Furnace Foundation Calculation

DOCUMENT TYPE:

CALCULATION REPORT DOCUMENT TITLE:

FURNACE FOUNDATION 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 ‘S Project Code Main Area Code Plant Group Equipment Document Project Contractor Code Type

GEG

7

119 NAME

1003

7

FU

Serial No.

C

002

15 MMTE No.

DATE

PREPARED

GGMMCF10C4-002

CHECKED APPROVED

Eng. Discipline

SHEET

REV.

B

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.

REVISION RECORD SHEET

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

1

GGMMCF10C4-002

Note: This Table is use for External Comments.

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GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

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Table of Contents 1.INTRODUCTION..........................................................................................................................................

2.GENERAL VIEW.........................................................................................................................................

3.STRUCTURAL SYSTEM...............................................................................................................................

13.

FOUNDATION................................................................................................................................ 7 23.

SUPER STRUCTURE...................................................................................................................... 7

3.2.1 VERTICAL LOADS.....................................................................................................................7 3.2.2 LATERAL LOADS......................................................................................................................7 3.2.3 FLOORS.................................................................................................................................7 4.LOADS.....................................................................................................................................................

14.

DEAD LOAD.................................................................................................................................. 8 24.

SUPER DEAD LOAD...................................................................................................................... 8 34.

LIVE LOAD.................................................................................................................................... 8 4.

VESSELS AND EQUIPMENT LOAD................................................................................................... 8 54.

SEISMIC LOAD:........................................................................................................................... 18

4.5.1 EVALUATION OF SEISMIC LOAD:...............................................................................................18 64.

W IND LOAD:............................................................................................................................... 19 74.

THERMAL LOAD.......................................................................................................................... 19 84.

ERECTION AND MAINTENANCE LOAD............................................................................................ 19 5.LOAD COMBINATIONS..............................................................................................................................

6.ANALYSIS...............................................................................................................................................

16.

MODELING.................................................................................................................................. 23

6.1.1 FOUNDATION MODELING.......................................................................................................23 6.1.2 FOUNDATION DIMENSIONS.....................................................................................................23 26.

DEFORMATIONS.......................................................................................................................... 23 36.

DYNAMIC ANALYSIS..................................................................................................................... 23 7.CALCULATION REPORT............................................................................................................................

17.

SETTLEMENT AND PRESSURE ON SOIL......................................................................................... 25 27.

SHEAR STRENGTH OF FOUNDATION............................................................................................. 25

7.2.1 ONE-WAY SHEAR..................................................................................................................25 7.2.2 TWO-WAY SHEAR..................................................................................................................25 37.

47.

57.

67.

7.

87.

REINFORCEMENT........................................................................................................................ 27 Anchor Bolts............................................................................................................................. 27 PEDESTALS................................................................................................................................ 30 OVERTURNING CONTROL............................................................................................................. 30 SLIDING CONTROL...................................................................................................................... 31 Column Base Design................................................................................................................ 31

7.8.1 Base Plate on Ped. 1:........................................................................................................31 7.8.2 Base Plate on Ped. 2:........................................................................................................34 7.8.3 Other Base Plates (on Ped. 3, 4 and 5):............................................................................36

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

1

GGMMCF10C4-002

Page:

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1. Introduction This document is a brief calculation report for the foundation of the Furnace structure. Furnace is a 107 m high steel structure.

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

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

FURNACE FOUNDATION CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

1

GGMMCF10C4-002

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

Figure 2: 3D View A

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GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

1

GGMMCF10C4-002

Figure 3: 3D View B

Page:

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GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

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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 FOUNDATION CALCULATION REPORT

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MMTE Rev .

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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

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FURNACE FOUNDATION CALCULATION REPORT

Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

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GGMMCF10C4-002

Page:

Table 1 - Vessels and Equipments

Ite m

Description

Mecha nical Weight (Ton)

Weight Of Material (Ton)

Refractory Weight (Ton)

Operation al Weight (Ton)

Elevatio n and Centre Of Gravity (mm)

13360 1

7.6

18.4

-

56

(COG)

26245 2

Product Discharge Chamber Duct

3

Product Discharge Chamber

4

Bottom Discharge Bubbler

38

-

-

38

(+100 0 COG) 21110

24

10

6

40

(COG) 21110

5

-

-

-

(COG)

26245 5

Product Cooler

75

870

48

993

(+154 6 COG)

3D Shape from Analytical Model

9 of 39

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

FURNACE FOUNDATION CALCULATION REPORT

Client Document NO: MMTE Document NO:

26245

6

86

500

-

-

7

CGS offtake

-

-

-

12

36135

8

Cooling Gas Duct

-

-

-

80

36135

9

Spring Hanger

-

-

-

13.5

37810

10

Top Gas Scrubber

(-1806 COG

37810 -

-

DATE:

1

GGMMCF10C4-002

Cooling Gas Scrubber

122

MMTE Rev .

710

(-1026 COG)

Page:

10 of 39

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

FURNACE FOUNDATION CALCULATION REPORT

Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

1

GGMMCF10C4-002

50500 11

Reduction Furnace

358

1500

516

2500

(+502 5 COG)

12

Top Gas Scrubber Duct

13

-

53

-70

60150

13

Top Gas Scrubber Ventrury

21

-

8

29

56170

14

Burden Feeder Water Tank

5

12.4

-

18

62350

Page:

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GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

FURNACE FOUNDATION CALCULATION REPORT

15

Charge Hopper

16

Bucket Elevator

17

18

19

Bustle Gas Duct

41

Client Document NO: MMTE Document NO:

327

-

MMTE Rev .

DATE:

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370

See Attached Drawing recieved from Mechanical Discipline.

