EPIC for Gas Sweetening Facilities Project Rev.

(GSF) at Mesaieed & Dukhan A

Part-2 AGRP (Dukhan) Date:
Doc. No 2971-1-12-0302 5/2/2014
Title: Design Calculation for TS-02 Monorail Beam
STRUCTURE: TS-02
HOIST TAG: 301-66-Y-01 A/B/C

INPUT DATA: REMARKS

MONORAIL BEAM: UB 406X178X67
SELF WEIGHT (kg/m) W = 67
C/S AREA (mm2) A = 8550
DEPTH OF SECTION (mm) d = 409.4
WIDTH OF FLANGE (mm) b = 178.8
THICKNESS OF WEB (mm) tw = 8.8
THICKNESS OF FLANGE (mm) tf = 14.3
MOMENT OF INERTIA ABOUT MAJOR AXIS (mm4) Iyy = 243310000
MOMENT OF INERTIA ABOUT MINOR AXIS (mm4) Izz = 13650000
ELASTIC SECTION MODULUS ABOUT MAJOR AXIS (mm4) Zyy = 1189000
ELASTIC SECTION MODULUS ABOUT MINOR AXIS (mm4) Zzz = 153000
PLASTIC SECTION MODULUS ABOUT MAJOR AXIS (mm3) Wply = 1346000
PLASTIC SECTION MODULUS ABOUT MINOR AXIS (mm3) Wplz = 237000
RADIUS OF GYRATION (mm) rx = 169
RADIUS OF GYRATION (mm) ry = 39.9
ROOT RADIUS (mm) r = 10.2
NET WEIGHT OF CHAIN PULLY BLOCK WITH TROLLEY (kg) = 102 from doc. No. 2971-5-13-1037
MAXIMUM WHEEL LOAD WITHOUT IMPACT (kg) = 750 from doc. No. 2971-5-13-1037
NO. OF LOAD WHEELS = 4 from doc. No. 2971-5-13-1037
WHEEL DIAMETER (mm) = 110 from doc. No. 2971-5-13-1037
C/C DISTNACE B/W WHEELS ALONG THE RUNWAY BEAM (mm) xw = 176 from dwg. No. 2971-0137-5-74-0004-sht.001
DISTANCE OF WHEELS ACROSS THE RUNWAY BEAM FROM ROOT RADIUS (mm) = 56.8 from dwg. No. 2971-0137-5-74-0004-sht.001
YIELD STRESS OF STEEL (N/mm2) Fy = 265
SAFE WORKING LOAD/ MAXIMUM LIFTING CAPACITY (kg) SWL = 3000 from doc. No. 2971-5-13-1037
PROOF LOAD (kg) PL = 3750 As per Cl. 8.3 of BS 2853:2011
UNFACTORED LONG. HORIZONTAL FORCE (kg) P = 155.1 As per Cl. 2.5.1.2 of BS EN 1991-3-2006
NO. OF CONNECTING BOLTS n = 4 Refer drawing.
GRADE OF STRUCTRAL BOLTS G = 8.8 Refer drawing.
DIAMETER OF STRUCTURAL BOLTS (mm) dbolts = 20 Refer drawing.
TENSILE STRESS AREA OF BOLT (mm2) At = 245 From "Joints in Simple Construction- BCSA"
REDUCED TENSION STRENGTH STRENGTH OF BOLTS (N/mm2) Ptr = 300 From "Joints in Simple Construction- BCSA"
LOAD FACTOR FOR SWL (for material strength design) = 1.35 As per BS EN 1990:2002
LOAD FACTOR FOR WIND LOAD = 0.9 As per BS EN 1990:2002

CALCULATION:
Calculation of Dynamic Factors As per section 2 of BS EN 1991-3-2006
Dynamic Factor 'Φ2' From table 2.4 of BS EN 1991-3-2006
Assuming Hand operated cranes
Assuming steady hoisting speed (m/min) vh = 6
Hoisting Class of appliance = HC1 From Annex B of BS EN 1991-3-2006
Φ2,min = 1.05 From table 2.5 of BS EN 1991-3-2006
β2 = 0.17 From table 2.5 of BS EN 1991-3-2006
Hence Dynamic Factor 'Φ2'= (Φ2,min+β2vh) = 1.067 From table 2.4 of BS EN 1991-3-2006

Dynamic Factor 'Φ3'

Φ3 = 1- (Δm/m)(1+β3) From table 2.4 of BS EN 1991-3-2006
Where Δm = released/ dropped part of the hoisting mass
m = total hoisting mass
Since, in this case monorail is purely manually opearted and no grabs or magnets are involved for instant release of payload,
it is assumed to be Δm = 0, refer table 2.1 of BS EN 1991-3-2006
Therefore Φ3 = 1 From table 2.4 of BS EN 1991-3-2006

