Project:

KAWAI THERMAL POWER PROJECT

1320 MW (2x660 MW Phase I) KAWAI, Rajasthan
Owner:

ADANI POWER RAJASTHAN LIMITED

KAWAI,RAJASTHAN

CONSULTANT : CONTRACTOR:

DEVELOPMENT CONSULTANTS PRIVATE LIMITED

ENERGO ENGINEERING PROJECTS LTD

CONSULTANTS FOR CIVIL WORKS: HBS INFRA ENGINEERS INDIA PVT LIMITED

DESIGN REPORT FOR ANALYSIS AND DESIGN COMPRESSOR ROOM

APRL DOC.NO. :

Revision

PROJECT DOC. TITLE : DESIGN REPORT FOR ANALYSIS AND DESIGN OF COMPRESSOR ROOM CONTRACTOR DOC.NO. : Revision APPROVAL STATUS :

6.15.11

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CHECKED

APPROVED

HBS INFRA ENGINEERS INDIA PVT LTD PROJECT TITLE 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN ANALYSIS AND DESIGN OF COMPRESSOR ROOM Date Revision Reference 1 2 Configuration Materials Concrete Gr Reinf. Steel Cover to reinf M30 Fe 500 RCC FRAMED STRUCTURE Jul-11 ZERO

Footings Columns floor slabs beams 3 Loading Dead load

75 mm 40mm 25 mm 35 mm Unit wt. Of concrete at 2.5 t/cum Unit wt. Of brick work at 1.9 t/cum

Live load

L SL

300 Kg/sqm on roof 150 kg/sqm for coal dust Load EARTH QUAKE Under ZONE-2

Wind loads

WL

As per IS:875, basic wind speed = 47 m/s, Terrain category -2 NOT CRITICAL

LOAD COBINATIONS

Primary Loads Cases 1 Dead Load 2 Live Load 3 WindLoad 4 Seismic Load Load Combinations 1. D.L.+l.L. 2. D.L.+ E.L. 3. D.L.+W.L. 4. D.L.+l.L.+W.L. 5. D.L.+l.L.+E.L. **3-D modeling using STAAD for Design of RC framed structure **RC Floor/ Roof slabs using IS:456 coefficients for various support conditions

ANALYSIS

Design RC floor/roof slabs , as per IS:456-2000 using Limit state method of design pedestals and footings

Check for Base pressure under foundations 7 Reference

SBC = 30 t/sq.m at 2.5m from NGL as per soil report

E-112-M-G-417 Sheet 1 0f 1 G.A. of COMPRESSOR ROOM

Designed by : Ahmed , Check by : S.Krishna , Approved by : CH.N.V.D.V.Prasad

HBS INFRA ENGINEERS INDIA PVT LTD PROJECT TITLE I DEAD LOAD 1 Self Wt 2 Wall load On Plinth Beams Th 0.23 depth/Ht 2.5 Density 1.9 Say Total Wt Mt/m 1.09 1.10 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN ANALYSIS AND DESIGN OF COMPRESSOR ROOM Date Rev. Jul-11 ZERO Remarks

T/m

3 Parapet load on Roof beams Roof proj of 0.3 roof finishes ` 0.23 0.15 0.025 0.9 0.3 0.3 1.9 2.5 2.5 Total Say 0.39 0.11 0.02 0.52 0.55

T/m

4 Wall load On Lintel

0.23

2.5

1.9 Say

1.09 1.10

T/m

5 On roof beams Self Weight Of slab Water Proofing + Floor Finish

0.15 0.05

1 1

2.5 2.5 Total Say

0.375 0.125 0.5 0.500

T/m2

II

LIVE LOAD On Roof ( includiing coal dust load of 150kg/sqm) Total Say Monorail Load self wt. of Mono rail 1x1.25 0.5t Total Say

300 150 450 500 1.25 0.5 1.75 2

Kg/m2

2.0T/m

III

Wind Load Design Wind pressure Vz = design wind velocity = Vb*k1*k2*k3 k1 = 1.08 ( risk coeff) k2 = 1 for terrain coeff k3 = 1 Vb = 47 m/s Vz = Pz = Say 50.76 1545.94656 157.630895 m/s N/m2 Kg/m2

Pz =

0.6*vz2

Designed by : Ahmed , Check by : S.Krishna , Approved by : CH.N.V.D.V.Prasad

HBS INFRA ENGINEERS INDIA PVT LTD PROJECT TITLE 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN ANALYSIS AND DESIGN OF COMPRESSOR ROOM Date Rev. Jul-11 ZERO Remarks

