DESIGN CALCULATION OF SPREADER BEAM

DOC. NO. 3103/DS002-55-V-001/PV/CAL/002 Rev.2 DATE 11.06.12 JOB No: 3103

INDEX

CHAPTER No. DESCRIPTION PAGE NO

1 DESIGN OF SPREADER BEAM 1 to 5

 1. DESIGN OF LIFTING BEAM

1.1.DESIGN DATA

Empty Weight of Vessel = 16000 kg

(Ref drg No.(3103/DS002-55-V-001/PV/D/101)
= 16 MT

Total weight = 16 MT

Consider 15% Weight additional for design lifting lug

= 18.4 MT

Impact factor = 2

Design load = 36.8 MT

No of lifting lugs = 4 Nos

BEAM DIMENSIONS: A
A = 30.00 cm 1 B
B = 2.25 cm
C = 36.00 cm
C D 2
D = 31.50 cm
E = 1.25 cm E
F = 2.25 cm
3 F

PROPERTIES OF BEAM

center of gravity of the section Y = 18 cm

MOI of the Beam section I = I1 + I2 + I3

AB^3 2
I1 = + A1 x h1
12

A1 = 30 x 2.25
= 67.5 cm²
h1 = C-(B/2)-Y
= 36-(2.25/2)-18
= 16.875 mm

I1 = (30*2.25^3)/12 + (67.5*16.875^2)

= 28.48 + 19221.67969

= 19250.16 cm4

ED^3 2
I2 = + A2 x h2
12

A2 = 1.25 x 31.5
= 39.375 cm²

h2 = F + (D/2) - Y
= 2.25+(31.5/2)-18)
h2 = 0 mm

I2 = 1.25*31.5^3)/12 + (39.375*0^2)

= 3255.82 + 0

4
= 3255.82 cm

AF^3 2
I3 = + A3 x h3
12

A3 = 30 x 2.25
= 67.5 cm²

h3 = Y - (F/2)
= 18-(2.25/2)
h3 = 16.875 mm

I3 = (30*2.25^3)/12 + (67.5*16.875^2)

= 28.48 + 19221.67969

4
= 19250.16 cm

I = I1 + I2 + I3
= 19250.16+3255.82+19250.16
= 41756.13 cm4
MOI of the I Beam section = 41756.13 cm4
Length of Beam = 820 cm
Area of cross section A = A1 + A2 + A3
= (67.5+39.375+67.5)
= 174.375 cm²
MOI at center of beam I = 41756.13 cm4
Total area of C.A A = 174.375 cm²
Radius of gyration rY = SQRT(41756.1328125/174.375)
= 15.47 cm
Slenderness ratio l/ry = 820/15.47
= 52.99 cm
Section modulus Z = I/ Y
= 41756.13/18
= 2319.8 cm3

Ra 4.1 m Rb

45.000 45.000

A 8.2 m B
9.2 MT 9.20 MT

Total Lifting Load = 36.80 MT

Number of Lifting Beam = 2 Nos.

Lifting load / Beam = 18.40 MT

Number of lugs Lower side = 2 Nos.

Number of lugs Lower side / Beam = 2 Nos.

Load / Lug = 9.20 MT

Number of lugs Upper side = 2 Nos

Ra x Sin 45 + Rb x Sin 45 = 18.40 MT

Since due to symmetry in loading, mirror loads will be equal

0.707 Ra + 0.707 Rb = 18.40 MT

Taking the moments about A

0.707 Rb x 8.2 = 36.8 x 4.1

Rb = 75.44 /(8.2 x 0.707)