Dynamic Factor 'Φ4' = 1 from table 2.4 of BS EN 1991-3-2006

Dynamic Factor 'Φ5'

Assuming the drive forces are changing smoothly
Therefore Φ5 = 1.5 from table 2.6 0f BS EN 1991-3-2006

Hence monorail design loads including dynamic magnification factors but without limit state load factors are

Total Safe Working Load applied as Hoist Load - SWL in STAAD (kg) = 3309.834 (with dynamic factors)
 EPIC for Gas Sweetening Facilities Project Rev.
(GSF) at Mesaieed & Dukhan A
Part-2 AGRP (Dukhan) Date:
Doc. No 2971-1-12-0302 5/2/2014
Title: Design Calculation for TS-02 Monorail Beam
Total Proof Load applied as Hoist Load - PL in STAAD (kg) = 4137.2925 (with dynamic factors)

Local Bending stresses in the bottom flange due to wheel loads from cl. 5.8 of BS EN 1993-6:2007

Ratio 'µ' = 2n/ (b-tw) µ = 0.21 Equation 5.7 of BS EN 1993-6:2007

Total available space on flange beyond root radius (m+n) = 74.8
Distance from the centreline of the wheel load to the free edge of the flange n = 18

From Fig. 6.1 of BS EN 1993-6-2007

From Fig. 5.6 of BS EN 1993-6-2007

Location 0- the web- to- flange transition
Location 1- centerline of the wheel load
Location 2- outside edge of the flange
Factored Vertical Wheel Load (kg) Fz,Ed = 4468.28
Longitudinal Bending Stresses σ0x,Ed
Cx0= 0.050-0.580µ+0.148e3.015µ Cx0 = 0.21 From table 5.2 of BS EN 1993-6-2007
Cx1=2.230-1.490µ+1.390e-18.33µ Cx1 = 1.94 From table 5.2 of BS EN 1993-6-2007
Cx2=0.730-1.580µ+2.190e-6.00µ Cx2 = 1.21 From table 5.2 of BS EN 1993-6-2007
Longitudinal Bending Stress at point 0 (N/mm2) for each wheels across web σ0x,Ed = 11.33 from cl. 5.8 of BS EN 1993-6:2007
Longitudinal Bending Stress at point 1 (N/mm2) for each wheels across web σ1x,Ed = 106.15 from cl. 5.8 of BS EN 1993-6:2007
Longitudinal Bending Stress at point 2 (N/mm2) for each wheels across web σ2x,Ed = 66.22 from cl. 5.8 of BS EN 1993-6:2007
Transverse Bending Stresses σ0y,Ed
Cy0= -2.110+1.977µ+0.0076e6.530µ Cy0 = -1.66 From table 5.2 of BS EN 1993-6-2007
Cy1= 10.108-7.408µ-10.108e-1.364µ Cy1 = 0.97 From table 5.2 of BS EN 1993-6-2007
Cy2= 0.0 Cy2 = 0 From table 5.2 of BS EN 1993-6-2007
Transverse Bending Stress at point 0 (N/mm2) for each wheels across web σ0y,Ed = -90.74 from cl. 5.8 of BS EN 1993-6:2007
Transverse Bending Stress at point 1 (N/mm2) for each wheels across web σ1y,Ed = 52.83 from cl. 5.8 of BS EN 1993-6:2007
Transverse Bending Stress at point 2 (N/mm2) for each wheels across web σ2y,Ed = 0.00 from cl. 5.8 of BS EN 1993-6:2007
1.5b (mm) = 268.20
Xw = 176.00

If Xw < 1.5b, single wheel stresses are superposed as point 8 of Cl. 5.8 of BS EN 1993-6-2007

Points
Direction 0 1 2
Final Longitudinal Bending Stress (N/mm2) 22.66 212.29 132.43
Final Transverse Bending Stress (N/mm2) -181.48 105.66 0.00

Loading condition as trolley placed at curved span.

