steel structural calculation report

79 Pages·2011·2.68 MB·English

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STEEL STRUCTURAL
CALCULATION REPORT

00 XX XX XX
REV. DATE DESCRIZIONE EMESSO CONTROLLATO APPROVATO
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1 CALCULATION ASSUMPTION
1.1 SCOPE

This report describes the calculation procedure and data considered in order to design the steel
structure of the HEATER.

1.2 REFERENCE DOCUMENTS & DRAWINGS

- Heater Assembly xx
- Foundation Assembly / Details with loads xx

1.3 CALCULATION CODES

- Uniform Building Code Volume 2 UBC-97
- Minimum Design Loads for Buildings and other Structures UBC-97
- Manual of steel construction - Allowable Stress Design AISC – ASD/01
- Specification for Structural Steel Buildings AISC 360-05

1.4 MATERIAL AND CODE ALLOWABLE VALUES

Material used for the structures : JIS SS400 or equivalent
Yield stress f : 235 N/mm2 (thickness ≤ 16 mm)
y
Minimum Tensile stress f : 400 N/mm2
u
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2 LOAD CALCULATION
2.1 PRIMARY LOADS

The decomposition of the loads into following primary loads :

Weighs of the structural components automatically
- Structure Self-Weight (SLF):
calculated by the program, and based on the model feature.
Extra Steelwork weights not directly included in the model
- Extra Steelwork Weight (EXTSTEEL):
and not automatically calculated.
Platform Extra Steelwork weights not directly included in
- Platform (EXTPLTF):
the model and not automatically calculated.
Weights of the refractory lining surfaces applied to the
- Refractory Loads (REFRACT):
structural elements.
Weights of all the operating pipes installed on the structure
- Pipe empty loads (PPEMPT):
considered empty.
Weights of the pipes filled with gas or liquid fluid as they
- Pipe Operating Loads (PPOPER) are during the normal operation of the plant and load at
terminal points.
Weights of the pipes considered full of water as they are
- Hydrostatic test loads (PPTEST)
during the hydrostatic test conditions
- Burners (BURN): Weights of the burners applied to the radiant floor
- Air Duct (ADUCT): Weights of air duct installed on heater
For the calculation of the foundation loads and structural
- Live Load 1 (LL1): analysis has been considered an overload of 500 Kg/m2 on
each platforms.
- Wind Load +X WLX According to UBC-97
- Wind Load +Y WLY According to UBC-97
- Earthquake Load +X EQX According to UBC-97
- Earthquake Load +Y EQY According to UBC-97
A thermal load has been considered on steel structures
during normal operation according to spec n° 00-ZA-E-
205001-rev.02
- Thermal Load TMP T on frame = 47°C
max
T on frame = 2°C
min
T on furnace skin = 83°C
max
T on furnace skin = 38°C
min
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2.2 LOADING DETAILS

2.2.1 Radiant cell

2.2.1.1 Radiant Floor

A.1 FLOOR

External Radius 2474 mm
Internal Radius 1697 mm
support internal Radius 515 mm
External Diameter 4948 mm
Internal surface diameter 3394 mm
support internal diameter 1060 mm
Floor thickness 6 mm
Overall Surface 19,2 m2
Floor surface weight 905,7 Kg 9,06 KN

burners supporting surface 8,16 m2
External surface 11,1 m2

Refractory (wet) 57,04KN
Wet D.ty M.W.C. 1:2:4 1930 Kg/m3
Thickness 75 mm
Wet D.ty VLWC 1:0:5 1215 Kg/m3
Thickness 125 mm

A 1.2 Burners
Weight of each burner considered 450 Kg
number of burners 6

Overall burners weight 2700 Kg 27,00KN

A 1.3 Steelwork
Extra steelwork not modelled 40,00 Kg/m2
Extra steelwork weight 769,15 Kg 7,69 KN

