Wagon Tippler Foundation Rev b

BGR Energy Energy Systems Ltd . POWER PROJECT DIVISION

DOCUMENT NO: GID-091-CV-CAL-3481C WAGON TIPPLER – DESIGN OF FOUNDATION

KHAPERKHEDA TPS (1X500 MW ) EXPANSION PROJECT

WAGON TIPPLER COMPLEX – DESIGN OF FOUNDATION



REVISION HISTORY

Rev_A

First Submission

Rev_B

Revised as per DCPL Comments vide DCPL_K5V14/KHP-BOP-C/V6/257 DATED 23-06-08 AND MEETING HELD AT DCPL VASHI FROM 24-0608 TO 26-06-08



REVISION HISTORY

Rev_A

First Submission

Rev_B

Revised as per DCPL Comments vide DCPL_K5V14/KHP-BOP-C/V6/257 DATED 23-06-08 AND MEETING HELD AT DCPL VASHI FROM 24-0608 TO 26-06-08

BGR Energy Energy Syst ems Ltd . Project

KHAPARKHEDA TPS 1X500MW Expansion Project

Title

WAGON TIPPLER – Design of Foundation

Doc. No.

GID-091-CV-CAL-3481C

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CONTENTS 1 GENERAL ............................................................................ ............................................................................................................................................ .................................................................... .... 4 1.1 SCOPE.......................................................................................................................................................4 1.2 UNITS OF MEASUREMENTS................................................................................................................... MEASUREMENTS................................................................................................................... 4 1.3 CODES AND REFERENCES....................................................................................................................4 1.4 MATERIAL PROPERTIES .......................................................................... ........................................................................................................................5 ..............................................5 1.5 PLANT SITE INFORMATION....................................................................................................................5 1.6 MACHINE DATA .................................................................................... .......................................................................................................................................5 ...................................................5 1.7 SOFTWARE REFERENCE ........................................................................................ .......................................................................................................................5 ...............................5 2 DESCRIPTION OF STRUCTURE & GEOMETRY................................................................................... GEOMETRY................................................................................... 6 3 ANA LYSIS OF STRUCTURAL SHED .............................................................................. ..................................................................................................... ....................... 9 3.1 STAA D INPUT FILE .............................................................................. ................................................................................................................................11 ..................................................11 3.2 SUPPORT REACTIONS.......................................................................................................................... REACTIONS.......................................................................................................................... 14 4 ANA LYSIS OF FOUNDATION...............................................................................................................15 FOUNDATION...............................................................................................................15 4.1 PRIMARY LOADS ............................................................................... ...................................................................................................................................16 ....................................................16



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6.3.2

STAAD-Pro Analysis Input For Frame – 2 ...........................................................................75

6.3.3

Support Reactions For Frame – 2 ........................................................................................83

6.4 FRAME - 3 ............................................................................ ...............................................................................................................................................88 ...................................................................88 6.4.1

STAAD SKETCHES ............................................................................. .............................................................................................................88 ................................88

6.4.2

STAAD-Pro Analysis Input For Frame – 3 .........................................................................101

6.4.3

Support Reactions For Frame – 3 ............................................................................. ...................................................................................... ......... 110

6.5 FRAME - 4 ............................................................................ .............................................................................................................................................111 .................................................................111 6.5.1

STAAD SKETCHES ............................................................................. ...........................................................................................................111 ..............................111

6.5.2


6.5.3

Support Reactions For Frame – 4 .............................................................................. ...................................................................................... ........ 131

6.6 FRAME - 5 ............................................................................ .............................................................................................................................................133 .................................................................133 6.6.1

STAAD SKETCHES ............................................................................. ...........................................................................................................133 ..............................133

6.6.2


6.6.3

Support Reactions For Frame – 5 .............................................................................. ...................................................................................... ........ 146

7 ANA LYSIS FOR COUNTERFORTS COUNTERFORTS ........................................................................................ .................................................................................................... ............ 147 7.1 CF – 8.......................................................................... 8................................................................................................................................................ ........................................................................... ..... 147



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7.6.2

STAAD-Pro Analysis Input For CF - 13..............................................................................181 13 ..............................................................................181

7.6.3

Support Reactions For CF – 13.......................................................................................... 182

8 ANA LYSIS OF BA SE RAFT ...................................................................................... ................................................................................................................183 ..........................183 8.1 STAA D SKETCHES .......................................................................... ..............................................................................................................................183 ....................................................183 8.2 STAA D-Pro ANA LYSIS INPUT ................................................................................. ............................................................................................................186 ...........................186 9 ANA LYSIS RESULTS – PRESSURE ON SOIL: .................................................................................232 10 DESIGN OF BA SE RAFT ............................................................................ ....................................................................................................................234 ........................................234 10.1

