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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

DESIGN OF SPREADER LIFTING BEAM of Hollow Circular Cross Section Belleli Energy srl, Dubai Branch prepared by R. Venkat Date
Project: Hitachi Zosen, Arzew Plant, Algeria "BLOCK-E" Job No. 4776 Safe Working Load, SWL 112.6 Tons Spreading Length 10.000 metres Safety Factor in Compression 1.6 Yield stress of the Beam material 240 MPa Allowable Tensile Stress 150 MPa Elastic Modulus of the material 210000 MPa Geometry of Lifting, Solved using the equations of Static Equillibrium

12/5/2013

SWL, W =

1109.7 kN

Tie Length = L =

10.000 metres a= 60.0 Degrees Tensile Force, P = 637.9 kN

y x Compressive Force, C = 318.9 kN

Spreading Length, L =

10.000 metres

W/2 =

552.4 kN

W/2 =

552.4 kN

As the Spreader beam is free for all its three planar DOF (x,y & R z Degrees Of Freedom) at the nodes of application of load, The bar behaves like a TRUSS member and it will resist only the AXIAL force (here, Compression) and it will NOT resist BENDING in the plane. This Spreader Beam is a typical case of Timoshenko's BEAM-COLUMN (Horizontal members having axial loads in addition to lateral loads) with both the ends HINGED. The Elastic Instability in the lateral direction causes the Spreader beam to BUCKLE due to the SLENDERNESS. This imposes the limitation on the Compressive load. The load at which the TRANSVERSE BUCKLING commenced is the CRITICAL load (Pcr). Hence, the STRUCTURAL analysis is made for (1) Direct Compressive Stress, and (2) Critical Load for Transverse Buckling. (A) Design for Normal Stress (Direct Compressive Stress) **** Selecting the Section initially based on this **** Considering the equillibrium of node B , We have 1) the vertical component of resolved P is balanced with W/2, hence P * Sin a = (W/2) => P * Sin a = 552.4 552.4 => P = kN
Sin(180-a)/2

Tensile Force in the tie,

637.9 kN

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

2) the horizontal component of resolved P induces a compressive force C in spreader beam, hence P * Cos a = C Compressive Force in Beam C = 318.9 kN

Minimum Area of Cross section required in mm2

Compressive Force in Newton X Safety Factor in Compression Allowable Stress in Mpa C * FOS sallow 3401.91 mm2
**** CLICK **** TO INCREASE THE SECTION BY SELECTING NEXT PIPE SIZE

Minimum Area of Cross section required in mm2

*****CLICK HERE TO SELECT THE PIPE****** [The Standard pipe (API 5L) selected shall be atleast 8" Sch20 with this cross section area and wall thickness is 219.1 minimum (i.e, maximum OD)] 8" Sch20

Signal Box "SAFE DESIGN" Load Factor is OK


Buckling Stress is OK Buckling Stress is OK

Critical Load is OK Safety Margin is OK


as perAPI 5L

The Pipe selected is OD of the Pipe Tk of the Pipe Cross section Area, As

12" Sch20 323.80 mm 6.35 mm 2 6332.85 mm

Signal Box "OPTIMALITY"


Load Factor is OPTIMUM
Buckling Stress is OPTIMUM Buckling Stress is OPTIMUM

4 Moments of Inertia, Ixx=Iyy=I= 8.0E+07 mm Radii of Gyration, rx=ry=r= 112.26 mm Unit Weight of the Pipe 49.71 kg / m Compressive Strength of the pipe selected = Allowable Stress = sallow*As

Safety Margin is OPTIMUM

Cross section area

Cactual Therefore the practical Safety Factor achieved nc

= =

949.93 kN Cactual C 2.98 Nr. SATISFACTORY OPTIMUM

(B) Design for Elastic Stability - Transverse Buckling [1] Slenderness Ratio (L/r) = Effective Length of the Spreader Beam Radius of gyration

For both ends HINGED members, the EFFECTIVE length equals the LENGTH of the member L/r The Crippling commencement factor, Cc Cc = = 89.08 Nr. 2p2 E sy 131.42 Nr. More than Euler's Critical Range

