10067-9-V01-G00Z-01671

00110067-9-V01-G00Z-01671

2011/03/10 , 02:04:35 PM

N/A 0

Ahmed E Soliman

2

-Study for permanent Project roads with Minimum1.5 m soil repalcement.specificed as following 0.50 meter sub-baseat top followed by 1.00 meter structural fill.

-Sub-base layer mateiral specification shall be updated for permanent roads as per AASHTOC.B.R value , layer Coefficient

DAMITTA SIMPLE CYCLE TURBINE UNITITS SOIL TREATEMENT UNDRNEATH CRANE PATH AND

LOADING AREA

February , 2011

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A&A Consultants Page 3

1 INTRODUCTION.

This report has been prepared upon the request of EL KHARAFY NATIONAL in order to carry out the engineering services of the site geotechnical engineering and technical support for design and construction of the temporary work of Damitta simple cycle turbine units. The EPC contractor is EL KHARAFY NATIONAL and the project owner is EDEPC while the project Engineer is PGESCo. This report is addressing the geotechnical analysis and design for the soil treatment underneath the crane for different loading cases. The report is based on the data collected from the site investigation performed on November 2010 by Hamza Associate (HA), the latest layout for the project, the site visit carried out dated 04/12//2010 and the project specifications.

2 GENERAL DESCRIPTION OF THE SITE AND THE PROJECT. The proposed site for the power plant is located at Damietta. The plant project main structures which are the turbine pedestal, the transformers, generator transformers and tanks (solar, service water, etc..). In addition, the plant project include many other structures such as fire fighting building, GIS substation, control building, etc. The zero project level is equivalent to +1.8 MSL. The existing ground level is range of +2.0 MSL (+0.2 project level)

3 REFERENCE DOCUMENTS This report is based on the following available documents: 1- Geotechnical investigation and foundation recommendation report prepare by

HA. 2- Crane stresses as concluded by EL KHARAFY NATIONAL. 3- Latest drawing for crane positions and the path of the the crane. 4- Egyptian code of soil mechanics(part 3- shallow foundation).

4 SCOPE OF WORK. 1. Reviewing the available documents. 2. Reviewing the available data for crane. 3. Presenting the method of soil treatment to improve the soil bearing capacity to

withstand the crane stresses. 4. Presenting the proposed materials for soil treatment and also the recommended

QC tests.

5 SITE INVESTIGATIONS AS PER HA REPORT. HA report had included in summary the following field and laboratory work: A- Field work

1- 4 Boreholes down to depth 60 m. 2- 25 boreholes down to 40 m below grade.


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3- 18 CPTU tests. 4- 3 seismic cross hole testes 5- 3 Thermal conductivity tests. 6- 3 Electrical resistively tests.

B- Laboratory tests 1- Bulk unit weights tests. 2- Water content tests: 3- Atterberg limits tests. 4- Grain size distribution tests. 5- Direct shear tests. 6- Consolidation tests 7- Triaxial tests 8- Chemical analysis of soil samples. 9- Calcium carbonate 10- Organic content.

6 SOIL FORMATION/ GEOTECHNICAL PARAMETERS AS PER HA REPORT.

6.1 General As per HA report, the main top formation is the upper clay which extends down to depth of 21 m. The top clay layer includes interlayers of sands in some locations at different depth. According to carne geometry and crane supporting points, as well as the soil underneath the crane, the depth of interest of the soil shall be in range of 0.7 to 2 time the width of loading, the maximum width of loading is 2.49m, consequently the depth of interest shall be about 5.0m. Accordingly the top silty clay layer shall be the soil layer which govern the bearing capacity.

6.2 Shear strength paramaters for upper clay According to HA report, the undrained shear strength parameters for the upper clay can be given as follows: Cu =15+ Z (Kpa).

7 CRANE GEOMETRY AND STRESSES

7.1 General The geometry of crane used for installation of the turbines is represented in Appendix 1. This Appendix shows that, the crane is supported by two crawlers with dimension of 15x2.1, also four supporting pads of dimensions of 4x2.49.