88550

15060 21110 97210

-

-

-

94

15960

-

-

-

20.5

50500

-

-

-

8.9

61870

Page:

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GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

FURNACE FOUNDATION CALCULATION REPORT

Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

1

GGMMCF10C4-002

20

Monorail

-

-

-

3.5

25110

21

Maintenan ce Hoist (one of the three parallel monorails)

-

-

-

15

56170

22

Maintenan ce Hoist

-

-

-

10

56170

23

Shaft Furnace Hoist

-

-

-

10

10375 0

24

Elevator Hoist

-

-

-

2.5

59112

25

Elevator

-

-

-

10

-

Page:

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GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No:

FURNACE FOUNDATION CALCULATION REPORT

Client Document NO: MMTE Document NO:

1

-

-

-

-

Fz=18

34740

27

-

-

-

-

Fz= -16 Fx=14.

7

34740

Fz= -2 Fx= -1.2

34740

-

-

-

-

DATE:

GGMMCF10C4-002

26

28

MMTE Rev .

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28

27

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.)

Joint Text PS-1001 PS-1002E PS-1002F PS-1003 PS-1003A PS-1004 PS-1004A PS-1004B PS-1005 PS-1010 PS-1012 PS-1013 PS-1014 PS-1015 PS-1017 PS-1018 PS-1020 PS-1023 PS-1024 PS-1027 PS-1029 PS-1030 PS-1031B PS-1031C PS-1032 PS-1033 PS-1035

CoordSys Text GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL

CoordType Text Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian

TABLE: Joint Coordinates XorR m 12.8002 9.5 8.80103 1.5003 1.5003 4.5003 4.5003 4.5003 11.33 11.33 10.49973 10.5 10.5 17.01791 24.3917 24.39 23.5 1.5005 7.6367 10.98 -2.09 11.524 11.524 11.524 12.9001 8.03207 10.5

Y m 30.9502 32.91587 34.24189 30.9505 34.2505 30.9505 34.9455 32.5955 30.1755 32.0065 17.96218 17.81162 20.5272 21.3754 14.85 14.8501 14.95275 37.4508 39.929 40.4083 17.96656 32.5004 36.0004 30.3004 28.6504 16.50022 17.99458

Z m 50.5 37.81 37.81 26.245 26.245 32.635 32.635 32.635 50.5 50.5 70.15 76.05 76.05 79.95 34.74 50.5 76.05 8.6 14.42 44.35 26.245 60.15 60.15 60.15 65.85 26.245 50.5

F3 KN -68.67 -10.8 -78.5 -88.3 -176.6 -200 -147.15 -1.77 -5 -4.9 -13.73 -3.73 -3.92 -10.8 -26.5 -200 -210 -88.3 -32.4 -117.7 -55.9 -18.15 -21.58 -18.15 -28.45 -23.55 -5.89

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

PS-1037 PS-1038 PS-1039 PS-1047 PS-1048 PS-1051 PS-1052 PS-1056 PS-1093 PS-1094 PS-1106B PS-1106C PS-1106F PS-11072 PS-11075 PS-11080 PS-11083 PS-11084 PS-1125 PS-1126 PS-1127 PS-1155 PS-1171 PS-1186A PS-1242 PS-1246 PS-1247 PS-1248 PS-1250 PS-1252 PS-1253 PS-1254 PS-1254A PS-1255 PS-1258 PS-1259 PS-1260 PS-1266 PS-1269 PS-1272 PS-1273 PS-1281 PS-1283 PS-1287 PS-1288 PS-1289 PS-1290 PS-1306 PS-1310 PS-1319 PS-1328A PS-1329A PS-1330

Document No: Client Document NO: MMTE Document NO: GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL

Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian

MMTE Rev .

DATE:

1

GGMMCF10C4-002 20.377 24.59629 24.5748 10.49982 9.7627 4.24268 5.7767 20.60886 0.775 8.55117 10.5 10.5 10.5 26.732 11.3753 -5.064E-13 1.57843 7.65638 3.149 5.324 7.5005 13.65 17.8001 23.4998 21.2001 23 24.203 23.08783 24.4003 21.85 20.1002 24.4928 24.4928 12.2502 7.637 7.6502 7.60791 22.798 22.798 22.798 23.4997 24.7418 24.7418 12.95671 8.2213 12.934 2.4403 11.6502 1.7 23.16363 25.25 25.25 24.8401

30.8732 35.78787 41.4221 38.03396 37.8 29.50026 36.2703 35.0005 40.4083 40.46946 31.90157 32.29364 34.03929 23.0003 37.0005 28.0203 19.1503 19.1503 17.3372 17.3372 17.3372 17.3393 28.6504 38.2071 34.2504 32.7005 32.8502 32.7005 32.8005 36.8222 38.05712 37.0441 36.0301 35.5003 29.5002 27.6005 20.0005 36.0005 32.5005 34.2505 38.1292 39.9241 36.0311 15.0005 29.5005 12.5003 17.7455 32.69384 27.5503 32.7005 17.52394 22.15976 29.5003

Page: 26.245 30.85 28.745 20.11 14.96 26.245 15.06 26.245 30.85 37.81 44.35 44.35 44.35 15.06 37.81 8.6 13.36 13.36 8.6 8.6 8.6 26.245 65.85 15.06 50.5 45 44.35 44.35 30.85 50.5 50.5 44.35 44.35 50.5 32.635 36.135 36.135 26.245 26.245 26.245 29.045 28.745 37.81 34.74 36.135 34.74 32.635 50.5 32.635 44.35 20.11 20.11 20.11

15 of 39 -88.3 -9.8 -103 -5.89 -5.65 -11.77 -117.7 -29.4 -187 -20 -10.8 -3.14 -98.1 -3 -6.87 -5.89 -3.52 -3.48 -8.95 -9.4 -5.06 -5.2 -28.45 -3.92 -7.36 -11.77 -11.77 -58.9 -93.2 -13.73 -19.6 -14.7 -34.33 -11.77 -24.5 -16.68 -9.8 -9.8 -9.8 -9.8 -13.73 -31.4 -22.56 -27.6 -3.43 -25.5 -60 -5.89 -5 -5.89 -8.83 -8.92 -4.02

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

PS-1330A PS-1330B PS-1331 PS-1334 PS-1336 PS-1337 PS-1343A PS-1344 PS-1344A PS-1345 PS-1345A PS-1346 PS-1348 PS-1350 PS-1352 PS-1354 PS-1356 PS-1357 PS-1359 PS-1362A PS-1376 PS-1377 PS-1386 PS-1388 PS-1400 PS-1405 PS-1407 PS-1408 PS-1409 PS-1410 PS-1411 PS-1412A PS-1423 PS-1424 PS-1425 PS-1426 PS-1460 PS-1460A PS-1460B PS-1460C PS-1460D PS-1460E PS-1461 PS-1462 PS-1463 PS-1465 PS-1465A PS-1466 PS-1467 PS-1486 PS-1486B PS-1487 PS-1487B

Document No: Client Document NO: MMTE Document NO: GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL

Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian

MMTE Rev .

