SÒPHIA HIGH TECH Experience on Special Doors_compressed.pdfPag. 1
In this document are described the experienced gained by SÒPHIA HIGH TECH in the development of special doors.
1 Nuclear Bunker doors for Extreme Light Infrastructure - Nuclear Physics (ELI-NP) Customer: STRABAG (Romania Plant); Object: SÒPHIA HIGH TECH designed, developed, manufactured and installed eleven (N°11) motorized bunker doors in the Extreme Light Infrastructure - Nuclear Physics (ELI-NP), Situated in Magurele, 12 km away from downtown Bucharest.
Figure 1 ELI-NP in Magurele
ELI-NP project [ http://www.eli-np.ro/ ], financed by the European Commission for Research, Innovation and Science, started in 2008. The job activity for SÒPHIA HIGH TECH involved the design and the manufacturing and installation management of eleven (N°11) automated bunker doors. the bunker doors differ in 3 different types
Object SÒPHIA HIGH TECH Experience on Special Doors
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1. DGR1 consists of a door of dimensions 3000 mm x 2550 mm x 2790 mm made of cement reinforced with metal reinforcement. The door has a single degree of freedom, represented by the translation along an axis. The assembly can be viewed below.
Figure 2 DGR1 door - rendering
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2. DGR4 consists of a door of dimensions 4550 mm x 2000 mm x 2925 mm made of cement reinforced with
metal reinforcement. The door has a single degree of freedom, represented by the translation along an axis. The assembly can be viewed below.
Figure 6 DGR4 door - rendering
on this link [ https://www.youtube.com/watch?v=cTRtH2yCRKI ] is possible appreciate the manufacturing and assembly phase carried out by SÒPHIA GH TECH for DGR4 door
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3. DGR7 consists of a door of dimensions 6000 mm x 4500 mm x 2050 mm made of cement reinforced with
metal reinforcement. The door has a single degree of freedom, represented by the rotation around an axis. The assembly can be viewed below.
Figure 9 DGR7 door - rendering
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Figure 11 DGR7 door installation (2)
Main tasks of the DGR 1/ DGR 4/ DGR 7 projects are: 1. Management: creation of the master planning of the supply. 2. Design of the doors, this phase has concerned the following activities: a. Design and Sizing of the structures; b. Static analysis and verification of the welds and Doors Frame through Finite Element Method (FEM); c. Design, Sizing and Verification of the kinematic mechanism for the opening/closing operations.
d. Creation of the executive drawing and BOM; e. Draw up and issue pertinent the Use And Maintenance Manual.
3. Manage of: a. Manufacturing; b. Material Supply; c. Shipping of the products;
d. Installation.
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The Project Manager defined each activity timeframe, the deliverables and the work packages at the start of the job. The design phase took into account the requests of the client and the requirements. After a first attempt design a numerical (using FE methods) validation ensured the static and dynamic integrity of the structure when subjected to the working loads. After FEM review the Design was updated and then validated again. This interactive phase continued until a structural optimised design had been reached. The next phase was the creation of the drawing and the BOM, these were needed to manufacture the parts, guide the installation procedures and manage the material supply. During all the phases of the project, SÒPHIA HIGH TECH managed all the process involved in the supply. Our supervisor came in Romania to ensure that the delivery and installation operations had been made according in the best practice and Customer requirements. We ensure, through our technical knowledge, an effective approach to the design of a Custom Security Door. This Technical Report will describe the process and the main activities for design, manufacturing and installation of anti-burglar door. The " Nuclear Physics Center of Magurele" experience gave us the right know how and confidence at our best the Z
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2 CLASS 5 Anti-Burglar & Antimissile Door (USACE - US Army Corps of Engineers) Customer: STRABAG US Army (Romania Plant); Object: Design, development, manufacturing, assemby, validation, insallation and qualification of 5.7 CLASS 5 Anti-Θ&h- Romania). VIDEO: https://www.youtube.com/watch?v=N_kriRVVXYg&t=4s
Figure 12 : CLASS 5 Anti-Burglar & Antimissile Door
The design process took place considering the technical requirements of the customer and according to the standard rules of structural design for the US defense: 1. DOD Manual 6055.09-M [Ammunition and Explosives Safety Standards] 2. NATO AASTP-1 [Safety principles for the storage of military admissions and explosives] 3. ASTM F 2927 - 12 [Door Systems Subject to Airblast Loadings] 4. ASTM F2247 [Metal Doors Used in Blast Resistant Applications (Equivalent Static Load) Method] 5. UFC 4-010-01 01 [Structures to resist the effects of accidental explosions] 6. CEI EN 60204-1: 2006 [Safety and Prevention] The characteristics of the anti-missile door are: 1. 6500 mm (length) x 4500 mm (width) x 200 mm (thickness); 2. Weight of the door: 6 tons; 3. Blasting resistance for 7 bar; 4. Material: galvanized steel, checked against impact and shock load; 5. Smart Lock of the NSN type 5340-01-585-7691.
