conveyor structure design

TenderTechnicalSpecification

TechnicalSpecificationforDevelopmentofParametricProgramsforcustomizationandOptimizationofVariousCoalHandlingPlant(CHP)structuresShortDescriptionoftender DevelopmentofDesignAutomationTools forCustomizationofAnalysisand Optimization of various Structuralcomponents inCoal Handling Plant (CHP) like Conveyor Galleries, Trestles andTransferTowersconsideringvarious loadsand theircombinationsas per Indian Standard Codes using FEMAP API for parametricmodeling and interfacing such toolwith the available softwaressuch as PROKON and STAAD Pro, with auto execution formodeling, analysis including design optimization with technicalreportsandBOMasperTechnicalSpecificationprovidedbyBHEL.CHPstructuresconsistsofvarioustypesofconveyorgalleriesandtrestlesalongwithjunctionhousesandotherstructuralsubsystemsAstherearehugenumberofvariantsinthetypesofgalleries,trestlesandtransfertowerswithvariousrequirementssuchaslengthsloadcarryingcapacities,single/doublegalleriesetc,itisproposedtodevelopaparametricprogramtodevelopthemathematicalmodelandinterfacewithanalyticalpackagesandrelevantdesigncodesasperIndianStandards.

Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA

Thetotalsystemofautomatedprogramisbasicallydividendintofollowingsections1)GeneralGuidelines2)Basictypesofgalleries,trestlesandtransfertowers.3)Developmentofparametricmathematicalmodelofgalleries,trestlesandtransfertowers4)Generationof3DMathematicalmodeland3Dframefromtheabove5)Impositionofloadscalculatedasperrelevantcodesandconstraintsforvariousconditions6)Developmentofinterfaceswithexistingsoftwarefortheaboveprogram7)Afterexecutionofprograminanalysispackage,retrievalofproperties,analysisdata,forcesandmoments8)DevelopmentofprogramtoreadthesevaluesintoaseparatelydevelopedcodeasperIndianStandardsandcrosscheckingforstrengthandstabilityusingthesecodes9)Preparemodelwithrevisedpropertiesforoptimization10)Recheckingresultsforsystemsafetyandfurtheroptimizationandcalculationofsectionalproperties11)Preparationofbillofmaterialandcuttingdiagramsandcalculationofrawmaterialweightsetc12)PreparationofdxffilefromanalysismodelsuitableforplottinginAutoCad.


ThetenderisinvitedforcarryingoutdevelopmentalworkwhichwouldresultintoacustomizedDesignandAnalysisToolforthespecifiedcomponentsofCoalHandlingPlant(CHP).Thebrieftechnicalscopeisasunder.

1. ComponentsConsideredareConveyorGalleries,TrestlesandTransferTowers.

2. Basic initialgeometry is tobearrivedatbasedonphysical requirementsof space,sizeandcapacity.

3. Development of parametric programs to convert the physical configuration intofiniteelementmodelsusingFEMAPwithparametersandconstraints.

4. Finiteelementanalysisofthecomponentunderthe loadingasper IndianstandardCodes.ThisistobedonebylinkingtheFEmodelstoanalysispackages,STAADPROandwithPROKON.

5. InterpretationofresultsaccordingtoIndianstandardcodes 6. Iterativeoptimization(repetitionofsteps2to5)togetacceptabledesign(Stressand

deflections)fromconsiderationofweight. 7. Convertsthefinalconfigurationintodrawings,BOM,andautogenerationofdesign

report. The Scope mentioned above is detailed with some more intermediate steps asmentionedbelow.


GeneralguidelinesforcustomizationfordevelopmentofParametricprogram1)ForcustomizationofcodesandinputofframesinprogramacontinuousinteractionwithBHELanddeveloperisrequiredforproperguidancefromtheIndentingdepartment.

2)Initially,afterplacementoforder,theDeveloperhastoworkwiththeindentingDepartmentatBHELR&DHyderabadtoformulatethedesignprocedureandproceduretobefollowedandworkshouldbecarriedoutjointlyduringthefirstphaseofdevelopment.DeveloperhastovisitR&DandstayathisownexpensesandBHELwillnotpayanyexpensestowardstravel,boardingandlodgingoranyothercharges.

3)Thelogicandguidancegivenforcustomizationareonlyindicativetoquantifytheamountofworkinvolved.Thelogicofpreparingtheframesmaychangesduringthecourseofdevelopment,ifneeded.Theremaybechangesinconfigurationofstructuresduringthecourseofdevelopment,whichneedstobeconsidered.

4)ThesoftwarelogicpreparedwillbethepropertyofBHELandthesupplierordeveloperwillnothaveanyrightsontheprogramsdevelopedandwillbecopywrited/patentedbyBHEL

5)TheDevelopershouldmaintainstrictconfidentialityofthejointworkbeingcarriedoutandshouldsigntheconfidentialityagreementbeforestartingthework.

6)ItisthedevelopersresponsibilitytotestthesoftwareandcustomizationpreparedfortypicalCHPstructuresofearlierjobsasgivenbytheindentingdepartment

7)ThedevelopershouldprovideOperatingmanualandotherprocedurestobefollowedforexecutingthestructuralanalysisjobs.

8)TheinitialmodelsandparametricprogramsmustbedevelopedusingthepreprocessorandAPIprogramcapabilityofFEMAPforcheckingatBHELTheprogramsmustinterfacewithPROKONandSTAADProsoftwares,whichareavailableatBHELandhavetobetestedatIndentingdepartment.Thecustomizationandmodelingdatahastocarriedontheexistingsoftwares.Howeverthesupplierisfreetodeveloptheprogramsonanyotherplatformsuitabletohimandthesamesoftwarealongwiththefullprogramcodeistobe


suppliedalongwiththedevelopedcodes,butfinalinterfacingmustbedonewiththeaboveavailablesoftwaresatBHEL(FEMAP,PROKONandSTAADPro).