*** Beam in the Intermediate-block, COMPRESSION & BUCKLING analyses needed *** Calculations for the Intermediate-block, Pls. ignore for the Slender Range FS Computing the factor, = (5/3) + (3/8) * [(L/r) / Cc] - (1/8) * [(L/r) / Cc]3 FS Allowable Stress in intermediate buckling sallow(ib) sallow(ib) = = = 1.88 Nr. (sy/Fs) * [1 - (1/2) * {(L/r) / Cc}2] 98.23 MPa OK OPTIMUM

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BELLELI ENERGY srl Dubai Technical dept. Calculations for the Slender Range, Pls. ignore for the Intermediate-block Allowable Stress in slender buckling sallow(sb) sallow(sb) = = (p2 * E) / [1.92 * (L/r)2] 136.04 MPa

Spreader Beam Design

OK OPTIMUM

Check for the Ultimate Buckling load Pu, which is the Euler's Critical load Pcr Euler's Critical Bucling load Pcr Buckling safety margin ncr = = = (p2 * E * I) / (L)2 1654.06 kN OK

Euler's Critical Buckling Load Actual Compressive Force on Beam X Safety Factor in Compression 3.24 Nr.

[1]

OK OPTIMUM This section is computed in accordance to the Manual Of Steel Construction , 9th edition, American Institute of Steel Construction, New Yark, 1959 = ('C) DESIGN OF ATTACHMENTS - (a) Design of eye bracket for strength L1 = 400 mm Height h1 = R1 = 125 mm Height h2 = R2 = 110 mm Thickness (Bkt & RF) t= d= 90 mm Weld joints' efficiency hj = ds = 76 mm Weld Fillet Size sw = syield = 248 MPa Elastic Modulus of the material sallow = 155 MPa

Length Radius of the bracket Radius of the reinforcement Dia of the hole for Shackle Dia of the Shackle ring Yield stress of the material Allowable Tensile Stress

150 100 15 70 10 210000

mm mm mm % mm MPa

! Initially "assume" then "Iterate" these values with the help of following Signal Boxes
Design Criterion (a-i) Tensile stress in the eye-bracket (a-ii) Bearing / Crushing stress in the eye-bracket (a-iii) Tearing stress in the eye-bracket (a-iv) Out-of plane buckling of the eye-bracket (a-v) Shearing stress in the shackle ring (b) Weld (set-on double fillet) size for eye-bracket with the beam Tensile Force, P = 3 * (t = 15 ) mm 637.9 kN R2 = 110 mm d= R1 = b= 125 mm 60.0 Degrees h2 = 70 mm 100 mm Signal Box "SAFE DESIGN" Signal Box "OPTIMALITY" OK OPTIMUM OK OPTIMUM OK OPTIMUM OK OPTIMUM OK OPTIMUM OK OPTIMUM

h1 =

150 mm

Comp.Force, C= 318.9

L1 =

400 mm

As the geometry reveals the criticality of the obligue tensile force from the tie is significant than the horizontal compressive force from the beam. Hence, the design for the tensile stress ensures the design for the compressive stress also.

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(a-i) Design of eye bracket for tensile strength - FAILURE MODE - 1 (allowable tensile stress is governing)

ds =

76 mm

~ 2R1 =

250 mm

3 * (t =

15

) mm

Resisting area for tension of the eye braket

= = At P = = = st = =

Diameteral Difference (2R1 - ds) * 3t


2 7830 mm

Total Thickness

Resisting Area Normal Force Tensile Stress

637.9 kN Normal Force 81.5 MPa 3.0 Nr. / Resisting Area OK OPTIMUM

Factor of safety with yield stress

n1

(a-ii) Design of eye bracket for bearing/crushing strength - FAILURE MODE -2 (80% of the yield stress is governing) ds = 76 mm

3 * (t =

15

) mm

Bearing area of the Sling hole for the Sling ring

= = Ab P = = =

Diameter of the Sling ring ds * 3(t)


