MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

33
- MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl 10 I 2 I 90 D-Zero Engineering Note #3740.225-EN -261 / -- .. - ... ---- ... ... --- ...

Transcript of MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

Page 1: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

-

MH TEST FILLER FORCE LIMITATIONS

Keith A Primdahl

10 I 2 I 90

D-Zero Engineering Note

3740225-EN-261

-- ~ - ---- ~-- ---

- The OH modules for the DO end calorimeter are being tested by supporting a load to simulate the MH IH and EM modules This test structure the MH filler is inserted into the previously assembled OH modules and then loaded with hydraulic jacks

The maximum test load applied by the jacks is 78600 lb which is via the two downstream jacks at 130 of the nominal load Bill Coopers memo of 91090 is include as appendix C

This note presents calculations for the AISC maximum allowable stressesloads of the various parts of the testing assembly Furthermore calculations show that the actual test load is less than the AISC allowable The limiting cases for each assembly component are summarized in Table 1 The calculations are included in appendix A related drawings can be found in appendix B

374022S-EN-261 Page 1

Table One

- Critical Stress Limitjnl Cases

-

Maximum AISC Actual test Page ELEMENT LIMITING CASE Allowable Maximum force Apx A

Bridge Beam Bending 161000 Ibjack 78600 Ibjack 2 Shear 312000 Ibjack 78600 Ibjack 2

Bridge to beam Tension 210000 Ibjack 78600 Ibjack 3 connector-plate Bearing on pin 189000 Ibjack 78600 Ibjack 3

Shear on weld 89000 Ibjack 78600 Ibjack 3

Bridge bar Tension 207000 Ibjack 78600 Ibjack 4 Bearing on pin 189000 Ibjack 78600 Ibjack 4

ObI shear on pin 98000 Ibjack 78600 Ibjack 4 Shear on weld 174000 Ibjack 78600 Ibjack 4

Filler beam Bending 150000 Ibjack 78600 Ibjack 6 Shear 312000 Ibjack 78600 Ibjack 6

Bridge weld Shear ampbending 174000 Ibjack 78600 Ibjack 1 5

Bridge plate Tension ampbending 333000 Ibjack 78600 Ibjack 13

Beam brace Buckling 105000 Ib 2370 Ib 5 Tension 24000 Ib 2370 Ib 5

ObI shear on bolt 9000 Ib 2370 lb 5 Bearing on bolt 5000 Ib 2370 Ib 5 Shear on weld 8000 Ib 2370 Ib 5

K-

DU Glacier Compression 67500 Ibpad 27600 Ibpad 7

Half Moon plate Buckling 89413 psi 4500 psi 8

MH filler lifting Shear on bolts 37000 Ib 7300 Ib 1 0 beams Shear on weld 155000 Ib 7300 Ib 10

Bending of welds 71000 Ib 7300 lb 10 Bending of beams 157000 Ib 7300 Ib 10

3740225-EN-261 Page 2

--

Appendix A

Force Calculations

Note 3740225-EN-261-

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Appendix B

Drawings

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Appendix C

Memo

Note 3740225-EN-261

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From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

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PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 2: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

- The OH modules for the DO end calorimeter are being tested by supporting a load to simulate the MH IH and EM modules This test structure the MH filler is inserted into the previously assembled OH modules and then loaded with hydraulic jacks

The maximum test load applied by the jacks is 78600 lb which is via the two downstream jacks at 130 of the nominal load Bill Coopers memo of 91090 is include as appendix C

This note presents calculations for the AISC maximum allowable stressesloads of the various parts of the testing assembly Furthermore calculations show that the actual test load is less than the AISC allowable The limiting cases for each assembly component are summarized in Table 1 The calculations are included in appendix A related drawings can be found in appendix B

374022S-EN-261 Page 1

Table One

- Critical Stress Limitjnl Cases

-

Maximum AISC Actual test Page ELEMENT LIMITING CASE Allowable Maximum force Apx A

Bridge Beam Bending 161000 Ibjack 78600 Ibjack 2 Shear 312000 Ibjack 78600 Ibjack 2

Bridge to beam Tension 210000 Ibjack 78600 Ibjack 3 connector-plate Bearing on pin 189000 Ibjack 78600 Ibjack 3

Shear on weld 89000 Ibjack 78600 Ibjack 3

Bridge bar Tension 207000 Ibjack 78600 Ibjack 4 Bearing on pin 189000 Ibjack 78600 Ibjack 4

ObI shear on pin 98000 Ibjack 78600 Ibjack 4 Shear on weld 174000 Ibjack 78600 Ibjack 4

Filler beam Bending 150000 Ibjack 78600 Ibjack 6 Shear 312000 Ibjack 78600 Ibjack 6

Bridge weld Shear ampbending 174000 Ibjack 78600 Ibjack 1 5

Bridge plate Tension ampbending 333000 Ibjack 78600 Ibjack 13

Beam brace Buckling 105000 Ib 2370 Ib 5 Tension 24000 Ib 2370 Ib 5

ObI shear on bolt 9000 Ib 2370 lb 5 Bearing on bolt 5000 Ib 2370 Ib 5 Shear on weld 8000 Ib 2370 Ib 5

K-

DU Glacier Compression 67500 Ibpad 27600 Ibpad 7

Half Moon plate Buckling 89413 psi 4500 psi 8

MH filler lifting Shear on bolts 37000 Ib 7300 Ib 1 0 beams Shear on weld 155000 Ib 7300 Ib 10

Bending of welds 71000 Ib 7300 lb 10 Bending of beams 157000 Ib 7300 Ib 10

3740225-EN-261 Page 2

--

Appendix A

Force Calculations

Note 3740225-EN-261-

-

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Appendix B

Drawings

Note 3740225-EN-261

erJshy 11IF~t1 r IJI~ F If It t J -shy

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 3: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