DATE:

1

GGMMCF10C4-002 25.09311 24.33011 24.8947 11.19646 12.556 7.64796 24.504 24.52421 24.325 24.596 24.504 24.306 24.316 -1.1902 17.025 12.0502 -1.2797 -1.2874 -5.124E-13 4.25 16.6502 22.23145 7.5777 7.5777 10.5 21.7002 10.5 9.12182 9.122 10.49991 10.49987 -0.0002 1.5 1.5 1.5005 5.7767 18.485 17.9 17.35 16.8 16.3 15.8 20.743 21.95005 21.95 23.17732 22.5575 23.5 21.774 15.53713 14.90366 15.5148 14.9068

29.5003 29.5003 38.66338 40.5859 36.4253 39.0003 28.5673 27.6121 28.2103 27.7262 28.5672 30.8732 30.8732 26.2901 27.1005 24.08 23.798 23.80735 32.43913 28.6003 28.2754 24.37705 39 32.08 35.86677 27.9754 33.64311 34.25035 39.0003 33.59791 35.49651 36.1001 30.9503 25.7713 22.5008 29.909 30.8003 30.8003 30.8003 30.8003 30.8003 30.8003 31.2703 33.56317 34.9002 30.4504 31.4004 36.96228 33.4364 39.87128 39.8713 39.6721 39.6721

Page: 20.11 20.11 20.11 26.245 26.245 26.245 97.21 83.35 83.35 76.05 76.05 56.17 37.81 35.495 26.245 26.245 26.245 18.36 15.06 18.36 56.17 56.17 15.06 15.06 56.17 50.5 50.5 26.245 26.245 20.11 20.11 20.11 8.6 8.6 8.6 15.06 60.15 60.15 60.15 60.15 60.15 60.15 60.15 56.17 56.17 56.17 56.17 60.15 60.15 15.06 15.06 26.245 26.245

16 of 39 -12.16 -4.02 -4.4 -26.5 -5.89 -34.33 -25.5 -0.8 -25 -35 -34.33 -35 -78.5 -450 -3.43 -4.9 -19.62 -98.1 -9.8 -9.8 -3.92 -5.89 -4.905 -4.9 -3.92 -3.92 -3.92 -8.15 -7.35 -14.7 -7.85 -5.89 -120 -30.6 -67.9 -49.05 -4.9 -8.2 -6.8 -4.42 -4.42 -4.42 -4.42 -4.905 -11.77 -8.83 -3.24 -13.25 -31.4 -3.43 -5.89 -5.89 -7.85

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

PS-1488 PS-1488B PS-1488C PS-1489B PS-1490 PS-1490B PS-1491 PS-1497 PS-1498A PS-1507 PS-1517A PS-1518A PS-1526B PS-1526C PS-1526D PS-1526E PS-1535 PS-1536 PS-1536A PS-1537 PS-1538 PS-1539 PS-1540 PS-1541 PS-1542 PS-1543 PS-1544 PS-1562 PS-1565 PS-1573 PS-1574 PS-1577 PS-1627 PS-1635 PS-1636 PS-1655 PS-1683 PS-1684 PS-1685 PS-1686 PS-1713 PS-1714

Document No: Client Document NO: MMTE Document NO: GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL

Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian Cartesian

MMTE Rev .

DATE:

1

GGMMCF10C4-002 15.61719 14.98751 14.41225 14.9606 15.50106 14.70194 14.80386 2.87942 9.666 14 24.23526 23.5 19.3001 19.3001 19.3001 19.3001 14.56653 12.5 10.5 10.5 10.50009 10.5 10.5 8.5003 9.375 9.33402 8.5005 3.45 15.7588 2.25 9.503 24.2028 15.1001 2.0503 3.8503 13.9002 3.9 6.884 9.338 9.3375 13.7 13.7

39.55706 39.55706 39.55706 39.85273 39.00026 39.00027 36.1504 39.0001 30.2252 0.0002 31.63564 31.81882 30.1484 29.9244 29.6744 29.5004 39.00027 28.55439 27.78918 27.72735 27.59887 27.41443 27.68986 28.93777 29.0252 29.5003 29.03819 39.0003 12.1221 25.8533 39.0003 38.1291 32.63111 19.0505 19.0505 38.05182 17.0173 17.0173 17.0173 17.3397 16.5003 12.7502

Page: 37.81 37.81 37.81 44.35 56.17 56.17 56.17 20.11 26.245 8.6 44.35 56.17 60.15 60.15 60.15 60.15 60.15 97.21 88.55 76.05 65.85 56.17 44.35 32.635 26.245 13.36 8.6 15.06 8.6 8.6 30.85 44.35 56.17 36.135 36.135 50.5 13.36 13.36001 13.36001 18.36 8.6 8.6

17 of 39 -5.89 -4.22 -3.35 -11.6 -3.14 -3.92 -5.89 -5.89 -3.92 -3.92 -3.92 -19.6 -22.95 -39.73 -29.45 -9.8 -39.25 -34.33 -18.85 -36.3 -14.7 -88.3 -11.78 -19.6 -14.7 -4.9 -5.89 -7.85 -11.77 -9 -3.63 -5.4 -8.15 -5.5 -35.3 -47 -9.8 -49 -44.65 -93.2 -3.43 -3.14

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

1

GGMMCF10C4-002

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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:

Soil Type :

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

To Ts S Massx = Massy = Tx dyn = Ty dyn = H= I= Ct x = Ct y = Rx= Ry= A=

3.0 2.5 2.0 1.5 1.0 0.5 0.0 B

Period (T Sec.)

