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In partial fulfillment for the award of the degree Of BACHELOR OF ENGINEERING IN CIVIL ENGINEERING
BONAFIDE CERTIFICATE
Certified that this project report on PLANNING, ANALYSIS, DESIGN
AND ESTIMATION OF NATURAL COOLING TOWER is a bonafide work of S.RAMANAN (08CER080) G.SWATHY (08CER103) J.ARUNACHALAM (08CEL118)
SIGNATURE
Prof.S.KRISHNAMOORTHY, M.E., Head of the Department School of Building and Mechanical Sciences Department of Civil Engineering Kongu Engineering College Perundurai, Erode-638 052
SIGNATURE
Mrs.S,SUCHITHRA. M.E., Assistant Professor School of Building and Mechanical Sciences Department of Civil Engineering Kongu Engineering College Perundurai, Erode-638 052
Internal Examiner
External Examiner
ACKNOWLEDGEMENT
ACKNOWLEDGEMENT
First and foremost we thank the almighty, the greatest architect of the universe for giving us such a speculate years. We wish to express our heartfelt thanks to our beloved Correspondent Thiru.R.K.VISHWANATHAN, B.A., and other philanthropic trust members for having provided us with the entire necessary infrastructure to undertake this project. We are greatly indebted to express our deep sense of gratitude to our principal, Prof.S.KUPPUSWAMI, B.E., Msc (Engg). Dr.Ing (France) for his valuable advice and encouragement during the project. We are grateful to thank our beloved Dean of School of Building and Mechanical Sciences Dr.K.KRISHNAMOORTHY, M.E., Ph.D., FIE, FIV for his infallible inspiration and guidance. We take immense pleasure to express our heartfelt thanks to our beloved Head of the Department Prof.S.KRISHNAMOORTHI, M.E., for his encouragement and kind co-operation. This work would not have been materialized without the great guidance given to us by our guide Mrs.S.SUCHITHRA, M.E., Ph.D who had been a constant source of ideas and inspiration with encouragement. We heartily thank our Project Co-ordinator for their valuable guidance. Last but not least, we thank our PARENTS and BELOVED FRIENDS for their moral support.
ABSTRACT
ABSTRACT
Our project involves the Planning, Analysis and Design of an Natural Cooling Tower. The entire design includes slab design, beam design, column design, and footing design. Calculations are made manually and using software packages. The various structural elements are designed using IS 456:2000. The concrete mix used for slabs, beams and footings are of M25 and the steel used for all members are high yield strength deformed bars of grade Fe415. Each and every part is designed by considering the safety point of view and economically. This project deals with a simple and effective Natural Cooling Tower design which is designed similar to Pyramid structure with slight modification to increase its efficiency instead of normal Sand-Clock like structure which involves tough calculations and tedious rafter column designs. This is a new concept in Cooling Tower design which strike in our mind when we were gone to Industrial Visit at Mettur Themal Power Station. The total area of Cooling tower is 662 m with three compartments which are used for cooling the hot water supplied to it. The first bottom compartment consists of filler material above which steel grill is placed to hold the distribution pipe with sprinklers which carries the hot water and sprinkles it. The Second compartment which is above the first compartment will have a big slab with opening at the centre which converges and reduces the area of vapour reaching the top. Obviously, the vapour starts to condense more and reaches the collecting chamber at the bottom. And the third, topmost compartment consists of empty space which has a large opening at the centre than at the Second compartment which allows the remaining vapour that comes out after condensing at second compartment to reach the top widely.
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The objectives of this project are Main objective: To create a new design in cooling tower construction instead of conventional structures which are tedious to built To prepare an economical and effective design using Pyramid like structure To make use of atmospheric air for natural cooling instead of electric fan To prepare simple design instead of complicated design (to avoid designing of Rafter Column as like in normal cooling tower)
Supplementary Objective: To draw a plan of Natural Cooling Tower showing the reinforcement details of slabs, columns, beams and footings are done AutoCAD 2009. To analyze the structure elements using STADD. Pro V8i.
