Transmittal Record Jab: Contr No, CV200009 Inst for Penns Bay Developmen CurRet ; sPTopos7rLoogts cont baie: 08103 Ione to: Mr €-E-€h- China State Kit CHAN [tia 6V7 2000709 ao epetoo roo ec: TTT (w/o) one CEIVED Dear Sir, Please find enclosed the following : No.of Document Reference Copies pees Drawing No. (Revision) ae 1 | Hydrate Winch 90t- Calculation Note 1PT02095/PP:PT/1252 (Rev. 0) 05-30-03 Status: For Certification Remarks: Please send that document to ICE Issue Approval : (Please contact the undersigned regarding content of above documents, if required). ‘Name Position =Signaire Dae Coniat No Pascal Burtet Project Manager x 8-1uL-03 2983-6261 Transmital By Name Postion Signanre Date Conci No sya Sin secretary So sito | 2083-0061 lease confirm receipt and rum tis page 0 Ms, Sylvia Sun (Fax Nos 2985-6520) Received By Signature / Company Full Name Chop Date» INFRASTRUCTURE FOR PENNY’S BAY CONTRACT 4 4PTO2 095 SOF [Contractor: CHINA STATE CONSTRUCTION ENGRC.(HONG KONG )LTD 0 | 50708 First sve Rev | Date PROJECT: Description Prepared INFRASTRUCTURE FOR PENNY’S BAY DEVELOPEMENT CONTRACT 1 Maunsell CONTROLLED [TITLE = HYDRAULIC WINCH 90t CALCULATION NOTE DOCUMENT NO.: 1PT02095 PP PT/1252 rev 0 Prepared Checked: COMTEC cvE Date: Date 05-06-03 05-07-03 Signed: a 7 rae Copan Reeves This documents the property of VSL and must not be copied, reproduced, duplicated no disclosed totally or patallyt any Tied ary, nor used in eny miner yhatsoever without prior writen consent of VSL Form0003-0 created 07-01-2003CALCULATION NOTE NO. 2042/03 COMPOSED OF NO. 41 PAGES FROM PAGE 1 TO PAGE 41 al “A VSL HONG KONG LIMITED HYDRAULIC WINCH 90 t 2042 - 03 CN 2042-1INDEX . Winch characteristics . Forecast safety devices . General considerations . Reference Standard . Materials used . Equipment classification . Load analysis . Spreader . Vertical lifting support Movable pulley . Lifting rope Drm Upper winch frame . Lower winch frame . Wheels spreader pag. 3 page 3 page 4 page 4 page 4 page 6 page 9 page 10 page 16 page 17 page 23 page 23 page 26 page 33 page 40 CN 2042-2. Winch characteristics The subject of this Calculation Note is the verification of the components of the lifting winch for Penny’s Bay - Hong Kong. Capacity under hook = 900 KN Hook stroke = 20m © Lifting speed: under 900KN) ———> max 1,25 m/min without load = ———» max 5,0 m/min ‘© Number of reevings : n° 2/6 ‘© Transversal movement : slide : + 1.000 mm hydraulic jack stroke : + 500 mm * Longitudinal slope : 7% max Power supply : 400V — 50 Hz © Lifting system : hydraulic gear boxes : n°2 TRASMITAL type 311L3 : 245Hz negative brake : n°2 TRASMITAL type WDASCHOBC axial piston variable motor : n°2 REXROT type A6VM 55 EZA - 24 UDC gear pump :°1 VIVOIL type KV2P 14D * Rope: 420 DSC-DYFORM ~K = 220 Kg/mm? - Kt= 41.000 Kg . Forecast safety devices Load limiter