2 3420 mm

Total Thickness

Bearing Area Normal Force Bearing Stress

637.9 kN Normal Force 186.5 MPa 1.3 Nr. / Bearing Area OK OPTIMUM

sbearing Factor of safety with yield stress n2

= =

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(a-iii) Design of eye bracket for tearing strength - FAILURE MODE - 3 (50% of the yield stress is governing)

3 * (t =

15

) mm

Radii Difference

The bracket is in tearing due to shear along two planes against the sling ring, i.e., resisting it with the chordal sections Chordal (assumed to be Radial) area resisting the tearing shear Radii difference for the bracket + Radii difference for the reinfrmnt X X Thickness Total Thickness

2X

= Tearing area Tearing Force Tearing Stress stearing Factor of safety with yield stress n3 At P = = = = =

2 * [(R1 - d/2) * t] + [(R2 - d/2) * (t*2)]


2 7200 mm

637.9 kN Tearing Force 88.6 MPa 2.8 Nr. / Tearing Area OK OPTIMUM
[2]

(a-iv) Design of eye bracket for out-of plane buckling - FAILURE MODE - 4 (as per David T. Ricker Requirement is the minimum thickness of the eye-bracket shall be ensured for 13 mm and 0.25 times the hole diameter d. Required thickness treq Factor of safety with thickness provided n4 = = = 0.25 * d 22.5 mm 2.0 Nr. OK

OPTIMUM

[2]

This section is computed in accordance to David T. Ricker, " Design and Construction of Lifting Beams ", Engineering Journal, 4th Quarter, 1991

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(a-v) Design of shackle ring for shearing strength - FAILURE MODE - 5 (50% of the yield stress is governing)

3 * (t =

15

) mm

The curved shackle ring is under double shear along two parallel planes of the faces of the bracket, i.e., resisting it with the cross section area The cross section area of the curved sling ring Shearing area Shearing Force Shearing Stress sshearing Factor of safety with yield stress n3 As P = = = = = = 2 * [p/4 * ds2]
2 9073 mm

637.9 kN Shearing Force 70.3 MPa 3.5 Nr. / Shearing Area OK OPTIMUM

(b) Design of weld joint of the eye-bracket with the spreader beam for shear strength (50% of the allowable stress is governing) Tensile Force, P = 3 * (t = 15 ) mm 637.9 kN R2 = 110 mm d= R1 = b= 125 mm 60.0 Degrees h2 = 70 mm 100 mm

h1 =

150 mm

Comp.Force, C= 318.9

L1 =

400 mm

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BELLELI ENERGY srl Dubai Technical dept. A) Shear Stress on the Weld joints between the eye-bracket and the beam (Set-on double fillet without any grooving) Total length of the weld joint parallel to the beam axis Lw1 Transverse load on these joints Pw1 Allowable Shear Stress on effective throat area tallow-w Effective throat thickness tw Minimum Fillet Size of the Welds sw Factor of safety with fillet size provided n4 = = = = = = = = = = = 2 * tw 7.09 mm 1.4 Nr. OK W/2 552.4 kN (sallow / 2) * hj 52.5 MPa Pw1 * 1000 / (sw * Lw1) 5.01 mm (2+2) * (L1 + R1) 2100 mm

Spreader Beam Design

OPTIMUM

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

DESIGN OF ADJUSTABLE SPREADER LIFTING BEAM of Standard Profile "HEB Series" Belleli Energy srl, Dubai Branch prepared by Venkat Date 12/5/2013
Project: Hitachi Zosen, Arzew Plant, Algeria "BLOCK-E" Job No. 4776 Safe Working Load, SWL 552.4 kN Spreading Length, L 4.000 metres Length, L1 1.998 metres Initial Assumpn. Cant.lvr. Length, L2 0.202 metres

Value brought from previous worksheet

After reaching Flexural Stress "safe", Iterate this dimension L2 sothat this agrees with computed L2

Yield stress of the Beam material 248 MPa Allowable Stress 155 MPa Elastic Modulus of the material 210000 MPa Geometry of Lifting at the each end of the HOLLOW PIPE Spreader Beam, Solved using the equations of Static Equillibrium