9)Thesuppliermaysendsamplesofsuchdevelopedcodeforanyotherproduct/structureinaboveformatsforassessingthetechnicalsuitability,ifavailable.

10)ThedesignmustcomplywithIndianStandardcodeslikeIS800bothworkingstressandlimitstatedesignsandthecodesshouldbeincorporatedintheanalyticalengineforautomaticdesignchecks

11)TheloadingsshouldfollowtherequiredIndiancodesasperIS875andIS1893(latestVersions)

12)Thedeveloperhastotesteachphaseofprogrambeforeproceedingtothenextphase

13)Therequiredeffectivelengthcalculations,Kfactordetermination,optimizationroutineswithdifferentloadcombinationsasperIndiancodesmustbeincorporatedandinterfacedwiththeabovementionedanalyticaltools.

14)TheInformationcontainedinTenderDocumentsisconfidentialandshouldnotbeusedforanyotherpurposeotherthanforquoting/executingforthisenvisagedwork.


TechnicalspecificationGeneralIntroductionofCHPStructures:The coalHandlingPlant (CHP) structures consistsof various conveyor galleries carryingcoal from coal yards to the bunkers in the boiler area of a thermal power plant. Thesegalleriesrunfromgroundleveltobunkerlevelwhichisapproximately50to60metreshigh.TypicalLayoutofaplantisasshownbelow:

TypicalLayoutofaPowerplant


TypicalConveyorsystem:Theconveyorsystemdesignedtocarrycoalisgenerallyinclinedconveyorsystemwithsingleordoubleconveyorsonasinglegallery.Thelengthofeachgallerysegmentvariesbetween8mto30minlengthandwidthsfrom4to10m.Theyaresupportedbyverticalsupportingstructurecalledtrestles.Thesemaybetwoleggedtrestlesor4leggedtrestles.TypicalGalleriesrunninginacoalplantareasshownbelow:


AsseenfromtheabovefiguresthegalleriesareofdifferentlengthsandinclinationsandtheserunfromgroundtobunkerheightwithvarioustypessupportingTrestlesinbetween.Thelocationoftrestlesdependonsiteconditionsuchaslayoutofroads,pipingandlocationofotherequipment


TypesofGalleries:Inordertostandardizethenumberandtypesofgalleries,itisproposedtostandardizebasedonthetypicallengthsforvarioussingle/doublegalleries.ThewillbebasicallyTWOtypesofgalleriesgalleriescarryingonebeltconveyororGallerycarryingtwoconveyorbeltsasshownbelow:ThecrosssectionaldetailsofSingleconveyorGalleryisasshownbelow:

ThecrosssectionaldetailsofaDoubleconveyorGalleryisasshownbelow:


LengthsofConveyorGalleries:Itisproposedtostandardize4lengthsofgalleriessuchas12m,18m,24mand30mforthepurposeofoptimizationanddevelopmentoftool.Thetypicalarrangementofsingleconveyorgalleryisasshownbelow:


SimilarlytypicalDoubleConveyorgalleriesareshownbelow:


Design Guidelines

Theoverheadgallerygirderconsistsoftwoverticallatticedgirderconnectedwithtwoendportal.Crossbeamssupportingwalkway runner&conveyor stringermadeofplategirderconnectingthebottomchordsoftheverticalgirder.Therooftrussessupportingthepurlinsareconnecting the topchordof theverticalgirder.The top&bottomplanof thegallerygirder are horizontally bracedwith V bracings.A space framemodel is required to bepreparedontheabovebasisforanalysisConveyorgallerygirdersaretobedesignedasapairofgirders,bracedattopandbottomlevels.Agallery consistsof two girdersofdepth approx 2.8m ,bracedat topandbottom chordlevels to transmit loads to end portals which in turn connected to trestles. Roof truss isprovidedatupperendpoints@3mc/ctoformanenclosure.Crossbeamsatbottomchordlevel spanning between the two girders is provided to support walk way and conveyorsupportingstructuresTypicalarrangementisasshowninabovefigures.DevelopmentToolRequirement:ThedesignOptimizationGUIbaseddevelopmenttooltobepreparedforeachtypeofgallery,trestle and transfer tower. InitialModel tobepreparedusing FEMAPAPI for checking andinterfacing.Theparameterizedmathematicalmodelhas tobedevelopedusing theFEMAPAPIprogramonly.Othermodesofdevelopmentarenotacceptable.The modelhas tobedeveloped fordifferent optimum configurations of various types of structures. For example there APIprogramsofa12mgalleryofasingleconveyorsystemwillbedifferenttothatofa12mgallerystructurefordoubleconveyorsystem.ThemathematicalmodeldevelopedbythetoolhastobeintegratedwithanalyticalsoftwaresPROKONand STAADPro for analysis,design andOptimization automaticallywithoutuserintervention.TheDetailsAre:

