.50 0.6 0.5 0
TOP - 0/1.502 03 0.7 0.5
The new generation of European standards is T S
- 0/1.50 2
03
0.5 0
VGB PowerTech - Autorenexemplar - © 2011
Table 3. Relevant ultimate and serviceability limit states acc. [1, 2]. towers, a simulation of the crack-evolution in
the shell is to be carried out early in the design
VGB 2005 [2] VGB 2010 [1]
phase [17]. The relevant load combinations
ULS
∙ ∙ ∙ ∙
γG G + 1.60 W γG G + 1.50 W under the dominant actions dead load G, wind
Ed ≤ Rd (fy/1.15) Ed ≤ Rd (fy/1.15)
γG G + 0.96 W + γQ T γG G + 0.90 W + γQ T load W and temperature T are to be investi-
1.00 TOP 0.50 TOP gated by an incremental-iterative procedure by
∙ ∙ ∙ ∙
SLS G + 0.50 W + G + 0.50 W +
wk G+ 1.00 TOP ≤ lim wk wk G+ 0.70 TOP ≤ lim wk means of an amplification factor λ. According
G+ 0.50 TS G+ 0.50 TS to [1] the following load combinations need to
G+ 1.00 TW G+ 0.50 TW
be investigated
T = TOP, TS, TW (TOP different for VGB 2005 [2] and VGB 2010 [1])
γG = 1.00 (favourable)/1.35 (unfavourable) λ (γG G + 1.50 T + 0.90 W) λu ≥ γR = 1.3,
γQ = 1.00 for linear analysis
γQ = 1.50 for non-linear analysis with global safety factor γR = 1.30 for system resistance
VGB 2010 [1], 3.3.2: γQ = 0 for linear analysis of general regions of the shell λ (γG G + 1.50 W) λu ≥ γR = 1.3.
1.69
0.20 0.30
Ø 74.180 m 1.19
178.100 0.10
0.30 m
Upper ring beam R = 37.090 m
0.20 m 178.10 m
171.000
1.20
176.60 m
0.30
Ø 71.216 m
Wall thickness 118.444
R = 35.500 m
VGB PowerTech - Autorenexemplar - © 2011
0.30
66.000
0.20 m
16.699 °
0.23 m 60.000
Columns 0.25
1.10
R = 61.00 m Wall of water basin
25.500 11 m
0.23 m 0.60 0.732
1.95 2.068
0.858 3.005 1.487 -1.10
10.444 Ø 114.388 m
Ring foundation
0.75 0.75
-1.85
1.00 m
1.50
R = 58.332 m
-1.85 R = 60.882 m -2.60
R = 63.682 m
Ø 121.764 m 5.35
Figure 7. D
imensions of representative cooling tower shell with axisymmetric geometry and boundary conditions; concrete quality of foundation
C30/37; concrete quality of columns and shell wall C35/45; concrete cover of shell wall 35 mm; soil stiffness moduli ks,stat = 10 MN/m3
and ks,dyn = 30 MN/m3; interference factor FI = 1.0 (solist); pressure distribution curve K1.1; terrain category II.
180 180
160 160
ULS acc. [1] ULS acc. [1]
ULS and SLS acc. [2] ULS and SLS acc. [2]
100 100
as, min acc. [1], 3.3.5.1 as, min acc. [1], 3.3.5.1
Level in m
Level in m
as, min acc. [1], 3.4.1.2 as, min acc. [1], 3.4.1.2
80 80
60 60
VGB PowerTech - Autorenexemplar - © 2011
40 40
20 20
0 0
0 2 4 6 8 10 12 14 16 18 20 22 24 0 2 4 6 8 10 12 14 16 18 20 22 24
Figure 9. R
equired circumferential reinforcement in case Figure 10. Required meridional reinforcement in case
of German wind zone 2. of German wind zone 2.
7. - 9 . 2 . 2 0 1 2
Essen /Germany
VGB PowerTech - Autorenexemplar - © 2011
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