SÒPHIA HIGH TECH Experience on Special Doors compressed
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Pag. 1 In this document are described the experienced gained by SÒPHIA HIGH TECH in the development of special doors. 1 Nuclear Bunker doors for Extreme Light Infrastructure - Nuclear Physics (ELI-NP) Customer: STRABAG (Romania Plant); Object: SÒPHIA HIGH TECH designed, developed, manufactured and installed eleven (N°11) motorized bunker doors in the Extreme Light Infrastructure - Nuclear Physics (ELI-NP), Situated in Magurele, 12 km away from downtown Bucharest. Figure 1 ELI-NP in Magurele ELI-NP project [ http://www.eli-np.ro/ ], financed by the European Commission for Research, Innovation and Science, started in 2008. The job activity for SÒPHIA HIGH TECH involved the design and the manufacturing and installation management of eleven (N°11) automated bunker doors. the bunker doors differ in 3 different types Object SÒPHIA HIGH TECH Experience on Special Doors
SÒPHIA HIGH TECH Experience on Special Doors compressed
SÒPHIA HIGH TECH Experience on Special Doors_compressed.pdfPag.
1
In this document are described the experienced gained by SÒPHIA
HIGH TECH in the development of special doors.
1 Nuclear Bunker doors for Extreme Light Infrastructure - Nuclear
Physics (ELI-NP) Customer: STRABAG (Romania Plant); Object: SÒPHIA
HIGH TECH designed, developed, manufactured and installed eleven
(N°11) motorized bunker doors in the Extreme Light Infrastructure -
Nuclear Physics (ELI-NP), Situated in Magurele, 12 km away from
downtown Bucharest.
Figure 1 ELI-NP in Magurele
ELI-NP project [ http://www.eli-np.ro/ ], financed by the European
Commission for Research, Innovation and Science, started in 2008.
The job activity for SÒPHIA HIGH TECH involved the design and the
manufacturing and installation management of eleven (N°11)
automated bunker doors. the bunker doors differ in 3 different
types
Object SÒPHIA HIGH TECH Experience on Special Doors
Pag. 2
1. DGR1 consists of a door of dimensions 3000 mm x 2550 mm x 2790
mm made of cement reinforced with metal reinforcement. The door has
a single degree of freedom, represented by the translation along an
axis. The assembly can be viewed below.
Figure 2 DGR1 door - rendering
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2. DGR4 consists of a door of dimensions 4550 mm x 2000 mm x 2925
mm made of cement reinforced with
metal reinforcement. The door has a single degree of freedom,
represented by the translation along an axis. The assembly can be
viewed below.
Figure 6 DGR4 door - rendering
on this link [ https://www.youtube.com/watch?v=cTRtH2yCRKI ] is
possible appreciate the manufacturing and assembly phase carried
out by SÒPHIA GH TECH for DGR4 door
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3. DGR7 consists of a door of dimensions 6000 mm x 4500 mm x 2050
mm made of cement reinforced with
metal reinforcement. The door has a single degree of freedom,
represented by the rotation around an axis. The assembly can be
viewed below.
Figure 9 DGR7 door - rendering
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Figure 11 DGR7 door installation (2)
Main tasks of the DGR 1/ DGR 4/ DGR 7 projects are: 1. Management:
creation of the master planning of the supply. 2. Design of the
doors, this phase has concerned the following activities: a. Design
and Sizing of the structures; b. Static analysis and verification
of the welds and Doors Frame through Finite Element Method (FEM);
c. Design, Sizing and Verification of the kinematic mechanism for
the opening/closing operations.
d. Creation of the executive drawing and BOM; e. Draw up and issue
pertinent the Use And Maintenance Manual.
3. Manage of: a. Manufacturing; b. Material Supply; c. Shipping of
the products;
d. Installation.