IV

seismic forces are critical for design Seismic Loads Seismic Zone Seismic coeff Z Importance factor R Length in x Direction 30.25m IN X DIRECTION Ta Zone II 0.1 1.75 3

0.09*7.4/SQRT(9.25) 0.21897945 2.5

In x direction

Sa/g

Length in z direction 12.9m IN Z DIRECTION Ta

0.09*7.4/SQRT(6.4) 0.26325962 2.5 ( 0.1 <T<0.55)

In Z direction

Sa/g

Designed by : Ahmed , Check by : S.Krishna , Approved by : CH.N.V.D.V.Prasad

HBS INFRA ENGINEERS INDIA PVT LTD 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN Project Sub ANALYSIS AND DESIGN OF COMPRESSOR ROOM Calculation for Monorail

date rev

Jul-11 ZERO

Monorail Load Calculation for 4.56m Span Postioned at Centre .2.0T A 4.625m 9.250m B Capacity of Monorail Total Load Reactions Moment @ Mispan Due to Monorail= wl/4=(2.0x9.25)/4=4.625 t.m Moment added to beam @ Mispan=0.6x4.625=2.775t.m Moment added to beam @ supports=0.4x4.625=1.85t.m Mid-span Moment Staad RB2 RB3 28.00 40 Monorail 2.775 2.775 Total Moment 30.78 42.78 Total Moment 1.85 1.85 22.85 17.35 =1tx 1.25=1.25t =2.0t

Self Weight of Monorail =0.5t

Support Moment RB2 RB3 2 21 15.5

Monorail Load Calculation for 4.56m Span Postioned at Centre .2.0T A 3.250m 6.450m B Capacity of Monorail Total Load Reactions Moment @ Mispan Due to Monorail= wl/4=(2.0x6.450)/4=3.225 t.m Moment added to beam @ Mispan=0.6x3.225=1.935t.m Moment added to beam @ supports=0.4x3.225=1.28t.m Mid-span Moment Staad RB2 28.00 Monorail 1.935 Total Moment 29.94 =1tx 1.25=1.25t =2.0t

Self Weight of Monorail =0.5t

Support Moment RB2 21 1.28

Total Moment 22.28

Designed by : Ahmed , Check by : S.Krishna , Approved by : CH.N.V.D.V.Prasad

HBS INFRA ENGINEERS INDIA PVT LTD 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN Project Sub beams at plinth level *refers to the staad beam number Beam Mkd. PB1 span supp - ve BM +ve BM SF (t) Beam Mkd. PB2 span supp 17 size (mm) 20 35 24 108 size (mm) - ve BM +ve BM SF (t) 9 18 16 300 Mu/bd2 Mu/bd2 Tv 300 Mu/bd2 Mu/bd2 Tv x 2.126 pt 3.720 pt 1.43 x 0.957 pt 1.913 pt 0.95 beta Vus/d = beta Vus/d = 600 600 ANALYSIS AND DESIGN OF COMPRESSOR ROOM refer staad analysis and design Grade of steel deff. = 0.537 1.034 3.37 2.293 deff. = 0.229 0.478 7.28 1.395 Ast Ast Tc Fe 500 560 min Ast 902 1737 0.664

date rev

Jul-11 ZERO

grade of concrete 286

M25

3-Y16+2-Y20(X)(BOT) 3-Y20+3-Y20(x)(TOP) Y8-2L-150 286 3-Y16(BOT) 3-Y16+2-Y16(TOP) Y8-2L-150

** +ve & -ve BM supp and span respectively

provided min shear 560 min Ast Ast Ast Tc 384 803 0.488

** +ve & -ve BM supp and span respectively

provided min shear

PLINTH BEAM LAYOUT IN STAAD PRO

Designed by : Ahmed , Check by : S.Krishna , Approved by : CH.N.V.D.V.Prasad

HBS INFRA ENGINEERS INDIA PVT LTD 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN Project Sub beams at plinth level *refers to the staad beam number Beam Mkd. LB1 span supp - ve BM +ve BM SF (t) Beam Mkd. LB2 span supp 17 size (mm) 11 22 14 108 size (mm) - ve BM +ve BM SF (t) 6 10 10 300 Mu/bd2 Mu/bd2 Tv 300 Mu/bd2 Mu/bd2 Tv x 1.169 pt 2.338 pt 0.83 x 0.638 pt 1.063 pt 0.60 beta Vus/d = beta Vus/d = 600 600 ANALYSIS AND DESIGN OF COMPRESSOR ROOM refer staad analysis and design Grade of steel deff. = 0.282 0.597 5.83 0.896 deff. = 0.150 0.255 13.64 0.669 Ast Ast Tc Fe 500 560 min Ast 474 1003 0.535

date rev

Jul-11 ZERO

grade of concrete 286 3-Y16(BOT)

