14668 604 2 trolley calculation at single failure

Saleorder : 14668 Doc. No : 14668 604/2

Client : M/s IGCAR Checked by : MKY

Date : Approved By : AMD / PMD

1.0 TROLLEY CALCULATION

Duty Class : M5

Duty Factor : 1.06 As per Clause 8.3.2, IS 807:2006

S.F. : 1.5 As per Table 15 8.3.2, IS 807:2006

Material of

construction: IS 2062

Yield strength : 250 N/mm2

: 25.5 Kg/mm2

Allowable stress =

= 25.5 / (1.5 x 1.06)

= 16.03 kg/mm2

1.1 MH CALCULATION

Capacity : 46 T

Total falls : 8

Impact factor : 1.32

No. of rotating

pulleys (n): 8

Bottom block

weight factor

BBTWF

: 1.07

Bottom block

weight= 46 x (1.07 - 1)

= 3.22 T

Load per fall =

= (46 x 1.32 + 3.22 ) / (8 x (.99^8 )

= 8.7 tonne

= 8661.7 kg

SHEET 1 of 9

TROLLEY CALCULATION AT SINGLE FAILURE

13-Jan-16

Yield strength

S.F. x Duty Factor

Capacity x Impact factor + Bottom block weight

fall x pulley efficiency

This image cannot currently be displayed.

Saleorder : 14668 Doc. No : 14668 604/2




13-Jan-16


1.2 At MH Top Block

A C D B

455 775

Load/fall x 2

= 8661.7 x 2

= 17323.3 kg

Load/fall

= 8661.7 kg

Therefore,

Load coming on point C = 8661.7 kg

&

Load coming on point D = 17323.3 kg

= 17323.3 kg

Reaction at

point B= (8661.7 x 455 + 17323.3 x ( 455 + 570 ) ) / 1800

= 12054.1 kg

Reaction at

point A= 8661.7 + 17323.3 - 12054.1

= 13930.8 kg

13930.8 x 455

= 6338530 kg-mm

13930.8 x ( 455 + 570 ) - 8661.7 x 570

= 9341960 kg-mmSHEET 2 of 9

1800

Load coming on each topblock

pulley =

Load coming on each Equiliser

pulley =

Bending moment at point C =

Bending moment at point D =

570

Saleorder : 14668 Doc. No : 14668 604/2




13-Jan-16


Section of top block

where

b = 16 mm

d = 410 mm

Section

modulus, z =4 x 16 x 410 ^ 2 / 6

= 1793067 mm4

Bending stress = 9341960.3 / 1793067

= 5.21 kg / mm2

1.3 At MH pedestal

Pedestal weight

=100 kg

Rope drum

weight =1200 kg

Force acting at

pedestal

assembly =

0.85 x Load/ fall + pedestal weight x 2 + rope drum weight / 2 x 2

= 8762.4 kg

1.4 At MH Equiliser bar

Force acting on equiliser bar = Load / fall

= 8661.7

= 8662 kg

1.5 AH CALCULATION

Capacity : 5.75 T

Total falls : 4

Impact factor : 1.32

No. of rotating

pulleys (n): 4

Bottom block

weight factor

BBTWF

: 1.07

Bottom block

weight= 5.75 x (1.07 - 1)

= 0.40 T

Load per fall =

= (5.75 x 1.32 + 0.40 ) / (4 x (.99^4 )