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The Project Manager defined each activity timeframe, the
deliverables and the work packages at the start of the job. The
design phase took into account the requests of the client and the
requirements. After a first attempt design a numerical (using FE
methods) validation ensured the static and dynamic integrity of the
structure when subjected to the working loads. After FEM review the
Design was updated and then validated again. This interactive phase
continued until a structural optimised design had been reached. The
next phase was the creation of the drawing and the BOM, these were
needed to manufacture the parts, guide the installation procedures
and manage the material supply. During all the phases of the
project, SÒPHIA HIGH TECH managed all the process involved in the
supply. Our supervisor came in Romania to ensure that the delivery
and installation operations had been made according in the best
practice and Customer requirements. We ensure, through our
technical knowledge, an effective approach to the design of a
Custom Security Door. This Technical Report will describe the
process and the main activities for design, manufacturing and
installation of anti-burglar door. The " Nuclear Physics Center of
Magurele" experience gave us the right know how and confidence at
our best the Z
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2 CLASS 5 Anti-Burglar & Antimissile Door (USACE - US Army
Corps of Engineers) Customer: STRABAG US Army (Romania Plant);
Object: Design, development, manufacturing, assemby, validation,
insallation and qualification of 5.7 CLASS 5 Anti-Θ&h-
Romania). VIDEO:
https://www.youtube.com/watch?v=N_kriRVVXYg&t=4s
Figure 12 : CLASS 5 Anti-Burglar & Antimissile Door
The design process took place considering the technical
requirements of the customer and according to the standard rules of
structural design for the US defense: 1. DOD Manual 6055.09-M
[Ammunition and Explosives Safety Standards] 2. NATO AASTP-1
[Safety principles for the storage of military admissions and
explosives] 3. ASTM F 2927 - 12 [Door Systems Subject to Airblast
Loadings] 4. ASTM F2247 [Metal Doors Used in Blast Resistant
Applications (Equivalent Static Load) Method] 5. UFC 4-010-01 01
[Structures to resist the effects of accidental explosions] 6. CEI
EN 60204-1: 2006 [Safety and Prevention] The characteristics of the
anti-missile door are: 1. 6500 mm (length) x 4500 mm (width) x 200
mm (thickness); 2. Weight of the door: 6 tons; 3. Blasting
resistance for 7 bar; 4. Material: galvanized steel, checked
against impact and shock load; 5. Smart Lock of the NSN type
5340-01-585-7691.
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6. Door Type: Double Leafs, rotational 7. Moving: completely
manually; 8. Weight of the door: 13.5 tonn; 9. Opening Rate: 5
times/day; 10. Warranty: 5 years; 11. Operating temperature: -40°C
to +60 °C; Following the WP (Work Package), carried out: WP1 |
Management, In this phase will be prepared the master planning of
supply. SLPHIA prepares and keep updated the master planning of
supply. After the KoM (Kick off Meeting), the planning is processed
with the Contractor to allow a full control of supply WPs.
Furtherly, the master planning is monthly reviewed by the Project
Manager of SLPHIA HIGH TECH, who issues a synthetic progress
report. In the management activities (WP1) are provided the main
documents process control and product quality related, including
the FEM specification according to DOD 6055.09-M & NATO
AASTP-1. After the KoM the mechanical design is started. The Design
Lead provides: 1. The first revision of assembly drawings,
installation drawings and the datasheet of auxiliary 2. components;
3. The first revision of detailed drawings and structural
inspections reports; 4. The first revision of the provision in the
field of instrumentation; 5. Reports of structural inspections.
After the design approval, received by the STRABAG, SLPHIA purchase
row materials and standard parts, provided by BOM and Drawing set.
Meanwhile the Production Manager compiles the working cycles for
the production of the items. The following step provide the
production of the doors. Manufacturing phase implies monitoring and
testing of quality as specified by the Quality Manager. Before
shipping the design department provides the installation procedures
and all files necessary to complete the final assembly. Supplier
ensures preparation of the operation and maintenance manual for the
door provided, which will be completed after its installation. WP2
| CAD Design, Structural FEM, Implementation of the requirements
and creation of the concept design of Antimissile Door, using CAD
software. Validation of the model through FE (Finite Eement) method
(static and dynamic), using FEM software. All the designed elements
of the assembly are verified to complain the requirements: DOD
6055.09-M & NATO AASTP-1. Static analysis of the metal
framework and Dynamic Analysis (non-linear) of the explosion in
order to certificate the door for 7 bar blast resistance are
carried out, according to ASTM F 2927 12 rule.
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Figure 13 : Internal side view of the anti-burglar door
assembly
Each door is equipped with 3 adequately sized hinges (following
figure). The right one (outside view) locks the left leaf (outside
view), so the latch of the door leaf can only be moved from the
inside.
Figure 14 : Hinges details
The door assembly is designed for closing with 2 padlocks for
military use supplied by the customer. The previously mentioned
padlocks are housed in a moving system (on the right leaf) which
prevents, in the "Close" position, the rotation of the
leaflet-opening bolt of the Right leaf. The aforementioned moving
system is equipped with specific shielding.