Table One

- Critical Stress Limitjnl Cases

-

Maximum AISC Actual test Page ELEMENT LIMITING CASE Allowable Maximum force Apx A

Bridge Beam Bending 161000 Ibjack 78600 Ibjack 2 Shear 312000 Ibjack 78600 Ibjack 2

Bridge to beam Tension 210000 Ibjack 78600 Ibjack 3 connector-plate Bearing on pin 189000 Ibjack 78600 Ibjack 3

Shear on weld 89000 Ibjack 78600 Ibjack 3

Bridge bar Tension 207000 Ibjack 78600 Ibjack 4 Bearing on pin 189000 Ibjack 78600 Ibjack 4

ObI shear on pin 98000 Ibjack 78600 Ibjack 4 Shear on weld 174000 Ibjack 78600 Ibjack 4

Filler beam Bending 150000 Ibjack 78600 Ibjack 6 Shear 312000 Ibjack 78600 Ibjack 6

Bridge weld Shear ampbending 174000 Ibjack 78600 Ibjack 1 5

Bridge plate Tension ampbending 333000 Ibjack 78600 Ibjack 13

Beam brace Buckling 105000 Ib 2370 Ib 5 Tension 24000 Ib 2370 Ib 5

ObI shear on bolt 9000 Ib 2370 lb 5 Bearing on bolt 5000 Ib 2370 Ib 5 Shear on weld 8000 Ib 2370 Ib 5

K-

DU Glacier Compression 67500 Ibpad 27600 Ibpad 7

Half Moon plate Buckling 89413 psi 4500 psi 8

MH filler lifting Shear on bolts 37000 Ib 7300 Ib 1 0 beams Shear on weld 155000 Ib 7300 Ib 10

Bending of welds 71000 Ib 7300 lb 10 Bending of beams 157000 Ib 7300 Ib 10

3740225-EN-261 Page 2

--

Appendix A

Force Calculations

Note 3740225-EN-261-

-

A G-rvLrll Tagt r Jbull t7f t 8 s

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Appendix B

Drawings

Note 3740225-EN-261

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 4: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

--

Appendix A

Force Calculations

Note 3740225-EN-261-

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Drawings

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 5: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

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Appendix B

Drawings

Note 3740225-EN-261

erJshy 11IF~t1 r IJI~ F If It t J -shy

L 2 r -

Fr- Co Jt 1tV r (fAP r r 1(1 r 1 ) rAmiddot Ie P-IJ If e E

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DO DtTEClDR bull ENO CALDRltlETE~ IAOOIApound CRAOIpound ASS TES r IXl

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 6: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

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UED 01 DIMIJt8tCINt M ACOCIIIID 3740220-Mt-27B946ttlNCI Y4_ sm-bull ~O--- - Ii

IIUAL 3- DII CRS2STrNa-shy AISltOt8 - ~ STlC bullbull1530-5230

H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

266 DIA DRILL T125 X 45deg CHAMFER TYP BOTH ENDS AS SHOWN 2 HOLES AS SHOW

~ IImiddotIlilliPT~------( 1

2 013908 lIS75 tNlusu+ shy

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3740220-MO-279951 __ It - bull TO

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406

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PARTS LIST PRIMOIIH SIZS99 1oIATpoundSK I

t ~t - - r-~===-I-----------t110 -c _ UIIED ON

~=W1L~~ 3740220-ME-78946

~I__ t

f2lr-iN HL _shy MATS1- 112 X 2 froiii X 114 ANGtpound V - ASTN II 36 -~ STK bullbull1536-1170

H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

BRACE BLOCK -c

FULL Sl5775

t II tSO

~--~--~~~

FULL R TYP

Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 7: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

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Appendix B

Drawings

Note 3740225-EN-261

erJshy 11IF~t1 r IJI~ F If It t J -shy

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H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 8: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

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Appendix B

Drawings

Note 3740225-EN-261

erJshy 11IF~t1 r IJI~ F If It t J -shy

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 9: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

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Appendix B

Drawings

Note 3740225-EN-261

erJshy 11IF~t1 r IJI~ F If It t J -shy

L 2 r -

Fr- Co Jt 1tV r (fAP r r 1(1 r 1 ) rAmiddot Ie P-IJ If e E

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 10: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

V1 H ()1 gt U~IJc I -9- 12 -tJIOJ7~rS

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(~ ) ($$egtIgt$ )(~ 7~ yen)-=-__-------00 PlA -shy

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Appendix B

Drawings

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BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 11: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

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Appendix B

Drawings

Note 3740225-EN-261

erJshy 11IF~t1 r IJI~ F If It t J -shy

L 2 r -

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00 JIA STOCK

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poundESCRlflTlON Of ZE QTY

PARTS LIST lA II()AH 82589 MA1ESIlt I 82S89 ~ II r~

t~t-- APIACIIIEJ) III MIT -II _

UED 01 DIMIJt8tCINt M ACOCIIIID 3740220-Mt-27B946ttlNCI Y4_ sm-bull ~O--- - Ii

IIUAL 3- DII CRS2STrNa-shy AISltOt8 - ~ STlC bullbull1530-5230

H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

266 DIA DRILL T125 X 45deg CHAMFER TYP BOTH ENDS AS SHOWN 2 HOLES AS SHOW

~ IImiddotIlilliPT~------( 1

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 12: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

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Drawings

Note 3740225-EN-261

erJshy 11IF~t1 r IJI~ F If It t J -shy

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17

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A

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H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

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3740220-MO-279951 __ It - bull TO

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ITEM DESCIII PT I CI4 CA SIZE QTY

PARTS LIST PRIMOIIH SIZS99 1oIATpoundSK I

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~=W1L~~ 3740220-ME-78946

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f2lr-iN HL _shy MATS1- 112 X 2 froiii X 114 ANGtpound V - ASTN II 36 -~ STK bullbull1536-1170

H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

BRACE BLOCK -c

FULL Sl5775

t II tSO

~--~--~~~

FULL R TYP

Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 13: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

