1. 1
LOAD CALCULATION, ANALYSIS AND DESIGN OF
CONTROL ROOM FOR FUEL OIL PUMP HOUSE
4X1000MW PUDIMADAKA (STAGE-I)
SUPER THERMAL POWER PLANT
PROJECT REPORT
SUBMITTED BY:- SHRADDHA VERMA
III YEAR CIVIL
MGMCOET NOIDA
UNDER GUIDANCE OF:- MR. SUSHIL KUMAR MAHATO
(CIVIL) BHEL PEM
2. 2
ACKNOWLEDGEMENT
I wish to express my gratitude to Mr. Sushil Kumar Mahato who as my mentor has
always been a source of inspiration and knowledge. Their suggestions and constructive
criticism helped me a lot in giving proper direction to my training and making me
familiar with the working culture of the organization. His methods really brought the best
out of me through hard work, dedication and research.
I also wish to express my deep gratitude to Ms. Paulomi Mitra who provided me valuable
information and knowledge. Her guidance helped me a lot to develop skills and complete
my project.
I also wish to thanks our department head Mr. AN Singh who gave me such a wonderful
opportunity to extend my knowledge and experience.
I am also thankful to all civil engineers and HR personnel of BHEL (PS-PEM) for their
help during my training
PS-PEM SHRADDHA VERMA
NOIDA (TRAINEE)
3. 3
ABSTRACT
For completing this project I had to go through various IS codes in depth especially IS
875 part 3 (wind load). I learned how to calculate and apply wind load and how it affects
the structure. I learned the usage of STAAD for load calculations, static and dynamic
analysis, design and foundation loading of trestle for Fuel oil Pump House 4X1000MW
Pundimadaka (stage-I) specification given by NTPC. I further verified the results of
STAAD output for various loads with hand calculations.
Dead load and live load were applied as per the specification from NTPC and input
drawing of control room.
In wind load, both dynamic and static wind loads in both the directions were calculated.
In dynamic wind load, both gust and 3 sec wind load were calculated and the governing
of two was selected as wind load in the form of UDL on columns. Wind load at roof and
drag wind load were also calculated.
Documentation on how to calculate wind load step by step with description of each
terminology is done.
Overall this training compelled me to go deep into the topics, which was very
professional to gain knowledge and experience. This training made me conversant with
the working culture and directed me how to achieve goals within stipulated time.
4. 4
TABLE OF CONTENT
S.NO TOPIC PAGE NO.
1. INTRODUCTION OF THE COMPANY 6
2. GENERAL 11
3. UNITS AND MEASUREMENT 11
4. DESCRIPTION OF THE STRUCTURE 12
5. PRIMARY LOAD CASES 15
6. LOAD COMBINATIONS 27
7. ANALYSIS AND DESIGN 29
8. COMPARISON BETWEEN STAAD
VALUES & HAND CALCULATIONS
30
9. REFERENCES 32
5. 5
LIST OF FIGURES
Fig Description Page
Fig.a Whole structure 12
Fig.b Nodes 13
Fig.c Beams 13
Fig.d 3D view of the building 14
Fig.e Self weight of the building 16
Fig.f Floor load 17
Fig.g Wind load in +X direction UNI GX 2.44N/mm 18
Fig.h BEAM NO.22 30
Fig.i COLUMN NO.11 31
6. 6
1.INTRODUCTION OF THE COMPANY
BHARAT HEAVY ELECTRICALS LIMITED
Embarking upon the 50th Golden Year of its journey of engineering
excellence, BHEL is an integrated power plant equipment manufacturer and
one of the largest engineering and manufacturing company of its kind in
India engaged in the design, engineering, manufacture, construction,
testing, commissioning and servicing of a wide range of products and
services for the core sectors of the economy, viz. Power, Transmission,
Industry, Transportation (Railway), Renewable Energy, Oil & Gas and
Defence with over 180 products offerings to meet the needs of these sectors.
Establishment of BHEL in 1964 was a breakthrough for upsurge in India's
Heavy Electrical Equipment industry. Consistent performance in a highly
competitive environment enabled BHEL attain the coveted 'Maharatna'
status in 2013.