CONTENTS
CONTENTS
CHAPTER NO TITLE
ABSTRACT 1. 2. 3. 4. INTRODUCTION LITERATURE REVIEW PLAN MANUAL DESIGN
PAGE NO
4.1 SLAB DESIGN 4.2 BEAM DESIGN 4.3 COLUMN DESIGN 5. SOFTWARE DESIGN 5.1 COOLING TOWER 6. REINFORCEMENT DETAILS 6.1 SLAB DETAILS 6.2 BEAM DETAILS 6.3 COLUMN DETAILS 7. 8. ESTIMATION OF COOLING TOWER CONCLUSION REFERENCE
9.
LIST OF FIGURES
S.NO
TITLE
3D VIEW OF COOLING TOWER
PAGE NO
1. 2.
3.
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LIST OF SYMBOLS
B D Breadth of beam or shorter dimension of a rectangular column
Overall depth of beam or slab or diameter of column, dimensions under considerations Total Dead load Total live load Effective depth of beam or slab or footing Characteristic compressive strength of concrete Characteristic strength of steel Effective span of beam or slab or effective length of column Shorter dimension of the slab Longer dimension of the slab Bending Moment Area of tension reinforcement Moment of resistance of a section without compression reinforcement
W d
W s
D
f ck
f
l
eff
l
l
x
y
M
A st
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M
M
x
y
Moments in strip per unit width of shorter span Moments in strip per unit width of longer span Permissible stress in concrete in bending compression Spacing of the stirrup legs or bent-up bar with in a distance Axial compressive force Bending moment at a cross section Percentage of compression reinforcement Percentage of tension reinforcement Axial compression on wall assumed to act at centre of wall Area of vertical steel Non dimensional parameters
cbc v
P u
M
P c
P t
Pw
Av
12
INTRODUCTION
13
INTRODUCTION
In this present era, the technology in advanced construction has developed to a very large extent. Some parts of constructions are still in improving stage which includes Cooling Tower construction. Some researches are going on to increase the efficiency of Cooling Tower by modifying its structure and design. Ordinary Sand-Clock shaped Cooling Towers are very tedious to design and calculate. In this chapter, we are going to deal with planning, analysis and design of Natural Cooling Tower in brief. The design is done by two methods. The first one is manual analysis and the other one is STADD Pro analysis. In manual design, all the Slabs, Beams and Columns are taken. The design philosophy and procedures are taken as per the Indian standards. This whole structure design is done by limit state design.
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LITERATURE REVIEW
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LITERATURE REVIEW
COOLING TOWER Cooling Towers are evaporative coolers used for cooling water or other working medium to near the ambient wet-bulb air temperature. Cooling towers use evaporation of water to reject heat from processes such as cooling the circulating water used in oil refineries and power plants, building cooling, or chemical reactions, for example.
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Mechanical Draft Cooling tower has following characteristics, Large fans to force air through circulated water Water falls over fill surfaces: maximum heat transfer Cooling rates depend on many parameters Large range of capacities Can be grouped, e.g. 8-cell tower DISADVANTAGES OF MECHANCIAL DRAFT COOLING TOWER Towers are very flexible High vibration values during startup. Complex gearbox (1800/120 RPM) Starting cell 2 can shut down cell 1 Reversing fans in cold climates Water build up in blades Speeds are slow and based on diameter Distance to control room Corrosion from bad pH
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II.
