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STRUCTURAL SEISMIC ANALYSIS

OF
Industrial PC Rack
Performed by:

Hi-Tech House, B/H V-Murti Complex, Near Gurukul Tower, Gurukul, Ahmedabad-380 052, Gujarat,
India.
Phone: +91-794-000-3000, +91-793-014-3000
Fax : +91-794-000-3202
E-Mail: info@hitechos.com

For

DL Custom
7250 Victoria Park Ave
Markham Ontario
L3R 2M5

00 11/02/2013 Seismic Qualification Bhaumik Dave

Revision Date Purpose Written By Reviewed By Approved By

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TABLE OF CONTENTS

1. TABLES AND FIGURES………………………………………………………………4


2. EXECUTIVE SUMMARY…………………………………………………………….6
3. INTRODUCTION……………………………………………………………………….7
4. SYSTEM DESCRIPTION……………………………………………………………..8
5. FINITE ELEMENT MODEL DESCRIPTION…………………………………. 10
6. MODAL ANALYSIS…………………………………………………………………. 16
7. SEISMIC ANALYSIS………………………………………………………………….17
8. MARGINS OF SAFETY CALCULATIONS……………………………………..19
9. SUMMARY AND RECOMMENDATION………………………………..……21

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A. LEAVE IT BLANK FOR REFERENCES SPECIFICATION OF PROJECT AND ATTACHMENTS, DL CUSTOM WILL FILL
THIS PAGE

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TABLES
1. Table 2-1 : The Industrial Rack system consists of following Components
2. Table 5-1 : Shows an overall Summary of FE Model with respect to Nodes and Elements
3. Table 5-2 shows the range of elements used in FE Model
4. Table 5-3 : Part Geometry and Weight Parameters Details
5. Table 5-4 : Material Properties
6. Table 6-1 Natural Frequencies
7. Table 7-1 Loading For Seismic Analysis (X Direction)
8. Table 7-2 Equivalent Stress due to Seismic Event (X Direction)
9. Table 7-3 Equivalent Stress due to Seismic Event (Y Direction)
10. Table 7-4 Equivalent Stress due to Seismic Event (Y Direction)
11. Table 8-1 Margins of Safety for Various Components(X Direction Spectrum)
12. Table 8-2 Margins of Safety for Various Components(Y Direction Spectrum)
13. Table 8-3 Margins of Safety for Various Components (Z Direction Spectrum)

FIGURES
1. Fig 2.1: System Description
2. Fig 2.2: Application Reference
3. Fig 5.1: Finite Element Model-Meshed
4. Fig 5.2: Coordinate System Used
5. Fig 5.3: Boundary Conditions
6. C1: Mode Shape for First Fundamental Frequency
7. C2: Maximum Deformation X for Columns( X Spectrum)
8. C3: Maximum Deformation Y for Columns( X Spectrum)
9. C4: Maximum Deformation Z for Columns( X Spectrum)
10. C5: Maximum Equivalent Stress(MPa) in Column(X Spectrum)
11. C6: Maximum Deformation X for Cross Members ( X Spectrum)
12. C7: Maximum Deformation Y for Cross Members ( X Spectrum)
13. C8: Maximum Deformation Z for Cross Members ( X Spectrum)
14. C9: Maximum Equivalent Stress(MPa) in Cross Members(X Spectrum)
15. C10: Maximum Deformation X for Bottom Parts ( X Spectrum)
16. C11: Maximum Deformation Y for Bottom Parts ( X Spectrum)
17. C12: Maximum Deformation Z for Bottom Parts ( X Spectrum)
18. C13: Maximum Equivalent Stress (MPa) in Bottom Parts(X Spectrum)
19. C14: Maximum Deformation X for Top Parts ( X Spectrum)
20. C15: Maximum Deformation Y for Top Parts ( X Spectrum)
21. C16: Maximum Deformation Z for Top Parts ( X Spectrum)
22. C17: Maximum Equivalent Stress (MPa) in Top Parts(X Spectrum)
23. C18: Maximum Deformation X for Columns( Y Spectrum)
24. C19: Maximum Deformation Y for Columns( Y Spectrum)
25. C20: Maximum Deformation Z for Columns( Y Spectrum)
26. C21: Maximum Equivalent Stress(MPa) in Column(Y Spectrum)
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27. C22: Maximum Deformation X for Cross Members ( Y Spectrum)


