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RSA Symposium, 28 Sept.

2011, NTU

RSA S Symposium on Design of Steel i D i f St l Structures using Eurocodes

Dynamic fatigue assessment and design f C t i d i of Container Quay Crane to Q C t Eurocode 3


Presented by Associate Professor Lee Chi King g Division of Structures and Mechanics School of Civil and Environmental Engineering, Nanyang Technological University 28 September 2011
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RSA Symposium, 28 Sept. 2011, NTU

Topics of presentation
Introduction Actions of fatigue Everything you need to know about fatigue in ten minutes Fatigue Design Philosophy of EN1993-1-9 Assessment methods Partial factors S-N Curves and fatigue assessment Comparison with BS 7608 Application example: Dynamic Fatigue Assessment of Container Quay Crane Introduction and structural form Operations and dynamic actions Quay crane fatigue assessment Conclusions
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RSA Symposium, 28 Sept. 2011, NTU

Introduction Actions of fatigue Everything you need to know about fatigue in ten minutes g

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RSA Symposium, 28 Sept. 2011, NTU

Introduction

Actions of fatigue
Fatigue
The process of initiation and propagation of crack through a structural part due to action of fluctuating stress (EN1993-1-9, 1.3.1.1) Fatigue design and assessment could be one of the main criteria for ultimate limit states check for many structures subjected to cyclic loadings

Cantilevered Headquarters, Lamar Construction Corporation Hudsonville, Michigan 4


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RSA Symposium, 28 Sept. 2011, NTU

Introduction

Everything you need to know about fatigue in 10 minutes


Basic actions, concept of fatigue failure
SNcurvesfor differentdetails Constantamplitude stressrange Q or Nominalstress Nominal stress time

Q =>
welding

or S
(log scale) 1 m=3

Q =>
bolts

Q => No. of cycles to failure or N


(log scale)

Higher stress and stress range =k, k>1 near connection => Modifiednominalstressrange

Constantamplitude cutofflimit cut off limit

Q =>

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RSA Symposium, 28 Sept. 2011, NTU

Introduction

Everything you need to know about fatigue in 10 minutes


How to use the S-N curves for assessment and design? Q =>
Q or

or S
(log scale)

N No. of cycles to failure or N


(log scale)

For fatigue assessment: time Determine Q, then and N, check for clients requirement client s (FAT check in EC3) For fatigue design: Determine Q, select plate thickness and other details, compute , and than N, check p , for clients requirement (FAT check in EC3)

Note: S N curves are drawn according to certain probability of failure (e g S-N (e.g.

5%, 2.3%)

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RSA Symposium, 28 Sept. 2011, NTU

Introduction

Everything you need to know about fatigue in 10 minutes


Some important remarks
Q => Q =>

k (depends on opening size) For a given values of Q, value of k depends on the geometry and details of the construction => Hence, different S N curves are needed Hence S-N needed. To help designers, many design guides (e.g. BS 7608 and EN1993-1-9) provide tables for different standard construction details (Detail Category) which related th nominal stress range t a given standard S N curve hi h l t d the i l t to i t d d S-N S-N curve No.

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RSA Symposium, 28 Sept. 2011, NTU

Introduction

Everything you need to know about fatigue in 10 minutes


Some important remarks S-N curve is a log-log curve => N quickly reduced as increases For any structural detail that is not included in the design guide or non-uniform stress distribution occurred, designers should use other aids and tools (e.g. stress concentration formula, charts and tables) to obtain the modified nominal stress (Hot Spot Stress) Finite element analysis may be needed to estimate the value of hot spot stress t t Use of numerical methods implies that both global and local structural analyses are often needed => Fatigue design could be y g g more demanding in both structural analysis and detail stress analysis than strength design

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RSA Symposium, 28 Sept. 2011, NTU

Introduction

Everything you need to know about fatigue in 10 minutes


Variable V i bl amplitude stress range lit d t In practice, constant amplitude stress range is anything but exception External loadings almost always produce variable amplitude stress range (or stress spectrum) The number of occurrences of different stress ranges can be counted by i the b using th reservoir method i th d
B B