M25

3-Y16+3-Y16(x)(TOP) Y8-2L-200 286 3-Y16(BOT) 3-Y16(TOP) Y8-2L-200

** +ve & -ve BM supp and span respectively

provided min shear 560 min Ast Ast Ast Tc 253 429 0.372

** +ve & -ve BM supp and span respectively

provided min shear

Designed by : Ahmed , Check by : S.Krishna , Approved by : CH.N.V.D.V.Prasad

HBS INFRA ENGINEERS INDIA PVT LTD Project Sub beams at Roof level *refers to the staad beam number Beam Mkd. RB1 span supp - ve BM +ve BM SF (t) ** +ve & -ve BM supp and span respectively Mid-span Moment Staad RB2 Beam Mkd. 28.00 RB2 span supp Monorail 1.935 Total Moment 29.935 7 and 25 size (mm) - ve BM +ve BM SF (t) ** +ve & -ve BM supp and span respectively Mid-span Moment Staad RB3 Beam Mkd. 40.00 RB3 span supp - ve BM +ve BM SF (t) ** +ve & -ve BM supp and span respectively Monorail 2.775 Total Moment 42.775 27 size (mm) 60 0 22 tm 300 Mu/bd2 Mu/bd2 Tv 35 20 20 tm 300 Mu/bd2 Mu/bd2 Tv 1 size (mm) 19 24 17 300 Mu/bd2 Mu/bd2 Tv x 2.020 pt 2.551 pt 1.01 beta Vus/d = Support Moment Staad 21 x 1.778 pt 1.016 pt 0.82 beta Vus/d = Support Moment Staad 15.5 x 3.048 pt 0.000 pt 0.91 beta Vus/d = Monorail Total Moment 1.85 850 17.35 tm deff. = 0.811 0.000 4.30 0.903 810 min Ast Ast Ast Tc 1970 0 0.604 Monorail Total Moment 1.28 850 22.28 tm deff. = 0.441 0.244 7.89 1.055 810 min Ast Ast Ast Tc 1073 592 0.471 600 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN ANALYSIS AND DESIGN OF COMPRESSOR ROOM refer staad analysis and design Grade of steel deff. = 0.507 0.659 5.28 1.367 Ast Ast Tc Fe 500

date rev

Jul-11 ZERO

grade of concrete

M30

560 min Ast 852 1107 0.556

286 4-Y16(BOT) 3-Y16+2-Y16(st)(TOP) Y8-2L-150

provided min shear

413 3-Y16+2-Y20(BOT) 4-Y16(ST)(TOP) Y8-2L-150

provided min shear

413 3-Y25+3-Y20(BOT) 4-Y16(TOP) Y8-2L-150

provided min shear

Designed by : Ahmed , Check by : S.Krishna , Approved by : CH.N.V.D.V.Prasad

HBS INFRA ENGINEERS INDIA PVT LTD Project Sub beams at Roof level *refers to the staad beam number 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN ANALYSIS AND DESIGN OF COMPRESSOR ROOM refer staad analysis and design Grade of steel Fe 500

date rev

Jul-11 ZERO

grade of concrete

M30

ROOF BEAM LAYOUT IN STAAD PRO

Designed by : Ahmed , Check by : S.Krishna , Approved by : CH.N.V.D.V.Prasad

HBS INFRA ENGINEERS INDIA PVT LTD Project Sub 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN ANALYSIS AND DESIGN OF COMPRESSOR ROOM

date rev

Jul-11 ZERO

Grade of steel

Fe 500

refer staad analysis and results

grade of concrete

M30

S.NO

Grid Mkd

SIZE

Column mb no in Staad

Req. Area of Steel 3240 4909 5160 4780

Rein. Prov.

