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analysis and design for conveyor gallery
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TenderTechnicalSpecification
TechnicalSpecificationforDevelopmentofParametricProgramsforcustomizationandOptimizationofVariousCoalHandlingPlant(CHP)structuresShortDescriptionoftender DevelopmentofDesignAutomationTools forCustomizationofAnalysisand Optimization of various Structuralcomponents inCoal Handling Plant (CHP) like Conveyor Galleries, Trestles andTransferTowersconsideringvarious loadsand theircombinationsas per Indian Standard Codes using FEMAP API for parametricmodeling and interfacing such toolwith the available softwaressuch as PROKON and STAAD Pro, with auto execution formodeling, analysis including design optimization with technicalreportsandBOMasperTechnicalSpecificationprovidedbyBHEL.CHPstructuresconsistsofvarioustypesofconveyorgalleriesandtrestlesalongwithjunctionhousesandotherstructuralsubsystemsAstherearehugenumberofvariantsinthetypesofgalleries,trestlesandtransfertowerswithvariousrequirementssuchaslengthsloadcarryingcapacities,single/doublegalleriesetc,itisproposedtodevelopaparametricprogramtodevelopthemathematicalmodelandinterfacewithanalyticalpackagesandrelevantdesigncodesasperIndianStandards.
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Thetotalsystemofautomatedprogramisbasicallydividendintofollowingsections1)GeneralGuidelines2)Basictypesofgalleries,trestlesandtransfertowers.3)Developmentofparametricmathematicalmodelofgalleries,trestlesandtransfertowers4)Generationof3DMathematicalmodeland3Dframefromtheabove5)Impositionofloadscalculatedasperrelevantcodesandconstraintsforvariousconditions6)Developmentofinterfaceswithexistingsoftwarefortheaboveprogram7)Afterexecutionofprograminanalysispackage,retrievalofproperties,analysisdata,forcesandmoments8)DevelopmentofprogramtoreadthesevaluesintoaseparatelydevelopedcodeasperIndianStandardsandcrosscheckingforstrengthandstabilityusingthesecodes9)Preparemodelwithrevisedpropertiesforoptimization10)Recheckingresultsforsystemsafetyandfurtheroptimizationandcalculationofsectionalproperties11)Preparationofbillofmaterialandcuttingdiagramsandcalculationofrawmaterialweightsetc12)PreparationofdxffilefromanalysismodelsuitableforplottinginAutoCad.
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
ThetenderisinvitedforcarryingoutdevelopmentalworkwhichwouldresultintoacustomizedDesignandAnalysisToolforthespecifiedcomponentsofCoalHandlingPlant(CHP).Thebrieftechnicalscopeisasunder.
1. ComponentsConsideredareConveyorGalleries,TrestlesandTransferTowers.
2. Basic initialgeometry is tobearrivedatbasedonphysical requirementsof space,sizeandcapacity.
3. Development of parametric programs to convert the physical configuration intofiniteelementmodelsusingFEMAPwithparametersandconstraints.
4. Finiteelementanalysisofthecomponentunderthe loadingasper IndianstandardCodes.ThisistobedonebylinkingtheFEmodelstoanalysispackages,STAADPROandwithPROKON.
5. InterpretationofresultsaccordingtoIndianstandardcodes 6. Iterativeoptimization(repetitionofsteps2to5)togetacceptabledesign(Stressand
deflections)fromconsiderationofweight. 7. Convertsthefinalconfigurationintodrawings,BOM,andautogenerationofdesign
report. The Scope mentioned above is detailed with some more intermediate steps asmentionedbelow.
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
GeneralguidelinesforcustomizationfordevelopmentofParametricprogram1)ForcustomizationofcodesandinputofframesinprogramacontinuousinteractionwithBHELanddeveloperisrequiredforproperguidancefromtheIndentingdepartment.
2)Initially,afterplacementoforder,theDeveloperhastoworkwiththeindentingDepartmentatBHELR&DHyderabadtoformulatethedesignprocedureandproceduretobefollowedandworkshouldbecarriedoutjointlyduringthefirstphaseofdevelopment.DeveloperhastovisitR&DandstayathisownexpensesandBHELwillnotpayanyexpensestowardstravel,boardingandlodgingoranyothercharges.
3)Thelogicandguidancegivenforcustomizationareonlyindicativetoquantifytheamountofworkinvolved.Thelogicofpreparingtheframesmaychangesduringthecourseofdevelopment,ifneeded.Theremaybechangesinconfigurationofstructuresduringthecourseofdevelopment,whichneedstobeconsidered.
4)ThesoftwarelogicpreparedwillbethepropertyofBHELandthesupplierordeveloperwillnothaveanyrightsontheprogramsdevelopedandwillbecopywrited/patentedbyBHEL
5)TheDevelopershouldmaintainstrictconfidentialityofthejointworkbeingcarriedoutandshouldsigntheconfidentialityagreementbeforestartingthework.
6)ItisthedevelopersresponsibilitytotestthesoftwareandcustomizationpreparedfortypicalCHPstructuresofearlierjobsasgivenbytheindentingdepartment
7)ThedevelopershouldprovideOperatingmanualandotherprocedurestobefollowedforexecutingthestructuralanalysisjobs.