1) For Single Conveyor and Double Conveyor Systems

TheprogramhastobedevelopedforeachoftheGallerylengthsa)12minlengthb)18minLength


c)24minlength.andd)30mlengthThemathematicalmodelspreparedwillalsodependonthetypeofmaterialtobecarried.ThestructuremaydifferforcarryingcoalfromthattocarryLigniteetc(ForLignitecarryinggallerythecablesetcaretobeplacedoutsidetheconveyorstructure).ThefollowingvariablesneedtobeconsideredforthedevelopmentofmathematicalmodelA)CoalfeedingratesVariablesareBoilerSpecificationsuchas110MW,250MWor500MWBoilerwithfeedingratesof400,600,800,1200,1400,1600,1800and2000Tonnes/Hr(Add20%ExtraLoad)B) InclinationofConveyor from0 to15Deg in stepsof1degree. (The loadonwalkwayincreasesforinclinationsmorethan10degduetothepresenceofstepsinsteadoffloor)C)TheendofPortaltobesuitablydesignedfortheaboveinclinationD)BeltspeedProgramshouldinputvariablebeltspeedforeachgallery.E)Walkwayfollowingtobeconsideredi)Singlesidewalkwayii)Walkwayonbothsidesofconveyor(maybeofdifferentwidths)forsingleconveyorsystemandiii) For double conveyor system , thewalkways in themiddle aswell as at end to beconsideredThe walk ways on both sides may differ in widths ( Variable width walk way to beconsidered)F)InclusionofsealplatelengthandweightofcoaltobeconsideredG)DeckPlatetobeconsideredanddustloadtobeconsideredH)Variablewindloadaspertheheightofgallery(Heightatwhichithastobeerectedisaparameter)I)SiteLocationJ)windspeedsasperIS875K)SeismicloadsasperIS1893L)Otherparametersasrequiredbythesiteconditionsandcustomerrequirement.


Design Codes to be Followed : IS:875(Part2)1987CodeofpracticeofDesignLoad(Otherthanearthquake)forBuilding&structureImposedLoadsIS:875(Part3)1987CodeofpracticeofDesignLoad(Otherthanearthquake)forBuilding&structureWindLoadsIS18932002Part1andIS18932005PartIVforseismicloadsIS:8002007CodeofpracticeforGeneralConstructionofSteelBothworkingstressandLimitstatedesignneedtobecheckedIS:8081989DimensionforHotRolledSteelBeams,Column,Channel&AngleSectionIS115922000CodeofPracticeforSelectionanddesignofBeltConveyorsLoadParametersThedetailedloadcalculationparameterstobeconsideredareasgivenbelow

DataTobeconsideredforLoadCalculations1.A DesignDataandVariables1) DepthofGallery2) WidthofPanel3) RoofSlope4) Beltwidth5) DesignCapacity6) BeltSpeed7) Wt.ofBelt(Carrying+Return)8) Wt.ofIdler(Carrying+Return)9) Wt.ofStringer,ShortPost,Etc.10) Wt.ofHandrail(assumed)11) Wt.ofLightingArrangements12) Wt.ofCableTray13) Wt.ofFirefightingpipe14) Wt.ofServicewaterpipe15) Wt.ofDSWaterpipe


16) Wt.ofpotablewaterpipe17)BasicWindSpeedB. LoadonGallery: 1) WindLoad: Basicwindspeedbasedonsitelocation DesignWindspeedshouldbecalculatedfordifferentheightsasperfactorsk1,k2(andvarieswithHeight)andk3ofIS:875Part3 DesignWindpressurefordifferentheightstobecalculatedVzforupto10.0mheightVzfor10to15mheightVzfor15to20mheightVzfor20to30mheightVzfor30to40mheightVzfor40to50mheightVzfor50to60mheightVzfor60to70mheightVzfor70to80mheightneedtobecalculated

2) MaterialLoad: HereCapacityoftheconveyor(TonnesperHourTPH)tobeconsideredThenwt.ofmaterialonbeltpermeterlengthtobecalculatedbasedontheBeltSpeedOtherParametersareWeightofbeltandconsider10%extra(asperIS11592)thencomputeTotalMaterialweightonbelt. 3) LiveLoadonWalkway: AspercodeLLonwalkway 4) LiveLoadonSealPlate: LiveLoadonsealplate 5) LiveLoadonDeckPlate: LiveLoadondeckplate Widthofeachdeckplate andLLfromeachdeckplatetobecomputed


6) WeightofPipe: Totalweightofservicewaterpipe TotalweightofDSwaterpipe Totalweightofpotablewaterpipe 7) LoadofCableTray: TotalWeightofCableTrayongalleryistobeconsidered Then,loadononesidegallerygirderduetocabletrayiscomputed Then,loadonotherside(pipeside)gallerygirderisalsotobecomputed 8) LoadonRoof: Hereroofslopetobeconsidered a)LiveLoad=AsperIS.875Part2LLonroof b)DustLoad=AsperDustLoad HenceUDLonroofistobecomputed 9) LoadofLightingArrangement: Hereloadoflightingarrangementforperlightpointistobeconsidered 10) LoadofFireFightingArrangement: LoadofFirefightingarrangementattwojointsineachrooftrusstobeconsidered 11) DeadLoadonGallerytobecomputedconsidering Selfweightofroofsheeting Selfweightofsidesheeting Selfweightofpurinsandsiderunner Selfweightofchequeredplate Selfweightofdeckplate Selfweightofsealplatewithstiffener

SelfweightofothermembersshallbetakenasapplicabletotherespectivemembersasperIS.808

12) Conveyorloadcalculationsshouldconsider

Conveyorloadstandsfordeadloadofconveyor

Weightofidler(Carrying+return) Wtofstringer,Sh.Post,etc. Wt.ofdeckplate


13) Wt.ofHandrail Wt.ofsidehandrail Wt.ofotherhandrail.C. LoadCalculation:I. DEADLOAD(DL): 1) InternalPanel:

Loadintensityoneffectivewidthoftruss 2) Loadonfloor:

DLon0.8mwideright/leftwalkwayand0.175mwidesealplatesupportingmemberswiths/w

DLonbottomchordmembersfrom0.175widesealplate

DLfrom0.175mwidesealplateand2.05mwidesealplatesupportingmembers

DLfrom1mwidemiddlewalkwayand0.175mwidesealplatesupportingmemberswiths/w

3) Loadofsidesheetingandsiderunner:

Loadintensityistobeassumedtobeactingon sidesheeting LoadonInternalPortion: loadontopandbottomnodesofeachverticalstobecomputed LoadonPortal Loadontopandbottomnodesofeachverticalstobecomputed 4) ConveyorLoad: Totalweightofconv.(excludingbeltwt.) Loadfromeachshortpost/sidetobecalculatedbasedonShortpostspacing