Input Sap Data
Overall floor weight 100,79 KN

Internal surface External surface load case
KN/m2 KN/m2
Overall refractory weight distribuited on surface 2,97 2,97 REFRACT
Overall steelwork weight distribuited on surface 0,4 0,4 EXTSTEEL
Overall burners weight distributed on surface 3,31 BURN
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2.2.1.2 Radiant Lateral walls

LATERAL WALL

External Diameter 4948 mm
Height 9198,0 mm
Thickness 5,0 mm
Lateral Surface 142,9 m2
Lateral surface weight 5609,1 Kg 56,1 KN

Refractory (wet) 323,7 KN
L.W.C. 124 1400 Kg/m3
Thickness 75 mm
V.L.W.C 105 1215 Kg/m3
Thickness 100 mm

Steelwork
Extra steelwork not
20,00 Kg
modelled
Extra steelwork weight 2858,1 Kg/m2 28,6 KN

tot. weight 408,4 KN

load

case
KN/m2
Overall refractory weight distribuited on surface 2,26 REFRACT
Overall steelwork weight distribuited on surface 0,20 EXTSTEEL
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2.2.1.3 Heater Arch

ARCH
Diameter 4948 mm
Thickness 6 mm
Surface 19,2 m2
Arch surface weight 905,7 Kg 9,1 KN

Rectangular hole
Lenght 4900 mm
Width 1453 mm
hole surface 7,1 m2

Arch surface without hole 12,11 m2

Refractory (wet) 31,105 KN

L.W.C. 124 1400 Kg/m3
Thickness 75 mm
V.L.W.C 105 1215 Kg/m3
Thickness 125 mm

Steelwork
Extra steelwork not modelled 20,00 Kg
Extra steelwork weight 242,2 Kg/m2 2,4 KN

tot. weight 42,6 KN

Overall refractory weight added to arch surface 2,57 KN/m2 REFRACT
Overall steelwork weight added to arch surface 0,20 KN/m2 EXTSTEEL
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2.2.2 Radiant Internal coil

Type of fuel Fuel Oil

Bare tubes O.D: 141,3 mm
Bare tubes thickness 6,55 mm
Bare tubes I.D. 128,2 mm
Maximum Operating fluid density 556 Kg/m3
Water density for hydrostatic test 1000 Kg/m3
Pipe weight per meter 21,77 Kg/m
Operating fluid weight per meter on each pipe 7,18 Kg/m
Water weight per meter inside each pipe 12,91 Kg/m
Number of tubes on each anchor 2,0
Medium pipe lenght 7,800 m
Return bends medium diameter 254,0 mm
Number of return bends on each anchor 2,0
Bends unit weight 8,7 Kg/each
Operating fluid on each return bend 2,9 Kg/each
Water weight on each return bend 5,1 Kg/each

Pipe empty weight on each anchor
(2 tube + 2 bend) 356,9 Kg
Pipe weight with operating fluid on each anchor
(2 tube + 2 bend) 474,6 Kg
Pipe full weight on each anchor
(2 tube + 2 bend) 568,6 Kg

Crossing Tubes
Number of crossing tubes 4,0
Medium pipe lenght 2,248 m
Empty crossing tubes weight 195,7 Kg
Operating crossing tube weight (pipes + Op. fluid) 260,3 Kg
Test crossing tube weight (pipes + water) 311,8 Kg

Anchor number 24,0
Total number of tubes on each anchor 48,0
Total number of bends on each anchor 48,0

Overall empty weight 8761,6 Kg 87,6 KN
Overall operating weight (Pipe + Operating fluid) 11650,5 Kg 116,5 KN
Overall test weight (Pipe + water) 13957,4 Kg 139,6 KN

Point empty weight applied on each anchor (ELEV. 19050) 3,65 KN PPEMPT
Point operating weight applied on each anchor (ELEV. 19050) 4,85 KN PPOPER
Point test weight applied on each anchor (ELEV. 19050) 5,82 KN PPTEST
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2.2.3 Convection cell

2.2.3.1 Convection Lateral vertical walls

Width 4900,0 mm
Height 3555,0 mm
Thickness 5,0 mm
Surface 17,4 m2
Weight of each convection wall 683,7 Kg 6,8 KN

