CALCULATION OF SPREADER BAR

FOR MODULE LIFTING AT FULL LOAD CONDITION

125 M.TON SWL, 5000 mm LENGTH

General Data

Total Vessel Weight = 0.00 Tons = 0 lbs

Total Structural Weight = 125.00 Tons = 275578 lbs
Total Empty Weight = 125.00 Tons = 275578 lbs
Rigging + Spreader Beam Weight = 2.00 Tons = 4409 lbs
Total Lifting Weight = 127.00 Tons = 279987 lbs
Weight Contingency, 10% = 0.00 Tons = 0 lbs
Total Weight = 127.00 Tons = 279987 lbs
Total Weight for Design, W = 127.00 Tons = 279987 lbs
(1)
Safety Factor, SF = 1.50
W SWL = 1.5 * W = 190.50 Tons = 419981 lbs
W SF = W SF = 190.50 Tons = 419981 lbs
Total Length, Lt(2) = 5000 mm = 196.85 in
Length to CoG, Lcg = 2500 mm = 98.43 in
Height to Center, HC = 292 mm = 11.50 in
Angle 1, 1 = 60.0 deg = 1.05 rad
Angle 2, 2 = 60.0 deg = 1.05 rad

Sketch :

1
2

Hc Fh1 Fh2

W1 W2

Lt
Lc.g
Z

X Y CoG
PACKAGE

Page 1
 Pipe Data ( 14 NB Sch 80 )

Outside Diameter, OD = 355.60 mm = 14.000 in

Inside Diameter, ID = 317.50 mm = 12.500 in
Nominal Thickness, tnom = 19.05 mm = 0.750 in
Minimum Thickness, tmin = 16.95 mm = 0.668 in
Calculated Inside Diameter, CID = 321.69 mm = 12.665 in
Section Area, A = 18037.7 mm 2 = 27.96 in2
Moment of Inertia x-x, Ix = 25922 cm 4 = 622.78 in4
3 3
Section Modulus x-x, Sx = 1458 cm = 88.97 in
Radius of Gyration x-x, rx = 120 mm = 4.72 in

Material Data (A106B)

Elastic Modulus, E = 199947.95 MPa = 29000000 psi

Yield Stress, Sy = 241.32 MPa = 35000 psi
Allowable stress based on AISC Code 9th Ed. :
Allow. Tensile Stress, Sta = 0.6 Sy = 144.79 MPa = 21000 psi
Allow. Comp. Stress, Sca = SCa (refer below) = 107.14 MPa = 15540 psi
Allow. Bending Stress, Sba = 0.66 Sy = 159.27 MPa = 23100 psi
Allow. Shear Stress, Ssa = 0.4 Sy = 96.53 MPa = 14000 psi
Allow. Bearing Stress, Sbra = 0.9 Sy = 217.18 MPa = 31500 psi

Allow. Comp. Stress Based on AISC Code 9th Ed

Effective Length Factor, K = 1.00

Ratio of Effective Profile Area, Qa = 1.00
Axial Stress Reduction Factor, Qs = 1.00
2
' 2 E
Slenderness Ratio, C c = = 127.89
Q sQa S
K.Lt
This image
cannot currently
be display ed.
= 41.71
rx
K.Lt / r x
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be display ed.

= 0.326
C 'c
Coefficient of Compressive Stress, Ca = 0.444 from table 4 AISC Specification
Allow. Comp. Stress, SCa = Sa Qa Qs Ca = 107.14 MPa = 15540 psi

Force & Moment Calculation

W 1 = [ (Lt - Lcg) / Lt ] W SF = 95.25 Tons = 209990 lbs

W 2 = ( Lcg / Lt ) W SF = 95.25 Tons
Fh1 = W 1 / tan (1) = 54.99 Tons
Fh2 = W 2 / tan (2) = 54.99 Tons
Moment x-x on Point 1, Mx1 = Fh1 HC = 157474 N.m
Moment x-x on Point 2, Mx2 = Fh2 HC = 157474 N.m
= 209990 lbs
= 121238 lbs
= 121238 lbs
= 1393759 lbs.in
= 1393759 lbs.in

Page 2
 Stress Calculation

Compressive Stress, Sc = Fh / A = 29.90 MPa = 4336 psi

Bending Stress, Sb = Mx / Sx = 108.01 MPa = 15666 psi

Calc'n Check

Compressive Stress y-axis, Sc/Sca = SAFE Ratio = 27.9%

Bending Stress x-axis, Sb/Sba = SAFE Ratio = 67.8%
Unity Check:
Coefficient Applied to Bending, Cm x = 1
12 2 E
F 'ex =
Euler Stress, KLt
2
= 85842
23
rx
Sc Cm x Sb
Formula 1.6-1a, + = OK Ratio = 99.3%
Sc a Sc
1 Sb a
F ' e x