A natural draft cooling tower is a means to remove waste heat from a system and release it into the atmosphere.Typically used at oil refineries, chemical plants and power plants to remove heat absorbed from circulating cool water systems.A common shape is the hyperboloid (See Fig. 1) Cooling towers have been around for over 100 years. However, in their early for were only about 20 meters high. Today, some can reach over 200 meters.As recently as 20 years ago, cooling towers were more the exception than the rule in the industry because of their severely high operating cost and the large amount of capital required for construction. But with today's need for water conservation and minimal environmental impact. industry is turning more and more to recycling water.(GC3) . It has following advantages, Hot air moves through tower Fresh cool air is drawn into the tower from bottom No fan required Concrete tower <200 m Used for large heat duties COMPONENTS Supply Basin Tower Pumps Cooling Towers Vertical Ribs Reinforced Concrete Shell
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Internal Void Diagonal Columns Hot Water Inlet Fill Splash Film Hot Water Distribution System Cold Water Collection Drift Eliminators - Drift is water lost from cooling towers as liquid droplets are entrained in the exhaust air. The drift loss is independent of the water lost by evaporation. The drift loss may be expressed in units of lb/hr or percentage of circulating water flow. Drift eliminators are used to control this drift loss from the tower. (Mist) There are two types of Natural Draft Cooling Towers. They are,
But our new design of Cooling Tower includes different mechanism. It has a structure with three compartments which are used for cooling the hot water supplied to it. The first bottom compartment consists of filler material above which steel grill is placed to hold the distribution pipe with sprinklers which carries the hot water and sprinkles it. The Second compartment which is above the first compartment will have a big slab with opening at the centre which converges and reduces the area of vapour reaching the top. Obviously, the vapour starts to condense more and reaches the collecting chamber at the bottom. And the third, topmost compartment consists of empty space which has a large opening at the centre than at the Second compartment which allows the remaining vapour that comes out after condensing at second compartment to reach the top widely.
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PLAN
21
22
MANUAL DESIGN
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For one column =17440/8 =2180 KN/m For one metre = 2180 KN SIDE RATIO OF THE SLAB: fck = 25 N/mm2
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ly/lx = 21.6/10.6 2.04>2.50 Hence it is considered as oneway slab DEPTH REQUIRED FOR STIFFNESS: Span/(depth x modification factor) = 20 Assume pt =1.2% 10600/(depth x 0.95) =20 Depth = 560mm D =600mm Effective span = 10.6+0.6 =11.2 m LOADS: Load calculation= 1 x 0.6 x 25 = 75KN/m Self weight of slab = 1 x 4 = 4KN/m Total= 19KN/m Ultimate load = 28.5 KN/m BENDING MOMENT: Mu = Wul2/8 = [28.5 x(11.2) 2]/8 = 446.88 KN/m Vu = Wul/2 = (28.5x 11.2)/2
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=159.6N/mm2 LIMITING MOMENT: Mu lim = 0.138 fck bd2 = 0.138 x 25 x 1000 x (560)2 = 1081KN-m Mulim >Mu Hence it is Under reinforced section MAIN STEEL REINFORCEMENT AND SPACING: Mu=0.87 fy Ast d[1-(Ast fy/bd fck)] Astreq=6662.40mm2 Spacing =110mm Provide 32dia @110mm c/c (Ast)pro = (1000 x ast)/spacing = 7307.63 mm2 (pt) req= 100 x Ast req bd 1.1>1.2 Hence it is safe DISTRIBUTION REINFORCEMENT: Ast min = 0.12 x bd = (0.12/100) bd = 720mm2 Spacing =270mm Provide 16mm dia @ 270mmc/c CHECK FOR DEFLECTION:
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fs =0.58 x fy x Ast req/ Ast pro = (0.58 x 415 x 6717)/7307.6 =221N/mm2 pst (assumed )=1.2% M.F=0.95 Depth d= span/(20 x M.F) = 10600/(20 x 1.2) =555mm< d (assumed) Hence it is safe CHECK FOR SHEAR: Vuc =(Tc x bd ) x k fck = 25 KN/mm2 p st = 100 x Ast pro/ bd = 0.53% Tc = 0.61 N/mm2 Vuc = 0.61 x 1000 x 560 x 0.95 = 324.52 KN Vuc>Vu Hence it is safe
BEAM DESIGN
DATA: fck = 25 N/mm2 fy = 415 N/mm2
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Working load =15 KN/m Ultimate load = 19 KN/m Width of support = 0.6m CROSS SECTIONAL DIMENSION: Span/depth = 20 10.2/20 = depth Depth= 510 mm D= 550mm Effective span = clear span+ effective depth = 10+0.55 = 10.55mm Center to center support = (10 + 0.6) = 10.6m length = 10.55m LOAD CALCULATION: Self weight of beam dead load = 0.6 x 0.6 x 25 = 9 KN /m Live load = 5KN/m Total load = 14 KN/m Ultimate load = 21KN/m (which ever is lesser)
ULTIMATE MOMENT AND SHEAR FORCE: Mu = (Wu x L) = ( 21x 10.55) Vu = (Wu x L) = (21x10.55) = 292.16KN-m =110.78KN
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LIMITING MOMENT OF RESISTANCE: Mu limit = 0.138 x fck x b x d = 0.138 x 25 x 600 x 550 =745.2KN/m Mu < Mu (limit) since the sec is under reinforcement Hence the section as singly reinforcement. DESIGN OF TENSION REINFORCEMENT: Mu=0.87 x 415 x Ast x 550 x (1-((Ast x fy)/ (b x d x fck))) 745.2x 10^6=0.87 x 415 x Ast x 550 x (1-((Ast x 415)/(600x 550 x 25)) Ast=1403.12mm (Ast) pro= (1000 x ast)/(spacing) , Assume 12mm dia bars, Provide 12mm dia bars @240mm c/c Also provide 2no.s of hanger bar of 12mm dia bars CHECK FOR SHEAR REINFORCEMENT: Tv =Vu/bd = 110.78x10^3/600*550 = 0.184 N/mm^2 Pt =(100*Ast)/bd =100*1404/600*550 =0.25% Refer table 19 IS 456:2000 ,Pg no;73 Tc =0.36 N/mm^2 Tv<Tc, Hence safe Assumed 10mm dia 2 legged stirrups Ast shear = 157mm2 SPACING: Sv = (0.87*Fy*Asv*d/Vus) = (0.87*415*157*350/110.8x10^3) = 223.27mm
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ULTIMATE MOMENT AND SHEAR FORCE: Mu = (Wu x L)/8 = ( 9x 14.75) /8 Vu = (Wu x L)/2 = (9x14.75) /2 = 244.75KN-m =66.38KN
LIMITING MOMENT OF RESISTANCE: Mu limit = 0.138 x fck x b x d = 0.138 x 25 x 400 x 400 =220.8KN/m Mu < Mu (limit) since the section is under reinforcement Hence the section as singly reinforcement. DESIGN OF TENSION REINFORCEMENT: Mu=0.87 x 415 x Ast x 410 x (1-((Ast x fy)/ (b x d x fck))) 220.8 10^6=0.87 x 415 x Ast x 410 x (1-((Ast x 415)/(400x 410 x 25)) Ast=1085mm (Ast) pro= (1000 x ast)/(spacing) , Assume 12mm dia bars, Provide 12mm dia bars @ 280mm c/c Also provide 2no.s of hanger bar of 12mm dia bars CHECK FOR SHEAR REINFORCEMENT: Tv =Vu/bd = 66.38x10^3/400*410 = 0.405N/mm^2 Pt =(100*Ast)/bd =100*1404/400*410 =0.66% Refer table 19 IS 456:2000 ,Pg no;73
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Tc =0.36 N/mm^2 Tv<Tc, Hence safe Assumed 10mm dia 2 legged stirrups Ast shear = 157mm2 SPACING: Sv = (0.87*Fy*Asv*d/Vus) = (0.87*415*157*350/110.8x10^3) = 223.27mm Sv = 0.75*d =0.75*350 =262.5mm Sv = 300mm
DESIGN OF FOOTING:
GIVEN: Pu = 2500KN b = 600 KN d= 600 KN Assume, S.B.C of Soil =185 KN/m2 SIZE OF FOOTING: Load on column = 2500 KN Self weight of footing = 250 KN Total factored load = 2750 KN Footing area = 10 mm Adopt square footing of size 3.2 m x 3.2 m Factored soil pressure at bars is, Pu= 244.14N/mm2 Hence, the footing is adequate in the soil pressure developed at the base is less than the factored bearing capacity of soil.