8)TheinitialmodelsandparametricprogramsmustbedevelopedusingthepreprocessorandAPIprogramcapabilityofFEMAPforcheckingatBHELTheprogramsmustinterfacewithPROKONandSTAADProsoftwares,whichareavailableatBHELandhavetobetestedatIndentingdepartment.Thecustomizationandmodelingdatahastocarriedontheexistingsoftwares.Howeverthesupplierisfreetodeveloptheprogramsonanyotherplatformsuitabletohimandthesamesoftwarealongwiththefullprogramcodeistobe
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
suppliedalongwiththedevelopedcodes,butfinalinterfacingmustbedonewiththeaboveavailablesoftwaresatBHEL(FEMAP,PROKONandSTAADPro).
9)Thesuppliermaysendsamplesofsuchdevelopedcodeforanyotherproduct/structureinaboveformatsforassessingthetechnicalsuitability,ifavailable.
10)ThedesignmustcomplywithIndianStandardcodeslikeIS800bothworkingstressandlimitstatedesignsandthecodesshouldbeincorporatedintheanalyticalengineforautomaticdesignchecks
11)TheloadingsshouldfollowtherequiredIndiancodesasperIS875andIS1893(latestVersions)
12)Thedeveloperhastotesteachphaseofprogrambeforeproceedingtothenextphase
13)Therequiredeffectivelengthcalculations,Kfactordetermination,optimizationroutineswithdifferentloadcombinationsasperIndiancodesmustbeincorporatedandinterfacedwiththeabovementionedanalyticaltools.
14)TheInformationcontainedinTenderDocumentsisconfidentialandshouldnotbeusedforanyotherpurposeotherthanforquoting/executingforthisenvisagedwork.
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
TechnicalspecificationGeneralIntroductionofCHPStructures:The coalHandlingPlant (CHP) structures consistsof various conveyor galleries carryingcoal from coal yards to the bunkers in the boiler area of a thermal power plant. Thesegalleriesrunfromgroundleveltobunkerlevelwhichisapproximately50to60metreshigh.TypicalLayoutofaplantisasshownbelow:
TypicalLayoutofaPowerplant
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
TypicalConveyorsystem:Theconveyorsystemdesignedtocarrycoalisgenerallyinclinedconveyorsystemwithsingleordoubleconveyorsonasinglegallery.Thelengthofeachgallerysegmentvariesbetween8mto30minlengthandwidthsfrom4to10m.Theyaresupportedbyverticalsupportingstructurecalledtrestles.Thesemaybetwoleggedtrestlesor4leggedtrestles.TypicalGalleriesrunninginacoalplantareasshownbelow:
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
AsseenfromtheabovefiguresthegalleriesareofdifferentlengthsandinclinationsandtheserunfromgroundtobunkerheightwithvarioustypessupportingTrestlesinbetween.Thelocationoftrestlesdependonsiteconditionsuchaslayoutofroads,pipingandlocationofotherequipment
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
TypesofGalleries:Inordertostandardizethenumberandtypesofgalleries,itisproposedtostandardizebasedonthetypicallengthsforvarioussingle/doublegalleries.ThewillbebasicallyTWOtypesofgalleriesgalleriescarryingonebeltconveyororGallerycarryingtwoconveyorbeltsasshownbelow:ThecrosssectionaldetailsofSingleconveyorGalleryisasshownbelow:
ThecrosssectionaldetailsofaDoubleconveyorGalleryisasshownbelow:
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
LengthsofConveyorGalleries:Itisproposedtostandardize4lengthsofgalleriessuchas12m,18m,24mand30mforthepurposeofoptimizationanddevelopmentoftool.Thetypicalarrangementofsingleconveyorgalleryisasshownbelow:
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
SimilarlytypicalDoubleConveyorgalleriesareshownbelow:
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Design Guidelines
Theoverheadgallerygirderconsistsoftwoverticallatticedgirderconnectedwithtwoendportal.Crossbeamssupportingwalkway runner&conveyor stringermadeofplategirderconnectingthebottomchordsoftheverticalgirder.Therooftrussessupportingthepurlinsareconnecting the topchordof theverticalgirder.The top&bottomplanof thegallerygirder are horizontally bracedwith V bracings.A space framemodel is required to bepreparedontheabovebasisforanalysisConveyorgallerygirdersaretobedesignedasapairofgirders,bracedattopandbottomlevels.Agallery consistsof two girdersofdepth approx 2.8m ,bracedat topandbottom chordlevels to transmit loads to end portals which in turn connected to trestles. Roof truss isprovidedatupperendpoints@3mc/ctoformanenclosure.Crossbeamsatbottomchordlevel spanning between the two girders is provided to support walk way and conveyorsupportingstructuresTypicalarrangementisasshowninabovefigures.DevelopmentToolRequirement:ThedesignOptimizationGUIbaseddevelopmenttooltobepreparedforeachtypeofgallery,trestle and transfer tower. InitialModel tobepreparedusing FEMAPAPI for checking andinterfacing.Theparameterizedmathematicalmodelhas tobedevelopedusing theFEMAPAPIprogramonly.Othermodesofdevelopmentarenotacceptable.The modelhas tobedeveloped fordifferent optimum configurations of various types of structures. For example there APIprogramsofa12mgalleryofasingleconveyorsystemwillbedifferenttothatofa12mgallerystructurefordoubleconveyorsystem.ThemathematicalmodeldevelopedbythetoolhastobeintegratedwithanalyticalsoftwaresPROKONand STAADPro for analysis,design andOptimization automaticallywithoutuserintervention.TheDetailsAre:
1) For Single Conveyor and Double Conveyor Systems
TheprogramhastobedevelopedforeachoftheGallerylengthsa)12minlengthb)18minLength
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
c)24minlength.andd)30mlengthThemathematicalmodelspreparedwillalsodependonthetypeofmaterialtobecarried.ThestructuremaydifferforcarryingcoalfromthattocarryLigniteetc(ForLignitecarryinggallerythecablesetcaretobeplacedoutsidetheconveyorstructure).ThefollowingvariablesneedtobeconsideredforthedevelopmentofmathematicalmodelA)CoalfeedingratesVariablesareBoilerSpecificationsuchas110MW,250MWor500MWBoilerwithfeedingratesof400,600,800,1200,1400,1600,1800and2000Tonnes/Hr(Add20%ExtraLoad)B) InclinationofConveyor from0 to15Deg in stepsof1degree. (The loadonwalkwayincreasesforinclinationsmorethan10degduetothepresenceofstepsinsteadoffloor)C)TheendofPortaltobesuitablydesignedfortheaboveinclinationD)BeltspeedProgramshouldinputvariablebeltspeedforeachgallery.E)Walkwayfollowingtobeconsideredi)Singlesidewalkwayii)Walkwayonbothsidesofconveyor(maybeofdifferentwidths)forsingleconveyorsystemandiii) For double conveyor system , thewalkways in themiddle aswell as at end to beconsideredThe walk ways on both sides may differ in widths ( Variable width walk way to beconsidered)F)InclusionofsealplatelengthandweightofcoaltobeconsideredG)DeckPlatetobeconsideredanddustloadtobeconsideredH)Variablewindloadaspertheheightofgallery(Heightatwhichithastobeerectedisaparameter)I)SiteLocationJ)windspeedsasperIS875K)SeismicloadsasperIS1893L)Otherparametersasrequiredbythesiteconditionsandcustomerrequirement.
