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Procedia Engineering 83 (2014) 462 – 468 1877-7058 © 2014 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/). Peer-review under responsibility of the Scientific Committee of SYMPHOS 2013 doi:10.1016/j.proeng.2014.09.079 ScienceDirect Available online at www.sciencedirect.com “SYMPHOS 2013”, 2nd International Symposium on Innovation and Technology in the Phosphate Industry Project Management Procedures Needed to Design the Newest Four Phosphoric Acid Evaporators in North America Richard Harrison* Professional Engineer, Florida , PegasusTSI, 5310 Cypress Center Drive Suite 200, Tampa, FL 33609 USA Abstract This paper presents the project management techniques needed to design the newest four evaporators installed in North America, and any similar project. The four evaporators included integral fluosilicic acid recovery systems, and were successfully designed, fabricated, erected and operational by mid 2009. Topics discussed in the paper include: Project Objectives, Project Stages, Scope Definition, Design Basis, Codes and Standards, Technology Selection, Capital Cost Estimation, Schedule Development and Control, Operating Cost Estimation, Value Improvement Practices, Equipment Specification, Contractor Bid Specification, Constructability Review, Construction Management, and Commissioning. Keywords: Phosphoric Acid; Phosphate; Fluosilicic Acid; Evaporators, Harrison 1. Introduction This paper seeks to review the essential activities required to reliably complete a project in the phosphate industry. Effective use of these procedures enabled the evaporator expansion project team to successfully design, erect and commission the last four phosphoric acid evaporators (with FSA recovery) to be erected in the United States. The detailed procedures required to complete a major project successfully, along with the documents generated during the course of the project fill many volumes. Only an overview is provided in this paper due to space limitations. Additional resource materials are provided in the references for further reference. * Corresponding author. Tel.: +01-813-310-3833; E-mail address: [email protected] © 2014 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/). Peer-review under responsibility of the Scientific Committee of SYMPHOS 2013

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Page 1: 450x 200 Us Sbm6 Grid 6_a-d

Project

LORESHO HOUSE

Job no.

S000

Calcs for

450X200 US SBM 6 GRID 6/A-D

Start page no./Revision

1

Calcs by

HA

Calcs date

4/3/2015

Checked by

MLM

Checked date

4/3/2015

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4/3/2015

RC BEAM ANALYSIS & DESIGN BS8110

TEDDS calculation version 2.1.12

mm 3900

1A B

Unfactored Loads

0.0

25.114

Self weight included

Dead Imposed

mm 3900

1A B

Load Envelope - Combination 1

0.0

81.309

mm 3900

1A B

Page 2: 450x 200 Us Sbm6 Grid 6_a-d

Project

LORESHO HOUSE

Job no.

S000

Calcs for

450X200 US SBM 6 GRID 6/A-D

Start page no./Revision

2

Calcs by

HA

Calcs date

4/3/2015

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Load Combination 1 (shown in proportion)

mm 3900

1A B

Dead

Imposed

Bending Moment Envelope

0.0

154.589

kNm

mm 3900

1A B

154.6

Shear Force Envelope

0.0

158.552

-158.552

kN

mm 3900

1A B

158.6

-158.6

Support conditions

Support A Vertically restrained

Rotationally free

Support B Vertically restrained

Rotationally free

Applied loading

Dead self weight of beam × 1

Span 1 loads Dead UDL 23.320 kN/m from 0 mm to 3900 mm

Imposed UDL 4.350 kN/m from 0 mm to 3900 mm

Dead UDL 1.950 kN/m from 0 mm to 3900 mm

Imposed UDL 0.490 kN/m from 0 mm to 3900 mm

Dead UDL 25.114 kN/m from 0 mm to 3900 mm

Page 3: 450x 200 Us Sbm6 Grid 6_a-d

Project

LORESHO HOUSE

Job no.

S000

Calcs for

450X200 US SBM 6 GRID 6/A-D

Start page no./Revision

3

Calcs by

HA

Calcs date

4/3/2015

Checked by

MLM

Checked date

4/3/2015

Approved by

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Approved date

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Load combinations

Load combination 1 Support A Dead × 1.40

Imposed × 1.60

Span 1 Dead × 1.40

Imposed × 1.60

Support B Dead × 1.40

Imposed × 1.60

Analysis results

Maximum moment support A; MA_max = 0 kNm; MA_red = 0 kNm;

Maximum moment span 1 at 1950 mm; Ms1_max = 155 kNm; Ms1_red = 155 kNm;

Maximum moment support B; MB_max = 0 kNm; MB_red = 0 kNm;