= 2.1 tonne

= 2080.1 kgSHEET 3 of 9

Capacity x Impact factor + Bottom block weight

fall x pulley efficiency

Saleorder : 14668 Doc. No : 14668 604/2




13-Jan-16


1.6 At AH Equiliser pulley

A C D B

1000 535

Load/fall

= 2080.1 kg

Therefore,

Load coming on point C = 2080.1 kg

&

Load coming on point D = 0.0 kg

(2080.1 x 1000 + 0.0 x ( 1000 + 265 ) ) / 1800

= 1155.6 kg

2080.1 + 0.0 - 1155.6

= 924.5 kg

924.5 x 1000

= 924489 kg-mm

924.5 x ( 1000 + 265 ) - 2080.1 x 265

= 618252 kg-mm

Section of AH Equiliser pulley

where

b = 10 mm

d = 350 mm

Section

modulus, z =2 x 10 x 350 ^ 2 / 6

= 408333 mm4

Bending stress = 924488.9 / 408333

= 1.51 kg / mm2

SHEET 4 of 9

Reaction at point B =

Reaction at point A =

Bending moment at point C =

Bending moment at point D =

265

1800

Load coming on each Equiliser

pulley =

Saleorder : 14668 Doc. No : 14668 604/2




13-Jan-16


1.7 At AH pedestal

Pedestal weight

=50 kg

Rope drum

weight =300 kg

Force acting at

pedestal

assembly =

pedestal weight + rope drum weight / 2

= 200.0 kg

1.8 Calculation of middle section

A C D E F B

415 110 220 411

Load at C = Force at AH Pedestal assembly x 2

= 200 x 2

= 400 kg

Load at D = Reaction RB at MH Top block assembly x 2

= 12054.1 x 2

= 24108.3 kg

Load at E = Force at MH Pedestal assembly

= 8762.4

= 8762.4 kg

Load at F = Force at MH Equiliser bar

= 8661.7 kg

Therefore,

Reaction at

point B =27969.2 kg

Reaction at

point A =13963.2 kg

Bending moment at C = 5794719.26 kg-mm

Bending moment at D = 16902963 kg-mm

Bending moment at E = 15743001 kg-mm

Bending moment at F = 11495347.7 kg-mm

Section at middle section

Section modulus ZXX = 2.38E+06 mm4

Therefore

Bending stress =

= 16902963 / 2380000

= 7.10 kg/mm2

SHEET 5 of 9

819

1975

Max. Bending moment

Section modulus

Saleorder : 14668 Doc. No : 14668 604/2




13-Jan-16


1.9 Calculation of section at MH motor side

A C D E F G B

281.5 516.5 1002 1002 516.5 281.5

Load at C = Weight of MH DCEM brake + weight of stool

= 200 kg

Load at D = Weight of MH Motor + stool

= 437+60

= 497 kg

Load at E = Reaction RB at middle section + CT gearbox weight

27969.2 + 600

= 28569.2 kg

Load at F = Weight of MH Motor + stool

= 437+60

= 497 kg

Load at G = Weight of MH DCEM brake + weight of stool

= 200 kg

Therefore,

Reaction at

point B =14981.6 kg

Reaction at

point A =14981.6 kg




Bending moment at F = 11852023 kg-mm

Bending moment at G = 4217322.6 kg-mm

Section at MH motor side


Therefore

Bending stress=

= 26165200 / 3410000

= 7.67 kg/mm2

SHEET 6 of 9

3600

Max. Bending moment

Section modulus

Saleorder : 14668 Doc. No : 14668 604/2




13-Jan-16


1.10 Calculation of section at AH motor side

A C D E F G H I B

391.5 330 403 675.5 675.5 403 330

Load at C = Weight of AH Gearbox + weight of stool

300 + 30

= 330 kg

Load at D = Weight of AH Brake + stool

= 30 + 25

= 55 kg

Load at E = Weight of AH motor + weight of stool

= 73 + 30

= 103 kg

Load at F = Reaction RA at middle section

= 13963.2 kg

Load at G = Weight of AH motor + weight of stool

73 + 30

= 103 kg

Load at H = Weight of AH Brake + stool

= 30 + 25

= 55 kg

Load at I = Weight of AH Gearbox + weight of stool

= 300 + 30

= 330 kg

Therefore,

Reaction at

point B =7469.6 kg

Reaction at

point A =7469.6 kg


Bending moment at D = 5280408.8 kg-mm

Bending moment at E = 8135498.4 kg-mm

Bending moment at F = 12851562 kg-mm

Bending moment at G = 8135498.4 kg-mm

Bending moment at H = 5280408.8 kg-mm

Bending moment at I = 2924344.3 kg-mm

Section at MH motor side


Therefore

Bending stress=

= 12851562 / 2020000

= 6.36 kg/mm2

SHEET 7 of 9

3600

Max. Bending moment

Section modulus

Saleorder : 14668 Doc. No : 14668 604/2




13-Jan-16


1.11 Calculation of Main end section

A C D E F B

375 110 631 550

Load at C = Reaction RB at AH Motor side frame

= 7469.6 kg

Load at D = Reaction RA at MH Top block assembly

= 13930.8 kg

Load at E = 0.15 x MH Load / fall + rope drum weight / 2 + gearbox weight + weight of gearbox stool