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7.2 Stress on soils due to crane weight and loading. According to the data sheet of the crane, the own weight of the crane is 400 ton and the weight of the turbine is 221ton. Accordingly, the total weight of the crane during loading is 621tons. Two positions of the crane is considered in the stress analysis as shown in Appendix 2. The stresses on the soil for each position can be summarized as follows. Position 1

Area of Crane (Crawler & Supports)=(15*2.1*2)+(4*4*2.49)= 102.84 m2 Stress of Crane on Soil (Loaded)= 621/102.84=6.04 ton/m2 Position 2

Area of Upper Crane (Crawler & Supports)=(15*2.1*1)+(4*2*2.49)=51.42 m2 Stress of Crane on Soil (Loaded)= 290/51.42 =5.64 ton/m2 Area of Lower Crane (Crawler & Supports)=(15*2.1*1)+(4*2*2.49)=51.42 m2 Stress of Crane on Soil (Loaded)= 331/51.42 =6.44 ton/m2 From the above, the maximum stress on the soil shall be 6.44 ton/m2. For path of the crane, the calculated stresses are in range of 6.0 t/m2. Based on the above, the analysis shall be performed considering a maximum stresses of 6.44 t/m2

8 BEARING CAPACITY OF THE SOIL.

8.1 General As mentioned above the maximum stress on the soil is 6.44 ton/m2. the soil beneath the crane should withstand this stress with satisfactory safety factor,

8.2 Safety factor according the to the Egyptian code for soil mechanics, the loading case of the crane can be categorized in load case (2) which represent the temporary stresses on the soil, for this load case the Egyptian code of soil mechanics state that the safety factor should not be less than 2.0.

8.3 Bearing capacity of the clayey soils. According to the Egyptian code for soil mechanics the ultimate bearing capacity of the soil shall follows the following .

qult = cNc . λc + γ1 Df Nq λq + γ2 BNγ λγ where: qult = ultimate bearing capacity (KN/m2)


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c = cohesion (kN/m2)

q = effective surcharge; (kN/m2) = (γ1*Df) in absence of external surcharge

where Df refers to footing depth.

γ1 = unit weight of subsoil above foundation level (KN/m3)

γ2 = unit weight of subsoil below foundation level (KN/m3)

B = width (diameter) of footing (m) Df = The depth of the base of footing (m) Nc, Nq, Nγ = bearing capacity factors due to cohesion, surcharge and weight of subsoil. λc, λq, λγ = shape factors and bearing capacity factors, The typical values for the bearing capacity factors Nc, Nq, Nγ and the shape factors λc, λq, λγ are given in Tables 1 and 2

Table (1) Bearing capacity factors Nc, Nq, Nγ for shallow foundations:

φ ° Nc Nq Nγ

0 5.00 1.00 - 5 6.50 1.50 - 10 8.50 2.50 0.50 15 11.00 4.00 1.00 20 15.00 6.50 2.00

22.5 17.50 8.00 3.00 25 20.50 10.50 4.50

27.5 25.00 14.00 7.00 30 30.00 18.00 10.00

32.5 37.00 25.00 15.00 35 46.00 33.00 23.00

37.5 58.00 46.00 34.00 40.0 75.00 64.00 53.00

Table (2): Shape factors for shallow foundation

Shape of

Foundation λc, λq λγ

• Strip 1 1

• Rectangular 1 + 0.3 B/L 1 - 0.3 B/L

Applying the above equation. The ulimate bearing capacity shall be :

- for strip load (crawler) : 8t/m2. - For rectangular pad : 9.5 t/m2.


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The safety factor for for case of strip load shall be 1.24 while for rectangular pad shall be 1.46, this shows that the above safety factors is less than the required by egyptian code, accordingly, the soil should be improved to withstand crane stresses.

9 SOIL TREATEMENT.

9.1 General As mentioned before, the existing soil condition can not withstand the stress of the crane with satisfactory safety factor, consequently, it is proposed to improve the soil underneath the crane by using replacement soil.

