EPIC for Gas Sweetening Facilities Project Rev.

(GSF) at Mesaieed & Dukhan A

Part-2 AGRP (Dukhan) Date:
Doc. No 2971-1-12-0306 5/2/2014
Title: Design Calculation for PR02-M-02 Monorail Beam
STRUCTURE: PR02-M-02
HOIST TAG: 301-41-Y-01/02

INPUT DATA: REMARKS

MONORAIL BEAM: UB 356X171X51
SELF WEIGHT (kg/m) W = 51
C/S AREA (mm2) A = 6490
DEPTH OF SECTION (mm) d = 355
WIDTH OF FLANGE (mm) b = 171.5
THICKNESS OF WEB (mm) tw = 7.4
THICKNESS OF FLANGE (mm) tf = 11.5
MOMENT OF INERTIA ABOUT MAJOR AXIS (mm4) Iyy = 141360000
MOMENT OF INERTIA ABOUT MINOR AXIS (mm4) Izz = 9680000
ELASTIC SECTION MODULUS ABOUT MAJOR AXIS (mm4) Zyy = 796000
ELASTIC SECTION MODULUS ABOUT MINOR AXIS (mm4) Zzz = 113000
PLASTIC SECTION MODULUS ABOUT MAJOR AXIS (mm3) Wply = 896000
PLASTIC SECTION MODULUS ABOUT MINOR AXIS (mm3) Wplz = 174000
RADIUS OF GYRATION (mm) rx = 148
RADIUS OF GYRATION (mm) ry = 38.6
ROOT RADIUS (mm) r = 10.2
NET WEIGHT OF CHAIN PULLY BLOCK WITH TROLLEY (kg) = 375 from doc. No. 2971-5-13-1037
MAXIMUM WHEEL LOAD WITHOUT IMPACT (kg) = 1875 from doc. No. 2971-5-13-1037
NO. OF LOAD WHEELS = 4 from doc. No. 2971-5-13-1037
WHEEL DIAMETER (mm) = 145 from doc. No. 2971-5-13-1037
C/C DISTNACE B/W WHEELS ALONG THE RUNWAY BEAM (mm) xw = 236 from dwg. No. 2971-0137-5-74-0016-sht.001
DISTANCE OF WHEELS ACROSS THE RUNWAY BEAM FROM ROOT RADIUS (mm) = 53.85 from dwg. No. 2971-0137-5-74-0016-sht.001
YIELD STRESS OF STEEL (N/mm2) Fy = 265
SAFE WORKING LOAD/ MAXIMUM LIFTING CAPACITY (kg) SWL = 7500 from doc. No. 2971-5-13-1037
PROOF LOAD (kg) PL = 9375 As per Cl. 8.3 of BS 2853:2011
UNFACTORED LONG. HORIZONTAL FORCE (kg) P = 393.75 As per Cl. 2.5.1.2 of BS EN 1991-3-2006
NO. OF CONNECTING BOLTS n = 4 Refer drawing.
GRADE OF STRUCTRAL BOLTS G = 8.8 Refer drawing.
DIAMETER OF STRUCTURAL BOLTS (mm) dbolts = 20 Refer drawing.
TENSILE STRESS AREA OF BOLT (mm2) At = 245 From "Joints in Simple Construction- BCSA"
REDUCED TENSION STRENGTH STRENGTH OF BOLTS (N/mm2) Ptr = 300 From "Joints in Simple Construction- BCSA"
LOAD FACTOR FOR SWL (for material strength design) = 1.35 As per BS EN 1990:2002
LOAD FACTOR FOR WIND LOAD = 0.9 As per BS EN 1990:2002

CALCULATION:
Calculation of Dynamic Factors As per section 2 of BS EN 1991-3-2006
Dynamic Factor 'Φ2' From table 2.4 of BS EN 1991-3-2006
Assuming Hand operated cranes
Assuming steady hoisting speed (m/min) vh = 6
Hoisting Class of appliance = HC1 From Annex B of BS EN 1991-3-2006
Φ2,min = 1.05 From table 2.5 of BS EN 1991-3-2006
β2 = 0.17 From table 2.5 of BS EN 1991-3-2006
Hence Dynamic Factor 'Φ2'= (Φ2,min+β2vh) = 1.067 From table 2.4 of BS EN 1991-3-2006

