Furnace structure calculation by Hamed

DOCUMENT TYPE:

CALCULATION REPORT DOCUMENT TITLE:

FURNACE STRUCTURE CALCULATION REPORT

4 3 2 1

REV.

DATE

PRE.

CHK.

APP.

CONTRACTOR

GEG

Issue For Approval

Client

Description

Purpose of Issue

PROJECT TITLE :

GOL-E-GOHAR MEGA MODULE PROJECT Client :

Contractor: MINES & METALS TECHNOLOGICAL ENGINEERING CO.

Client â&#x20AC;&#x2DC;S Project

Project Code

GEG

Main Area Code Plant Group Equipment Document Contractor Code Type

119 NAME

1003

7 DATE

Eng. Discipline

Serial No.

001

15 MMTE No.

SHEET

REV.

PREPARED

GGMMSF10C4-001 CHECKED APPROVED

Contract No. : 90/1942

This document and the information disclosed are the property of MMTE and are not to be used to furnish any information for making of documents or apparatus except where approved by written agreement.

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

MMTE

Document No: Client Document NO: MMTE Document NO:

FURNACE STRUCTURE CALCULATION REPORT

Rev.

DATE: 1

GGMMSF10C4-001

Page:

REVISION RECORD SHEET P 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 5

Note: This Table is use for External Comments.

P 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7 7 7 8 8 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 1

2 of 24

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE STRUCTURE CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev.

DATE: 1

GGMMSF10C4-001

Page:

3 of 24

Table of Contents 1. INTRODUCTION ............................................................................................................................................4 2. GENERAL VIEW ...........................................................................................................................................4 3. STRUCTURAL SYSTEM .................................................................................................................................7 3.1 FOUNDATION ................................................................................................................................. 7 3.2 SUPER STRUCTURE ....................................................................................................................... 7

3.2.1 VERTICAL LOADS ...................................................................................................................... 7 3.2.2 LATERAL LOADS ....................................................................................................................... 7 3.2.3 FLOORS .................................................................................................................................. 7 4. LOADS........................................................................................................................................................8 4.1 DEAD LOAD ................................................................................................................................... 8 4.2 SUPER DEAD LOAD ........................................................................................................................ 8 4.3 LIVE LOAD ..................................................................................................................................... 8 4.4 VESSELS AND EQUIPMENT LOAD ..................................................................................................... 8 4.5 SEISMIC LOAD: ............................................................................................................................. 18

4.5.1 EVALUATION OF SEISMIC LOAD: ............................................................................................... 18 4.6 WIND LOAD: ................................................................................................................................ 19 4.7 THERMAL LOAD ............................................................................................................................ 19 4.8 ERECTION AND MAINTENANCE LOAD ............................................................................................. 19 5. LOAD COMBINATIONS ...............................................................................................................................20 6. ANALYSIS & DESIGN .................................................................................................................................23 6.1 MODELING ................................................................................................................................... 23

6.1.1 STRUCTURE MODELING .......................................................................................................... 23 6.2 DEFORMATIONS ........................................................................................................................... 23 6.3 DYNAMIC ANALYSIS ...................................................................................................................... 23 7.1 INTERNAL FORCES ....................................................................................................................... 24 7.2 DESIGN RATIO ............................................................................................................................. 24

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE STRUCTURE CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev.

DATE: 1

GGMMSF10C4-001

Page:

4 of 24

1. INTRODUCTION This document contains Calculation Report for analysis and design of Furnace structure. For material characteristics and construction considerations, refer to Document No. GGMMSF10C0-001 and GGMMCF10C0-001. Overall structural systems  Foundation Reinforced Concrete  Grade slab Reinforced Concrete  Structure Steel Structure above GL+ (0.00) m  Stairs Steel Structure + Grating  Walkways and platforms Steel Structure + Grating

2. GENERAL VIEW Location of structure in plant site is shown in Figure 1.

Figure 1: Location in Plant Site

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

FURNACE STRUCTURE CALCULATION REPORT

Client Document NO: MMTE Document NO:

MMTE Rev.

DATE: 1

GGMMSF10C4-001

In Figure 2 and Figure 3, three dimensional views of the structure are shown:

second Part

Main Part

Figure 2: 3D View A

Page:

5 of 24

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE STRUCTURE CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev.

DATE: 1

GGMMSF10C4-001

Figure 3: 3D View B

Page:

6 of 24

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE STRUCTURE CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev.

DATE: 1

GGMMSF10C4-001

Page:

7 of 24

In Figure 4 the foundation configuration is shown.

Figure 4 - Furnace Foundation

3. STRUCTURAL SYSTEM 3.1 FOUNDATION Foundation structural system is a 3 m thick reinforced concrete mat foundation. The top level of the foundation is 1 m under the finished ground level.

3.2 SUPER STRUCTURE 3.2.1 VERTICAL LOADS Vertical loads are supported by Steel Frames.

3.2.2 LATERAL LOADS According to ISIRI No. 2800 Iranian code of seismic resistant design of buildings for structures with height of 70m and more, Dual system composed of special moment resisting frames and braces should be used. For this type of structural systems, behavior factor is R=9 and there are some restrictions on columns to be stronger than beams. But in this structure, at some points such as beams under the furnace equipment, this cannot be achieved. Because at that level there are heavy beams to support the furnace equipment which are much stronger than the columns. On the other hand at that level there are still other columns that satisfy the beam to column strength ratio, so even if there may hinges occur in some columns, only part of lateral stability will be lost. Knowing that the main masses are below 70m level, and the above mentioned characteristics of this structure and applying all requirements of special moment resisting frames in members and connection design (except for the above mentioned points), behavior factor will be considered R=7 instead of 9. 3.2.3 FLOORS All floors are mainly covered by 32mm grating and there is a platform covered with 8mm chequered plate at the top of elevator.