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Design Codes to be Followed : IS:875(Part2)1987CodeofpracticeofDesignLoad(Otherthanearthquake)forBuilding&structureImposedLoadsIS:875(Part3)1987CodeofpracticeofDesignLoad(Otherthanearthquake)forBuilding&structureWindLoadsIS18932002Part1andIS18932005PartIVforseismicloadsIS:8002007CodeofpracticeforGeneralConstructionofSteelBothworkingstressandLimitstatedesignneedtobecheckedIS:8081989DimensionforHotRolledSteelBeams,Column,Channel&AngleSectionIS115922000CodeofPracticeforSelectionanddesignofBeltConveyorsLoadParametersThedetailedloadcalculationparameterstobeconsideredareasgivenbelow
DataTobeconsideredforLoadCalculations1.A DesignDataandVariables1) DepthofGallery2) WidthofPanel3) RoofSlope4) Beltwidth5) DesignCapacity6) BeltSpeed7) Wt.ofBelt(Carrying+Return)8) Wt.ofIdler(Carrying+Return)9) Wt.ofStringer,ShortPost,Etc.10) Wt.ofHandrail(assumed)11) Wt.ofLightingArrangements12) Wt.ofCableTray13) Wt.ofFirefightingpipe14) Wt.ofServicewaterpipe15) Wt.ofDSWaterpipe
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
16) Wt.ofpotablewaterpipe17)BasicWindSpeedB. LoadonGallery: 1) WindLoad: Basicwindspeedbasedonsitelocation DesignWindspeedshouldbecalculatedfordifferentheightsasperfactorsk1,k2(andvarieswithHeight)andk3ofIS:875Part3 DesignWindpressurefordifferentheightstobecalculatedVzforupto10.0mheightVzfor10to15mheightVzfor15to20mheightVzfor20to30mheightVzfor30to40mheightVzfor40to50mheightVzfor50to60mheightVzfor60to70mheightVzfor70to80mheightneedtobecalculated
2) MaterialLoad: HereCapacityoftheconveyor(TonnesperHourTPH)tobeconsideredThenwt.ofmaterialonbeltpermeterlengthtobecalculatedbasedontheBeltSpeedOtherParametersareWeightofbeltandconsider10%extra(asperIS11592)thencomputeTotalMaterialweightonbelt. 3) LiveLoadonWalkway: AspercodeLLonwalkway 4) LiveLoadonSealPlate: LiveLoadonsealplate 5) LiveLoadonDeckPlate: LiveLoadondeckplate Widthofeachdeckplate andLLfromeachdeckplatetobecomputed
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
6) WeightofPipe: Totalweightofservicewaterpipe TotalweightofDSwaterpipe Totalweightofpotablewaterpipe 7) LoadofCableTray: TotalWeightofCableTrayongalleryistobeconsidered Then,loadononesidegallerygirderduetocabletrayiscomputed Then,loadonotherside(pipeside)gallerygirderisalsotobecomputed 8) LoadonRoof: Hereroofslopetobeconsidered a)LiveLoad=AsperIS.875Part2LLonroof b)DustLoad=AsperDustLoad HenceUDLonroofistobecomputed 9) LoadofLightingArrangement: Hereloadoflightingarrangementforperlightpointistobeconsidered 10) LoadofFireFightingArrangement: LoadofFirefightingarrangementattwojointsineachrooftrusstobeconsidered 11) DeadLoadonGallerytobecomputedconsidering Selfweightofroofsheeting Selfweightofsidesheeting Selfweightofpurinsandsiderunner Selfweightofchequeredplate Selfweightofdeckplate Selfweightofsealplatewithstiffener
SelfweightofothermembersshallbetakenasapplicabletotherespectivemembersasperIS.808
12) Conveyorloadcalculationsshouldconsider
Conveyorloadstandsfordeadloadofconveyor
Weightofidler(Carrying+return) Wtofstringer,Sh.Post,etc. Wt.ofdeckplate
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
13) Wt.ofHandrail Wt.ofsidehandrail Wt.ofotherhandrail.C. LoadCalculation:I. DEADLOAD(DL): 1) InternalPanel:
Loadintensityoneffectivewidthoftruss 2) Loadonfloor:
DLon0.8mwideright/leftwalkwayand0.175mwidesealplatesupportingmemberswiths/w
DLonbottomchordmembersfrom0.175widesealplate
DLfrom0.175mwidesealplateand2.05mwidesealplatesupportingmembers
DLfrom1mwidemiddlewalkwayand0.175mwidesealplatesupportingmemberswiths/w
3) Loadofsidesheetingandsiderunner:
Loadintensityistobeassumedtobeactingon sidesheeting LoadonInternalPortion: loadontopandbottomnodesofeachverticalstobecomputed LoadonPortal Loadontopandbottomnodesofeachverticalstobecomputed 4) ConveyorLoad: Totalweightofconv.(excludingbeltwt.) Loadfromeachshortpost/sidetobecalculatedbasedonShortpostspacing
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
5) Loadfromhandrail:
Wt.ofsidehandrail Wt.ofotherhandrail Loadfromhandrail(otherthansideHR)tobeconsidered
II. LIVELOAD(LL):1) LoadonRoof: LoadintensityassumedtobeactingonInternalPannelandtransferredtothetrusses2) Loadonfloor:
LLon0.8mwideright/leftwalkwayand0.175mwidesealplatesupportingmembers
LLonbottomchordmembersfrom0.175widesealplate
LLfrom0.175mwidesealplateand2.05mwidesealplatesupportingmembers
LLfrom1mwidemiddlewalkwayand0.175mwidesealplatesupportingmembers
3) MaterialWeight:
TotalMaterialweightofconv.(beltwt.+liveloadondeckplate) Loadfromeachshortpost/sideiscalculatedbasedonShortpostspacing 4) Loadfrompipe: Weightofservicewaterpipetobeconsidered WeightofDSwaterpipetobeconsidered Weightofpotablewaterpipetobeconsidered 5) LoadfromCableTray: Loadintensityofcabletrayononegirdertobeconsidered
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Loadintensityofcabletrayonotherside(pipeside) girdertobeconsidered 6) LoadfromLightingArrangement: 30kgoneachnode 7) LoadfromFireFightingPipeLine: WeightofFireFightingpipetobeconsidered.III. WINDLOAD:AsperIS.875(Part.3) 1) LoadonRoof: Basedonheightandwidthofthegallery Andangleofroof WindpressurecoefficientsforrooftobecalculatedasperIS875(Part3)andConsider Whenwindblowsacrosstheconv. Whenwindblowsalongtheconv.ThepressurecoefficientstobecalculatedonWindwardSideandLeewardsidewithdifferentconfigurationstobecomputed.Fromthis,UDLonRooftrussandendpanelsaretobecomputed 2) LoadonSideSheeting:
Considerheight,widthandlengthofthegallery andcalculatetheWindpressurecoefficientsforroofasperIS875 Whenwindblowsacrosstheconv.andWhenwindblowsalongtheconv.Computethefollowingloadcases
Whenwindisblowingacrosstheconv. Windpressureinwindwardside Windpressureinleewardside Windloadonverticals(IntermediatePanels) Windwardside(onTopsupport)
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Windwardside(Bottomsupport) Leewardside(onTopsupport) Leewardside(Bottomsupport) WindloadonPortal Windwardside(Topsupport) Windwardside(Bottomsupport) Leewardside(Topsupport) Leewardside(Bottomsupport)
Whenwindisblowingalongtheconv. (BothwindwardandLeewarddirectionareoppositeinsign) windpressureinperpendiculardirectiontowindflow ForIntermediatePanels WindLoadontheverticals(Topsupport) WindLoadontheverticals(Bottomsupport) ForEndPortal WindLoadontheportals(Topsupport) WindLoadontheportals(Bottomsupport)OtherloadstobeconsideredareSeismicloadsasperIS1893ifapplicableSummationofLoadcasesandLoadcombinationstobeconsideredforanalysisanddesign************************************************LOAD1[DL]************************************************SELFWEIGHT*****LoadonRoof:JOINTLOADMEMBERLOAD*****LoadonFloor****DLonleftwalkwayandsealplatesupportingmembers*******DLonrightwalkwayandsealplatesupportingmembers****DLonBottomchordmembersfromSealplate*****DLfromsealplateandsealplatesupportingmembers***DLfrommiddlewalkwayandsealplatesupportingmembers****LoadofsideSheetingandSideRunner:***ConveyorLoad:*****Loadfromhandrail
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
*****WtofotherHandrail*******LoadofsideHandrail************************************************LOAD2[LL]*********************************************************LoadonRoof:JOINTLOADMEMBERLOAD*****LoadonFloor*****LLonleftwalkwaysealplatesupportingmembers****LLonrightwalkwayandsealplatesupportingmembers*****LLonBottomchordmembersfromSealplateMEMBERLOAD*****LLfromsealplateandsealplatesupportingmembers****LLfrommiddlewalkwayandsealplatesupportingmembers****MaterialLoad:MEMBERLOAD****LoadfromPipes:****LoadfromCableTray:*****LoadfromLightingArrangement:JOINTLOAD*****LoadfromFireFightingPipeLine:MEMBERLOADLOAD3[WL(+X)]******************************************************LoadonRoof:*****loadonrooftrussesJOINTLOAD*****LoadonSideSheeting:****WindwardsideMEMBERLOADLOAD4[WL(X)]******************************************************LoadonRoof:*****loadonrooftrussesJOINTLOAD*****LoadonSideSheeting:****Windwardside****leewardside************************************************LOAD5[WL(+Z)]******************************************************LoadonRoof:JOINTLOAD*****LoadonSideSheeting:****WindwardsideMEMBERLOAD***leewardside************************************************LOAD6[WL(Z)]************************************************
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
******LoadonRoof:JOINTLOAD*****LoadonSideSheeting:****WindwardsideMEMBERLOAD***leewardside************************************************FollowingLoadcombinationstobeconsideredinanalysisLOADCOMB101[DL+LL]11.021.0LOADCOMB1020.75[DL+LL+WL(+X)]10.7520.7530.75LOADCOMB1030.75[DL+LL+WL(X)]10.7520.7540.75LOADCOMB1040.75[DL+LL+WL(+Z)]10.7520.7550.75LOADCOMB1050.75[DL+LL+WL(Z)]10.7520.7560.75LOADCOMB106[0.9DL+WL(+X)]10.931.0LOADCOMB107[0.9DL+WL(X)]10.941.0LOADCOMB108[0.9DL+WL(+Z)]10.951.0LOADCOMB109[0.9DL+WL(Z)]10.961.0*************************************************
MathematicalmodelInputrequirements