UDL, q =

0.1 kN/m y

SWL, W =

552.9 kN

A
x

Lgth, L1 =

1.998 metres

Lgth, L2 =

0.202 metres

Spreading Length, L =

4.000 metres

P= 276.2 kN P= 276.2 kN As this Adjustable Spreader beam is constrained for all its three planar DOF (x,y & R z Degrees Of Freedom) at the nodes of application of load, The bar behaves like a FRAME member and it will resist BOTH the AXIAL force and BENDING in the x-y plane. This Spreader Beam is a typical case of Both the ends fixed with a Cantilever for Counter-weight, having a point load at an offset and UDL for the entire length. The governing stress for such a configuration is the FLEXURAL STRESS (sb). Hence, the STRUCTURAL analysis is made for the FLEXURAL Stress (A) STRENGTH DESIGN - Design for FLEXURAL Bending Stress **** Selecting the Section initially based on this **** Ensuring the Translational equillibrium along y axis, We have to equate the downward forces with upward reactions => W W = = (2 * P) + q * (L + L2) 552.90 kN

Ensuring the Rotational equillibrium about z axis, We have to equate the clockwise moments with counter clockwise moments

Taking the moments about the node C (W * L1) + ((q * L2) * L2/2)) L2 L2 = = = (P * L) + ((q * L) * L/2) (2/q) * [(P * L) + ((q * L) * L/2) - (W * L1)] 4.312 m
PLS. CHANGE THE INITIAL ASSUMPTION

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BELLELI ENERGY srl Dubai Technical dept. Bending Moment M We have, Maximum Flexural Stress = = = = sf(max) Factor of Safety achieved on yield stress n1 = = = (P * L) + ((q * L) * L/2) 1105.760 kN-m Bending Moment M / Zx 21264.6 MPa syield / sf(max) 0.01 Nr.
/

Spreader Beam Design

Section Modulus of the section about the axis perpendicular to plane of bending

PLS. INCREASE THE SECTION

OPTIMUM

*********** CLICK HERE ********** TO SELECT THE SECTION [The Standard Section (EN 53-62) selected shall be atleast with this Moment of Inertia]
Structural member section Unit Weight of the member Moments of Inertia, Ixx= Moments of Inertia, Iyy= Radius of Gyration, rx= Radius of Gyration, ry= Elastic Section Modulus, Zx= Elastic Section Modulus, Zy= Depth of the section, h = Width of the section, b = HE 100 AA 12.20 kg/m 4 2370000 mm
4 921000 mm 38.90 mm 24.30 mm 3 52000 mm 3 18400 mm 91 mm 100 mm

**** CLICK **** TO INCREASE THE SECTION BY SELECTING NEXT SECTION

Signal Block "SAFE DESIGN"


Counter Weight is NOT OK

Flexural Stress is NOT OK


Max. deflection is NOT OK

as per EN 53-62

Signal Block "OPTIMALITY"


Bending Stress is OPTIMUM

(B) STIFFNESS DESIGN - Design for DEFLECTION

The maximum deflection of the beam between loaded nodes and

W * L1* (L2 - L12)3/2 9 * 31/2 * L * E * I

dmax

1481.222 mm

PLS. INCREASE THE SECTION

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(C) DESIGN OF ATTACHMENTS - (a) Design of adjustable (CG location variations) suspension bracket for strength Length of the bracket Lb = 200 mm Radius of the lug end R= 120 mm Clearance above the beam c= 40 mm Diameter of the hole dh = 60 mm Total Height of the lug h1 = 300 mm Diameter of the pin dp = 50 mm Height of the cut in the lug h2 = 50 mm Thickness of the lug t1 = 30 mm Height of taper in the lug h3 = 145 mm Thk of all other plates t2 = 10 mm Total Width of the lug w1 = 350 mm Weld joints' efficiency hj = 70 % Width of the cut in the lug w2 = 120 mm Weld Fillet Size sw = 10 mm Yield stress (all matl ex. pin) syield = 248 MPa Elastic Modulus of the material 210000 MPa Allowable Stress sallow = 155 MPa Yield stress (pin matl) sy(pin) = 300 MPa

