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Date: 18-Oct-2019
REVISIONS
OWNER / PROJECT:
BANGLADESH-INDIA FRIENDSHIP POWER
COMPANY PVT. LTD, DHAKA, BANGALADESH
2x660 MW MAITREE STPP, RAMPAL, BANGLADESH
CUSTOMER CONSULTANT:
M/s FICHTNER GmbH & Co KG,
Stuttgart, GERMANY
EPC CONTRACTOR:
Date: 18-Oct-2019
TABLES OF CONTENTS
SL.NO. ITEM
1 DESIGN OF SILO 3-8
2 DESIGN OF RING BEAM 9 - 12
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DESIGN OF SILO.
Silo is supported on Ring Girder at waist or transition level at El. 27.4 m which further transfers the load on Silo Building
supporting beams through stub columns at 6 support locations.
Ring Girder is designed such that it not only transfers the vertical load but also enhances the stiffness of Silo at transition level and caters to the circumferential thrust at the same
through skirt girder. Ring Girder, therefore, is subjected to axial, bending, torsion and shear forces. Manual calculation of forces and checks have been carried out for design of Ring
Girder.
Height of conical hopper, h'h (in m) 13.278 Refer Drg. No. MAITREE-00-ETH-LH-176047-ISG
Bulk density of Coal, Wb (Y) (in T/m3) 1.100 As per specification Clause 84.3.1.
Angle of repose, Ør,(in degrees) 30.000 Refer Drg. No. MAITREE-00-ETH-LH-176047-ISG
Mean Angle of internal friction, Øm (in degrees) 30.000
[As per Table E.1, Annex E, EN 1991 - 4 :2006,
0.490
Mean Wall friction coefficient, µm =tan Øw (for Wall Type D2) Pg-99)
0.550
Mean Lateral pressure ratio, Km 1.1*(1-sinØim), [As per EN 1991 - 4 : 2006, Pg-38)
Conversion factor, aØ 1.160
Conversion factor, aµ 1.120 [As per Table E.1, Annex E, EN 1991 - 4 : 2006,
Conversion factor, ak 1.150 Pg-99)
Upper characteristic value of ØiU (in degrees) (aØ.Øim) 34.800
Lower characteristic value of ØiL (in degrees) (Øim/aØ) 25.862
Upper characteristic value of µU (aµ.µm) 0.549
[As per EN 1991 - 4 : 2006, Pg-36)
Lower characteristic value of µL (µm/aµ) 0.438
Upper characteristic value of Ku (aKKm) 0.633
Lower characteristic value of KL(Km/aK) 0.478
Grade of steel, Fy (N/mm2) 350.000
Unit weight of steel, Ws Ku (t/m3) 7.850
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68.000
Inclination of hopper wall with horizontal (in degrees) Refer Drg. No. MAITREE-00-ETH-LH-176047-ISG
Hopper apex half angle,(in degrees) 15.000 [As per EN 1991 - 4: 2006, Pg-66]
tanβ 0.268
µh 0.970 [As per Fig. - 6.1, EN 1991 - 4 : 2006, Pg-66]
(1-KL)/(2µh) 0.269 [As per EN 1991 - 4: 2006, Pg-66]
Classification of hopper Steep hopper [As per EN 1991 - 4 : 2006, Pg-66]
Capacity of Silo (MT) (approx.)