assembled on the lifting; Anti-tilting pads between winch and frame; Screw end of stroke assembled for up and down; Cross end of stroke assembled for translation; Rotating end of stroke for spreader rotation. CN 2042 -33. General considerations Calculation It takes into consideration the service load with increasing factor due at dynamic effect equal to the minimum stated by F.E.M. rules 1.001 3° Edition of 1987.10.01, that is to say y= 1,15. 4, Reference Standard © Design and structure verifications are carried out following F.E.M. rules 1001 3rd edition on 10.01.87 "Régles pour le calcul des appareils de levage"; © Materials quality reference is made to En 10025 rules. 5. Materials used Si) Steel structure: S355 JR (fy=355 Nimm?) o Lall oll,all = 355=266,7 Nimm* 1,33 oT, all = 355=322,7 Némm? ae 8.275 JR (fy = 280 Nimm?) = 210 Nimm* oT, all = 280 41 55 Nimm* CN 2042-4Si) Pins and shaft a) 39 Ni Cr Mo 3 (Euronorm 83/70) R= 910 N/mm? b) C.40 tempered : R= 410 N/cm* Sifi) Bolts: Grade 8.8 (Fy b = 640 N/mm?) cl,all = 0,48x 640=310 Nimm? tI, all 179 Nimam* CN 2042-56. Equipment classification 6i) Steel structure class Useclass UO: nmax 16,000 Tableau 7.2.1.2.2. Classes d'utilisation Durge totale utilisation Symbol (nombre n max de cycles de levage) U0 nmax < _ 16.000 Ul 16.000_< nmax_< _ 32.000 w2 32.000 _< nmax_< 63.000 U3 63.000 < nmax < 125.000 U4 125.000_<_nmax__< 250,000 US 250.000. << nmax < 500,000 U6 500.000 < nmax < 1.000.000 U7 1,000.000__< nmax _< 2.000.000 U8 2.000.000_<_nmax < 4.000.000 vw 4,000,000 Service load = 1048,8 KN CN 2042 - 1810ii)_Movable pulley : CN 2042 - 19a) Central ball pos.6 : # 230 * 100 - FeS10B For calculation simplicity, we assume that the load is distributed on 4 points (see above figure) F = 1048,8/2 = 524,4 KN M = 524,4* (23 — 12,7)/2 = 2700 KN em We consider as working only 100 mm plate. CN 2042 - 20A=2* 10 * 9,2= 184 cm*, W=2/6 * 10* 9,2? = 282 cm* & = 2700 = 9,58 KN/cm? <21 KN/cm? (oall. for thickness 100 mm) 282 tmax= 1,5 * 5244= 4,28 vem? < 21 = 12,12 KNicm* 184 3 b) Main transversal plates : 2 380 * 15 - Fe510B A=2*38*1,5= 114 cm, W=2/6 * 1,5* 38°= 722 cm® F/6 = load of ¥% pulley = traction on rope = 87,4 KN V = 5/12 * F=5/12 * 524,4 = 218,5 KN M=218,5 * 21,65 = 4730,525 KNom (see scheme of point 10ii) o = 4730,525 = 6,55 KN/em? < 24 KN/cm? 722 tmax= 1,5* 218.5= 4,28 vem? < 24 = 13,85 KN/cm? 114 1B ) Plate supporting pulleys : # 380 * 15 - FeS10B (A=57 cm; W=361 cm’) Each plate of pos. 3 is loaded with one pulley load and it loads the longitudinal plates in pos. 1 Load on each rope = 1048,8 = 87,4 KN 2*6 Load on each pulley = 87,4 * 2 = 174,8 KN V = 174,8/2 = 87,4 KN M= 1748 * 56 = 2447,2 KN cm 4 o = 2447,2 = 6,78 KN/cm? < 24 KNicm? 361 tmax= 1,5" 87.4= 2,30KN/om? < 24 37 B 13,85 KNicm? CN 2042 - 214) Pressure on hole : pin 6 35 mm o 174.8 = 33,5 KN/om?