! Initially "assume" then "Iterate" these values with the help of following Signal Boxes
Design Criterion (a-i) Tensile stress in the lug (a-ii) Bearing / Crushing stress in the lug (a-iii) Tearing stress in the lug (a-iv) Out-of plane buckling of the lug (a-v) Shearing stress in the pin (b) Weld (set-on double fillet) size for lug with other plates (c) Tensile stress in the end plate (d) Weld (set-on double fillet) size for the bottom plate with other plates Signal Box "SAFE DESIGN" Signal Box "OPTIMALITY" OK NOT OPTIMUM OK OPTIMUM OK OPTIMUM OK OPTIMUM OK OPTIMUM OK OPTIMUM OK OPTIMUM OK OPTIMUM W= w1 = 350 R= dp = w2 = 120 dh = h3 = h2 = 120 50 60 145 50 552.9 kN t1 = 30

h1 =

300

(h + c) =

131

Lb = t2 = 10 b= 100

200

The load on the bracket is the straight forward lifting force acting vertically upwards against the load.

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(a-i) Design of lugs on the bracket for tensile strength - FAILURE MODE - 1 (allowable tensile stress is governing) wcs = 309 R= 120 W= 552.9 kN t1 = 30

dh = t1 = 30 h3 =

60

145

h1 =

300

w1 =

350

h2 =

50

h3 - R

The width of the critical section i.e., across the diameter of the hole

w1 - 2 *

R tan sin-1 (h3 - R)2 + (w1 / 2)2 + tan-1

h3 - R (w1 / 2)

wcs The effective width at the critical section

= = =

309 mm Width at the critical section wcs - dh 249 mm Diameter of the hole

wef

The effective normal area at the critical section resisting the force per lug

= = Aef =
wef * t1

Effective width

Thickness

7480 mm

As these two lugs are placed, with the lifting lug in-between, at a closer clearance always, the bending effects on the lug and the pin are ignored. And also, it could be reasonably assumed that the entire force of lifting is shared equally without any moments on them. The tensile stress on this critical section
= Force on the lug (W/2) / Aef 36.96 MPa OK / Effective normal area

= st Factor of Safety achieved on yield stress n2 = = =

syield / st 6.71 Nr.


NOT OPTIMUM

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(a-ii) Design of lugs on the bracket for bearing/crushing strength - FAILURE MODE -2 (80% of the yield stress is governing) W= wb = 50 552.9 kN t1 = 30

t1 =

30

dp =

50

The effective area bearing the crushing force per lug

= =

Bearing width

Thickness

wb * t1

( Note: Bearing width equals the projected diameter


1500 mm
2

Ab The bearing / crushing stress

= = =

Crushing force (W/2) / Ab 184.30 MPa

Bearing area

sb Factor of Safety achieved on yield stress n3

= = =

OK

syield / sb 1.35 Nr.


OPTIMUM

(a-iii) Design of lug on the bracket for tearing strength - FAILURE MODE - 3 (50% of the yield stress is governing) W= 552.9 kN t1 = 30

t1 =

30

(R - dh/2)=

90

Area resisting lateral tension (tearing) per lug

= = At =

Radii difference (R - dh/2) * t1


2700 mm
2

Thickness

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BELLELI ENERGY srl Dubai Technical dept. Tearing stress = = stear Factor of Safety achieved on yield stress n4 = = = Tearing force
(W/2) / At

Spreader Beam Design / Area resisting lateral tension (tearing)

( Note: Tearing force conservatively equals lifiting force


OK

102.39 MPa

syield / sbtear 2.42 Nr.