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE STRUCTURE CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev.

DATE: 1

GGMMSF10C4-001

Page:

8 of 24

4. LOADS 4.1 DEAD LOAD Weight of structural components is included in analytical model based on specific weight of 25KN/m3 for concrete and 78.5KN/m3 for steel parts.

4.2 SUPER DEAD LOAD Super dead loads are dead load of non-structural components such as following items: Grating floors: Chequered plate floors

0.55 KN/m2 0.65 KN/m2

4.3 LIVE LOAD Live loads include the followings: Main Platforms: Auxiliary Platforms: Gangways and stairs: Roof

5.0 KN/m² 5.0 KN/m² 3.5 KN/m² 1.5 KN/m²

4.4 VESSELS AND EQUIPMENT LOAD Location and amount of each vessel or equipment point loads for individual cases are tabulated in Table 1.

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

Rev.

DATE:

Client Document NO: MMTE Document NO:

FURNACE STRUCTURE CALCULATION REPORT

MMTE

GGMMSF10C4-001

Page:

Table 1 - Vessels and Equipments

Item

Description

Mecha nical Weight (Ton)

Weight Of Material (Ton)

Refractory Weight (Ton)

Operationa l Weight (Ton)

Elevation and Centre Of Gravity (mm)

13360 1

7.6

18.4

(COG)

26245 2

Product Discharge Chamber Duct

Product Discharge Chamber

Bottom Discharge Bubbler

Product Cooler

(+100 0 COG) 21110 (COG)

21110 (COG)

26245 75

870

993

(+154 6 COG)

3D Shape from Analytical Model

9 of 24

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

GGMMSF10C4-001

26245

Cooling Gas Scrubber

500

CGS offtake

36135

Cooling Gas Duct

36135

Spring Hanger

13.5

37810

Top Gas Scrubber

(-1806 COG

37810 122

Rev.

DATE:

Client Document NO: MMTE Document NO:

FURNACE STRUCTURE CALCULATION REPORT

MMTE

710

(-1026 COG)

Page:

10 of 24

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

Rev.

DATE:

Client Document NO: MMTE Document NO:

FURNACE STRUCTURE CALCULATION REPORT

MMTE

GGMMSF10C4-001

50500 (+502 5 COG)

Reduction Furnace

358

1500

516

2500

Top Gas Scrubber Duct

-70

60150

Top Gas Scrubber Ventrury

56170

Burden Feeder Water Tank

12.4

62350

Page:

11 of 24

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

GGMMSF10C4-001

Charge Hopper

Bucket Elevator

See Attached Drawing recieved from Mechanical Discipline.

Bustle Gas Duct

327

Rev.

DATE:

Client Document NO: MMTE Document NO:

FURNACE STRUCTURE CALCULATION REPORT

MMTE

370

88550

15060 21110 97210

15960

20.5

50500

8.9

61870

Page:

12 of 24

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

Rev.

DATE:

Client Document NO: MMTE Document NO:

FURNACE STRUCTURE CALCULATION REPORT

MMTE

GGMMSF10C4-001

Monorail

3.5

25110

Maintenanc e Hoist (one of the three parallel monorails)

56170

Maintenanc e Hoist

56170

Shaft Furnace Hoist

10375 0

Elevator Hoist

2.5

59112

Elevator

Page:

13 of 24

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No: Client Document NO: MMTE Document NO:

FURNACE STRUCTURE CALCULATION REPORT

MMTE

Rev.

DATE: 1

GGMMSF10C4-001

Fz=-18

Fz= -16 Fx=14. 7

34740

Fz= -2 Fx= 1.2

34740

Page:

14 of 24

34740

Important Note: -All equipments are assumed rigid in analytical model. -All piping loads are tabulated as below. Refer to appendices which show the location of loads. (x,y = 0,0 refers to Grids : "1,DT" and also z=0 refers to elevation +0.000.) TABLE: Joint Coordinates Joint