X Direction T 1x= Ct x x H3/4 Static Period Multiplier (0.8 or 1) T x st T = MIN(1.25 x T x st ,T x dyn ) Bx1 Bx min=0.1 x Rx Bx Cx (Flexible)=ABI/Rx Vx=Max(V flexible , 0.7 V Fixed base )

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

Y Direction 3/4

T 1y = Ct y x H 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=Max(V flexible , 0.7 V Fixed base )

1.663 Sec. 1.0 1.663 Sec. 1.540 Sec. 1.181 0.700 1.181 0.06074 5932 KN

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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 C q x q Ce = According to table below Cq= As shown below

P (Kg/m2) Height

Ce

V

q

cq= 0.5

cq= 0.7

cq= 0.8

0-10

2

130

84.5

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

3

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.

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5. Load Combinations In order to analyze the structural model, the following load cases are defined.

Following tables describe the load cases and combination factors for design of foundation, concrete and steel parts.

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

TL

Therma l

-------

Main Load cases

ALLLive=Live20+ EMLL100

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

FvEnv=env(Fv, FvN)

FvN= - Fv

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% Additional Equipment Earthquake Load in X dir Local Additional Equipment Earthquake Load in Y dir Local 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. ** In foundation analysis and design monorails loads were not considered.

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Table 3: Load Combination Factors

Design Combinatio ns (for Soil Pressure Evaluation and Steel Design)

ALLDead

ALLLive

CRV

ASD1

1

1

1

ASD2

1

ASD3

0.75

0.75

0.375

ASD4

0.75

0.75

0.375

ASD5

0.75

0.75

0.375

ASD6

0.75

0.75

0.375

ASD7

0.75

ASD8

0.75

TL

WLX

WLY

WLXN

WLYN

SpecX

SpecY

FvEnv

EMEYLO

EMEXLO

0.75

0.225

0.75 0.75 0.75 0.75 0.75 0.75

ASD9

0.75

ASD10

0.75

0.75

ASD11

0.75

0.75

0.375

0.75

0.225

0.225

ASD12

0.75

0.75

0.375

0.225

0.75

0.225

ASD13

0.75

0.75

0.375

0.225

0.225

0.75

ASD14

0.75

0.75

0.225

0.225

ASD15

0.75

0.225

0.75

0.225

ASD16

0.75

0.225

0.225

0.75

0.75

ASD17-1

1

ASD17-2

0.67

0.67

0.67

0.9 0.67

0.201

0.201

ASD17-3

0.67

0.67

0.67

0.201

0.67

0.201

ASD17-4

0.67

0.67

0.67

0.201

0.201

0.67

ASD17-5

0.67

0.67

0.67

0.201

0.201

ASD17-6

0.67

0.67

0.201

0.67

0.201

0.67

0.201

0.201

0.67

ASD17-7

0.67

Design

ASD18

0.75

0.75

0.375

0.225

Combinatio ns

ASD19

0.75

0.75

0.375

0.225

0.75

-0.225

ASD20

0.75

0.75

0.375

0.225

-0.75

0.225

ASD21

0.75

0.75

0.375

0.225

-0.75

-0.225

ASD22

0.75

0.75

0.375

0.225

0.225

0.75

ASD23

0.75

0.75

0.375

0.225

0.225

-0.75

ASD24

0.75

0.75

0.375

0.225

-0.225

0.75

ASD25

0.75

0.75

0.375

0.225

-0.225

-0.75

ASD26

0.75

0.75

0.375

0.75

0.225

0.225

ASD27

0.75

0.75

0.375

0.75

0.225

-0.225

ASD28

0.75

0.75

0.375

0.75

-0.225

0.225

ASD29

0.75

0.75

0.375

0.75

-0.225

-0.225

ASD30

0.75

0.225

0.75

0.225

ASD31

0.75

0.225

0.75

-0.225

ASD32

0.75

0.225

-0.75

0.225

(for Equipment Supporting Elements Design) *

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ASD33

0.75

0.225

-0.75

ASD34

0.75

0.225

0.225

0.75

ASD35

0.75

0.225

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

0.75

0.225

0.225

ASD39

0.75

0.75

0.225

-0.225

ASD40

0.75

0.75

-0.225

0.225

0.75

-0.225

-0.225

ASD41

0.75

Design Combinatio ns

ASDF1

0.75

0.75

1.8

0.54

0.225

ASDF2

0.75

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

Design Combinatio ns (for Concrete Design)

Checking Combinatio ns

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1.7

USD2

1.4

USD3

1.05

1.275

USD4

1.05

1.275

USD5

1.05

1.275

USD6

1.05

1.275

USD7

0.9

USD8

0.9

USD9

0.9

1.275 1.275 1.275 1.275 1.3 1.3 1.3

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

1.4

ASD USD

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

1.3

-0.225

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6. Analysis 6.1 Modeling According to standard No. 2800-05 3rd editions in Dual system, Flexural Frame must resist against 25% of Seismic Loads. In order for this purpose to be satisfied two Different SAP Analysis Model is prepared.

6.1.1 Foundation Modeling According to DEISIGN CRITERIA soil allowable pressure is q allowable = 2 kg/cm2 and deflection has been restricted to 10cm for Furnace Foundation. thus, in foundation analysis soil sub grade reaction is assumed Ks = 0.2 kg/m3 for reinforcement design (soft model). This note should be taken into account that Ks in margin of the foundation was doubled and in corners quadruplicated according to the Geotechnique Specification. For more information about the deflection of the foundation please refer to appendices.

6.1.2 Foundation Dimensions Based on the results from many different analyses foundation is selected as mat foundation and dimensions are as per given in Foundation drawings. Thickness of the foundation has been considered 3 m.