OPTIMUM
[1]

(a-iv) Design of lug on the bracket for out-of plane buckling - FAILURE MODE - 4 (as per David T. Ricker Requirement is the minimum thickness of the lug on the bracket shall be ensured for 13 mm and 0.25 times the hole diameter d. Required thickness treq = = 0.25 * dh 15.0 mm OK

Factor of safety with thickness provided

n5

2.0 Nr.

OPTIMUM

[1]

This section is computed in accordance to David T. Ricker, " Design and Construction of Lifting Beams ", Engineering Journal, 4th Quarter, 1991 (a-v) Design of pin for shearing strength - FAILURE MODE - 5 (50% of the yield stress of the pin is governing) W= 552.9 kN t1 = 30

dp =

50

The pin under double shear along two parallel planes of the inner faces of the lugs, i.e., resisting it with the cross section area The cross section area of the pin Shearing area Shearing Force Shearing Stress sshearing Factor of safety with yield stress n6 As P = = = = = = 2 * [p/4 * dp2]
2 3927 mm

552.9 kN Shearing Force 140.8 MPa 2.1 Nr. / Shearing Area OK OPTIMUM

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(b) Design of weld joint of the lug with other plates for shear strength (50% of allowable stress is governing) W= w1 = 350 552.9 kN t1 = 30

w2 =

120 h3 = 145

h4 = h1 =

116 300

h2 =

50

t2 =

10

b=

100

Fixing the height h4 at 75% of the straight height (h1 - h3) h4 Total weld-length provided per lug Lw1 Transverse force on the weld joint per lug Pw1 Allowable Shear Stress on effective throat area tallow-w Effective throat thickness tw1 Minimum Fillet Size of the Welds sw1 Factor of safety with fillet size provided n7 = = = = = = = = = = = = 2 * tw 5.26 mm 1.9 Nr. OK OPTIMUM W/2 276.5 kN (sallow / 2) * hj 54.25 MPa Pw1 * 1000 / (sw * Lw1) 3.72 mm 116 mm 2 * [2 * (h2 + h4 + t2 + h4) + b] 1370 mm

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(c) Design of end plates of the adjustable bracket for tensile strength (allowable tensile stress is governing) W= 552.9 kN

Lb = t2 = 10

200

The load on the end plates of the bracket is the straight forward lifting force acting vertically against the load. The normal area per end plate resisting tensile force = = Aep = Length of the bracket
Lb * t2
2 2000 mm

Thickness

As these two end plates are fabricated as box and the thickness is sufficiently large, the membrane effects and bending effects are ignored. And also, it could be reasonably assumed that the entire force of lifting is shared equally without any moments on them. The tensile stress on the cross section
= Force on the end plate (W/2) / Aef 138.23 MPa OK / Normal area

= st(ep) Factor of Safety achieved on yield stress n8 = = =

syield / st(ep) 1.79 Nr.


OPTIMUM

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(d) Design of weld joint for the bottom plate of the adjustable bracket for shear strength (50% of allowable tensile stress is governing) W= 552.9 kN

h5 =

67

Lb = b= Fixing the height h5 at one-third of length of the bracket, Lb h5 Total weld-length provided Total weld-length provided Lw2 Transverse force on the weld joint Pw2 Allowable Shear Stress on effective throat area tallow-w Effective throat thickness tw2 Minimum Fillet Size of the Welds sw2 Factor of safety with fillet size provided n9 = = = = = = = = = = = = = 2 * tw 9.20 mm 1.1 Nr. W 552.9 kN (sallow / 2) * hj 54.25 MPa Pw1 * 1000 / (sw * Lw1) 6.51 mm 67 mm Directly for bottom plate 2 * (Lb + b) + 4 *4* h5 1567 mm X 100

200

Indirectly for ribs supporitng bottom plate

OK OPTIMUM

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(D) DESIGN OF ATTACHMENTS - (a) Design of adjustable (Span variations) suspension bracket for strength Length of the bracket Lb = 150 mm Radius of the lug end R= 120 Clearance above the beam c= 20 mm Diameter of the hole dh = 60 Total Height of the lug h1 = 200 mm Diameter of the pin dp = 48 Height of the cut in the lug h2 = 50 mm Thickness of the lug t1 = 15 Height of taper in the lug h3 = 150 mm Thk of all other plates t2 = 8 Total Width of the lug w1 = 350 mm Weld joints' efficiency hj = 70 Width of the cut in the lug w2 = 116 mm Weld Fillet Size sw = 8 Yield stress (all matl ex. pin) syield = 248 MPa Elastic Modulus of the material 210000 Allowable Stress sallow = 155 MPa Yield stress (pin matl) sy(pin) = 300

