Constant Values

The following constants are used in the program:

Oil density of 0.000863 g/ mm3
Gravity of 9,81 m/s2
Safety factor of 1,0
AlfaConst of 0,036 (dimensionless steel factor)
BetaConst of 0,36 (dimensionless steel factor)

The steel type used for the tank is St. 37, which has the following constants
Elasticity modulus of 210,000 N/mm2
Density of 0.00000785 kg/mm3
Yield stress of 235 N/mm2

Changing the formulas

Although it is not recommended, it is possible to change the formulas used in
the program. For example this could be done after a Finite Element analysis
shows that the solutions of for tank of the existing program are too strong.
The explanation and the assumptions of the formulas used in the program are
described in the report.
Changing the formulas concerning the stress in the plate will involve
changing the following formula in the functions: Zero_Reinf,
CornerDistance and Solution.
p * ( DBP) 2
=*
Tw2
Most of the times this will imply changing the value of beta
0.36
=
DBP 2
1+ ( )
Hw
The following formulas concern the deflection of the plate:
p * ( DBP) 4 0.036
f = * 3
; =
E * Tw DBP 2
1+ ( )
Hw
Also in this case most of the times the value of alfa will be changed.
This has to be done in the following formula in the functions:
Zero_Reinf, CornerDistance and Solution.
Changing the formulas of the calculation of the stress in the profile will
involve the changing of the following formulas in the function solution.
p * ( DBP ) * H w2 p * ( DBP) * H w2
S req := ; =
8 * max 8* Sp
The following formulas in the function solution concern the calculation
of the required inertia:
4
5 p * DBP * H p 5qL4
I req := * =
384 defl max * H p * E 384 EI
Deflection
The deflection f of a clamped plate can be estimated with as dimensionless
steel factor. The calculated displacement has to be smaller than the deflection
factor times the smallest length of the plate. In this case it will be the
distance between the profiles (DBP). The Distance Between Profiles will be
discussed in the next paragraphs.
p * ( DBP) 4 0.036
f = * 3
; =
E * Tw DBP 2
1+ ( )
Hw
f max = defl max * DBP

Stress
The stress of a clamped plate can be estimated with as dimensionless
steel factor. The calculated stress has to be smaller than the maximum
allowable stress max of the plate, given by the yield stress and the safety
factor (SF).
p * ( DBP) 2 0.36
=* 2
; =
Tw DBP 2
1+ ( )
Hw
Y
max = ; SF 1
SF

Maximum Plate dimensions

The maximum values of the plate dimensions are limited by the maximum
allowable stress. The dimensions are also limited by the maximum deflection,
but in order to get an starting value of these dimensions an iterative process
starts with the maximum stress. Afterwards these values have to be checked
0.36 p * ( DBP) 2
max = *
DBP 2 Tw2
1+ ( )
Hw
DBP 2
max *1 + ( )
Hw
for the maximum displacement. DBP = Tw * ; DBP << H w
p * 0.36
Tw max
DBPlim *
0 .6 p
The Distance Between Profiles is considered to be much smaller than the
Height of the Tank (min. 1500 mm), which means that in this case becomes
0,36.
The value for the limit Distance Between Profiles (DBPlim) has to be checked
again for restraints in the displacement or the stress, with the new value for
DBP.

Page 2 of 14
For a plate with the width of DBPlim and the height of the tank wall Hw the
deflection and stress are calculated with the following formulas:
0.036 p * ( DBP) 4
f = * ; f = f defl * DBPlim
DBP 2 E * Tw3
1+ ( )
Hw
1
DBPlim 2 4
3 1+ ( )
f defl * DBPlim * E * Tw Hw
DBPdefl = *
p 0.036


2
0.36 p * ( DBP)
= *
1+ (
DBP 2
) Tw2
Hw
DBP 2
1+ ( )
max * T 2
Hw
DBPstress = w
*
p 0.36

If one of the values of DBPdefl or DBPstress is smaller than the value of DBPlim,
the maximum distance between profiles is limited by the deflection or stress.
In this cased the value of DBPlim is equal to the smallest value of these two.
DBPdefl < DBPlim DBPlim = DBPdefl
If
DBPstress < DBPlim DBPlim = DBPstress

Distance Between Profiles

When the maximum Distance Between Profiles (DBPmax) is fixed, according to
the previous paragraph, the real DBP can be calculated. This DBP depends of
the number of reinforcements and the width of the profile.

