Basic design criteria for hand calculations of design of tailing and lifting lugs for lifts of equipment.
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Lifting Lug Stress
untuk perhitungan pengangkatanFull description
Lifting GearFull description
Lifting Plan & ProcedureFull description
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Lifting PadeyeFull description
Lifting Machines
hazard identification, risk assessment, risk control
Lug Design
Lifting MachinesFull description
LIFT ANALYSIS L2(liftig lug to vessel C.G.) L3(Vessel C.G. to tailing lug) L1=L2+L3 L4(Vessel center line to tailing lug hole) WO (Erection weight) Impact factor W(with Impact Factor)
(Refer Procedure 7-5 of Pressure Vessel Design Manual by Dennis R Moss.) Tailing Lug
T
Skirt Bracing
Rm Dist from N.Axis from CL
MATERIAL : Ys - YIELD STRESS MATERIAL : SA 285 GR C Ys - YIELD STRESS 2109 kg/cm² Sba - ALLOW.BENDING STRESS = 0.66 x Ys 1391.94 kg/cm² F2 - MAXIMUM LOAD (in horiz. position) : 16198 kg Z - SECTION MODULUS OF BASE RING+SKIRT 213500 mm3 Di - INSIDE DIAMETER OF BASERING 2830 mm Rm - MEAN RADIUS OF SECTION 1625 mm BM - MAX.BENDING MOMENT PRODUCED AROUND RING F2 x Rm x 0.0229 (0.0229 = Internal moment Coefficient for Base Ring for 3 point lifting at Zero deg) 602768 kg-mm BENDING STRESS IN BASE RING = BM / Z 282.33 kg/cm² SAFE HENCE BASE RING IS SAFE WITH ADDITIONAL STIFFENING BEAM. CHECK FOR SUFFICIENCY OF BRACING BEAM STIFFNER BEAMS PROVIDED AS INDICATED ABOVE WITH THE TAILING LUG MATERIAL : SA 36 TAILING BEAM SIZE SELECTED H 200*200*12*12 YIELD (Ys): 2530 ALLOW.BENDING STRESS (Sba = 0.66 Ys) : 1669.8 SECTION MODULUS OF BEAM : 479221.76 SECTION MODULUS OF BEAM (Z) : 479221.76
kg/cm² kg/cm² mm3 mm3
MAXIMUM LOAD F2 : (0.453*T) FOR 3 BEAM CONST L: MAX.BENDING STRESS (F2*L/Z) :
kg mm kg/cm2
HENCE BRACING BEAM OF HE 200 B OR OF EQUIVALENT IS PROVIDED.
7337.69 200 306.23 safe
BASE RING
for two point
(Refer Procedure 7-5 of Pressure Vessel Design Manual by Dennis R Moss.) Tailing Lug
T
Skirt Bracing
Rm Dist from N.Axis from CL
MATERIAL : Ys - YIELD STRESS MATERIAL : SA 285 GR C Ys - YIELD STRESS 2109 kg/cm² Sba - ALLOW.BENDING STRESS = 0.66 x Ys 1391.94 kg/cm² F2 - MAXIMUM LOAD (in horiz. position) : 31290 kg Z - SECTION MODULUS OF BASE RING+SKIRT 650328 mm3 Di - INSIDE DIAMETER OF BASERING 5630 mm Rm - MEAN RADIUS OF SECTION 3025 mm BM - MAX.BENDING MOMENT PRODUCED AROUND RING F2 x Rm x 0.0795 (0.0795 = Internal moment Coefficient for Base Ring for 2 point lifting at Zero deg) 7524854 kg-mm BENDING STRESS IN BASE RING = BM / Z 1157.09 kg/cm² SAFE HENCE BASE RING IS SAFE WITH ADDITIONAL STIFFENING BEAM. CHECK FOR SUFFICIENCY OF BRACING BEAM STIFFNER BEAMS PROVIDED AS INDICATED ABOVE WITH THE TAILING LUG MATERIAL : SA 36 TAILING BEAM SIZE SELECTED H 250*250*9*14 YIELD (Ys): 2530 ALLOW.BENDING STRESS (Sba = 0.66 Ys) : 1669.8 SECTION MODULUS OF BEAM : 846305 SECTION MODULUS OF BEAM (Z) : 846305
kg/cm² kg/cm² mm3 mm3
MAXIMUM LOAD F2 : (0.5*T) FOR 1 BEAM CONST L: MAX.BENDING STRESS (F2*L/Z) :
kg mm kg/cm2
HENCE BRACING BEAM OF HE 200 B OR OF EQUIVALENT IS PROVIDED.