9.2 Soil replacement. It is proposed to use a replacement soil of thickness 1.25m, the replacement soil should achieve minimum friction angle of 35 degree.

9.3 Bearing capacity of treated soil using conventional methods. For the case of treated soil using a replacement of non-cohesive soil over a clayey soil, the bearing capacity for the treated soil shall follows the following formulas according to method given by Barja M. Das (priciples of geotechnical engineering) For strip load.

fsf

cu DB

KHD

HNcqu γφγ +⎟⎟⎠

⎞⎜⎜⎝

⎛++=

'tan212

For rectangular load.

fsf

cu DB

KHD

HLBNc

LBqu γφγ +⎟⎟

⎠

⎞⎜⎜⎝

⎛+⎟

⎠⎞

⎜⎝⎛ ++⎟

⎠⎞

⎜⎝⎛ +=

'tan2112.01 2

Where Ks is punching shear coefficient which equal to 4.45 for sand of friction angle 35degrees. Applying the above equation. The ultimate bearing capacity shall be as follows :

- for strip load (crawler) : 12.8 t/m2. - For rectangular pad : 15.0 t/m2.

The safety factor for for case of strip load shall be 2.0 and for rectangular pad shall be 2.33, this shows that the above safety factors is satisfying the required safety factor according to the Egyptian code of practice.

9.4 Bearing capacity of treated soil using slope analysis. Additional method of the analysis for the calculation of the bearing capacity, is to calculate the safety factor against the soil shear failure using slip circle method.


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The analysis has been carried using the computer software Geosolve SLOPE, and adopting the Bishop method. The result of the analysis shows that safety factor against shear failure is about 2.0 which can be accepted. The detailed results of the analysis is enclosed in appendix 3.

10 METHOD STATEMENT AND SPECIFICATION FOR SOIL REPLACEMENT The method statement as well as the specification for the replacement soil 1. Excavate down to 1.25 m for both crawler and support at position of lifting as

well as the path of the crane. The width of excavation shall be minimum 1.0 m outside the loading areas and the crane path.

2. Start the replacement work. The top 0.5 m of replacement shall be subase materials (crushed stone) while the rest of the replacement (lower part) may be clean graded sand. The materials specifications shall be as follows:

For subbase : The maximum grain size shall be 1.5 inch to 2.0 inch. The percent of fines (passing through sieve 200).shall not exceed 10%. The plasticity index shall not exceed 6%. The material classification as per AASHTO classification system shall be A-1-a.

For sand The maximum grain size shall be 19 mm. The percent of fines (passing through sieve 200).shall not exceed 12%. The plasticity index shall not exceed 12%. The material classification as per USCS classification system shall be SP or SW or SP-SM or SW-SM.

3. In general , the replacement shall be carried out on layers each not exceeding 30 cm. Each layer shall be wetted (soaking is preferred for sand) and shall be compacted prefatorily using impact rollers.

4. Sand cone tests shall be performed for sand layers and the minimum required relative compaction shall be 95% concluded from modified Proctor test.

5. Plate bearing tests shall be performed for the last layer of the subbase materials. The tests shall be performed using plate 600 mm diameter loaded to 3.75 kg/cm2 (three time allowable stresses). The criteria for testing acceptance shall be in light of no shear failure should occur and the modulus of deformation up to design stress should not be less than 300 kg/cm2

6. It highly recommended to postpone all foundation had conflict with the path of the crane until finishing the instillation of the turbines.

7. For areas had a limited space where no compaction can be carried out, cement stabilized sand can be used as a soil replacement with cement content not less than 150 kg/m3.


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APPENDIX 1 CRANE DATA AND CONFIGURATION.


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APPENDIX 2 CRANE STRESSES CALCULATION AS PER ELKHARAFI NATIONAL.

