Computing Structural Solutions for Penthouse & Tunnel

Prepared By Submitted To

Jay Senjalia

Prof. M K Hamirwasia PS II Station: DCPL, Mumbai Mentor: Mr. Sujith Kumaran

BITS Pilani
Pilani Campus

Project Information
Project Title: UPL Jhagadia COGEN Plant Owner: United Phosphorus Ltd Location: Jhagadia, Gujarat Owners Consultant: DCPL, Mumbai Status: Ongoing Project Work Done: Analysis and Design of Penthouse and Tunnel
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1. Analysis and Design of Penthouse

Operational room provided on the way of conveyer belt equipped with Monorail. Design of following structural elements 1) 2) 3) 4) 5) 6) R.C.C. Footings Columns Plinth Beams Lintel Beams Slab Beams R.C.C. Slab

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Sectional Elevation

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Plan at Plinth Level

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Preparing Staad Model

1) Geometry: Preparing 3D model by allocating columns and aligning beams as per architectural and structural requirement and Member Release.

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2) Loading and Support conditions:

LOAD CASES
LOAD 1 PESUDOSTATIC X LOAD 1 PESUDOSTATIC X DEAD LOAD (DL) LIVE LOAD (DL) MONORAIL LOAD (ML) WIND LOAD ALONG +WLX WIND LOAD ALONG +WLZ WIND LOAD ALONG -WLX WIND LOAD ALONG -WLZ SEISMIC LOAD ALONG (SLX) SEISMIC LOAD ALONG (SLZ)

While applying EQ load, DL and LL values to be added in EQ definition in Staad Editor.

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BITS Pilani, Pilani Campus

3) Load combinations
LOAD COMBINATIONS

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4) Post processing and Designing

Design Code: IS 456 Defined parameters:
FC 25000 ALL FYMAIN 500000 ALL FYSEC 415000 ALL ELZ 1.2 MEMB 14 TO 19 32 33 35 36 45 46 48 50 ELY 1.2 MEMB 15 16 18 19 32 33 35 36 47 TO 50 ELY 1.92 MEMB 14 17 ELY 3.22 MEMB 37 39 ELY 6.76 MEMB 31 34 ELY 1.46 MEMB 45 46 ELZ 5.42 MEMB 37 39 ELZ 1.83 MEMB 47 49 ELZ 9.67 MEMB 31 34 CLEAR 0.04 MEMB 14 TO 19 31 TO 37 39 45 TO 50 CLEAR 0.04 MEMB 1 TO 13 24 TO 30 41 TO 44 RFACE 4 MEMB 14 TO 19 31 TO 37 39 45 TO 50

Defined Commands:
DESIGN BEAM 1 TO 13 24 TO 30 41 TO 44 DESIGN COLUMN 14 TO 19 31 TO 37 39 45 TO 50

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 Design of Footing
Type of Footings: Isolated Design : Using Excel spreadsheet Depth of footing: Considering one way and two way shear Reinforcement: Considering 1m Strip (Design as cantilever beam)

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 Design of Columns
Type of Columns: Design : Rectangular Staad Pro. Result (Uni Axial and Bi-axial)(No Curtailment of reinforcement) % Reinf(Main Bars): 0.8-6 (Generally upto 4% only) Transverse Reinf: Spacing-Min(Least Dim, 16 x #, 300) Dia- Max(#/4, 6mm) Special Confining Reinf: Asper IS:13920 Confining Zone: Max( Large lateral dim, L/6, 450mm) Spacing: As per CL:7.4_IS:13920

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BITS Pilani, Pilani Campus

 Design of Beams
Type of Beams: Design : % Reinf(Main Bars): Stirrups: Rectangular Staad Pro. Result 0.85/fy Spacing-Min(0.75Xd, 300)

Special Confining Reinf: Asper IS:13920 Confining Zone: 2d Spacing: <=d/4

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INTRODUCTION
The Pipe Rack is a structure (RCC or Steel) used for supporting pipes of different sizes running across the plant These pipe racks are modeled in STAAD.Pro, according to the mechanical drawings of the pipes that are to be carried by them Also carries the cable trays

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BITS Pilani, Pilani Campus

Pipe Rack(isometric view)

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Pipe Rack (Elevation)

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How We Work
Design of Superstructure and pedestals is carried out using design commands in STAAD on basis of general arrangement provided by client, which includes complete layout of site along with layout of pipes. Footings are designed using excel spreadsheets Angle of bracings with horizontal maintained between 30-60 deg. ISMB members used under concentrated loads of pipes Supports fixed but release Mx and Mz

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Basic Load Cases

Pipes Empty Load (PE): This includes the dead load of the Super structure, Pipes empty load and Cable trays load. Pipes Full Load (PF): includes the dead load of the Super structure, Pipes running full load, Friction load and Cable trays Load Wind Load (WL) Seismic Load (SL)
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Load Combinations
Pipes Full Load Pipes Empty Load Pipes Full Load + Wind Load Pipes Full Load - Wind Load Pipes Empty Load + Wind Load Pipes Empty Load - Wind Load Pipes Full Load + Seismic Load Pipes Full Load - Seismic Load Pipes Empty Load + Seismic Load Pipes Empty Load - Seismic Load

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BITS Pilani, Pilani Campus

Seismic Load
Seismic Loads are calculated based on IS 1893 2002.