15645.00 250 462.16 safe
BASE RING ADEQUACY
(For One Point)
(Refered Procedure 7-5 of Pressure Vessel Design Manual by Dennis R Moss.) Tailing Lug
T
MATERIAL : Ys - YIELD STRESS Sba - ALLOW.BENDING STRESS = 0.66 x Ys F2 - MAXIMUM LOAD (in horiz. position) : Z - SECTION MODULUS OF BASE RING+SKIRT Di - INSIDE DIAMETER OF BASERING Rm - MEAN RADIUS OF SECTION BM - MAX.BENDING MOMENT PRODUCED AROUND RING
(0.2387 = Internal moment Coefficient for Base Ring for One point lifting at Zero deg) BM = BENDING STRESS IN BASE RING = BM / Z HENCE BASE RING IS UNSAFE WITHOUT ADDITIONAL STIFFENING BEAM
(For One Point)
ual by Dennis R Moss.)
IS 2062 GR B 2249 1484.34 86274 766398 3640 1111.45
kg/cm² kg/cm² kg mm3 mm mm
F2 x Rm x 0.2387
r One point lifting at Zero deg)
IONAL STIFFENING BEAM
22888761 2986.54 UNSAFE
kg-mm kg/cm²
CALCULATION FOR LIFTING FORCES FOR RIGGING WO (Erection weight) Impact factor W L (with impact factor) CG(distance from bottom) Distance between tail lug hole to bottom Distance between lift lug hole to bottom Distance from C.G. to tailing lug hole (L3) Distance from lifting lug hole to C.G. (L2) Distance from vessel centerline to tailing lug hole (L4) Distance between lifting lug hole to tailing lug hole (L1)
STRESSES WHILE LIFTING WO (Erection weight) Impact factor W L (with impact factor) CG(distance from bottom) Distance between tail lug hole to bottom Distance between lift lug hole to bottom Distance from C.G. to tailing lug hole (L3) Distance from lifting lug hole to C.G. (L2) Distance from vessel centerline to tailing lug hole (L4) Distance between lifting lug hole to tailing lug hole (L1)
w L (dist. Of top of the vessel to mid of the span) H (Height of the vessel) Allowable bending stress in shell Allowable tensile stress in shell Do (vessel OD) Di (vessel ID) Z A
LIFTING LUG CALCULATIONS Calculation based on Procedure 7-6 of Vessel Design Manual by Moss Erection Weight (Kg) Impact factor for Lifting Total Lifting Wt. (Kg) No. of Lifting Lug Load on one Lifting lug PL (Kg) LUG DIMENSIONS C = (mm)
D R T E
Lifting Lug Material Yield Strenght at Room Temp Code Allowable Stress Allowable Tensile ( St ) Allowable Bearing Allowable Shear Allowable Bending Stress
= (mm) = (mm) = (mm) = (mm) f =(mm) b+a+H = (mm) H = (mm) A = (mm) B = (mm) W = (mm) Bearing pad Diameter (S) = (mm) Bearing Pad THK (t) = (mm) a = (mm) b = (mm) SA 516 GR 70 Sy = 2672 kg/cm² Sa = 1406 Sa 1406 kg/cm² 0.8 Sy 2137.6 kg/cm² 0.4 Sy 1068.8 kg/cm² 0.66 Sy 1763.52 kg/cm²