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6. Door Type: Double Leafs, rotational 7. Moving: completely manually; 8. Weight of the door: 13.5 tonn; 9. Opening Rate: 5 times/day; 10. Warranty: 5 years; 11. Operating temperature: -40°C to +60 °C; Following the WP (Work Package), carried out: WP1 | Management, In this phase will be prepared the master planning of supply. SLPHIA prepares and keep updated the master planning of supply. After the KoM (Kick off Meeting), the planning is processed with the Contractor to allow a full control of supply WPs. Furtherly, the master planning is monthly reviewed by the Project Manager of SLPHIA HIGH TECH, who issues a synthetic progress report. In the management activities (WP1) are provided the main documents process control and product quality related, including the FEM specification according to DOD 6055.09-M & NATO AASTP-1. After the KoM the mechanical design is started. The Design Lead provides: 1. The first revision of assembly drawings, installation drawings and the datasheet of auxiliary 2. components; 3. The first revision of detailed drawings and structural inspections reports; 4. The first revision of the provision in the field of instrumentation; 5. Reports of structural inspections. After the design approval, received by the STRABAG, SLPHIA purchase row materials and standard parts, provided by BOM and Drawing set. Meanwhile the Production Manager compiles the working cycles for the production of the items. The following step provide the production of the doors. Manufacturing phase implies monitoring and testing of quality as specified by the Quality Manager. Before shipping the design department provides the installation procedures and all files necessary to complete the final assembly. Supplier ensures preparation of the operation and maintenance manual for the door provided, which will be completed after its installation. WP2 | CAD Design, Structural FEM, Implementation of the requirements and creation of the concept design of Antimissile Door, using CAD software. Validation of the model through FE (Finite Eement) method (static and dynamic), using FEM software. All the designed elements of the assembly are verified to complain the requirements: DOD 6055.09-M & NATO AASTP-1. Static analysis of the metal framework and Dynamic Analysis (non-linear) of the explosion in order to certificate the door for 7 bar blast resistance are carried out, according to ASTM F 2927 12 rule.
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Figure 13 : Internal side view of the anti-burglar door assembly
Each door is equipped with 3 adequately sized hinges (following figure). The right one (outside view) locks the left leaf (outside view), so the latch of the door leaf can only be moved from the inside.
Figure 14 : Hinges details
The door assembly is designed for closing with 2 padlocks for military use supplied by the customer. The previously mentioned padlocks are housed in a moving system (on the right leaf) which prevents, in the "Close" position, the rotation of the leaflet-opening bolt of the Right leaf. The aforementioned moving system is equipped with specific shielding.
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Figure 15 : Latches structure
After the definition of all the components, the behaviour of the structure under the working load is verified through static FE analysis, according to ASTM F2247 [Metal Doors Used in Blast Resistant Applications (Equivalent Static Load Method]. The principle of the finite element analysis (FEA) is to subdivide a large problem into many smaller ones; this simpler method divides the body in a large number of finite elements (mesh). The simple equations that model these finite elements are then assembled into a larger system of equations that models the entire problem. This method permits to simulate the behaviour of the structure under working load and constraint condition. Following an example of FE model (mesh with working load and constrain).