* 5 * 1,5) e) Main longitudinal plates pos.1 : 2 380 * 20 - Fe510B A=2*38*2=152 cm W=2/6 * 2 * 38" =962 cm F=5244KN=V M = 524,4 * 154,5 = 8102 KN cm 8102 = 8,43 KN/cm? < 24 KN/em? 962 tmax= 1,5" 524,4= 5,18 KN/em? < 24 = 13,85 KN/em* 152 B CN 2042 - 2211) Lifting rope: ¢ 20 DSC - DYFORM; KT =410 KN Maximum load to be lifted = 900 KN (service load) + 12 KN (spreader) + 18 KN (rope self load) = 930 KN - Traction on each rope section= 930 = 77,5 KN 2*6 v=4il 410 = 5,29 > 4= Zp for group M4 (Table T.4.2.2.1.2 of FEM. STANDARD) 15 12) Drum : CN 2042 - 23,1240 CN 2042 - 24$= 900 mm; §1=854 mm; thk=23mm; - FeS10B A= 633,69 om; W= 13551 cm* ~ Tension of compression in the middle section oc = 1,12 * 0,5 * 77,5 = 1,12 * 8,03 = 9,0 KNicm? 2,1 *2,3 - Tension of compression in the lateral section oc = 1,12 * 0,8 * 77.5 = 1,12 * 12,84 = 14,38 KN/cm? 2,1 * 2,3 ~ Local bending moment in the middle section ofl,l = 1,12* 0.8 *77,5_=1,12* 2,25 =2,52 KNiem* (90 * 2,35)4 - Global bending moment in the middle section oflg = [(( 8*77.5* 46 * 139)*2] * 1,12=1,12 * 0,203 = 0,23 KN/om? n* (90%4 * 85,4"4) - Admissible tension of breaking load (oR = 5,1 KN/em’) o bw =0,5 * oR=25,5 KN/om? - Admissible tension for bending moment fatigue owk= obw = Ks * Kd * Kv * Ke * geometrical coefficient : Ks * dimensional coefficient : Kd = 1,8 # working coefficient : Kv = 1,05 * crosion coefficient : Ke = 1,0 owk= 255 = 11,34 KN/em? (1 * 1,8 * 1,05 * 1,0) «@ global = [oc? + (ofl + ofg)* + oo(ofl + ofg)]%* 1,12= = [8,037 + (2,25 + 0,203)? + 8,03(2,25 + 0,803)]% * 1,12 = = 1,12 * 9,5 = 10,64 KN/em? < 11,34 KN/cm? CN 2042 - 25er winch frame: 13) CN 2042 - 261030 4 44 — a or Haseterees tates —[ eat ee et ae eee el a = CN 2042-27Q=77,5 KN (traction in one rope) + 7,5 KN (load of drum and lifting equipment) Q=85KN W=77,5 * 0,92/2 = 35,65 KN m 13i) Plate pos.04 : #300 * 20 - FeS10B Traction in one bolt : Z = (85 * 68/190)/5 + _35,65_=6 +20=26KN GB * 0,59) o (M24) = 2 3, = 7,36 KN/em? < 37,7 KN/em? = all. 13ii) Supporting base of gear box : H A= 192,5 cm; Sx = 1452 cm’; Ix= 56200 om*4; Wx = 2270 cm’; Sy =993,4 em’; i Jy= 22304 cm™4; Wy = 1784 cm’; ty TSE 120-415 Z=85KN My =85 * 16,8 = 1428 KN cm Mx = W = 35,65 KNm o = (85, + 1428 + 3565 )= 2,82 KN/em? << 24 KN/em? =o all 192,5 1784 2270 CN 2042 - 2813iii) Longitudinal box girder Rmax = [1,15 * (900 + 12) + 18 + 120] /4=296,7 KN Mmax = 296,7 * 59,75 = 17730 KN cm a A=180cm?; Sx = 1046 cm’; Ix= 29092 cm“4; Wx = 1763 cm’; S web = 30 * 1,5 * 15,75 = 708,75 om’; 15 omax = 17730 1763 0,1 KN/em? << 24 KN/em? = all. tmax = _296,7* 1046_ = 3,57 KNicm? < 13,85 KNicm* 29092 *2*1,5 o web = 10,1 * 300 =9,19 KN/cm* 330 tweb= 3,57* 708.75. =2,42 KN/em? 1046 c total web = (9,19? + 3 * 2,422) = 10,1 KN/em? < 24 KN/cm* CN 2042 - 2913iv) Plates for pulley : + 360 * 15 - FeS10B Load on rope = [1,15 * (900 + 12) + 18] / (2+ 