CHECK FOR PUNCHING SHEAR ................................................................................ ............................................................................................. ............. 237

11 DESIGN OF COUNTERFORTS COUNTERFORTS .................................................................................. ...........................................................................................................239 .........................239 11.1

DESIGN OF CF8.........................................................................................................................239

11.2

DESIGN OF CF9.........................................................................................................................245

11.3

DESIGN OF CF11.......................................................................................................................253

11.4

DESIGN OF CF12.......................................................................................................................258

11.5

DESIGN OF CF13.......................................................................................................................263

12 DESIGN OF WALLS WAL LS .......................................................................... ............................................................................................................................268 ..................................................268 13 CHECK FOR BUOYANCY BUOYA NCY IN BUILDING PORTION PORTION ..........................................................................271

BGR Energy Syst ems Ltd .

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GENERAL

1.1

SCOPE

This document covers the design of Base Raft, Columns, Walls & Counterforts for Wagon tippler complex for 1x500 MW Expansion project for Khaparkheda TPS.

1.2

UNITS OF MEASUREMENTS

Units of measurements used in analysis shall be of SI Units.

1.3

CODES AND REFERENCES

The following codes and standards have been referred: Project Reference Drawings / Documents 1 2 3

GID-091-CV-DWG3001 207060-II GID-091-CHP-1503

Civil Design Basis Report Interim Geotechnical Investigation Report


1.4

Project


Title


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Property

Value

Units

25

kN/ cum

Concrete, M25

Density Characteristic Strength Modulus of Elasticity

25

N/ Sq mm

Reinforcing Steel

1.5

5 of Rev

MATERIAL PROPERTIES Material

Density Characteristic Strength Modulus of Elasticity

PLA NT SITE INFORMATION

25000

N/ sq mm

78.5

kN/ cum

500

N/ sq mm

200000

N/ sq mm

Page

Remarks IS : 875 Part - 1 IS-456 (2000) IS-456 (2000)

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DESCRIPTION OF STRUCTURE & GEOMETRY

The geometry is considered as per ELECON drawings Ref [3] to [9]. Wagon Tippler complex Comprises of an Underground RCC portion and a structural steel shed with sheeting. The Underground portion ( Coal Hopper and machinery Hatches) consists of RCC frames spaced at 3.5m c/c with RCC wall panels on the sides and RCC raft at the bottom fixed to the frames. The counterfort columns along the sides and the raft beam forms a closed continuous structural frame placed at the stated intervals. The intermediate space is filled by RCC panels all around except at the top. The coal hopper arrangement can be seen from the GA drawing as below Basic geometric dimensions assumed for counterforts, coulmns and beams are furnished in the figures shown below. :

BGR Energy Syst ems Ltd . Project


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Soil Support Below Foundation :

The soil support is modeled as spring supports and details of spring stiffness used in the analysis are as below. The foundation for the structure has been modeled as a raft on elastic soil. The soil spring value for the frame spaced at 3.5 m c/c and support placed at 0.9965 m c/c has been calculated as follows As the soil investigation repo rt allowable bearing pressure at 10 m below FGL is 300 kN/m2 corresponds to 25 mm settlement. In the Hopper portion As the soil investigation repo rt allowable bearing pressure at 20 m below FGL is 400 kN/m2 corresponds to 25 mm settlement in the Tunnel portion For Frame 1 & Frame 1a spring constants are calculated as follows The soil spring constants are estimated using cross hole shear test results furnished by client. From test results, Shear modulus of soil below the foundation, G

= 1.11E+6 KN/m2

Poissons ratio of soil

= 0.33



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For Base Raft spring constants are calculated as follows

The soil spring constants are estimated using cross hole shear test results furnished by client. From test results, Shear modulus of soil below the foundation, G

= 1.095E+6 KN/m2

Poissons ratio of soil

= 0.3386

Depth of embedment below ground level

= 17.6m

Total area of the raft

= 353.187 m2

Average horizontal dimension perpendicular to rocking axis(L)

= Raft area/length = 353.187/22.86 = 15.45m

Raft dimension parallel to rocking

= 22.86m

From fig. 4.12 of “Hand Book of Machine Foundations by Sri P. Srinivasulu and C.V Vaidyanathan” 2.1