1 2 3

1 3
A

2
A C Time

Cycles

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RSA Symposium, 28 Sept. 2011, NTU

Introduction

Everything you need to know about fatigue in 10 minutes


Fatigue assessment f variable amplitude stress range F ti t for i bl lit d t For variable amplitude stress range assessment, assessment the concept of damages contributed by different stress ranges is used For F a given stress range i th i t the corresponding cycle to failure, NRi is found from an appropriate S-N curve Damage factor: nEi/ NRi Damage Dd=
nEi Frequ uency Stress range

i =1

(Palmgren-Miners summation) Acceptable if Dd < 1.0 p

n Ei N Ri

Stress range spectrum

i (Qk)

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RSA Symposium, 28 Sept. 2011, NTU

Fatigue Design Philosophy of EN1993-1-9 Assessment methods Partial factors S-N Curves and fatigue assessment Comparison with BS 7608

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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9

Assessment methods
The two different assessment methods in EN1993-1-9 EN1993 1 9 The damage tolerance method Provide acceptable reliability so that a structure will p p y perform satisfactorily y for its design life, provide that a prescribed inspection and maintenance regime for detecting and correcting fatigue is implemented (EN1993-1-9) Inspection programme given in National Annex (NA) Potential fatigue crack initiation size should be accessible Checks on crack initiation Specified minimum size of detectable fatigue crack Specified maximum tolerable size of crack (using fracture mechanics) Time taken for fatigue crack to grow from minimum to maximum size (T1) Maximum time interval between inspections should be less thanT1/2 Inspection/out of service and repair/strengthening plans
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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9

Assessment methods
The two different assessment methods in EN1993-1-9 EN1993 1 9 The safe life method Provide acceptable reliability so that a structure will p p y perform satisfactorily y for its design life without the need for regular in-service inspection for fatigue damage. It should be applied in cases where local formation of cracks in one component could rapidly lead to failure of the element or structure (EN1993-1-9) The safe life method is recommended by BS and SS NA for new buildings or civil engineering structures i il i i t t What are the differences in the design procedures for the damage tolerance method and the safe life method? Same assessment procedure but the damage tolerance method allows for higher stress range (17%) than the safe design method Main diff M i different is caused by a higher partial f i db hi h i l factor Mf value f the safe life l for h f lif method
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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9

The partial factors The partial load factors Ff for safe life method
As usual, appears everywhere when stress ranges are used Depends on how the characteristic loads are determined Values given in BS and SS NA (only for safe life design) No. of S.D. on load intensity 0 +1 +2 2 No. of S.D. on no. of cycles 0 +2 1.5 1.4 1.3 1.2 1.1 11 1.0 10
S.D on intensity

Q or

time S.D on cycles

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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9

The partial factors p The partial material factors Mf


Appears whenever resistances/strengths (N) are used Depends on how the assessment method used EN1993-1-9 suggested values (Clause 3.7 (b), Table 3.1) Assessment method Damagetolerant Safelife Consequenceoffailure Low High consequence consequence 1.00 1.15 1.15 1.35
Unreasonable to use 1.15 >1.10 here. Hence 1.10 BS and SS NA suggested a value of 1.10 1 10

Remarks: If a value of Mf =1.10 is used throughout, no difference between the damage tolerant method and the safe life method

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Fatigue design philosophy of EN1993-1-9

The S-N curves and fatigue assessment The S N curves used in EN1993 1 9 (Fig 7.1) S-N EN1993-1-9 (Fig. 7 1)
Tri-linear log-log curves of stress range vs endurance (life to failure) cycles Based on 5% probability of failure f il Curves labeled by the detail category nominal g y stress range corresponding to 2 million cycles, C Constant amplitude f C fatigue limit at 5 million cycles Cut off Cut-off limit at 100 million cycles

C at 2 million
cycles (curve ) labels)