6.2 Deformations Height of structure H=107 m In X and Y direction: Max ∆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 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

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1.912 1.540 1.267 1.081 1.052 0.975 0.967 0.926 0.913 0.803 0.719 0.706 0.670 0.665

0.727 0.006 0.000 0.000 0.001 0.000 0.006 0.003 0.000 0.009 0.098 0.000 0.000 0.000

0.006 0.723 0.005 0.000 0.000 0.000 0.000 0.000 0.002 0.000 0.000 0.002 0.003 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.727 0.733 0.733 0.733 0.734 0.734 0.739 0.742 0.742 0.751 0.848 0.849 0.849 0.849

0.006 0.730 0.734 0.734 0.734 0.734 0.734 0.735 0.737 0.737 0.737 0.739 0.741 0.742

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MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL MODAL 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 Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode Mode

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0.652 0.644 0.601 0.595 0.578 0.576 0.560 0.558 0.551 0.542 0.519 0.511 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

0.002 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.001 0.000 0.000 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

0.014 0.076 0.001 0.000 0.000 0.001 0.000 0.000 0.003 0.000 0.001 0.000 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 0.000 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

0.851 0.851 0.851 0.851 0.851 0.851 0.851 0.851 0.851 0.852 0.852 0.852 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

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.

24 of 39

0.756 0.832 0.833 0.833 0.833 0.834 0.834 0.834 0.837 0.837 0.838 0.838 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

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7. Calculation report 7.1 Settlement and Pressure on Soil Max soil pressure (evaluated by rigid model) = 1.45 kg/cm 2 < 2.00kg/cm2 For more information Please refer to appendices.

7.2 Shear Strength of Foundation 7.2.1 ONE-WAY SHEAR In order to check the shear strength of the foundation V12 and V13 in SAP analysis Model are checked. At first the sole capacity of the concrete part of the foundation without shear reinforcement is checked. If the existing shear exceeds the concrete capacity, the shear reinforcement is provided.

Design of cross sections subject to shear shall be based on: Vn ≥ Vu where Vu is factored shear force at section considered and V n is nominal shear strength computed by:

Vn = Vc + Vs where Vc is nominal shear strength provided by concrete in accordance with:

Vc=0.85x0.53√f'c x bd = 0.85 x 0.53 x √250 x 100 x 282.5 = 201.2 Ton and Vs is nominal shear strength provided by shear reinforcement in accordance with: Vs= Avfyd ∕ s

7.2.2 TWO-WAY SHEAR For square columns, the shear stress due to ultimate loads in slabs subjected to bending in two directions is limited to: Vc=0.85 x 1.06 √f'c x b0d In order to check the punching shear a Visual Basic Program has been prepared as shown below : For example : Shear Stress = Pu / (Perimeter x d) = =3000 / (2800 x 300) = 3.57 kg/cm2 ~ 3.6 kg/cm2 Perimeter= 2 x ( a+d + b + d ) = =2 x (400 + 300 + 400 + 300 ) = 2800 cm Allowable Shear Stress = 0.85 x 1.06 x √f'c = = 0.85 x 1.06 x √250 = 14.24 kg/cm2 ~ 14.2 kg/cm2 Ratio = Shear Stress / Allowable Shear Stress = = 3.6 / 14.2 = 0.25

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TABLE: Element Forces - Frames Frame OutputCase CaseType Text Text Text PED1-1 ENLUSD Combination PED1-1 ENLUSD Combination PED1-2 ENLUSD Combination PED1-2 ENLUSD Combination PED1-3 ENLUSD Combination PED1-3 ENLUSD Combination PED1-4 ENLUSD Combination PED1-4 ENLUSD Combination PED1-5 ENLUSD Combination PED1-5 ENLUSD Combination PED1-6 ENLUSD Combination PED1-6 ENLUSD Combination PED2-1 ENLUSD Combination PED2-1 ENLUSD Combination PED2-2 ENLUSD Combination PED2-2 ENLUSD Combination PED2-3 ENLUSD Combination PED2-3 ENLUSD Combination PED2-4 ENLUSD Combination PED2-4 ENLUSD Combination PED2-5 ENLUSD Combination PED2-5 ENLUSD Combination

7.2.2.1Pedestal 400x400 :

MMTE Rev .

StepType Text Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min

Page:

P Tonf -427.0711 -1521.6025 -419.5571 -2078.732 -531.4166 -1631.7464 -534.1137 -2162.1749 -372.2167 -1812.0328 -509.0314 -2287.3753 -470.3786 -2122.3631 -364.8197 -1757.1952 -151.5252 -1200.3368 -76.9338 -970.2937 -182.8423 -923.602

26 of 39

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7.2.2.2Pedestal 350x350 :

7.3 Reinforcement According to ABA: 8-7-3-1, minimum reinforcement considering 3 m thick slab is prepared.

Asmin = 0.0018x100x300 = 54 cm2/m Use : 2 T28 @ 200 (Top & Bot.) Additional Bars was provided as per shown in drawings.

For more information Please refer to appendices.

7.4 Anchor Bolts For more information about the development length of the anchor bolts refer to anchor bolts drawings.

Distance ×QTY . Of anchor Bolts (each side) ¿ Distance ×QTY . Of anchor Bolts (each side) ¿ ¿ P(Tension) M2 T max= + QTY . Of anchor Bolts ¿ Please refer to table below : TABLE: Element Forces - Frames Frame