5) Loadfromhandrail:

Wt.ofsidehandrail Wt.ofotherhandrail Loadfromhandrail(otherthansideHR)tobeconsidered

II. LIVELOAD(LL):1) LoadonRoof: LoadintensityassumedtobeactingonInternalPannelandtransferredtothetrusses2) Loadonfloor:

LLon0.8mwideright/leftwalkwayand0.175mwidesealplatesupportingmembers

LLonbottomchordmembersfrom0.175widesealplate

LLfrom0.175mwidesealplateand2.05mwidesealplatesupportingmembers

LLfrom1mwidemiddlewalkwayand0.175mwidesealplatesupportingmembers

3) MaterialWeight:

TotalMaterialweightofconv.(beltwt.+liveloadondeckplate) Loadfromeachshortpost/sideiscalculatedbasedonShortpostspacing 4) Loadfrompipe: Weightofservicewaterpipetobeconsidered WeightofDSwaterpipetobeconsidered Weightofpotablewaterpipetobeconsidered 5) LoadfromCableTray: Loadintensityofcabletrayononegirdertobeconsidered


Loadintensityofcabletrayonotherside(pipeside) girdertobeconsidered 6) LoadfromLightingArrangement: 30kgoneachnode 7) LoadfromFireFightingPipeLine: WeightofFireFightingpipetobeconsidered.III. WINDLOAD:AsperIS.875(Part.3) 1) LoadonRoof: Basedonheightandwidthofthegallery Andangleofroof WindpressurecoefficientsforrooftobecalculatedasperIS875(Part3)andConsider Whenwindblowsacrosstheconv. Whenwindblowsalongtheconv.ThepressurecoefficientstobecalculatedonWindwardSideandLeewardsidewithdifferentconfigurationstobecomputed.Fromthis,UDLonRooftrussandendpanelsaretobecomputed 2) LoadonSideSheeting:

Considerheight,widthandlengthofthegallery andcalculatetheWindpressurecoefficientsforroofasperIS875 Whenwindblowsacrosstheconv.andWhenwindblowsalongtheconv.Computethefollowingloadcases

Whenwindisblowingacrosstheconv. Windpressureinwindwardside Windpressureinleewardside Windloadonverticals(IntermediatePanels) Windwardside(onTopsupport)


Windwardside(Bottomsupport) Leewardside(onTopsupport) Leewardside(Bottomsupport) WindloadonPortal Windwardside(Topsupport) Windwardside(Bottomsupport) Leewardside(Topsupport) Leewardside(Bottomsupport)

Whenwindisblowingalongtheconv. (BothwindwardandLeewarddirectionareoppositeinsign) windpressureinperpendiculardirectiontowindflow ForIntermediatePanels WindLoadontheverticals(Topsupport) WindLoadontheverticals(Bottomsupport) ForEndPortal WindLoadontheportals(Topsupport) WindLoadontheportals(Bottomsupport)OtherloadstobeconsideredareSeismicloadsasperIS1893ifapplicableSummationofLoadcasesandLoadcombinationstobeconsideredforanalysisanddesign************************************************LOAD1[DL]************************************************SELFWEIGHT*****LoadonRoof:JOINTLOADMEMBERLOAD*****LoadonFloor****DLonleftwalkwayandsealplatesupportingmembers*******DLonrightwalkwayandsealplatesupportingmembers****DLonBottomchordmembersfromSealplate*****DLfromsealplateandsealplatesupportingmembers***DLfrommiddlewalkwayandsealplatesupportingmembers****LoadofsideSheetingandSideRunner:***ConveyorLoad:*****Loadfromhandrail


*****WtofotherHandrail*******LoadofsideHandrail************************************************LOAD2[LL]*********************************************************LoadonRoof:JOINTLOADMEMBERLOAD*****LoadonFloor*****LLonleftwalkwaysealplatesupportingmembers****LLonrightwalkwayandsealplatesupportingmembers*****LLonBottomchordmembersfromSealplateMEMBERLOAD*****LLfromsealplateandsealplatesupportingmembers****LLfrommiddlewalkwayandsealplatesupportingmembers****MaterialLoad:MEMBERLOAD****LoadfromPipes:****LoadfromCableTray:*****LoadfromLightingArrangement:JOINTLOAD*****LoadfromFireFightingPipeLine:MEMBERLOADLOAD3[WL(+X)]******************************************************LoadonRoof:*****loadonrooftrussesJOINTLOAD*****LoadonSideSheeting:****WindwardsideMEMBERLOADLOAD4[WL(X)]******************************************************LoadonRoof:*****loadonrooftrussesJOINTLOAD*****LoadonSideSheeting:****Windwardside****leewardside************************************************LOAD5[WL(+Z)]******************************************************LoadonRoof:JOINTLOAD*****LoadonSideSheeting:****WindwardsideMEMBERLOAD***leewardside************************************************LOAD6[WL(Z)]************************************************


******LoadonRoof:JOINTLOAD*****LoadonSideSheeting:****WindwardsideMEMBERLOAD***leewardside************************************************FollowingLoadcombinationstobeconsideredinanalysisLOADCOMB101[DL+LL]11.021.0LOADCOMB1020.75[DL+LL+WL(+X)]10.7520.7530.75LOADCOMB1030.75[DL+LL+WL(X)]10.7520.7540.75LOADCOMB1040.75[DL+LL+WL(+Z)]10.7520.7550.75LOADCOMB1050.75[DL+LL+WL(Z)]10.7520.7560.75LOADCOMB106[0.9DL+WL(+X)]10.931.0LOADCOMB107[0.9DL+WL(X)]10.941.0LOADCOMB108[0.9DL+WL(+Z)]10.951.0LOADCOMB109[0.9DL+WL(Z)]10.961.0*************************************************