Constants amplitude fatigue limit

m=3

m=5

Cut-off limit

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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9

The S-N curves and fatigue assessment The S-N curves used in EN1993-1-9 (Fig. 7.1)
The nominal stress range corresponding to 2 million constant g p g amplitude cycles, C, is used as the reference fatigue strength for the curve. It also labels the curve (detail category). For example, for the detail category 100 a constant amplitude example 100, nominal stress range of 100MPa will able to fail the detail in 2 million cycles The S-N curve can be written as (R)mNR= (c)m(2x106)

R and NR are respectively the design strength and life of the


detail category

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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9

The S-N curves and fatigue assessment The S N curves used in EN1993 1 9 (Fig 7.1) S-N EN1993-1-9 (Fig. 7 1)
Some important remarks The curves are factored by neither Ff nor Mf yet Between the constant amplitude limit (5 million cycles) and the cutoff limit, the slope of the curve is 1/m = 1/5 The 1/m=1/5 part is for stress spectrum that consists of stress ranges both above and below the constant amplitude limit Stress ranges above the constant amplitude limit will cause St b th t t lit d li it ill damage or growth of flaw => Reduce the constant amplitude limit As time goes on, more stress ranges below the constant g , g amplitude limit shall contribute to crack growth (but at a lower rate with 1/m=1/5)

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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9

The S-N curves and fatigue assessment Fatigue design/checking to EN1993 1 9 EN1993-1-9
Two approaches: the stress domain approach and the damage domain approach The stress domain approach In EN1993-1-1 yield strength fy and ultimate strength fu are EN1993 1 1, frequently used => They are mainly material properties However, buckling strength, fbuc does not exist (but does) In EN1993-1-9, the reference fatigue strength C corresponding to 2 million cycles of failure is used even it is not a material property t i l t C is used in EN993-1-9 to (1) label the S-N curves and (2) for stress domain fatigue design/check

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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9

The S-N curves and fatigue assessment Fatigue design/checking to EN1993 1 9 EN1993-1-9
Damage equivalent factors i Can we replace a stress range spectrum (Qk) by an equivalent constant stress range? Yes: Through the concept of equivalent damage
n1
Freque ency Freque ency

n2

Stress range spectrum: Dd = n1/NR1+ n2/NR2 NR1 and NR2 from SN curve

n3

Stress range

Stress range

Same damage f a constant S d for t t stress range E for n3 cycle Dd = (n3)/NE 1. 1 n3 selected by designer 2. Calculate NE 3. From S-N Curve => E

E can be expressed as E=1(Qk), or in general for n stress range spectra


Equivalent constant amplitude stress range Damage equivalent E=1 2n (Qk) factors

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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9

The S-N curves and fatigue assessment Fatigue design/checking to EN1993 1 9 EN1993-1-9
The stress domain approach

While i depends on the distribution of ni , i and n3 , but neither on the detail category nor C If i are known and E is calculated, fatigue verification against, say 2 million cycles, is reduced to (EN1993-1-9, Clause 8(2))

Ff

E ,2 Mf

1 .0

Warning: Actual fatigue life required may be more than 2 million cycles

where E,2 is the equivalent constant amplitude stress range

i are not given in EN1993-1-9 and should be specified in the relevant


parts of EN1993 (e.g. crane loading in EN1991-3) which generally are p g based on simplified loading model

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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9

The S-N curves and fatigue assessment Fatigue design/checking to EN1993 1 9 EN1993-1-9
The damage domain approach When i are not given, designers are supposed to use loading model given which is more representative of the loading expected Designer needs to obtain information on the loading ranges, frequencies and th i actions t th structures (or similar structures) d their ti to the t t ( i il t t ) Steps for damage domain assessment 1. Loading spectra: Carry out a study on the loadings (ranges (ranges, frequency, actions) on the structure (or similar structures) 2. Global Structural model: Create a global model of the structure 3. Global responses: Compute the responses of the global model (natural frequencies, nominal forces or stresses etc). If possible, verify the results based on in-situ measurements or scaled model test