1506 Hence, Silo is classified under Action Assessment
Class 2 (AAC 2) [As per EN 1991 - 4 : 2006, Pg-24]
(Height from top,
Location of points where stresses are to be calculated, Ztop in m)
Point 1 1.7
Point 2 3.4
Point 3 5.1
Point 4 6.8
Point 5 8.5
Point 6 10.2
Point 7 11.9
Point 8 13.6
Point 9 15.3
Point 10 16.983
DESIGN EXPLANATIONS
Height of natural fill, hn (in m) 0.924 b*tan Ø
Diameter of fill at top (in m) 12.300 d-2*b
Base of central trianqle at top(in m) 9.000 d-2*(d1+b)
volume of ash above line x-x, Vcx(in m 3) Volume of conical frustum - Volume of central
triangular diversion i.e
23.370
pi*hn/3*((d/2)2+(df/2)2+(d/2)*(df/2)-
0.5*hn*d2*d
Average height of coal fill above line x- x, hcx (ho) (in m) 0.124 Vcx/(pi*d2/4)
Average height of stored material in cylindrical part, hav (in m) 2.683 hc-hn+hcx
Volume of cylinder +Volume of conical frustum-
Volume of the Silo, V (in m3) 1755.220 Less Vol. for Inner cone equipment (30m3)- Less
Vol. Support arm for Inner Cone equipment
Wb*V + Rotary Extractor+Cone Assembly+Other
1982.742
Total weight of the coal, W (in T) Auxiliary (52 T)
a (In m) 0.000 do*hc/(d-do)
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Zo 14.378
ho 1.491
n -1.414
Ph 8.699
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DESIGN PRESSURE
Maximum values out of filling & emptying conditions have been considered for design of Silo ( Ph= normal pressure for Verticalwall , Pn = normal
pressure for hopper wall , pw =frictional traction for vertical wall, Pt = frictional traction for hopper wall, pv =vertical stress in stored solid )
Depth from top in m, Z Ph,max , Pn,max (t/m2) Pw,max , Pt,max (t/m2) Pv,max (t/m2) Silo Zone
1.7 0.203 0.110 0.290
Vertical wall
3.4 1.713 0.948 2.220
3.483 2.291 1.255 3.066 Transition Point
5.1 2.870 1.561 3.912
6.8 3.777 2.091 5.317
8.5 4.729 4.586 8.508
10.2 6.367 6.188 13.185
Hopper
11.9 8.096 7.858 16.765
13.6 10.311 10.033 21.350
15.3 12.013 11.647 24.875
16.983 12.409 12.036 25.694
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DESIGN OF SHELL
Design of Wall Plate & Hopper Plate has been carried out using Membrane Theory (as per EN 1993-1-6: 2007) due to the following
* Both the Cylindrical part & Hopper shall be adequately stiffened so as to transfer stresses in the shell into
support reactions without causing significant bending effects;
* the shell geometry varies smoothly in shape (without discontinuities);
* the loads have a smooth distribution (without locally concentrated or point loads).
Ph, max (t/m2 ) 3.777 max. value of Ph from top to waist (transition point)
Ph,max*r (considering uniform internal pr. with max. value of Ph as per EN 1993-1-6: 2007,
Circumferential Tension, Th (in t/m width) 29.272 Pg-51]
Structural thickness, tshell (in mm) 8
Minimum additional thickness required for abrasion loss Δta = 2mm [as per EN 1993-4-1 :
Total thickness (in mm) 10 2007, Pg-27]
Circumferential Membrane Stress, ϭθ (T/m2 ) 2927.190 Ph,max *r/t = Ph,max *(d/2)/t [as per EN 1993-1-6 : 2007, Pg-51]
Circumferential Membrane Stress, ϭθ ( in kg/cm2 ) 292.719
2
Weight of stored material in the cylindrical part, W Ash(T) 556.637 Y*pi*(d /4)*hav
