appendix a (rfi) for the fabrication of multiple steel reaction structures for nasa-msfc structural...
TRANSCRIPT
APPENDIX A
(RFI) FOR THE FABRICATION OF MULTIPLE STEEL REACTION STRUCTURES FOR NASA-MSFC STRUCTURAL TESTING
Mike Roberts12/2/09
Large Steel Structure Procurements• 28 steel structures totaling >4.5 million lb• Special Test Equipment (STE or Test Fixtures) Groupings:
– Group 1 - Interface Rings (8)– Group 2 - Spiders (4)– Group 3 - Pedestals (3)– Group 4 - Reaction Structure (13)
• 20,000 lb - 600,000 lb (most <100,000 lb)• Delivery to MSFC
– build up and deliver one piece– build up and teardown for delivery
• Schedule– Procurement Cycle starts January 2014– All deliveries end of 2014 through middle of 2015.
12/20/2013 2APPENDIX – RFI – MSFC STEEL STRUCTURES
General Procurements Schedule– Schedule data below is for a typical item from
each group (fabrication time – red bar).
12/20/2013 3
DESCRIPTIONFabrication
(weeks)Delivery O N D J F M A M J J A S O N D J F M A M J J A S
GROUP #1 INTERFACE RING 30 10/16/2014
GROUP #2 SPIDER 34 10/16/2014
GROUP #3 PEDESTAL 35 01/16/2015
GROUP #4 REACTION STRUCTURE 35 11/17/2014
20142013 2015Schedule
APPENDIX – RFI – MSFC STEEL STRUCTURES
GROUP 1 – INTERFACE RINGS• Qty 8 – 7 items, qty 1 of each item except qty 2 of Interface Ring #6• General design requirements for each ring:
– General Design Geometry• 27.5’ barrel diameter• 10”-4’ Height• Plate thicknesses – 1” – 4”• Flanged interfaces top and bottom with multiple holes (“T” x-section; 200-400 holes; 1”-3” hole D)• STRESS RELIEF REQUIRED for each interface ring.
– Material• Steel plate per ASTM A572, Grade 50
– Tolerances • Typical tolerances, except:• One Flange must be machined to tight tolerances (see charts for details):
– Welding• CJP welds, groove welds, fillet welds (see charts for typical weld callouts)• Flanges are multi-piece welded together and welded to rolled barrel/web• Gussets welded to flanges/web• Welds per AWS D1.1, certified inspection (mag particle/ultrasonic/visual by supplier)
– Weight• 30,000 lb – >200,000 lb
– Transportation• All interface rings are ONE PIECE delivered to MSFC12/20/2013 4APPENDIX – RFI – MSFC STEEL STRUCTURES
Weight: ~210K lbs
2.5” Top Ring
1” thick plateBarrel and Gussets
4” thick plateBase
35 ft
4 ft
30 ft
INTERFACE RING #1
TIGHT TOLERANCE INTERFACE – See pg. 13 for tolerances for this interface
3” D bolt holes (qty 200)
INTERFACE RING #2
12/20/2013 6APPENDIX – RFI – MSFC STEEL STRUCTURES
30 ft
TIGHT TOLERANCE INTERFACE – See pg. 13 for tolerances for this interface
.5” THK gusset2.5” top2.0” bottom1.0” web
W 10x49 beam
Weight: ~50k lbs
Weight: ~45k lbs
36”
Dia 348”
2.0” THK top and bottom
1.0” THK web
1.5” THK plate.5” THK plate
INTERFACE RING #3
12/20/2013 APPENDIX – RFI – MSFC STEEL STRUCTURES 7
2.5” THK bottom
2.0” THK top
Dia 343”
W 10x49 beam
.75” THK gusset
1.0” THK web.5” THK gusset
10”
INTERFACE RING #4
Weight:22K lbs
12/20/2013 APPENDIX – RFI – MSFC STEEL STRUCTURES 8
TIGHT TOLERANCE INTERFACE – See pg. 13 for tolerances for this interface
Weight: ~23K lbs
.5” THK gusset2.5” top2.0” bottom1.0” web
Dia 346”
13”
INTERFACE RING #5
12/20/2013 APPENDIX – RFI – MSFC STEEL STRUCTURES 9
TIGHT TOLERANCE INTERFACE – See pg. 13 for tolerances for this interface