Dynamic Factor 'Φ3'

Φ3 = 1- (Δm/m)(1+β3) From table 2.4 of BS EN 1991-3-2006
Where Δm = released/ dropped part of the hoisting mass
m = total hoisting mass
Since, in this case monorail is purely manually opearted and no grabs or magnets are involved for instant release of payload,
it is assumed to be Δm = 0, refer table 2.1 of BS EN 1991-3-2006
Therefore Φ3 = 1 From table 2.4 of BS EN 1991-3-2006

Dynamic Factor 'Φ4' = 1 from table 2.4 of BS EN 1991-3-2006

Dynamic Factor 'Φ5'

Assuming the drive forces are changing smoothly
Therefore Φ5 = 1.5 from table 2.6 0f BS EN 1991-3-2006

Hence monorail design loads including dynamic magnification factors but without limit state load factors are

Total Safe Working Load applied as Hoist Load - SWL in STAAD (kg) = 8402.625 (with dynamic factors)
 EPIC for Gas Sweetening Facilities Project Rev.
(GSF) at Mesaieed & Dukhan A
Part-2 AGRP (Dukhan) Date:
Doc. No 2971-1-12-0306 5/2/2014
Title: Design Calculation for PR02-M-02 Monorail Beam
Total Proof Load applied as Hoist Load - PL in STAAD (kg) = 10503.28125 (with dynamic factors)

Local Bending stresses in the bottom flange due to wheel loads from cl. 5.8 of BS EN 1993-6:2007

Ratio 'µ' = 2n/ (b-tw) µ = 0.22 Equation 5.7 of BS EN 1993-6:2007

Total available space on flange beyond root radius (m+n) = 71.85
Distance from the centreline of the wheel load to the free edge of the flange n = 18

From Fig. 6.1 of BS EN 1993-6-2007

From Fig. 5.6 of BS EN 1993-6-2007

Location 0- the web- to- flange transition
Location 1- centerline of the wheel load
Location 2- outside edge of the flange
Factored Vertical Wheel Load (kg) Fz,Ed = 11343.54
Longitudinal Bending Stresses σ0x,Ed
Cx0= 0.050-0.580µ+0.148e3.015µ Cx0 = 0.21 From table 5.2 of BS EN 1993-6-2007
Cx1=2.230-1.490µ+1.390e-18.33µ Cx1 = 1.93 From table 5.2 of BS EN 1993-6-2007
Cx2=0.730-1.580µ+2.190e-6.00µ Cx2 = 1.16 From table 5.2 of BS EN 1993-6-2007
Longitudinal Bending Stress at point 0 (N/mm2) for each wheels across web σ0x,Ed = 44.93 from cl. 5.8 of BS EN 1993-6:2007
Longitudinal Bending Stress at point 1 (N/mm2) for each wheels across web σ1x,Ed = 413.44 from cl. 5.8 of BS EN 1993-6:2007
Longitudinal Bending Stress at point 2 (N/mm2) for each wheels across web σ2x,Ed = 249.53 from cl. 5.8 of BS EN 1993-6:2007
Transverse Bending Stresses σ0y,Ed
Cy0= -2.110+1.977µ+0.0076e6.530µ Cy0 = -1.64 From table 5.2 of BS EN 1993-6-2007
Cy1= 10.108-7.408µ-10.108e-1.364µ Cy1 = 0.99 From table 5.2 of BS EN 1993-6-2007
Cy2= 0.0 Cy2 = 0 From table 5.2 of BS EN 1993-6-2007
Transverse Bending Stress at point 0 (N/mm2) for each wheels across web σ0y,Ed = -352.63 from cl. 5.8 of BS EN 1993-6:2007
Transverse Bending Stress at point 1 (N/mm2) for each wheels across web σ1y,Ed = 212.05 from cl. 5.8 of BS EN 1993-6:2007
Transverse Bending Stress at point 2 (N/mm2) for each wheels across web σ2y,Ed = 0.00 from cl. 5.8 of BS EN 1993-6:2007
1.5b (mm) = 257.25
Xw = 236.00

If Xw < 1.5b, single wheel stresses are superposed as point 8 of Cl. 5.8 of BS EN 1993-6-2007

Points
Direction 0 1 2
Final Longitudinal Bending Stress (N/mm2) 89.86 826.88 499.05
Final Transverse Bending Stress (N/mm2) -705.25 424.11 0.00

Loading condition as trolley placed at uniformly supported span.