One Crawler Dimension (Catina) = 2.1m*15m=31.5 m2 Turbine Weight= 221ton Heavy Lift Crawler Crane Weight(Unloaded)=400 ton Crane Lifting Capacity at 14 m radius = 272 ton Total Wight=400+221=621 ton Existing Soil Stress=3.65 ton/m2 Stress on Crawler & Supports: Position 1 Area of Crane (Crawler & Supports)=(15*2.1*2)+(4*4*2.49)= 102.84 m2 Stress of Crane on Soil (Loaded)= 621/102.84=6.04 ton/m2 Variance = 6.04 – 3.65= 2.39 ton /m2 Position 2 Area of Upper Crane (Crawler & Supports)=(15*2.1*1)+(4*2*2.49)=51.42 m2 Stress of Crane on Soil (Loaded)= 290/51.42 =5.64 ton/m2 Variance = 5.64 – 3.65= 1.99 ton /m2 Area of Lower Crane (Crawler & Supports)=(15*2.1*1)+(4*2*2.49)=51.42 m2 Stress of Crane on Soil (Loaded)= 331/51.42 =6.44 ton/m2 Variance = 6.44 – 3.65= 2.79 ton /m2


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APPENDIX 3 SLIP CIRCLE ANALYSIS.

Licensed to LND | Sheet No. Program: SLOPE Version 12.01 Revision A07.B06.R29 | Licensed from GEOSOLVE | Job No. 44-4 Run ID. 1 | Made by : A.sh Damietta Power plant | Date:17-02-2011 Crane road - bearing capacity | Checked : ----------------------------------------------------------------------------- Units: kN,m INPUT DATA PROFILE DATA Grid line 1 2 X-Coord -10.00 10.00 ------------------------ Stratum Y-Coordinates 1(GL) 0.00 0.00 2 -1.25 -1.25 SOIL PROPERTIES Bulk unit wt. -------Strength parameters------- ----- S t r a t u m ----- below above C Phi dC/dY Datum No. Description GWL GWL (deg) for C kN/m3 kN/m3 kN/m2 kN/m2/m 1 Sand 19.00 19.00 0.00 35.00 2 Soft Clay 16.50 16.50 15.00 0.00 1.00 0.00 GROUND WATER CONDITIONS Unit wt. of water = 10.00 kN/m3 Grid line 1 2 X-Coord -10.00 10.00 ------------------------ Ground water level -0.80 -0.80 SURCHARGE LOADS Load Loaded area ---- Line load ----- Equiv. distrib. load No. from to vertical horizontal vertical horizontal kN/m run kN/m run kN/m2 kN/m2 1 -1.05 1.05 D ( 135.2) ( 0) 64.40 0 CIRCULAR SLIP SURFACE DATA Grid of centres: X Y Corner of grid -5.00 5.00 Grid increment 1.00 1.00 No. of grid lines 10 10 The grid of centres will be extended automatically until a minimum factor of safety has been found. Common point(s): X Y Coordinates of (first) point 1.50 0.00 Increment between points 1.00 0.00 Number of points = 5 ANALYSIS OPTIONS Method of analysis: BISHOP - Simplified : Horizontal interslice forces Factors of safety calculated on Soil Strength Partial factor of safety on tan(phi) = 1.000 Partial factor of safety on drained cohesion = 1.000 Partial factor of safety on undrained cohesion = 1.000 Partial factor of safety on soil weight = 1.000 Partial factor of safety on surcharge loads = 1.000 Minimum number of slices = 10 Program SLOPE - Copyright (C) 2005 by DL Borin, distributed by GEOSOLVE 69 Rodenhurst Road, London SW4, UK. www.geosolve.co.uk

Licensed to LND | Sheet No. Program: SLOPE Version 12.01 Revision A07.B06.R29 | Licensed from GEOSOLVE | Job No. 44-4 Run ID. 1 | Made by : A.sh Damietta Power plant | Date:17-02-2011 Crane road - bearing capacity | Checked : ----------------------------------------------------------------------------- Units: kN,m