Formula 1.6-1b, Sc Sb = OK Ratio = 95.7%
+
Sc a Sb a
Note:
1. SF including DAF(1.1), SKL (1.0), CF (1.35)
2. Lt is total length taken between padeyes

Page 3
 CALCULATION OF LIFT LUG ON SPREADER BAR
FOR MODULE LIFTING AT FULL LOAD CONDITION
125T SWL,5000 m Length

Generals Data:
Max vertical load = 95.3 Ton = 209988 lbs
Uncertainty factor for CG, 5% = 4.8 Ton = 10499 lbs
Total weight, W = 100.0 Ton = 220488 lbs
Number of lug, NL = 2.0
Angle, = 60.0 deg = 1.05 rad
Max vertical force, Fz = W = 100.0 Ton = 220488 lbs
Max horizontal force (in-plane), Fy = W / tan () = 57.7 Ton = 127299 lbs
Max lateral force (out-of-plane), Fx = 0.05 Fz (1) = 5.0 Ton = 11024 lbs
2 2 2 0.5
Max tension force in sling, Fsl = (Fz + Fy + Fx ) = 115.5 Ton = 254597 lbs

Shackles Data: (Shackle Crosby G-2130 85T WLL)

Shackle working load limit, WLLs = 85.0 Ton = 187391 lbs
Safety factor of shackle, SFs = 2.0
Shackle max. proof load, MPLs = 170.0 Ton = 374782 lbs
Pin diameter, DP = 83 mm = 3.25 in
Jaws width, W J = 127 mm = 5.00 in
Jaws height, HJ = 330 mm = 12.99 in

Sling Data: (12T WLL)

Diameter of sling, Ds = 80 mm = 3.15 in
Working Load Limit = 80.0 Ton = 176368 lbs
Safety factor of sling, SFsl = 4.0
Sling ultimate load, Usl = 320.0 Ton = 705472 lbs

FZ Fsl

R

FY
HT

HH
DH
Z

Hw

X Y
CL of Pipe - spreader bar

WL
Lug Dimensions:
Total Height of lift lug, HT = 528 mm = 20.78 in
Height of hole centreline, HH = 150 mm = 5.91 in
Height of slot in, Hw = 178 mm = 7.00 in
Width of lug, W L = 400 mm = 15.75 in
Radius of lug, R = 200 mm = 7.87 in
Diameter of hole, DH = 90 mm = 3.54 in

Page 4
Thickness of lug, tL = 75 mm = 2.95 in
Radius of cheek, r = 0 mm = 0.00 in
Thickness of cheek, tC = 0 mm = 0.00 in
Check shackle strength, Fsl / MPLs = Safe Ratio = 67.93%
Check sling strength, Fsl / Usl = Safe Ratio = 36.09%
Check space of hole and pin, Dp / DH = Clear Ratio = 91.67%
Dp - DH = 7.50 mm = 0.30 in
Check space of jaws and lug thickness, tL+2tC / W J = Clear Ratio = 59.06%
(W J - tL - 2 tC)/2 = 26.00 mm = 1.02 in
Check space of jaws, lug height and dia. of sling = Clear Ratio = 83.33%
HJ - R - 1.5Ds + DH/2 = 55.00 mm = 2.17 in

Material, Stress and Properties Data:

Lug material = A-36
Yield stress, Sy = 248.21 MPa = 36000 psi
Allowable stress based on AISC Code 9th Ed. :
Allow. Tensile Stress, Sta = 0.6 Sy = 148.93 MPa = 21600 psi
Allow. Bending Stress, Sba = 0.66 Sy = 163.82 MPa = 23760 psi
Allow. Shear Stress, Ssa = 0.4 Sy = 99.28 MPa = 14400 psi
Allow. Bearing Stress, Sbra = 0.9 Sy = 223.39 MPa = 32400 psi
DH/2R = 0.23
(2)
Stress-Concentration factor (near hole), K = 2.50
(for flat plate with centrally located circular hole in tension based on DH/2R value)
Section modulus of lugs, SLy = tL2 W L / 6 = 375.00 cm3 = 22.88 in3
2
Section modulus of lugs, SLx = tL W L / 6 = 2000.00 cm3 = 122.05 in3

Stresses at Lug:
Tension stress z-axis, Stz = Fz /(W L tL) = 32.69 MPa = 4742 psi
Bending stress z-axis, Sbz = HH(Fy/SLx+Fx/SLy) = 62.08 MPa = 9005 psi
Shear stress y-axis, Ssy = Fy / (W L tL) = 18.88 MPa = 2738 psi
Shear stress x-axis, Ssx = Fx / (W L tL) = 1.63 MPa = 237 psi
Total stress, ST = Sqrt( (Stz+Sbz)2+ Ssy2+ Ssx2) = 96.65 MPa = 14018 psi
Check tension stress z-axis, Stz/Sta = Safe Ratio = 21.95%
Check bending stress z-axis, Sbz/Sba = Safe Ratio = 37.90%
Check shear stress y-axis, Ssy/Ssa = Safe Ratio = 19.01%
Check shear stress x-axis, Ssx/Ssa = Safe Ratio = 1.65%
Check total stress, ST/Sy = Safe Ratio = 38.94%
Unity Check, Stz/Sy + Sbz/Sy + Ssy/Sy + Ssx/Sy = Safe Ratio = 46.45%