= 0.15 x 8661.7 + 1200 / 2 + 1700 + 50

= 3649.2 kg

Load at F = Reaction RA at MH motor side frame

= 14981.6 kg

Therefore,

Reaction at

point B =22998.5 kg

Reaction at

point A =17032.8 kg




Bending moment at F = 12649174.5 kg-mm

Section at middle section


Therefore

Bending stress =

= 18188273 / 3430000

= 5.3 kg/mm2

SHEET 8 of 9

1234

2900

Max. Bending moment

Section modulus

Saleorder : 14668 Doc. No : 14668 604/2




13-Jan-16


1.12 Seismic Calculation

1.12.1 From Above Calculations :-

Bending stress of MH Top block = 5.21 kg/mm2

Bending stress of AH Top block = 1.51 kg/mm2

Bending stress of Middle section = 7.10 kg/mm2

Bending stress of MH motor side section = 7.67 kg/mm2

Bending stress of AH motor side section = 6.36 kg/mm2

Bending stress of Main end section = 5.30 kg/mm2

1.12.2 From IS: 1893-2002 (Table 2 page - 16), for Zone III

Horizontal seismic zone factor,

Ah = ((Z x I X Sa )/(2 x R x g))

= 0.075

where, Z = 0.16,

I = 1.5 For power station

R = 4 For steel frame

Sa/g = 2.5

Vertical seismic zone factor, F0(v) = 0.05 (Refer CL. 6.4.5 Page - 16)

1.12.3 Induced stresses due to Seismic forces are :-

Bending stress of MH Top block = 1.05 x 5.21 = 5.47 kg/mm2

Bending stress of AH Top block = 1.05 x 1.51 = 1.59 kg/mm2

Bending stress of Middle section = 1.05 x 7.10 = 7.46 kg/mm2

Bending stress of MH motor side section = 1.05 x 7.67 = 8.06 kg/mm2

Bending stress of AH motor side section = 1.05 x 6.36 = 6.68 kg/mm2

Bending stress of Main end section = 1.05 x 5.30 = 5.57 kg/mm2

1.12.4 Allowable stress

As per IS:1893 CL. 6.3.5.1, while considering seismic forces the allowable stresses are increased by 33%

Allowable bending stress = 1.33 X Allowable stress (without considering seismic effect)

= 1.33 x 16.03

= 21.32 kg/mm2

1.13 Summary of results for selected section

1.0 Bending stress of MH Top block = Section is ok.

2.0 Bending stress of AH Top block = Section is ok.

3.0 Bending stress of Middle section = Section is ok.

4.0 Bending stress of MH motor side section = Section is ok.

5.0 Bending stress of AH motor side section = Section is ok.

6.0 Bending stress of Main end section = Section is ok.

7.0 Bending stress of MH Top block with seismic effect = Section is ok.

8.0 Bending stress of AH Top block with seismic effect = Section is ok.

9.0 Bending stress of Middle section with seismic effect = Section is ok.

10.0 Bending stress of MH motor side section with seismic effect = Section is ok.

11.0 Bending stress of AH motor side section with seismic effect = Section is ok.

12.0 Bending stress of Main end section with seismic effect = Section is ok.

SHEET 9 of 9

Hence considering seismic forces, we increase the induced stresses in girder section by 7.5% & 5% in

horizontal & vertical direction respectively.

14668 604 2 trolley calculation at single failure

Engineering

Transcript of 14668 604 2 trolley calculation at single failure