1.1.BACKGROUND OF THE COMPANY:
BHEL as a part of Pt. Jawaharlal Nehru's vision was bestowed with the onus to make the
country self reliant in manufacturing of heavy electrical equipment. This dream has been
more than realised and the contribution in nation building endeavour is going to
continue likewise. Today, with 20,000 MW per annum capacity for power plant
equipment manufacturing, BHEL's mammoth size of operations is evident from its
widespread network of 17 Manufacturing Units, two Repair Units, four Regional Offices,
eight Service Centres, eight Overseas Offices, six Joint Ventures, fifteen Regional
Marketing Centres and current project execution at more than 150 project sites across
India and abroad. The total installed capacity base of BHEL supplied equipment -138
GW in India speaks volumes about the contribution made by BHEL to Indian power
sector. BHEL's 57% share in India's total installed capacity and 65% share in the
country's total generation from thermal utility sets (coal based) as of March 31, 2014
stand testimony to this. The company has been earning profits continuously since 1971-
72 and paying dividends since 1976-77 which is a reflection of company's commendable
performance throughout.
7. 7
BHEL also has a widespread overseas footprint in 76 countries with cumulative overseas
installed capacity of BHEL manufactured power plants nearing 10,000 MW including
Malaysia, Oman, Libya, Iraq, the UAE, Bhutan, Egypt and New Zealand.
The high level of quality & reliability of BHEL products and systems is an outcome of
strict adherence to international standards through acquiring and adapting some of the
best technologies from leading OEM companies in the world together with technologies
developed in our own R&D centres. Most of our manufacturing units and other entities
have been accredited to Quality Management Systems (ISO9001:2008), Environmental
Management Systems (ISO14001:2004) and Occupational Health & Safety Management
Systems (OHSAS18001:2007).
Our greatest strength is our highly skilled and committed workforce of 47,525
employees. Every employee is given an equal opportunity to develop himself/herself and
grow in his/her career. Continuous training and retraining, career planning, a positive
work culture and participative style of management - all these have engendered
development of a committed and motivated workforce setting new benchmarks in terms
of productivity, quality and responsiveness.
1.3.PRODUCT S
POWER
Air Preheaters
Boilers
Control Relay Panels
Electrostatic Precipitators
Fabric Filters
Gas Turbines
Hydro Power Plant
Piping Systems
Pulverizers
Pumps
Seamless Steel Tubes
Soot blowers
Steam Generators
8. 8
Steam Turbines
Turbogenerators
Valves
INDUSTRY
Capacitors
Ceralin
Compressors
Desalination Plants
Diesel Generating Sets
Industrial Motors & Alternators
Gas Turbines
Oil Field Equipment
Solar Photovoltaics
Power Semiconductor Devices
Seamless Steel Tubes
Sootblowers
Steel Castings & Forgings
Steam Generators
Steam Turbines
Turbogenerators
Valves
TRANSMISSION
Power Transformers/Reactors
Instrument Transformers
Switchgears
Control & Protection Equipments
Thyristor equipments
Insulators
Bushing
Capacitors
9. 9
TRANSPORTATION
Electric Rolling Stock
Electrics for Rolling Stock
Electrics for Urban Transportation System
Non Conventional Energy Source
Mini/Micro Hydro Sets
Solar Lanterns
Solar Photovoltaics
Solar Water Heating Systems
Wind Electric Generators
R&D PRODUCTS
Fuel Cells
Surface Coatings
Automated storage & Retrivals
Load Sensors
Transparent Conducting Oxide
1.4.SYSTEMS AND SERVICES
POWER GENERATION SYSTEMS
Turnkey power stations
Combined-cycle power plants
Cogeneration systems
Modernisation and rehabilitation of power stations
Erection commissioning, operation and maintenance services
Spares management
Consultancy services
TRANSMISSION SYSTEMS
EHV & UHV Substations/switchyards
HVDC transmission systems
10. 10
Flexible AC Transmission Systems(FACTS) & smartgrid solutions
Power System Studies
Testing facilities
TRANSPORTATION SYSTEMS
Traction systems
Urban transportation systems
Erection commissioning, operation and maintenance services
Consultancy services
INDUSTRIAL SERVICES
Industrial drives and control systems
Erection commissioning, operation and maintenance services
Spares management
Consultancy services
11. 11
2.GENERAL
This document covers the load establishment and analysis of control room building of
Fuel Oil Pump House 4X1000MW Pudimadaka (stage-I) Super Thermal Power Plant.