INDUCED STRESSES IN LIFTING LUG Tensile str area of Lug [ 2R - D] x T Tensile Stress Induced Bearing Area = D x (T + 2t) Bearing Stress Induced Shear Area 2T x (√[R² - (D/2)²]) Shear Stress Induced Max Load normal at Lifting Lug (PT) = (Refer Calculated Max Load during lifting) Maximum Moment Arm (L2=C+b) Bending Moment (M=P*L2) Sec Modulus Bending Stress Induced WELD CHECK Allowable Weld Shear CHECKING LUG WELDS Location of CG (Long) from bot of lug (c ) = c=(H^2/(W+2*H))
Polar Moment of Inertia (Jw) = Jw=((W+2*H)^3/12)-(H^2(W+H)^2/(W+2H)) Finding Shear Loads on Weld i) Transverse Shear due to P (f1) = f1 = P / (2*H + 2*H + W+2*a) ii) Transverse Shear due to M (f2) = f2 = [(C+b+a+H-c)*P*(H-c)] / Jw iii) Longitudinal Shear due to M (f3) = f3 = (C+b+a+H-c)*P*H/Jw iv) Combined Load (fc) = fc = sqrt ((f1+f2)^2+f3^2) Fillet Size Throat unit area (w) Maximum Shear Stress = fc / w Hence Provided Leg to Pad/ Shell fillet size is safe CHECKING PAD WELDS Maximum Moment Arm (L1=C+b+0.5A) = Bending Moment (M1=P*L1) = Polar Moment of Inertia (Jw=(A+B)^3/6) = Lifting Lug pad thickness = Finding Shear Loads on Weld i) Transverse Shear due to P (f1) = f1 = P / (2*A + 2*B) ii) Transverse Shear due to M (f2) = f2 = 0.5*M1*A / Jw iii) Longitudinal Shear due to M (f3) = f3 = M1*A/Jw iv) Combined Load (fc) = fc = sqrt ((f1+f2)^2+f3^2) Fillet Size Throat unit area (w) Maximum Shear Stress = fc / w Hence Provided Leg to Pad/ Shell fillet size is safe
94793495.36
mm3
23.34
Kg/mm
102.77
Kg/mm
136.12
Kg/mm
185.56
Kg/mm
34 24.04 771.82
mm mm kg/cm²
849.5 38756739 246924000.00 28
mm kg-mm mm3 mm
20.01
Kg/mm
31.78
Kg/mm
63.57
Kg/mm
82.00
Kg/mm
20 14.14 579.81
mm mm kg/cm²
SAFE
SAFE
LOCAL LOADS Vessel is horizontal position : Vessel is vertical position :
MT = [ H+F+E-(h2/2) ]xP FC = P FL = PL
kg / kg-mm N / N-m 39897314 391261 45623 447412 7550 74041
TAILING LUG ANALYSIS LOADS
CASE A MAX BENDING
CASE B MAX TENSION
WITH IMPACT AXIAL LOAD / TAILING LUG Kg RADIAL LOAD / TAILING LUG Kg (Refer calculated maximum reaction values in lifting analysis) TAILING LUG CALCULATION: MATERIAL:
C TAILING LUG DIMENSIONS: (…mm) (MIN.) H - DEPTH M - MOMENT ARM D - PIN HOLE DIA T - THK. R - RADIUS OF TAILING LUG D' - DIAMETER OF BEARING PAD T' - THK OF BEARING PAD
A
284 92 75 32 142 150 16
CHECK ON SEC 'AA' IN TENSION: (LOAD CASE B) WIDTH mm THK mm AREA mm² STRESS: kg/cm²
284 32 18176 463.15
CHECK ON SEC 'BB' IN SHEAR: (LOAD CASE B) SEC. WIDTH ( w' ) mm
136.96
safe
R
THK ( T + 2 * T' ) AREA ( 2 x w' x (T + 2 * T' ) STRESS:
mm mm² kg/cm²
64 17530.74 480.20