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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9

The S-N curves and fatigue assessment Fatigue design/checking to EN1993 1 9 EN1993-1-9
Steps for damage domain approach (continued) 4. 4 Stress spectra: From the global responses, devise the nominal stress responses at locations/details of interests and then their corresponding variable stress range spectra.
Note that if the interested detail could not be found in the detail category of EN1993 (or further stress concentration appears), local models (e.g. FE models) should be created to compute the stress range spectra (i)

5. Cycles to failure: Factor the stress range spectra to generate the design spectra (Ffi) and then check against the factored S-N curve (C /Mf vs N) 6. Damage verification: Compute damage due to different stress range and then the total damage by the Miners summation
For variable amplitude stress range, damage caused by both stress range above and below the constant stress range limit must be computed

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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9

The S-N curves and fatigue assessment Fatigue design/checking to EN1993 1 9 EN1993-1-9 What to do if a given detail failed the verification?
Increase the thickness of members/details ( re-design I th thi k f b /d t il (no d i needed) Reduce nominal stress range Thickness correction factor for some details with thickness > 25mm Upgrade the details to next details category (12% increase in stress range) => local re-design (e.g. connection details) needed Re-design of global structural form (e.g. damping, members arrangement and sizes) => Improve overall responses of structure, reduce forces in members

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RSA Symposium, 28 Sept. 2011, NTU

Fatigue design philosophy of EN1993-1-9 Structural Mechanics Structural Dynamic Fracture mechanics In general: BS more comprehensive Easier to use Less iterations in reading More designer friendly But (perhaps) similar results Similar details given PD6695-1-9-2008 Recommendations, information for design and use

Comparison with BS 7608


BS5950 steel structures Other EN: EN1991, O EN1993, NCCI and PD EN1993-1-9 Design of steel structures: Fatigue Minimum Annexes NA to EN1993-1-9: Choices of parameters

BS7608 F ti Fatigue d i design and assessment of steel structures Informative annexes A-G I f ti AG and references

BS5400 Steel, concrete and composite bridges Some design differences

Partial factors in EN More complete detail category in EN Differences in S N curves: EN: 5% failure probability BS 2 3% S-N probability, 2.3% Shear and combine stress failure in some EN details Thickness correction: BS >16mm, EN >25mm 25

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RSA Symposium, 28 Sept. 2011, NTU

Application A li ti example: Dynamic l D i Fatigue Assessment of Container Quay Crane Introduction and structural form Operations and dynamic actions Quay crane fatigue assessment

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RSA Symposium, 28 Sept. 2011, NTU

Dynamic Fatigue assessment of Container Quay Crane

Introduction and structural form Container Quay Crane (CQC)


A special from of gantry crane Key machinery for efficient port operations Main functions: load and unload container to/from ships Special lifting device called a spreader for loading and discharging of containers Horizontal gantry rails for quayside movement Driven by an operator that sits in a cabin suspend from the trolley runs along rails (hoist block) Lorries/straddle-carriers move underneath the base of the th quay crane

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RSA Symposium, 28 Sept. 2011, NTU

Dynamic Fatigue assessment of Container Quay Crane

Introduction and structural form


Structural system Typical dimensions: Boom level: +44m Forestay Overall height: 75m Boom length: 55m Boom Trolley girder length: 56m Leg spacing: 30m Outreach:18 containers Self Weight: up to 2000 Trolley tons Spreader Capacity: 40 tons container Trolley, machine and spreader (Hoist block) weight:100 tons i h 100
A-frame Backstay Support beams

Trolley girder Landside upper leg Landside lower leg

Portal girders Sill beams 28


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RSA Symposium, 28 Sept. 2011, NTU