vertical force due to frictional traction in the cylindrical
part, Pw (T) 354.518 Pw,max*hc*(pi*d)
Self weight of cylindrical shell, Wshell (T) 13.307 Ws *pi*d*hc
(Wash+Pw+Wshell) (Since, Silo is supported at waist level, there will be no meridional tension
in cylindrical portion. However, weight of cylindrical part & material stored by it has still been
Total Vertical load on the side wall, Fx (T) 924.462 considered for design purpose)
Meridional stress, ϭx ( T/m2) 1899.449 Fx/(pi*d*t) [as per EN 1993-1-6: 2007, Pg-51]
Meridional stress, ϭx ( in Kg/cm2) 189.945
2 2
Combined stress, CJe (in Kg/cm2) 257.222 √(ϭ θ + ϭ x- ϭθ*ϭx) [as per EN 1993-4-1 : 2007, Pg-37]
Permissible stress, fe,Rd (in Kg/cm2) 350 fy/YMo [as per EN 1993-4-1 : 2007, Pg-23, 37]
Result O.K. O.K. if Permissible stress> Combined stress
Angle of hopper wall from horizontal,θ (in degrees) 68.000 tan- 1(h'h/(d-do)/2))
Surface area of cone, (m2) 1520.328 pi*(d+d0)/2*I*(1-d0/d)
[Ws*pi*(d+do)/2*I*(1-do/d)] [Surface area* Weight per unit surface area ( For 12mm thk
Weight of cone, Wcone (in t) 193.672 pl+6mm liner)]
Weight per unit area (t/m2) 0.127
Pressure normal to hopper slope, Pn (t/m2) 4.729 Pn, max considered for design
Circumferential Membrane Stress, ϭθ (t/m2 ) 4392.323 Pn*r/(t*cosβ) = Pn*(d/2)/(t*sinθ) [as per EN 1993-1-6 : 2007, Pg-52]
Circumferential Membrane Stress, ϭθ (kg/cm2 ) 439.232
Total vertical load at waist level, Fx (T) 8646.634 (Pw+Wcone+Wash) = Pt,max*{pi*(d+do)/2*I*(1-do/d)}+Wcone+ Y*pi*(d/2)2*h'h/3
[ Fx/(pi*d*t*cosβ) = Fx/(pi*d*t*sinθ)] + Pn.component [(Pn*r')/(2*t*cosβ)*[(r/r')2] [as per
Meridional stress, ϭx (Kg/cm2 ) 53225.206 EN 1993-1-6 : 2007, Pg-52]
Meridional stress, ϭx (Kg/cm2 ) 1569.140
Combined stress, ϭe (Kg/cm2 ) 1402.109 v(ϭ2θ + ϭ2x - ϭθ*ϭx) [as per EN 1993-4-1 : 2007, Pg-37]
Permissible stress, fe,Rd (in Kg/cm2 ) 3500
Result O.K. O.K. if Permissible stress> Combined stress
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Following criteria checks are made to ensure that the effect of discrete forces from supports should not be included in
determining the internal forces in the shell [as per EN 1993-4-1 : 2007, Pg-60]:
(r/t)max 400
Radius to thickness ratio (r/t) = 775.000 < (r/t)max Hence, OK
k1 2
k1*t = 20
Support eccentricity beneath shell wall (mm)= 10 ( < k1*t) Hence, OK
k2 1
k2*t = 10
Hopper Wall thickness at the transition (mm) = 10 (= k2*t) with 6mm additional liner. Hence OK
k3 1
k3 * √(r*t) = 278.388
Width of support provided (mm) = 350 > k3 * √(r*t) Hence, OK
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Input
Width of bottom flange of ring girder, Wr mm 1036
Width of top flange of ring girder, Wt mm 225
Thickness of bottom flange of ring girder, Tb mm 40
Thickness of web of ring girder, Tr mm 25
Thickness of top flange of ring girder, Tt mm 40
Total Depth, D mm 2033
Effective length, l m 8.11
Design Bending Moment about major axis, M Tm 249.39
Design Shear Force T 180.22
Max Torsional Moment Tm 25.41
Design Axial force T 877.27
Yield Stress of Steel, f
y N/mm2 250
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Calculation of C.G.