11343.54 kg

Length of the simply supported beam span (mm) L = 3500

 EPIC for Gas Sweetening Facilities Project Rev.
(GSF) at Mesaieed & Dukhan A
Part-2 AGRP (Dukhan) Date:
Doc. No 2971-1-12-0306 5/2/2014
Title: Design Calculation for PR02-M-02 Monorail Beam

Resultant Biaxial Stress

σx = (σn,x, Ed + σf, Ed) + (P/ Area of Bottom Flange)
σn,x, Ed = local flange bending stresses at various points
σf, Ed = stress at the midline of the flange due to the overall internal moment in the beam

Section classification i.e., Class 1, 2, 3 & 4 (from STAAD) Class 1 from Cl. 5.5 of BS EN 1993-1-1-2005
Section Modulus (mm3) Z = 896000.00
Maximum Moment for L/C 7 from STAAD (KNm) M = 98
stress at the midline of the flange due to the overall internal moment in the beam (N/mm2) σf, Ed = 109.38

Area of Bottom flange (mm2) Abf = 1972.25

Reversible Behaviour from cl. 7.5 of BS EN 1993-6:2007

σn,Ed,ser = direct stresses
τEd,ser = co- existing shear stresses τEd,ser = 0

σn,Ed,ser <= fy/λM,ser as per eq. 7.2a of BS EN 1993-6:2007

Partial Factor λM,ser = 1 from cl. 7.5 of BS EN 1993-6:2007

Points
Stress 0 1 2
Combined Longitudinal Stress(σx,Ed,ser) N/mm2 202.11 939.13 611.30
Transverse Bending Stress (σ0y,Ed) N/mm2 -705.25 424.11 0.00
Resultant Biaxial stresses N/mm2 825.08 814.58 611.30
Design Check Check Check Check

Resistance of Bottom Flanges to Wheel Loads from cl. 6.7 of BS EN 1993-6:2007

Figure 6.1: Bending of bottom flange remote from ends and at non-reinforced jointsof BS EN 1993-6:2007

Effective length (mm) leff = 321.19 from table 6.2 of BS EN 1993-6:2007

Assuming "wheel remote from the end a member"

The design resistance (kN) Ff,rd = 52.18 from eq. 6.2 of BS EN 1993-6:2007

Design Check CHECK

Partial factor λm0 = 1 from cl. 6.1 of BS EN 1993-6:2007

Check for the Web from cl. 5.7 of BS EN 1993-6:2007

 EPIC for Gas Sweetening Facilities Project Rev.
(GSF) at Mesaieed & Dukhan A
Part-2 AGRP (Dukhan) Date:
Doc. No 2971-1-12-0306 5/2/2014
Title: Design Calculation for PR02-M-02 Monorail Beam

LOADED AREA

321.19

Stress in the Web (N/mm2) σweb = 47.73

Design Check OK

Design of Stopper

Stopper section provided = L100X100X10 Refer drawing.

Thickness of the section (mm) Dt = 30
Depth of the section 'a' (mm) Da = 100
Depth of the section 'b' (mm) Db = 100
Depth of the provided stopper (mm) Ds = 300 Refer modified stopper detail

Accidental Force from cl. 2.11 of BS EN 1991-3:2006

Dynamic Factor 'Φ7' Φ7 = 1.25 from table 2.10 0f BS EN 1991-3-2006

Factored Buffer Force (kN) (10% of the total vertical load) Bf = 132.89 from Cl. 2.11.2 of BS EN 1991-3-2006
Design Moment (kNm) Bm = 3.58

Section Class from Cl. 5.5 of BS EN 1993-1-1-2005

Depth/ Thickness ratio D/Dt = 3.33

ε = SQRT(235/Fy) ε = 0.94

Section Classification Class 3

Section Modulus (mm3) Z = 45000.00

Stress in the stopper (N/mm2) σ = 79.51
Design Check OK

Connection Design

Verification for Bolts in Tension

Tension Capacity of Bolt Group (kN) Tgroup = 588.00 From "Joints in Simple Construction- BCSA"

Design Check OK

Since for the moment, the provided section is not adequate for resultant biaxial stresses, section to be modified.