6) = 88,9 KN (considering the rope weight too) Load on the pulley = load on plate = 2 * 88,9 = 177,8 KN = Section A: A = (8 ~3,55/2) * 1,5 ,33 cm? o = 1778 =19,1 KN/em? <24 KNicm* = all 9,33 ~ Section B: A= (24—3,55) * 1,5 = 30,67 cm* o= 1,4* 177.8 =8,12 KN/cm? <24 KN/em? = all. 30,67 (where, 1,4 is a “breaking possibility” coefficient stated by the Italian Rule CNR 10011). CN 2042 - 3013v) Plates pos. 12 for adjustment pulleys support 2#300*15 - FeS10B (A=90cm?; W=2/6 * 1,5 * 30?= 450 cm’) V=1778KN M=177,8 * (26 ~ 13/2) =3467,1 KN cm o = 3467.1. =7,71 KN/em? <24 KNiem? =o all 450 (not considering pos.14 and 13) t= 1,5*1778. =3,0 KN/cm* 90 CN 2042 - 3113vi) Main transverse for pulley support of the G.A. drawing ~ point 13 of Calculation Note. We have: S=177,8KN; Q=85KN - For vertical load V=2,5"S=2,5* 177,8=444,5 KN M=177,8 * (53,65 + 63,95) + 177.8 * 58,8 + (85 * 16,8) = 27565 KN cm 2 Torque moment (adjustment pulley) = 177.8 * 45 = 4005 KN cm - For longitudinal slope effect (7%) a inertial forces effect (1,5%) we have: Longitudinal component of S = 17,8 * 0,085 = 15,12 KN ML = 15,12 * (53,65 + 63,95) + 15,12 * 58,8 =2223 KNem 2 Torque moment = 15,12 * 2 * (28 + 33/2) 15,12/2* (30+ 5)=1195 KNem 2 eee] 15 A=253,5 om’; Sx = 1625 cm; Ix= 47338 om“4; Wx = 2869 cm?; ene 300, Jy = 93395 em%4; Wy = 3427 cm? 7 15 +485 +-— 45 ——++ omax= 27565. + 2223 =9,61 + 0,65 = 10,26 KN/em? < < 24 KN/cm? 2869 3427 tmax = _444,5 #1625 + __(4005+1195)_ =5,1+1,14= 47338*2*1,5 2*31,5* 48,5 *1,5 = 6,24 KN/cm? < 13,85 KN/em? CN 2042 - 3214) Lower winch frame: 4335 CN 2042 - 33CN 2042 - 34We only check the displaced load combinations producing the maximum moment on the transverse (scheme A) and the one producing the maximum reaction on the wheels (scheme B). For simplicity and for safety reasons, we consider the whole self load concentrated with the service load. - Scheme A (vertical loads) A 1643,5 —}—— 1726 ——+- 780, 5- ———— 4150 ——___+ P=[L,15 * (900+ 12 + 18) + 120)/4 = 297,4 KN S = 297,4 * (2 * 780,5) + 1726 = 235,6 KN 4150 MA=235,6 * 1,644 = 387,14 KN m D=297,4 * (2 * 1643.5) + 1726 = 359,25 KN 4150 MB=359,25 * 0,781 = 280,4 KNm - Scheme A for longitudinal components of loads (M max) A B 13735 —+— 172 —+ 50,5: +-———__—— 610 ——_—_—_—_+ L=1/2* (900 + 12 + 120 + 18) * (0,07 + 0,015) = 44,625 KN 8 =33,96 KN M A= 33,96 * 1,374 = 46,65 KN m. D=55,3 KN M B= 55,3 * 0,51 = 28,23 KNm CN 2042 - 35- Scheme B for vertical loads (V max for 1 m load displacement): 2212: ——- 1726}. 