28. C23: Maximum Deformation Y for Cross Members ( Y Spectrum)
29. C24: Maximum Deformation Z for Cross Members ( Y Spectrum)
30. C25: Maximum Equivalent Stress(MPa) in Cross Members(Y Spectrum)
31. C26: Maximum Deformation X for Bottom Parts ( Y Spectrum)
32. C27: Maximum Deformation Y for Bottom Parts ( Y Spectrum)
33. C28: Maximum Deformation Z for Bottom Parts ( Y Spectrum)
34. C29: Maximum Equivalent Stress (MPa) in Bottom Parts(Y Spectrum)
35. C30: Maximum Deformation X for Top Parts ( Y Spectrum)
36. C31: Maximum Deformation Y for Top Parts ( Y Spectrum)
37. C32: Maximum Deformation Z for Top Parts ( Y Spectrum)
38. C33: Maximum Equivalent Stress (MPa) in Top Parts(Y Spectrum)
39. C34: Maximum Deformation X for Columns( Z Spectrum)
40. C35: Maximum Deformation Y for Columns( Z Spectrum)
41. C36: Maximum Deformation Z for Columns( Z Spectrum)
42. C37: Maximum Equivalent Stress(MPa) in Column(Z Spectrum)
43. C38: Maximum Deformation X for Cross Members ( Z Spectrum)
44. C39: Maximum Deformation Y for Cross Members ( Z Spectrum)
45. C40: Maximum Deformation Z for Cross Members ( Z Spectrum)
46. C41: Maximum Equivalent Stress(MPa) in Cross Members(Z Spectrum)
47. C42: Maximum Deformation X for Bottom Parts ( Z Spectrum)
48. C43: Maximum Deformation Y for Bottom Parts ( Z Spectrum)
49. C44: Maximum Deformation Z for Bottom Parts ( Z Spectrum)
50. C45: Maximum Equivalent Stress (MPa) in Bottom Parts(Z Spectrum)
51. C46: Maximum Deformation X for Top Parts ( Z Spectrum)
52. C47: Maximum Deformation Y for Top Parts ( Z Spectrum)
53. C48: Maximum Deformation Z for Top Parts (Z Spectrum)
54. C49: Maximum Equivalent Stress (MPa) in Top Parts(Z Spectrum)

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Executive Summary
A detailed three-dimensional (3-D) finite element (FE) computer model was constructed for seismic Qualification
analysis of the Industrial Rack manufactured by DL Custom. This Seismic Qualification was done for Bellcore zone
4 requirements.

The analysis was performed to determine structural integrity and performance characteristics of the Industrial
Rack System under different seismic loading conditions. The objective of the work performed is to quantify the
System performance characteristics under the influence of seismic inertia loads based of specification and
applicable regulatory documents and industry standards.

Modal and seismic analyses were carried out.

The modal analysis was performed in order to determine the lowest natural Frequencies and associated mode
shapes of the Assembly. The Seismic Analysis was done using the spectrum available. It was done using
Response Spectrum Method (SPRS: Single Point Response System).

The Seismic Analysis results were obtained in terms of Deformation and Stress for the respective components of
the system.

Results indicate that all investigated components Industrial Rack Assembly will maintain their structural integrity
during and after the specified seismic events for Bellcore zone 4.

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Introduction
A detailed three-dimensional (3-D) finite element (FE) computer model was constructed for Seismic Qualification
Analysis of the Industrial Rack manufactured by DL Custom. The Seismic qualification was performed
specification required Response Spectra.