Depth Width Dist Dist from Y-Y
Area (mm2) from X-X Ax (mm3) Ay (mm3)
(mm) (mm) (mm)
(mm)
D1*W1 (A1)
D1 W1 X' Y' A1*X' A1*Y'
SECTION CLASSIFICATION
Check for Web
Part subjected to compression
c (Outstand plate) = 225 mm
t (thickness of plate) = 40 mm
c/t = 5.63
ε = 0.97
33ε = 31.99
c/t <= 33ε , So, class of section is 1 Table 5.2 , EN 1993-1-1:2005
Part subjected to compression
α= 0.38 <= 0.5
c = Outstand of web plate = 1973
t (thickness of flange) 25
c/t = 78.92
36ε/α = 91.85
c/t <= 36ε/α , So, class of section is 1 Table 5.2 , EN 1993-1-1:2005
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Area of the resisting section (skirt girder, shaded area) mm2 58825 A1
(plate3)
Design resistance of cross section in compression 'N 1471 A*fy/Ƴ (for class 3 cross-section) BS
c,Rd' M0 EN 1993-1-1:2005
(T) Clause 6.2.4
N /N 0.60 BS EN 1993-1-1:2005 Clause 6.2.4
Ed c,Rd
CHECK Hence Ok
CHECK Hence Ok
DESIGN FOR SHEAR
Design value of Shear Force 'V ' (T) 180.22
Ed
Shear area, A (mm2) 49825 (A1 )
v (plate 2)
Design resistance for Shear 'V ' (T) 719.16 A *f /(√3*Ƴ ) BS EN 1993-1-1:2005
c,Rd v y M0
Clause 6.2.6
V /V 0.251 BS EN 1993-1-1:2005 Clause 6.2.6
Ed c,Rd
CHECK Hence Ok
CHECK Hence Ok
CHECK FOR COMBINED BENDING & SHEAR
(2*V /V -1)2
Reduction factor for moment capacity due to shear, ρ 0.249 Ed c,Rd
1-ρ 0.751
Design resistance for bending 'M ' (Tm) 1515.57 W *(1-ρ)*f /Ƴ
cv,Rd pl y M0
M /M
Ed cv,Rd 0.165
CHECK Hence Ok
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MEMBERS IN COMPRESSION
Compression force 'N ' (T)
Ed 877.27 T
λ 91.01 π*sqrt(E/f ) BS EN 1993-1-1:2005
1 y
Clause 6.3.1.3(1)
L /i*(1/λ ) BS EN 1993-1-1:2005
Non dimensional slenderness ƛ cr 1
0.16 Clause 6.3.1.3(1)
for buckling curve 'a0' BS EN 1993-1-1:2005 Table
Imperfection factor 'α' 0.13 6.1 & 6.2
Factor Ф 0.5*[1+α*(ƛ-0.2)+ƛ2] BS EN 1993-1-1:2005
0.51 Clause 6.3.1.2
2
Factor χ
1.01 1/(Ф+sqrt(Ф2-ƛ )) BS EN 1993-1-1:2005
Clause 6.3.1.2
N χ*A*f /ϒ BS EN 1993-1-1:2005
b,Rd y M1
1252.47 Clause 6.3.1.2
Interaction Ratio 'N / N 0.70
Ed b,Rd,y'
CHECK Hence Ok
MEMBERS IN BENDING (LATERAL
TORSIONAL BUCKLING)
α
LT 0.76 Buckling Curve 'd' from
Table 6.3
C 1
1
I 37281542 mm4
t
I (I ) 3875014856 mm4
z y
I (Warping Constant)
w 2.35539E+14
mm6
G 80770 N/mm2
C *π2*E*Iz/L2*sqrt(Iw/Iz+L2
Elastic critical moment for lateral torsional buckling 1 BS EN 1993-1-1:2005
50407.29651
M
cr
*G*I /(π2*E*Iz)
t
Clause 6.3.2.2
sqrt(W *f /M ) BS EN 1993-1-1:2005
ƛ y y cr
LT 0.15 Clause 6.3.2.2
ƛ 0.4 BS EN 1993-1-1:2005
LT,0
Clause 6.3.2.3
M /M
Ed cr 0.0049
ƛ2
LT,0 0.1600
Since, ƛ <ƛ & M /M < ƛ2
LT LT,0 Ed cr LT,0 Lateral torsional buckling is ignored
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