The distance between profiles is calculated for three different scenarios,

namely:
1. There is only one reinforcement on the tank wall
Lw W p
DBP :=
2
2. The position of the profiles are not fixed and the remaining length is
equally divided by the number of plates (equal to number of
reinforcements +1)
Re inf
Lw W p
DBP := 1

(# Re inf + 1)
3. The distance from one or both sides of the corner to the first
reinforcement is fixed (e.g. placing of lifting lugs) in Corner Distance
Left (CDL).

Page 3 of 14
 Re inf
Lw W p CDL CDR
DBP := 1

(# Re inf 1)
CDL = DBPlim
CDR = DBPlim 2 * CoG

The displacement of CoG is assumed to the right. If CDR is smaller then 30 *

wall thickness, e.g. a big displacement CoG, then the CDR is set to
30* Wall thickness. This statement eliminates the stiffening of virtual
and negative length of the tank wall. CDR < 30 * Tw CDR = 30 * Tw

If the calculated DBP is bigger then DBPlim then the solution for DBP and the
profile is rejected because of restraints in stress or deflection in the
plate: DBP DBPlim

For scenario1 and 2 the remaining length of the tank wall, excluding the
width of the profile, is equally divided over the number of plates.
For scenario 3 however is chosen for a different approach. In order to be able
to calculate on the position of the reinforcements for placing the lifting lugs,
one of the reinforcements has to have a rigid position to calculate on the
positions of the others.
For an optimal solution, the position of the fist reinforcement is set to the
maximum value of DBP.

Required inertia
The reinforcements are welded on both long sides on the tank wall, on the
top to the frame and to the bottom plate with a certain construction. The
reinforcements are modelled as a simple beam, on side rigid and the other
side is free to move in longitudinal direction.
The deflection of a simple beam
with uniform load is

5qL4
= (Mechanics of Materials; Gere and Timoshenko)
384 EI
Since the maximum deflection is known, namely the maximum deflection
factor times the length of the reinforcement, the required inertia can be
calculated to make sure that the deflection is below the limits.
4
5 p * DBP * H p
I req := *
384 defl max * H p * E
The uniform load (N/m) of the simple beam is translated into the vacuum
load (N/mm2) times the DBP. This Ireq is the minimum value the combination
of the wall and the profile has to satisfy.

Page 4 of 14
Profiles
The inertia of the I and U profiles to the axis parallel to the length of the wall (Ix) can
be calculated as:
W p * H 3p
I profiles: I xp :=
12
Bend U profiles:
W p * T p3 Tp * (H p Tp )3
I xp := + 2*( )
12 12
Tp H p Tp 2
+ (W p * T p ) * (( H p ) y p ) 2 + 2 * (( H p T p ) * T p * ( y p ( ))
2 2

The inertia of the H- and equal L-profiles are given by the manufacturer in
numeric format.

Wall
The wall behind and beside the
reinforcement also prohibits the
reinforcement bending. That is why the
inertia of that part of the wall should be
included. It is assumed that at both sides
of the reinforcement the affective
prohibiting the bending of the
reinforcement by the wall will last for the
half of the DBP. The Inertia of the this part
of the wall is calculated as a simple plate
and the length of the plate is considered
as the width of the reinforcement and on
both sides taken the half of DBP into
account.

( DBP + W p ) * Tw3
Iw =
12

Neutral axis wall + profile

The Neutral axis of the combination of the wall and of the welded profile on
T
A p * (Y p + Tw ) + Aw * w
the wall can be calculated by: Y p + w := 2
A p + Aw

Total Inertia
The total inertia of the welded profile and the section of the wall, together
can be calculated as a superposition of all the calculated moments and their
contribution of moving their neutral axes to the neutral axes of the whole
combination:

Page 5 of 14
 T
Itot := I p + Iw + Ap *(Yp +Tw Yp+w)2 + Aw *(Yp+w w )2
2

The inertia of the section of one profile and the two plates on both side with
length DBP/2 has to be bigger than the required inertia for an allowable
solution.
5 p * ( DBP + W p ) * H p
4