The analysis was performed to determine structural integrity and performance characteristics of the Industrial
Rack under different seismic loading conditions. The objective of the work performed is to quantify the System
performance characteristics under the influence of seismic inertia loads based of specification and applicable
regulatory documents and industry standards.

This report documents in details the technical approach, FE computer modeling, maximum seismic deflections at
different locations, maximum seismic stresses in different components and corresponding margins of safety
(M.S.).

Section 2 outlines the Industrial Rack system description. Details of the FE modeling of the Assembly and
assumptions considered are presented in Section 3.

The natural frequency analysis results are presented in Section 6.

Details of Seismic Analysis basis, calculations, and results are presented in Section 7.

Summary of Margins of Safety (M.S.) calculations for the Assembly components is presented in Section 8.

The Conclusions and recommendations are presented in Section 9.

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SYSTEM DESCRIPTION
Table 2-1 : The Industrial Rack system consists of following Components

Sr. No Item Component


1 1 Cross Members
2 1 Bottom Portion
3 1 Top Portion
4 1 Four Pillars

CROSS MEMBERS

TOP PORTION

FOUR PILLARS

BOTTOM PORTION

Fig 2.1 : SYSTEM DESCRIPTION

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Fig 2.2 : APPLICATION REFERENCE

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FINITE ELEMENT MODEL DESCRIPTION

1. Finite Element Analysis Assumptions


The various assumptions made in the analysis of the equipment are listed here:

A. The FE analysis performed is based on linear elastic behavior of the equipment.


B. Interaction forces between modeled equipment and supporting structure can be transmitted through
the bolts shear and tension reaction forces only. The assumption underlines the common
conservative practice of not counting on frictional forces in resisting applied loads for Seismic
Qualification of systems.
C. Rigid boundary conditions were assumed at the base mounting area.

All the components were modeled using Solid Elements with a mixed mesh containing of Tetrahedron
and Hexahedron elements.

2. Finite Element Analysis Assumptions

A 3-D .STEP geometry was directly imported into ANSYS v14.5Mechanical Program.

Three different types of elements were used to create the Finite Element Mesh : Tetrahedrons, Hexahedrons,
Pyramids and Wedges with majority of elements having Tetrahedrons.

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Table 5-1 : Shows an overall Summary of FE Model with respect to Nodes and Elements

Description Quantity
Total Nodes 645181
Total Elements 469680
Total Body Elements 277627
Total Contact Elements 192053
Total Spot Weld Elements 0
Element Types 7
Coordinate Systems 0
Materials 1
Thicknesses 0
Layered Composites 0
Rod Properties 0
Bar Properties 0
Beam Properties 0
Curved Pipe Properties 0
Mass Properties 0
Spring Properties 0
Components 5
Contacts 185
Spot Welds 0
Constraint Equations 0
Constraints 2
Forces 1
Pressures 0

Table 5-2 shows the range of elements used in FE Model

Generic Element Type Name ANSYS Element Name


Quadratic Tetrahedron Mesh200
Quadratic Hexahedron Mesh200
Quadratic Wedge Mesh200
Quadratic Pyramid Mesh200
Quadratic Quadrilateral Contact Conta174
Quadratic Quadrilateral Target Targe170
Quadratic Triangular Contact Conta174
Quadratic Triangular Target Targe170

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Figure- 5.1 shows combinations of Tetrahedrons, Hexahedron,Wedges and Pyramids used for Meshing of
Industrial PC rack system.