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Figure 15 : Latches structure
After the definition of all the components, the behaviour of the
structure under the working load is verified through static FE
analysis, according to ASTM F2247 [Metal Doors Used in Blast
Resistant Applications (Equivalent Static Load Method]. The
principle of the finite element analysis (FEA) is to subdivide a
large problem into many smaller ones; this simpler method divides
the body in a large number of finite elements (mesh). The simple
equations that model these finite elements are then assembled into
a larger system of equations that models the entire problem. This
method permits to simulate the behaviour of the structure under
working load and constraint condition. Following an example of FE
model (mesh with working load and constrain).
Figure 16 : Boundary Condition (constrain and load) of the
Antimissile door
Static analysis, in the FEM environment, verifies the integrity of
the door and the distribution of stress/displacements when the
structures is under the working load.
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Figure 17 : Map of displacements for the verification on the
Antimissile door
The FEM analyses is performed using following software:
1. MSC Software PATRAN (pre-processing and post-processing) 2. MSC
Software NASTRAN (static/dynamic processing) 3. MSC Software ADAMS
(kinematic and Dynamic processing) 4. MSC Software MARC (non-linear
processing). Output of this process is a report showing:
5. Stress plot of each loading condition; 6. Ratio to requirements
value between FEM and requirements. Dynamic simulation is the
impact test with explicit numerical methods. The Analysis is used
in order to verify the 7 bar blast resistance of the antiex door,
according to ASTM F2927-12 (Standard Test method for Door Systems
Subject to Air blast Loadings). For the modelling of impact
phenomena on antiex door, following steps are performed: 1.
Pre-processing: starting from the CAD model, in this phase (using
MSC software Patran), the structure is subdivided into a finite
number of small parts ("mesh" of elements). it is necessary to
choose the most appropriate type of mesh element (membrane, shell,
solid, rod, etc.) as well as the material for each part of the
model. Moreover, are applied the loads and constraints according to
the project requirements and the ASTM F2927-12 and ASTM F2247
reference standards; 2. FEM Simulation: in this phase the model is
transferred to the dynamic solver. After assigned to the elements
the geometric properties and the mechanical and thermal properties
of the materials, a numerical algorithm solves the problem being
analysed by constructing the stiffness matrix of the entire
structure. The output of the analysis is represented by the
displacement field that undergoes the constrained structure,
due
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to the blast load. The software automatically calculates the
distribution of stresses and strains starting from the calculated
displacements. This phase is performed using MSC software MARC; 3.
Post-processing: the output file is analysed using the
post-processing software (such as LS- Prepost and MSC Patran).
Through these codes it is possible to extract the values to be
compared with the admissible ones to verify the integrity of the
structure. Following it is possible to appreciate the
results.
Figure 18 : Impact Door Analysis Sequence on Antimissile door
In the verification of impact on metal components, two comparisons
are used: plastic deformation at break (or elastic) and the
relative plastic energy (elastic). This technique allows to
evaluate the structural integrity and the amount of energy
dissipated by innumerable elements.A further example of impact
analysis, due to the explosive load, is shown in following figure.
The simulation allowed to verify the behavior of Antimissile door
subjected to the pressure wave generated by an explosion triggered
in the vicinity of the same.
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Figure 19 : Antimissile door subjected to the shock wave generated
by an explosive load
Through these analyzes, the stress of the Antimissile door is
checked as a function of time. The following image reports the
variation of the Von-D
Figure 20 : Variation of the von Mises equivalent stress over time
on the Anitmissile door under blast load
WP3 | Kinematics Analysis, After the analysis the final CAD
geometry of the antiex door is designed. A virtual kinematic
analysis, according to DOD 6055.09-M & NATO AASTP-1, is used to
define, validate and certificate the opening/closing of the door
leafs. In this phase the validated 3D geometry is build. WP4 |
Drawing set, BOM (Bill of Material) and the technical drawings,
needed for manufacturing and assembly the parts, are carried out.