CoordSys

CoordType

XorR

Text

KN -68.67

PS-1001

GLOBAL

Cartesian

12.8002

30.9502

50.5

PS-1002E

GLOBAL

Cartesian

9.5

32.91587

37.81

-10.8

PS-1002F

GLOBAL

Cartesian

8.80103

34.24189

37.81

-78.5

PS-1003

GLOBAL

Cartesian

1.5003

30.9505

26.245

-88.3

PS-1003A

GLOBAL

Cartesian

1.5003

34.2505

26.245

-176.6

PS-1004

GLOBAL

Cartesian

4.5003

30.9505

32.635

-200

PS-1004A

GLOBAL

Cartesian

4.5003

34.9455

32.635

-147.15 -1.77

PS-1004B

GLOBAL

Cartesian

4.5003

32.5955

32.635

PS-1005

GLOBAL

Cartesian

11.33

30.1755

50.5

-5

PS-1010

GLOBAL

Cartesian

11.33

32.0065

50.5

-4.9

PS-1012

GLOBAL

Cartesian

10.49973

17.96218

70.15

-13.73

PS-1013

GLOBAL

Cartesian

10.5

17.81162

76.05

-3.73

PS-1014

GLOBAL

Cartesian

10.5

20.5272

76.05

-3.92

PS-1015

GLOBAL

Cartesian

17.01791

21.3754

79.95

-10.8

PS-1017

GLOBAL

Cartesian

24.3917

14.85

34.74

-26.5

PS-1018

GLOBAL

Cartesian

24.39

14.8501

50.5

-200

PS-1020

GLOBAL

Cartesian

23.5

14.95275

76.05

-210

PS-1023

GLOBAL

Cartesian

1.5005

37.4508

8.6

-88.3

PS-1024

GLOBAL

Cartesian

7.6367

39.929

14.42

-32.4

PS-1027

GLOBAL

Cartesian

10.98

40.4083

44.35

-117.7

PS-1029

GLOBAL

Cartesian

-2.09

17.96656

26.245

-55.9

PS-1030

GLOBAL

Cartesian

11.524

32.5004

60.15

-18.15

PS-1031B

GLOBAL

Cartesian

11.524

36.0004

60.15

-21.58

PS-1031C

GLOBAL

Cartesian

11.524

30.3004

60.15

-18.15

PS-1032

GLOBAL

Cartesian

12.9001

28.6504

65.85

-28.45

PS-1033

GLOBAL

Cartesian

8.03207

16.50022

26.245

-23.55

PS-1035

GLOBAL

Cartesian

10.5

17.99458

50.5

-5.89

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

FURNACE STRUCTURE CALCULATION REPORT

Client Document NO: MMTE Document NO:

MMTE Rev.

DATE: 1

GGMMSF10C4-001

Page:

15 of 24

PS-1037

GLOBAL

Cartesian

20.377

30.8732

26.245

PS-1038

GLOBAL

Cartesian

24.59629

35.78787

30.85

-88.3 -9.8

PS-1039

GLOBAL

Cartesian

24.5748

41.4221

28.745

-103

PS-1047

GLOBAL

Cartesian

10.49982

38.03396

20.11

-5.89

PS-1048

GLOBAL

Cartesian

9.7627

37.8

14.96

-5.65

PS-1051

GLOBAL

Cartesian

4.24268

29.50026

26.245

-11.77

PS-1052

GLOBAL

Cartesian

5.7767

36.2703

15.06

-117.7

PS-1056

GLOBAL

Cartesian

20.60886

35.0005

26.245

-29.4

PS-1093

GLOBAL

Cartesian

0.775

40.4083

30.85

-187

PS-1094

GLOBAL

Cartesian

8.55117

40.46946

37.81

-20

PS-1106B

GLOBAL

Cartesian

10.5

31.90157

44.35

-10.8

PS-1106C

GLOBAL

Cartesian

10.5

32.29364

44.35

-3.14

PS-1106F

GLOBAL

Cartesian

10.5

34.03929

44.35

-98.1

PS-11072

GLOBAL

Cartesian

26.732

23.0003

15.06

-3

PS-11075

GLOBAL

Cartesian

11.3753

37.0005

37.81

-6.87

PS-11080

GLOBAL

Cartesian

-5.064E-13

28.0203

8.6

-5.89

PS-11083

GLOBAL

Cartesian

1.57843

19.1503

13.36

-3.52

PS-11084

GLOBAL

Cartesian

7.65638

19.1503

13.36

-3.48

PS-1125

GLOBAL

Cartesian

3.149

17.3372

8.6

-8.95

PS-1126

GLOBAL

Cartesian

5.324

17.3372

8.6

-9.4

PS-1127

GLOBAL

Cartesian

7.5005

17.3372

8.6

-5.06

PS-1155

GLOBAL

Cartesian

13.65

17.3393

26.245

-5.2

PS-1171

GLOBAL

Cartesian

17.8001

28.6504

65.85

-28.45

PS-1186A

GLOBAL

Cartesian

23.4998

38.2071

15.06

-3.92

PS-1242

GLOBAL

Cartesian

21.2001

34.2504

50.5

-7.36

PS-1246

GLOBAL

Cartesian

32.7005

-11.77

PS-1247

GLOBAL

Cartesian

24.203

32.8502

44.35

-11.77

PS-1248

GLOBAL

Cartesian

23.08783

32.7005

44.35

-58.9

PS-1250

GLOBAL

Cartesian

24.4003

32.8005

30.85

-93.2

PS-1252

GLOBAL

Cartesian

21.85

36.8222

50.5

-13.73

PS-1253

GLOBAL

Cartesian

20.1002

38.05712

50.5

-19.6

PS-1254

GLOBAL

Cartesian

24.4928

37.0441

44.35

-14.7

PS-1254A

GLOBAL

Cartesian

24.4928

36.0301

44.35

-34.33

PS-1255

GLOBAL

Cartesian

12.2502

35.5003

50.5

-11.77

PS-1258

GLOBAL

Cartesian

7.637

29.5002

32.635

-24.5

PS-1259

GLOBAL

Cartesian

7.6502

27.6005

36.135

-16.68

PS-1260

GLOBAL

Cartesian

7.60791

20.0005

36.135

-9.8

PS-1266

GLOBAL

Cartesian

22.798

36.0005

26.245

-9.8

PS-1269

GLOBAL

Cartesian

22.798

32.5005

26.245

-9.8

PS-1272

GLOBAL

Cartesian

22.798

34.2505

26.245

-9.8

PS-1273

GLOBAL

Cartesian

23.4997

38.1292

29.045

-13.73

PS-1281

GLOBAL

Cartesian

24.7418

39.9241

28.745

-31.4

PS-1283

GLOBAL

Cartesian

24.7418

36.0311

37.81

-22.56

PS-1287

GLOBAL

Cartesian

12.95671

15.0005

34.74

-27.6

PS-1288

GLOBAL

Cartesian

8.2213

29.5005

36.135

-3.43

PS-1289

GLOBAL

Cartesian

12.934

12.5003

34.74

-25.5

PS-1290

GLOBAL

Cartesian

2.4403

17.7455

32.635

-60

PS-1306

GLOBAL

Cartesian

11.6502

32.69384

50.5

-5.89

PS-1310

GLOBAL

Cartesian

1.7

27.5503

32.635

-5

PS-1319

GLOBAL

Cartesian

23.16363

32.7005

44.35

-5.89

PS-1328A

GLOBAL

Cartesian

25.25

17.52394

20.11

-8.83

PS-1329A

GLOBAL

Cartesian

25.25

22.15976

20.11

-8.92

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

FURNACE STRUCTURE CALCULATION REPORT

Client Document NO: MMTE Document NO:

MMTE Rev.

DATE: 1

GGMMSF10C4-001

Page:

16 of 24

PS-1330

GLOBAL

Cartesian

24.8401

29.5003

20.11

-4.02

PS-1330A

GLOBAL

Cartesian

25.09311

29.5003

20.11

-12.16 -4.02

PS-1330B

GLOBAL

Cartesian

24.33011

29.5003

20.11

PS-1331

GLOBAL

Cartesian

24.8947

38.66338

20.11

-4.4

PS-1334

GLOBAL

Cartesian

11.19646

40.5859

26.245

-26.5

PS-1336

GLOBAL

Cartesian

12.556

36.4253

26.245

-5.89

PS-1337

GLOBAL

Cartesian

7.64796

39.0003

26.245

-34.33

PS-1343A

GLOBAL

Cartesian

24.504

28.5673

97.21

-25.5

PS-1344

GLOBAL

Cartesian

24.52421

27.6121

83.35

-0.8

PS-1344A

GLOBAL

Cartesian

24.325

28.2103

83.35

-25

PS-1345

GLOBAL

Cartesian

24.596

27.7262

76.05

-35 -34.33

PS-1345A

GLOBAL

Cartesian

24.504

28.5672

76.05

PS-1346

GLOBAL

Cartesian

24.306

30.8732

56.17

-35

PS-1348

GLOBAL

Cartesian

24.316

30.8732

37.81

-78.5

PS-1350

GLOBAL

Cartesian

-1.1902

26.2901

35.495

-450

PS-1352

GLOBAL

Cartesian

17.025

27.1005

26.245

-3.43

PS-1354

GLOBAL

Cartesian

12.0502

24.08

26.245

-4.9

PS-1356

GLOBAL

Cartesian

-1.2797

23.798

26.245

-19.62

PS-1357

GLOBAL

Cartesian

-1.2874

23.80735

18.36

-98.1

PS-1359

GLOBAL

Cartesian

-5.124E-13

32.43913

15.06

-9.8

PS-1362A

GLOBAL

Cartesian

4.25

28.6003

18.36

-9.8

PS-1376

GLOBAL

Cartesian

16.6502

28.2754

56.17

-3.92

PS-1377

GLOBAL

Cartesian

22.23145

24.37705

56.17

-5.89

PS-1386

GLOBAL

Cartesian

7.5777

15.06

-4.905

PS-1388

GLOBAL

Cartesian

7.5777

32.08

15.06

-4.9

PS-1400

GLOBAL

Cartesian

10.5

35.86677

56.17

-3.92

PS-1405

GLOBAL

Cartesian

21.7002

27.9754

50.5

-3.92

PS-1407

GLOBAL

Cartesian

10.5

33.64311

50.5

-3.92

PS-1408

GLOBAL

Cartesian

9.12182

34.25035

26.245

-8.15

PS-1409

GLOBAL

Cartesian

9.122

39.0003

26.245

-7.35

PS-1410

GLOBAL

Cartesian

10.49991

33.59791

20.11

-14.7

PS-1411

GLOBAL

Cartesian

10.49987

35.49651

20.11

-7.85

PS-1412A

GLOBAL

Cartesian

-0.0002

36.1001

20.11

-5.89

PS-1423

GLOBAL

Cartesian

1.5

30.9503

8.6

-120

PS-1424

GLOBAL

Cartesian

1.5

25.7713

8.6

-30.6

PS-1425

GLOBAL

Cartesian

1.5005

22.5008

8.6

-67.9

PS-1426

GLOBAL

Cartesian

5.7767

29.909

15.06

-49.05

PS-1460

GLOBAL

Cartesian

18.485

30.8003

60.15

-4.9

PS-1460A

GLOBAL

Cartesian

17.9

30.8003

60.15

-8.2

PS-1460B

GLOBAL

Cartesian

17.35

30.8003

60.15

-6.8

PS-1460C

GLOBAL

Cartesian

16.8

30.8003

60.15

-4.42

PS-1460D

GLOBAL

Cartesian

16.3

30.8003

60.15

-4.42

PS-1460E

GLOBAL

Cartesian

15.8

30.8003

60.15

-4.42

PS-1461

GLOBAL

Cartesian

20.743

31.2703

60.15

-4.42

PS-1462

GLOBAL

Cartesian

21.95005

33.56317

56.17

-4.905

PS-1463

GLOBAL

Cartesian

21.95

34.9002

56.17

-11.77

PS-1465

GLOBAL

Cartesian

23.17732

30.4504

56.17

-8.83

PS-1465A

GLOBAL

Cartesian

22.5575

31.4004

56.17

-3.24

PS-1466

GLOBAL

Cartesian

23.5

36.96228

60.15

-13.25

PS-1467

GLOBAL

Cartesian

21.774

33.4364

60.15

-31.4

PS-1486

GLOBAL

Cartesian

15.53713

39.87128

15.06

-3.43

PS-1486B

GLOBAL

Cartesian

14.90366

39.8713

15.06

-5.89

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

FURNACE STRUCTURE CALCULATION REPORT

Client Document NO: MMTE Document NO:

MMTE Rev.

DATE: 1

GGMMSF10C4-001

Page:

17 of 24

PS-1487

GLOBAL

Cartesian

15.5148

39.6721

26.245

PS-1487B

GLOBAL

Cartesian

14.9068

39.6721

26.245

-5.89 -7.85

PS-1488

GLOBAL

Cartesian

15.61719

39.55706

37.81

-5.89

PS-1488B

GLOBAL

Cartesian

14.98751

39.55706

37.81

-4.22

PS-1488C

GLOBAL

Cartesian

14.41225

39.55706

37.81

-3.35

PS-1489B

GLOBAL

Cartesian

14.9606

39.85273

44.35

-11.6

PS-1490

GLOBAL

Cartesian

15.50106

39.00026

56.17

-3.14

PS-1490B

GLOBAL

Cartesian

14.70194

39.00027

56.17

-3.92

PS-1491

GLOBAL

Cartesian

14.80386

36.1504

56.17

-5.89 -5.89

PS-1497

GLOBAL

Cartesian

2.87942

39.0001

20.11

PS-1498A

GLOBAL

Cartesian

9.666

30.2252

26.245

-3.92

PS-1507

GLOBAL

Cartesian

0.0002

8.6

-3.92

PS-1517A

GLOBAL

Cartesian

24.23526

31.63564

44.35

-3.92

PS-1518A

GLOBAL

Cartesian

23.5

31.81882

56.17

-19.6

PS-1526B

GLOBAL

Cartesian

19.3001

30.1484

60.15

-22.95

PS-1526C

GLOBAL

Cartesian

19.3001

29.9244

60.15

-39.73

PS-1526D

GLOBAL

Cartesian

19.3001

29.6744

60.15

-29.45

PS-1526E

GLOBAL

Cartesian

19.3001

29.5004

60.15

-9.8

PS-1535

GLOBAL

Cartesian

14.56653

39.00027

60.15

-39.25

PS-1536

GLOBAL

Cartesian

12.5

28.55439

97.21

-34.33

PS-1536A

GLOBAL

Cartesian

10.5

27.78918

88.55

-18.85

PS-1537

GLOBAL

Cartesian

10.5

27.72735

76.05

-36.3

PS-1538

GLOBAL

Cartesian

10.50009

27.59887

65.85

-14.7

PS-1539

GLOBAL

Cartesian

10.5

27.41443

56.17

-88.3

PS-1540

GLOBAL

Cartesian

10.5

27.68986

44.35

-11.78

PS-1541

GLOBAL

Cartesian

8.5003

28.93777

32.635

-19.6

PS-1542

GLOBAL

Cartesian

9.375

29.0252

26.245

-14.7

PS-1543

GLOBAL

Cartesian

9.33402

29.5003

13.36

-4.9

PS-1544

GLOBAL

Cartesian

8.5005

29.03819

8.6

-5.89

PS-1562

GLOBAL

Cartesian

3.45

39.0003

15.06

-7.85

PS-1565

GLOBAL

Cartesian

15.7588

12.1221

8.6

-11.77

PS-1573

GLOBAL

Cartesian

2.25

25.8533

8.6

-9

PS-1574

GLOBAL

Cartesian

9.503

39.0003

30.85

-3.63

PS-1577

GLOBAL

Cartesian

24.2028

38.1291

44.35

-5.4

PS-1627

GLOBAL

Cartesian

15.1001

32.63111

56.17

-8.15

PS-1635

GLOBAL

Cartesian

2.0503

19.0505

36.135

-5.5

PS-1636

GLOBAL

Cartesian

3.8503

19.0505

36.135

-35.3

PS-1655

GLOBAL

Cartesian

13.9002

38.05182

50.5

-47

PS-1683

GLOBAL

Cartesian

3.9

17.0173

13.36

-9.8

PS-1684

GLOBAL

Cartesian

6.884

17.0173

13.36001

-49

PS-1685

GLOBAL

Cartesian

9.338

17.0173

13.36001

-44.65

PS-1686

GLOBAL

Cartesian

9.3375

17.3397

18.36

-93.2

PS-1713

GLOBAL

Cartesian

13.7

16.5003

8.6

-3.43

PS-1714

GLOBAL

Cartesian

13.7

12.7502

8.6

-3.14

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

Rev.