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FACTORED BENDING MOMENT : Cantilever projection from side face of column =1.3m Bending moment at side face of column =206.30 KN/m DEPTH OF FOOTING : Moment consideration, Mu =0.138 fck bd2 d= 273 mm Shear force for metre width is, Vud = 250(1250 - d)N Assume Tc = 0.36 N/mm2 For M20 grade of concrete with nominal % of Pt=0.25 Tc= Vul/bd =0.36 Adopt effective depth = 550mm Overall depth =600mm reinforcement,
REINFORCEMENT IN FOOTING: Mu=0.87 fy Ast d[1-(Ast fy/bd fck)] Ast = 1083.15mm2 Adopt 16mm dia. Bars @ 160mm c/c Astpro =1257mm2 CHECK FOR SHEAR STRESS:
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Vu =550 x[1250-550] = 175 mm The permissible shear stress is, KsTc = 0.33 N/mm2 Nominal shear stress = Tv = Vu/bd =0.32 N/mm2 Hence it is safe.
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STADD.Pro RESULTS
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STADD.PRO RESULT
SLAB DESIGN
(KN-M/M)
60 TOP : BOTT:
696. 696.
14.08 / 3 -1.26 / 2
696. 696.
4.98 / 3 -0.24 / 2
61 TOP : BOTT:
696. 696.
3.02 / 3 -0.08 / 2
696. 696.
15.85 / 3 -1.48 / 2
62 TOP : BOTT:
696. 696.
3.20 / 3 -0.10 / 2
696. 696.
17.02 / 3 -1.60 / 2
63 TOP : BOTT:
696. 696.
3.04 /
696. 696.
15.53 / 3 -1.47 / 2
-0.08 / 2
BEAM DESIGN
FOR BOTTOM BEAM
B E A M N O. M25
Fe415 (Main)
LENGTH: 10500.0 mm mm
SUMMARY OF REINF. AREA (Sq.mm) ---------------------------------------------------------------------------SECTION 0.0 mm 2625.0 mm 5250.0 mm 7875.0 mm 10500.0 mm
---------------------------------------------------------------------------TOP REINF. 619.58 (Sq. mm) 585.78 (Sq. mm) 585.78 585.78 723.91 (Sq. mm)
(Sq. mm)
(Sq. mm)
BOTTOM REINF.
---------------------------------------------------------------------------SUMMARY OF PROVIDED REINF. AREA ---------------------------------------------------------------------------SECTION 0.0 mm 2625.0 mm 5250.0 mm 7875.0 mm 10500.0 mm
BOTTOM
2-16
4-16
4-16
4-16
2-16
SHEAR 2 legged 8 2 legged 8 2 legged 8 2 legged 8 2 legged 8 REINF. @ 160 mm c/c @ 160 mm c/c @ 160 mm c/c @ 160 mm c/c @ 160 mm c/c
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---------------------------------------------------------------------------SHEAR DESIGN RESULTS AT DISTANCE d (EFFECTIVE DEPTH) FROM FACE OF THE SUPPORT
SHEAR DESIGN RESULTS AT 815.0 mm AWAY FROM START SUPPORT VY = 40.97 MX = 2.91 LD= 3
SHEAR DESIGN RESULTS AT 815.0 mm AWAY FROM END SUPPORT VY = -53.86 MX = 2.91 LD= 3
Provide 2 Legged 8 @ 160 mm c/c Similar results for 8 bottom beams. FOR INCLINED BEAM B E A M N O. M25 mm SUMMARY OF REINF. AREA (Sq.mm) --------------------------------------------------------------------------SECTION 0.0 mm 3659.4 mm 7318.8 mm 10978.2 mm 14637.6 mm 53 D E S I G N R E S U L T S Fe415 (Sec.)
Fe415 (Main)
LENGTH: 14637.6 mm
---------------------------------------------------------------------------TOP REINF. 582.40 (Sq. mm) 582.40 (Sq. mm) 582.40 582.40 582.40 (Sq. mm)
(Sq. mm)
(Sq. mm)
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BOTTOM REINF.
---------------------------------------------------------------------------SUMMARY OF PROVIDED REINF. AREA ---------------------------------------------------------------------------SECTION 0.0 mm 3659.4 mm 7318.8 mm 10978.2 mm 14637.6 mm
BOTTOM
2-16
4-16
4-16
4-16
2-16
SHEAR 2 legged 8 2 legged 8 2 legged 8 2 legged 8 2 legged 8 REINF. @ 160 mm c/c @ 160 mm c/c @ 160 mm c/c @ 160 mm c/c @ 160 mm c/c FOR TOP BEAM B E A M N O. M25 mm STAAD SPACE -- PAGE NO. 17 56 D E S I G N R E S U L T S Fe415 (Main) Fe415 (Sec.)