Maximum shear support A; VA_max = 159 kN; VA_red = 159 kN

Maximum shear support A span 1 at 400 mm; VA_s1_max = 126 kN; VA_s1_red = 126 kN

Maximum shear support B; VB_max = -159 kN; VB_red = -159 kN

Maximum shear support B span 1 at 3491 mm; VB_s1_max = -125 kN; VB_s1_red = -125 kN

Maximum reaction at support A; RA = 159 kN

Unfactored dead load reaction at support A; RA_Dead = 102 kN

Unfactored imposed load reaction at support A; RA_Imposed = 9 kN

Maximum reaction at support B; RB = 159 kN

Unfactored dead load reaction at support B; RB_Dead = 102 kN

Unfactored imposed load reaction at support B; RB_Imposed = 9 kN

Rectangular section details

Section width; b = 200 mm

Section depth; h = 450 mm

450

200

Concrete details

Concrete strength class; C20/25

Characteristic compressive cube strength; fcu = 25 N/mm2

Modulus of elasticity of concrete; Ec = 20kN/mm2 + 200 × fcu = 25000 N/mm2

Maximum aggregate size; hagg = 20 mm

Reinforcement details

Characteristic yield strength of reinforcement; fy = 460 N/mm2

Characteristic yield strength of shear reinforcement; fyv = 460 N/mm2

Nominal cover to reinforcement

Nominal cover to top reinforcement; cnom_t = 25 mm

Page 4: 450x 200 Us Sbm6 Grid 6_a-d

Project

LORESHO HOUSE

Job no.

S000

Calcs for

450X200 US SBM 6 GRID 6/A-D

Start page no./Revision

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Calcs by

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Calcs date

4/3/2015

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Checked date

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Nominal cover to bottom reinforcement; cnom_b = 25 mm

Nominal cover to side reinforcement; cnom_s = 25 mm

Mid span 1

450

200

2 x 8φ shear legs at 150 c/c

2 x 16φ bars2 x 25φ bars

2 x 16φ bars

Multiple layers of bottom reinforcement

Reinforcement provided - layer 1; 2 × 16φ bars

Area of reinforcement provided - layer 1; As_L1 = 402 mm2

Depth to layer 1; dL1 = 409 mm

Reinforcement provided - layer 2; 2 × 25φ bars

Area of reinforcement provided - layer 2; As_L2 = 982 mm2

Depth to layer 2; dL2 = 373 mm

Total area of reinforcement; As,prov = As_L1 + As_L2 = 1384 mm2

Centroid of reinforcement; dbot = (As_L1 × dL1 + As_L2 × dL2) / As,prov = 383 mm

Design moment resistance of rectangular section (cl. 3.4.4) - Positive moment

Design bending moment; M = abs(Ms1_red) = 155 kNm

Depth to tension reinforcement; d = dbot = 383 mm

Redistribution ratio; βb = min(1 - m rs1, 1) = 1.000

K = M / (b × d2 × fcu) = 0.211

K' = 0.156

K > K' - Compression reinforcement is required

Lever arm; z = d × (0.5 + (0.25 - K' / 0.9)0.5) = 298 mm

Depth of neutral axis; x = (d - z) / 0.45 = 190 mm

Depth of compression reinforcement; d2 = cnom_t + φv + φtop / 2 = 41 mm

Area of compression reinforcement required; As2,req = (K - K') × fcu × b × d2 / (0.87 × fy × (d - d2)) = 293 mm2

Compression reinforcement provided; 2 × 16φ bars

Area of compression reinforcement provided; As2,prov = 402 mm2

Maximum area of reinforcement (cl.9.2.1.1(3)); As,max = 0.04 × b × h = 3600 mm2

PASS - Area of reinforcement provided is greater than area of reinforcement required

Area of tension reinforcement required; As,req = K' × fcu × b × d2 / (0.87 × fy × z) + As2,req = 1254 mm2

Tension reinforcement provided; 2 × 16 φbars + 2 × 25 φbars

Area of tension reinforcement provided; As,prov = 1384 mm2

Minimum area of reinforcement (exp.9.1N); As,min = 0.0024 × b × h = 216 mm2

PASS - Area of reinforcement provided is greater than area of reinforcement required

Rectangular section in shear

Shear reinforcement provided; 2 × 8φ legs at 150 c/c

Page 5: 450x 200 Us Sbm6 Grid 6_a-d

Project

LORESHO HOUSE

Job no.