DATE:

Client Document NO: MMTE Document NO:

FURNACE STRUCTURE CALCULATION REPORT

MMTE

GGMMSF10C4-001

Page:

18 of 24

4.5 SEISMIC LOAD: According to ISIRI No. 2800 Iranian code of seismic resistant design of buildings for structures with height of 70m and more, Dual system composed of special moment resisting frames and braces should be used. For this type of structural systems, behavior factor is R=9 and there are some restrictions on columns to be stronger than beams. But in this structure, at some points such as beams under the furnace equipment, this cannot be achieved. Because at that level there are heavy beams to support the furnace equipment which are much stronger than the columns. On the other hand at that level there are still other columns that satisfy the beam to column strength ratio, so even if there may hinges occur in some columns, only part of lateral stability will be lost. Knowing that the main masses are below 70m level, and the above mentioned characteristics of this structure and applying all requirements of special moment resisting frames in members and connection design (except for the above mentioned points), behavior factor will be considered R=7 instead of 9.

4.5.1 EVALUATION OF SEISMIC LOAD: Important Note: Shear base in Flexible Model should be more than that in Fixed Base Model. Soil Type : To Ts S Mass x = Mass y = T x dyn (Flexible Model) = T y dyn (Flexible Model) = T x dyn (Fixed Base) = T y dyn (Fixed Base) = H= I= Ct x = Ct y = Rx= Ry= A=

X Direction T 1x = Ct x x H3/4 Static Period Multiplier (0.8 or 1) T x st

II 0.1 0.5 1.5 97668 97668 1.912 Sec. 1.540 Sec. 1.249 Sec. 1.105 Sec. 107 m 1.2 0.05 0.05 7 7 0.30 g

T = MIN(1.25 x T x st ,T Bx1 Bx min=0.1 x Rx Bx Cx (Flexible)=ABI/Rx Vx

x dyn

)

Y Direction T 1y = Ct y x H3/4 Period Multiplier (0.8 or 1) T y st T = MIN(1.25 x T y st ,T y dyn ) B By min=0.1xRy By Cy (Flexible)=ABI/Ry Vy

Flexible Model

Fixed Base

1.663 Sec 1.0 1.663 Sec. 1.912 Sec. 1.022 0.700 1.022 0.05258 5135 KN

1.663 Sec 1.0 1.663 Sec. 1.249 Sec. 1.358 0.700 1.358 0.06984 6821 KN

1.663 S1.0

1.663 Sec. 1.0 1.663 Sec. 1.105 Sec. 1.473 0.700 1.473

1.663 S 1.540 S 1.181 0.700 1.181 0.06074 5932 KN

Spectrum Diagram

3.0 2.5 2.0 1.5 1.0 0.5 0.0 0.0

0.5

1.0

1.5

2.0

Period (T Sec.)

2.5

3.0

3.5

4.0

0.07578 7401 KN

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

Rev.

DATE:

Client Document NO: MMTE Document NO:

FURNACE STRUCTURE CALCULATION REPORT

MMTE

GGMMSF10C4-001

Page:

19 of 24

4.6 WIND LOAD: Wind loads are evaluated as mentioned in General Design Criteria and are applied on analytical model of the structure. INBC Part 6: V= 130 km/h q = 0.005 x V2= 0.005 x 1302 = 84.5 Kg/m2 P = Ce x Cq x q C e = According to table below C q = As shown below

P (Kg/m2) Height

cq= 0.5

cq= 0.7

cq= 0.8

0-10

130

84.5

118.3

135.2

10-20

2.2

130

84.5

93.0

130.1

148.7

20-30

2.4

130

84.5

101.4

142.0

162.2

30-40

2.5

130

84.5

105.6

147.9

169.0

40-50

2.6

130

84.5

109.9

153.8

175.8

50-60

2.7

130

84.5

114.1

159.7

182.5

60-80

2.8

130

84.5

118.3

165.6

189.3

80-100

2.9

130

84.5

122.5

171.5

196.0

100-120

130

84.5

126.8

177.5

202.8

4.7 THERMAL LOAD Effect of +/-30 degrees Celsius change in steel parts will be taken into account.

4.8 ERECTION AND MAINTENANCE LOAD No special erection load is noted on drawings. Refractory lining is assumed to be completed gradually and in a symmetrical pattern.

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE STRUCTURE CALCULATION REPORT

Document No:

MMTE Rev.

DATE:

Client Document NO: MMTE Document NO:

GGMMSF10C4-001

Page:

20 of 24

5. LOAD COMBINATIONS Following tables describe the load cases and combination factors for design of foundation, concrete and steel parts. Table 2, includes load cases and Table 3, includes load combination factors that are used in this structure. In tables 1 & 2 env (…) means the envelop effect of loads written in parentheses Table 2: Load Cases Definition Load Cases Structural Loads

Type

Description

Intermediate Load cases

Dead00

Dead

Weight of structure alone

ALLDead= Soil+Dead00+Supd100+EMDL100

Supd100

Dead

Soil

Dead

Live20

Live

SpecX* SpecY*

Weight of floors+grating+internal walls+finishing+… Weight of the soil over the foundation Live loads that contribute in Earthquake 20% Earthquake Loads in X dir: Spectrum Analysis Earthquake Loads in Y dir: Spectrum Analysis Earthquake Loads in X dir: Auto Lateral Loading Earthquake Loads in Y dir: Auto Lateral Loading