Creation of Use and Maintenance Manual of Antiex Door (it will be
finalize in the WP7). WP5 | Manufacturing, In this WP, SLPHIA
performs the construction of details and assembly parts according
to: 1. Assembly drawing approved by the Client;
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2. Production cycle drawn by Production Manager; 3. Planning of
supply. Mechanical machining and surface treatments will be carried
out in accordance with the technical specifications. In the
manufactory WP it will be built the necessary number of doors for
the delivery to the Clients. The manufacturing Process is
transferred to the mechanical construction area and then to the
mechanical workshop area. The mechanical construction area uses
specialized workers that, starting from the geometrical information
concerning the parts to be made, process the optimal sequence of
operations that must be performed by metal machining. The sequence
is then translated into a series of instructions that are
transmitted and used by machines for the automatic production of
the piece. The Workshop area is equipped with a room with
instrumentations and precision equipment which ensure the
compliance of the product during the production process. The
company employs the following skilled metalworkers: 1. crimping
machines operator, 2. pre-testing and testing benches operator, 3.
pallet assembly operator, 4. welding and prototyping operator with
International Welding Institute and TUV Qualification. WP6 |
Checks, inspections and tests, SLPHIA HIGH TECH performs all
inspections and tests required to ensure the quality of the
products and the qualification needed. All the inspection test are
performed according to DOD Manual 6055.09-M [Ammunition and
Explosives Safety Standards] and to NATO AASTP-1 [Safety principles
for the storage of military ammunition and explosives]. In
particular, the following checks are performed: 1. visual
inspection and dimensional checks; 2. testing of materials and
treatments used; 3. checks on welds; The Quality Manager writes the
"Test specifications" documents, which will be submitted to the
Customer. In this document, for each type of test, it will be
described the methods, the means employed and the acceptance
conditions. The tests for the certification of blast-resistance
will be executed by a certified software and explicit FEM solver.
The output of this work packages are: 9 Internal Test
Specifications Documents; 9 Blast Resistance Certification. WP7 |
Documentation and Reporting, The Structural FE Analysis and FE Test
Result Report are written. Validation and release of the Use and
Maintenance Manual. SLPHIA Project Manager, in course of execution,
creates and manage all specified documentation. At the end of the
activities SLPHIA shall collect in a "Dossier of End Manufacturing
"all the documents produced in the course of the activities, i.e.:
9 Test reports; 9 Installation drawings; 9 Material quality report;
9 Use and Maintenance Instructions. The Use and Maintenance Manual
is part of the product and must accompany it for all its life. WP8
| Packaging, Shipping and Installation to the site of the
door.
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Planning the shipping of the components. In situ installation of
the door, opening and closing validation. In this case, SLPHIA HIGH
TECH anticipate the supply of Counterframe to be installed before
the door. Then, a team of four workers composed by metalworkers,
welders and engineers installed the antimissile door in the
construction site. The Program Manager monitor the installation on
site for the entire endurance of the work.
Figure 21 : CLASS 5 Anti-Burglar & Antimissile Door, installed
in FETESTI (Romania)
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3 Anti-missile doors for EUREX plant Customer: SAIPEM (ENI GROUP);
Object: SÒPHIA HIGH TECH designed, developed, manufactured and
installed (N°15) anti-missile doors and gates for process and
storage buildings. At the EUREX plant (Saluggia, in Italy), liquid
waste from the reprocessing of fuels irradiated in MTR and CANDU
reactors is currently stored. Following the category of the
doors
Model #1 E1, E2, E3
Model #2 E6,E10
Model #4 E7, E11, E15
Model #5 E4, E9, E13
Table 1 anti-missile doors models
The verification and qualification took place in the FEM
environment. The structural verifications were performed by means
of finite element analysis and analytical calculations. In
particular, dynamic nonlinear dynamical analyzes were carried out,
with which the phenomenon of impact was simulated realistically,
and linear, nonlinear, equivalent static analyzes, with which the
different parts constituting the doors and gates were verified. :
doors, hinges and frame. Following the example concerning the E1
door model.
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Figure 22 anti-missile doors E1 model
Modeling of anti-missile doors was performed using the MSC PATRAN
software. The calculation models employ two-dimensional four-node
elements (QUAD4) with 6 degrees of freedom per node, with membrane
and flexural behavior to represent the outer mantle of the doors,
the stiffening plates and the profiles. The closing posts have been
discretized with two-dimensional monodimensional elements, with 6
degrees of freedom each.
The nodes in correspondence of the welded connections between the
different components were connected by rigid elements or by
equivalence operations (union of several overlapping nodes). The
model FE (Finite element) is shown below:
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The following figure show the von-mises tensions distribution
(equivalent tension) for one of loading case
Figure 24 anti-missile doors E1 model: FEM results
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4 MSA Anti-Blast / Anti-Explosion Doors with high impact resistance
according to USACE STD 421-80-13
Customer: USACE US ARMY CORPS OF ENGINEERS (EUROPE DISTRICT)
Object: SÒPHIA HIGH TECH designed, developed, manufactured and
installed (N°2) Anti-Blast / Anti- Explosion Door for COSTRUCT
MUNITIONS OF STORAGE AREA, located in the military base of CAMPIA
TURZII (EU - Romania).