Fig 5.1: Finite Element Model : Meshed

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COORDINATE SYSTEM

Figure 5.2 shows Co-ordinate system used for analysis:

Fig 5.2: Coordinate System Used

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3. Part wise characteristics Details:


Table 5-3 : Part Geometry and Weight Parameters Details

Object Name Cross Members Bottom Parts Top Parts Four Pillars

Coordinate System 11 11 11 11

Assignment Plain Carbon Steel Plain Carbon Steel Plain Carbon Steel Plain Carbon Steel

Nonlinear Effects Yes Yes Yes Yes


Length X 1008 mm 1062.7 mm 1062.7 mm 1066.8 mm

Length Y 1941.3 mm 78.181 mm 98.501 mm 2125.5 mm

Length Z 566.76 mm 605.54 mm 605.54 mm 609.6 mm

Volume 1.4572e+006 mm³ 1.8495e+006 mm³ 8.4364e+005 mm³ 2.6879e+006 mm³

Mass 11.293 kg 14.333 kg 6.5382 kg 20.832 kg

Centroid X 531.42 mm 531.41 mm 520.62 mm 533.73 mm

Centroid Y -969.72 mm -2028.3 mm 55.122 mm -972.32 mm

Centroid Z -302.8 mm -302.81 mm -297.61 mm --304.12 mm


6.3148e+006
Moment of Inertia Ip1 6.3474e+005 kg·mm² 4.2186e+005 kg·mm² 8.934e+006 kg·mm²
kg·mm²
1.7978e+006
Moment of Inertia Ip2 2.3254e+006 kg·mm² 1.5237e+006 kg·mm² 7.1066e+006 kg·mm²
kg·mm²
6.4287e+006
Moment of Inertia Ip3 1.708e+006 kg·mm² 1.1128e+006 kg·mm² 1.2672e+006 kg·mm²
kg·mm²

4. Material and Material Properties Used for the Analysis:

Table 5-4 : Material Properties

Material Property Plain Carbon Steel


Young's Modulus MPa 1.93E+05

Poisson's Ratio 0.31

Bulk Modulus MPa 1.69E+05

Shear Modulus MPa 73664

Compressive Yield
Strength MPa 207
Tensile Yield Strength
MPa 207
Tensile Ultimate
Strength MPa 586
Density 7.75e-006 kg mm^-3

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5. FE Model Description and Loads and Boundary Conditions:


- For solution of Analysis ANSYS v14.5 Mechanical software is used. The version used for Analysis
ANSYSv14.5 is the latest tested release available at the time of Analysis.
- The case of Industrial Rack Assembly is solved using the above mentioned material properties with base
being fixed.
- Load conditions varies for different types of analyses:
1. Modal Analysis
2. Seismic Analysis

- Constraints are applied at the bottom surface of the Mounting. Translations and rotations are fixed at
this support.

Fig 5.3: Boundary Conditions

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MODAL ANALYSIS

Modal Analysis was carried out to extract first 10 Natural Frequencies of the assembly. A Block Lancoz algorithm
was used to find the natural frequencies.

Table 6-1 Natural Frequencies

Frequency
Mode
[Hz]
1. 8.8071

2. 11.385

3. 17.684

4. 24.092

5. 35.228

6. 35.779

First Natural frequency is at 8.8 Hz

Mode Shapes Plot:

C1: Deformation at first fundamental Frequency

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SEISMIC ANALYSIS

Seismic Analysis was performed using an Equivalent Static Analysis loading case. For this, the First Natural
Frequency found out using Modal analysis was used in connection with the Spectrum to be analyzed for.

Table 7-1 Loading for Seismic Analysis (X Direction Spectrum)

Sr Freq(Hz) G(mm/sec2)
1 0.3 1962
2 0.6 19620
3 2 49050
4 5 49050
5 15 15696
6 50 15696

Maximum Equivalent Stress induced due to Seismic Loading for all components is shown in Table7-2. It is
predicted that the induced stress is far below the yield strength of the materials.

Same Spectrum has been used for Y and Z direction loading.