Stresses near the Hole:

Tension stress, Stz = K Fz / [(W L - DH) tL] = 105.46 MPa = 15296 psi
Tension stress, Sty = K Fy / [(HH + R - DH) tL] = 72.60 MPa = 10529 psi
Shear stress, Ssx = K Fx / [(W L - DH) tL] = 5.27 MPa = 765 psi
2 2 2
Total stress, ST = Sqrt( Stz + Sty + Ssx ) = 128.14 MPa = 18585 psi
Bearing stress, Sbr = Fsl / [Dp (tL + 2tc)] = 183.03 MPa = 26546 psi
Pull-out shear, Ssp = Fsl / [tL(R - DH) + 2tc(r - DH)] = 97.42 MPa = 14130 psi
Check tension stress z-axis, Stz/Sta = Safe Ratio = 70.81%
Check tension stress y-axis, Sty/Sta = Safe Ratio = 48.75%
Check shear stress x-axis, Ssx/Ssa = Safe Ratio = 5.31%
Check total stress, ST/Sy = Safe Ratio = 51.63%
Check bearing stress, Sbr/Sba = Safe Ratio = 81.93%
Check pull-out shear stress, Ssp/Ssa = Safe Ratio = 98.12%
Unity Check, Stz/Sy + Sty/Sy + Ssx/Sy = Safe Ratio = 73.86%

Note:
1. Lateral force is calculated based on 5% vertical force
2. Taken from Roy Craig Jr., "Mechanic of Materials", page : 619, Figure: 12.3

Page 5
 WELD CALCULATION OF LIFT LUG ON SPREADER BAR
FOR MODULE LIFTING AT FULL LOAD CONDITION
#REF!
150T SWL,5000 m Length

General Data:
Max vertical load = 95.3 Ton = 209988 lbs
Uncertainty factor for CG, 10% = 4.8 Ton = 10499 lbs
Total weight, W = 100.0 Ton = 220488 lbs
Number of lug, NL = 2.0
Angle, = 60 deg = 1.05 rad
Vertical force z-axis, Fz = 100.0 Ton = 220490 lbs
Horizontal force y-axis, Fy = 57.7 Ton = 127300 lbs
Lateral force x-axis, Fx = 5.0 Ton = 11024 lbs
Sling force, Fsl = 115.5 Ton = 254599 lbs

FZ Fsl

R

FY
HT

HH
DH
Z

Hw

X Y

WL

Weld length (assume only top and bottom side welded -conservative method)
Weld length around on lug, Aw = 4W L = 1600 mm = 62.99 in
Length of weld around on each cheek, Ac = 2r = 0 mm = 0.00 in
Fillet weld dimension on lug, w = 25 mm = 0.98 in
Fillet weld dimension on cheek, wc = 0 mm = 0.00 in
Allowable weld stress, Sw = 66.19 MPa = 9600 psi

Load on fillet weld per linear inch of weld:

Tension stress of weld, St = Fz / Aw = 24.13 MPa = 3500 lbs/in
Shear stress of weld, Ss = Fy / Aw = 13.93 MPa = 2021 lbs/in
Lateral stress of weld, Sl = Fx / Aw = 1.21 MPa = 175 lbs/in
Cheek plate stress of weld, Scp = Fsl tc / [Ac (tL + 2tc)] = 0.00 MPa = 0 lbs/in

Load on weld:
Tension stress of weld, ft = St / (0.707w) = 34.68 MPa = 5030 psi
Shear stress of weld, fs = Ss / (0.707w) = 20.02 MPa = 2904 psi
Lateral stress of weld, fl = Sl / (0.707w) = 1.73 MPa = 252 psi
Total stress of weld, fT = Sqrt( ft2 + fs2 + fl2 ) = 40.08 MPa = 5814 psi
Each cheek pl. stress of weld, fc = Scp / (0.707wc) = 0.00 MPa = 0 psi

Check tension stress, ft/Sw = OK Ratio = 52.40%

Check shear stress, fs/Sw = OK Ratio = 30.25%
Check lateral stress, fl/Sw = OK Ratio = 2.62%
Check total stress, fT/Sw = OK Ratio = 60.56%
Unity Check, ft/Sw + fs/Sw +fl/Sw = OK Ratio = 85.27%
Check cheek plate stress = OK Ratio = 0.00%

Book Reference : Eugene F.Megyesy, "Pressure Vessel Handbook-Eleventh Edition", page : 459.

Page 6