Seismic Zone = III

Seismic zone factor Z = 0.16 Response reduction factor R =4 (for Steel Frames)

Importance factor I = 1.5

Rock and soil type factor SS = 2 (Medium Soil) Type of structure ST = 2 (Steel Frame Building)

Damping ratio DM = 0.05 (5% for Steel Frame Building)

Seismic loads on pipes racks are generated through STAAD which includes Full dead load (There is no live load in the structure).
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Seismic Load
Empirical method:

Ah = (z/2)x(I/R)x(Sa/g)
z= zone factor I= importance factor R= response reduction factor Sa/g= acceleration coefficient Response spectrum method Lumping is done along X and Z directions

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Wind Load
Calculation of Static Wind Pressure

Basic wind speed,

Vb = 44 m/s

Probability factor, (Risk coefficient for 100 yrs Design life and 50 yrs return period) k1 = 1.07 (from table -1 of IS: 875 Part - 3)

Terrain, Height and Structure size factor, k2 = 0.93 ( upto 10m height) = 0.97 ( upto 15m height) =1 ( upto 20m height) (Terrain category 2/Class C)

Topography factor. k3 = 1

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Wind Load
Wind Load acting on pipes
Force coefficient for Circular Pipe, Cf = 1.2 (from Table -23 of IS: 875 Part - 3)

Assuming maximum diameter of pipes = 250 mm Wind load on pipe = 1.2* Diameter of pipe * Pz = 1.2* 0.250*0.887 = 0.266KN/m

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Wind Load

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Pipes Empty and Full Load

Depends on the number and diameter of the pipes carried by the rack. Also depends on the effective span of the pipe for the beam and width of the pipe rack

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Pipes Empty and Full Load

The total load is calculated in kg/m and divided by the width of the pipe rack to get load/sq m This intensity multiplied by the span, gives the UDL to be applied on each transverse beam Same exercise is carried out for both pipe full and pipe empty load Typical job to be done again and again Visual Basic Applications and Excel can be used

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S.No. PIPE DESCRIPTION

Pipe Weight of water filled pipe for 1 m length (kg)s Full Load(kg/m) 28.804 134.573 43.377 7.625 7.625 5.541 5.541 5.541 5.541 43.362 43.362 11.326

Weight of empty pipe for 1 m length (kg)

Total Weight Load of pipe (kg) in KN for 1m length

2 3
4 5 6 7 8 9 10 11 12

Condensate to Deaerator PRDS-1 to STG IP Steam header to HP Heater-1 HSD Supply header HSD Return header Service Water header Potable Water header Instrument Air header Service Air header Auxiliary CW Supply header Auxiliary CW Return header Desuperheating line to PRDS-3 & 4

18.646 65.525 16.824 1.903 1.903 2.163 2.163 2.163 2.163 32.283 32.283 1.44

47.45 200.097 60.201 9.527 9.527 7.704 7.704 7.704 7.704 75.645 75.645 12.766

0.47 2 0.6 0.1 0.1 0.08 0.08 0.08 0.08 0.76 0.76 0.13

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Members Used

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Calculation of loads
Pipe loads obtained from mechanical department whereas load of grating will depend on its type. Friction Loads: Applied in X and Z direction are to be taken as 15% of pipe loads. Wind Loads

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Design Parameters
Design parameters are as per IS 800:1984 Maximum deflection allowed in beams = L/300 Maximum slenderness ratio allowed is: 180 for columns 250 for beamsgs 160 for bracin

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Learning Outcomes
Use of STAAD.Pro
Preparing model Applying loads Review results

Designing beams and columns

Deciding beam/column dimensions Detailing of reinforcements

Microsoft Visual Basic Applications

Using Excel to handle a large volume of design data Data can be loads, reactions, etc

Design Foundation
Optimize size and reinforcement

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Standards Referred
IS 800: 1984, Code of Practice for General Construction in Steel, Bureau of Indian Standards IS 456: 2000, Code of Practice for Design of Plain and Reinforced Concrete, Bureau of Indian Standards IS 875(Part 3): 1987, Code of Practice for Design loads for Buildings and Structures- Wind Loads, Bureau of Indian Standards IS 1893(Part-1): 2002, Criteria for Earthquake Resistant Design of Structures-General Provisions and Buildings, Bureau of Indian Standards

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BITS Pilani
Pilani Campus

THANK YOU !!