Refractory (wet) 36,6 KN
D.ty LWC 1:2:4 1400 Kg/m3
Thickness 150 mm

Steelwork not modelled
Extra steelwork not modelled 20,00 Kg/m2
Extra steelwork weight 348,4 Kg 3,5 KN

Overall convection wall weight (2X) 93,8 KN

Overall refractory weight distributed each surface 2,10 KN/m2 REFRACT
Overall steelwork weight added to each surface 0,20 KN/m2 EXTSTEEL

2.2.3.2 Convection End tube sheets (E.T.S.)

width 1453,0 mm
Height 3555,0 mm
Thickness 13,0 mm
Surface 5,2 m2
Weight of each convection wall 527,1 Kg 5,3 KN

Refractory (wet) 7,2 KN
Wet D.ty LWC 1400 Kg/m3
Thickness 100 mm

Steelwork not modelled 1,0 KN
Unit Weight 20 Kg/m2
tot. weight of each End Tube Sheet 13,5 KN
Overall End Tube Sheet weight 27,1 KN

Overall refractory weight added to each E.T.S. surface 1,40 KN/m2 REFRACT
Overall steelwork weight added each E.T.S. surface 0,20 KN/m2 EXTSTEEL
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2.2.3.3 Convection Header Boxes

Deep considered for the Header boxes 450 mm
Width 2353,0 mm
Height 4455,0 mm
Surface 10,5 m2

Steelwork not modelled
sheet thickness 5,0 mm
Plate steelwork weight 411,4 Kg 4,1 KN

Refractory (wet) 7,3 KN
D.ty LWC 1:2:4 1400 Kg/m3
Thickness 50 mm

Extra Steelwork not modelled 5,24 KN
Unit Weight 50 Kg/m2
tot. weight of each Header Box 16,7 KN
Overall Header Boxes weight 33,4 KN

Overall refractory weight distributed on each E.T.S. surf. 1,42 KN/m2 REFRACT
Overall steelwork weight distributed on each E.T.S. surf. 1,81 KN/m2 EXTSTEEL
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2.2.3.4 Convection Piping (coil, inlet &outlet piping)

CONVECTIVE PROCESS COIL

type of fuel fuel oil
Operating fluid density 556 Kg/m3
Water density for Hydrostatic test 1000 Kg/m3

Bare tube external diameter 141,3 mm
Bare tube thickness 6,55 mm
Bare tube internal diameter 128,2 mm
Bare tube length 5,226 m
Nr of flow passes 4
Number of tubes 44
N° tubes/row 4
Number of rows 11

Number of 180° return bends 40
Medum diameter of 180° return bends 254 mm

single empty tube weight per meter 21,76 Kg/m
Operating fluid weight per meter inside each tube 7,17 Kg/m
Water weight per meter inside each pipe 12,90 Kg/m

Weight of each empty bend 8,68 Kg/each
Operating fluid weight per meter inside each bend 2,86 Kg/each
Water weight per meter inside each bend curve 5,14 Kg/each

Overall empty coil weight (pipes + bends) 5350 Kg 53,50 KN
Overall Operating coil weight
7113 Kg 71,13 KN
(pipes + bends + operating fluid)
Overall Test coil weight (pipes + bends + water) 8522 Kg 85,22 KN

STUDDED SURFACE AROUND CONVECTIVE COIL
Stud height 25,40 mm
Studs diameter 12,70 mm
studs per meter 1260 stud /m
Number of bare tubes not finned
Number of studded tubes 28
studded surface length (on each tube) 5,026 m
exposed surface of each stud 0,001013 m2
studded exposed surface of each tube 6,414 m2
total exposed surface calculated (studs+ tubes) 242,04 m2
Weight of studded surface 4476,4 Kg 44,76

Overall empty coil weight 9826 Kg 98,26 KN
Overall Operating coil weight (tube + Op. fluid) 11590 Kg 115,90 KN
Overall test coil weight (tube + water) 12998 Kg 129,98 KN