ThemathematicalmodelpreparedshouldhaveNodalDataMemberconnectivityDataMembersectionalDatabaseofallthedifferenttypesofsections(Standardrolledaswellasbuiltupsections)MembermaterialspecificationsMemberendreleasedataMembertrussinformationSupportspecificationinappropriatecoordinatesystem(shouldconsiderinclinedgalleriesanditsinclinedsupports)LoadingdataasspecifiedaboveDesignParametersfordesignofmembersasperIS800likeEffectivelengthofeachmemberinbothdirectionsfordesignCodeparameterslikeKY,KZ,LY,LZ
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
DesigndeflectionlimitsDesignallowableyieldstressNeteffectiveallowableinteractionfactorsforwind/seismicaswellasDeadloadcasesAnalysisanddesigncommandsAutomatediterativeprocedureforcarryingoutOptimizationTheOptimizationruntobecarriedoutinside the softwares ( PROKON and STAAD Pro) The programs should choose automatically therequired section from the software database of similar sections and perform the optimizationinteractively togetbestpossibleweight reduction to satisfy the relevant codesofpracticeunderconsiderations.(theOptimizedsectionsizesmaybedifferentforIS800workingstresscodeandtothatof IS800Limitstatedesign foragivenproblem).Themain requirementofdeveloped tool isthatthecompleteoptimization runs tobecarried insidethePROKONandSTAADProwithoutanyuserintervention.TheoutputshouldincludeDesignresultswithinteractionfactorsorreservestrengthavailableforeachmemberTheoptimizedsectionsizesandSteelrequirementtablessectionwiseandplatethicknesswiseifapplicable.*PROKONisregisteredsoftwareofM/s Prokon Software Consultants (Pty) Ltd, South Africa*FEMAPisregisteredpre/postprocessorsoftwareofM/sSiemens*STAADProisregisteredsoftwareofM/sBentleyLtdDesignofvariousothermembers:Designofvariousothermemberswhicharenotthepartofanalyticalmodelneedtodesignedseparately.Suchmembersare:Siderunners,Conveyorsupportingmembers,Sidewalkwaysupportingmember,purlinsandothermembers
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
AnalysisandDesignChecksandOptimization1)Calculate theseismiccoefficientsand loadingasper IS1893and imposethe loadings inbothhorizontaldirectionsasseparate loadcases inthepreprocessor ifseismic analysis isrequired.2)generatedifferentloadcombinationsasperIS8003)Calculateeffective lengthsofeachofcolumnmembers inbothXandZdirections(Y isverticaldirection)4)Executethejobforalltheloadcases5)CodechecktheresultsasperIS800workingstressandlimitstatedesign6) Optimize or resize /modify the properties as per code check results and rerun andrecheckandrepeatifnecessary7)Calculateapprox.weightofstructurebasedonanalysiswithdetailssuchasweightofmemberspropertywise8)CalculateRawmaterialweightifdifferentfromabove9)DesignBaseplateandnumberandsizeoffixingbolts10)Compute finalweight and also report consolidatedweights asper thicknesses andsizes11)ExportvariousfigurestoAutocadorDXFfiles12)Preparationofcompletereportautomatically13)Thedevelopedtoolalongwithsourcecodetobesubmitted14)InstallationandUsermanualtobepreparedandsubmitted
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
SoftwaretoolRequirementforGalleriesThe following tools to be developed based on the above logic and instructions forcalculationofloadsforpreparationofmathematicalmodelandforanalysisanddesignwithfinaloptimizedstructure.(GUIbasedDesign)inasinglestokeofinputs.Automated Development tool ( for seamless execution at the push of a button) to bedevelopedfor1)SingleConveyorGalleryStructureoflength12musingPROKON2)SingleConveyorGalleryStructureoflength12musingSTAADPro3)SingleConveyorGalleryStructureoflength18musingPROKON4)SingleConveyorGalleryStructureoflength18musingSTAADPro5)SingleConveyorGalleryStructureoflength24musingPROKON6)SingleConveyorGalleryStructureoflength24musingSTAADPro7)SingleConveyorGalleryStructureoflength30musingPROKON8)SingleConveyorGalleryStructureoflength30musingSTAADPro9)DoubleConveyorGalleryStructureoflength12musingPROKON10)DoubleConveyorGalleryStructureoflength12musingSTAADPro11)DoubleConveyorGalleryStructureoflength18musingPROKON12)DoubleConveyorGalleryStructureoflength18musingSTAADPro13)DoubleConveyorGalleryStructureoflength24musingPROKON14)DoubleConveyorGalleryStructureoflength24musingSTAADPro15)DoubleConveyorGalleryStructureoflength30musingPROKON16)DoubleConveyorGalleryStructureoflength30musingSTAADProAll the above tools should be preparedwith the parameters (like different inclinations,differentloadsonbelt,differentwindloadsetc)asmentionedinthisspecification.Theanalyticalmodeldataistobepreparedinitially(inFEMAPAPIlanguage)shouldbecheckedandapprovedbytheindentingdepartmentbeforeproceedingwiththeprocessofanalyzing and interfacingwith the analytical softwares fordesign and optimizationwithautomation.