2.1.SCOPE
This document contains the following
Structural framing. .
Method of analysis and design basis
Load cases considered
Load establishment calculations for 3-Dimensional analysis of the Building
Load combinations considered
Analysis and Design
3.UNITS OF MEASUREMENT
Units of Measurement in design shall be SI/Metric systems.
12. 12
4.DESCRIPTION OF THE STRUCTURE
FOPH Control Room is a RCC structure of plan dimension 23X6m and height of the
building is 4.5m. It is a single storey building housing the control panels.
Fig.a
14. 14
4.3.ANALYSIS METHADOLOGY
3-D modelling of th FOPH Control Room has been done in Staadpro, analysis of the
structure as well as design has been done for the load cases & the load combinations
given below.
Design of beams and columns has been done based on the values of the design forces
obtained from staad
4.4.ISOMETRIC VIEW OF THE BUILDING
Fig.d
15. 15
5.PRIMARY LOAD CASES
SL. LOAD CASE
1 Self-weight of Members modelled in STAAD DL
2 Live Load LL
3 Wind Load in positive X-Dir (pressure) WLX1
4 Wind Load in positive X-Dir (suction) WLX2
5 Wind Load in negative X-Dir (pressure) WLX3
6 Wind Load in negative X-Dir (suction) WLX4
7 Wind Load in positive Z-Dir (pressure) WLZ1
8 Wind Load in positive Z-Dir (suction) WLZ2
9 Wind Load in negative Z-Dir (pressure) WLZ3
10 Wind Load in negative Z-Dir (suction) WLZ4
16. 16
5.1.LOAD CASE 1:-
Self weight: This includes self-weight of all the structural elements like columns,
main beams and longitudinal beams.
Wall load: Assigned at plinth level due to corresponding wall height.
Wall load =0.23X(brick density=18KN/m3)X(height of the wall=4.5m
=18.63N
Parapet load:
Parapet load=0.125X(density of RCC=25KN/m3)X0.9
=2.8125N
Moment=0.150X25X0.65X0.65/2
=792.1N-mm
Roof load =5 KN/m2
Floor slab load=5 KN/m2
Fig.e
18. 18
5.3. WIND LOAD (LOAD CASE 3 TO 10 ):-
The basic wind speed=50m/s
Risk coefficient K1=1.2
Length of the building= 23m
Breadth of the building=6m
Height of the building=4.5m
Fig.g
19. 19
5.3.1.WIND LOAD IN +X DIRECTION
External pressure coffecient on Face Cpe
A B C D
0.70 -0.30 -0.70 -0.70
Net pressure coffecients on Face (Internal
pressure)
A B C D
0.20 -0.80 -1.20 -1.20
Net pressure coffecients on Face (Internal
suction)
A B C D
1.20 0.20 -0.20 -0.20
5.3.1.1.LOAD 3 WLX1 (PRESSURE)
S.No Member Number
Cont.
width
(m)
Dir. Cp
Load
(kN/m)
Grid
FACE A
1 11 12 6.00 GX 0.20 2.44 Grid 1
FACE B
1 19 20 6.00 GX 0.80 9.76 Grid 6
FACE C
1 11 19 2.88 GZ -1.20 -7.01 Grid C
2 13 15 17 5.75 GZ -1.20 -14.02 Grid C
FACE D
1 12 20 2.75 GZ 1.20 6.71 Grid A
2 14 16 18 5.75 GZ 1.20 14.02 Grid A
20. 20
5.3.1.2.LOAD 4 WLX2 (SUCTION)
S.No Member Number
Cont.