PT

Column Mkd

1 2 3 4

A1 A2 B1 B2

450x750 450x750 450x750 450x750

1001,.1002,.1003 2001,.2002,.2003 3001,.3002,.3003 4001,.4002,.4003

16-Y20 16-Y20 16-Y20 16-Y20

1.48% 1.48% 1.48% 1.48%

C1 C1 C1 C1

Designed by : Ahmed , Check by : S. Krishna, Approved by : CH.N.V.D.V Prasad

HBS INFRA ENGINEERS INDIA PVT LTD

HBS INFRA ENGINEERS INDIA PVT LTD

date rev

Jul-11 ZERO

Project Sub

2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN

ANALYSIS AND DESIGN OF COMPRESSOR ROOM

Remarks
Design of roof slab SLAB NUMBER ASSUME SLAB TK. mm EFF.DEPTH IN mm d SELF WT. LIVE LOAD FLOOR FINISHES TOTAL LOAD Kg/M2 TYPE OF PANEL SHORTER SPAN lx Mts LONGER SPAN ly Mts ly/lx TYPE OF SLAB +Mux coeff +Muy coeff -Mux coeff -Muy coeff +Mux KGM +Muy KGM -Mux KGM -Muy KGM +ptx +pty -ptx -pty ALONG+x,$CNG DIA mm 10 ALONG+y,$CNG DIA mm 10 ALONG-x,$CNG DIA mm 10 ALONG-y,$CNG DIA mm 10 CHECK FOR DEFLECTION: SHORT SPAN IN mm SPAN/EFF.DEPTH (FROM CHART 22) ALLOWABLE DEPTH ADOPT DEPTH (Types panels 3.250x9.250) S1 150.00 125.00 375.00 500.00 125.00 1000.00 7.00 3.250 9.25 2.85 ONE WAY 0.043 0.043 0.057 0.000 681.28 681.28 903.09 0.00 0.125 NA NA NA 375 523.6 NA NA 3250.00

10 10 10 10

47.19
69 150.00 ` OK

Proving

Y10-150 ALONG X Y10-150 ALONG Y dir

Y10-150 TOP at Supports

Designed by : Ahmed , Check by : S. Krishna, Approved by : CH.N.V.D.V Prasad

HBS INFRA ENGINEERS INDIA PVT LTD Project Doc Title 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN ANALYSIS AND DESIGN OF COMPRESSOR ROOM Date Rev Footing Size Details in mm Footing Node-no Thickness L B at Edge Thickness at Faceof Pedestal Ast1 Ast2 Footing Reinforcement FOOTIN G MKD PEDESTAL SIZE Jul-11 ZERO

S.No

Grid Mkd

A1,A2,B1,B2

1,2,3,4

1500

1500

400

400

Y10-125

Y10-125

F1

450 x 750

FOOTING LAYOUT

Designed by : Ahmed , Check by : S. Krishna, Approved by : CH.N.V.D.V Prasad

HBS INFRA ENGINEERS INDIA PVT LTD PROJECT TITLE 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN Date Jul-11 ANALYSIS AND DESIGN OF COMPRESSOR ROOM Rev ZERO Support Reactions from Staad Unit for Force : Mton, Unit for Moment :Mton/m Load Combination FY MX MZ Remarks EQ +X -0.29 0 2.36 EQ -X 0.29 0 -2.36 EQ +Z -0.61 -1.73 0 EQ -Z 0.61 1.73 0 DEAD LOAD 62.71 2.47 -4.74 F1 LIVE LOAD 7.46 0.03 0.1 WIND +X -0.28 0 2.45 WIND -X 0.28 0 -2.46 WIND +Z -0.87 -2.61 0 WIND -Z 0.87 2.62 0 EQ +X 0.29 0 2.36 EQ -X -0.29 0 -2.36 EQ +Z -0.61 -1.73 0 EQ -Z 0.61 1.73 0 DEAD LOAD 60.94 2.53 4.73 F1 IS DESIGNED FOR THIS NODE LIVE LOAD 7.46 0.03 -0.1 WIND +X 0.28 0 2.46 WIND -X -0.28 0 -2.45 WIND +Z -0.87 -2.61 0 WIND -Z 0.87 2.62 0 EQ +X -0.29 0 2.36 EQ -X 0.29 0 -2.36 EQ +Z 0.61 -1.73 0 EQ -Z -0.61 1.73 0 DEAD LOAD 62.71 -2.47 -4.74 F1 LIVE LOAD 7.46 -0.03 0.1 WIND +X -0.28 0 2.45 WIND -X 0.28 0 -2.46 WIND +Z 0.87 -2.62 0 WIND -Z -0.87 2.61 0 EQ +X 0.29 0 2.36 EQ -X -0.29 0 -2.36 EQ +Z 0.61 -1.73 0 EQ -Z -0.61 1.73 0 DEAD LOAD 60.94 -2.53 4.73 F1 LIVE LOAD 7.46 -0.03 -0.1 WIND +X 0.28 0 2.46 WIND -X -0.28 0 -2.45 WIND +Z 0.87 -2.62 0 WIND -Z -0.87 2.61 0

NODE

Load Case No 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

Designed by : Ahmed , Check by : S. Krishna, Approved by : CH.N.V.D.V Prasad

HBS INFRA ENGINEERS INDIA PVT LTD PROJECT TITLE 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN ANALYSIS AND DESIGN OF COMPRESSOR ROOM DETAILS Date Revision F-1 Jul-11 ZERO