CHECK ON PIN HOLE BEARING AREA (LOAD CASE B) WIDTH mm THK (T + 2 * T' ) mm PROJECTED AREA mm² STRESS: kg/cm² ALLOWABLE STRESS (0.8 x Sy) kg/cm²
75 64 4800 1420.67 1799.2
CHECK ON SEC 'CC' IN BENDING: (LOAD CASE A) DEPTH mm WIDTH mm MOMENT ARM mm AREA mm² SECTION MODULUS BENDING MOMENT BENDING STRESS TENSILE STRESS TOTAL STRESS
TAILING LUG ANALYSIS No. of Tailing lugs IMPACT FACTOR
1 1.4
LOADS
CASE A CASE B MAX BENDING MAX TENSION WITHOUT WITH WITHOUT WITH IMPACT IMPACT IMPACT IMPACT AXIAL LOAD / TAILING LUG Kg 66755 93457 0 0 RADIAL LOAD / TAILING LUG Kg 86274 120783.6 86274 120783.6 (Refer calculated maximum reaction values in lifting analysis) TAILING LUG CALCULATION: MATERIAL:
TAILING LUG DIMENSIONS: (…mm) (MIN.) H - DEPTH 327 M - MOMENT ARM 95 D - PIN HOLE DIA 75 T - THK. 32 R - RADIUS OF TAILING LUG 163.5 D' - DIAMETER OF BEARING PAD 150 T' - THK OF BEARING PAD 16 CHECK ON SEC 'AA' IN TENSION: (LOAD CASE B) WIDTH mm THK mm AREA mm² STRESS: kg/cm²
327 32 10464 1154.28
safe
R
CHECK ON SEC 'BB' IN SHEAR: (LOAD CASE B) SEC. WIDTH ( w' ) mm THK ( T + 2 * T' ) mm AREA ( 2 x w' x (T + 2 * T' ) mm² STRESS: kg/cm²
159.14 64 20370.11 592.95
CHECK ON PIN HOLE BEARING AREA (LOAD CASE B) WIDTH mm THK (T + 2 * T' ) mm PROJECTED AREA mm² STRESS: kg/cm² ALLOWABLE STRESS (0.75 x Sy) kg/cm²
75 64 4800 2516.33 1686.75
CHECK ON SEC 'CC' IN BENDING: (LOAD CASE A) DEPTH mm WIDTH mm MOMENT ARM mm AREA mm² SECTION MODULUS BENDING MOMENT BENDING STRESS TENSILE STRESS TOTAL STRESS
LIFTING LUG CALCULATIONS Calculation based on Procedure 7-6 of Vessel Design Manual by Moss
H
F
E
Lifting Lug Material Yield Strenght at Room Temp Allowable Tensile ( St ) Allowable Bearing Allowable Shear Allowable Bending Stress
Sy = Sa 0.8 Sy 0.4 Sy 0.66 Sy Sa
INDUCED STRESSES IN LIFTING LUG Tensile str area of Lug = [ 2R - d] x T Tensile Stress Induced Bearing Area (= d x T) Bearing Stress Induced Shear Area = 2T x (√[R² - (d/2)²]) Shear Stress Induced Max Load normal at Lifting Lug (P) = (Refer Calculated Max Load during lifting) Maximum Moment Arm (L2=H) Bending Moment (M=P*L2) Sec Modulus Bending Stress Induced WELD CHECK Allowable Weld Shear
2800 188.75 1200.00 440.42 3815.76 138.50 79625
0.55*Sa=
CHECKING LUG WELDS Location of CG (Long) from bot of lug (c ) = c=(h2^2/(2*h2+2*R)) Polar Moment of Inertia (Jw) = Jw=(((2*R+2*h2)^3/12)-(h2^2(2*R+h2)^2/(2*R+2*h2)) Finding Shear Loads on Weld i) Transverse Shear due to P (f1) = f1 = (P / (2*R + 4* h2)) ii) Transverse Shear due to M (f2) = f2 = M*(h2-c) / Jw iii) Longitudinal Shear due to M (f3) =