MathematicalmodelInputrequirements

ThemathematicalmodelpreparedshouldhaveNodalDataMemberconnectivityDataMembersectionalDatabaseofallthedifferenttypesofsections(Standardrolledaswellasbuiltupsections)MembermaterialspecificationsMemberendreleasedataMembertrussinformationSupportspecificationinappropriatecoordinatesystem(shouldconsiderinclinedgalleriesanditsinclinedsupports)LoadingdataasspecifiedaboveDesignParametersfordesignofmembersasperIS800likeEffectivelengthofeachmemberinbothdirectionsfordesignCodeparameterslikeKY,KZ,LY,LZ


DesigndeflectionlimitsDesignallowableyieldstressNeteffectiveallowableinteractionfactorsforwind/seismicaswellasDeadloadcasesAnalysisanddesigncommandsAutomatediterativeprocedureforcarryingoutOptimizationTheOptimizationruntobecarriedoutinside the softwares ( PROKON and STAAD Pro) The programs should choose automatically therequired section from the software database of similar sections and perform the optimizationinteractively togetbestpossibleweight reduction to satisfy the relevant codesofpracticeunderconsiderations.(theOptimizedsectionsizesmaybedifferentforIS800workingstresscodeandtothatof IS800Limitstatedesign foragivenproblem).Themain requirementofdeveloped tool isthatthecompleteoptimization runs tobecarried insidethePROKONandSTAADProwithoutanyuserintervention.TheoutputshouldincludeDesignresultswithinteractionfactorsorreservestrengthavailableforeachmemberTheoptimizedsectionsizesandSteelrequirementtablessectionwiseandplatethicknesswiseifapplicable.*PROKONisregisteredsoftwareofM/s Prokon Software Consultants (Pty) Ltd, South Africa*FEMAPisregisteredpre/postprocessorsoftwareofM/sSiemens*STAADProisregisteredsoftwareofM/sBentleyLtdDesignofvariousothermembers:Designofvariousothermemberswhicharenotthepartofanalyticalmodelneedtodesignedseparately.Suchmembersare:Siderunners,Conveyorsupportingmembers,Sidewalkwaysupportingmember,purlinsandothermembers


AnalysisandDesignChecksandOptimization1)Calculate theseismiccoefficientsand loadingasper IS1893and imposethe loadings inbothhorizontaldirectionsasseparate loadcases inthepreprocessor ifseismic analysis isrequired.2)generatedifferentloadcombinationsasperIS8003)Calculateeffective lengthsofeachofcolumnmembers inbothXandZdirections(Y isverticaldirection)4)Executethejobforalltheloadcases5)CodechecktheresultsasperIS800workingstressandlimitstatedesign6) Optimize or resize /modify the properties as per code check results and rerun andrecheckandrepeatifnecessary7)Calculateapprox.weightofstructurebasedonanalysiswithdetailssuchasweightofmemberspropertywise8)CalculateRawmaterialweightifdifferentfromabove9)DesignBaseplateandnumberandsizeoffixingbolts10)Compute finalweight and also report consolidatedweights asper thicknesses andsizes11)ExportvariousfigurestoAutocadorDXFfiles12)Preparationofcompletereportautomatically13)Thedevelopedtoolalongwithsourcecodetobesubmitted14)InstallationandUsermanualtobepreparedandsubmitted


SoftwaretoolRequirementforGalleriesThe following tools to be developed based on the above logic and instructions forcalculationofloadsforpreparationofmathematicalmodelandforanalysisanddesignwithfinaloptimizedstructure.(GUIbasedDesign)inasinglestokeofinputs.Automated Development tool ( for seamless execution at the push of a button) to bedevelopedfor1)SingleConveyorGalleryStructureoflength12musingPROKON2)SingleConveyorGalleryStructureoflength12musingSTAADPro3)SingleConveyorGalleryStructureoflength18musingPROKON4)SingleConveyorGalleryStructureoflength18musingSTAADPro5)SingleConveyorGalleryStructureoflength24musingPROKON6)SingleConveyorGalleryStructureoflength24musingSTAADPro7)SingleConveyorGalleryStructureoflength30musingPROKON8)SingleConveyorGalleryStructureoflength30musingSTAADPro9)DoubleConveyorGalleryStructureoflength12musingPROKON10)DoubleConveyorGalleryStructureoflength12musingSTAADPro11)DoubleConveyorGalleryStructureoflength18musingPROKON12)DoubleConveyorGalleryStructureoflength18musingSTAADPro13)DoubleConveyorGalleryStructureoflength24musingPROKON14)DoubleConveyorGalleryStructureoflength24musingSTAADPro15)DoubleConveyorGalleryStructureoflength30musingPROKON16)DoubleConveyorGalleryStructureoflength30musingSTAADProAll the above tools should be preparedwith the parameters (like different inclinations,differentloadsonbelt,differentwindloadsetc)asmentionedinthisspecification.Theanalyticalmodeldataistobepreparedinitially(inFEMAPAPIlanguage)shouldbecheckedandapprovedbytheindentingdepartmentbeforeproceedingwiththeprocessofanalyzing and interfacingwith the analytical softwares fordesign and optimizationwithautomation.


