project report FOPH

LOAD CALCULATION, ANALYSIS AND DESIGN OF

CONTROL ROOM FOR FUEL OIL PUMP HOUSE

4X1000MW PUDIMADAKA (STAGE-I)

SUPER THERMAL POWER PLANT

PROJECT REPORT

SUBMITTED BY:- SHRADDHA VERMA

III YEAR CIVIL

MGMCOET NOIDA

UNDER GUIDANCE OF:- MR. SUSHIL KUMAR MAHATO

(CIVIL) BHEL PEM

1

ACKNOWLEDGEMENT

I wish to express my gratitude to Mr. Sushil Kumar Mahato who as my mentor has

always been a source of inspiration and knowledge. Their suggestions and constructive

criticism helped me a lot in giving proper direction to my training and making me

familiar with the working culture of the organization. His methods really brought the best

out of me through hard work, dedication and research.

I also wish to express my deep gratitude to Ms. Paulomi Mitra who provided me valuable

information and knowledge. Her guidance helped me a lot to develop skills and complete

my project.

I also wish to thanks our department head Mr. AN Singh who gave me such a wonderful

opportunity to extend my knowledge and experience.

I am also thankful to all civil engineers and HR personnel of BHEL (PS-PEM) for their

help during my training

PS-PEM SHRADDHA VERMA

NOIDA (TRAINEE)

2

ABSTRACT

For completing this project I had to go through various IS codes in depth especially IS

875 part 3 (wind load). I learned how to calculate and apply wind load and how it affects

the structure. I learned the usage of STAAD for load calculations, static and dynamic

analysis, design and foundation loading of trestle for Fuel oil Pump House 4X1000MW

Pundimadaka (stage-I) specification given by NTPC. I further verified the results of

STAAD output for various loads with hand calculations.

Dead load and live load were applied as per the specification from NTPC and input

drawing of control room.

In wind load, both dynamic and static wind loads in both the directions were calculated.

In dynamic wind load, both gust and 3 sec wind load were calculated and the governing

of two was selected as wind load in the form of UDL on columns. Wind load at roof and

drag wind load were also calculated.

Documentation on how to calculate wind load step by step with description of each

terminology is done.

Overall this training compelled me to go deep into the topics, which was very

professional to gain knowledge and experience. This training made me conversant with

the working culture and directed me how to achieve goals within stipulated time.

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TABLE OF CONTENT

S.NO TOPIC PAGE NO.

1. INTRODUCTION OF THE COMPANY 6

2. GENERAL 11

3. UNITS AND MEASUREMENT 11

4. DESCRIPTION OF THE STRUCTURE 12

5. PRIMARY LOAD CASES 15

6. LOAD COMBINATIONS 27

7. ANALYSIS AND DESIGN 29

8. COMPARISON BETWEEN STAAD

VALUES & HAND CALCULATIONS

30

9. REFERENCES 32

4

LIST OF FIGURES

Fig Description PageFig.a Whole structure 12Fig.b Nodes 13Fig.c Beams 13Fig.d 3D view of the building 14Fig.e Self weight of the building 16Fig.f Floor load 17Fig.g Wind load in +X direction UNI GX 2.44N/mm 18Fig.h BEAM NO.22 30Fig.i COLUMN NO.11 31

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1.INTRODUCTION OF THE COMPANY

BHARAT HEAVY ELECTRICALS LIMITED

Embarking upon the 50th Golden Year of its journey of engineering excellence, BHEL is an integrated power plant equipment manufacturer and one of the largest engineering and manufacturing company of its kind in India engaged in the design, engineering, manufacture, construction, testing, commissioning and servicing of a wide range of products and services for the core sectors of the economy, viz. Power, Transmission, Industry, Transportation (Railway), Renewable Energy, Oil & Gas and Defence with over 180 products offerings to meet the needs of these sectors. Establishment of BHEL in 1964 was a breakthrough for upsurge in India's Heavy Electrical Equipment industry. Consistent performance in a highly competitive environment enabled BHEL attain the coveted 'Maharatna' status in 2013.