width
(m)
Dir. Cp
Load
(kN/m)
Grid
FACE A
1 11 12 6.00 GX 1.20 14.63 Grid 1
FACE B
1 19 20 6.00 GX -0.20 -2.44 Grid 5
FACE C
1 11 19 2.88 GZ -0.20 -1.17 Grid D
2 13 15 17 5.75 GZ -0.20 -2.34 Grid D
FACE D
1 12 20 2.88 GZ 0.20 1.17 Grid A
2 14 16 18 5.75 GZ 0.20 2.34 Grid A
21. 21
5.3.2.WIND LOAD IN -X DIRECTION :
External pressure coffecient on Face Cpe
A B C D
-0.30 0.70 -0.70 -0.70
Net pressure coffecients on Face (Internal
pressure)
A B C D
-0.80 0.20 -1.20 -1.20
Net pressure coffecients on Face (Internal
suction)
A B C D
0.20 1.20 -0.20 -0.20
5.3.2.1.LOAD 5 WLX3 (PRESSURE)
S.No Member Number
Cont.
width
(m)
Dir. Cp
Load
(kN/m)
Grid
FACE A
1 11 12 6.00 GX -0.80 -9.76 Grid 1
FACE B
1 19 20 6.00 GX -0.20 -2.44 Grid 7
FACE C
1 11 19 2.88 GZ -1.20 -7.01 Grid D
2 13 15 17 5.75 GZ -1.20 -14.02 Grid D
FACE D
1 12 20 2.88 GZ 1.20 7.01 Grid A
2 14 16 18 5.75 GZ 1.20 14.02 Grid A
22. 22
5.3.2.2.LOAD 6 WLX4 (SUCTION)
S.No Member Number
Cont.
width
(m)
Dir. Cp
Load
(kN/m)
Grid
FACE A
1 11 12 6.00 GX 0.20 2.44 Grid 1
FACE B
1 19 20 6.00 GX -1.20 -14.63 Grid 7
FACE C
1 11 19 2.88 GZ -0.20 -1.17 Grid D
2 13 15 17 5.75 GZ -0.20 -2.34 Grid D
FACE D
1 12 20 2.88 GZ 0.20 1.17 Grid A
2 14 16 18 5.75 GZ 0.20 2.34 Grid A
23. 23
5.3.3.WIND LOAD IN +Z DIRECTION :
External
pressure
coffecient on
Face Cpe
A B C D
-0.50 -0.50 0.70 -0.10
Net pressure
coffecients
on Face
(Internal
pressure)
A B C D
-1.00 -1.00 0.20 -0.60
Net pressure
coffecients
on Face
(Internal
suction)
A B C D
0.00 0.00 1.20 0.40
24. 24
5.3.3.1.LOAD 7 WLZ1 (PRESSURE)
S.No Member Number
Cont.
width
(m)
Dir. Cp
Load
(kN/m)
Grid
FACE A
1 11 12 6.00 GX -1.00 -12.19 Grid 1
FACE B
1 19 20 6.00 GX 1.00 12.19 Grid 7
FACE C
1 11 12 2.88 GZ 0.20 1.17 Grid D
2 13 15 17 5.75 GZ 0.20 2.34 Grid D
FACE D
1 12 20 2.88 GZ 0.60 3.51 Grid A
2 14 16 18 5.75 GZ 0.60 7.01 Grid A
5.3.3.2.LOAD 8 WLZ2 (SUCTION)
S.No Member Number
Cont.
width
(m)
Dir. Cp
Load
(kN/m)
Grid
FACE A
1 11 12 6.00 GX 0.00 0.00 Grid 1
FACE B
1 19 20 6.00 GX 0.00 0.00 Grid 7
FACE C
1 11 19 2.50 GZ 1.20 6.10 Grid D
2 13 15 17 5.75 GZ 1.20 14.02 Grid D
FACE D
1 12 20 2.88 GZ -0.40 -2.34 Grid A
2 14 16 18 5.75 GZ -0.40 -4.67 Grid A
25. 25
5.3.4.WIND LOAD IN -Z DIRECTION :
External pressure coffecient on Face Cpe
A B C D
-0.50 -0.50 -0.10 0.70
Net pressure coffecients on Face (Internal
pressure)
A B C D
-1.00 -1.00 -0.60 0.20
Net pressure coffecients on Face (Internal
suction)
A B C D
0.00 0.00 0.40 1.20
5.3.4.1.LOAD 9 WLZ3 (PRESSURE)
S.No Member Number
Cont.
