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TATA STEELSUMMER INTERNSHIP PROGRAM
2011
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DESIGN OF JUNCTION HOUSE FOR CONVEYOR GALLERY AT RAW MATERIAL HANDLING PROJECT
Presented By:
ARIJIT MONDAL 08CE1013, 4th Yr. UG IIT Kharagpur
Under the Guidance Of
Mr. Manoj Kumar Head Civil & Structural
TATA STEEL
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Introduction
TATA STEEL Ltd. is presently undergoing 3 MTPA expansion project .
This include a new blast furnace –I , new coke oven battery – 10 & 11 , a new steel making shop LD-3 etc.
Raw materials are conveyed by conveyors which in turn are supported by trestles and transferred to the Junction Houses.
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Objective
Check the original
structure
Suggest better Designs
Reduction in Steel Consump
tion
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Purpose of Junction House
Transfer points of Conveyor
systemsSieving and
Purification of the Raw material
Dumping of Raw material
Often starting point or ending point of number
of conveyor galleries
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Requirements
Functional Requirement
Adequacy & Strength
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General Features of Junction House
Steel structure building with Beams , Columns & Bracings
Consists of (1)Platform for monorail maintenance (2)Prism gate operation platforms etc.
Supports for the conveyor galleries
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General Features of Junction House
Steel sheets are used for Side sheeting & Roofing
R.C.C Floors or chequered Plate
Proper floor slope for drainage
The floor openings such as Erection Hatches , Stair Case entries etc. should be covered with Removable covers or Hand rails
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General Features of Junction House
Junction House may be equipped with Lifting devices like EOT cranes , Electrical Hoists (as per requirement)
Pulley frames , Base frames , chutes are be provided
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Provisions for Junction House
Effective ventilation
Adequate lighting
Cleaning facilities
Fire fighting arrangements
Adequate space for maintenance
Power socket outlets
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Description of JP11
• 36.7 meterHeight
• 11.5 meterLength
• 9 meter Width
• 9Floors
• PC 13• CKC 7• SCI 3 & SCI 4
Conveyors
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Main Components of JP 11
Beams (IS sections)
Columns (IS sections & Crucified I sections)
Trusses
Chequered plates
R.C.C slabs
Monorails
Stair cases
Pulley (for SCI - 3)
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Sections Used
I Sections
Ex:-ISMB200
Channel Sections
Ex:-ISMC150
Single Angle
sections
Ex:-ISA50×50×6
Double Angle
sectionsEx:-
ISA50×50×6LD
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Approach
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IS Code Followed
IS 800-2007 : for Steel Design purpose
IS 875 part 1 : for dead load calculation
IS 875 part 2 : for live load calculation
IS 875 part 3 : for wind load calculation
SP 6(1)–1964 : for sectional properties
IS 456-2000 : for R.C.C foundation design
SP 16 : for reinforcement of R.C.C Foundation Design
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Loads Considered
Dead loadsLive loadsWind loads Dust loads Belt tension of the conveyor
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Loads in form of UDLDead Load & Live
LoadWind Load
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Failed Members
Here the red marked members are failing in Original Design
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Alternate Design 1
Design (original) Design 1
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Comparisons of Support Reaction
Footing Design (original) Design 1Fy(-1) Fy(+1) Fx Fz Fy(-1) Fy(+1) Fx Fz
1 348 516 -2.175 -0.543 380 398 -3.5 -2.25
2 160 377 70 4 278 349 59 -1.4
3 185 638 19.43 -0.785 247 458 22 1
4 187 222 0.56 0.144 175 413 -0.6 95
5 0 449 64 5.4 0 496 69 25
6 0 238 0.40 14.25 0 435 0.053 65
7 173 280 16.43 53 274 241 -7 3
8 0 569 59 16 0 635 55 27
9 0 267 2.2 23 146 297 -1 5
10 107 795 2 15.37 161 743 -0.832 4.17
11 0 435 69.5 1 0 538.452 69 0.754
12 0 952 10 54 0 852 14 47
13 518 224 -2.273 2.25 488 184 -2.4 2
14 0 800 76.1 0.506 0 719 72 -0.113
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Alternate Design 2
Design (original) Design 2
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Comparisons of Support Reaction
Footing Design (original) Design 2Fy(-1) Fy(+1) Fx Fz Fy(-1) Fy(+1) Fx Fz
1 348 516 -2.175 -0.543 372 382 -3 -2
2 160 377 70 4 207 343 62 0.6
3 185 638 19.43 -0.785 225 469 22 2
4 187 222 0.56 0.144 228 290 0.4 -2
5 0 449 64 5.4 0 485 66 8
6 0 238 0.40 14.25 0 320 0.26 12.5
7 173 280 16.43 53 197 346 17 56
8 0 569 59 16 0 619 61.71 19
9 0 267 2.2 23 0 339 2.3 21.6
10 107 795 2 15.37 161 651 -2 6.3
11 0 435 69.5 1 0 523 67 1
12 0 952 10 54 0 811 12.25 54
13 518 224 -2.273 2.25 489 204 -3.6 1.7
14 0 800 76 0.506 0 715 73 0.325
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Comparisons in Steel Consumption
Original Design
Design 1 Design 2
Steel Consumption
(Tonnes)142.4089 115.3388 116.0277
Reduction Of
Steel - 19% 18.52%
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Why Design-2 is better than Design-1
Higher uplift force is coming in case of Design-1 compared to Design-2
Horizontal sway of the top most point is less
More adequate in strength
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Final Outcome
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Economically viable designs
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Benefits to Company
Reduction of steel consumption
Cost reduction
Expertise in analysis of structures
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Personal Learnings
Proper Practical application of Theoretical knowledge
How to study engineering drawing in detail
Multiple sites visit increase 3-D visualization
Sound knowledge in application of Staad.Pro
Load analysis of giant structures
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Pics of Sites Visit
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