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    Analysis in Indeterminate Structures

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    maloy
    This case study analyzes the failure of a structural beam at an oil refinery. Key findings include: 1) The beam failed at an expansion joint where the connection was supposed to allow sliding but had been tack welded, preventing expansion. 2) Three of four hold fasteners connecting the insert plate to a concrete column had rusted and sheared. 3) Lessons included ensuring expansion joints allow movement, improving insert plate connections, and strengthening quality control during construction.

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    Analysis in Indeterminate Structures

    Uploaded by

    maloy
    68 views4 pages
    This case study analyzes the failure of a structural beam at an oil refinery. Key findings include: 1) The beam failed at an expansion joint where the connection was supposed to allow sliding but had been tack welded, preventing expansion. 2) Three of four hold fasteners connecting the insert plate to a concrete column had rusted and sheared. 3) Lessons included ensuring expansion joints allow movement, improving insert plate connections, and strengthening quality control during construction.

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    This case study analyzes the failure of a structural beam at an oil refinery. Key findings include: 1) The beam failed at an expansion joint where the connection was supposed to allow sliding but had been tack welded, preventing expansion. 2) Three of four hold fasteners connecting the insert plate to a concrete column had rusted and sheared. 3) Lessons included ensuring expansion joints allow movement, improving insert plate connections, and strengthening quality control during construction.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    68 views4 pages

    Analysis in Indeterminate Structures

    Uploaded by

    maloy
    This case study analyzes the failure of a structural beam at an oil refinery. Key findings include: 1) The beam failed at an expansion joint where the connection was supposed to allow sliding but had been tack welded, preventing expansion. 2) Three of four hold fasteners connecting the insert plate to a concrete column had rusted and sheared. 3) Lessons included ensuring expansion joints allow movement, improving insert plate connections, and strengthening quality control during construction.

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    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    of 4

    CASE ANALYSIS OF INDETERMINATE STRUCTURES

    I. Purpose
    The purpose of this case study is to document
    • The cause and analysis of failure
    • Preventive measures taken to avoid recurrence of such failures in future.

    II. Scope
    The scope of this case study is limited to the study details adopted at Jamnagar
    Refinery; analysis and conclusion arrived for dealing with such issues. This study is
    for internal use of Reliance only for facilitating the decision-making process.

    III. Case Study and Analysis


    The case under study is combination of both RCC and Structural Steel. Structural
    steel is connected to RCC through insert plates or with the help of anchor fasteners
    – mechanical / chemical. In this case structural steel connection plate was
    supposed to be welded to insert plate embedded in RCC column and bolted to the
    beam. This being a expansion joint, slotted holes were provided in the beam. After
    approximately one year of commissioning of plant one beam of section UC254 X
    73, collapsed at Crude Unit 311 between column A-23 and A-24. There were
    several brainstorming sessions among the team members of construction, FDC,
    and CES departments for analyzing cause and implementing corrective measures.
    This case study gives the details of analysis and conclusion arrived for dealing with
    such cases to avoid similar failures in other areas.

    A. Observations made during this case study


    1. It was expansion Bay of the main pipe rack. The joining connection plate
    between beam and insert plate had slotted holes to provide expansions.
    Instead these got anchored because the connection plate was tack welded with
    beam and the bolts were missing.
    2. It was a connection providing support to a 10” dia expansion loop of diesel to
    feed filter 311-PA-184-10”-EC34EA-HC-75 insulated line and b) 6” dia
    expansion loop of RICH OIL FROM UNIT 321, 321-PA- 086-6”-EC12EA-HC-50
    insulated line.
    3. The case under study is combination of both RCC and Structural Steel.
    Structural steel is connected to RCC through insert plates or with the help of
    anchor fasteners – mechanical / chemical. In this case structural steel
    connection plate was supposed to be welded to insert plate embedded in RCC
    column and bolted to the beam. This being a expansion joint, slotted holes were
    provided in the beam. After approximately one year of commissioning of plant
    one beam of section UC254 X 73, collapsed at Crude Unit 311 between column
    A-23 and A-24. There were several brainstorming sessions among the team
    members of construction, FDC, and CES departments for analyzing cause and
    implementing corrective measures. This case study gives the details of analysis
    and conclusion arrived for dealing with such cases to avoid similar failures in
    other areas.