Dynamic Fatigue assessment of Container Quay Crane

Introduction and structural form


Structural form
Machine-on-trolley design => Crane machinery moves with trolley for container loading/unloading operation Designed as a structure of thin-plate box girder (plate thickness22mm) with many longitudinal and transverse stiffeners Low stress level in STR limit state: Typical stress level < 50MPa ( fy of steel = 420MPa). For EQU limit: Only 4 legs provide no redundancy Boom rail design based on th consideration of crane actions B il d i b d the id ti f ti FAT limit state is critical in design and services: Owner may prefer to specific the FAT limit state in terms of the numbers of cycles of p y operations instead of years of service Frequent maintenance and services check (4-6 days per year) Dynamic fatigue analysis is deemed to be compulsory

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Dynamic Fatigue assessment of Container Quay Crane

Operations and dynamic actions y


Operations
Hoist block load and unloading container to ship and truck Two movements of hoist block with and without containers Ship-to-Truck (S-T) and Truck-to-Ship (T-S)

Dynamic loadings
Movement of crane along wharf-line railway (gantry movement) Slow and relativity low frequency of occurrence: not critical Wind loading More severe when the forestay is stowed Not critical for Singapore terminals but critical for places like HK due to yp typhoon Dynamic loadings due to S-T and T-S movements of hoist block High frequency operations (S-T and T-S Cycles) Major sources of dynamic loading for cranes in Singapore terminals Effect could be highly localized

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Dynamic Fatigue assessment of Container Quay Crane

Operations and dynamic actions y


Cycle counting: one cycle per every ST (or T-S) operation Forces acting on crane during operations ms: mass of spreader mt: mass of t ll ( ith machine) f trolley (with hi ) mc: mass of container (variable) av av : vertical acceleration of spreader aH : horizontal acceleration of trolley With container Vertical : FV = (ms+mc)(av) ( )( Ship Shi Horizontal : FH = (ms+mt+mc)(aH) Without container Vertical : FV = (ms)(av) Horizontal : FH = (ms+mt)(aH)
18 rows for the CQC studied, row 1 nearest to dock

aH

Sea-to-truck Truck-to-sea

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Dynamic Fatigue assessment of Container Quay Crane

Quay crane fatigue assessment y g


Overall assessment procedure
Obtain loading data (aV, aH, mt, mc, ms and frequencies) Create C t FE model d l for global dynamic analysis Identify fatigue prone l locations ti and obtain the stress range spectrum Could be obtained from either in situ measurements or by detailed 3D solid FE modelling
Butt weld Fillet weld

Fatigue assessment by using suitable rules

Some could only be obtained by in situ measurements

Global dynamic analysis using wireframe models

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Backstay tip

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Dynamic Fatigue assessment of Container Quay Crane

Quay crane fatigue assessment y g


Global dynamic analysis
G Governing equation of the system in term of displacement u g q y p
Self-weight g Operations Temperature Environmental p p

&& & Mu + Cu + Ku = F (mg, oper(t), T(t), env(t))


Wireframe model for dynamic analysis Dimensions and sections details from construction drawings t ti d i 430 joints, 353 beam-column elements, approx. 2600 DOF Hoist block modelled as point mass and point load while other utilities as distributed loads Lump mass matrix, single damping factor

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Dynamic Fatigue assessment of Container Quay Crane

Quay crane fatigue assessment y g


Global dynamic analysis
To predict the following structural properties of the CQC under dynamic loading Natural frequencies and mode shapes ( (1st horizontal 0.64Hz, 1st vertical 1.16Hz) ) Member forces and force ranges Fatigue prone location(s) Members nominal stress and stress ranges => Design spectra due to different operations Key parameters to be calibrated: Accuracy of natural frequencies and mode shape (for different locations of hoist block) Ground support conditions (spring stiffness for wheels) Damping factors

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Dynamic Fatigue assessment of Container Quay Crane

Quay crane fatigue assessment


In situ measurements
Two different tests done with real time measurements: C t l t t and t Control test d Operation test Control test Separated horizontal hoisting and S veridical lifting operations with maximum container weight followed by free vibration Provide specific excitations Responses monitored: Deflection at sea side boom end by HD video Accelerations: Two accelerometers g g Member forces: Strain gauges at two levels, on the four side walls of one of the lower land side legs
Extreme land position Row 18