Figure 16 : Boundary Condition (constrain and load) of the Antimissile door
Static analysis, in the FEM environment, verifies the integrity of the door and the distribution of stress/displacements when the structures is under the working load.
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Figure 17 : Map of displacements for the verification on the Antimissile door
The FEM analyses is performed using following software:
1. MSC Software PATRAN (pre-processing and post-processing) 2. MSC Software NASTRAN (static/dynamic processing) 3. MSC Software ADAMS (kinematic and Dynamic processing) 4. MSC Software MARC (non-linear processing). Output of this process is a report showing:
5. Stress plot of each loading condition; 6. Ratio to requirements value between FEM and requirements. Dynamic simulation is the impact test with explicit numerical methods. The Analysis is used in order to verify the 7 bar blast resistance of the antiex door, according to ASTM F2927-12 (Standard Test method for Door Systems Subject to Air blast Loadings). For the modelling of impact phenomena on antiex door, following steps are performed: 1. Pre-processing: starting from the CAD model, in this phase (using MSC software Patran), the structure is subdivided into a finite number of small parts ("mesh" of elements). it is necessary to choose the most appropriate type of mesh element (membrane, shell, solid, rod, etc.) as well as the material for each part of the model. Moreover, are applied the loads and constraints according to the project requirements and the ASTM F2927-12 and ASTM F2247 reference standards; 2. FEM Simulation: in this phase the model is transferred to the dynamic solver. After assigned to the elements the geometric properties and the mechanical and thermal properties of the materials, a numerical algorithm solves the problem being analysed by constructing the stiffness matrix of the entire structure. The output of the analysis is represented by the displacement field that undergoes the constrained structure, due
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to the blast load. The software automatically calculates the distribution of stresses and strains starting from the calculated displacements. This phase is performed using MSC software MARC; 3. Post-processing: the output file is analysed using the post-processing software (such as LS- Prepost and MSC Patran). Through these codes it is possible to extract the values to be compared with the admissible ones to verify the integrity of the structure. Following it is possible to appreciate the results.
Figure 18 : Impact Door Analysis Sequence on Antimissile door
In the verification of impact on metal components, two comparisons are used: plastic deformation at break (or elastic) and the relative plastic energy (elastic). This technique allows to evaluate the structural integrity and the amount of energy dissipated by innumerable elements.A further example of impact analysis, due to the explosive load, is shown in following figure. The simulation allowed to verify the behavior of Antimissile door subjected to the pressure wave generated by an explosion triggered in the vicinity of the same.
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Figure 19 : Antimissile door subjected to the shock wave generated by an explosive load
Through these analyzes, the stress of the Antimissile door is checked as a function of time. The following image reports the variation of the Von-D
Figure 20 : Variation of the von Mises equivalent stress over time on the Anitmissile door under blast load
WP3 | Kinematics Analysis, After the analysis the final CAD geometry of the antiex door is designed. A virtual kinematic analysis, according to DOD 6055.09-M & NATO AASTP-1, is used to define, validate and certificate the opening/closing of the door leafs. In this phase the validated 3D geometry is build. WP4 | Drawing set, BOM (Bill of Material) and the technical drawings, needed for manufacturing and assembly the parts, are carried out. Creation of Use and Maintenance Manual of Antiex Door (it will be finalize in the WP7). WP5 | Manufacturing, In this WP, SLPHIA performs the construction of details and assembly parts according to: 1. Assembly drawing approved by the Client;
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2. Production cycle drawn by Production Manager; 3. Planning of supply. Mechanical machining and surface treatments will be carried out in accordance with the technical specifications. In the manufactory WP it will be built the necessary number of doors for the delivery to the Clients. The manufacturing Process is transferred to the mechanical construction area and then to the mechanical workshop area. The mechanical construction area uses specialized workers that, starting from the geometrical information concerning the parts to be made, process the optimal sequence of operations that must be performed by metal machining. The sequence is then translated into a series of instructions that are transmitted and used by machines for the automatic production of the piece. The Workshop