LENGTH: 10000.0 mm
SUMMARY OF REINF. AREA (Sq.mm) ---------------------------------------------------------------------------SECTION 0.0 mm 2500.0 mm 5000.0 mm 7500.0 mm 10000.0 mm
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---------------------------------------------------------------------------TOP REINF. 395.68 (Sq. mm) 0.00 (Sq. mm) 0.00 0.00 391.28 (Sq. mm) (Sq. mm)
(Sq. mm)
BOTTOM REINF.
---------------------------------------------------------------------------SUMMARY OF PROVIDED REINF. AREA ---------------------------------------------------------------------------SECTION mm 0.0 mm 2500.0 mm 5000.0 mm 7500.0 mm 10000.0
BOTTOM
4-10
4-10
4-10
4-10
4-10
SHEAR 2 legged 8 2 legged 8 2 legged 8 2 legged 8 2 legged 8 REINF. @ 170 mm c/c @ 170 mm c/c @ 170 mm c/c @ 170 mm c/c @ 170 mm c/c
COLUMN DESIGN
C O L U M N N O. M25 13 D E S I G N R E S U L T S Fe415 (Sec.)
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Fe415 (Main)
LENGTH: 3000.0 mm CROSS SECTION: 600.0 mm X 600.0 mm COVER: 40.0 mm ** GUIDING LOAD CASE: 3 END JOINT: REQD. STEEL AREA : 7395.32 Sq.mm. 1 SHORT COLUMN
REQD. CONCRETE AREA: 352604.69 Sq.mm. MAIN REINFORCEMENT : Provide 24 - 20 dia. (2.09%, 7539.82 Sq.mm.) (Equally distributed) TIE REINFORCEMENT : Provide 8 mm dia. rectangular ties @ 300 mm c/c
SECTION CAPACITY BASED ON REINFORCEMENT REQUIRED (KNS-MET) ---------------------------------------------------------Puz : 6268.60 Muz1 : 265.71 Muy1 : 265.71
SECTION CAPACITY BASED ON REINFORCEMENT PROVIDED (KNS-MET) ---------------------------------------------------------WORST LOAD CASE: 3 0.00 Muy : 0.00 IR: 0.95
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REINFORCEMENT DETAILS
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REINFORCEMENT DETAILS
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ESTIMATION
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N O
L in m
B in m
D in m
QTY
REMARKS
3 2
2.5 2.5 3.6 67.5m3 1.8 1.8 3.2 20.74m3 Total 88.24m3 21. 5.4 2.9 6 21. 4.4 2.9 6 Total 676.512m 3 551.232m 3 1227.744 m3 7.5 0.9 0.9 12.15m3 ()x7.5x0.9x0 .9 5.4 0.8 0.8 6.912m3 (1/2)x5.4x0.8x 0.8 Total 19.062m3 Total 1208.682 Sand m3 Fillin g
2.
2 2
Deduction
4 4
3.
4.
3 2 3 2
2.5 2.5 0.2 1.8 1.8 .2 2.5 2.5 1.6 1.8 1.8 1.1
4 8
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CONCLUSION
CONCLUSION:
This project gives us a good practice for designing of our future projects.This helps us to gain a lot of training and experience in planning, designing and estimation of different components in a Multi Storey Residential Building ,
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REFERENCE
REFERENCES
Reinforced Concrete (Limit State Design) by, A.K.JAIN. Published by Khanna Publishers. IS: 456 2000, Indian Standard Plain and Reinforced Concrete code of practice (Fourth Revision) Published by Bureau of Indian Standard. IS: 875 (Part I) 1987, Indian Standard code of practice for design loads (other than earthquake) for buildings and structures. (Second Revision), Published by Bureau of Indian Standard. SP-16: 1978, published by Bureau of Indian Standard (12th edition). Advanced reinforced concrete design (second edition) by P.C.Varghese.
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