Provided new plate at the bottom flange

Thickness of the new plate to be welded (mm) tnp = 20
Assumed welding space (mm) w = 10
Width of the new plate to be welded (mm) wnp = 151.50
 EPIC for Gas Sweetening Facilities Project Rev.
(GSF) at Mesaieed & Dukhan A
Part-2 AGRP (Dukhan) Date:
Doc. No 2971-1-12-0306 5/2/2014
Title: Design Calculation for PR02-M-02 Monorail Beam

WELDED 20mm PLATE

Total area moment about NA (mm3) NA = 1294556.75

Total Area of the section (mm2) Atotal = 9520.00
Neutral Axis of the modified section from the bottom most fiber (mm) NA = 135.98

Plasctic section modulus of the modfiied section Mpmodifed = 1291114.58

stress at the midline of the flange due to the overall

internal moment in the modified beam (N/mm2) σf, Ed = 75.90
For modified bottom flange
Longitudinal Bending Stresses σ0x,Ed
Cx0= 0.050-0.580µ+0.148e3.015µ Cx0 = 0.21 From table 5.2 of BS EN 1993-6-2007
Cx1=2.230-1.490µ+1.390e-18.33µ Cx1 = 1.93 From table 5.2 of BS EN 1993-6-2007
Cx2=0.730-1.580µ+2.190e-6.00µ Cx2 = 1.16 From table 5.2 of BS EN 1993-6-2007
Longitudinal Bending Stress at point 0 (N/mm2) for each wheels across web σ0x,Ed = 5.99 from cl. 5.8 of BS EN 1993-6:2007
Longitudinal Bending Stress at point 1 (N/mm2) for each wheels across web σ1x,Ed = 55.10 from cl. 5.8 of BS EN 1993-6:2007
Longitudinal Bending Stress at point 2 (N/mm2) for each wheels across web σ2x,Ed = 33.26 from cl. 5.8 of BS EN 1993-6:2007
Transverse Bending Stresses σ0y,Ed
Cy0= -2.110+1.977µ+0.0076e6.530µ Cy0 = -1.64 From table 5.2 of BS EN 1993-6-2007
Cy1= 10.108-7.408µ-10.108e-1.364µ Cy1 = 0.99 From table 5.2 of BS EN 1993-6-2007
Cy2= 0.0 Cy2 = 0 From table 5.2 of BS EN 1993-6-2007
Transverse Bending Stress at point 0 (N/mm2) for each wheels across web σ0y,Ed = -47.00 from cl. 5.8 of BS EN 1993-6:2007
Transverse Bending Stress at point 1 (N/mm2) for each wheels across web σ1y,Ed = 28.26 from cl. 5.8 of BS EN 1993-6:2007
Transverse Bending Stress at point 2 (N/mm2) for each wheels across web σ2y,Ed = 0.00 from cl. 5.8 of BS EN 1993-6:2007
1.5b (mm) = 257.25
Xw = 236.00

If Xw < 1.5b, single wheel stresses are superposed as point 8 of Cl. 5.8 of BS EN 1993-6-2007
Modifed area of bottom flange (mm2) Ambf = 5002.25
Points
Direction 0 1 2
Final Longitudinal Bending Stress (N/mm2) 11.98 110.21 66.52
Final Transverse Bending Stress (N/mm2) -94.00 56.53 0.00

Points
Stress 0 1 2
Combined Longitudinal Stress(σx,Ed,ser) N/mm2 89.01 187.25 143.55
Transverse Bending Stress (σ0y,Ed) N/mm2 -94.00 56.53 0.00
Resultant Biaxial stresses N/mm2 158.51 166.35 143.55
Design Check OK OK OK