I req :=
384 defl max * H p * E

I tot I req

Stress
For the calculation of the stress in the reinforcement the reinforcement is still
modelled as a simple beam, but the beam is clamped at both sides. The
stress is calculated with the following formula:
M
max = max
S
The maximum moment will occur at both ends of the beam. The maximum
moment has the following value:
H
( w)
q* Hw p * DBP * H w H w
M max = * 2 = *( )
2 2 2 4
p * DBP * H w2
max =
8* Sp
I xp
Sp =
max( y z ; H p y z )

The uniform load q (N/m) of the simple beam is translated into the vacuum
load p (N/mm2) times the DBP. The formula for the stress is rewritten to find
the minimal required moment of resistance. The required moment of
resistance is found when the maximum allowable stress in the profile occurs.
p * ( DBP ) * H w2
S req :=
8 * max
The moment of resistance of one profile has to be at the least the value of
Sreq to ensure the stress in the reinforcement is lower than the maximum
allowable stress.
S p S req
In the two previous paragraphs the calculations for the plates, DBP and the
profiles are discussed. These elements are dependent of the number of
reinforcements, the wall thickness, the width of the profile. The actual order
of calculations described above differs with the computer program. A detailed
impression of the several loops for the optimalisation of the weight can be
found in Appendix Flowcharts

Page 6 of 14
The wall thickness, number, type and dimensions of the profile and the
distance between the profiles are calculated and fixed. The next step is
making calculations for the assembly of the different tank walls with their
profiles. The assembly has to be checked for buckling and also the corner
welding between the different walls. Also the frame and the base plate have
to be designed after the walls and profiles are determined.

Buckling
Buckling in the vertical reinforcements, besides bending, will occur when
vacuum is applied to the tank. The calculation of the buckling is difficult,
because:
The Buckling force acts not centric in the reinforcement axes.
A free buckling length will not exist.

With a simplified method it is possible to calculate the buckling stress. This

method is based on the following assumptions:
The pressure works vertically in the center of the profiles
The profiles will carry all the pressure on the tank cover. Each profile
carries a fraction of that load according to the ratio Ap /Atotal. So it is
possible that the profiles of the short walls carry another fraction of
the load than the profiles of the long wall.
Re inf Long Re inf Short
Atotal = 2 * Ap + 2 *
1
A1
p

Since the profiles are fixed to the tank wall, tensional or lateral
buckling can be neglected. The profile can only bend or buckle in a
direction perpendicular to the tank wall.
The free buckling length is 0.75*Hw.
Buckling will not occur in plates of the walls.

With these assumptions the following formulas are valid (TOP 1.130.05). First
of all the aspect ratio is calculated. This aspect ratio is used in the
calculation of the buckling factor , which is used in the calculation of the
buckling stress.

Lk * H p A p * lim
= *
E*I p
1
=
0.5 + 0.532 2 + (0.5 + 0.532 2 ) 2 0.377 * 2

p * Acov er
buckling =
* Atotal
The buckling is most critical during the vacuum test. So the maximum
bending stress in the profile must be increased with the buckling stress to
prevent buckling:

Page 7 of 14
 p + buckling max
p * DBP * H w2
p =
8* S p

Welding
The corner welding between the tank walls is constructed like figure??. The
strength of this welding should be checked to be sure that the welding is able
withstand the vacuum load. The long wall extends beyond the welding
between the inside long side and outside short sidewall. The dimension of this
extension has no significant impact on the strength of the welding. Therefore
this extension is not included in the calculation method.

Checking the corner welding between the tank walls, it is assumed that the
welding strength is equal to the strength of the welded material. To avoid
stress concentrations and ensure the quality of the welding, it is necessary to
keep the difference 2 mm or less between the plate thickness of the long wall
and of the short wall small.

With these assumptions the stress components, tensile and shear stress, in
the welding can be calculated. In these calculations the Ratio Rw is used.
Combining the shear and the tensile stress will result in the actual stress in
the welding

Tws 3
CS + C 3L *(
3
)
Twl
Rw =
T
CS + C L * ( ws ) 3
Twl
q
tw = * (0.25 * C l arg e * Rw + 0.625 * T small * C 2 l arg e 0.125 * Tsmall * Rw
C l arg e * T 2 small
q
=w
* (0.625 * T 2 small 0.125 * R w
C small * T small

Tsmall T
welding = 0.125 * ( tw + w ) 2 * + 1.125 * ( tw w ) 2 * small lim
Tsmall + 1 Tsmall + 1

Page 8 of 14
Frame

The main load on the frame occurs when the cover is removed from the
frame. At the time the active part is still in the tank and the oil is nearly up to
the frame. The cover will not support that oil load anymore and the frame has
to support that load. This situation is the worst case loading of the frame.
Thereby it is assumed that the cover supports the vacuum loading and the
internal pressures during process.