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Part2SpecificationforTrestles
Similarly the trestles on which the above galleries rest, have to be designed withappropriatesystemconfigurations.TheGalleriesaresupportedmainlyonTWOtypesofTrestlesa)DoubleleggedTrestleandb)FourleggedTrestleTypicalarrangementofthesetrestlesisasshownbelow:
Thespacingwilldependontheconfigurationoflayout,gallerylengthsetc.ThetrestleswidthwillbedifferentforSingleconveyorgalleryandthatforDoubleconveyorgallery.Typicaltwoleggedtrestlesandtheirarrangementisshownbelow:
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
AsseenfromtheabovetheheightofTrestleanditsconfigurationvariesdependingonthelocationandheights.Typical4leggedTrestlesareasshownbelow:
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Thedesignoftrestleisbasedonthefollowingparameters:ForTWOLEGGEDTRESTLEHeightofthetrestle=inm
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
WidthofbaseOftrestleinm(DifferentforSingleandDoubleConveyorsystem)LoadcomingfromSideLHSandRHSlongGalleriesDeadLoad=LiveLoad=ForLHS Gallerydesignwindpressureconsidered, foragiven height (tobetakenfromGalleryCalculations)andherewindpressuretobeconsidered,alongtheheightoftrestle(differentvaluesfordifferentheights)SimilarlyForRHSGallerydesignwindpressureconsidered,foragiven height (tobetakenfromGalleryCalculations)andherewindpressuretobeconsidered,alongtheheightoftrestle(differentvaluesfordifferentheights)Hence,totalWindLoadtobecomputedHorizontal(max)Horizontal(min)Vertical(max)Vertical(min)Therefore,UDL,windloadtobeconsideredas(Forupto10.0mheight)(For10.0mto15.0mheight)(For15.0mto20.0mheight)(For20.0mto30.0mheight)(For30.0mto40.0mheight)(For40.0mto50.0mheight)And Calculatewind Pressure , Pz (For up to 10.0m height) for Class ? Structure and TerrianCategory?asperIndianDesigncodesPz(For10.0mto15.0mheight)forClass?StructureandTerrianCategory?Pz(For15.0mto20.0mheight)forClass?StructureandTerrianCategory?Pz(For20.0mto30.0mheight)forClass?StructureandTerrianCategory?
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Calculatethebaseplateandshearkeydetailsaspercodes
DESIGNOFTRESTLESBaseplateVerticalDLUnitintonesandLLalongwithWL(for()Z)tobeconsideredMaximumbearingpressureonconcrete,tobecomputedaspercodeandshouldbelessthanallowablebearingcapacity.Thefoundationboltsaretobedesignedaspertherequirement.ConsideringxnosbolttensionperboltiscomputedDesignofBolt:HeremaximumtensionperboltDesignofShearKey:Here,maximumshearperlegisconsideredConsideringxxxmmwideXxxxmmdeepshearkeywithxxmmthk.andcheckgroutingBMatthebottomfaceofbaseplateanddesigntheshearkeyaccordingly.
SoftwaretoolRequirementforTrestlesThe following tools to be developed based on the above logic and instructions forcalculationofloadsforpreparationofmathematicalmodelandforanalysisanddesignwithfinaloptimized structure.(GUIbasedDesign)As inearlier case the initialmathematicalmodeltobedevelopedandinterfacedinFEMAPAPI.AutomatedDevelopmenttool(forseamlessexecutionatthepushofabutton)for1)2leggedTrestleStructureofHeightsupto25mforSingleConveyorusingPROKON2)2leggedTrestleStructureofHeightsupto25mforSingleConveyorusingSTAADPro3)2leggedTrestleStructureofHeightsabove25mforSingleConveyorusingPROKON
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
4)2leggedTrestleStructureofHeightsabove25mforSingleConveyorusingSTAADPro5)4leggedTrestleStructureofHeightsupto25mforSingleConveyorusingPROKON6)4leggedTrestleStructureofHeightsupto25mforSingleConveyorusingSTAADPro7)4leggedTrestleStructureofHeightsabove25mforSingleConveyorusingPROKON8)4leggedTrestleStructureofHeightsabove25mforSingleConveyorusingSTAADPro9)2leggedTrestleStructureofHeightsupto25mforDoubleConveyorusingPROKON10)2leggedTrestleStructureofHeightsupto25mforDoubleConveyorusingSTAADPro11)2leggedTrestleStructureofHeightsabove25mforDoubleConveyorusingPROKON12)2leggedTrestleStructureofHeightsabove25mforDoubleConveyorusingSTAADPro13)4leggedTrestleStructureofHeightsupto25mforDoubleConveyorusingPROKON14)4leggedTrestleStructureofHeightsupto25mforDoubleConveyorusingSTAADPro15)4leggedTrestleStructureofHeightsabove25mforDoubleConveyorusingPROKON16)4leggedTrestleStructureofHeightsabove25mforDoubleConveyorusingSTAADProTheanalyticalmodeldataistobepreparedinitially(inFEMAPAPIlanguage)shouldbecheckedandapprovedbytheindentingdepartmentbeforeproceedingwiththeprocessofanalyzing and interfacingwith the analytical softwares fordesign and optimizationwithautomation.