28”
Material: ASTM A572, Grade 50
WebDiameter: 27.5’Thickness: 1.5”
Height: 23”
INTERFACE RING #6
FlangesOD: 28.7’ID: 26.3’T: 2.5”
Holes (Top): 1” holes (2 rows of 192 each)Holes (Bot): 1.5” holes (2 rows of 120 each)
Inner D: 27’Outer D: 28’
Interface Ring GussetsDimensions: 23” X 6” X 1”
24 @ 15 degrees apart (inside and out)
APPENDIX – RFI – MSFC STEEL STRUCTURES12/20/2013 10
TIGHT TOLERANCE INTERFACE – See pg. 13 for tolerances for this interface
Weight: ~40K lbs
INTERFACE RING #7
12/20/2013 11APPENDIX – RFI – MSFC STEEL STRUCTURES
TIGHT TOLERANCE INTERFACE – See pg. 13 for tolerances for this interface
2.5” THK bottom
2.0” THK top
Dia 343”
1.0” THK web.5” THK gusset
10”
Weight: 22K lbs
Typical INTERFACE RING Weld Callouts
12/20/2013 12APPENDIX – RFI – MSFC STEEL STRUCTURES
13
Typical INTERFACE RING Tight Tolerance Details
12/20/2013 13APPENDIX – RFI – MSFC STEEL STRUCTURES
0.050” flatness (+/-0.25”) over entire interface surface
GROUP 2 - SPIDERS• Qty 4 – 4 items, qty 1 of each item• General design requirements for each Spider:
– General Design Geometry• Welded wide-flange I-beams stiffened by plates• Large sections (e.g. W36x441)• 28’ – 44’ Diameter• 3’-4’ Height• Plate thicknesses – 1” – 2”• STRESS RELIEF REQUIRED for each spider
– Material• ASTM A992 Beams • Steel plate per ASTM A572, Grade 50
– Tolerances • Typical tolerances for I-beam construction• Some machined surfaces (see charts for details)
– Welding• CJP welds, groove welds, fillet welds (see charts for typical weld callouts)• Gussets welded to flanges/web• Welds per AWS D1.1, certified inspection (mag particle/ultrasonic/visual by supplier)
– Weight• 66,000 lb – 278,000 lb
– Transportation• 3 of 4 spiders are ONE PIECE delivered to MSFC• 1 spider (Spider #4) is MULT-PIECE delivery12/20/2013 14APPENDIX – RFI – MSFC STEEL STRUCTURES
Spider #1 Beams – W36X330One piece – all weldedWeight – 180,000 lbMachined interface plate at 27.5’ D
3.2’
35’27.5’
17’
APPENDIX – RFI – MSFC STEEL STRUCTURES12/20/2013 15
Spider #1
Top Level Assembly
Sub-Assembly
4X
1X
4X
Sub-Assembly
Sub-Assembly
8X
8X
APPENDIX – RFI – MSFC STEEL STRUCTURES
8X
4X8X
12/20/2013 16
223.25”
99.437”
229.66”
115.992”
136.093”
Doublers: 1.5” thickness
Plates: 1.85” thickness
Spider #1
APPENDIX – RFI – MSFC STEEL STRUCTURES12/20/2013 17
Machined Inner Ring Plating: 8X @ 45 deg
Spider #1
APPENDIX – RFI – MSFC STEEL STRUCTURES12/20/2013
18
SPIDER #2
411” (34.25 ft.)
39.2”(3.27 ft.)
APPENDIX – RFI – MSFC STEEL STRUCTURES
Beams – W36X330One piece – all weldedWeight – 220,000 lbMachined interface plate at 27.5’ D
12/20/2013 19
Spider #2Yellow: 1.5” Flange Doubler Plates
Hole Diameter: 2.563”
Yellow Triangle Plates: 1” Thickness
1.5” Thick Plate
Upper Spider Assembly w/ Modifications to Weldment_2_FS_LOXassembly.
APPENDIX – RFI – MSFC STEEL STRUCTURES
12/20/2013 20
W 14x2331.0” THK gusset
28’ Diameter
SPIDER #3
12/20/2013 APPENDIX – RFI – MSFC STEEL STRUCTURES 21
Beams – W14X233One piece – all weldedWeight – 66,000 lbMachined interface plate at 27.5’ D
SPIDER #4
44’ 4”
43”
Beams – W36X441MULTI-piece – welded then bolted via splice platesWeight – ~278,000 lbMachined interface plate at 27.5’ D
Quadrant Weldment50,000 lbs.
Cross-Member61,500 lbs.