mm mm mm mm mm % mm MPa MPa

! Initially "assume" then "Iterate" these values with the help of following Signal Boxes
Design Criterion (a-i) Tensile stress in the lug (a-ii) Bearing / Crushing stress in the lug (a-iii) Tearing stress in the lug (a-iv) Out-of plane buckling of the lug (a-v) Shearing stress in the pin (b) Weld (set-on double fillet) size for lug with other plates (c) Tensile stress in the end plate (d) Weld (set-on double fillet) size for the top plate with other plates t2 = 8 b= 100 Lb = = = 150 Signal Box "SAFE DESIGN" Signal Box "OPTIMALITY" OK NOT OPTIMUM OK OPTIMUM OK OPTIMUM OK OPTIMUM OK OPTIMUM OK OPTIMUM OK OPTIMUM NOT OK OPTIMUM

h2 =

50

(h + c) = h1 = 200

111

h3 = dh = w2 = w1 = 116 dp = 350 R=

150 60 48 120 t1 = W= 276.2 kN 15

The load on the bracket is the straight forward load acting vertically downwards.

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(a-i) Design of lugs on the bracket for tensile strength - FAILURE MODE - 1 (allowable tensile stress is governing) w1 = 350 h2 = 50

h1 =

200

h3 = dh = t1 = 15

150 60

R=

120 t1 = 15

wcs =

304

W=

276.2 kN
h3 - R

The width of the critical section i.e., across the diameter of the hole

w1 - 2 *

R tan sin-1 (h3 - R)2 + (w1 / 2)2 + tan-1

h3 - R (w1 / 2)

wcs The effective width at the critical section

= = =

304 mm Width at the critical section wcs - dh 244 mm Diameter of the hole

wef

The effective normal area at the critical section resisting the force per lug

= = Aef =
wef * t1

Effective width

Thickness

3653 mm

As these two lugs are placed, with the lifting lug in-between, at a closer clearance always, the bending effects on the lug and the pin are ignored. And also, it could be reasonably assumed that the entire force of lifting is shared equally without any moments on them. The tensile stress on this critical section
= Force on the lug (W/2) / Aef 37.80 MPa OK / Effective normal area

= st Factor of Safety achieved on yield stress n2 = = =

syield / st 6.56 Nr.


NOT OPTIMUM

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(a-ii) Design of lugs on the bracket for bearing/crushing strength - FAILURE MODE -2 (80% of the yield stress is governing)

dp = t1 = 15

48

t1 = wb = The effective area bearing the crushing force per lug = = Ab The bearing / crushing stress = = = sb Factor of Safety achieved on yield stress n3 = = = 48
Bearing width

15

W=
X

276.2 kN
Thickness

wb * t1

( Note: Bearing width equals the projected diameter


720 mm
2

Crushing force (W/2) / Ab 191.81 MPa

Bearing area

OK

syield / sb 1.29 Nr.


OPTIMUM

(a-iii) Design of lug on the bracket for tearing strength - FAILURE MODE - 3 (50% of the yield stress is governing)

(R - dh/2) =

90

t1 =

15

t1 = W= Area resisting lateral tension (tearing) per lug = = At = Radii difference (R - dh/2) * t1
1350 mm
2

15

276.2 kN Thickness

Prepared By: R.Venkat

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

Tearing stress

= = stear = = n4 =

Tearing force
(W/2) / At

Area resisting lateral tension (tearing)

( Note: Tearing force conservatively equals lifiting force


OK

102.30 MPa

Factor of Safety achieved on yield stress

syield / sbtear 2.42 Nr.