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Appendix B

Drawings

Note 3740225-EN-261

erJshy 11IF~t1 r IJI~ F If It t J -shy

L 2 r -

Fr- Co Jt 1tV r (fAP r r 1(1 r 1 ) rAmiddot Ie P-IJ If e E

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1

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XISTING W24 REf OWG

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II I U25000 I I ~Er---==r==--

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X 162 BEAM 3740220-tlE-273862

It MampflDW

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17

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A

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H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

266 DIA DRILL T125 X 45deg CHAMFER TYP BOTH ENDS AS SHOWN 2 HOLES AS SHOW

~ IImiddotIlilliPT~------( 1

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3740220-MO-279951 __ It - bull TO

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 14: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

II BT~ LP - tA e c eN~1 if

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Appendix B

Drawings

Note 3740225-EN-261

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 15: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

12

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Appendix B

Drawings

Note 3740225-EN-261

erJshy 11IF~t1 r IJI~ F If It t J -shy

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Fr- Co Jt 1tV r (fAP r r 1(1 r 1 ) rAmiddot Ie P-IJ If e E

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I I I I I I I IIII I I I I I I I I I-ttt----------M--r r

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00 JIA STOCK

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UED 01 DIMIJt8tCINt M ACOCIIIID 3740220-Mt-27B946ttlNCI Y4_ sm-bull ~O--- - Ii

IIUAL 3- DII CRS2STrNa-shy AISltOt8 - ~ STlC bullbull1530-5230

H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

266 DIA DRILL T125 X 45deg CHAMFER TYP BOTH ENDS AS SHOWN 2 HOLES AS SHOW

~ IImiddotIlilliPT~------( 1

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3740220-MO-279951 __ It - bull TO

(( ( 1

406

1 000

5000

I

L bull rfTTTTTJT~FT

u bullbullbull ~ bull bull bull

I -I 812

-I

2500

~

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ITEM DESCIII PT I CI4 CA SIZE QTY

PARTS LIST PRIMOIIH SIZS99 1oIATpoundSK I

t ~t - - r-~===-I-----------t110 -c _ UIIED ON

~=W1L~~ 3740220-ME-78946

~I__ t

f2lr-iN HL _shy MATS1- 112 X 2 froiii X 114 ANGtpound V - ASTN II 36 -~ STK bullbull1536-1170

H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

BRACE BLOCK -c

FULL Sl5775

t II tSO

~--~--~~~

FULL R TYP

Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 16: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