EQX

Quake

EQY

Quake

WLX

Wind

Wind Load in +X dir

WLXN

Wind

Wind Load in -X dir

WLY

Wind

Wind Load in +Y dir

WLY

Wind

Wind Load in -Y dir

Thermal

-------

Main Load cases

ALLLive=Live20+ EMLL100

Fv=( 0.7AI=0.2625) x ALLDead (Seismic Vertical Effect) FvN= - Fv

FvEnv=env(Fv, FvN)

Equipment Loads EMDL100

Dead

EMLL100

Live

EMEXLO

Quake

EMEYLO

Quake

CRV1 ~ CRV6

Other

Equipment Dead Loads that contribute in Earthquake 100% Equipment Live loads that contribute in Earthquake100% Equipment Earthquake Load in X dir (Local Earthquake) Equipment Earthquake Load in Y dir (Local Earthquake) Vertical Crane load at different levels (including impact factor : 1.25)

CRV= ENV(CRV1 ~ CRV6)

*: This note should be taken into account that in Load Combinations The positive and negative sign of SpecX and SpecY will be considered by software SAP2000.

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

FURNACE STRUCTURE CALCULATION REPORT

Client Document NO: MMTE Document NO:

MMTE Rev.

DATE: 1

GGMMSF10C4-001

Page:

21 of 24

Table 3: Load Combination Factors

Design Combinations (for Soil Pressure Evaluation and Steel Design)

Design Combinations (for Equipment Supporting Elements Design) *

ALLDead

ALLLive

CRV

ASD1

ASD2

ASD3

0.75

0.375

ASD4

0.75

0.375

ASD5

0.75

0.375

ASD6

0.75

0.375

ASD7

0.75

ASD8

0.75

ASD9

0.75

ASD10

0.75

ASD11

0.75

ASD12

0.75

ASD13

0.75

ASD14

WLX

WLY

WLXN

WLYN

SpecX

SpecY

FvEnv

0.375

0.75

0.225

0.375

0.225

0.75

0.225

0.375

0.225

0.75

0.225

ASD15

0.75

0.225

0.75

0.225

ASD16

0.75

0.225

0.75

ASD17-1

ASD17-2

0.67

ASD17-3

0.67

ASD17-4

0.67

ASD17-5

0.67

ASD17-6 ASD17-7

EMEYLO

EMEXLO

0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75

0.9 0.201

0.201

0.67

0.201

0.67

0.201

0.67

0.201

0.67

0.201

0.67

0.201

0.67

ASD18

0.75

0.375

0.225

0.75

0.225

ASD19

0.75

0.375

0.225

0.75

-0.225

ASD20

0.75

0.375

0.225

-0.75

0.225

ASD21

0.75

0.375

0.225

-0.75

-0.225

ASD22

0.75

0.375

0.225

0.75

ASD23

0.75

0.375

0.225

-0.75

ASD24

0.75

0.375

0.225

-0.225

0.75

ASD25

0.75

0.375

0.225

-0.225

-0.75

ASD26

0.75

0.375

0.75

0.225

ASD27

0.75

0.375

0.75

0.225

-0.225

ASD28

0.75

0.375

0.75

-0.225

0.225

ASD29

0.75

0.375

0.75

-0.225

ASD30

0.75

0.225

0.75

0.225

ASD31

0.75

0.225

0.75

-0.225

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

FURNACE STRUCTURE CALCULATION REPORT

Client Document NO: MMTE Document NO:

MMTE Rev.

DATE: 1

GGMMSF10C4-001

Page:

22 of 24

ASD32

0.75

0.225

-0.75

0.225

ASD33

0.75

0.225

-0.75

-0.225

ASD34

0.75

0.225

0.75

ASD35

0.75

0.225

-0.75

ASD36

0.75

0.225

-0.225

0.75

ASD37

0.75

0.225

-0.225

-0.75

ASD38

0.75

0.225

ASD39

0.75

0.225

-0.225

ASD40

0.75

-0.225

0.225

ASD41

0.75

-0.225

Design Combinations

ASDF1

0.75

1.8

0.54

0.225

ASDF2

0.75

0.54

1.8

0.225

(With Over Strength Factor)

ASDF3

0.75

1.8

0.54

0.225

ASDF4

0.75

0.54

1.8

0.225

USD1

1.4

USD2

1.4

USD3

1.05

1.275

USD4

1.05

1.275

USD5

1.05

1.275 1.275

1.7

1.275 1.275 1.275

USD6

1.05

Design Combinations

USD7

0.9

(for Concrete Design)

USD8

0.9

USD9

0.9

USD10

0.9

USD11

1.05

1.275

1.4025

0.4208

USD12

1.05

1.275

0.4208

1.4025

USD13

1.05

1.4025

0.4208

USD14

1.05

0.4208

1.4025

USD15 Checking Combinations

ASD USD

1.4 env(ASD1 to ASD16) env(USD1 to USD15)

1.275 1.3 1.3 1.3 1.3

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE STRUCTURE CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev.

DATE: 1

GGMMSF10C4-001

Page:

23 of 24

6. ANALYSIS & DESIGN 6.1 MODELING According to standard No. 2800-05 3rd editions in Dual system, Flexural Frame must resist against 25% of Seismic Loads.