Licensed to LND | Sheet No. Program: SLOPE Version 12.01 Revision A07.B06.R29 | Licensed from GEOSOLVE | Job No. 44-4 Run ID. 1 | Made by : A.sh Damietta Power plant | Date:17-02-2011 Crane road - bearing capacity | Checked : ----------------------------------------------------------------------------- Units: kN,m Brief results for selected circles through common point no.1 ---Centre--- Radius Factor Slipped Overturning Restoring Delta X Y R of mass moment moment safety ( Out of balance forces ) (Itera ( Vert. Horiz. Moment ) tions) kN/m kN.m/m -1.00 0.00 2.50 2.020 175 136 275 ( 0) ( 0) ( 0) ( 5 ) -1.00 0.00 2.50 2.020 175 136 275 ( 0) ( 0) ( 0) ( 5 ) -1.00 0.00 2.50 2.020 175 136 275 ( 0) ( 0) ( 0) ( 5 ) -2.00 0.00 3.50 2.091 335 274 573 ( 0) ( 0) ( 0) ( 4 ) -2.00 0.00 3.50 2.091 335 274 573 ( 0) ( 0) ( 0) ( 4 ) -2.00 0.00 3.50 2.091 335 274 573 ( 0) ( 0) ( 0) ( 4 ) 1.00 0.00 0.50 2.130 7 8 17 ( 0) ( 0) ( 0) ( 4 ) 1.00 0.00 0.50 2.130 7 8 17 ( 0) ( 0) ( 0) ( 4 ) 1.00 0.00 0.50 2.130 7 8 17 ( 0) ( 0) ( 0) ( 4 ) 1.00 0.00 0.50 2.130 7 8 17 ( 0) ( 0) ( 0) ( 4 )


Licensed to LND | Sheet No. Program: SLOPE Version 12.01 Revision A07.B06.R29 | Licensed from GEOSOLVE | Job No. 44-4 Run ID. 1 | Made by : A.sh Damietta Power plant | Date:17-02-2011 Crane road - bearing capacity | Checked : ----------------------------------------------------------------------------- Units: kN,m Analysis options Method of analysis: BISHOP - Simplified : Horizontal interslice forces Factors of safety calculated on Soil Strength Partial factor of safety on tan(phi) = 1.000 Partial factor of safety on drained cohesion = 1.000 Partial factor of safety on undrained cohesion = 1.000 Exclusion options The summary results and selected results for each exit point exclude: All slip surfaces where the interlock value in any slice is less than 0 All slip surfaces where the slipped mass is less than 0 kN/m run Critical Factor of Safety for each Common Point ---- Common point ----- ----------- Critical circle --------- Point X Y ---- Centre ---- Radius Factor of no. coord coord X Y safety 1 1.50 0.00 -1.00 0.00 2.50 2.020 <--- 2 2.50 0.00 1.00 0.00 1.50 2.023 3 3.50 0.00 1.00 0.00 2.50 2.021 4 4.50 0.00 2.00 0.00 2.50 2.075 5 5.50 0.00 2.00 0.00 3.50 2.092

Run ID. 1 | Sheet No. Damietta Power plant | Crane road - bearing capacity | Date:17-02-2011 ----------------------------------------------------------------------------- FACTORS OF SAFETY AT CENTRES OF CIRCLES X-coordinates -4.00 -2.00 0.00 2.00 4.00 Y-coord 14.00 5.333 5.472 6.455 * . * 6.455 6.216 . 13.00 5.137 5.265 6.121 * . * 6.121 5.910 . 12.00 4.943 5.060 5.791 9.603 . 9.603 5.754 5.607 . 11.00 4.874 4.836 5.464 8.921 . 8.921 5.358 5.305 . 10.00 4.749 4.603 5.143 8.244 . 8.244 4.965 5.008 . 9.00 4.572 4.368 4.830 7.571 . 7.571 4.575 4.715 . 8.00 4.369 4.139 4.527 6.907 . 6.907 4.190 4.430 . 7.00 3.911 4.038 4.237 6.254 . 6.254 3.813 4.156 . 6.00 3.491 3.693 3.930 5.617 . 5.617 3.447 3.900 . 5.00 3.108 3.254 3.632 5.008 . 5.008 3.101 3.674 . 4.00 2.882 2.825 3.164 4.446 . 4.446 2.789 3.502 . 3.00 2.738 2.501 2.651 3.770 . 3.658 2.526 3.397 . 2.00 2.686 2.363 2.206 3.382 . 2.877 2.205 3.375 . 1.00 2.925 2.517 2.191 2.213 . 2.213 2.120 3.935 . 0.00 2.805 2.398 2.091 2.020 . 2.021 2.075 4.447 . Legend: * Factor of Safety > 10