1.1.BACKGROUND OF THE COMPANY:

BHEL as a part of Pt. Jawaharlal Nehru's vision was bestowed with the onus to make the country self reliant in manufacturing of heavy electrical equipment. This dream has been more than realised and the contribution in nation building endeavour is going to continue likewise. Today, with 20,000 MW per annum capacity for power plant equipment manufacturing, BHEL's mammoth size of operations is evident from its widespread network of 17 Manufacturing Units, two Repair Units, four Regional Offices, eight Service Centres, eight Overseas Offices, six Joint Ventures, fifteen Regional Marketing Centres and current project execution at more than 150 project sites across India and abroad. The total installed capacity base of BHEL supplied equipment -138 GW in India speaks volumes about the contribution made by BHEL to Indian power sector. BHEL's 57% share in India's total installed capacity and 65% share in the country's total generation from thermal utility sets (coal based) as of March 31, 2014 stand testimony to

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this. The company has been earning profits continuously since 1971-72 and paying dividends since 1976-77 which is a reflection of company's commendable performance throughout.

BHEL also has a widespread overseas footprint in 76 countries with cumulative overseas installed capacity of BHEL manufactured power plants nearing 10,000 MW including Malaysia, Oman, Libya, Iraq, the UAE, Bhutan, Egypt and New Zealand.

The high level of quality & reliability of BHEL products and systems is an outcome of strict adherence to international standards through acquiring and adapting some of the best technologies from leading OEM companies in the world together with technologies developed in our own R&D centres. Most of our manufacturing units and other entities have been accredited to Quality Management Systems (ISO9001:2008), Environmental Management Systems (ISO14001:2004) and Occupational Health & Safety Management Systems (OHSAS18001:2007).

Our greatest strength is our highly skilled and committed workforce of 47,525 employees. Every employee is given an equal opportunity to develop himself/herself and grow in his/her career. Continuous training and retraining, career planning, a positive work culture and participative style of management - all these have engendered development of a committed and motivated workforce setting new benchmarks in terms of productivity, quality and responsiveness.

1.3.PRODUCT S

POWERAir PreheatersBoilersControl Relay Panels Electrostatic PrecipitatorsFabric FiltersGas TurbinesHydro Power Plant

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Piping SystemsPulverizersPumpsSeamless Steel Tubes Soot blowersSteam Generators Steam TurbinesTurbogeneratorsValves

INDUSTRYCapacitorsCeralinCompressorsDesalination PlantsDiesel Generating SetsIndustrial Motors & AlternatorsGas TurbinesOil Field EquipmentSolar PhotovoltaicsPower Semiconductor DevicesSeamless Steel TubesSootblowersSteel Castings & ForgingsSteam GeneratorsSteam TurbinesTurbogeneratorsValves

TRANSMISSIONPower Transformers/Reactors

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Instrument TransformersSwitchgearsControl & Protection EquipmentsThyristor equipmentsInsulatorsBushingCapacitors

TRANSPORTATIONElectric Rolling Stock Electrics for Rolling Stock Electrics for Urban Transportation SystemNon Conventional Energy SourceMini/Micro Hydro SetsSolar LanternsSolar PhotovoltaicsSolar Water Heating SystemsWind Electric Generators

R&D PRODUCTSFuel CellsSurface CoatingsAutomated storage & RetrivalsLoad Sensors Transparent Conducting Oxide

1.4.SYSTEMS AND SERVICES

POWER GENERATION SYSTEMSTurnkey power stationsCombined-cycle power plantsCogeneration systems

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Modernisation and rehabilitation of power stationsErection commissioning, operation and maintenance servicesSpares managementConsultancy services

TRANSMISSION SYSTEMSEHV & UHV Substations/switchyardsHVDC transmission systemsFlexible AC Transmission Systems(FACTS) & smartgrid solutionsPower System StudiesTesting facilities

TRANSPORTATION SYSTEMSTraction systemsUrban transportation systemsErection commissioning, operation and maintenance servicesConsultancy services

INDUSTRIAL SERVICESIndustrial drives and control systemsErection commissioning, operation and maintenance services Spares managementConsultancy services

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2.GENERAL

This document covers the load establishment and analysis of control room building of

Fuel Oil Pump House 4X1000MW Pudimadaka (stage-I) Super Thermal Power Plant.

2.1.SCOPE

This document contains the following

Structural framing. .

Method of analysis and design basis

Load cases considered

Load establishment calculations for 3-Dimensional analysis of the Building

Load combinations considered

Analysis and Design

3.UNITS OF MEASUREMENT

Units of Measurement in design shall be SI/Metric systems.

11

4.DESCRIPTION OF THE STRUCTURE

FOPH Control Room is a RCC structure of plan dimension 23X6m and height of the

building is 4.5m. It is a single storey building housing the control panels.