Loading from Super Structure Load description Dead load Live load WL/EQ Vertical loads 63.00 t 7.50 t 0.87 t (+ or -) Bm at bottom Staad Node no : 2 2.61 t

(Wrt x/y)

Configuration of Pedestal & Footing Width of Pedestal Along X axis Width of Pedestal along Y axis Height of Pedestal above GL Depth of Foundation Thickness of footing at edge Thickness of foot. at face of Ped. Width of footing along X axis Width of footing along Y axis Self weight of footing Soil weight above footing Load Combination For Design Load combination (1) DL+LL (2) DL+WL(Y)/EQ(Y)+LL (3) DL+WL(-Y)/EQ(-Y) (3) DL+WL(Y)/EQ(Y) For Footing Design P MX1 (in t) wrt. X axis 79.98 0.00 80.85 2.61 71.61 2.61 73.35 2.61 0.75 0.45 0.00 2.50 0.40 0.40 1.50 1.50 m m m m m m m m

Design Specifications Grade of Concrete M Grade of Steel Fe Cover to Reinf.(ped) in mm Cover to Reinf.(foot) in mm 30 500 40 75

2.25 t 7.23 t

Load factor for design 1.5 1.2 1.5 1.5

Calulation of Gross and Net Base pressures Load combination (1) DL+LL (2) DL+WL(x)/EQ(x)+LL (3) DL+WL(-X)/EQ(-X) (4) DL+WL(x)/EQ(x) Pmax (t/sqm) 35.55 40.57 36.47 37.24 Net SBC (t/sqm) 31.05 36.07 31.97 32.74 Remarks < Allow SBC < Allow SBC < Allow SBC < Allow SBC Pmin 35.55 31.29 27.19 27.96 Remarks no tension no tension no tension no tension

Increase allowable stress by 25% for WL/EQ condition 30x1.25=37.5

Critical Design Forces and Moments at bottom of footing Loads 71.37 t 2.61 tm Load factors 1.5 P = Load from Super structure

P Mx

Designed Vertical load Moment with respect to X-axis Flexural Design of Footing Ox Oy

= =

107.80 t 3.92 tm

= =

0.375 m 0.525 m

Designed by : Ahmed , Check by : S. Krishna, Approved by : CH.N.V.D.V Prasad

HBS INFRA ENGINEERS INDIA PVT LTD PROJECT TITLE 2 x 600 MW COAL BASED TPP KAWAI RAJASTHAN ANALYSIS AND DESIGN OF COMPRESSOR ROOM DETAILS Date Revision F-1 Jul-11 ZERO

Calculation of net base pressures p1 p2 p3 p4 p1p2 p2p4 p3p4 p1p3 = = = = = = = = 54.87 54.87 40.95 40.95 54.87 50.00 40.95 50.00 t/sqm t/sqm t/sqm t/sqm t/sqm t/sqm t/sqm t/sqm * p1/p2/p3/p4 +(x) t/sqm 54.87 t/sqm 54.87 t/sqm 40.95 t/sqm 40.95 t/sqm x= 0 * If p4 comes to -ve Value then a dummy pressure (x t/sqm) added from bottom and top to counteract the negative effect

Max. BM with respect to X-Axis (at face of pedestal) BMx = 11.01 bx = 1.50 M/bd2 = 0.63 pt = 0.15 Ast = 763.61 Ast per metre width = 509.07 Provide Y10-125 = 628.3 pt = 0.18 Shear Design :

tm m

sqmm sqmm sqmm/M

minimum Ast =

480

sqmm

tpeff. (A) Check for Two Way shear (ie Punching shear) Desiged P a1 a2 t1 t2 Therefore Tv Tc (B) Check for One way Shear Calculation for Net base pressures at various points p1'p2' p1'p3' p2'p4' p3'p4' a1 a2 t1 t2 Tv with respect to X-Axis pt at this section Tc from SP:16-1980 = = = = = = = = = 54.87 53.15 53.15 40.95 t/sqm t/sqm t/sqm t/sqm = = = = = = = 66.54 1.090 0.790 0.400 0.400 t m m m m < Allowable Stress

0.34

0.52 N/sqmm 1.369306 N/sqmm

Hence OK

1.500 m 1.500 m 0.400 m 0.400 m 0.29 N/sqmm t1eff. t2eff < Tc = = 0.340 m 0.340 m Hence ok

= 0.18 = 0.32 N/sqmm > Tv Designed by : Ahmed , Check by : S. Krishna, Approved by : CH.N.V.D.V Prasad