area is equipped with a room with instrumentations and precision equipment which ensure the compliance of the product during the production process. The company employs the following skilled metalworkers: 1. crimping machines operator, 2. pre-testing and testing benches operator, 3. pallet assembly operator, 4. welding and prototyping operator with International Welding Institute and TUV Qualification. WP6 | Checks, inspections and tests, SLPHIA HIGH TECH performs all inspections and tests required to ensure the quality of the products and the qualification needed. All the inspection test are performed according to DOD Manual 6055.09-M [Ammunition and Explosives Safety Standards] and to NATO AASTP-1 [Safety principles for the storage of military ammunition and explosives]. In particular, the following checks are performed: 1. visual inspection and dimensional checks; 2. testing of materials and treatments used; 3. checks on welds; The Quality Manager writes the "Test specifications" documents, which will be submitted to the Customer. In this document, for each type of test, it will be described the methods, the means employed and the acceptance conditions. The tests for the certification of blast-resistance will be executed by a certified software and explicit FEM solver. The output of this work packages are: 9 Internal Test Specifications Documents; 9 Blast Resistance Certification. WP7 | Documentation and Reporting, The Structural FE Analysis and FE Test Result Report are written. Validation and release of the Use and Maintenance Manual. SLPHIA Project Manager, in course of execution, creates and manage all specified documentation. At the end of the activities SLPHIA shall collect in a "Dossier of End Manufacturing "all the documents produced in the course of the activities, i.e.: 9 Test reports; 9 Installation drawings; 9 Material quality report; 9 Use and Maintenance Instructions. The Use and Maintenance Manual is part of the product and must accompany it for all its life. WP8 | Packaging, Shipping and Installation to the site of the door.
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Planning the shipping of the components. In situ installation of the door, opening and closing validation. In this case, SLPHIA HIGH TECH anticipate the supply of Counterframe to be installed before the door. Then, a team of four workers composed by metalworkers, welders and engineers installed the antimissile door in the construction site. The Program Manager monitor the installation on site for the entire endurance of the work.
Figure 21 : CLASS 5 Anti-Burglar & Antimissile Door, installed in FETESTI (Romania)
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3 Anti-missile doors for EUREX plant Customer: SAIPEM (ENI GROUP); Object: SÒPHIA HIGH TECH designed, developed, manufactured and installed (N°15) anti-missile doors and gates for process and storage buildings. At the EUREX plant (Saluggia, in Italy), liquid waste from the reprocessing of fuels irradiated in MTR and CANDU reactors is currently stored. Following the category of the doors
Model #1 E1, E2, E3
Model #2 E6,E10
Model #4 E7, E11, E15
Model #5 E4, E9, E13
Table 1 anti-missile doors models
The verification and qualification took place in the FEM environment. The structural verifications were performed by means of finite element analysis and analytical calculations. In particular, dynamic nonlinear dynamical analyzes were carried out, with which the phenomenon of impact was simulated realistically, and linear, nonlinear, equivalent static analyzes, with which the different parts constituting the doors and gates were verified. : doors, hinges and frame. Following the example concerning the E1 door model.
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Figure 22 anti-missile doors E1 model
Modeling of anti-missile doors was performed using the MSC PATRAN software. The calculation models employ two-dimensional four-node elements (QUAD4) with 6 degrees of freedom per node, with membrane and flexural behavior to represent the outer mantle of the doors, the stiffening plates and the profiles. The closing posts have been discretized with two-dimensional monodimensional elements, with 6 degrees of freedom each.
The nodes in correspondence of the welded connections between the different components were connected by rigid elements or by equivalence operations (union of several overlapping nodes). The model FE (Finite element) is shown below:
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The following figure show the von-mises tensions distribution (equivalent tension) for one of loading case
Figure 24 anti-missile doors E1 model: FEM results
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4 MSA Anti-Blast / Anti-Explosion Doors with high impact resistance according to USACE STD 421-80-13
Customer: USACE US ARMY CORPS OF ENGINEERS (EUROPE DISTRICT) Object: SÒPHIA HIGH TECH designed, developed, manufactured and installed (N°2) Anti-Blast / Anti- Explosion Door for COSTRUCT MUNITIONS OF STORAGE AREA, located in the military base of CAMPIA TURZII (EU - Romania).