OutputCase

StepType

P

M2

M3

Capacity

Anchor Bolt

Text

Text

Text

KN

KN-m

KN-m

1170 KN

Type

PED1-1

ASDF1

Max

-3473.4

-532.02

1323.98

232

16 M100

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PED1-1

ASDF1

Min

-10905

-1330.8

-1516.49

PED1-1

ASDF2

Max

-4457.3

-41.256

PED1-1

ASDF2

Min

-9920.7

-1821.6

PED1-1

ASDF3

Max

-1537.6

PED1-1

ASDF3

Min

-8968.8

PED1-1

ASDF4

Max

PED1-1

ASDF4

PED1-2

ASDF1

PED1-2

ASDF1

Min

PED1-2

ASDF2

Max

PED1-2

ASDF2

Min

PED1-2

ASDF3

PED1-2

ASDF3

PED1-2 PED1-2

Page: 356

16 M100

486.958

66

16 M100

-679.46

313

16 M100

-424.15

1338.7

220

16 M100

-1222.9

-1501.77

341

16 M100

-2521.5

66.6135

501.678

71

16 M100

Min

-7984.9

-1713.7

-664.741

297

16 M100

Max

-2665

-524.39

3929.77

557

16 M100

-17223

-1817.1

-67.8625

236

16 M100

-5748.8

93.4911

2791.46

361

16 M100

-14140

-2435

1070.45

438

16 M100

Max

-145.1

-400.42

3601.99

500

16 M100

Min

-14703

-1693.1

-395.646

261

16 M100

ASDF4

Max

-3228.8

217.465

2463.67

335

16 M100

ASDF4

Min

-11620

-2311

742.667

382

16 M100

PED1-3

ASDF1

Max

-4842.1

1033.6

409.695

180

16 M100

PED1-3

ASDF1

Min

-10587

228.8

-1725.77

244

16 M100

PED1-3

ASDF2

Max

-5640.4

1601.63

-103.828

213

16 M100

PED1-3

ASDF2

Min

-9788.9

-339.23

-1212.25

194

16 M100

PED1-3

ASDF3

Max

-2659

979.095

581.714

195

16 M100

PED1-3

ASDF3

Min

-8404.2

174.298

-1553.75

216

16 M100

PED1-3

ASDF4

Max

-3457.4

1547.12

68.1903

202

16 M100

PED1-3

ASDF4

Min

-7605.8

-393.73

-1040.23

179

16 M100

PED1-4

ASDF1

Max

-3815.8

2159.99

3252.38

677

16 M100

PED1-4

ASDF1

Min

-17036

363.133

202.435

71

16 M100

PED1-4

ASDF2

Max

-7087.2

2696.68

2391.88

636

16 M100

PED1-4

ASDF2

Min

-13764

-173.56

1062.93

155

16 M100

PED1-4

ASDF3

Max

-1280.2

1990.57

2948.06

617

16 M100

PED1-4

ASDF3

Min

-14500

193.719

-101.881

37

16 M100

PED1-4

ASDF4

Max

-4551.7

2527.26

2087.57

577

16 M100

PED1-4

ASDF4

Min

-11229

-342.97

758.614

138

16 M100

PED1-5

ASDF1

Max

-4498

3832.23

983.05

602

16 M100

PED1-5

ASDF1

Min

-12395

2028.19

-1801.98

479

16 M100

PED1-5

ASDF2

Max

-1538.6

4912.71

369.111

660

16 M100

PED1-5

ASDF2

Min

-15354

947.713

-1188.04

267

16 M100

PED1-5

ASDF3

Max

-2878.1

3432.98

1045.02

560

16 M100

PED1-5

ASDF3

Min

-10775

1628.94

-1740.01

421

16 M100

PED1-5

ASDF4

Max

81.314

4513.46

431.083

623

16 M100

PED1-5

ASDF4

Min

-13734

548.46

-1126.07

209

16 M100

PED1-6

ASDF1

Max

-2912.4

5059.3

3702.51

1095

16 M100

PED1-6

ASDF1

Min

-19037

1689.17

-57.3668

218

16 M100

PED1-6

ASDF2

Max

-2695

5867.12

2678.49

1068

16 M100

28 of 39

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

1

GGMMCF10C4-002

PED1-6

ASDF2

Min

-19254

PED1-6

ASDF3

Max

-678.67

PED1-6

ASDF3

Min

-16803

PED1-6

ASDF4

Max

-461.27

PED1-6

ASDF4

Min

-17021

PED2-1

ASDF1

Max

PED2-1

ASDF1

PED2-1

ASDF2

PED2-1

ASDF2

PED2-1

ASDF3

PED2-1

ASDF3

PED2-1 PED2-1

881.356

Page:

966.657

231

16 M100

4606.7

3365.91

997

16 M100

1236.57

-393.964

204

16 M100

5414.51

2341.89

970

16 M100

428.754

630.06

132

16 M100

-5058.4

-1881

1876.66

704

12 M100

Min

-15444

-3634.8

-395.655

553

12 M100

Max

-2589

-814.53

1260.2

417

12 M100

Min

-17914

-4701.3

220.811

643

12 M100

Max

-2949.8

-1479.9

1768.37

627

12 M100

Min

-13336

-3233.7

-503.947

530

12 M100

ASDF4

Max

-480.37

-413.43

1151.9

340

12 M100

ASDF4

Min

-15805

-4300.2

112.519

566

12 M100

PED2-2

ASDF1

Max

-3488.7

-1548.8

739.401

378

12 M100

PED2-2

ASDF1

Min

-13060

-3037.3

-912.504

608

12 M100

PED2-2

ASDF2

Max

-1560.4

-757.13

286.765

166

12 M100

PED2-2

ASDF2

Min

-14988

-3828.9

-459.868

594

12 M100

PED2-2

ASDF3

Max

-1948.9

-1241.1

759.165

345

12 M100

PED2-2

ASDF3

Min

-11520

-2729.6

-892.74

564

12 M100

PED2-2

ASDF4

Max

-20.56

-449.43

306.529

133

12 M100

PED2-2

ASDF4

Min

-13448

-3521.2

-440.104

550

12 M100

PED2-3

ASDF1

Max

61.235

-753.06

419.96

204

12 M100

PED2-3

ASDF1

Min

-10421

-1951.1

-2096.3

768

12 M100

PED2-3

ASDF2

Max

-2096.7

-160.05

-286.792

92

12 M100

PED2-3

ASDF2

Min

-8263

-2544.1

-1389.54

665

12 M100

PED2-3

ASDF3

Max

1074.9

-608.17

555.72

305

12 M100

PED2-3

ASDF3

Min

-9407.3

-1806.2

-1960.54

716

12 M100

PED2-3

ASDF4

Max

-1083.1

-15.156

-151.031

40

12 M100

PED2-3

ASDF4

Min

-7249.3

-2399.2

-1253.78

613

12 M100

PED2-4

ASDF1

Max

529.53

1153

225.937

245

12 M100

PED2-4

ASDF1

Min

-8465.2

-79.734

-2170.26

553

12 M100

PED2-4

ASDF2

Max

-1765.7

1742.91

-333.274

301

12 M100

PED2-4

ASDF2

Min

-6170

-669.65

-1611.04

486

12 M100

PED2-4

ASDF3

Max

1372.3

1074.7

401.178

349

12 M100

PED2-4

ASDF3

Min

-7622.5

-158.03

-1995.02

519

12 M100

PED2-4

ASDF4

Max

-922.95

1664.62

-158.034

248

12 M100

PED2-4

ASDF4

Min

-5327.2

-747.95

-1435.8

452

12 M100

PED2-5

ASDF1

Max

-246.11

3084.06

144.284

422

12 M100

PED2-5

ASDF1

Min

-7928.9

1119.31

-2276.1

709

12 M100

PED2-5

ASDF2

Max

-556.96

3709.92

-242.102

524

12 M100

PED2-5

ASDF2

Min

-7618.1

493.458

-1889.71

534

12 M100

PED2-5

ASDF3

Max

308.89

2833.76

307.162

457

12 M100

29 of 39

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

PED2-5

ASDF3

Min

PED2-5

ASDF4

PED2-5

ASDF4

MMTE Rev .

DATE:

1

GGMMCF10C4-002

Page:

-7373.9

869.008

-2113.22

637

12 M100

Max

-1.963

3459.61

-79.2241

452

12 M100

Min

-7063.1

243.152

-1726.83

462

12 M100

30 of 39

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

MMTE Rev .

Document No: Client Document NO: MMTE Document NO:

DATE:

1

GGMMCF10C4-002

Page:

31 of 39

7.5 Pedestals Reinforcement in pedestal must be design for capacity of anchor bolts For Pedestal 4000x4000 16 M100: 16x78.5 =1256 cm2 16x78.5x3500/4000 = 1100 cm2  use min 180 T28 For Pedestal 3500x3500 12 M100: 12x78.5=942cm2 12x78.5x3500/4000 = 825 cm2  use min 135 T28

7.6 Overturning control SF = Global MY(Mr-E) /Global MY(SpecX) >1.75 SF = Global MY(Mr-E) /Global MY(SpecY) >1.75 Mr-E = Dead00+Soil+Supd100+EMDL100+EMLL100+(0.2xLive20) TABLE: Base Reactions OutputCase

CaseType

StepType

GlobalFX

GlobalFY

GlobalFZ

GlobalMX

GlobalMY

Text

Text

Text

KN

KN

KN

KN-m

KN-m

SpecX

LinRespSpec

Max

4146.045

502.093

688.831

32068.9036

220804.481

SpecY

LinRespSpec

Max

507.213

4773.234

250.402

259274.094

27983.6408

Mr-E

Combination

-131.899

-4.4E-05

242098.7

-5498453.2

4101603.81

S.F. My =

18.58

( point : 32,47.6,-1)

S.F. Mx =

21.21

688.831

30898.5475

222951.825

( point : -3.5,44,-1) SpecX

LinRespSpec

Max

SpecY

LinRespSpec

Max

Mr-E

Combination

4146.045

502.093

507.213

4773.234

250.402

259070.919

29465.8234

-131.899

-4.4E-05

242098.7

-4626897.8

-4492901.7

S.F. My =

20.15

S.F. Mx =

17.86

( point : -3.5,12.5,-1) SpecX

LinRespSpec

Max

4146.045

502.093

688.831

28887.9224

222951.825

SpecY

LinRespSpec

Max

507.213

4773.234

250.402

257420.987

29465.8234

Mr-E

Combination

-131.899

-4.4E-05

242098.7

2999212.79

-4492901.7

S.F. My =

20.15

S.F. Mx =

11.65

688.831

29532.5775

221007.243

( point :29.85,9.5,-1) SpecX

LinRespSpec

Max

SpecY

LinRespSpec

Max

Mr-E

Combination

4146.045

502.093

507.213

4773.234

250.402

257275.912

28755.9863

-131.899

-4.4E-05

242098.7

3725509.03

10844053.9

S.F. My =

49.07

S.F. Mx =

14.48

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

7.7 Sliding control

7.8 Column Base Design 7.8.1 Base Plate on Ped. 1: 7.8.1.1Shear key Design:

ABA: 1-10-11: Vmax=3054 KN (Member : Ped1-6 , ASDF2)

V max = 2395 cm2 so it is used 160x35 cm2 0.85 ×0.6 × f c V max Kg = 305400/5600=54 f a= 160× 35 cm2 A sk =

I=11437 cm4

11437 =762.5 cm3 15

M=54x23x402/2=993600

f a=1303<1440

Vr =54x23x40=49680 Kg

f v=

49680 =331 <0.55xFy =1320 5× 30

DATE:

1

GGMMCF10C4-002

Assume= 0.2 " Ff = FN x = 242098 x 0.2 = 48420 KN " and " V=4773 KN "  SF = 48420/ 4773 = 10.15 > 1.5 OK.

S=

MMTE Rev .

Kg =¿> ok . cm2

Kg =¿> ok .

2 cm

7.8.1.2Pressure Control under Base Plate: The maximum Pressure occurs under the PED1-2 where

P=2695 KN, M2=5867 KN-m and M3=2699 KN-m

Page:

32 of 39

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No: Client Document NO: MMTE Document NO:

FURNACE FOUNDATION CALCULATION REPORT

MMTE Rev .