Part2SpecificationforTrestles

Similarly the trestles on which the above galleries rest, have to be designed withappropriatesystemconfigurations.TheGalleriesaresupportedmainlyonTWOtypesofTrestlesa)DoubleleggedTrestleandb)FourleggedTrestleTypicalarrangementofthesetrestlesisasshownbelow:

Thespacingwilldependontheconfigurationoflayout,gallerylengthsetc.ThetrestleswidthwillbedifferentforSingleconveyorgalleryandthatforDoubleconveyorgallery.Typicaltwoleggedtrestlesandtheirarrangementisshownbelow:


AsseenfromtheabovetheheightofTrestleanditsconfigurationvariesdependingonthelocationandheights.Typical4leggedTrestlesareasshownbelow:


Thedesignoftrestleisbasedonthefollowingparameters:ForTWOLEGGEDTRESTLEHeightofthetrestle=inm


WidthofbaseOftrestleinm(DifferentforSingleandDoubleConveyorsystem)LoadcomingfromSideLHSandRHSlongGalleriesDeadLoad=LiveLoad=ForLHS Gallerydesignwindpressureconsidered, foragiven height (tobetakenfromGalleryCalculations)andherewindpressuretobeconsidered,alongtheheightoftrestle(differentvaluesfordifferentheights)SimilarlyForRHSGallerydesignwindpressureconsidered,foragiven height (tobetakenfromGalleryCalculations)andherewindpressuretobeconsidered,alongtheheightoftrestle(differentvaluesfordifferentheights)Hence,totalWindLoadtobecomputedHorizontal(max)Horizontal(min)Vertical(max)Vertical(min)Therefore,UDL,windloadtobeconsideredas(Forupto10.0mheight)(For10.0mto15.0mheight)(For15.0mto20.0mheight)(For20.0mto30.0mheight)(For30.0mto40.0mheight)(For40.0mto50.0mheight)And Calculatewind Pressure , Pz (For up to 10.0m height) for Class ? Structure and TerrianCategory?asperIndianDesigncodesPz(For10.0mto15.0mheight)forClass?StructureandTerrianCategory?Pz(For15.0mto20.0mheight)forClass?StructureandTerrianCategory?Pz(For20.0mto30.0mheight)forClass?StructureandTerrianCategory?


Pz(For30.0mto40.0mheight)forClassBStructureandTerrianCategory2Pz(For40.0mto50.0mheight)forClassBStructureandTerrianCategory2max.Min.loadstobecomputedThencheckforrhorizontaldeflectionofTrestlefromtheoutputtobe.

i)DeadLoadandLiveLoadLoadoneachlegcomingfromeachRHSmlongGalleryDeadLoadLiveLoadLoadoneachlegcomingfromeachLHSmlongGalleryDeadLiveLoadoneachlegcomingfromlonggalleryHence,totalWindLoadtobecomputedHorizontal(max)Horizontal(min)Vertical(max)Vertical(min)Therefore,UDL,windloadtobeconsideredas(Forupto10.0mheight)(For10.0mto15.0mheight)(For15.0mto20.0mheight)(For20.0mto30.0mheight)(For30.0mto40.0mheight)(For40.0mto50.0mheight)And Calculatewind Pressure , Pz (For up to 10.0m height) for Class ? Structure and TerrianCategory?asperIndianDesigncodesPz(For10.0mto15.0mheight)forClass?StructureandTerrianCategory?Pz(For15.0mto20.0mheight)forClass?StructureandTerrianCategory?Pz(For20.0mto30.0mheight)forClass?StructureandTerrianCategory?Pz(For30.0mto40.0mheight)forClassBStructureandTerrianCategory2Pz(For40.0mto50.0mheight)forClassBStructureandTerrianCategory2max.Min.loadstobecomputedThencheckforrhorizontaldeflectionofTrestlefromtheoutputtobe.

Calculatethebaseplateandshearkeydetailsaspercodes

DESIGNOFTRESTLESBaseplateVerticalDLUnitintonesandLLalongwithWL(for()Z)tobeconsideredMaximumbearingpressureonconcrete,tobecomputedaspercodeandshouldbelessthanallowablebearingcapacity.Thefoundationboltsaretobedesignedaspertherequirement.ConsideringxnosbolttensionperboltiscomputedDesignofBolt:HeremaximumtensionperboltDesignofShearKey:Here,maximumshearperlegisconsideredConsideringxxxmmwideXxxxmmdeepshearkeywithxxmmthk.andcheckgroutingBMatthebottomfaceofbaseplateanddesigntheshearkeyaccordingly.

SoftwaretoolRequirementforTrestlesThe following tools to be developed based on the above logic and instructions forcalculationofloadsforpreparationofmathematicalmodelandforanalysisanddesignwithfinaloptimized structure.(GUIbasedDesign)As inearlier case the initialmathematicalmodeltobedevelopedandinterfacedinFEMAPAPI.AutomatedDevelopmenttool(forseamlessexecutionatthepushofabutton)for1)2leggedTrestleStructureofHeightsupto25mforSingleConveyorusingPROKON2)2leggedTrestleStructureofHeightsupto25mforSingleConveyorusingSTAADPro3)2leggedTrestleStructureofHeightsabove25mforSingleConveyorusingPROKON


4)2leggedTrestleStructureofHeightsabove25mforSingleConveyorusingSTAADPro5)4leggedTrestleStructureofHeightsupto25mforSingleConveyorusingPROKON6)4leggedTrestleStructureofHeightsupto25mforSingleConveyorusingSTAADPro7)4leggedTrestleStructureofHeightsabove25mforSingleConveyorusingPROKON8)4leggedTrestleStructureofHeightsabove25mforSingleConveyorusingSTAADPro9)2leggedTrestleStructureofHeightsupto25mforDoubleConveyorusingPROKON10)2leggedTrestleStructureofHeightsupto25mforDoubleConveyorusingSTAADPro11)2leggedTrestleStructureofHeightsabove25mforDoubleConveyorusingPROKON12)2leggedTrestleStructureofHeightsabove25mforDoubleConveyorusingSTAADPro13)4leggedTrestleStructureofHeightsupto25mforDoubleConveyorusingPROKON14)4leggedTrestleStructureofHeightsupto25mforDoubleConveyorusingSTAADPro15)4leggedTrestleStructureofHeightsabove25mforDoubleConveyorusingPROKON16)4leggedTrestleStructureofHeightsabove25mforDoubleConveyorusingSTAADProTheanalyticalmodeldataistobepreparedinitially(inFEMAPAPIlanguage)shouldbecheckedandapprovedbytheindentingdepartmentbeforeproceedingwiththeprocessofanalyzing and interfacingwith the analytical softwares fordesign and optimizationwithautomation.