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~ Ygt t J

(i1rT-PCV -P ce relA p

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Appendix B

Drawings

Note 3740225-EN-261

erJshy 11IF~t1 r IJI~ F If It t J -shy

L 2 r -

Fr- Co Jt 1tV r (fAP r r 1(1 r 1 ) rAmiddot Ie P-IJ If e E

ra~ eA~ ( l C4-v r~ IFI ) Sgt1 tt ( ~ ( h-

FltF - P If )111 rpM r IF If 17 ItrrJJ tU Ir ~ jshy

f8 ~ el~ -J f r d Jr 6 lt-- rG- ()~e amp--shy

I 1FF

_ F--rI bulli I I i_-- I

r===d=-- shy I 1shy

1

6625

~295 i REf

XISTING W24 REf OWG

fJlf~1T

4- n tc== Illy

OWG

REf

F= shy

I ~

I I~ iitIT

1-_I~-1====

l I~=~

-=~===4

-1- ___ I i lit = ___ fi- ---=- f4=r~~-

i c

107813

- - bullbull-I t71)1

II I U25000 I I ~Er---==r==--

1 I

14625 1amp 8997

X 162 BEAM 3740220-tlE-273862

It MampflDW

( t

-===

I I bull 1662s-1I

~TCJIIl LAII)IlampttJilfV amp_ 1III1IIIIM bull

DO DtTEClDR bull ENO CALDRltlETE~ IAOOIApound CRAOIpound ASS TES r IXl

It4IA TQR ASSpoundM6LY

181 -~2o-EZ78961-

1 j i

~ TfPr-~~ 38

r---z4 I

ibull

20S04

34204

-4690 I 0) Imiddot SS390

JI~1r

------1--------1080001500 I

39015

REF

17

II I 15000

000 STOCK

1813

A

l1S781 t

r-------iii4000 I

12000 I t also~A~d g 4J 0+

I L-29I-1 - + ----1 1110000I

19_415t-7S3amp-J

bull975 CIA CRILL T 8 HOLES AS SHOWN

IIIOElll

I -t-I

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+ f- ~-

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i er U

- --1shy~I

Imiddot 9000 1ITmiddotOOO

10500

~

+031 ~ 3000_ 000 OIA THRU ~Iii 031 I

5IiIS r- 3

lIf

15M Ian-IW _n

bull375 X 45 CHAMFER TWO SIDES AS SHOWN

- - shy( ( (

I- 6500 -I

I +063750- -I- 5000_ 000 -

bull I I bull

I I I I I I I IIII I I I I I I I I I-ttt----------M--r r

3 I iii iliU IIII 1111I I I I I I I I I I I I

00 JIA STOCK

RU

5g-e ~A etshy

poundESCRlflTlON Of ZE QTY

PARTS LIST lA II()AH 82589 MA1ESIlt I 82S89 ~ II r~

t~t-- APIACIIIEJ) III MIT -II _

UED 01 DIMIJt8tCINt M ACOCIIIID 3740220-Mt-27B946ttlNCI Y4_ sm-bull ~O--- - Ii

IIUAL 3- DII CRS2STrNa-shy AISltOt8 - ~ STlC bullbull1530-5230

H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

266 DIA DRILL T125 X 45deg CHAMFER TYP BOTH ENDS AS SHOWN 2 HOLES AS SHOW

~ IImiddotIlilliPT~------( 1

2 013908 lIS75 tNlusu+ shy

-bullbullIi I

n w n bullbullbull 1 s ttj- J

44 diUb

1amp 15

r 2500 REF

8125 OIA DRILL THAU 2 HOLES AS SHOWN

I

i r j i I

j

--~--- -- tt III -bullbull l1li

I I

$trl$ pA~ If S

flAlfIIIOIJl Ie MYr1KOI

fllfUoMt IUJ

~ 1I4bullbulllJct

o DETECTOR - END CALOAIMETE MH SIMULATOR ASSEMaLY BRIDGE TO BEAM BRACE

3740220-MO-279951 __ It - bull TO

(( ( 1

406

1 000

5000

I

L bull rfTTTTTJT~FT

u bullbullbull ~ bull bull bull

I -I 812

-I

2500

~

Ishy 1 1375

ITEM DESCIII PT I CI4 CA SIZE QTY

PARTS LIST PRIMOIIH SIZS99 1oIATpoundSK I

t ~t - - r-~===-I-----------t110 -c _ UIIED ON

~=W1L~~ 3740220-ME-78946

~I__ t

f2lr-iN HL _shy MATS1- 112 X 2 froiii X 114 ANGtpound V - ASTN II 36 -~ STK bullbull1536-1170

H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

BRACE BLOCK -c

FULL Sl5775

t II tSO

~--~--~~~

FULL R TYP

Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 17: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

I 1YrampP6lti1i e-vettgt amp6 1gt SII~ 4 6spr- 9- ~- Pzgt

I

T r

J lt

-10 ft- 8

-Jgt-1

(7f)6)

1 shyIr r--------plusmn

8 ---1middot1

12

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Appendix B

Drawings

Note 3740225-EN-261

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DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 18: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

(i1rT-PCV -P ce relA p

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Appendix B

Drawings

Note 3740225-EN-261

erJshy 11IF~t1 r IJI~ F If It t J -shy

L 2 r -

Fr- Co Jt 1tV r (fAP r r 1(1 r 1 ) rAmiddot Ie P-IJ If e E

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r===d=-- shy I 1shy

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IIUAL 3- DII CRS2STrNa-shy AISltOt8 - ~ STlC bullbull1530-5230

H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

266 DIA DRILL T125 X 45deg CHAMFER TYP BOTH ENDS AS SHOWN 2 HOLES AS SHOW

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H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

BRACE BLOCK -c

FULL Sl5775

t II tSO

~--~--~~~

FULL R TYP

Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 19: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

-

Appendix B

Drawings

Note 3740225-EN-261

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17

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1813

A

l1S781 t

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12000 I t also~A~d g 4J 0+

I L-29I-1 - + ----1 1110000I

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bull375 X 45 CHAMFER TWO SIDES AS SHOWN

- - shy( ( (

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PARTS LIST lA II()AH 82589 MA1ESIlt I 82S89 ~ II r~

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UED 01 DIMIJt8tCINt M ACOCIIIID 3740220-Mt-27B946ttlNCI Y4_ sm-bull ~O--- - Ii

IIUAL 3- DII CRS2STrNa-shy AISltOt8 - ~ STlC bullbull1530-5230

H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

266 DIA DRILL T125 X 45deg CHAMFER TYP BOTH ENDS AS SHOWN 2 HOLES AS SHOW

~ IImiddotIlilliPT~------( 1

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8125 OIA DRILL THAU 2 HOLES AS SHOWN

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flAlfIIIOIJl Ie MYr1KOI

fllfUoMt IUJ

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o DETECTOR - END CALOAIMETE MH SIMULATOR ASSEMaLY BRIDGE TO BEAM BRACE

3740220-MO-279951 __ It - bull TO

(( ( 1

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5000

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u bullbullbull ~ bull bull bull

I -I 812

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ITEM DESCIII PT I CI4 CA SIZE QTY

PARTS LIST PRIMOIIH SIZS99 1oIATpoundSK I

t ~t - - r-~===-I-----------t110 -c _ UIIED ON

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H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

BRACE BLOCK -c

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 20: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

erJshy 11IF~t1 r IJI~ F If It t J -shy

L 2 r -

Fr- Co Jt 1tV r (fAP r r 1(1 r 1 ) rAmiddot Ie P-IJ If e E

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DO DtTEClDR bull ENO CALDRltlETE~ IAOOIApound CRAOIpound ASS TES r IXl

It4IA TQR ASSpoundM6LY

181 -~2o-EZ78961-

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JI~1r

------1--------1080001500 I

39015

REF

17

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1813

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10500

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+031 ~ 3000_ 000 OIA THRU ~Iii 031 I

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15M Ian-IW _n

bull375 X 45 CHAMFER TWO SIDES AS SHOWN

- - shy( ( (

I- 6500 -I

I +063750- -I- 5000_ 000 -

bull I I bull

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PARTS LIST lA II()AH 82589 MA1ESIlt I 82S89 ~ II r~

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UED 01 DIMIJt8tCINt M ACOCIIIID 3740220-Mt-27B946ttlNCI Y4_ sm-bull ~O--- - Ii

IIUAL 3- DII CRS2STrNa-shy AISltOt8 - ~ STlC bullbull1530-5230

H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

266 DIA DRILL T125 X 45deg CHAMFER TYP BOTH ENDS AS SHOWN 2 HOLES AS SHOW

~ IImiddotIlilliPT~------( 1

2 013908 lIS75 tNlusu+ shy

-bullbullIi I

n w n bullbullbull 1 s ttj- J

44 diUb

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I

i r j i I

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3740220-MO-279951 __ It - bull TO

(( ( 1

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5000

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u bullbullbull ~ bull bull bull

I -I 812

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2500

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PARTS LIST PRIMOIIH SIZS99 1oIATpoundSK I

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H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

BRACE BLOCK -c

FULL Sl5775

t II tSO

~--~--~~~

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Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 21: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