width
(m)
Dir. Cp
Load
(kN/m)
Grid
FACE A
1 11 12 6.00 GX -1.00 -12.19 Grid 1
FACE B
1 19 20 6.00 GX 1.00 12.19 Grid 7
FACE C
1 11 19 2.88 GZ -0.60 -3.51 Grid D
2 13 15 17 5.75 GZ -0.60 -7.01 Grid D
FACE D
1 12 20 2.88 GZ -0.20 -1.17 Grid A
2 14 16 18 5.75 GZ -0.20 -2.34 Grid A
26. 26
5.3.4.2.LOAD 10 WLZ4 (SUCTION)
S.No Member Number
Cont.
width
(m)
Dir. Cp
Load
(kN/m)
Grid
FACE A
1 11 12 6.00 GX 0.00 0.00 Grid 1
FACE B
1 19 20 6.00 GX 0.00 0.00 Grid 7
FACE C
1 11 19 2.88 GZ 0.40 2.34 Grid D
2 13 15 17 5.75 GZ 0.40 4.67 Grid D
FACE D
1 12 20 2.88 GZ -1.20 -7.01 Grid A
2 14 16 18 5.75 GZ -1.20 -14.02 Grid A
29. 29
7.ANALYSIS AND DESIGN
PERFORM ANALYSIS PRINT STATICS CHECK
*************************
START CONCRETE DESIGN
CODE INDIAN
UNIT MMS NEWTON
FC 30 ALL
FYMAIN 500 ALL
FYSEC 500 ALL
TORSION 0 ALL
TRACK 2 ALL
**************
BRACE 3 MEMB 11
CLEAR 40 MEMB 11
RFACE 4 MEMB 11
***********
ELY 1.2 MEMB 11
ELZ 1.2 MEMB 11
**************
DESIGN COLUMN 11 TO 20 31 TO 40
DESIGN BEAM 1 TO 10 21 TO 30 41 TO 43
*******************
END CONCRETE DESIGN
FINISH
30. 30
8.COMPARISON BETWEEN STAAD VALUES AND HAND
CALCULATIONS
For beam 22.
Fig.h
D=0.449m
B=0.349m
L=5.75m
Fy=500
Fck=30
Design load
Mz=45.45KN-m at mid span
According to staad we need to provide 4 bars of 10mm dia at 30mm spacing.
Verifying the result for the same by hand calculations
We know Ast=0.5 ×
𝑓𝑐𝑘
𝑓𝑦
× (1 − (√1 −
4.2×𝑀𝑧
30×𝐵×𝑑2 ) × 𝐵 × 𝑑
d= D−clear cover−(dia of bar)/2
d=450−5−10/2
d=395mm
therefore, Ast=0.5 ×
30
500
× (1 − (√1 −
4.2×45 .45×10^6
30×350 ×3952 ) × 350 × 395
Ast=290.32mm2
31. 31
Area of one steel bar of diameter 10mm ,Asb = 𝜋(
10
4
)2
=78.53mm2
No. of bars required =
𝐴𝑠𝑡
𝐴𝑠𝑏
=
290.32
78.53
=3.69
= 4 bars
Result is same
Hence verified!
For column 11:
Fig.i
According to staad:
Pu=3.14
Fy=500
Fck=30
B=0.50m
D=0.70m
Verifying the result with hand calculations:
We know
32. 32
Pu=0.4×Fck×(Ag−0.01Ag)+0.67×Fy×(0.01Ag)
From the above eqn we get Ag=206172.02mm2
Since the column cross section is rectangular i.e. Ag = B×D
&D =2B
So, Ag =2B2
B=√
𝐴𝑔
2
We get B =321.07mm =0.32m
And D =642.14mm =0.64m
Which is less than the provided values
Thus the design of column is safe
Hence verified!
The Diameter of the Ties shall not be lesser than the Greatest of the following two
values
1. 5mm
2. 1/4th of the Diameter of the Largest Diameter Bar
The Spacing of Ties shall not exceed the least of the followings three values
1. Least Lateral Dimension
2. 16 Times of the Diameter of the Smallest Diameter Longitudinal Bar
3. 48 Times of the Diameter of Ties
33. 33
9.REFERENCES
The following codes, standards and drawings have been referred
Codes and standards
IS:875(1987) part 1 Dead loads
IS:875(1987) part 2 Imposed loads
IS:875(1987) part 3 Wind loads
IS:875(1987) part 5 Load combinations