= 13.011 MT

0.707 Ra + 0.707x30.026 = 18.40 MT

0.707 Ra = 18.40 - 9.20

0.707 Ra = 9.20

Ra = 13.01 MT

Maximum compressive load = Ra Cos θ + Rb Cos θ

acting in lift beam
= 13.01 x cos 45 + 13.011 x cos 45
= 18.40 MT

Area of cross section provided = 174.375 cm²

Compressive stress developed in the beam = 18399.626 / 174.375

= 105.52 kg/cm²

Allowable compressive stress ( SA36) = 1602.99 kg/cm²

105.518 < 1602.994 Kg/cm2

Hence Safe
CHECK FOR BENDING MOMENT

Total Load = 18.40 MT

Bending Moment = Tot. Load*Length

4

= (18.4 x 8.2)/ 4

Bending Moment = 37.72 MT-m

= 3772000.0 Kg-cm

Allowable Bending Stress ( SA 36) = 1749.8 Kg/cm2

Section Modulus Required = Bending Moment

Allowable Bending Stress

3
Section Modulus Required = 2155.63 cm

Provided Section Modulus = 2319.8 cm3

2155.634 < 2319.785 cm3

Hence Safe

CHECK FOR DEFLECTION

Deflection = W*L3 Pressure vessel

(E*I) *48 Hand book
Eugene
where, W = 18400 kg F.Megyesy
Page - 456
E = Young's Modulus
2
= 2039432 Kg/cm

I = Moment of Inertia About X-X

4
= 41756.1 cm

L = 820 cm

Deflection = 2.482 cm

Allowable Deflection = L / 250

= 820/250
= 3.280 cm

2.482 < 3.280 cm

Hence Safe
 1.1 DESIGN OF LIFTING BEAM

CALCULATION FOR WELD STRENGTH CHECK FOR LIFTING BEAM

Reference - (1) ASME Sec VIII Div I Appendix.L7

DESIGN DATA

Material of Stub end,RF pad = A 36

Allowable stress for SA 516 Gr 70 = 1406.2 Kg/cm2

Maximum Vertical Load per Lifting beam = 18400.00 kgs

Case (I) : Vertical load

Load can be carried by Weld on beam

Length of lifting beam = 7000 x 20 thk mm

Length of Actual fillet weld in the region of web to flange

= 700.00 cm

Size of Fillet = 14 mm
weld
Allowable load = Length of weld x weld leg x Allowable Stress

= ((700)x0.707)x1.4x1406.2
= 974299.7 Kgs

= 974299.7 Kgs
= 974299.7 > 18400 Kgs
Since the allowable maximum Load is greater than maximum induced load the weld strength is safe
Case (II): Horizontal shear load

Stress value of welds

Fillet Weld = 49 % of allowable stress

Shear stress
= ((0.49x1406.2) Kg/cm2

= 689.038 Kg/cm2

Allowable Weld Shear of Beam

= Length of weld x weld leg x fillet weld shear stress

= ((700)x0.707)x1.4x689.038

= 477406.9 Kg

Maximum horizontal Load = 9790.44 kgs

Shear weld for Beam

Allowable weld 477407 kgs > 9790.44 kgs

Since the allowable weld shear load is greater than the horizontal seismic shear load the weld strength is safe
 1.DESIGN OF LIFTING LUG
1.1.DESIGN DATA
Empty Weight of Vessel = 16000 kg

= 16 T

Total weight = 16 T
Consider 15% Weight additional for
= 18.4 T
design lifting lug
IMPACT FACTOR = 2

Design load = 36.8 T

No of lifting lugs = 4 Nos

1.2. MATERIAL PROPERTIES OF LIFTING LUG

Material of lifting lug A 36

Yield strength fy = 2587.00 Kg/cm2
Allowable factors are taken from IS-800 =
Allowable tensile & compressive stress = 0.6 x fy
= 1552.20 Kg/cm2
Allowable shear stress = 0.45 x fy
= 1164.15 Kg/cm2
Allowable bending stress = 0.66 x fy
= 1707.42 Kg/cm2
NOMENCLATURE
P : Lifting force in kg
q : Angle made by lifting force with the axis in degree
F : Horizontal force in kg
R : Load on each lug in
M1, M2 : Bending moment induced in lug Kg-cm
t : Thickness of lifting lug in cm
w : Breadth of lifting lug in cm
ss : Shear stress in Kg/cm2
st : Tensile stress in Kg/cm2
sc : Compressive stress in Kg/cm2
sb : Bending stress in Kg/cm2
ssa : Allowable shear stress 1164.150 Kg/cm2
sta : Allowable tensile stress 1552.200 Kg/cm2
sca : Allowable compressive stress 1552.200 Kg/cm2
sba : Allowable bending stress 1707.420 Kg/cm2
 P = 36800
R = 9200 kg
q = 20 deg (assumed)
F = P x sin q
= 9200 x sin 20
= 3146.59 kg