6.1.1 STRUCTURE MODELING In order for the purpose which goes in the previous section to be satisfied two Different SAP Analysis Model is prepared. Furthermore, the other model -Fixed Base Model- was prepared for comparing the design results between Flexible Model and Fixed Base one.

6.2 DEFORMATIONS Height of structure H=107 m In X and Y direction: Max â&#x2C6;&#x2020; W = (0.02x107)/(0.7x7)= 0.436 m For more information about the lateral drift refer to the appendices.

6.3 DYNAMIC ANALYSIS Dynamic analysis of structure will be performed in order to evaluate the seismic effect on structural components. 90 percent of the mass in each direction should be activated. TABLE: Modal Participating Mass Ratios OutputCase StepType StepNum Period UX UY UZ SumUX SumUY Text Text Unitless Sec Unitless Unitless Unitless Unitless Unitless MODAL Mode 1 1.912 0.727 0.006 0.000 0.727 0.006 MODAL Mode 2 1.540 0.006 0.723 0.000 0.733 0.730 MODAL Mode 3 1.267 0.000 0.005 0.000 0.733 0.734 MODAL Mode 4 1.081 0.000 0.000 0.000 0.733 0.734 MODAL Mode 5 1.052 0.001 0.000 0.000 0.734 0.734 MODAL Mode 6 0.975 0.000 0.000 0.000 0.734 0.734 MODAL Mode 7 0.967 0.006 0.000 0.000 0.739 0.734 MODAL Mode 8 0.926 0.003 0.000 0.000 0.742 0.735 MODAL Mode 9 0.913 0.000 0.002 0.000 0.742 0.737 MODAL Mode 10 0.803 0.009 0.000 0.000 0.751 0.737 MODAL Mode 11 0.719 0.098 0.000 0.000 0.848 0.737 MODAL Mode 12 0.706 0.000 0.002 0.000 0.849 0.739 MODAL Mode 13 0.670 0.000 0.003 0.000 0.849 0.741 MODAL Mode 14 0.665 0.000 0.000 0.000 0.849 0.742 MODAL Mode 15 0.652 0.002 0.014 0.000 0.851 0.756 MODAL Mode 16 0.644 0.000 0.076 0.000 0.851 0.832 MODAL Mode 17 0.601 0.000 0.001 0.000 0.851 0.833 MODAL Mode 18 0.595 0.000 0.000 0.000 0.851 0.833 MODAL Mode 19 0.578 0.000 0.000 0.000 0.851 0.833 MODAL Mode 20 0.576 0.000 0.001 0.000 0.851 0.834 MODAL Mode 21 0.560 0.000 0.000 0.000 0.851 0.834 MODAL Mode 22 0.558 0.000 0.000 0.000 0.851 0.834 MODAL Mode 23 0.551 0.000 0.003 0.000 0.851 0.837 MODAL Mode 24 0.542 0.001 0.000 0.000 0.852 0.837 MODAL Mode 25 0.519 0.000 0.001 0.000 0.852 0.838 MODAL Mode 26 0.511 0.000 0.000 0.000 0.852 0.838

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No: Client Document NO: MMTE Document NO:

FURNACE STRUCTURE CALCULATION REPORT

MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL

Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

MMTE Rev.

DATE: 1

GGMMSF10C4-001

0.496 0.492 0.489 0.488 0.484 0.483 0.475 0.475 0.473 0.471 0.469 0.466 0.457 0.455 0.447 0.444 0.442 0.440 0.433 0.431 0.425 0.424 0.416 0.412

0.000 0.001 0.002 0.000 0.000 0.000 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.001 0.033 0.000 0.000 0.000 0.005 0.017

0.000 0.000 0.000 0.000 0.000 0.001 0.000 0.000 0.000 0.000 0.000 0.001 0.004 0.017 0.000 0.000 0.000 0.003 0.000 0.000 0.000 0.002 0.001 0.007

Page:

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.003 0.002 0.001 0.000 0.000 0.000 0.000 0.002 0.008 0.000 0.000 0.006 0.032

0.853 0.853 0.855 0.855 0.855 0.855 0.856 0.856 0.856 0.856 0.856 0.856 0.857 0.857 0.857 0.857 0.857 0.859 0.891 0.891 0.891 0.891 0.896 0.913

24 of 24

0.838 0.838 0.838 0.839 0.839 0.839 0.839 0.840 0.840 0.840 0.840 0.841 0.845 0.862 0.862 0.862 0.862 0.865 0.865 0.865 0.865 0.867 0.868 0.875

TABLE: Modal Load Participation Ratios OutputCase ItemType Item Static Dynamic Text Text Text Percent Percent MODAL Acceleration UX 99.846 91.307 MODAL Acceleration UY 99.461 87.462 MODAL Acceleration UZ 7.1176 5.671

As the result show, almost 90% of the mass in each direction is activated.

7.1 INTERNAL FORCES For internal forces in ASD and ASDF level refer to SAP analysis Model.

7.2 DESIGN RATIO For all design results refer to GGMM-Furnace-Flexible Model and also GGMMFurnace-Fixed Base Model. In fact, these two Model were prepared to compare their design results.(Monorail Loads was considered in Fixed Base Model.) For Design results of Flexural Frame refer to GGMM-Furnace-C=25% Model.