1 j i

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5IiIS r- 3

lIf

15M Ian-IW _n

bull375 X 45 CHAMFER TWO SIDES AS SHOWN

- - shy( ( (

I- 6500 -I

I +063750- -I- 5000_ 000 -

bull I I bull

I I I I I I I IIII I I I I I I I I I-ttt----------M--r r

3 I iii iliU IIII 1111I I I I I I I I I I I I

00 JIA STOCK

RU

5g-e ~A etshy

poundESCRlflTlON Of ZE QTY

PARTS LIST lA II()AH 82589 MA1ESIlt I 82S89 ~ II r~

t~t-- APIACIIIEJ) III MIT -II _

UED 01 DIMIJt8tCINt M ACOCIIIID 3740220-Mt-27B946ttlNCI Y4_ sm-bull ~O--- - Ii

IIUAL 3- DII CRS2STrNa-shy AISltOt8 - ~ STlC bullbull1530-5230

H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

266 DIA DRILL T125 X 45deg CHAMFER TYP BOTH ENDS AS SHOWN 2 HOLES AS SHOW

~ IImiddotIlilliPT~------( 1

2 013908 lIS75 tNlusu+ shy

-bullbullIi I

n w n bullbullbull 1 s ttj- J

44 diUb

1amp 15

r 2500 REF

8125 OIA DRILL THAU 2 HOLES AS SHOWN

I

i r j i I

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--~--- -- tt III -bullbull l1li

I I

$trl$ pA~ If S

flAlfIIIOIJl Ie MYr1KOI

fllfUoMt IUJ

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o DETECTOR - END CALOAIMETE MH SIMULATOR ASSEMaLY BRIDGE TO BEAM BRACE

3740220-MO-279951 __ It - bull TO

(( ( 1

406

1 000

5000

I

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u bullbullbull ~ bull bull bull

I -I 812

-I

2500

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Ishy 1 1375

ITEM DESCIII PT I CI4 CA SIZE QTY

PARTS LIST PRIMOIIH SIZS99 1oIATpoundSK I

t ~t - - r-~===-I-----------t110 -c _ UIIED ON

~=W1L~~ 3740220-ME-78946

~I__ t

f2lr-iN HL _shy MATS1- 112 X 2 froiii X 114 ANGtpound V - ASTN II 36 -~ STK bullbull1536-1170

H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

BRACE BLOCK -c

FULL Sl5775

t II tSO

~--~--~~~

FULL R TYP

Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 22: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

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Imiddot 9000 1ITmiddotOOO

10500

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+031 ~ 3000_ 000 OIA THRU ~Iii 031 I

5IiIS r- 3

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15M Ian-IW _n

bull375 X 45 CHAMFER TWO SIDES AS SHOWN

- - shy( ( (

I- 6500 -I

I +063750- -I- 5000_ 000 -

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I I I I I I I IIII I I I I I I I I I-ttt----------M--r r

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PARTS LIST lA II()AH 82589 MA1ESIlt I 82S89 ~ II r~

t~t-- APIACIIIEJ) III MIT -II _

UED 01 DIMIJt8tCINt M ACOCIIIID 3740220-Mt-27B946ttlNCI Y4_ sm-bull ~O--- - Ii

IIUAL 3- DII CRS2STrNa-shy AISltOt8 - ~ STlC bullbull1530-5230

H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

266 DIA DRILL T125 X 45deg CHAMFER TYP BOTH ENDS AS SHOWN 2 HOLES AS SHOW

~ IImiddotIlilliPT~------( 1

2 013908 lIS75 tNlusu+ shy

-bullbullIi I

n w n bullbullbull 1 s ttj- J

44 diUb

1amp 15

r 2500 REF

8125 OIA DRILL THAU 2 HOLES AS SHOWN

I

i r j i I

j

--~--- -- tt III -bullbull l1li

I I

$trl$ pA~ If S

flAlfIIIOIJl Ie MYr1KOI

fllfUoMt IUJ

~ 1I4bullbulllJct

o DETECTOR - END CALOAIMETE MH SIMULATOR ASSEMaLY BRIDGE TO BEAM BRACE

3740220-MO-279951 __ It - bull TO

(( ( 1

406

1 000

5000

I

L bull rfTTTTTJT~FT

u bullbullbull ~ bull bull bull

I -I 812

-I

2500

~

Ishy 1 1375

ITEM DESCIII PT I CI4 CA SIZE QTY

PARTS LIST PRIMOIIH SIZS99 1oIATpoundSK I

t ~t - - r-~===-I-----------t110 -c _ UIIED ON

~=W1L~~ 3740220-ME-78946

~I__ t

f2lr-iN HL _shy MATS1- 112 X 2 froiii X 114 ANGtpound V - ASTN II 36 -~ STK bullbull1536-1170

H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

BRACE BLOCK -c

FULL Sl5775

t II tSO

~--~--~~~

FULL R TYP

Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 23: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