R = P/ cos q
= 9200/cos 20
= 9790.4 kg

length of lug (l) = 10.0 cm R

q
thickness of lug(t) = 2.50 cm R 100 Dia 50

width of lug (w) = 31 cm

P
Outside Radius = 10 cm
Outside diamete(D) = 20 cm 100

Inside Radius = 2.5 cm

Inside diameter (d) = 5 cm 150 100
310
Weld joint efficiency = 0.5

1.3. CHECK FOR BENDING STRESS:

Section modulus of lug Z = 1/12 x t x w3

= 1/12 x 2.5 x 31^3
= 6206.46 cm3 t

Bending moment Mb = R*(l-d/2)

= 9790.44*(10-(5/2))
= 85666.4 kg-cm
w
Bending stress = Mb/Z
= 85666.35/6206.46
= 13.803 Kg/cm2

13.803 < 1707.42 Kg/cm2

Sb/Sa = 0.01
Hence Safe
1.4. CHECK FOR TENSILE STRESS:
t
2
A = (D/2-d/2)*t cm
= (10-2.5) x 2.5
= 18.75 cm2
D d
st = P/ A
= 9200 / 18.75
st = 490.67 Kg/cm2

490.67 Kg/cm2 < 1552.20 Kg/cm2

St/Sa = 0.316
Hence Safe

1.5. CHECK FOR COMBINED BENDING STRESS & TENSILE STRESS:

sb / sba + st / sta < 1

0.01 + 0.316 = 0.324

0.324 > 1
Hence Safe

1.6 .CHECK FOR SHEAR STRESS:

shear area = (D-d)*t

shear area = 37.5 cm2

shear stress = R/A

= 9790.44 / 37.5
= 261.078 Kg/cm2

261.078 < 1164.150 Kg/cm2

Hence Safe

1.7. CHECK FOR COMBINED SHEAR STRESS & TENSILE STRESS:

ss / ssa st / sta
+ < 1
0.22 + 0.316 = 0.540
0.540 < 1

The Provided Lifting Lug size is Safe

1.8. WELD DESIGN FOR VERTICAL LOAD:

Length of weld ( L ) = (31 x 2) + (2.5 x 2)

= 67.0 cm

Fillet dimension ( fd ) = 3.0 cm

Throat dimension ( f ) = 0.707 * fd

= 2.121 cm

Area A = L*f
= 67 x 2.121
= 142.107 cm2

Stress , Stw = P/AE

= 9200 / (142.107 x 0.5)

= 129.48 Kg/cm2

129.480 < 1552.200 Kg/cm2

Hence Safe

1.9. WELD DESIGN FOR HORIZONTAL LOAD

Shear Stress = R/AE
= 9790.44 / (142.107 x 0.5)

= 137.790 Kg/cm2

137.790 < 1164.150 Kg/cm2

Hence Safe
 Ixx Ixx
w

thickness of lug t = 2.5 cm

width of lug w = 31 cm

Throat dimension f = 2.121 cm

Moment of inertia:
Ixx = 2*(tf^3/12+(tf)*(w/2)^2))+2*(f/12*w^3)

= 2 x (2.5 x 2.121^3/12) + (2.5 x 2.121) x (31/2)^2) + 2 x (2.121 /12 x 31^3)

= 11809.020 cm4

Bending stress in the weld

sb = (Mb*Y)/Ixx

y = w/2
= 31/2
= 15.5 cm

Mb = Fxy
= 3146.59 x 15.5
= 48772.1 kg-cm

sb = (48772.145 x 15.5)/11809.02

= 64.0 Kg/cm2
= 128.0 Kg/cm2 (including a joint efficiency of 0.5)
Maximum Shear stress in the weld
τ = ( (sb)^2) / 2+Stw^2

= sqrt [(128.04^2 /2) + 129.48^2 ]

= 158.0 Kg/cm2
157.994 < 1164.150 Kg/cm2
The Provided weld size is Safe