Anti-Blast / Anti-Explosion Door with high impact resistance,
according to USACE STD 421-80-13
Dimensions 7820 mm (length) x 4900 mm (height) x 230 mm
(thickness)
Weight 13.5 tons Opening mode Right side
Typology One single Door sliding on Structural frame
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Design and Manufacturing has been developed according to the
following Standard Regulations: DOD 6055.09 - Ammunition And
Explosives Safety Standards USACE Design Manual
USACE STD 421-80-13 European Version NATO AASTP-1 - Manual of NATO
safety principles for the storage of military ammunition and
explosives
UFC 3-340-02 - Structures to resist the effects of accidental
explosions UFC 4-010-01 01 - Minimum Antiterrorism Standards For
Buildings ASTM F2927 - Standard Test Method for Door Systems
Subject to Airblast Loadings
Design models, created according to USACE STD 421-80-13, has been
developed in compliance to the DWGs: S-201; S-202; S-302; S-303;
S-505; S-701; S-702; S-703; S-704; S-704(A); E-103; E-104.
General Features
Actuation System
Automatic control. The door kinematic is equipped with: Electric
engine auto-braked 2,2 Kw, 4 Poles, 50 Hz 230/400V, 1400 rpm
commanded by a main board. Engine Reduction with a Gear Ratio 1/125
Gear/Rack System to assure an opening/closing speed in the range of
4-5.5
m/min The system is equipped with a Manual Brake Release System and
a Manual opening/closing door Handling System.
Locking System
Manually operated using a Padlock. Padlock: Sargent & Greenleaf
(S&G) 951 Padlock - Type NSN 5340-01-585-
7691 (not included in the furniture)
[https://securitysnobs.com/Sargent-Greenleaf-S-amp-G-951-Padlock.html]
Hasp: Sargent & Greenleaf 833/951 NAPEC Padlock Hasp
[https://securitysnobs.com/Sargent-Greenleaf-833-951-NAPEC-Padlock-
Hasp.html] Right Handed (ITEM 0957), according to door opening
mode
Security Equipments
External Totem Warning Lights Photocells (4 couples) Mechanical
Safety Edge (2 Front and Rear) Deceleration and Stopping Swithces
Internal and External Emergency Arrest Button
Quality Requirement
Quality Management System EN 9100:2009; Welding Quality
Requirements ISO 3834; Welding Procedure Qualification Record ISO
15614; Welders with approved test certificated in accordance with
EN ISO 9606-
1:2013 NDC Operators qualified at the level 2 according to EN ISO
9712:2012
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Engineering 2D Assembly Drawings in *.PDF Static Analysis certified
by FEM software (MSC Nastran) Digital Mock Up of the
structure
Procurement EN 10204 type 3.1 material certification
Manufacturing & Shipping
Manufacturing of Part and Assembly according to drawings approved
by the Client;
Internal and external (in the certified laboratories) inspections
and tests required to ensure the quality of the products and the
qualification needed;
Packaging, Shipping and on-site Installation.
Documentation
CE certification Use and Maintenance Manual according to Standard
regulation Basis of Design and Calculations REport 2D Assembly
Drawings (*.PDF)
Door
Material
Steel S355 J2+N EN 10025-2 Metal Sheet min. thickness 15 mm
Internal structure made in Square-shape 200x200 mm profiles of 12.5
mm
thickness
Sandblasting grade SA 2,5 Zinc layer: Inorganic two-/
(EN ISO 1461 nominal zinc content at least 99,5 EN 1179:2005)
Epoxi-polyamide two-component layer (i.e. Intergard 475HS)
thickness layer
50:75µm RAL 7013 - Double layer of protective paint; min thickness
100 µm
Fixing Type Anti-Blast Door is hanged to the IPN 400 by 4 Trolleys
of 5 tons weight size.
Frame Material Structure made of carbon steel Steel S355 J2+N EN
10025-2
Surface Treatments and Finishing
Sandblasting grade SA 2,5 Zinc layer: Inorganic two- /
(EN ISO 1461 nominal zinc content at least 99,5 EN 1179:2005)
Epoxi-polyamide two-component layer (i.e. Intergard 475HS)
thickness layer
50:75µm RAL 7013 - Double layer of protective paint; min thickness
100 µm