IIT PATNA

DEPARTMENT OF MECHANICAL ENGINEERING

DESIGN OF STEEL STRUCTURE

FOR OVERHEAD CRANE

Kartik Agarwal
1401ME20
 OVERVIEW OF BSP

It was set up with the help of the USSR in 1955 and has an area of about 36 sq. kms.
BSP has been eleven-time winner of the Prime Ministers Trophy for best integrated plant in the
country.
BSP is Indias first and main producer of rails for Indian Railways including 260m long rail.
It has an annual capacity of 3.153MT of saleable steel.
Over 70% of total exports in steel products are from BSP.
It recorded Rs 3,886.36 crore as revenue from operations during the quarter ended June 30,
2017.
 FOUNDRY & PATTERN SHOP

T h e f o u n d r y s h o p i s l a i d o u t i n f i v e b a y s , e a c h o f l e n g t h 2 7 0 m e t e r s. V a r i o u s t y p e s o f
castings are as follows:
Iron Castings Spare parts for machines, Ingot moulds.
Steel Castings - Skull cracker balls, Ladle covers for SMS, Pig casting moulds.
Non-Ferrous Castings - Bushings, slide blocks for machines, Al. Cubes & Al. Shots.
Main sections of foundry shop are :
Charging and moulding material store
Sand preparation section
Iron foundry
Steel foundry
Non-ferrous foundry
Fettling section
T h e p a t t e r n s h o p i s d e s i g n e d t o p r o d u c e p a t t e r n s f o r f o u n d r y n e e d s. T h e a n n u a l o u t p u t
i s r a t e d a t 2 2 0 C u . m e t e r s . H a n d l i n g o f h e a v y p a t t e r n s a t t h e s h o p a n d s t o r a g e i s c a r r ie d
o u t b y t e l l p h e r c r a n e s o p e r a te d f r o m f l o o r l e v e l .
T h e p a t t e r n s a r e p a i n t e d a c c o r di n g t o a c o d e , t i c k e d , l a b e ll e d a n d s t o r e d t o e n a b le t h e
p a t t e r n s t o b e i s s u e d t o f o u n d r y a s a n d w h e n r e q u i r ed , a c c o r d i n g t o a w e l l - l a i d o u t
procedure.
 OBSERVATIONS OF THE SHOPS

C r i t ic a l m a c h i n e s a n d t h e i r n u m b e r :
Hot Metal Mixture 2 in no. (100 tons capacity each)
Electric Arc Furnace 2 in no. (5 tones capacity each)
Induction Furnace 1 (1 ton capacity)
Continuous Sand Mixer - 2 in no. (30T/hr. capacity each)
E.O.T. Crane 24 in no.
E a c h i n g o t m o ul d w e i g h s 8 . 8 T o r 9 . 8 T a n d t h e d a i l y p r o d uct i o n o f i n g o t m o ul d s a r e
17 n o s . o n av e r a g e , i n 2 s h i f t s .
P a t te r n s h o p h a s a w e l d i n g s e c t i on i n t h e b a c k w h e r e a l l t h e w e l d i n g t a ke s p l a c e ,
f r o m l i g h t p a r t s to h e av y p a r t s w h i c h m i g h t w e i g h u p to 2 to n s .
 PROBLEM STATEMENT

T h e m a i n te n a n c e s e c t i o n i n t h e Fo u n d r y S h o p h a d a n u n u s e d E . O . T. C r a n e o f 3 to n s
c a p a c i t y. T h e b a c k s e c t i o n o f t h e P a t te r n S h o p r e q u i r e d a s m a l l c r a n e to a i d i n
w e l d i n g p r o c e s s . T h e t a s k w a s to d e s i g n a s te e l s u p p o r t s t r uc t ur e f o r t h e c r a n e to b e
o p e r a te d .

INITIAL STEPS:
T h e s e s te p s i n c l ud e d i n s p e c t io n o f t h e a r e a w h e r e t h e c r a n e w a s to b e i n s t a l le d a n d
g et t h e r e l eva n t d i m e n s i o n s .
A p p r ox im a te h e i g h t av a i l a b l e = 5 . 5 m , l e n g t h o f t h e r e q u i r e d g i r d e r = 7. 2 m
D et a i l s o f t h e c r a n e a n d i t s d i m e n s i o n s w e r e t a ke n f r o m t h e d a t a h a n d b o o k i s s u e d
f r o m t h e a r c h i ve .
Fo r ex a m pl e R a i l s i z e ( K P - 8 0 ) , s p a n o f t h e c r a n e , w i d t h o f t h e c r a n e , w e i g h t o f
c r a b a n d c r a n e ( w i t h o ut c r a b ) .
 INITIAL MODEL

T h e I n i t i a l m o d e l h a d t w o c o l um n s f o r e a c h g i r d e r.
T h e m a te r i a l to b e u s e d w a s s e l e c te d o n t h e b a s i s o f g e n e r a l av a i l a bi l it y, w h i c h w a s
2 0 6 2 / 2 01 1 E 2 5 0 G r a d e B .
A f te r c a l c ul a t i o n o f w h e e l l o a d , l o n g i t ud i n al f o r c e a n d t r a n s v e r s e f o r c e , a s i m p l e I
s e c t i o n b e a m w a s s e l e c te d f r o m I S 8 0 8 1 9 8 9 .
To s a t i s f y t h e m i ni m um d e f l e c t io n i n t h e g i r d er, a c h a n n e l s e c t i o n M C 2 0 0 w a s u s e d
along with MB300.
E v e n a f te r t h a t t h e d e f l ec t i o n ex c e e d e d t h e s p e c i fi e d l i m it . T h u s , a t h i r d c o l um n
w a s i n t r o duc e d w h i c h r e d uc e d t h e d e f l e c t i o n s i g n i fi c a n t l y.
I n t h e f i r s t d e s i g n , a c o n n e c t i n g p l a te w a s i n t r o d uc e d to a i d i n t h e w e l d i n g p r o c e s s
o f g i r d e r to t h e c o l um n . H o w ev er, t h e e f f e c t i f t h i s p l a te w a s n o t a c c o un te d f o r i n
t h e g i r d e r d e s i g n w h i c h ev e n t u a l l y l e d to o v e r d e s i g n e d m o d el .
 SUPPORTING BEAM