Anti-Blast / Anti-Explosion Door with high impact resistance, according to USACE STD 421-80-13
Dimensions 7820 mm (length) x 4900 mm (height) x 230 mm (thickness)
Weight 13.5 tons Opening mode Right side
Typology One single Door sliding on Structural frame
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Design and Manufacturing has been developed according to the following Standard Regulations: DOD 6055.09 - Ammunition And Explosives Safety Standards USACE Design Manual
USACE STD 421-80-13 European Version NATO AASTP-1 - Manual of NATO safety principles for the storage of military ammunition and
explosives
UFC 3-340-02 - Structures to resist the effects of accidental explosions UFC 4-010-01 01 - Minimum Antiterrorism Standards For Buildings ASTM F2927 - Standard Test Method for Door Systems Subject to Airblast Loadings
Design models, created according to USACE STD 421-80-13, has been developed in compliance to the DWGs: S-201; S-202; S-302; S-303; S-505; S-701; S-702; S-703; S-704; S-704(A); E-103; E-104.
General Features
Actuation System
Automatic control. The door kinematic is equipped with: Electric engine auto-braked 2,2 Kw, 4 Poles, 50 Hz 230/400V, 1400 rpm
commanded by a main board. Engine Reduction with a Gear Ratio 1/125 Gear/Rack System to assure an opening/closing speed in the range of 4-5.5
m/min The system is equipped with a Manual Brake Release System and a Manual opening/closing door Handling System.
Locking System
Manually operated using a Padlock. Padlock: Sargent & Greenleaf (S&G) 951 Padlock - Type NSN 5340-01-585-
7691 (not included in the furniture) [https://securitysnobs.com/Sargent-Greenleaf-S-amp-G-951-Padlock.html]
Hasp: Sargent & Greenleaf 833/951 NAPEC Padlock Hasp [https://securitysnobs.com/Sargent-Greenleaf-833-951-NAPEC-Padlock- Hasp.html] Right Handed (ITEM 0957), according to door opening mode
Security Equipments
External Totem Warning Lights Photocells (4 couples) Mechanical Safety Edge (2 Front and Rear) Deceleration and Stopping Swithces Internal and External Emergency Arrest Button
Quality Requirement
Quality Management System EN 9100:2009; Welding Quality Requirements ISO 3834; Welding Procedure Qualification Record ISO 15614; Welders with approved test certificated in accordance with EN ISO 9606-
1:2013 NDC Operators qualified at the level 2 according to EN ISO 9712:2012
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Engineering 2D Assembly Drawings in *.PDF Static Analysis certified by FEM software (MSC Nastran) Digital Mock Up of the structure
Procurement EN 10204 type 3.1 material certification
Manufacturing & Shipping
Manufacturing of Part and Assembly according to drawings approved by the Client;
Internal and external (in the certified laboratories) inspections and tests required to ensure the quality of the products and the qualification needed;
Packaging, Shipping and on-site Installation.
Documentation
CE certification Use and Maintenance Manual according to Standard regulation Basis of Design and Calculations REport 2D Assembly Drawings (*.PDF)
Door
Material
Steel S355 J2+N EN 10025-2 Metal Sheet min. thickness 15 mm Internal structure made in Square-shape 200x200 mm profiles of 12.5 mm
thickness
Sandblasting grade SA 2,5 Zinc layer: Inorganic two-/
(EN ISO 1461 nominal zinc content at least 99,5 EN 1179:2005) Epoxi-polyamide two-component layer (i.e. Intergard 475HS) thickness layer
50:75µm RAL 7013 - Double layer of protective paint; min thickness 100 µm
Fixing Type Anti-Blast Door is hanged to the IPN 400 by 4 Trolleys of 5 tons weight size.
Frame Material Structure made of carbon steel Steel S355 J2+N EN 10025-2
Surface Treatments and Finishing
Sandblasting grade SA 2,5 Zinc layer: Inorganic two- /
(EN ISO 1461 nominal zinc content at least 99,5 EN 1179:2005) Epoxi-polyamide two-component layer (i.e. Intergard 475HS) thickness layer
50:75µm RAL 7013 - Double layer of protective paint; min thickness 100 µm