12/20/2013 SLS Core Stage Structural Testing
GROUP 3 - PEDESTALS• Qty 3 – 3 items, qty 1 of each item• General design requirements for each Pedestal:
– General Design Geometry• Welded wide-flange I-beams stiffened by plates; sections connected via bolted joints• Sections (e.g. W14x193)• 32’ – 42’ Diameter• 20’-34’ Height• Plate thicknesses – .5” – 2” • Modular design • STRESS RELIEF REQUIRED for each Pedestal
– Material• ASTM A992 Beams • Steel plate per ASTM A572, Grade 50
– Tolerances • Typical tolerances with some machined surfaces (see charts for details)
– Welding• CJP welds, groove welds, fillet welds (see charts for typical weld callouts)• Gussets welded to flanges/web• Welds per AWS D1.1, certified inspection (mag particle/ultrasonic/visual by supplier)
– Weight• 160,000 lb – 500,000 lb when together; 20,000 – 40,000 lb per section
– Transportation• All pedestals are MULTI-PIECE delivery
12/20/2013 23APPENDIX – RFI – MSFC STEEL STRUCTURES
Pedestal #1
12/20/2013
8 Pedestal Sections bolted togetherBEAM SIZE = Vert – W14X193; Hor – W12X53Weight = ~180,000 lbs (22,500 lb per section)
24APPENDIX – RFI – MSFC STEEL STRUCTURES
42 ft
34 ft
Pedestal #2 and #3Pedestal #2 Pedestal #3
20’
21.25’
21.25’
10’
20’
10’
10’
section
sectionsection
section
32.4’10.625’
10.625’
10.625’
10.625’
10’
25
12/20/2013 25APPENDIX – RFI – MSFC STEEL STRUCTURES
Pedestal #2 and #3General Beams • W14X176 (Vertical)• W12X58 (Horizontal)
Cross Brace Angles – L6X4X3/4
3” Base Plate
3” Weld Plates Top
3” Weld Plates Opening¾” Cross Brace Gussets
¾” Cross Brace Splice Plate
½” Section Connection Plates
26
Weight per Section: ~40,000 lbsAPPENDIX – RFI – MSFC STEEL
STRUCTURES12/20/2013 26
4 welded pedestal sections bolted togetherBEAM SIZE = Vert – W14X176; Hor – W12X58Weight #2 = 160,000 lbs (40,000 lb per section)Weight #3 = 500,000 lbs (42,000 lb per section)
GROUP 4 – REACTION STRUCTURE• Qty 13 – 6 items (#1=1; #2-#6=>1)• General design requirements for each Reaction Structure:
– General Design Geometry• Welded wide-flange I-beams stiffened by plates with some bolted joints• Welded plate structure• Plate structure joined by bolts• Some Large I-beam sections (e.g. W36x441)• See charts for sizes, geometry, plate thicknesses, etc.• STRESS RELIEF REQUIRED for welded Reaction Structure
– Material• ASTM A992 Beams • Steel plate per ASTM A572, Grade 50• ASTM A514- 115 ksi Ult Tensile for Reaction Structure #3
– Tolerances • Typical tolerances for steel structure construction• Some machined surfaces (see charts for details)
– Welding• CJP welds, groove welds, fillet welds (see charts for typical weld callouts)• Gussets welded to flanges/web• Welds per AWS D1.1, certified inspection (mag particle/ultrasonic/visual by supplier)
– Weight• 60,000 lb – 600,000 lb
– Transportation• Some are ONE PIECE delivered to MSFC• Others are MULT-PIECE delivery
12/20/2013 27APPENDIX – RFI – MSFC STEEL STRUCTURES
Reaction Structure #1
Splice Plate Joint (High Stressed Joints)
43’
59’
Multi-piece welded sections bolted togetherBEAM SIZE = Vert – W36X441Weight = 600,000 lbs total (all sections truckable)
12/20/2013 SLS Core Stage Structural Testing
Reaction Structure #1
Base Frame Assembly – 90M13927• BEAM SIZE = W36 X 441• VERT BEAM SIZE = W14 X 193• TUBE SIZE = 14 X 14 X 5/8
Splice Plate Joint (High Stressed Joints)
43’
21’
59’
11’
12/20/2013 APPENDIX – RFI – MSFC STEEL STRUCTURES 29
SLS Core Stage Structural Testing
Base Frame Assembly
Reaction Structure #1
12/20/2013
Reaction Structure #2
12/20/2013
Qty 2Modular welded sections with bolted X-braces and I-beamsBEAM SIZE = W18x330; W18X106 and smallerWeight = 1,200,000 lbs (600,000 lb per
tower, TBD weight per modular section; assume all sections truckable)
55’
37’17’
SLS Core Stage Structural Testing
Qty 2Matl: ASTM A514- 115 ksi Ult TensileOther: Spherical Bearings, fasteners, and machined load lugs Weight: ~120,000 lb (60,000 lb each)
4” thick plate and3” thick plate sandwiched
~19 ft
~11 ft
Reaction Structure #3
Qty 2All welded plate structureWeight: 160,00K lbs (80,000 lb each)
2” thick plateTop Plate and Vertical Plate
1” thick plateGussets
4” thick plateBase
34 ft
8.5 ft
4 ft
Reaction Structure #4
Reaction Structure #5
12/20/2013 APPENDIX – RFI – MSFC STEEL STRUCTURES 34
50’
12’ 15’
Qty 4Welded towerBEAM SIZE = W18x330; W14X176Weight = 600,000 lbs (150,00 lb per tower)
157”
108”
108”
W 21x101 Beam
W 14x61Beam
.75” THK Plate
.625” THK Plate
Reaction Structure #6Qty 2 Welded beam structureWeight: 13,000 lb (6500 lbs each)
12/20/2013 APPENDIX – RFI – MSFC STEEL STRUCTURES 35