Design Calculations for Lifting of Screw Pump

DESIGN CALCULATIONS FOR

LIFTING OF EXISTING SCREW PUMP

CLIENT : PUBLIC UTILITIES BOARD

SUBMITTED BY : M/s SANLI

PREPARED BY : PRAFUL J DESAI

DATE : 14th FEBRUARY 2022

 Design Calculations for Lifting of Screw Pump

Calculations of Existing Screw Pump

The existing screw pump has to lift up from the trough. It is proposed to lift the pump
from 2 points on the pump as shown. Holes of dia 45 mm are cut on the pump and 2
nos of circular plate of 100 mm diameter and thickness of 10 mm are welded to
reinforce the flight plates. Another reinforcing plates of 10 mm thickness are provided
between this circular plate and edge of flight (approx 20mmL) on both sides

Weight of screw pump= 8227 Kg

Distance between the 2 lifting points= 6m
Wire rope used to lift pump = 8m

1) Determine the Loading at Lifting Points

Weight of screw pump (include bearings etc) =9000kg = 88 kN

There are 2 wire ropes to lift the pump
Vertical component of the tension along the wire rope = 88 kN/2 = 44 kN.

We determine the loading when pump is on horizontal position, both the inclined
length will be 8 m long

The angle of each rope = cos β = 3/8 = 0.375, Hence β = 68

With this we can work out the tension in the rope and the forces on the lifting lug/
Tension in the wire rope = vertical force /sin β
= 44kN/sin 68
= 44/0.9272 = 47.45kN

With this we can work out the tension in the rope and the forces on the lifting lug.

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 Design Calculations for Lifting of Screw Pump

CALCULATION OF LIFTING LUG CAPACITY        

Material Properties            
Yield strength, Fy         275 N/mm2
Young's modulus of steel         210000 N/mm2
Weld ultimate strength, E70XX Electrode (for calculation purposes),
Fu         450 N/mm2
Allowable weld stress, Fws = 0.3*Fu         135 N/mm2
             
Loading Detail            
Load factor on dead load, LF         2  
Maximum upper sling load, SU         48 kN
             
Static load:            
Centre of Gravity shift factor, SF         1.1  
Static lower sling load, SLS = SL*SF*LF         106 kN
             
Rigging            
Consider Grade 1960 6x36WS-IWRC ropes and G-2130 shackles.
Refer Catalog            
FOS on MBL to static sling load,         2  
           
Rope diameter RDL = 24 mm      
MBLL
Rope MBL = 310.9 kN      
SWL = MBL/FOS   155 kN      
SWL > Static sling loads?   OK         OK
             
Shackle WLL SHL = 25 T      
  = 245 kN      
WLL > Static sling loads?   OK         OK
             
Shackle Properties            
Pin diameter pdL = 51 mm      
Jaw width jwL = 73 mm      
Inside length ILL = 178 mm      
             

             
             
             
             
             
             
             
             
             
             

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 Design Calculations for Lifting of Screw Pump

Lifting Lug on screw pump          

Yield stress, Fy   275 N/mm2    
Maximum factored lower sling load, SL   106 kN with load factor on dead load, LF & SF (2 x 1.1)
Consider sling angle of Ø   68 degs and sling out-of-plane angle of 0 degs
           

         
           

Lifting Lug plate Properties     Stiffener Properties    

Hole diameter, DH 55 mm Stiffener thickness, ts 0 mm
Pin diameter, DP 51 mm Ls 0 mm
Hole centre above base, H 98 mm ws 0 mm
Main plate length, L 240 mm yc = L/2 120 mm
Lug plate Thickness, T 25 mm Edge from centre Lug in x, eSX 12.5 mm
Radius Lug plate, RP 42 mm Edge from centre of lug in y, eSY 120 mm
Cheek plate 1, t1 24 mm  
Cheek plate 2, t2 24 mm  
Radius cheek plate 1, RC1 42 mm  
Radius cheek plate 2, RC2 42 mm  
Cheek plate weld 1, TW1 8 mm  
Cheek plate weld 2, TW2 8 mm  
Lug base weld(x2), TWP 8 mm  
Lug thickness, Tpad = (T+t1+t2) 73 mm  
Half of Lug section to hole,Hm 120 mm  
       

Chain Block Properties

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 Design Calculations for Lifting of Screw Pump

The general effort force equation for a

block or tackle to raise or pull a load
can be expressed as

PL = SLs / (μ n)
mechanical efficiency of the system (μ) 0.8

Number of block rope or chain (n) 4

PL = SLs / (μ n) 33.125 KN
Choose 10 ton capacity 4 rope chain
block with Grade 43 grade chain as
shown in below catalog

Wire Rope properties

Lifting Lug - Plate check                

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 Design Calculations for Lifting of Screw Pump