Licensed to LND | Sheet No. Program: SLOPE Version 12.01 Revision A07.B06.R29 | Licensed from GEOSOLVE | Job No. 44-4 Run ID. 1 | Made by : A.sh Damietta Power plant | Date:17-02-2011 Crane road - bearing capacity | Checked : ----------------------------------------------------------------------------- Units: kN,m Analysis options Method of analysis: BISHOP - Simplified : Horizontal interslice forces Factors of safety calculated on Soil Strength Partial factor of safety on tan(phi) = 1.000 Partial factor of safety on drained cohesion = 1.000 Partial factor of safety on undrained cohesion = 1.000 DETAILED RESULTS FOR CRITICAL CIRCLE Factor of safety = 2.020 Slipped mass = 175 kN/m Out of balance vertical force = 0 kN/m Out of balance horizontal force = -13 kN/m Centre of circle: X = -1.00 Y = 0.00 Radius = 2.50 Overturning moment = 136 kN.m/m Restoring moment= 275 kN.m/m Slip surface coordinates Piezometric ------- Interslice forces -------- ------------------------ elevation ----- horizontal ------ vertical No. X Y Y(w) E(total) E'(effective) Q kN/m kN/m kN/m 1 -3.50 -0.00 -0.80 0 0 0 2 -3.38 -0.76 -0.80 6 6 0 3 -3.03 -1.45 -0.80 42 40 0 4 -2.49 -2.00 -0.80 69 62 0 5 -1.81 -2.37 -0.80 90 78 0 6 -1.05 -2.50 -0.80 103 89 0 7 -0.56 -2.46 -0.80 103 89 0 8 -0.09 -2.33 -0.80 93 82 0 9 0.35 -2.11 -0.80 75 66 0 10 0.73 -1.80 -0.80 50 45 0 11 1.05 -1.43 -0.80 21 19 0 12 1.30 -0.99 -0.80 16 16 0 13 1.45 -0.50 -0.80 13 13 0 14 1.50 -0.00 -0.80 13 13 0 Slice Cohesion Tan(phi) Pore Weight Forces on base of slice No. pressure of slice --- normal --- shear (avge) (avge) (avge) W P P' S kN/m2 kN/m2 kN/m kN/m kN/m kN/m 1 0.00 0.7002 0.00 1 6 6 -0 2 4.79 0.4937 3.09 7 36 34 10 3 16.73 0.0000 9.29 17 31 24 6 4 17.18 0.0000 13.85 27 34 23 7 5 17.43 0.0000 16.32 33 35 22 7 6 17.48 0.0000 16.80 22 53 45 4 7 17.39 0.0000 15.95 20 51 43 4 8 17.22 0.0000 14.17 17 49 42 4 9 16.95 0.0000 11.55 14 46 40 4 10 16.62 0.0000 8.17 9 41 37 4 11 6.68 0.4141 4.09 6 7 5 3 12 0.00 0.7002 0.37 2 4 3 1 13 0.00 0.7002 0.00 0 1 1 0

Slice -- Surcharge loads -- Water load on No. vertical horizontal submerged ground load load vertical horizontal kN/m kN/m kN/m kN/m 1 0 0 0 0 2 0 0 0 0 3 0 0 0 0 4 0 0 0 0 5 0 0 0 0 6 31 0 0 0 7 30 0 0 0 8 28 0 0 0 9 25 0 0 0 10 21 0 0 0 11 0 0 0 0 12 0 0 0 0 13 0 0 0 0 (1+Tan(alpha).Tan(phi)/F) = -1.21 in slice 1


10067-9-V01-G00Z-01671

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material classification