Report on Design adequacy of 150 Tons Sugar Bin

1. Period of investigation: 14 to 31st of July 2003

2. Nature of Investigation:
The Proposed 150 Tons Sugar Bin (Drg. no: 24600080, Rev.‘0’) and supporting
structure for Bin (Drg. No: 24100995, Rev. ‘A’) was investigated for design adequacy
by the finite element method. The bin was subjected to vertically downward pressure
of sugar in the inclined bottom half of the bin and subjected to horizontal pressure as
given in table 8.5 and Eq. 8.16 of Ref. [1]. Specific gravity of sugar is assumed to be
0.9.

The square cross section constituting the bin is modeled by plate elements, the
stiffened horizontal and vertical members (replacing by equal angle by ISMB 150),
the horizontal beam at the junction and the four vertical columns by the 3D beam
elements. The corners of the top shell vertical portions and bottom hopper inclined
portion corners were provided with angle 100 x 100 x 10tk size, addition to that corner
plate 8mm thickness strips shall be provided for top shell and bottom hopper
throughout the length. The Number of vertical stiffeners were reduced from 5 to 3 and
horizontal stiffeners from 8 to 5. The program was run using MSC/NASTRAN.

The stresses obtained by the different members and deflections are computed. The
bending stresses obtained were less than 100 N/mm2 and the horizontal outward
deformation of the square cross section around 48 mm. The foundation bolts (M32 x
1200 long, 10 Nos. for each column) were investigated for shear and bending stresses.
They were also within permissible limits. The forces and moments of each column are
shown in table 1. Table II gives the details of weight reduction.

3) Conclusion :
The net weight reduction in the order of 4.8 T original weight of 34.0 T given in the
drawing. The unit is now optimally designed. It is suggested to replace ISMB 150 by
ISMC 150 if it is acceptable in construction / manufacturing.
Table 1

T1 T2 T3 R1 R2 R3

x 10 5 x 10 5 x 10 5

34,400 632,000 22,000 280.0 19.0 595.0

T2 axial force T1 & T3 shear force in N

R2 Twisting moment, R1 & R3 Bending moment in N-mm

There are ten foundation bolts M32 in size

1) Direct Normal stress = 632,000 / ( 10 x PI x 322 / 4 .0)

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 = 78.5 N / mm 2
2) Bending Stress = 595 x 10 5 / ( 4 x 700 x PI x 322 / 4.0)
= 26.4 N / mm 2
Shear stress magnitude is very small.

Table II

Member weight Details

Original Opt 1

Total 34.6 T 29.82 T

PL-WT 17.72 T 16.673 T

PL-TOP 8.78 T 9.3 T

PL-BOT 6.13 T 5.976 T

BEAM ALL 16.87 T 13.145 T

BEAM – STIFF 9.46 T 5.547 T

Material Reference: Design of Steel Structure Vol-2 Ramachandra 7th Edition 1991,
Standard Publisher, New Delhi.

a)Sizes and thickness Provided for Square Top Shell

(Drawing No : 24600078, Rev 0)

1) Top Shell thickness = 8 mm

2) Shell horizontal stiffener size = ISMC 150

(5 nos. on each side from bottom;
distance 1350 , 1060, 1060, 1640 &
1590 mm )

3) Shell bottom horizontal stiffener size = 100x 100 x 8 Tk. (All four sides)

4) Shell vertical stiffener size = ISMC 150

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 (3 nos. on each side; distance at
one end 1315, 1160 & 1160 mm)

5) Shell inner corner angle size = 100 x 100 x 10 Tk.

( All four sides)

6) Shell inner corner plate size and length = 6688 x 180 x 8 Tk.

7) Connecting flange thickness for top shell = 12 Tk.

b)Sizes and thickness provided for Bottom Hopper

(Drawing No : 24600081,Rev 0)
1) Bottom hopper shell thickness = 8 mm

2) Bottom hopper shell horizontal stiffener size = ISMC 150

(5nos. on each side from
bottom; distance at 365, 1000,
800, 500, 700mm)

3) Bottom hopper vertical stiffener size = ISMC 150

(3 nos. on each side; one
stiffner at the centre of bin
and
other two stiffener 1235 mm
on both sides from the centre
of the bin )

4) Bottom hopper corner angle size = 100 x 100 x 10 Tk.

(All four sides)

5) Bottom hopper corner plate size and length = 4600 x 220 x 8tk

6) Connecting flange thickness for bottom hopper = 12 Tk.

7) Bottom opening flange thickness = 16 Tk

8) Frame for bottom hopper thickness & Frame

Stiffner sizes = 25 Tk , 25 Tk
(corners), 20Tk (otherplaces)

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c)150 T Sugar Bin Structural staging member sizes and
thickness

1) Column size = 2 Nos. of ISMB450spacing at

300 mm distance constructed
as column with batten plates; 6
nos. of column; spacing
distance is 5420 and 5420.

2) Cross beam size = ISMB 600 Beam with 12 Tk.

Top and Bottom Continuous
plate.

3) Continuous beam size = ISMB 600 Beam with 12 Tk.

Top and Bottom Continuous
plate

4) Column base plate size and column

top plate size = 1000 x 1000 x 32 Tk,
1000 x 1000 x 28 Tk.

5) Foundation bolt size = M32 x 1200 Lg, 10 Nos. on

each Bin supporting column.

Dr.V. Ramamurti ,
Formerly professor,
I.I.T, Madras.

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