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Part3SpecificationforTransferTowersSimilarlythetransfertowersonwhichtheabovegalleriesrest,havetobedesignedwithappropriatesystemconfigurations.TheTransfertowersaresupportedmainlyonTWOtypesoftransferpointsa)Type1BunkerTransferPointStructurefor500MWBoilersandb)Type2BunkerTransferPointStructurefor600MWBoilersThesewillforDoubleconveyorsystemforthepresentTypicalarrangementofthesetrestlesisasshownbelow:
TypicalArrangementofaTransferTower
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
TypicalCrosssectionsatTopsectionofTransferTowers
TypicalSideviewsofTransferTowersThedesignofTransferTowersisbasedonthefollowingparameters:HeightoftheTower=inmWidthofbaseOfTPinm(forDoubleConveyorsystem)LoadcomingfromSideLHSandRHSlongGalleries
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
SoftwaretoolRequirementforTransferTowersThe following tools to be developed based on the above logic and instructions forcalculationofloadsforpreparationofmathematicalmodelandforanalysisanddesignwithfinaloptimizedstructure.(GUIbasedDesign)consideringinterferencefreecolumnjoints(1000mm away from floors), chute loads, machinery loads. As in earlier case the initialmathematicalmodeltobedevelopedandinterfacedinFEMAPAPI.AlsodesignhastobequalifiedandcheckedfornaturalfrequencyofthesystemAutomatedDevelopmenttool(forseamlessexecutionatthepushofabutton)for1)Type1BunkerTPStructurefor500MWBoilerDoubleConveyorusingPROKON2))Type1BunkerTPStructurefor500MWBoilerDoubleConveyorusingSTAADPro3))Type2BunkerTPStructurefor600MWBoilerDoubleConveyorusingPROKON4)Type2BunkerTPStructurefor600MWBoilerDoubleConveyorusingSTAADProTheanalyticalmodeldata istobeprepared initially( inFEMAPAPI language) shouldbecheckedandapprovedbytheindentingdepartmentbeforeproceedingwiththeprocessofanalyzing and interfacingwith the analytical softwares fordesign and optimizationwithautomation.CombinedPrograms:Finally2softwaretoolsaretobedevelopedoneachforPROKONandSTAADProcombiningtherequirednumberofgalleriesand trestlesasasingle file forexecutionconsidering theloadsfromgalleries,windloadsandseismicloadsetc.Tool1Combine4 to6gallerieswith trestlesand transfer towers. if requiredasper theplantlayoutrequirementusingPROKONSoftwareTool2Combine4 to6gallerieswith trestlesand transfer towers. if requiredasper theplantlayoutrequirementusingSTAADProSoftware
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
General:Alltheabovetoolsshouldbepreparedwiththeparameters(likedifferentheights,differentloadsduetowind,differentgalleryloadsetc)asmentionedinthisspecification.Therewillatotalof38differenttools(16forGalleries,16forTrestlesand4forTransferTowers)Plus 2programs for combinedentriesof galleriesand trestles forPROKON andSTAADPro.Theanalyticalmodeldataistobepreparedinitially(inFEMAPAPI)andshouldbecheckedandapprovedbytheindentingdepartmentbeforeproceedingwiththeprocessofanalyzingandinterfacingwiththeanalyticalsoftwaresfordesignandoptimizationwithautomation.FinallyacommonGUIistobepreparedtochooseappropriatetypeofstructureeitherforagalleryorfortrestle,thenchoose forsingleordoubleconveyorsystembeforeproceedingfurtherforchoosinglengthofgalleryorheightoftrestleasthecasemaybe.Theprojectdatalikeloads,inclinationsetcshouldthenbechoseninasteppedmannerforcreatingthemathematicalmodel.Theanalysishas tobecarriedout,designandoptimizationbedoneseamlesslyandautomaticallywithoutuser interventionby interfacingthecodedevelopedwiththeanalysisprogramsasgivenabove.The output will be optimum design of the structure with relevant sectional data andrequireddrawingsinAutoCADDXFfileformatsandwithautomaticgenerationofrequiredreport.
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
DeliveryScheme:Thedeliveryofthedevelopedtoolsmustbemadeinapropersteppeddelivery(deliveryinparts)forimmediateimplementationoftheprogramsatBHELfortheiruseStage1:
a) PreliminaryGUIforinputdata:
The typical GUI screens consist of different parameter to be input for propermathematicalmodelingandanalysisrequirementsTypical Forms required ( not limited to those shown as an example here) are asshownbelow:
The above form should have links to show basic wind speed map and values ofvariousIndianCitiesasperIS875codeandalsoshowtheseismiczonesIndianmapandzonefactorsforvariouscitiesinIndiaasperIS1893codeofIndiaThe First form should also include option for designing Trestles or Galleries orTransfertowers(Onlyfirsttwoareshownaboveasanexample)
Nextformwilldependonthechosenstructure,itcanbeforgalleriesorforTrestlesorTransfertowersA typical input data forms are shown below forGalleries ( please note that thevariablesshowninthefiguresaretentativeandwilldependontheactualproblem,theymemorevariablesorlessthanshownbelow)
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Theaboveformatshowsonlyfor12m18mand24mgalleries,theoptiontodesign30m gallery as per earlier specification also has to be included and also modelgenerationinFEMAPalsotobeincluded.Theremaybeotherparametersneedtobeincludedduringthecourseofinteraction.
