ANALYSIS & DESIGN EXPERIENCE
CALCET Company Team members have used a number of analytical tools in their Analysis and Design work. CALCET Company personnel are familiar with a host of numerical analysis software tools including:
CALCET Company personnel have also designed software control systems for Programmable Logic Controllers.
Team members have first hand experience with the application of a number of industry codes and standards including ACI-318, ACI-349, ASTM, ASME B&PV Sections III, VIII, IX, XI, ASME/ANSI AG-1-1991 and Code Cases N-47-28, N-248, and N-253-6, ANSI B31.1 and B31.3, AISC, ASCE 7-88 (Formerly ANSI A58.1), UBC, 10 CFR Parts 21, 50, and 71, 40 CFR Parts 265 and 270, DOE Order 6430.1A, and Hanford Plant Standard SDC 4.1.
Team personnel have followed design projects through startup procedures up to final equipment qualification. Because they have worked to design the equipment, Team personnel can better troubleshoot the system, train personnel in the operation of the system, and qualify the system for final use. Below is a representative sampling of the Team’s work experience in the design phase.
1.1 Appliance Parts Distributor
Design of Structural Modification to Building at 16200 E. 14th Street, San Leandro, CA
CALCET Company performed the structural design for the remodeling of the building structure at 16200 E. 14th Street in San Leandro, California. This building is of steel rigid frame type, having 80-ft unsupported spans. The bays between frames are 20 ft, 12 ft, and 16 ft long, with the bays being separated by concrete masonry unit (CMU) walls. The remodeling plan called for providing an opening in the CMU wall between the 20 ft and 12 ft bays to combine the two spaces into one connected space. CALCET has provided the following:
Structural design of the steel members, concrete footing and connections for the selected structural configuration
One PE stamped size "D" drawing including general notes, specifications, and bill of materials
Evaluation of the seismic resistance of the modified framing section, to ensure that the lateral resistance has not been reduced from that of the existing configuration
Review and approval of the fabrication of the structural steel members
Construction interface and approval of the installation of the reinforced concrete footing and steel members
1.2 Arizona Public Service
Tank Certification of Chemical Cleaning Tank System, Palo Verde Nuclear Generating Station Unit 1
As part of the ongoing maintenance operations at PVNGS, a proprietary chemical cleaning process of Unit 1 steam generators was conducted. The Team performed an independent structural integrity assessment of the hazardous waste tank system per the requirements of 40 CFR 265 Subpart J. The work consisted of the site inspection of the tank system in place, the review of the manufacturing data reports, the assessment of the structural adequacy of the tank system for the storing and treating of the hazardous waste and the certification of the tank system per 40 CFR 270.11(d). The remaining structural integrity of the tank system, considering the process services, was attested by the external inspection demonstrating that there are no potential leakage, through-wall cracks, or other structure defects. The analysis of the available laboratory/field data pertaining to the corrosion potential penetration revealed that all the installed tanks were susceptible to a maximum wall thinning, after a service exposure of 17,500 hours plus 2,500 hours for the Unit 1 operation, within the good practice allowance of 1/16 inches. Based upon this conservative estimation of the wall deterioration, the safe Unit 1 operation of the tank system was qualified and certified, excluding any leakage of waste, collapse, or rupture, in compliance with 40 CFR 265.192(a).
1.3 Bayer Pharmaceutical
Design of Monorail for Hydraulic Ram Removal
CALCET Company designed a lifting system to raise the hydraulic ram on Freeze Dryer "F" in Building 49A of Bayer's Complex in Berkeley, California. Conceptually, the lifting system consisted of a monorail that will support a travelling lifting rig, which will:
Raise the hydraulic ram about 12 inches vertically
Transport it while suspended on the lifting rig from its location above the freeze-dryer chamber through the clearance above the space between freeze dryers "F" and "D"
Maneuver it to a horizontal operation
Lower it in a vertical orientation to the floor
The monorail, its supports, the hand trolley, trolley hoist, ceiling hoist, and various components and fittings were designed for a lift load of 2,000 pounds and a safety factor of 4.0. The design was performed for Seismic Zone IV and included one structural calculation and three engineering size "D" drawings PE stamped with all details, connections, and design and material specifications.