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ANALYSIS OF STRUCTURAL SHED

Loading on Portal Roof Spacing of Portal Spacing of Purlins

= =

1.00m

14.75m

1.00m

14.75m

7.0 m 1.3 m

1.00m

13.15m 16.15m

Y Z

X

Load 1

LOAD COMPUTATION a) DEAD LOAD 1) Selfweight of Sheeting + Fixtures 2) Selfweight of Purlin (MC150) 3) D L d

= =

2

0.060 kN / m 2 0.168 kN / m 2 0 2 0 kN /



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b) LIVE LOAD 2

1) Live load = 0.59 KN/m

=

0.59 kN / m

2

LOAD DISTRIBUTION AT NODES AT NODE 101 TO 120 O

0.59 X 7.0 X ( 1.3/2 + 1.3/2 ) X COS 18 = 5.132 KN AT NODE 99 100

O

0.59 X 7.0 X ( 1.05/2 + 1.3/2 ) X COS 18 = 4.638 KN AT NODE 96, 97, 121, 122 O

0.59 X 7.0 X ( 1.31/2 ) X COS 18 = 2.585 KN AT NODE 95, 98 O

0.59 X 7.0 X ( 1.05/2 ) X COS 18 = 2.062 KN

C) WIND LOADS k1 = k2 = k3 = Vb = Vz =

1.07 1.06 1 44 49.905

wind pressure on first span(a) wind pressure on next span(b)

External pressure coeff (cpe) a b c d -0.78 -0.60 -0.3 -0.48

(for category II & class B structure) m/sec m/sec Design pressure Pd = 1.49 (-0.78+-0.7) = 1.49 (-0 6+-0 7)

= = =

1.49 -2.21 -1.94

cpi As per Table 16 of IS: 875 (Part-3)

-0.7 2

kN / m 2 kN / m 2 kN / m


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STAA D INPUT FILE

STAAD SPACE START JOB INFORMATION ENGINEER DATE 03-APR-08 END JOB INFORMATION INPUT WIDTH 79 UNIT METER KN JOINT COORDINATES 1 0 0 0; 2 1 0 0; 5 31.5 0 0; 6 32.5 0 0; 7 0 1.5 0; 8 1 1.5 0; 11 31.5 1.5 0; 12 32.5 1.5 0; 13 0 3 0; 14 1 3 0; 15 15.75 3 0; 16 16.75 3 0; 17 31.5 3 0; 18 32.5 3 0; 19 0 4.5 0; 20 1 4.5 0; 21 15.75 4.5 0; 22 16.75 4.5 0; 23 31.5 4.5 0; 24 32.5 4.5 0; 25 0 6 0; 26 1 6 0; 27 15.75 6 0; 28 16.75 6 0; 29 31.5 6 0; 30 32.5 6 0; 31 0 7.5 0; 32 1 7.5 0; 33 15.75 7.5 0; 34 16.75 7.5 0; 35 31.5 7.5 0; 36 32.5 7.5 0; 37 0 9 0; 38 1 9 0; 39 15.75 9 0; 40 16.75 9 0; 41 31.5 9 0; 42 32.5 9 0; 43 0 10.5 0; 44 1 10.5 0; 45 15.75 10.5 0; 46 16.75 10.5 0; 47 31.5 10.5 0; 48 32.5 10.5 0; 49 0 12 0; 50 1 12 0; 51 15.75 12 0; 52 16.75 12 0; 53 31.5 12 0; 54 32.5 12 0; 55 0 13.5 0; 56 1 13.5 0; 57 15.75 13.5 0; 58 16.75 13.5 0; 59 31.5 13.5 0; 60 32.5 13.5 0; 61 0 15 0; 62 1 15 0; 63 15.75 15 0; 64 16.75 15 0; 65 31.5 15 0; 66 32.5 15 0; 67 0 16.15 0; 68 1 16.15 0; 69 2.24321 16.15 0; 70 3.48641 16.15 0; 71 4.72968 16.15 0; 72 5.97289 16.15 0; 73 7.2161 16.15 0; 74 8.375 16.15 0; 75 9.60942 16.15 0; 76 10.8375 16.15 0; 77 12.0657 16.15 0;

