personnel between the Tebodin offices.
Services offered by Tebodin EC
Consultancy, site selection
Conceptual studies
Project management
Permitting
Basic and detail engineering
Tendering and procurement
Construction supervision and Commissioning.
These are offered as single engineering or consultancy
packages or on an EPC-Contract (Engineering, Procurement,
Construction) or even turnkey basis.
The services and know-how offered by Tebodin EC cover the
following technological areas:
Process Technology
Power Plants
Logistics
Environment
Automotive
Telecommunications
Steel and machine building
Logistics and Manufacturing
Buildings and Infrastructure: Construction,
Architecture,
Building physics, Installations, Transport, Estimating/Bid
documents
One of the main activities of Tebodin EC is to provide the full
range of services for new facilities for foreign investors in
Hungary, specifically in the areas
of industrial
plants,
commercial
and logistics
centres
and infrastructural
development.
Your Project:
The project covers a very old blast furnace in a Hungarian steel
work factory in the town of Dunaujvaros, (built in 1960). The
statical system of this furnace was so that the base concrete
block on soil supported the lower part of the furnace and the
furnaces is also supported at 1/3 of the height with a spring
on the surface mantle.
A horizontal plate divided the two parts of the body. This plate
functioned like a compensator, because the whole furnaces
was heated of course and was supported in vertical direction
on two different levels.
The furnace was rebuild in 1989 when every element of the
furnace
was removed and rebuilt exactly as before.
More
space around the furnace
was needed and they simply
removed the supporting structures without reinforcements of
the body.
Now the horizontal plate in the middle served as
support of the upper part, turning the furnace into a self-
supporting construction. It is interesting that the construction
still stands with the changed statical system and the 40 mm
thick middle plate. The steel
work decided to remove the old
furnace in 2001 and they build a new one. Satisfied with the
old technology, the new furnace was built around the same
kind of furnace. So they chose the same shape as before.
Knowing that there were open questions about the earlier
rebuilding, they commissioned Tebodin EC Ltd to do a stress
analysis of the body of the furnace, to examine what point
had to be reinforced for safe working over the next 10-15
years.
We examined the whole furnace body and made a
model from 2D members adding all the loads acting on the
furnace.
Technical data of the project
Height:
Base on Level +1.50 m, Top on Level+37.47 m
Diameter:
11.576 m down, 10.43 in the middle, 4.28 m the throat
Weight:
368 tons
Material:
Steel Fe510: (Ultimate strength: 510
Mpa/Yield strength:
355 Mpa)
Thickness of the plates:
Lower part 40 mm, Upper part 30 mm, Upper truncated
cone 40 mm
4 connecting smoke ducts
D=1891mm, t=25 mm on Level +36.0 m
16 pieces of oxygen blasting each
D=990mm, thickness of the rim is 40 mm on Level +12.20 m.
Loads:
Dead load of the structure by ESA-Prima Win, loads in the
inside of the body simulated by changing thickness of brick
and other insulation materials
Live load (long lasting/not long lasting):
according to the technology
Wind load:
acc. to the Hungarian Standard, acting on the body and
connecting structures direct
Pressure inside:
1.5-2.5 bar
Temperature load:
temperature of the shell during work was measured by the
plant & taken into consideration in two different load cases:
Case 1: 12-60 °C, Case 2: 30-80 °C
Load Combination according to the Hungarian Standards
As a result of our analysis we could say that the stresses in the
shell of the furnaces are nowhere bigger than the allowable
limit. Some plate thickness had to be increased. The
main
problem was the above-mentioned horizontal plate; it was 40
mm before and had to be increased to 50 mm. The upper part
of the body was made from 30 mm of plate before, but the
part that connected to the horizontal plate was not strong
enough, this part had to be reinforced too to 40 mm.
Use of ESA-Prima Win
Modules used
Base module
3D shell
Intersection
Experiences with ESA-Prima Win
As
we
wanted to
make better and better
model for this
furnace we were keeping the point when we had to make
intersections for different 3D members.
We had not have the
right module for it before, and we had to buy it, and the life
was easy after that action. It was very comfortable to work
with this module and I use it really very frequently for other
projects too.
I have other remarks too.
At that time we could not apply the
temperature load
with the value of °C, but
with relative
displacement of the member. This question is not a question
any more, because it has been changed.
It would be useful if the local distributed load on a 3Dmember
not only with one arrow would be marked but in the same
form like the global loads.
39
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