212. D + 4150 ———___++ P=297,4 KN S=154,1 KN MA=154,1 * 2,212 =340,9 KNm D=440,73 KN MB= 440,73 * 0,212 = 93,5 KNm - Scheme B for loads longitudinal components (M max for 1 m L load displacement): 4 1942 te + 10> L=44,625 KN S = 44,625 * ( 1,668 — 0,058 ) = 19,9 KN 3,61 MA=19,9 * 1,942 = 38,65 KNm D = 44,625 * ( 1,942 + 3,61 + 0,058 )= 69,4 KN 3,61 M B= 44,625 * 0,058 = 2,59 KNm CN 2042 - 3614i) Transversal effect of inertial forces: M torg. = DL * 0,72 KNem 14ii) Maximum bending moment section (mat. Fe510B): A=207,5 cm; Sx=1913 cm’; x= 21,54 om. Jx= 83350 em*4; W1x = 3697 om’; 475 500 © W2,x = 3034 cm*; W3,x = 3960 cm’; 4 W4,x = 3149 cm, Sx,3 = 1470 cm’; Sx,4= 1213 om?; Jy =37968 em*4; Wy, = 1521 em’; Wy,2 = 1853,5 cm’, Wy,3 = 2281 cm?; ‘Wy,4 = 2780 cm’; ol max =~ 38714 + 4665 =- 10,47 + 3,07 =- 13,54 KNiem* 36971521 o2max=+ 38714 + 4665 = 12,76 + 2,52=+ 15,28 KNicm? 3034 (1853,5 <2 = _72*33.96_=0,84 KN/cm? 48,5 *2*30 6 2 tot. = (15,28? + 3 * 0,84")4 = 15,35 KN/em? < 24 KN/em? o3=- 38714 + 4665 = - 9,78 + 2,05 =- 11,83 KNicm* 3960 ©2281 13 = _297.4* 1470_ +72 * 33,96 =2,63 + 0,84 83330"2*1 48,5 *2*30 47 KN/cm* 3 tot. = (11,83 +3 * 3,42") = 13,27 KN/em? < 24 KNiem? CN 2042 - 37o4=+ 38714 + 4665= 12,3+1,7=+ 14,0 KN/em* 3149-2780 <4 = _297.4* 1213 + 72 * 33,96 = 3,0 KNicm? 83330"2*1 48,5 *2*30 4 tot. = (147 +3 * 3,08) = 14,94 KNiem? < 24 KN/em? 14iii) Reduced end section (at 100 mm from the support - mat. FeS10B): Jx= 24212 om™4; WLx = 1894 om’; 290 W2,x=1492 m*; W3,x = 2146 cm’, W4,x = 1590 cm’; Sx,3 = 812 em’; Sx,4= 707 em; Jy= 30900 cm™4; Wy,1 = 1210 cm; Wy,2 = 1535 cm’; Wy,3 = 1815 cm’; Wy,4 = 2300 em’; Vumax=440,73KN = MU=440,73 + 10 = 4407,3 KNcm Vi max = 69,4 - 44,65 = 24,75 KN ML = 69,4 * (10 — 5,8) - (44,65 * 10) = 155 KNem Torque Moment = 69,4 * 72 = 4997 KN cm 33 +12, - 15,13 KN/em* o2max=+ 44073 + 15500 = 2,95 + 10,1 =+ 13,05 KN/em? 1492 1535 t1= 4997 = 2,02 KNicm* 27,5*2*30* 1,5 CN 2042 - 38 A=165,5 cm’; Sx =939 cm’; x= 12,78 cm1 tot. = (15,134 + 3 * 2,022)% = 15,55 KN/om? < 24 KNicm* © 3= 4407.3 + 15504 2146 1815 2,06 + 8,54 = 10,6 KN/cm? 13 = 4407.3 *812_ + 24212*2*1 4997 __ = 7,39 + 3,02 = 10,41 KN/cm? < 13,85 KN/cr_ 27,5 * 2 *30 * 1,5 @ 3 tot. = (10,6? + 3 * 10,41)% = 20,92 KN/cm? < 24 KNicm? oo 4=+ 1407.3 + 15500 = 2,78 +8,54=+ 11,32 KN/cm* 1590 1815 <4 = _440,73*707 + ___4997_—= 6,43 + 3,02 = 9,45 KN/em? 24212*2* 1 27,5*2*30* 1,5 oA tot. = (11,32? + 3 * 9,45*)%4 = 19,9 KN/cm? < 24 KN/cm* tmax = _440,73 #939 + 3,02 = 11,55 KN/em? 24212 *2* 1 lili) Connection of translation juipment, F=69,4KN A= 69,4 * 200 +107 = 106,5 KN 200 N°2 M24: on=__106,5__=15 KN/cm* 23,53 CN 2042 - 3915) Wheels spreader ; 440,13 KN o_o Max reaction total = 440,73 KN Max reaction wheel = 220,5 KN V=220,5KN; M=440,73 * 70 =7713 KNcm 4 2 i A= 98,4 cm; Sx =353 om’; ff 200 Ix= 6319 m4; Wx = 564 cm’; | 12 y 15, it 15 omax= 7713 = 13,68 KN/em* < 24 KN/em? 564 tmax = _220,5 * 353_=4,1 KN/cm? < 13,85 KN/em? 6319 * 2 *1,5 CN 2042 - 40- pind 70 - C40 (A=38,4cm*; W=33,6 cm) V=220,5 KN; M=220,5*3 =661,5KNom o= 661.5 = 19,69 KN/om? < 24 KNicm* 33,6 <=4/3* 220.5 = 7,7 KN/em? < 13,85 KNicm* 38,4 ~ pressure on hole : o= __2205 = 12,6 KN/em* < 24 KNicm? 7*(15+1) CN 2042 - 41