- --1shy~I

Imiddot 9000 1ITmiddotOOO

10500

~

+031 ~ 3000_ 000 OIA THRU ~Iii 031 I

5IiIS r- 3

lIf

15M Ian-IW _n

bull375 X 45 CHAMFER TWO SIDES AS SHOWN

- - shy( ( (

I- 6500 -I

I +063750- -I- 5000_ 000 -

bull I I bull

I I I I I I I IIII I I I I I I I I I-ttt----------M--r r

3 I iii iliU IIII 1111I I I I I I I I I I I I

00 JIA STOCK

RU

5g-e ~A etshy

poundESCRlflTlON Of ZE QTY

PARTS LIST lA II()AH 82589 MA1ESIlt I 82S89 ~ II r~

t~t-- APIACIIIEJ) III MIT -II _

UED 01 DIMIJt8tCINt M ACOCIIIID 3740220-Mt-27B946ttlNCI Y4_ sm-bull ~O--- - Ii

IIUAL 3- DII CRS2STrNa-shy AISltOt8 - ~ STlC bullbull1530-5230

H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

266 DIA DRILL T125 X 45deg CHAMFER TYP BOTH ENDS AS SHOWN 2 HOLES AS SHOW

~ IImiddotIlilliPT~------( 1

2 013908 lIS75 tNlusu+ shy

-bullbullIi I

n w n bullbullbull 1 s ttj- J

44 diUb

1amp 15

r 2500 REF

8125 OIA DRILL THAU 2 HOLES AS SHOWN

I

i r j i I

j

--~--- -- tt III -bullbull l1li

I I

$trl$ pA~ If S

flAlfIIIOIJl Ie MYr1KOI

fllfUoMt IUJ

~ 1I4bullbulllJct

o DETECTOR - END CALOAIMETE MH SIMULATOR ASSEMaLY BRIDGE TO BEAM BRACE

3740220-MO-279951 __ It - bull TO

(( ( 1

406

1 000

5000

I

L bull rfTTTTTJT~FT

u bullbullbull ~ bull bull bull

I -I 812

-I

2500

~

Ishy 1 1375

ITEM DESCIII PT I CI4 CA SIZE QTY

PARTS LIST PRIMOIIH SIZS99 1oIATpoundSK I

t ~t - - r-~===-I-----------t110 -c _ UIIED ON

~=W1L~~ 3740220-ME-78946

~I__ t

f2lr-iN HL _shy MATS1- 112 X 2 froiii X 114 ANGtpound V - ASTN II 36 -~ STK bullbull1536-1170

H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

BRACE BLOCK -c

FULL Sl5775

t II tSO

~--~--~~~

FULL R TYP

Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 24: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

I- 6500 -I

I +063750- -I- 5000_ 000 -

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UED 01 DIMIJt8tCINt M ACOCIIIID 3740220-Mt-27B946ttlNCI Y4_ sm-bull ~O--- - Ii

IIUAL 3- DII CRS2STrNa-shy AISltOt8 - ~ STlC bullbull1530-5230

H flEAM I NAT IONAL AcCeIEAATOA LAIORATDRY -wshy IMTED STATES DEJiAIIIIeIT Q DERIn

DO DETECTOR - END CALORIMEtER MH SIMULATOR ASSEMBLY

BRIDGE TO BEAM CONNECTOR PIN -II MY

FULL 3740220-MC-278950 -77S

266 DIA DRILL T125 X 45deg CHAMFER TYP BOTH ENDS AS SHOWN 2 HOLES AS SHOW

~ IImiddotIlilliPT~------( 1

2 013908 lIS75 tNlusu+ shy

-bullbullIi I

n w n bullbullbull 1 s ttj- J

44 diUb

1amp 15

r 2500 REF

8125 OIA DRILL THAU 2 HOLES AS SHOWN

I

i r j i I

j

--~--- -- tt III -bullbull l1li

I I

$trl$ pA~ If S

flAlfIIIOIJl Ie MYr1KOI

fllfUoMt IUJ

~ 1I4bullbulllJct

o DETECTOR - END CALOAIMETE MH SIMULATOR ASSEMaLY BRIDGE TO BEAM BRACE

3740220-MO-279951 __ It - bull TO

(( ( 1

406

1 000

5000

I

L bull rfTTTTTJT~FT

u bullbullbull ~ bull bull bull

I -I 812

-I

2500

~

Ishy 1 1375

ITEM DESCIII PT I CI4 CA SIZE QTY

PARTS LIST PRIMOIIH SIZS99 1oIATpoundSK I

t ~t - - r-~===-I-----------t110 -c _ UIIED ON

~=W1L~~ 3740220-ME-78946

~I__ t

f2lr-iN HL _shy MATS1- 112 X 2 froiii X 114 ANGtpound V - ASTN II 36 -~ STK bullbull1536-1170

H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

BRACE BLOCK -c

FULL Sl5775

t II tSO

~--~--~~~

FULL R TYP

Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 25: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

-bullbullIi I

n w n bullbullbull 1 s ttj- J

44 diUb

1amp 15

r 2500 REF

8125 OIA DRILL THAU 2 HOLES AS SHOWN

I

i r j i I

j

--~--- -- tt III -bullbull l1li

I I

$trl$ pA~ If S

flAlfIIIOIJl Ie MYr1KOI

fllfUoMt IUJ

~ 1I4bullbulllJct

o DETECTOR - END CALOAIMETE MH SIMULATOR ASSEMaLY BRIDGE TO BEAM BRACE

3740220-MO-279951 __ It - bull TO

(( ( 1

406

1 000

5000

I

L bull rfTTTTTJT~FT

u bullbullbull ~ bull bull bull

I -I 812

-I

2500

~

Ishy 1 1375

ITEM DESCIII PT I CI4 CA SIZE QTY

PARTS LIST PRIMOIIH SIZS99 1oIATpoundSK I

t ~t - - r-~===-I-----------t110 -c _ UIIED ON

~=W1L~~ 3740220-ME-78946

~I__ t

f2lr-iN HL _shy MATS1- 112 X 2 froiii X 114 ANGtpound V - ASTN II 36 -~ STK bullbull1536-1170

H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

DO DETECTOR - END CALORIMETER MH SIMULATOR ASSEMBLY

BRACE BLOCK -c

FULL Sl5775

t II tSO

~--~--~~~

FULL R TYP

Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 26: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

406

1 000

5000

I

L bull rfTTTTTJT~FT

u bullbullbull ~ bull bull bull

I -I 812

-I

2500

~

Ishy 1 1375

ITEM DESCIII PT I CI4 CA SIZE QTY

PARTS LIST PRIMOIIH SIZS99 1oIATpoundSK I

t ~t - - r-~===-I-----------t110 -c _ UIIED ON

~=W1L~~ 3740220-ME-78946

~I__ t

f2lr-iN HL _shy MATS1- 112 X 2 froiii X 114 ANGtpound V - ASTN II 36 -~ STK bullbull1536-1170