OPTIMUM
[1]

(a-iv) Design of lug on the bracket for out-of plane buckling - FAILURE MODE - 4 (as per David T. Ricker Requirement is the minimum thickness of the lug on the bracket shall be ensured for 13 mm and 0.25 times the hole diameter d. Required thickness treq = = 0.25 * dh 15.0 mm OK

n5 Factor of safety with thickness provided = 1.0 Nr. OPTIMUM This section is computed in accordance to David T. Ricker, " Design and Construction of Lifting Beams ", Engineering Journal, [1] 4th Quarter, 1991 (a-v) Design of pin for shearing strength - FAILURE MODE - 5 (50% of the yield stress of the pin is governing)

dp =

48

t1 = W= 276.2 kN

15

The pin under double shear along two parallel planes of the inner faces of the lugs, i.e., resisting it with the cross section area The cross section area of the pin Shearing area Shearing Force Shearing Stress sshearing Factor of safety with yield stress n6 As P = = = = = = 2 * [p/4 * dp2]
2 3619 mm

276.2 kN Shearing Force 76.3 MPa 3.9 Nr. / Shearing Area OK OPTIMUM

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(b) Design of weld joint of the lug with other plates for shear strength (50% of allowable stress is governing) t2 = 8 b= 100

h2 =

50

h4 = h1 =

38 200

h3 =

150

w2 = w1 =

116 350 t1 = W= 276.2 kN 15

Fixing the height h4 at 75% of the straight height (h1 - h3) h4 Total weld-length provided per lug Lw1 Transverse force on the weld joint per lug Pw1 Allowable Shear Stress on effective throat area tallow-w Effective throat thickness tw1 Minimum Fillet Size of the Welds sw1 Factor of safety with fillet size provided n7 = = = = = = = = = = = = 2 * tw 4.92 mm 1.6 Nr. OK OPTIMUM W/2 138.1 kN (sallow / 2) * hj 54.25 MPa Pw1 * 1000 / (sw * Lw1) 3.48 mm 38 mm 2 * [2 * (h2 + h4 + t2 + h4) + b] 732 mm

Prepared By: R.Venkat

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(c) Design of end plates of the adjustable bracket for tensile strength (allowable tensile stress is governing) t2 = 8 Lb = = = 150

W=

276.2 kN

The load on the end plates of the bracket is the straight forward lifting force acting vertically against the load. The normal area per end plate resisting tensile force = = Aep = Length of the bracket
Lb * t2
2 1200 mm

Thickness

As these two end plates are fabricated as box and the thickness is sufficiently large, the membrane effects and bending effects are ignored. And also, it could be reasonably assumed that the entire force of lifting is shared equally without any moments on them. The tensile stress on the cross section
= Force on the end plate (W/2) / Aef 115.08 MPa OK / Normal area

= st(ep) Factor of Safety achieved on yield stress n8 = = =

syield / st(ep) 2.15 Nr.


OPTIMUM

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BELLELI ENERGY srl Dubai Technical dept.

Spreader Beam Design

(d) Design of weld joint for the top plate of the adjustable bracket for shear strength (allowable tensile stress is governing) b= 100 Lb = = = 150

h5 =

50

W= Fixing the height h5 at one-third of length of the bracket, Lb h5 Total weld-length provided Total weld-length provided Lw2 Transverse force on the weld joint Pw2 Allowable Shear Stress on effective throat area tallow-w Effective throat thickness tw2 Minimum Fillet Size of the Welds sw2 Factor of safety with fillet size provided n9 = = = = = = = = = = = = = 2 * tw 9.00 mm 0.9 Nr. W 276.2 kN (sallow / 2) * hj 54.25 MPa Pw1 * 1000 / (sw * Lw1) 6.36 mm 50 mm Directly for bottom plate 2 * (Lb + b) + 2*4 * h5] 800 mm X

276.2 kN

Indirectly for ribs supporitng bottom plate

! NOT OK, INCREASE THE FILLET SIZE OPTIMUM

(E) DESIGN OF ATTACHMENTS - (a) Design of fixed suspension bracket for strength ***** Design procedure for the adjustable (Span variations) suspension bracket for strength shall be followed but for the additional consideration of welding with the adjustable cross beam ***** *** IMPORTANT NOTES *** 1) All the basic assumptions about material properties and their linear beaviour, as made in elementary STRENGTH OF MATERIAL and ELASTICITY THEORY will hold good 2) The adjustments for the load carrying brackets considered throughout this computation are of small quantities compared to the span of the beam and will be well within the operating range of the beam selected.
Prepared By: R.Venkat 23 of 23 Printed on: 12/5/2013

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