12

Fig.a

4.1.NODES

13

29

27

9

30

19

25

7

28

10

17

23

5

20

26

8

15

21

3

18

24

6

13

1

16

22

4

11

14

2

12

Load 1

XY

Z

Fig.b

4.2.BEAMS

39

19

37

510

40

25

17

35

4

26

20

38

9

24

15

33

3

4330

18

36

8

23

13

31

2

4229

16

34

7

22

11

41

1

28

14

32

6

2127

12

Load 1

XY

Z

Fig.c

14

4.3.ANALYSIS METHADOLOGY

3-D modelling of th FOPH Control Room has been done in Staadpro, analysis of the

structure as well as design has been done for the load cases & the load combinations

given below.

Design of beams and columns has been done based on the values of the design forces

obtained from staad

4.4.ISOMETRIC VIEW OF THE BUILDING

Fig.d

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5.PRIMARY LOAD CASES

SL. LOAD CASE

1 Self-weight of Members modelled in STAAD DL

2 Live Load LL

3 Wind Load in positive X-Dir (pressure) WLX1

4 Wind Load in positive X-Dir (suction) WLX2

5 Wind Load in negative X-Dir (pressure) WLX3

6 Wind Load in negative X-Dir (suction) WLX4

7 Wind Load in positive Z-Dir (pressure) WLZ1

8 Wind Load in positive Z-Dir (suction) WLZ2

9 Wind Load in negative Z-Dir (pressure) WLZ3

10 Wind Load in negative Z-Dir (suction) WLZ4

16

5.1.LOAD CASE 1:-

Self weight: This includes self-weight of all the structural elements like columns,

main beams and longitudinal beams.

Wall load: Assigned at plinth level due to corresponding wall height.

Wall load =0.23X(brick density=18KN/m3)X(height of the wall=4.5m

=18.63N

Parapet load:

Parapet load=0.125X(density of RCC=25KN/m3)X0.9

=2.8125N

Moment=0.150X25X0.65X0.65/2

=792.1N-mm

Roof load =5 KN/m2

Floor slab load=5 KN/m2

Load 1 (SELF Y)

XY

Z

Fig.e

17

5.2.LOAD CASE 2:-

Live load=1.5KN/m2

Load 2

XY

Z

Fig.f

5.3. WIND LOAD (LOAD CASE 3 TO 10 ):-

18

The basic wind speed=50m/s

Risk coefficient K1=1.2

Length of the building= 23m

Breadth of the building=6m

Height of the building=4.5m

Load 3

XY

Z

Fig.g

5.3.1.WIND LOAD IN +X DIRECTION

19

External pressure coffecient on Face Cpe

A B C D

0.70 -0.30 -0.70 -0.70

Net pressure coffecients on Face (Internal

pressure)

A B C D

0.20 -0.80 -1.20 -1.20


suction)

A B C D

1.20 0.20 -0.20 -0.20

5.3.1.1.LOAD 3 WLX1 (PRESSURE)

S.No Member Number

Cont.

width

(m)

Dir. CpLoad

(kN/m)Grid

FACE A

1 11 12 6.00 GX 0.20 2.44 Grid 1

FACE B

1 19 20 6.00 GX 0.80 9.76 Grid 6

FACE C

1 11 19 2.88 GZ -1.20 -7.01 Grid C

2 13 15 17 5.75 GZ -1.20 -14.02 Grid C

FACE D

1 12 20 2.75 GZ 1.20 6.71 Grid A

2 14 16 18 5.75 GZ 1.20 14.02 Grid A

20

5.3.1.2.LOAD 4 WLX2 (SUCTION)

S.No Member Number

Cont.

width

(m)

Dir. CpLoad

(kN/m)Grid

FACE A

1 11 12 6.00 GX 1.20 14.63 Grid 1

FACE B

1 19 20 6.00 GX -0.20 -2.44 Grid 5

FACE C

1 11 19 2.88 GZ -0.20 -1.17 Grid D

2 13 15 17 5.75 GZ -0.20 -2.34 Grid D

FACE D

1 12 20 2.88 GZ 0.20 1.17 Grid A

2 14 16 18 5.75 GZ 0.20 2.34 Grid A

5.3.2.WIND LOAD IN -X DIRECTION :

21


A B C D

-0.30 0.70 -0.70 -0.70


pressure)

A B C D

-0.80 0.20 -1.20 -1.20


suction)

A B C D

0.20 1.20 -0.20 -0.20

5.3.2.1.LOAD 5 WLX3 (PRESSURE)

S.No Member Number

Cont.

width

(m)