Part3SpecificationforTransferTowersSimilarlythetransfertowersonwhichtheabovegalleriesrest,havetobedesignedwithappropriatesystemconfigurations.TheTransfertowersaresupportedmainlyonTWOtypesoftransferpointsa)Type1BunkerTransferPointStructurefor500MWBoilersandb)Type2BunkerTransferPointStructurefor600MWBoilersThesewillforDoubleconveyorsystemforthepresentTypicalarrangementofthesetrestlesisasshownbelow:

TypicalArrangementofaTransferTower


TypicalCrosssectionsatTopsectionofTransferTowers

TypicalSideviewsofTransferTowersThedesignofTransferTowersisbasedonthefollowingparameters:HeightoftheTower=inmWidthofbaseOfTPinm(forDoubleConveyorsystem)LoadcomingfromSideLHSandRHSlongGalleries


DeadLoadLiveLoadFor Gallerydesignwindpressure considered, foragiven height ( tobe taken fromGalleryCalculations)andherewindpressuretobeconsidered,alongtheheightoftrestle(differentvaluesfordifferentheights)Hence,totalWindLoadtobecomputedalongtheheightofTowerHorizontal(max)Horizontal(min)Vertical(max)Vertical(min)AndCalculatewindPressure,PzforClassxStructureandTerrianCategoryxAndmax.Min.loadstobecomputedThencheckforrhorizontaldeflectionofTPfromtheoutputtobe.

SoftwaretoolRequirementforTransferTowersThe following tools to be developed based on the above logic and instructions forcalculationofloadsforpreparationofmathematicalmodelandforanalysisanddesignwithfinaloptimizedstructure.(GUIbasedDesign)consideringinterferencefreecolumnjoints(1000mm away from floors), chute loads, machinery loads. As in earlier case the initialmathematicalmodeltobedevelopedandinterfacedinFEMAPAPI.AlsodesignhastobequalifiedandcheckedfornaturalfrequencyofthesystemAutomatedDevelopmenttool(forseamlessexecutionatthepushofabutton)for1)Type1BunkerTPStructurefor500MWBoilerDoubleConveyorusingPROKON2))Type1BunkerTPStructurefor500MWBoilerDoubleConveyorusingSTAADPro3))Type2BunkerTPStructurefor600MWBoilerDoubleConveyorusingPROKON4)Type2BunkerTPStructurefor600MWBoilerDoubleConveyorusingSTAADProTheanalyticalmodeldata istobeprepared initially( inFEMAPAPI language) shouldbecheckedandapprovedbytheindentingdepartmentbeforeproceedingwiththeprocessofanalyzing and interfacingwith the analytical softwares fordesign and optimizationwithautomation.CombinedPrograms:Finally2softwaretoolsaretobedevelopedoneachforPROKONandSTAADProcombiningtherequirednumberofgalleriesand trestlesasasingle file forexecutionconsidering theloadsfromgalleries,windloadsandseismicloadsetc.Tool1Combine4 to6gallerieswith trestlesand transfer towers. if requiredasper theplantlayoutrequirementusingPROKONSoftwareTool2Combine4 to6gallerieswith trestlesand transfer towers. if requiredasper theplantlayoutrequirementusingSTAADProSoftware


General:Alltheabovetoolsshouldbepreparedwiththeparameters(likedifferentheights,differentloadsduetowind,differentgalleryloadsetc)asmentionedinthisspecification.Therewillatotalof38differenttools(16forGalleries,16forTrestlesand4forTransferTowers)Plus 2programs for combinedentriesof galleriesand trestles forPROKON andSTAADPro.Theanalyticalmodeldataistobepreparedinitially(inFEMAPAPI)andshouldbecheckedandapprovedbytheindentingdepartmentbeforeproceedingwiththeprocessofanalyzingandinterfacingwiththeanalyticalsoftwaresfordesignandoptimizationwithautomation.FinallyacommonGUIistobepreparedtochooseappropriatetypeofstructureeitherforagalleryorfortrestle,thenchoose forsingleordoubleconveyorsystembeforeproceedingfurtherforchoosinglengthofgalleryorheightoftrestleasthecasemaybe.Theprojectdatalikeloads,inclinationsetcshouldthenbechoseninasteppedmannerforcreatingthemathematicalmodel.Theanalysishas tobecarriedout,designandoptimizationbedoneseamlesslyandautomaticallywithoutuser interventionby interfacingthecodedevelopedwiththeanalysisprogramsasgivenabove.The output will be optimum design of the structure with relevant sectional data andrequireddrawingsinAutoCADDXFfileformatsandwithautomaticgenerationofrequiredreport.


DeliveryScheme:Thedeliveryofthedevelopedtoolsmustbemadeinapropersteppeddelivery(deliveryinparts)forimmediateimplementationoftheprogramsatBHELfortheiruseStage1:

a) PreliminaryGUIforinputdata:

The typical GUI screens consist of different parameter to be input for propermathematicalmodelingandanalysisrequirementsTypical Forms required ( not limited to those shown as an example here) are asshownbelow:

The above form should have links to show basic wind speed map and values ofvariousIndianCitiesasperIS875codeandalsoshowtheseismiczonesIndianmapandzonefactorsforvariouscitiesinIndiaasperIS1893codeofIndiaThe First form should also include option for designing Trestles or Galleries orTransfertowers(Onlyfirsttwoareshownaboveasanexample)

Nextformwilldependonthechosenstructure,itcanbeforgalleriesorforTrestlesorTransfertowersA typical input data forms are shown below forGalleries ( please note that thevariablesshowninthefiguresaretentativeandwilldependontheactualproblem,theymemorevariablesorlessthanshownbelow)


Theaboveformatshowsonlyfor12m18mand24mgalleries,theoptiontodesign30m gallery as per earlier specification also has to be included and also modelgenerationinFEMAPalsotobeincluded.Theremaybeotherparametersneedtobeincludedduringthecourseofinteraction.