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Dynamic Fatigue assessment of Container Quay Crane

Quay crane fatigue assessment


Control test results and calibrations C l l d lib i
Stiff (150kN/mm) ground support condition g gave best modelling results g Natural frequencies correctly predicted by the model There is a small change in natural frequencies when the hoist block moved from extreme sea side to extreme land side (5%) Deflections and strain gauges readings compared well with the model
Under static loading deflection range at sea side boom end 240mm 1/460 of boom+ girder lengths, lengths Maximum static stress range level = 37MPa

Damping factors obtained by tracing the peak p y g response decay rate during free vibration Horizontal actions: 1%, vertical actions: 0.25% of critical damping ratio

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RSA Symposium, 28 Sept. 2011, NTU

Dynamic Fatigue assessment of Container Quay Crane

Quay Crane fatigue assessment


Critical locations and key parameters From the control test and global model, one potential fatigue prone location is the stiffener ends of sea facing walls of the lower land side legs The horizontal motions of the hoist block is more critical (3-5 times higher in stress range) than vertical lifting of g ) g container Other critical parameters that affecting stress range spectrum are
Loading and unloading rows Weight of container Horizontal and vertical accelerations of th H i t l d ti l l ti f the hoist block and container during operation => operators style 38
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Dynamic Fatigue assessment of Container Quay Crane

Quay Crane fatigue assessment


Operation test
To obtain magnitudes, distributions and frequency of critical parameters: Horizontal and vertical motions velocities and accelerations of trolley and motions, containers Loading/unloading times Data bt i d from 35 l di and unloading operations (R D t obtained f loading d l di ti (Runs) on a small ) ll container ship (operation rows 1 to 6), 7 runs from ship-to-truck and 28 runs from truck-to-ship HD video records f h i t bl k h i id d for hoist block horizontal motions and container vertical t l ti d t i ti l motions Accelerometers (on trolley) and strain gauges measurements (side walls of lower l d side l ) l land id leg) In addition, the starting/ending rows distributions during loading/unloading operations from 10 years record (0.85 million operations) from crane owner

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RSA Symposium, 28 Sept. 2011, NTU

Dynamic Fatigue assessment of Container Quay Crane

Quay Crane fatigue assessment


Motions paths for hoist block and container
The horizontal acceleration of the hoist block and the vertical acceleration of the container are the two most important parameters that affect the dynamic forces applied and stress range induced

Motion pathof container

Position S Sm

h
hm Sd Position P iti T

hs

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RSA Symposium, 28 Sept. 2011, NTU

Dynamic Fatigue assessment of Container Quay Crane

Quay Crane fatigue assessment


Motions paths for hoist block and container
Operator accelerated/braked whenever he/she felt necessary for operations or to achieve a minimum time of travel

Motion plot Velocity plot


Velocity and acceleration for a typical cycle 41
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Dynamic Fatigue assessment of Container Quay Crane

Quay Crane fatigue assessment


Motions equations
Velocity and acceleration limits of hoist block and container:

Vh = 2.8m/s, ah 1 0m/s2 =1.2m/s Hmax =1 0m/s2 =1.0m/s hmax 2 8m/s hmax = 1.0m/s , Vvmax=1 2m/s , aH
All operators would try to minimize the time needed for each operation (within safety limits). Actual travel time depends on the skill and style of operator Different forms of motion equations were employed to represent the ff f f style and skill of operator Six variables (Initial and final positions, velocities and accelerations) are required to define the initial and final conditions of the hoist block Assuming the position of the hoist block is a fifth order polynomial of time

S=c1+c2t + c3t2 + c4t3+ c5t4 + c6t5


Acceleration is then a cubic polynomial:

aH=2c3 + 6c4t+ 12c5t2 + 20c6t3

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Dynamic Fatigue assessment of Container Quay Crane