DATE:

1

GGMMCF10C4-002

Page:

33 of 39

in Load combination ASDF1. For pressure control under the base plate please refer to the spreadsheet as attachment. In this case :

M H =217 cm> =100 cm P 2 K 1=353 , K 2=2992 , K 3=−598551=¿ ≫Y =35.58 cm kg 4×4 kg T =133.97 Ton=¿ q max=130.38 < min 0.3 ×250 , 0.6∗250 =150 2 A cm c m2

 e=

(

√

7.8.1.3Design of PL-1: Zone A Zone B Zone C

According to "Yield Line Theory" required thickness can be estimated as follow: For zone A & B:

√(

4 q max a2 (3 K −2 R) t= 1 12 + 2 K ×2400 R 1 3 R2 + × R− =0 K 4 b K= a Kg q max=130.38 2 cm

)

Zone A: a=b=57.5 cm R=0.5 t=5.47 cm Zone B: a=27.5 cm b= 59.5 cm  K=2.16 R=0.665t= 3.48 cm For Zone C: a= 33 cm

√

4 qmax a2 = 4.44 cm t= 2400 ×12

Use t=7cm

)

Ok.

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No: Client Document NO: MMTE Document NO:

FURNACE FOUNDATION CALCULATION REPORT

MMTE Rev .

DATE:

1

GGMMCF10C4-002

7.8.1.4Design of PL-6:

According to "Yield Line Theory" required thickness can be estimated as follow:

t=

√

2P a 3b Fy× + c c

(

)

P=117800x1.7 Kg (Ultimate Capacity of M100) a=59.5 cm, b=37 cm, c=12.5 cm 

t=

√

2 ×117800 ×1.7 =5.3 cm 59.5 3 ×37 2150 × + 12.5 59.5

(

)

a Simple edge c

b

P

Free edge

7.8.1.5Design of Stiffeners:

I=1099885 cm4 S=21000 cm3 M=130.38x98.1x0.332/2=696 KN-m

Page:

34 of 39

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No: Client Document NO: MMTE Document NO:

FURNACE FOUNDATION CALCULATION REPORT 4

Use : 5 cm THK. Plate

DATE:

1

GGMMCF10C4-002

M 696 ×10 Kg = =331 2 S 21000 cm V 130.38 × 98.1× 2× .33× 102 f v= = =¿ n× t × h 3 ×5 ×68 Kg ¿ 827 2 cm 2 2 f =√ ( 331 + 3× 827 ) =1470<0.6 ×2400=¿ Kg ¿ 1440 2 Say ok. cm f a=

MMTE Rev .

Page:

35 of 39

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

1

GGMMCF10C4-002

Page:

36 of 39

7.8.2 Base Plate on Ped. 2: 7.8.2.1Shear key Design:

ABA: 1-10-11: Vmax=3091 KN ( ASDF2 ON PED2-1)

V max = 2424 cm2 so it is used 1200x350 cm2 0.85 ×0.6 × f c V max Kg f a= =55.19 2 160× 35 cm A sk =

I=11437 cm4 S=

11437 =762.5 cm3 15

M=55.19x23x402/2=1015496 Vr =55.19x23x40=50775 Kg

f v=

f a=1331<1440 ok .

50775 Kg =338<0.55 × Fy=1320 2 5 × 30 cm

7.8.2.2Pressure Control under Base Plate: The maximum Pressure occurs under the PED2-5 where

P=557 KN, M2=3710 KN-m and M3=242 KN-m

in Load combination ASDF1. For pressure control under the base plate please refer to the spreadsheet as attachment. In this case :

M H =666 cm> =100 cm P 2 K 1=1698 , K 2=7216 , K 3=−1443328=¿≫Y =26.91 cm T =170.91Ton=¿≫¿

 e=

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No: Client Document NO: MMTE Document NO:

FURNACE FOUNDATION CALCULATION REPORT

q max=84.62

(

√

MMTE Rev .

DATE:

1

GGMMCF10C4-002

)

kg 4×4 kg < min 0.3 ×250 , 0.6 ×250 =150 2 A cm c m2

Page:

Ok.

7.8.2.3Design of PL-1: Zone A Zone B Zone C

According to "Yield Line Theory" required thickness can be estimated as follow: For zone A & B:

√(

4 q max a2 (3 K −2 R) t= 1 12 + 2 K ×2400 R 1 3 R2 + × R− =0 K 4 b K= a Kg q max=84.62 2 cm

)

Zone A: a=b=58.5 cm R=0.5 t=4.48 cm Zone B: a=29 cm b= 58.5 cm  K=2.16 R=0.652t= 2.9 cm For Zone C: a= 34 cm For Zone C:

√

4 qmax a2 = 3.68 cm t= 2400 ×12 Use t = 7cm

37 of 39

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

Document No: Client Document NO: MMTE Document NO:

FURNACE FOUNDATION CALCULATION REPORT

MMTE Rev .

DATE:

1

GGMMCF10C4-002

7.8.2.4Design of PL-6 and 7:

According to "Yield Line Theory" required thickness can be estimated as follow:

t=

√

2P a 3b Fy× + c c

(

)

P=117800x1.7 Kg (Ultimate Capacity of M100) a=59.5 cm, b=37 cm, c=12.5 cm 

t=

√

2 ×117800 ×1.7 =5.32 cm 59.5 3 ×37 2150 × + 12.5 59.5

(

)

a Simple edge c

b

P

Free edge

7.8.2.5Design of Stiffeners: I=1099885 cm4 S=21000 cm3 M=84.62x98.1x0.332/2=452 KN-m 4

f a=

M 452 ×10 Kg = =215 2 S 21000 cm

Page:

38 of 39

GOL-E-GOHAR MEGA MODULE PROJECT DOCUMENT TITLE

FURNACE FOUNDATION CALCULATION REPORT

Document No: Client Document NO: MMTE Document NO:

MMTE Rev .

DATE:

1

GGMMCF10C4-002

Page:

39 of 39

2

V 84.62× 98.1× 2× .33× 10 = =¿ n× t × h 3 ×5 ×68 Kg ¿ 537 2 cm 2 2 f =√ ( 215 +3 ×537 ) =954< 0.6 ×2400=¿ Kg ¿ 1440 2 ok. cm f v=

Use : 5 cm THK. Plate

7.8.3 Other Base Plates (on Ped. 3, 4 and 5): For more information about the design of these base plates refer to spreadsheet as attachment.