    Out of four hold fastener bars welded to insert plate on RCC side
    found sheared at weld joint, three were rusted and one was fresh,
    indicating that separation occurred sometime back.

    As per drawing Change proposed through this case study

    Connection between insert plate and hold fastener rod

    Sl.
    Requirement Observation
    No.
    1 In stud type connection weld Connection between insert plate and each
    length is limited to perimeter hold fastener should have been with at least
    the cross section of the hold 160mm bearing and double-flare bevel
    fastener rod. groove welding between M.S. rod and plate,
    as proposed in the above schematic sketch.
    2 Fillet welds size between Hold Fillet weld size actual found between
    fastener to insert plate to be 5mm to 6mm.
    10 mm
    3 Connection plate is required to There was a gap between insert plate and
    be directly welded to insert connection plate. This gap was bridged with
    plate with no gap. additional plate. This additional plate had
    incomplete welding all-round.
    4 Connection plate at sliding Connection plate tack welded to beam
    connection with bolt nuts section thus arresting the sliding movement
    required to just snug-fitted and and making it an anchor joint.
    bolt threads peened to prevent
    back-off nut for sliding action
    during expansion.
    5 As per ITP 22960-ITP-230,  Scope of inspection for structural steel
    inspection record to be items / sliding joint not identified clearly.
    prepared for structural steel  Quality records prepared were not in line
    erection in form No FM-CIV- with the ITP.
    0030. As per the above ITP  Contractor Quality Control Engineer
    most of the check / hold points (CQCE) failed to produce evidence that all
    were left on Contractor Quality structures were inspected religiously.
    Control Engineer.  For key checkpoints we should not have
    relied on CQCE.
     Most of the left out punch points were
    liquidated during first shut down of this
    unit after commissioning of the unit.

    B. Analysis
    1. Being expansion joint one side of the beam was supposed to be with sliding
    connection. Bolts should have been at the center of the slotted with nuts just
    snug-fitted to provide provision for expansion. Instead connection plates were
    tack welded to beam and thus making sliding joint as fixed one which caused
    additional stresses in the whole assembly.
    2. By this stressing, the weakest link i.e. holds fasteners and insert plate gave
    away, leading to collapse of the beam.

    C. Conclusion

    1. Sliding joint required in the expansion bay as per drawing was not existing and
    this has exerted extra force on the connection and was the cause of failure.
    2. Rusted fracture of three hold fasteners of insert plate indicates that failure
    started from this weakest link. Because hold fasteners were just stud welded to
    insert plate.
    3. Later on because of falling of the beam, connection plate connected to insert
    plate through extended additional plate by welding also failed and subsequently
    tack welds between connection plate with beam section also gave away.
    D. Lessons Learnt
    1. During erection of structural steel proper attention should be paid for sliding
    joints and instructions given in the drawing should be properly followed. For this
    we cannot rely on Contractor Quality Control Engineer alone, key check points
    should also be ‘HOLD’ point for Reliance– QMD.
    2. Bolts in the slotted holes should be at the center of the slot at the time of
    construction and have free movement in the direction of expansion. As
    recommended by Designer expansion bay connection shall have nuts snug-
    fitted and bolt threads peened to prevent back-off of nut.
    3. Proper quality control should be exercised during fabrication of insert plates to
    ensure sound welding between hold fasteners and plate.
    4. Temporary tack welds between connection plates and beam shall not be used
    as practice at expansion bays, however if tack welded during fabrication should
    be removed by grinding before erection.
    5. Welding between connection plate and insert plate should be sound and as
    specified in the drawing.
    6. Quality record as per the relevant ITP shall be prepared.

    E. Recommendation
    1. Expansion joint shall be ‘Hold Point’ for all concerned e.i. for Execution as well
    as Quality Control. This point shall be incorporated in ITP for structural steel
    erection.
    2. Joint design between hold fasteners and insert plate shall be double-flare-bevel
    groove weld type instead of stud type.

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