Table 7-2 Equivalent Stress due to Seismic Event (X Direction)

Maximum Deformation(mm) Maximum


Equivalent Stress
Component Acceleration(mm/sec2) X Y Z (MPa)
X

Four Columns Spectrum 0.09 0.15 0.48 28


X

Cross Members Spectrum 4.9 0.3 0.41 54


X

Bottom Parts Spectrum 0.089 0.12 0.1 126


X

Top Parts Spectrum 4.9 0.06 0.33 78

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Table 7-3 Equivalent Stress due to Seismic Event (Y Direction)

Maximum Deformation(mm) Maximum


Equivalent Stress
Component Acceleration(mm/sec2) X Y Z (MPa)

Y
Four Columns Spectrum 0.015 0.005 0.034 7.7

Y
Cross Members Spectrum 0.0004 0.024 0.037 13

Y
Bottom Parts Spectrum 0.0009 0.003 0.0224 1.76

Y
Top Parts Spectrum 0.05 0.09 0.32 15.85

Table 7-4 Equivalent Stress due to Seismic Event (Y Direction)

Maximum Deformation(mm) Maximum


Equivalent Stress
Component Acceleration(mm/sec2) X Y Z (MPa)

Four Columns Z Spectrum 0.8 0.33 0.096 112

Cross Members Z Spectrum 0.075 0.18 0.3 104

Bottom Parts Z Spectrum 0.08 0.14 1.2 71

Top Parts Z Spectrum 0.21 0.25 3.31 65

Results : Deformation and Stress Plots for all cases

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MARGINS OF SAFETY CALCULATIONS

The Seismic analysis results presented above are used to determine minimum margins of Safety(M.S.) for
different components of the Industrial Rack System. Table below presents summary of margins of safety of the
system.

The Margin of Safety is calculated as follows:

S.R. = Allowable stress/Maximum Seismic Stress

M.S.= 1 - 1/S.R.

The calculated M.S. values shall be greater than 0.0 in order to maintain structural integrity and operability of the
system during specified seismic events.

Table 8-1 Margins of Safety for Various Components(X Direction Spectrum)

Maximum Deformation(mm) Maximum


Acceleration(m Equivalent Stress
Component m/sec2) X Y Z (MPa) Margin of Safety(M.S.)
X

Four Columns Spectrum 0.09 0.15 0.48 28 0.866666667


X
Cross
Members Spectrum 4.9 0.3 0.41 54 0.742857143
X

Bottom Parts Spectrum 0.089 0.12 0.1 126 0.4


X

Top Parts Spectrum 4.9 0.06 0.33 78 0.628571429

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Table 8-2 Margins of Safety for Various Components(Y Direction Spectrum)

Maximum Deformation(mm) Maximum


Acceleration( Equivalent Stress
Component mm/sec2) X Y Z (MPa) Margin of Safety(M.S.)

Y
Four Columns Spectrum 0.015 0.005 0.034 7.7 0.963333333

Cross Y
Members Spectrum 0.0004 0.024 0.037 13 0.938095238

Y
Bottom Parts Spectrum 0.0009 0.003 0.0224 1.76 0.991619048

Y
Top Parts Spectrum 0.05 0.09 0.32 15.85 0.92452381

Table 8-3 Margins of Safety for Various Components (Z Direction Spectrum)

Maximum Deformation(mm) Maximum


Equivalent
Component Acceleration(mm/sec2) X Y Z Stress (MPa) Margin of Safety(M.S.)

Four Columns Z Spectrum 0.8 0.33 0.096 112 0.466666667

Cross Members Z Spectrum 0.075 0.18 0.3 104 0.504761905

Bottom Parts Z Spectrum 0.08 0.14 1.2 71 0.661904762

Top Parts Z Spectrum 0.21 0.25 3.31 65 0.69047619

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CONCLUSIONS AND RECOMMENDATIONS

As can be seen from the results obtained by FE Analysis, the rack manufactured by DL Customl is safe under the
conditions applied and used. The stresses produced under conditions were compared to the SSE allowable values
and all components are safe from a strength point of view.

We can conclude that the analyzed Industrial PC Rack system manufactured by DL Custom is safe (will not
collapse or disintegrate) under the specified seismic loading and hence passes the Bellcore Seismic Testing
Standard.