1.4 Bayer Pharmaceutical
Design of Mounting Frame for Lyophilizer Oil-Vacuum Pump
CALCET Company has performed the dynamic analysis and the design of a three-dimensional (3-D) steel frame structure to support a back-up oil vacuum pump located directly above the existing main oil-vacuum pump. Additionally, the structure was provided with a monorail on the top to allow for the installation of the vacuum pump for maintenance, as needed without interference. The analysis of the structure was performed using a 3-D finite element model for the ADINA program to analyze the structure for seismic zone IV and dead loads. Structural damping of 2% was used. The frame stiffness was designed to obtain a minimum fundamental frequency of 15 Hz to preclude resonance with the vacuum pump motor, which runs at about 500 rpm. CALCET Company has provided the following deliverables:
One engineering calculation, which included the results of the dynamic analysis results of the ADINA 3-D model, the design response spectrum, the frame beam calculations, welding design, and design of anchor bolts and base plates
Review and approval of the fabrication of the structural steel members and components
Four PE stamped engineering size "D" drawings, including fabrication details, general notes, specifications, and bill of meterials
Construction interface and approval of the installation of the reinforced concrete, embedded plates, base plates, welding, and expansion anchors
1.5 Bayer Pharmaceutical Engineering Study to Replace York Refrigeration Compressors
CALCET Company performed an Engineering Study to find a replacement for the YORK refrigeration two-stage low temperature compressors for use in freeze drying operation. This study was part of CALCET's re-design scope of work for Bayer's Freeze Dryer "D" with a freeze drying capacity of 200 lb ice. Due to space limitation for the refrigeration system and similar or better thermodynamic parameters than the York compressors, the choice of choosing Bitzer S6F-30.2Y two-stage, low temperature (-70 ˚C) semi-hermetic reciprocating compressors proved to be the optimum. CALCET Company's scope of work for the Freeze Dryer "D" upgrade was later expanded and consisted of:
Design the addition of a new refrigeration skid (loop number 4) for additional Lexsol cooling capacity
Design the replacement of all the existing liquid sub-coolers with new plate-and-frame SWEP type B8x16
Design the replacement of the existing York compressors (loops 1 and 2) with Bitzer compressors
1.6 Bayer Pharmaceutical Lyophilizer Seismic Calculations and Design
CALCET Company performed a seismic Zone IV design and analysis for the chamber and the condenser supporting structures of a 200 lb ice capacity lyophilizer. The supporting structure design allowed for relative movement of the chamber and condenser due to thermal expansion and the anchor bolts of the structure to the concrete base were seized accordingly. CALCET Company has also designed the reinforced concrete base for a third refrigeration unit structure and the anchorage of the skid to the concrete base.
1.7 Bayer Pharmaceutical Purified Water Conceptual Design
The Team provided a conceptual design of a self-contained, cGMP based USP grade purified water system used for final rinse of passivated and electro-polished parts with product contact. The purified water system utilized a novel approach: an on-demand heating station coupled with a custom de-ionization system. The system used no storage tanks, but contained a recirculation loop with UV exposure. The system was chosen after a review of other WFI or Purified Water supply options. These options included the inclusion of an additional loop or drop to nearby existing WFI and Purified Water system.
1.8 Biogen Inc. Control Systems Design
CALCET Company personnel have worked on the design of a Eurotherm PLC for the CIP system of a biotechnology pilot plant and the subsequent scaled-up manufacturing plant. Team members documented and validated the installation and implementation of the control system and aided in the programming of a PLC for a newly designed carboy CIP system.
1.9 Genentech, Inc., Control System Software Support
The Team personnel provided control system software support to integrate Moore single loop controllers into an existing plant wide UNIX based, client/host software environment. The Team wrote script files, designed and configured CIM/21 and Moore controllers. The scope of work included configuring the historian database for real time process trending display and establishing data communication to the existing Oracle Relational Database.