Dir. CpLoad

(kN/m)Grid

FACE A

1 11 12 6.00 GX -0.80 -9.76 Grid 1

FACE B

1 19 20 6.00 GX -0.20 -2.44 Grid 7

FACE C

1 11 19 2.88 GZ -1.20 -7.01 Grid D

2 13 15 17 5.75 GZ -1.20 -14.02 Grid D

FACE D

1 12 20 2.88 GZ 1.20 7.01 Grid A

2 14 16 18 5.75 GZ 1.20 14.02 Grid A

5.3.2.2.LOAD 6 WLX4 (SUCTION)

22

S.No Member Number

Cont.

width

(m)

Dir. CpLoad

(kN/m)Grid

FACE A

1 11 12 6.00 GX 0.20 2.44 Grid 1

FACE B

1 19 20 6.00 GX -1.20 -14.63 Grid 7

FACE C

1 11 19 2.88 GZ -0.20 -1.17 Grid D

2 13 15 17 5.75 GZ -0.20 -2.34 Grid D

FACE D

1 12 20 2.88 GZ 0.20 1.17 Grid A

2 14 16 18 5.75 GZ 0.20 2.34 Grid A

5.3.3.WIND LOAD IN +Z DIRECTION :

23

External

pressure

coffecient on

Face Cpe

A B C D

-0.50 -0.50 0.70 -0.10

Net pressure

coffecients

on Face

(Internal

pressure)

A B C D

-1.00 -1.00 0.20 -0.60

Net pressure

coffecients

on Face

(Internal

suction)

A B C D

0.00 0.00 1.20 0.40

5.3.3.1.LOAD 7 WLZ1 (PRESSURE)

24

S.No Member Number

Cont.

width

(m)

Dir. CpLoad

(kN/m)Grid

FACE A

1 11 12 6.00 GX -1.00 -12.19 Grid 1

FACE B

1 19 20 6.00 GX 1.00 12.19 Grid 7

FACE C

1 11 12 2.88 GZ 0.20 1.17 Grid D

2 13 15 17 5.75 GZ 0.20 2.34 Grid D

FACE D

1 12 20 2.88 GZ 0.60 3.51 Grid A

2 14 16 18 5.75 GZ 0.60 7.01 Grid A

5.3.3.2.LOAD 8 WLZ2 (SUCTION)

S.No Member Number

Cont.

width

(m)

Dir. CpLoad

(kN/m)Grid

FACE A

1 11 12 6.00 GX 0.00 0.00 Grid 1

FACE B

1 19 20 6.00 GX 0.00 0.00 Grid 7

FACE C

1 11 19 2.50 GZ 1.20 6.10 Grid D

2 13 15 17 5.75 GZ 1.20 14.02 Grid D

FACE D

1 12 20 2.88 GZ -0.40 -2.34 Grid A

2 14 16 18 5.75 GZ -0.40 -4.67 Grid A

5.3.4.WIND LOAD IN -Z DIRECTION :

25


A B C D

-0.50 -0.50 -0.10 0.70


pressure)

A B C D

-1.00 -1.00 -0.60 0.20


suction)

A B C D

0.00 0.00 0.40 1.20

5.3.4.1.LOAD 9 WLZ3 (PRESSURE)

S.No Member Number

Cont.

width

(m)

Dir. CpLoad

(kN/m)Grid

FACE A

1 11 12 6.00 GX -1.00 -12.19 Grid 1

FACE B

1 19 20 6.00 GX 1.00 12.19 Grid 7

FACE C

1 11 19 2.88 GZ -0.60 -3.51 Grid D

2 13 15 17 5.75 GZ -0.60 -7.01 Grid D

FACE D

1 12 20 2.88 GZ -0.20 -1.17 Grid A

2 14 16 18 5.75 GZ -0.20 -2.34 Grid A

5.3.4.2.LOAD 10 WLZ4 (SUCTION)

26

S.No Member Number

Cont.

width

(m)

Dir. CpLoad

(kN/m)Grid

FACE A

1 11 12 6.00 GX 0.00 0.00 Grid 1

FACE B

1 19 20 6.00 GX 0.00 0.00 Grid 7

FACE C

1 11 19 2.88 GZ 0.40 2.34 Grid D

2 13 15 17 5.75 GZ 0.40 4.67 Grid D

FACE D

1 12 20 2.88 GZ -1.20 -7.01 Grid A

2 14 16 18 5.75 GZ -1.20 -14.02 Grid A

6.LOAD COMBINATIONS:

27

LOAD COMB 101 DL+LL

1 1.5 2 1.5

LOAD COMB 102 DL+LL+WLX1

1 1.2 2 1.2 3 1.2


1 1.2 2 1.2 4 1.2


1 1.2 2 1.2 5 1.2


1 1.2 2 1.2 6 1.2

LOAD COMB 106 DL+LL+WLZ1

1 1.2 2 1.2 7 1.2


1 1.2 2 1.2 8 1.2


1 1.2 2 1.2 9 1.2


1 1.2 2 1.2 10 1.2

LOAD COMB 110 DL+WLX1

1 1.5 3 1.5


1 1.5 4 1.5


1 1.5 5 1.5


1 1.5 6 1.5

LOAD COMB 114 DL+WLZ1

1 1.5 7 1.5


1 1.5 8 1.5

28


1 1.5 9 1.5


1 1.5 10 1.5


1 0.9 3 1.5


1 0.9 4 1.5

LOAD COMB 120 LL+WLX3

1 0.9 5 1.5

LOAD COMB 121 LL+WLX4

1 0.9 6 1.5

LOAD COMB 122 LL+WLZ1

1 0.9 7 1.5


1 0.9 8 1.5


1 0.9 9 1.5


1 0.9 10 1.5

7.ANALYSIS AND DESIGN

29

PERFORM ANALYSIS PRINT STATICS CHECK

*************************

START CONCRETE DESIGN

CODE INDIAN

UNIT MMS NEWTON

FC 30 ALL

FYMAIN 500 ALL

FYSEC 500 ALL

TORSION 0 ALL

TRACK 2 ALL

**************

BRACE 3 MEMB 11

CLEAR 40 MEMB 11

RFACE 4 MEMB 11

***********

ELY 1.2 MEMB 11

ELZ 1.2 MEMB 11

**************

DESIGN COLUMN 11 TO 20 31 TO 40

DESIGN BEAM 1 TO 10 21 TO 30 41 TO 43

*******************

END CONCRETE DESIGN

FINISH

8.COMPARISON BETWEEN STAAD VALUES AND HAND

CALCULATIONS

30

For beam 22.

39

19

37

510

40

25

17

35

4

26

20

38

9

24

15

33

3

4330

18

36

8

23

13

31

2

4229

16

34

7

22

11

41

1

28

14

32

6

2127

12

Load 1X

Y

Z

Fig.h

D=0.449m

B=0.349m

L=5.75m

Fy=500

Fck=30

Design load

Mz=45.45KN-m at mid span

According to staad we need to provide 4 bars of 10mm dia at 30mm spacing.

Verifying the result for the same by hand calculations

We know Ast=0.5× fckfy× ¿

d= D−clear cover−(dia of bar)/2

d=450−5−10/2

d=395mm

therefore, Ast=0.5× 30500

× ¿

Ast=290.32mm2

Area of one steel bar of diameter 10mm ,Asb ¿ π ( 104

)2

31

=78.53mm2

No. of bars required = AstAsb

=290.3278.53

=3.69

= 4 bars

Result is same

Hence verified!

For column 11:

39

19

37

510

40

25

17

35

4

26

20

38

9

24

15

33

3

4330

18

36

8

23

13

31

2

4229

16

34

7

22

11

41

1

28

14

32

6

2127

12

Load 1

XY

Z

Fig.i

According to staad:

Pu=3.14

Fy=500

Fck=30

B=0.50m

D=0.70m

Verifying the result with hand calculations:

We know

32

Pu=0.4×Fck×(Ag−0.01Ag)+0.67×Fy×(0.01Ag)

From the above eqn we get Ag=206172.02mm2

Since the column cross section is rectangular i.e. Ag = B×D

&D =2B

So, Ag =2B2

B=√ Ag2 We get B =321.07mm =0.32m

And D =642.14mm =0.64m

Which is less than the provided values

Thus the design of column is safe

Hence verified!

The Diameter of the Ties shall not be lesser than the Greatest of the following two

values

1. 5mm

2. 1/4th of the Diameter of the Largest Diameter Bar

The Spacing of Ties shall not exceed the least of the followings three values

1. Least Lateral Dimension

2. 16 Times of the Diameter of the Smallest Diameter Longitudinal Bar

3. 48 Times of the Diameter of Ties

33

9.REFERENCES

The following codes, standards and drawings have been referred

Codes and standards

IS:875(1987) part 1 Dead loads

IS:875(1987) part 2 Imposed loads

IS:875(1987) part 3 Wind loads

IS:875(1987) part 5 Load combinations

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Documents

project report FOPH