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149 87 86; 150 88 87; 151 89 88; 152 90 89; 153 91 90; 154 92 91; 155 93 92; 156 94 93; 157 95 67; 158 95 68; 159 96 79; 160 96 80; 161 81 97; 162 97 82; 163 98 93; 164 94 98; 165 68 99; 166 99 69; 167 100 92; 168 93 100; 169 101 78; 170 79 101; 171 82 102; 172 102 83; 173 69 103; 174 103 70; 175 104 91; 176 92 104; 177 105 77; 178 78 105; 179 83 106; 180 106 84; 181 96 97; 182 70 107; 183 107 71; 184 108 90; 185 91 108; 186 109 76; 187 77 109; 188 84 110; 189 110 85; 190 95 99; 191 98 100; 192 96 101; 193 97 102; 194 71 111; 195 111 72; 196 112 89; 197 90 112; 198 113 75; 199 76 113; 200 85 114; 201 114 86; 202 72 115; 203 115 73; 204 116 88; 205 89 116; 206 99 103; 207 100 104; 208 117 74; 209 75 117; 210 86 118; 211 118 87; 212 73 119; 213 119 74; 214 120 87; 215 88 120; 216 101 105; 217 102 106; 218 74 121; 219 87 122; 220 103 107; 221 104 108; 222 105 109; 223 106 110; 224 107 111; 225 108 112; 226 109 113; 227 110 114; 228 111 115; 229 112 116; 230 113 117; 231 114 118; 232 115 119; 233 116 120; 234 117 121; 235 118 122; 236 119 121; 237 120 122; 240 123 76; 241 124 85; 242 75 123; 243 124 86; MEMBER PROPERTY INDIAN 181 TABLE ST ISMB250 143 TABLE ST ISMB450 130 TO 137 139 TO 142 144 TO 147 149 TO 156 240 TO 243 TABLE ST ISMB600 190 TO 193 206 207 216 217 220 TO 237 TABLE LD ISA65X65X6 SP 0.008 158 159 162 163 165 TO 180 182 TO 189 194 TO 205 208 TO 215 218 219 TABLE LD ISA50X50X6 SP 0.008 2 8 14 20 26 29 32 38 41 44 50 53 56 62 65 68 74 77 80 86 89 92 98 101 104 110 113 116 122 125 128 TABLE LD ISA50X50X6 SP 0.008

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*DUE TO MONORAIL LOAD 123 FY -150 124 FY -150 **-------------LOAD 2 LIVE LOAD JOINT LOAD 101 TO 120 FY -5.11 99 100 FY -4.62 95 98 FY -2.06 96 97 121 FY -2.57 121 122 FY -2.57 **-------------LOAD 3 WIND LOAD JOINT LOAD 103 107 111 115 FX -6.21 FY 19.13 101 105 109 113 117 FX 5.46 FY 16.79 102 106 110 114 118 FX -4.19 FY 12.89 104 108 112 116 FX 4.95 FY 15.23 99 FX -5.62 FY 17.29 95 FX -2.87 FY 8.83 119 FX -6 FY 18.46 121 FX 2.89 FY 8.9 121 FX -2.54 FY 7.81 96 FX 3.04 FY 9.36

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CMY 0.85 MEMB 1 TO 3 7 TO 10 12 TO 15 19 TO 22 24 TO 137 139 TO 147 149 TO 237 240 241 CMZ 0.85 MEMB 1 TO 3 7 TO 10 12 TO 15 19 TO 22 24 TO 137 139 TO 147 149 TO 237 240 241 KY 0.85 MEMB 2 8 10 12 14 20 22 24 26 29 32 34 TO 36 38 41 44 46 TO 48 50 53 56 58 TO 60 62 65 68 70 TO 72 74 77 80 82 TO 84 86 89 92 94 TO 96 98 101 104 106 TO 108 110 113 116 118 TO 120 122 125 128 130 143 156 TO 237 KZ 0.85 MEMB 2 8 10 12 14 20 22 24 26 29 32 34 TO 36 38 41 44 46 TO 48 50 53 56 58 TO 60 62 65 68 70 TO 72 74 77 80 82 TO 84 86 89 92 94 TO 96 98 101 104 106 TO 108 110 113 116 118 TO 120 122 125 128 130 143 156 TO 237 *LY 3.35 MEMB 1 13 25 37 49 61 73 85 97 109 121 161 *LZ 3.35 MEMB 1 22 31 60 78 89 *DEFLECTION CHECK *DFF 500 MEMB 7 19 31 43 55 67 79 91 103 115 127 TRACK 0 MEMB 1 TO 3 7 TO 10 12 TO 15 19 TO 22 24 TO 137 139 TO 147 149 TO 237 240 241 *RATIO 1 ALL RATIO 1.33 ALL CHECK CODE ALL STEEL TAKE OFF ALL FINISH

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