S000

Calcs for

450X200 US SBM 6 GRID 6/A-D

Start page no./Revision

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Calcs date

4/3/2015

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Area of shear reinforcement provided; Asv,prov = 670 mm2/m

Minimum area of shear reinforcement (Table 3.7); Asv,min = 0.4N/mm2 × b / (0.87 × fyv) = 200 mm2/m

PASS - Area of shear reinforcement provided exceeds minimum required

Maximum longitudinal spacing (cl. 3.4.5.5); svl,max = 0.75 × d = 287 mm

PASS - Longitudinal spacing of shear reinforcement provided is less than maximum

Design concrete shear stress; vc = 0.79N/mm2 × min(3,[100 × As,prov / (b × d)]1/3) × max(1, (400mm

/d)1/4) × (min(fcu, 40N/mm2) / 25N/mm2)1/3 / γm = 0.778 N/mm2

Design shear resistance provided; vs,prov = Asv,prov × 0.87 × fyv / b = 1.341 N/mm2

Design shear stress provided; vprov = vs,prov + vc = 2.119 N/mm2

Design shear resistance; Vprov = vprov × (b × d) = 162.4 kN

Shear links provided valid between 0 mm and 3900 mm with tension reinforcement of 1384 mm2

Spacing of reinforcement (cl 3.12.11)

Actual distance between bars in tension; s = (b - 2 × (cnom_s + φv + φbot,L1/2)) /(Nbot,L1 - 1) - φbot,L1 = 102 mm

Minimum distance between bars in tension (cl 3.12.11.1)

Minimum distance between bars in tension; smin = hagg + 5 mm = 25 mm

PASS - Satisfies the minimum spacing criteria

Maximum distance between bars in tension (cl 3.12.11.2)

Design service stress; fs = (2 × fy × As,req) / (3 × As,prov × βb) = 277.9 N/mm2

Maximum distance between bars in tension; smax = min(47000 N/mm / fs, 300 mm) = 169 mm

PASS - Satisfies the maximum spacing criteria

Span to depth ratio (cl. 3.4.6)

Basic span to depth ratio (Table 3.9); span_to_depthbasic = 20.0

Design service stress in tension reinforcement; fs = (2 × fy × As,req)/ (3 × As,prov × βb) = 277.9 N/mm2

Modification for tension reinforcement

ftens = min(2.0, 0.55 + (477N/mm2 - fs) / (120 × (0.9N/mm2 + (M / (b × d2))))) = 0.819

Modification for compression reinforcement

fcomp = min(1.5, 1 + (100 × As2,prov / (b × d)) / (3 + (100 × As2,prov / (b × d)))) = 1.149

Modification for span length; flong = 1.000

Allowable span to depth ratio; span_to_depthallow = span_to_depthbasic × ftens × fcomp = 18.8

Actual span to depth ratio; span_to_depthactual = Ls1 / d = 10.2

PASS - Actual span to depth ratio is within the allowable limit

Support B

450

200

2 x 8φ shear legs at 175 c/c

2 x 16φ bars

2 x 16φ bars

Rectangular section in shear

Design shear force span 1 at 3491 mm; V = abs(min(VB_s1_max, VB_s1_red)) = 125 kN

Page 6: 450x 200 Us Sbm6 Grid 6_a-d

Project

LORESHO HOUSE

Job no.

S000

Calcs for

450X200 US SBM 6 GRID 6/A-D

Start page no./Revision

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Calcs date

4/3/2015

Checked by

MLM

Checked date

4/3/2015

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Approved date

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Design shear stress; v = V / (b × d) = 1.532 N/mm2

Design concrete shear stress; vc = 0.79 × min(3,[100 × As,prov / (b × d)]1/3) × max(1, (400 /d)1/4) ×

(min(fcu, 40) / 25)1/3 / γm

vc = 0.499 N/mm2

Allowable design shear stress; vmax = min(0.8 N/mm2 × (fcu/1 N/mm2)0.5, 5 N/mm2) = 4.000 N/mm2

PASS - Design shear stress is less than maximum allowable

Value of v from Table 3.7; (vc + 0.4 N/mm2) < v < vmax

Design shear resistance required; vs = max(v - vc, 0.4 N/mm2) = 1.033 N/mm2

Area of shear reinforcement required; Asv,req = vs × b / (0.87 × fyv) = 516 mm2/m

Shear reinforcement provided; 2 × 8φ legs at 175 c/c

Area of shear reinforcement provided; Asv,prov = 574 mm2/m

PASS - Area of shear reinforcement provided exceeds minimum required

Maximum longitudinal spacing; svl,max = 0.75 × d = 307 mm

PASS - Longitudinal spacing of shear reinforcement provided is less than maximum

;