Geometry Checks              
Pin diameter, DP 51 mm < Hole diameter, DH     55 mm OK
DP - DH 4 mm ≤ 5mm allowance     5 mm OK
The main plate radius, 42 mm
Sum cheeks (one side) 24 mm < main plate thickness     25 mm OK
Padeye thickness, Tpad = (T+t1+t2) 73 mm < 80% of shackle jaw width     58 mm OK
      < jaw width - 5mm     68 mm OK
Radius Lug plate, RP 42 mm   Sling diameter, RDL     24 mm
Pin diameter, DP 51 mm   Allow tolerance, e, 10%*IL     18 mm
Rp - Dp/2+RDL+e 58 mm < Internal length     178 mm OK
                 
Padeye Strength Checks                
Sling
Factored lower sling load, SL     106 kN angle 68 degs
Out of plane sling angle     0 degs      
Total out
of plane
angle
Additional out of plane as per API (Ag)     5 % (OPL)   2.9 degs
OPL = ASIN(Ag/100)*180/   = 2.9 degs   = 5 %
Contact Stress/Hertz Pressure                
σHertz = 0.418 * ( (SL * E * (DH/2 - DP/2) ) /
(Tpad * DH * DP /4) )0.5             389 N/mm2
Allowable hertz pressure = 2.5*Fy             687.5 N/mm2
            UC 0.57   OK
Bearing Stress                
Bearing area, Ap = Dp*(T+t1+t2)             3723 mm2
Bearing stress, fp = SL / Ap             28 N/mm2
Allowable bearing stress, Fp = 0.9*Fy             247.5 N/mm2
            UC 0.11   OK
Pullout Shear                
Shear area = Av = (T*(RP-D/2) +t1*(Rc1-
D/2)+ t2(Rc2-D/2))             1058.5 mm2
Pullout shear stress, fv = SL / Av             100 N/mm2
Allowable shear stress, Fp = 0.4*Fy             110 N/mm2
            UC 0.91   OK
Tensile Stress                

Tensile area, At = Rp*T           1050 mm2

Tensile stress, ft = SL / At         100.57 N/mm2

Allowable Tensile stress, Ft = 0.6*Fy             165 N/mm2
            UC 0.61   OK

Lifting Lug - Plate on Screw pump              

Lug Plate              

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 Design Calculations for Lifting of Screw Pump

Factored lower sling load, SL 106 kN Sling angle (Ø 68 degs

Fv = SL * sin θ   98 kN Fh = SL * cos Ø   39.558 kN
FOPL = SL * OPL   5 kN        
Section properties              
Area, A = L*T + 4*Ls*ts   6000 mm2 Shear area, Ayy = L*T   6000 mm2
Ixx = T*L3/12+4*Ls*ts*eSY2   3E+07 mm4 Sxx = Ixx / (yc)   240000 mm3
Iyy = L*T3/12 +4*(ts*Ls3/12+Ls*ts*eSX2)   312500 mm4 Syy = Iyy / (T/2+ws)   25000 mm3
Hor. half of
padeye section
Hole centre above base, H 98 mm to hole, Hm     120 mm
Mxx = Fh*H - Fv*(Hm-yc) 3876.7 kN.mm          
Myy = H*FOPL 517.44 kN.mm          
               
1. Shear stress              
Shear stress, fvx = Fh / Ayy           7 N/mm2
Allowable shear stress, Fvx = 0.4Fy           110 N/mm2
         Utilization Factor UF 0.06   OK
2. Tensile stress              
Tensile stress, ft = Fv / A           16 N/mm2
Allowable tensile stress, Ft = 0.6Fy           165 N/mm2
  Utilization Factor        Utilization Factor UF 0.10   OK
3. Bending stress              
Allowable bending stress, Fb = 0.6Fy           165 N/mm2
In-plane, fbx = Mxx/Sxx           16 N/mm2
Out-of-plane, Myy/Syy           21 N/mm2
         Utilization Factor UF 0.13   OK
4. Combined stress ratio, ft/Ft +
(fbx+fby)/Fb           0.27   OK
               
5. Combined von Mises              
Von Mises stress, fc = ((ft+fbx+fby)2 +
3*fvx2)0.5           54 N/mm2
Allowable combined stress, Fc =
0.66Fy           181.5 N/mm2
         Utilization Factor UF 0.3   OK
               
6. Welding Strength at joint              
Welding Length, WL = 2L           480 mm
Welding Strength, Ws = WL*Fws* Twp  (Fws is Allowable welding stress)     518.4 KN
Lifting Load, Su           106 KN

         Utilization Factor UF 0.20   OK

Welding Strength capacity is higher than Maximum Lifting load 

Lifting Lug Plate’s Shear stress, Tensile stress, Pullout Shear, Combined stress, combined von Mises and Welding
Strength at joint are checked and it is safe