To a c c o un t f o r t h e m o m e n t g e n e r a te d d u e to t r a n s v e r s e f o r c e s , a s u p p o r t i n g b e a m
w a s r e q u i r e d a c r o s s t h e s p a n o f t h e c r a n e to g i v e t h e d e s i g n a s t r u c t ur al r i g i d i t y.

Fr o m h i t a n d t r i a l I - s e c t i o n b e a m M B 17 5 w a s s e l e c te d f o r t h e s u p p o r t . Fo l l owi n g t h e
( ) ( )
I S : 8 0 0 - 1 9 8 4 , t h e s a f et y c r i te r io n , + 1 w a s s a t i s fi e d .

A c c . to t h e m o m e n t s d u e to s e l f w e i g h t a n d t r a n s v e r s e f o r c e , a n a p p r o p r i a te l e g
s i z e w a s s e l e c te d f o r w e l d i n g o n to t h e a t t a c h m e n t p l a te , w h i c h w a s to b e b o l te d
o n to t h e c o l um n .

G o i n g b y t h e g e n e r a l av a i l a b il it y o f b o l t s , d i m e n s i o n s o f t h e a t t a c h m e n t p l a te w a s
f i xe d .
 BASE PLATE

A f te r t h e s e l e c t i o n o f c o l um n m e m b e r, d i m e n s i o n s f o r b a s e p l a te w a s s e l e c te d .
T h i c k n e s s o f t h e p l a te w a s c a l c ul a te d u s i n g t h e c r i te r i o n g i v e n i n C l a u se 5 . 4 . 3 , I S :
3 2
800 1984: t = (2 ) = 17. 3 3 m m
4

w h e r e , w = b a s e p l a te p r e s s u r e
a = b = P r o j e c t i o n b eyo n d I B e a m [ S q u a r e b a s e p l a te ]
= a l l owa b l e b e n d i n g s t r e n g t h o f s te e l p l a te = 0 . 6 6 f y
T h u s , a 2 0 m m p l a te w a s c h o s e n .
B a s e p l a te w a s to b e w e l d e d to t h e c o l um n . H e n c e , a
weld leg was chosen as 7mm.
L a te r c a l c ula t i o n s s h o w e d t h a t t h e w e l d i n g w i l l f a i l i n
s o m e o f t h e ex t r e m e l o a d i ng c o n d i t i o n s s o t h e w e l d l e g
w a s i n c r e a s e d to 9 o r h i g h e r b y m u l t i p le p a s s i n g .
 GUSSET PLATE

A f te r t h e s e l e c t i o n o f b r a c i n g m e m b e r a c c o r d i n g to t h e c r i te r i o n g i v e n i n t h e I n d i a n
S t a n d a r d , d i m e n s i o n s o f g u s s et p l a te w a s c h o s e n .
B y C h e c k i n g f o r t h e w e l d i n g s t r e n g t h , d i m e n s i o n s d a n d a w e r e c a l c ula te d .
T h e s e d i m e n s i o n s w e r e f u r t h e r v e r i f i e d b y c h e c k i n g f o r t h e p e a k s t r e s s d ev e l o p e d
i n t h e p l a te d u e b o l t s .

Pe a k s t r e s s =

 OPTIMIZATION

A f te r g e n e r a t i n g A n s y s r e p o r t i t w a s f o u n d t h a t t h e d e s i g n w a s o v e r d e s i g n e d a n d
s o m e o f t h e p a r t s c o ul d b e r e d e s i g n e d .
The major changes were done in the girder and supporting beam, which
a u to m a t i c al l y i n d u c e d c h a n g e s i n s e l e c t i o n o f c o l um n a n d b r a c i n g m e m b e r.
T h e i n i t i a l g i r d e r w a s to o h e av y a n d d i f fi cul t to w e l d .
A s i m p le d e s i g n w a s a p p r o a c h e d u s i n g o n l y s te e l p l a te s to i n c r e a s e t h e b e n d i n g
s t r e n g t h o f t h e g i r d e r. T h i s t i m e t h e c o n n e c t in g p l a te w a s t a ke n i n to a c c o un t a n d
a n e q u i v al e n t f l a n g e w a s c a l c ul a te d to s i m p l i f y t h e c a l c ul a t i o n s .
T h e n ew s u p po r t in g w e i g h e d m o r e b u t t h i s s te p w a s t a ke n b e c a us e o f u n av a i l a bi l it y
o f M B 17 5 .
 CONCLUSION

T h e w e i g h t o f t h e f i r s t m o d e l i s 71 2 2 . 8 k g , w h e r e a s w e i g h t o f t h e s e c o n d m o d e l i s
4 4 4 3 . 6 k g , a f te r o p t i m iz a t io n .
A n s y s r e s u l t s h o w e d i n c r e a s e i n f a c to r o f s a f et y, d u e to d e c r e a s e d f o r c e s i n t h e
s t r uc t ur e d u e to s e l f w e i g h t .
Fu r t h e r o p t i m i z a t i o n c o u l d b e a c h i ev e d b y r e d u c i n g t h e b e a m s i z e b u t w a s n t
p e r fo r m e d d u e to u n av a i l a b i li t y o f t h o s e s i z e s .
THANK YOU