TheaboveshowsatypicalinputsheetandTheremaybeotherparametersneedtobeincludedasperrequirementofloadcalculationsandmodelpreparation.Similarlydifferent forms for Trestles and Transfer Towersneed to beprepared taking intoconsiderations all the possible input data as required for correct mathematicalmodelingandpreparationofdesigndatainputfiles.

Therewillcertainnumberofinputsasdefaultvaluesandtheusershouldbeabletomodifythesevalueswithpropercheckbuttoncontrols.Controlsarealsorequiredtomovebackandforththeforms.


Stage1b)ThemathematicalmodelShouldconsistof(butnotlimitedtothefollowing)i)nodalCoordinatesii)memberconnectivity,iii)preparationofdatabaseofallthesectionsasperIndianCodes,iv)identificationoftrusselementsandmemberendreleasecodes,v)supportandmaterialspecifications,vi)materialspecificationsvii)identificationofmemberswithpropersectionwithsectionaldatabasetables.Stage22i)calculationofeffectivelengthsofvariousmembersaspertheirendconnections,2ii)DeadLoadcalculations2iii)Liveloadcalculations,2iv)WindloadcalculationsasperIS875code2v)Seismicloadgeneration,ifrequiredasperIS18932vi)Allotherloadsandrelevantloadcombinationsaspercodalrequirements(IS800)2vii)GenerationofvariousparametersrequiredforIS800codecheck2viii)ImpositionofloadsinthemodelandcreationofdifferentloadsandtheircombinationsasrequiredbyIndianDesigncodesofpractice.Stage22ix)Automaticcreationofinputfilesasrequiredfordifferentsoftwaresmentionedabove2x)AutomaticexecutionofanalyticalmodelandtabulatingtherequiredforcesandmomentsrequiredforcodecheckingasperIS8002xi)FindingoutthereservestrengthandcarryouttheoptimizationautomaticallywithintheGUIpreparedwithoutanyuserinterventionwiththeavailabledatabaseofsectionalsizesasspecifiedbyBHEL2xii)PreparationoffinalOptimizedinputfilesandrunningautomaticallyandtabulatingtheresultsofcodechecks2xiii)Calculationofbillofmaterialandrawmaterialrequirements2xiv)PreparationofdesignreportautomaticallywithallthetablesofinputaswellasoutputresultsandcodecheckresultswithBOM2xv)PreparationofdxffilesofmodelforuseinAutoCAD


DeliveryscheduleDeliveryPart1)FirstPhasetobecompletedwithin12weeksafterplacementofPurchaseorderconsistsofOfstage1criteriaabovepartaandinpart(b)upto(i)to(vii)thedetailsofmathematicalmodelandtoolforgeneratingthemodelinFEMAPforthefollowinga)4typesofSingleconveyorgalleriesfor12m,18m,24mand30mlengthgalleries(4GUIprogramsforinFEMAP)b)4typesofDoubleconveyorgalleriesfor12m,18m,24mand30mlengthgalleries(4GUIprogramsforinFEMAP)DeliveryPart2)Similartoolsfor2typesof2leggedtrestlesforSingleConveyorsystem(2GUIPrograms)2typesof2leggedtrestlesforDoubleConveyorsystem(2GUIPrograms)2typesof4leggedtrestlesforSingleConveyorsystem(2GUIPrograms)2typesof4leggedtrestlesforDoubleConveyorsystem(2GUIPrograms)DeliveryPart1andPart2asabovetobesubmittedinFEMAPAPIformattoolwithin16weeksafteraboveperiodDeliveryPart3)Preparationofotherdatasuchaseffectivelengthcalculations,loadcalculationsasperStage2itoStage2ViiiandpreparationofinputfilesinPROKONandintegratingwithPROKONsoftwarewithin12weeksafterdeliveryofabovewithvalidation(fromBHEL)forGalleries,within8weeksforTrestlesandwithin16weeksforTransfertowersincludingtherequiredGUIProgramsDeliveryPart4)PreparationofinputfileandintegratingwithotherstandardsoftwareslikeSTAADPro,DesigncheckswithPROKONandSTAADPro,AutomaticrunsforgenerationofOptimizedstructures(2ixto2xiii),Validationofallfilesofgalleries,trestlesandTransfertowersetctobedeliveredwithin12weeksafterpart3aboveDeliveryPart5)DeliveryoffinalpartConsistingofoneFinalGUI(OneeachforPROKONandSTAADPro)incorporatingalltheaboverequiredmodulesandsubmissionofUsermanuals,detailsofsoftwarecodes,listoffilesgeneratedasrequiredinthespecificationsetctobesubmittedwithin12weeksafterPart4delivery.ThisshouldincludetheFinalGUIforcombinedStructuralSystemofGalleries,trestlesandTransferTowersasperlayoutforPROKONandSTAADProTheabovedeliveryperiodsaretobeadheredstrictlyinordertocompletetheProjectintime.Note:ThedeveloperhastoenterintoNDAwithBHELbeforetakingupthisworkandtheInformationcontainedinTenderDocumentsisconfidentialandshouldnotbeusedforanyotherpurposeotherthanforquoting/executingforthisenvisagedwork.

EndofTenderSpecification


2010-10-11T09:28:31+0530PML Prasad