The following assumptions is made:

Lw
The maximum allowable deflection of the frame, all , is: .
300
Otherwise localized buckling will occur.

Required Moments
oil * H w2
w=
600
w
I req = 2.602 *10 4 * * L2w * ( L2w + 4 * Lw *W w 4 *W w2 )
E * all

w
S req = 8.334 *10 2 * * ( L2w L w *W w W w2 )
lim

Actual moments of frame

Under loading the frame will undergo a deflection along the y axes (see
figure??) The actual moments are the following:
Plaatje plus tekst over om d

T fr *W fr3 T fr *W fr23
I= S=
12 6

Page 9 of 14
Base
Two types of bases exist; flat base and skid base. The first is just a thick
plate, while the last one is a thinner plate, but profiles are welded under plate
to ensure the strength and the stiffness.

Flat base
The base has to withstand the most severe loading condition of the following
occurring:
The lifting of the fully assembled transformer. The base has to
withstand the weight of the active part. The weight of the oil is
neglected, because it has a very small contribution to the pressure.
wc * (2 * c + b) * (4 * a *W w + 2 * bl * c + bl 2 )
p lifting =
W w4 L w
The vacuum loading. The loading will be not the pressure of 100%
vacuum, because the pressure of the active part will diminish the
pressure of the vacuum loading. The actual loading will be
p = pvacuum plifting

The worst case loading will be used in calculating the base thickness. It is
assumed that the stress will be the constraint. The formula for calculating the
stress in a plate (used in the calculating of the walls) is rewritten to find the
minimum required base thickness.
0.36 p * ( DBP ) 2
Tw = *
1+ (
DBP 2
) max
Hw

Skid Base

The standard rule for the baseplate of a skidbase is: max(Tshort , Tlong ) + 2

Total Tank
After the wall thickness, the type, number and dimensions of the profile are
fixed, the walls are checked on corner welding and the profiles on buckling
and also the bottom plate and frame are designed some general calculations
can be done for the total transformer tank. In this paragraph discusses
calculations on the area, total weight of the tank, total inertia and the position
of the Lifting Lugs.

Page 10 of 14
Area
The length and width of the wall is equal to the inner dimensions times the
wall thickness on both sides. The Area in x-y projection is equal to the area of
the tank inclusive the area of all the reinforcements on the walls.
Ltot := Lw + 2 * Tw short
Wtot := Ww + 2 * Tw long
Re inf Re inf
Atot := ( Ltot * Wtot ) ( Lw * Ww ) + 2 * ( A p short ) + 2 * ( A p long )
1 1

Weight
The total weight of the transformer tank is calculated in three subparts:

1. Wall and Reinforcements

Re inf_ long
Hw
Ww+ r _ Long = steel * ( Lw + 2 * Tw _ short ) * H w + 1 1000
* W p _ long
Re inf_ short
Hw
Ww+ r _ short = steel * (Ww + 2 * Tw _ long ) * H w +
1 1000

* W p _ short

With Wp is the weight of the profile per millimeter (kg/m)

2. Bottom plate
Wbottom = steel * ( Lw + 2 * Tw _ short ) * (Ww + 2 * Tw _ long ) * Tbottom

3. Frame
W frame = steel * T frame * (( Lw + 2 * Tw _ short + 2 * T frame ) *
(Ww + 2 * Tw _ long + 2 * T frame ) ( Lw * Ww ))
Total Weight:

Wtot = 2 * Ww+ r _ long + 2 * Ww+ r _ short + Wbottom + W frame

Total Inertia:
The Inertia of the total tank inclusive the reinforcements can be calculated as
the inertia of the tank walls on the x-x and y-y axis plus the inertia of all the
reinforcements and their areas translated to the x-x or y-y axis.
Wtot * L3tot Ww * L3w Re inf Re inf
I xx := ( ) + 2 * ( I p _ long + A p _ short * y ) + 2 * ( I p _ short + A p _ short * y 2 )
2

12 12 1 1

Ltot * Wtot3 Lw * Ww3 Re inf Re inf

I yy := ( ) + 2 * ( I p _ long + A p _ short * x 2 ) + 2 * ( I p _ short + A p _ short * x 2 )
12 12 1 1

The values for the total Inertia on both

axes can be used for the Seismic
analyse of the tank.