1.10 Merrick and Company
Waste Characterization Facility, Title II Design, Structural Analysis of HVAC Ductwork and Stacks
CALCET Company personnel performed the structural analysis of the safety class portion of the HVAC system in the Waste Characterization Facility (WCF) at the Idaho National Engineering Laboratory (INEL), according to the requirements of the Design and Evaluation Guidelines for Department of Energy Facilities Subjected to Natural Phenomena Hazards UCRL 15910. Computer static and dynamic analyses of Zones I, II, and III HVAC Systems were performed using ANSYS General Purpose Finite Element Code, Full Version, Revision 4.4A. The applicable design loads were: dead weight, wind and seismic loads and load combinations for normal, severe and extreme conditions to meet the allowable stresses based on the requirements of Article D-2000 of Appendix AA-D of ASME/ANSI AG-1-1991. The seismic load was the frequency-acceleration spectra developed from the ground spectra of the WCF Building. To ensure that all modes were accounted for in the structural response, the missing mass response associated with modes having frequencies in the rigid domain of the spectra, was combined with the flexible mode response in each of the three-orthogonal directions using SRSS method. The directional responses were then combined using SRSS. The wind load considered for the part of the stack exiting the top of the WCF Building was based on an extreme wind speed of 84 mph, and the wind pressures were calculated in accordance with Section 6.4 of the ASCE 7-88 (Formerly ANSI A58.1). A complete structural evaluation of the ductwork, the stacks and the supporting structure was performed. The HVAC supports included: (a) the floor standing supports; (b) the hanging supports; and (c) the stack supports at roof. An evaluation of the anchor bolts that secure the stacks to the foundation was also performed.
1.11 Merrick and Company
Thermal and Structural Analysis of HALPAK Insert Retrofit to the Existing NUPAC-72B Cask
CALCET Company personnel performed a thermal and structural analysis of the High Activity Liquid Packaging (HALPAK) insert retrofit to the existing NUPAC-72B cask for shipment of Type B quantities of high activity liquids, in accordance with the provisions of Title 10 of the Code of Federal Regulations (10 CFR) Part 71. The following loads were considered in the analyses of the HALPAK: 2,000 psig internal pressure produced after one year of internal gas generation, insolation of 1,475 BTU/ft2 over a period of 12 hours, internal heat generation of 3 W/gal and a postulated accident of 30 minutes fire at 1,475 ºF. Three heat transfer analyses were performed utilizing ANSYS/General Purpose Finite Element Code: (a) steady state analysis at an ambient of 100 ºF with the 10 CFR 71 specified insolation; (b) steady state analysis at 100 ºF without insolation as initial conditions for the hypothetical accident conditions; and (c) transient analysis of fire per 10 CFR 71 requirements. Other accident analyses performed were the 9-meter drop with 74.7 g’s acceleration in combination with the normal thermal conditions and, 200-meter submergence in water for an external pressure of 284 psig. Protection against stress rupture was demonstrated in compliance with ASME B&PV Code Section III, Subsection NB-3200 and against buckling in compliance with ASME Code Case N-284.
1.12 Westinghouse Hanford Company
Structural Analysis of the 241 AY/AZ Tanks to Resolve Dome Overload Issues
CALCET Company personnel performed analyses of the 241 AY/AZ underground liquid waste, double shell, million-gallon tanks to resolve dome overload issues and to demonstrate that the tanks can sustain loads resulting from additional soil overburden depth, increased soil density, and increased concentrated load. Additionally, a qualitative evaluation of the tanks for seismic and thermal loading was performed. Three axisymmetric models of the tanks were developed using ANSYS (SASI 1989) General Purpose Finite Element Program. All three models included the dome, the cylindrical wall, the tank base slab, and the soil surrounding the tank. The extent of the soil modeling was out to the outer perimeter of the tank base. The soil was allowed to slide in the vertical direction along the surface of the tank wall and was not connected to the tank wall in the horizontal direction. The bounding load case was selected and the forces and moments for both the longitudinal and the circumferential directions were evaluated using the ultimate strength method of ACI 318-93 Code. Shear forces in the concrete base slab were evaluated using the requirements of the ACI Code. Interaction of axial loads and bending moments (M-P Capacity Curves) were calculated according to ACI 349-93 Code, Section 10 assuming elastic-perfectly-plastic behavior of the concrete rebar.