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C1: Mode Shape at First Fundamental Frequency

C2: Maximum Deformation X for Columns( X Spectrum)

C3: Maximum Deformation Y for Columns( X Spectrum)

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C4: Maximum Deformation Z for Columns( X Spectrum)

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C5: Maximum Equivalent Stress(MPa) in Column(X Spectrum)

C6: Maximum Deformation X for Cross Members ( X Spectrum)

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C7: Maximum Deformation Y for Cross Members ( X Spectrum)

C8: Maximum Deformation Z for Cross Members ( X Spectrum)

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C9: Maximum Equivalent Stress(MPa) in Cross Members(X Spectrum)

C10: Maximum Deformation X for Bottom Parts ( X Spectrum)

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C11: Maximum Deformation Y for Bottom Parts ( X Spectrum)

C12: Maximum Deformation Z for Bottom Parts ( X Spectrum)

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C13: Maximum Equivalent Stress (MPa) in Bottom Parts(X Spectrum)

C14: Maximum Deformation X for Top Parts ( X Spectrum)

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C15: Maximum Deformation Y for Top Parts ( X Spectrum)

C16: Maximum Deformation Z for Top Parts ( X Spectrum)

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C17: Maximum Equivalent Stress (MPa) in Top Parts(X Spectrum)

C18: Maximum Deformation X for Columns( Y Spectrum)

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C19: Maximum Deformation Y for Columns( Y Spectrum)

C20: Maximum Deformation Z for Columns( Y Spectrum)

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C21: Maximum Equivalent Stress(MPa) in Column(Y Spectrum)

C22: Maximum Deformation X for Cross Members ( Y Spectrum)

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C23: Maximum Deformation Y for Cross Members ( Y Spectrum)

C24: Maximum Deformation Z for Cross Members ( Y Spectrum)

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C25: Maximum Equivalent Stress(MPa) in Cross Members(Y Spectrum)

C26: Maximum Deformation X for Bottom Parts ( Y Spectrum)

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C27: Maximum Deformation Y for Bottom Parts ( Y Spectrum)

C28: Maximum Deformation Z for Bottom Parts ( Y Spectrum)

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C29: Maximum Equivalent Stress (MPa) in Bottom Parts(Y Spectrum)

C30: Maximum Deformation X for Top Parts ( Y Spectrum)

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C31: Maximum Deformation Y for Top Parts ( Y Spectrum)

C32: Maximum Deformation Z for Top Parts ( Y Spectrum)

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C33: Maximum Equivalent Stress (MPa) in Top Parts(Y Spectrum)

C34: Maximum Deformation X for Columns( Z Spectrum)

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C35: Maximum Deformation Y for Columns( Z Spectrum)

C36: Maximum Deformation Z for Columns( Z Spectrum)

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C37: Maximum Equivalent Stress(MPa) in Column(Zpectrum)

C38: Maximum Deformation X for Cross Members ( Z Spectrum)

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C39: Maximum Deformation Y for Cross Members ( Z Spectrum)

C40: Maximum Deformation Z for Cross Members ( Z Spectrum)

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C41: Maximum Equivalent Stress(MPa) in Cross Members(Z Spectrum)

C42: Maximum Deformation X for Bottom Parts ( Z Spectrum)

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C43: Maximum Deformation Y for Bottom Parts ( Z Spectrum)

C44: Maximum Deformation Z for Bottom Parts ( Z Spectrum)

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C45: Maximum Equivalent Stress (MPa) in Bottom Parts(Z Spectrum)

C46: Maximum Deformation X for Top Parts ( Z Spectrum)

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C47: Maximum Deformation Y for Top Parts ( Z Spectrum)

C48: Maximum Deformation Z for Top Parts ( Z Spectrum)

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C49: Maximum Equivalent Stress (MPa) in Top Parts(Z Spectrum)

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