Page 11 of 14
Lifting Lugs
The Lifting Lugs are placed preferably on the vertical reinforcements to avoid
shear stresses in the tank wall. This means that the positions of
reinforcements are determined by the required position of the lifting lugs for
the lifting of the transformer.

From the left side of the tank, the first profile will be placed on the maximum
allowable distance (DBPlim) from the corner. The profiles between the first and
the last one will be placed on the following positions (from the left side of the
tank)
x 1 x 1
Position _ x = CDL + DBP + W p
1 1

Position _ Re inf = CLR

x {1, Re inf 1}
The last reinforcement will be placed on a rigid position (CDR), which is
determined by DBPlim-2*CoG.
For the lifting two different lifting Slings are used, namely 4,1 and 4,7 m.
Those Slings may not have an angle bigger than 600 with each other. If the
distance between de first and the last reinforcement is bigger than the length
of the sling, the lifting lugs are both moved one reinforcement to the next one
in the direction of the tank inside

If 2 * CoG > DBP then the program will place the last reinforcement outside
the dimensions of the tank. In that case the position of the Lifting Lugs have
to be calculated by hand.

Plate Stress
After a research for the stresses and displacements in a steel plate, on the
internet (eFunda) and in the Pauwels documentation two the same formulas
are found. The only difference is the constant dimensionless steel factor (
and ), which the stresses and displacements are multiplied.
p * ( DBP) 4 p * ( DBP) 2
f = * ; = *
E * Tw3 Tw2
The displacement and stress is plotted in the graphics below, the only
difference is the constant dimensionless steel factor. The displacement shows
a little difference between the two, the stress however shows a big difference
and more than 50 %.
The values used with eFunda are discreet and determined by a least Square
Method (Appendix xx

Maximum Distance Between Profiles

If the distance between the profiles is considered as a clamped plate, the
maximum dimension of this plate is limited by the deflection and the stress.

Page 12 of 14
 Tw max
Since DBPlim * and max and p are known values, the DBP only
0 .6 p
depends on the wall thickness and therefore: DBPlim 80 * Tw

For the maximal displacement also a same calculation can be made

1
DBPlim 2 4
3 1+ ( )
f defl * DBPlim * E * Tw Hw
DBPdefl = *
p 0.036


With DBPlim=80*Tw and DBPlim<<Hw
1
0,005 * 80 * Tw * E * T 1 + (max 0.1)
3 4
DBPdefl = w
*
p 0.036
1
1 + (max 0.1) 4
DBPdefl = 840000 * Tw4 *
0.036
DBPdefl 70 * Tw
This means that the maximum distance between the profiles is limited by the
deflection of the plate. The note has to be made that these are the limitations
of the model, the plate considered as clamped and a deflection factor of
0,5%.
With a Final Element Analyses has the real deflections to be checked but only
DBPlim 2
1+ ( )
Hw
the constant values of shall be modified to adjust to the real
0.036
situation.
Tw DBPmax
6
8
10
12

Seismic Analyse
In some projects there has a seismic analyse to be made. Therefore the total
inertia of the tank on xx and yy axes has to be calculated. Also the Area of
the tank is necessary to calculate on the stresses during an earthquake. In
those reports are the reinforcements neglected, which means that only the
area and inertia of the tank is calculated.
Depend on the number of reinforcements on the walls, the area including
reinforcements can be 2-3 times larger, the inertia with reinforcements can a
factor 10 or more be larger than without.

Page 13 of 14
For the calculation of the natural frequency of the total tank, the following
formula is used and means that, with a bigger Inertia, the frequency will be
higher than the case calculated without reinforcements.
1 8 EIg
f =
2 L3WT

In practice the frequency of tanks are bigger than the required 30 Hz for the
assumption the tank is rigid. With the calculation of the reinforcements, the
natural frequency will exceed the required frequency.
Because of the area is bigger, also the stresses will be lower than calculated
without the reinforcements.

Page 14 of 14