Quay crane fatigue assessment


Motions equations
From the maximum velocity and acceleration, the minimum time of travel Tmin(cubic) could be obtained ( ) The cubic acceleration form is corresponding to a gentle operator who tries to achieve a gentle acceleration/deceleration throughout the operation More aggressive (or skillful) operation style could be obtained by reducing aggressive the order and smoothness of the acceleration equation to
1. Linear acceleration form => Tmin(linear) 2. Constant acceleration form=> Tmin(const)

The constant acceleration form is corresponding to a swift operator who always able to use the hoist block engine up to its mechanical limit so that y g p

Tmin(cubic) > Tmin(linear) > Tmin(const)


The main function of motion equations is not to reproduce the measured results but to obtain lower bound of travel time (hence upper bound of acceleration forces)

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Dynamic Fatigue assessment of Container Quay Crane

Quay Crane fatigue assessment


Motions equations
Checking with actual travel time from HD video records confirmed that the constant acceleration form could give a lower bound of the travel time => maximum dynamic forces For vertical motions of spreader, similar approach was used and it was found that a linear form is appropriate
50 45

Cubic form

40

Minim mum time (s)

35

Linear form
30

25

Constant form

20

15

10 30 40 With container 50 Tmin(Con) 60 Sm(m) without container 70 Tmin(Lin) 80 Tmin(Cubic)

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Dynamic Fatigue assessment of Container Quay Crane

Quay crane fatigue assessment


Dynamic loading on quay crane The final dynamic loading is the combination of horizontal and vertical loadings. loadings From the HD video records, horizontal and vertical motions records were not synchronized as the operator needed to avoid obstacles (other containers in ship) during operation They were applied simultaneously to generate maximum dynamic loads The dynamic loadings were applied with the following combinations to obtained the member force ranges 7 6 Rows 1 to 18 5 S-T and T-S operations 4 Container weights: 3 0, 20, 40 tons 2 =>Totally 108 analyses
Precentage of operations 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Row Number

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Dynamic Fatigue assessment of Container Quay Crane

Quay crane fatigue assessment


Damage assessment No special treatment on resonance since period of operations >> natural periods (operation>20sec => 1-2 sec natural periods) (operation 20sec 12 Lower land side leg walls nominal stress ranges: From operation test measurement (Rows 1-6): 22MPa to 40MPa Predicted from dynamic models (Rows 1-6): 31MPa to 55MPa Higher stress ranges from S-T operations Maximum stress range from S-T operation with 40 ton container, Row 18 operation => 83MPa (c.f. static range = 37MPa) A value of Ff =1 0 was used 1.0 For other parts such as backstay and addition bracing, FE analysis needed to calculate stress range from member force ranges

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RSA Symposium, 28 Sept. 2011, NTU

Dynamic Fatigue assessment of Container Quay Crane

Quay crane fatigue assessment


Damage assessment
Butt weld Mast Fillet weld

Backstay tip

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Dynamic Fatigue assessment of Container Quay Crane

Damage assessment

Quay crane fatigue assessment

From nominal/Hot spot stress, perform fatigue design/check by using the appropriate S-N curves 2.3 % failure probability curve was used (or 5% failure probability curve with Mf =1.10) Lower land side leg wall details shall be safe for at least 20 years services Damage contributions from different rows operations
12 Precentage of damage contribution

10

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Row Number

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Conclusions

Summary and conclusions


A concise introduction of the basic theory of fatigue assessment Essential basic knowledge: Structural mechanics and structural dynamic Fracture mechanics Basic finite element for linear elastic stress analysis Behaviors and response of the structures, importance of connection details A b i f introduction to the EN1993-1-9 and it fatigue design philosophy, brief i t d ti t th EN1993 1 9 d its f ti d i hil h comparison with BS 7608 A practice application example on dynamic fatigue analysis of container quay crane

More fatigue or even fracture experience needed? NTU, NTU CEE MSc course CV6807: Fatigue & Fracture of Steel Structures 39hrs of lectures and 3 hrs of examination

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