TheaboveshowsatypicalinputsheetandTheremaybeotherparametersneedtobeincludedasperrequirementofloadcalculationsandmodelpreparation.Similarlydifferent forms for Trestles and Transfer Towersneed to beprepared taking intoconsiderations all the possible input data as required for correct mathematicalmodelingandpreparationofdesigndatainputfiles.
Therewillcertainnumberofinputsasdefaultvaluesandtheusershouldbeabletomodifythesevalueswithpropercheckbuttoncontrols.Controlsarealsorequiredtomovebackandforththeforms.
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
Stage1b)ThemathematicalmodelShouldconsistof(butnotlimitedtothefollowing)i)nodalCoordinatesii)memberconnectivity,iii)preparationofdatabaseofallthesectionsasperIndianCodes,iv)identificationoftrusselementsandmemberendreleasecodes,v)supportandmaterialspecifications,vi)materialspecificationsvii)identificationofmemberswithpropersectionwithsectionaldatabasetables.Stage22i)calculationofeffectivelengthsofvariousmembersaspertheirendconnections,2ii)DeadLoadcalculations2iii)Liveloadcalculations,2iv)WindloadcalculationsasperIS875code2v)Seismicloadgeneration,ifrequiredasperIS18932vi)Allotherloadsandrelevantloadcombinationsaspercodalrequirements(IS800)2vii)GenerationofvariousparametersrequiredforIS800codecheck2viii)ImpositionofloadsinthemodelandcreationofdifferentloadsandtheircombinationsasrequiredbyIndianDesigncodesofpractice.Stage22ix)Automaticcreationofinputfilesasrequiredfordifferentsoftwaresmentionedabove2x)AutomaticexecutionofanalyticalmodelandtabulatingtherequiredforcesandmomentsrequiredforcodecheckingasperIS8002xi)FindingoutthereservestrengthandcarryouttheoptimizationautomaticallywithintheGUIpreparedwithoutanyuserinterventionwiththeavailabledatabaseofsectionalsizesasspecifiedbyBHEL2xii)PreparationoffinalOptimizedinputfilesandrunningautomaticallyandtabulatingtheresultsofcodechecks2xiii)Calculationofbillofmaterialandrawmaterialrequirements2xiv)PreparationofdesignreportautomaticallywithallthetablesofinputaswellasoutputresultsandcodecheckresultswithBOM2xv)PreparationofdxffilesofmodelforuseinAutoCAD
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
DeliveryscheduleDeliveryPart1)FirstPhasetobecompletedwithin12weeksafterplacementofPurchaseorderconsistsofOfstage1criteriaabovepartaandinpart(b)upto(i)to(vii)thedetailsofmathematicalmodelandtoolforgeneratingthemodelinFEMAPforthefollowinga)4typesofSingleconveyorgalleriesfor12m,18m,24mand30mlengthgalleries(4GUIprogramsforinFEMAP)b)4typesofDoubleconveyorgalleriesfor12m,18m,24mand30mlengthgalleries(4GUIprogramsforinFEMAP)DeliveryPart2)Similartoolsfor2typesof2leggedtrestlesforSingleConveyorsystem(2GUIPrograms)2typesof2leggedtrestlesforDoubleConveyorsystem(2GUIPrograms)2typesof4leggedtrestlesforSingleConveyorsystem(2GUIPrograms)2typesof4leggedtrestlesforDoubleConveyorsystem(2GUIPrograms)DeliveryPart1andPart2asabovetobesubmittedinFEMAPAPIformattoolwithin16weeksafteraboveperiodDeliveryPart3)Preparationofotherdatasuchaseffectivelengthcalculations,loadcalculationsasperStage2itoStage2ViiiandpreparationofinputfilesinPROKONandintegratingwithPROKONsoftwarewithin12weeksafterdeliveryofabovewithvalidation(fromBHEL)forGalleries,within8weeksforTrestlesandwithin16weeksforTransfertowersincludingtherequiredGUIProgramsDeliveryPart4)PreparationofinputfileandintegratingwithotherstandardsoftwareslikeSTAADPro,DesigncheckswithPROKONandSTAADPro,AutomaticrunsforgenerationofOptimizedstructures(2ixto2xiii),Validationofallfilesofgalleries,trestlesandTransfertowersetctobedeliveredwithin12weeksafterpart3aboveDeliveryPart5)DeliveryoffinalpartConsistingofoneFinalGUI(OneeachforPROKONandSTAADPro)incorporatingalltheaboverequiredmodulesandsubmissionofUsermanuals,detailsofsoftwarecodes,listoffilesgeneratedasrequiredinthespecificationsetctobesubmittedwithin12weeksafterPart4delivery.ThisshouldincludetheFinalGUIforcombinedStructuralSystemofGalleries,trestlesandTransferTowersasperlayoutforPROKONandSTAADProTheabovedeliveryperiodsaretobeadheredstrictlyinordertocompletetheProjectintime.Note:ThedeveloperhastoenterintoNDAwithBHELbeforetakingupthisworkandtheInformationcontainedinTenderDocumentsisconfidentialandshouldnotbeusedforanyotherpurposeotherthanforquoting/executingforthisenvisagedwork.
EndofTenderSpecification
Design Analysis Group (DNA), Corporate R&D Division, BHEL, HYDERABAD,INDIA
2010-10-11T09:28:31+0530PML Prasad
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