H rEAM I NAT IONAL ACCELERATOR LABORATORY yen IMITED STATES DEPAIITM5NT OF fHMt

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~--~--~~~

FULL R TYP

Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 27: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

Appendix C

Memo

Note 3740225-EN-261

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 28: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

bull t

From FNAL COOPER 11-SEP-1990 19125061 To ANDREWS

A COOPER bj OH Test Ring

shy

PRELIMINARY

September 10 1990

TO R ANDREWS FROM W COOPER SUBJECT OH TEST RING

The assembly of the OH modules into a test ring has been completed in IB4 The last module was installed without interference with its neighbors The effective mean inner surface ring radius is 60 mils larger than design at the upstream end and 48 mils larger than design at the downstream end The modules have an RMS deviation from a circle of 40 mils All of these values are conshysistent with the departure of actual module dimensions from design dimensions and with the module-to-module shims Studs and shear keys have been installed at all module-to-module interfaces

The equipment to apply a load to the OH test ring simulating the load of the EM IH and MH modules has been installed Shims between the fixturingand the OH modules have been adjusted so that the effective shape of the

~ixture conforms to that of the OH ring at the 5 mil level

We are prepared to carry out the OH test ring load test and request the Panels agreement to proceed

Following the Panels verbal suggestion dial indicators will be installed to measure the lateral motion of the two support posts which have DU glacierplate below them

Measurements of the loading fixturing have been made The hydraulic jacks to load the structure are at z = -21251 and z = +6881 where z is defined as before from the upstream inner radius corner of OH plate 1 Because of imperfections in the I-beams of the loading structure the zs of individual jacks differ from the values given by as much as 25 the values given are the averages of two jacks

Using these z-positions the following hydraulic pressures to be applied to each jack and jack forces have been calculated

Load of nominal Upstream jack Downstream jack Total force step load (per jack) (per jack) (4 jacks)

pepsi) F(lb) pepsi) F(lb) (Ib)

0 0 0 0 0 0 0 1 50 2495 24950 3025 30250 110400 2 80 3990 39900 4840 48400 176600 100 4990 49900 6050 60500 220800

~ 110 5490 54900 6655 66550 242900 5 120 5990 59900 7260 72600 265000 6 125 6240 62400 7560 75600 276000 7 130 6490 64900 7860 78600 287000

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 29: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

Our present intent is to increase the applied load in the steps indicated through step 6 We plan to limit the maximum applied load to values between ~ose listed for step 6 and those listed for step 7 ie we will really

crease the load to middotstep 65ft bull At this time the load will be decreased to r- zero i n the same steps

Three cycles will be made from step 0 through step 65 and back to step O On the last of the 3 cycles a pause will be made at lOOK load as loading is being increased a survey will be made of the ring at l00~ load and then the loading cycle will be continued to completion A survey has already been made at zero load A third survey will be made at zero load at the end of the test shying

Strain gages and dial indicators will be recorded at each load step Our knowledge of initial strains is limited because of the substantial time that has elapsed between initial strain gage readings and the present time a number of the original strain gages were damaged and have been replaced also For these reasons strain gages will be seroedat the beginning of the load test sequence

The Panel has been supplied with calculations of beam and strap stresses and of forces transmitted from the beam and strap assembly at 1001 load hence no further analysis of the beam and strap assembly should be needed The load transfers from the OH modules to the beam and strap assembly have been calculated under the assumptions that friction is negligible and that the beam and strap assembly complies with the contour of the OH modules Load transfers from the MH filler to the OH modules has been calculated with the following assumptions

I 1) Friction is negligible 2) The MH filler is rigid within a plane of fixed z 3) The OH modules can be characterized with a radial compliance ie

(change in module radial dimension) = (constant) x (radial load carried through module)

4) The MH filler and OH module contours match at zero MH filler load

To first order the addition of the MH filler load affects module-toshymodule loads only at the module 3l-2L connection and below Using the equations from earlier notes the load transfers from the beam and strapassembly into the number 1 2 and 3 modules at 1001 load are

F1B 68803 I b F2B = 68803 Ib F3B =149961 lb

Each of thes forces acts inward toward the center of the ring

Assume that the MH filler moves downward an amount (delta y) under load The forces exerted upon the number 1 2 and 3 modules are

FlY = (delta y) (k) (cos(1125 degreesraquo F2M =(delta y)(k)(cos(3375 degreesraquoF3M = (delta y)(K)(cos(5625 degreesraquo

where k is a constant Each of these forces points radially outward The sum of the vertical components of the forces must equal half of the l00~ load Therefore

(delta y)(k) = (220779 Ib)(2laquocos(1125 degreesraquo bullbull2 + (cos(3375 degreesraquo bullbull2 + (cos(5625 degreesraquo bullbull2)

en- FlY =55184 Ib F2M = 46783 I b FaY =31259 lb

These are the MH filler loads transmitted radially through the modules to the

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 30: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

beam and strap assembly

The net forces acting radially inward on the three modules are F1 = 68803 - 55184 = 13619 Ib F2 =68803 - 46783 =22020 Ib F3 =149961 - 31259 =118702 lb

These forces can be plugged into the equations used for OH module-to-module loads with OH only the results are

Location F outer F inner F shear (Ib) (Ib) (Ib)

1L-1R +104011 -217599 o 2L-1L +83913 -186842 -41383 3L-2L +32666 -107590 -64654

Separating these into upstream and downstream portions by scaling from ANSYS results (as in the last analysis provided to the panel) gives

Location Upstream Downstream Total Shear Shear Shear

1L-1R 0 0 0 2L-1L -17431 -23952 -41383 3L-2L -27329 -37325 -64654

The shear loads are shared by the friction connections at the studs and by the ~ear keys Although the shear key design loads would be exceeded if the shear

e carried only by the shear keys the shear keys plus the friction connecshyIons are more than sufficient to carry the shear loads This will be discussed later

Locat i on Upstream Downstream Stud Upstream Downstream Inner Studs Stud Sum Inner Inner Sum