Refer to Beam Force Detail Summary from STAAD
Shear due to major axis bending (fy1)
Check for Shear
Selected Load Combination L/C = 43
Torsion from STAAD for the selected L/C (kNm) T = 1.013
 EPIC for Gas Sweetening Facilities Project Rev.
(GSF) at Mesaieed & Dukhan A
Part-2 AGRP (Dukhan) Date:
Doc. No 2971-1-12-0302 5/2/2014
Title: Design Calculation for TS-02 Monorail Beam

POINT A

POINT B

Area moment about NA for point A (mm2) Q = 505103.74

Shear force from STAAD for the selected L/C (kN) V = 36.174
Shear Stress (N/mm2) τs = 0.01
Torsional Constant (mm4) J = 461000
Shear Stress due to St. Venant Torsion (N/mm2) τT = 31.42
Hence Total Shear Stress (N/mm2) τtotal = 31.43
Design Check OK

Area moment about NA for point B (mm2) Q = 4275.00

CG distance y = 155.47
Shear stress at point 'B' due tomajor axis bending (N/mm2) τMA = 11.23
Shear Stress due to St. Venant Torsion (N/mm2) τT = 19.34
Hence Total Shear Stress (N/mm2) τtotal = 30.57
Design Check OK

Resultant Biaxial Stress

σx = (σn,x, Ed + σf, Ed) + (P/ Area of Bottom Flange)
σn,x, Ed = local flange bending stresses at various points
σf, Ed = stress at the midline of the flange due to the overall internal moment in the beam

Section classification i.e., Class 1, 2, 3 & 4 (from STAAD) Class 1 from Cl. 5.5 of BS EN 1993-1-1-2005
Section Modulus (mm3) Z = 1346000.00
Maximum Moment for L/C 43 from STAAD (KNm) M = 6.394
stress at the midline of the flange due to the overall internal moment in the beam (N/mm2) σf, Ed = 4.75

Area of Bottom flange (mm2) Abf = 2556.84

Reversible Behaviour from cl. 7.5 of BS EN 1993-6:2007

σn,Ed,ser = direct stresses
τEd,ser = co- existing shear stresses τEd,ser = 31.42

σn,Ed,ser <= fy/λM,ser as per eq. 7.2a of BS EN 1993-6:2007

Partial Factor λM,ser = 1 from cl. 7.5 of BS EN 1993-6:2007

Points
Stress 0 1 2
Combined Longitudinal Stress(σx,Ed,ser) N/mm2 28.29 217.92 138.06
Transverse Bending Stress (σ0y,Ed) N/mm2 -181.48 105.66 0.00
Resultant Biaxial stresses N/mm2 204.52 188.75 138.06
Design Check OK OK OK

Resistance of Bottom Flanges to Wheel Loads from cl. 6.7 of BS EN 1993-6:2007

 EPIC for Gas Sweetening Facilities Project Rev.
(GSF) at Mesaieed & Dukhan A
Part-2 AGRP (Dukhan) Date:
Doc. No 2971-1-12-0302 5/2/2014
Title: Design Calculation for TS-02 Monorail Beam

Figure 6.1: Bending of bottom flange remote from ends and at non-reinforced jointsof BS EN 1993-6:2007

Effective length (mm) leff = 299.53 from table 6.2 of BS EN 1993-6:2007

Assuming "wheel remote from the end a member"

The design resistance (kN) Ff,rd = 71.44 from eq. 6.2 of BS EN 1993-6:2007

Design Check OK

Partial factor λm0 = 1 from cl. 6.1 of BS EN 1993-6:2007

Check for the Web from cl. 5.7 of BS EN 1993-6:2007

LOADED AREA

299.53

Stress in the Web (N/mm2) σweb = 16.95

Design Check OK

Design of Stopper

Stopper section provided = L100X100X10 Refer drawing.

Thickness of the section (mm) Dt = 30
Depth of the section 'a' (mm) Da = 100
Depth of the section 'b' (mm) Db = 100
Depth of the provided stopper (mm) Ds = 300 Refer drawing.

Accidental Force from cl. 2.11 of BS EN 1991-3:2006

Dynamic Factor 'Φ7' Φ7 = 1.25 from table 2.10 0f BS EN 1991-3-2006

Factored Buffer Force (kN) (10% of the total vertical load) Bf = 52.35 from Cl. 2.11.2 of BS EN 1991-3-2006
Design Moment (kNm) Bm = 1.49

Section Class from Cl. 5.5 of BS EN 1993-1-1-2005

Depth/ Thickness ratio D/Dt = 3.33

 EPIC for Gas Sweetening Facilities Project Rev.
(GSF) at Mesaieed & Dukhan A
Part-2 AGRP (Dukhan) Date:
Doc. No 2971-1-12-0302 5/2/2014
Title: Design Calculation for TS-02 Monorail Beam
ε = SQRT(235/Fy) ε = 0.94

Section Classification Class 3

Section Modulus (mm3) Z = 45000.00

Stress in the stopper (N/mm2) σ = 33.04
Design Check OK Refer modified detail

Connection Design

Verification for Bolts in Tension

Tension Capacity of Bolt Group (kN) Tgroup = 588.00 From "Joints in Simple Construction- BCSA"

Design Check OK