Erection Weight (Kg) Impact factor for Lifting Total Lifting Wt. (Kg) No. of Lifting Lug Load on one Lifting lug PL (Kg) LUG DIMENSIONS d = (mm) R = (mm) T = (mm) H= (mm) F=(mm) E = (mm) h2 = (mm) A = (mm) B = (mm) SA 516 GR 70 2672 kg/cm² 1406 kg/cm² 2137.6 kg/cm² 1068.8 kg/cm² 1763.52 kg/cm² 1406 mm² kg/cm² mm² kg/cm² mm² kg/cm²
f3 = M*h2/Jw iv) Combined Load (fc) = fc = sqrt ((f1+f2)^2+f3^2) Fillet Size Throat unit area (w) Maximum Shear Stress = fc / w Hence Provided Leg to Pad/ Shell fillet size is safe CHECKING PAD WELDS Maximum Moment Arm (L1=H+F+E) = Bending Moment (M1=P*L1) = Polar Moment of Inertia (Jw=(A+B)^3/6) = Lifting Lug pad thickness = Finding Shear Loads on Weld i) Transverse Shear due to P (f1) = f1 = (P / (2*A + 2* B)) ii) Transverse Shear due to M (f2) = f2 = 0.5*M1*B / Jw iii) Longitudinal Shear due to M (f3) = f3 = M1*B/Jw iv) Combined Load (fc) = fc = sqrt ((f1+f2)^2+f3^2) Fillet Size Throat unit area (w) Maximum Shear Stress = fc / w Hence Provided Leg to Pad/ Shell fillet size is safe LOCAL LOADS Vessel is horizontal position : Vessel is vertical position :
690.19
Kg/mm
35 24.75 2788.80
mm mm kg/cm²
559.5 44550188 0.00 22
mm kg-mm mm3 mm
#DIV/0!
Kg/mm
#DIV/0!
Kg/mm
#DIV/0!
Kg/mm
#DIV/0!
Kg/mm
22 15.56 #DIV/0!
mm mm kg/cm²
MT = [ H+F+E-(h2/2) ]xP FC = P FL = PL
UNSAFE
#DIV/0!
kg / kg-mm N / N-m 39374563 386135 79625 780859 7550 74041
LIFTING TRUNNION ANALYSIS IMPACT FACTOR
2
LOADS
Axial Load Kg Tangential Load Kg (Refer calculated maximum reaction values in lifting analysis)
Case C Axis Horizontal Without Without Impact Impact 0 0 20000 40000 Sa
ALLOWABLE STRESS (Kg/cm²) DIMENSIONS ID OF TRUNNION mm THK OF TRUNNION mm OD OF TRUNNION mm CROSS SECTION AREA mm^2 SECTION MODULUS mm^3 STRESSES IN TRUNNION BENDING STRESS IN TRUNNION (LOAD CASE D) MOMENT ARM mm BENDING MOMENT Kg-mm BENDING STRESS Kg/cm² SHEAR STRESS IN TRUNNION (LOAD CASE D) Kg/cm²
Case D Axis Vertical Without Without Impact Impact 21000 42000 0 0 1104
Shear Bending (0.4 * Sy) (0.66 * Sy) 1068.8
1763.52
288.89 17.48 323.85 16824.32 1223031.32
500 21000000 1717.05
safe
249.64
safe
CHECK TRUNNION TO SHELL ATTACHMENT WELD FOR SHEAR (LOAD CASE D) SHEAR STRESS IN WELD Kg/cm^2 249.64 safe RF PAD THK. mm 18 RF PAD DIAMETER mm 550 VALUES USED FOR LOCAL LOAD CALCULATION: CASE C: (AXIS HORIZONTAL) CIRECUMFERENTIAL SHEAR 392268 LONGITUDINAL SHEAR 0 CIRECUMFERENTIAL MOMENT 500 mm Moment arm 196134 LONGITUDINAL MOMENT 0
N N N-m N-m
CASE D: (AXIS VERTICAL) LONGITUDINAL SHEAR LONGITUDINAL MOMENT