1L-1R 40356 63655 104011 -140569 -77030 -217599 2L-1L 32390 51523 83913 -120700 -66142 -186842 3L-2L 12380 20286 32666 -68750 -38849 -107590

The most highly loaded upstream studs are at the 1L-1R location Four small Inconel studs are used The load per stud is 10089 Ib which is 393 x design load and about 123 x ultimate load The most highly loaded downstream stud is at the 1L-1R location A large Inconel stud is used The load of 63655 Ib is 341 x design load and 106 x ultimate load

AISC appears to address allowable ahear in friction type connections only in material specific ways for each of the AISC permitted bolting materials

and for each type of friction connection allowable shear forces are given Because these allowable forces are given absolutely rather than relative to yield or ultimate strengths of the materials in use it isnt clear to me how to apply the AISC criteria to other materials The AISC criteria are given in Table 1521 Appendix E and Commentary 1521

~ Although the holes in the ears roughly correspond to standard sized holes - used upon the stud thread diameter the main portions of the studs are reduced

in diameter Accordingly the holes for the friction connections will be considered to be oversized holes Because the ear-to-ear interface contains no stud threads AISC values with threads excluded from the shear plane will be used AISC allowable stresse relative to yield and ultimate stresses are

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 31: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

compared with the OH connection stresses in the table which follows The load carrying capacity of the shear keys is ignored

Stress Shearultimate Shearyield Tensionultimate Tensionyield

AISC A325 143 185 419 543 AISC A490 127 146 360 415 Upstreamstud

lL-lR 000 000 131 157 2L-IL 057 068 105 126 3L-21 089 106 040 048

Downstream stud

1L-1R 000 000 114 137 2L-IL 043 051 092 111 3L-2L 067 080 036 044

Each of the ratios for the actual connections is substantially lower than the corresponding AISC ratio for either A325 or A490 bolts

The table which follows compares loads with minimum preloads

Location Shearpreload Tensionpreload

AISC A325 204 599 AISC A490 181 514

-~stream _iud lL-lR 000 390 2L-L 168 313 3l-2L 264 119

Downstream stud

lL-lR 000 330 2L-IL 124 267 3L-2L 193 105

The ratios of actual tension to preload are substantially lower than the corresshyponding AISC ratio The ratios of shear to preload exceed the AISC ratios in some cases however if the shear capacity of the shear keys is subtracted from the shear load the ratios are acceptable as shown below

location Shearpreload

Upstreamstud

lL-lR 000 2L-IL 033 3L-2L 129

Downstream stud

lL-lR 000 ~2L-IL 020

-- 3L-2L 090

The ring loads have been calculated assuming no connection between the 8L and 8R modules In reality the ring closed well and the stud and shear k~ connections were made at this location Because this could be done

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream

Page 32: MH TEST FILLER FORCE LIMITATIONS Keith A. Primdahl

without distorting the ring the ring loads calculated should be correct in the absense of MH filler load

- The radial spring constant of an OH module has been measured to be

~100000 Ib)(064 inch) at the downstream end and (100000 Ib)(l00 inch) at the downstream end where the 100000 Ib is appropriately distributed to match the MH filler z distribution This means that outer OH module surface should move radially inward (31259)(064)(100000) = 020 at the downstream end and (31259)(100)(100000) = 031 at the downstream end as the result of the application of 1~ MH filler load The overlap that would occur at the 8L-8R module interface if the modules were free to overlap is 2(020)cos(3375 degrees) =033 at the downstream end and 2(031)cos(3375 degrees) =052 at the upstream end If the modules are constrained not to overlap at their inner contact points the gaps at the studs are 013 at the downstream end and 020 at the upstream end The strain from closing this gap is evenlydistributed over 16 module-to-module interfaces so it is 000SI per interface at the downstream end and 00125 per interface at the upstream end

The downstream ear connection has been modelled by R Wands (Analysis of Bolted Ear Connection 3740-222-EN-133) His results assume a bolt stress area of 356 sq in and are summarized at three bolt preloads 30 ksi 60 ksi and 90 ksi The actual tensile area of the large studs is 3108 sq in and the minimum preload is 193000 lb These correspond to a preload stress of 64213 ksi for the bolt Bob modelled Scaling Table III of the note to 64213 ksi gives a boltmember sharing such that the stud sees 391 of the external load An increase in stud elongation of 000SI corresponds to an increase in stud load of 7800 Ib or an increase in connection load of 20000 lb This is an overestimate since elastic deformation of the module plate accomodates a porshy

rion of the oooSI a I so In any case a 20000 I b increase takes the 1L-1R ad from 64000 Ib to 84000 Ib (stud design load = IS6000 Ib ear design load

= 130000 Ib) which is sti II acceptable A 20000 Ib increase takes the most highly loaded SS stud from 15000 Ib to 35000 Ib (stud design load =62000 Ib ear design load =130000 Ib) Hence the downstream loads with an SL-SR connection are satisfactory

The design of the downstream ear was scaled from the design of the upstream ears Although the upstream ears were not specifically modelled they were designed for a load of 30000 Ib per ear and should be 43 times as compliant as the downstream ear Hence their load is expected to increase by (20000 Ib) x (001250008)43 or 3900 lb Then the 1L-1R connection load increases from 10089 Ibplate to 14000 Ibplate (ear design load =30000 Ibplate stud design load =26000 Ibstud) which is satisfactory

The expected lateral motion of the feet can be calculated from the elongation of the straps of the beam and strap assembly At 1001 MH filler load the upstream strap tension increases by 20782 Ib and the downstream strap tension increase by 71004 lb The strap cross-section is 12 sq in and the elastic modulus is taken to be 2S3 x 10bullbull6 psi Then the unit changes in strap length are 612 x 10 bullbull-5 and 209 x 10 bullbull-4 respectively The expected lateral motion of the feet is OOS upstream and 029 downstream