Professional Documents
Culture Documents
To From Page 1 o f 1
Distribution B. L. Coverdell H5-53 Date Nov. 29. 1994
Equipment Stress Analys is
Project Title/Work Order EDT No. 142167
ANALYSIS OF LIFTING BEAM AND REDESIGNED LIFTING LUG FOR ECN No.
241AZ01A DECANT PUMP / E18146
16. KEY
Approval Designator Reason for Transmittal (G) Disposition (H) & (I)
(F)
E, S, Q, D or N/A 1. Approval 4. Review 1. Approved 4. Reviewed no/comment
(see UHC-CM-3-5, 2. Release 5. Post-Review 2. Approved w/comment 5. Reviewed w/comment
Sec.12.7) 3. Information. Dist. (Receipt Acknow. 3. Disapproved w/comment6. Receipt acknowledged
Required)
(G) (H) 17. SIGNATURE/DISTRIBUTION (G) (H)
(See Approval Designator for required signatures)
Rea Dis (J) Name (K) Signature ( I ) Date (J) Name (K) Signature (L) Date Rea Dis
M.
P- (M) MSIN (M) MSIN P-
son
{st&UXcVp
*t
Cog.Eng. T. W. Staehr
Cog. Mgr. J. E. Van Bj
w ys>-\pp-*z-?'Ti -t
QA
S a f e t
V { ^ . g . m - ^ t S t ^ Q K ^ ^ ? . . /Wet /J-f-fr SZ-<4
Env. -
ESA Mngr. R. B. Pai '//<?*/ H5-53
1 I Indep. Review J
18. 19. 20. 21. DOE APPROVAL (if required)
Ctrl. No.
T. U. S, eek; [] Approved
M'&fH [] Approved w/comments
Signature of EDT Authorized Representative Cognizant Manager U Disapproved w/comments
Date Date Date i2. ~d> *
Originator for Receiving Organization
BD-7400-172-1 (02/89)
RELEASE AUTHORIZATION
Document Number:
WHC-SD-WM-DA-179, REV. 0
AASTER
National Technical Information Service (NTIS)
5285 Port Royal Road K.
Springfield, VA 22161 M
Telephone: (703)487-4650 '
DISCLAIMER
This report was prepared as an account of work sponsored by an agency of the United States
Government. Neither the United States Government nor any agency thereof, nor any of their
employees, makes any warranty, express or implied, or assumes any legal liability or responsi-
bility for the accuracy, completeness, or usefulness of any information, apparatus, product, or
process disclosed, or represents that its use would not infringe privately owned rights. Refer-
ence herein to any specific commercial product, process, or service by trade name, trademark,
manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recom-
mendation, or favoring by the United States Government or any agency thereof. The views
and opinions of authors expressed herein do not necessarily state or reflect those of the
A-6001-400.2 (09/94) WEF256 United States Government or any agency thereof.
RELEASE STAMP
OFFICIAL RELEASE O n
BY WHC &
DATE DEC J.4.1994
/^^f^fdt
SkL ^
ANALYSIS OF LIFTING BEAM AND REDESIGNED LIFTING LUGS FOR 241AZ01A DECANT PUMP
REVIEWED BY:
J. S. Burgess, Advanced Engineer <
Equipment Stress Analysis
i
WHC-SD-WM-DA-179
Rev. 0
The need for design verification has been reviewed with the method selected as
indicated below: (ESR/Work Plan # NA / WP-8D430-331.
Independent Review
Alternate Calculations
Qualification Testing
R. B. Pan ^K^'A
Cognizant/froject/Design Manager
SD #WHC-SD-kJM-DA-179
ECN # NA
DWG(S) #_
n
WHC-SD-WM-DA-179
Rev. 0
Document Reviewed ANALYSIS OF LIFTING BEAM AND REDESIGNED LIFTING LUG FOR 241AZQ1A DECANT
PUMP
Author B. L. Coverdell
No. WA
C] Problem completely defined.
[] Code output consistent with input and with results reported in analysis
documentation.
J. S. Buraess )I/3~9/f4
Reviewer Date
m
WHC-SD-WM-DA-179
Rev. 0
ENGINEERING ANALYSIS SOFTWARE REPORT FORM
DESCRIPTION OF ANALYSIS:
The use of the finite-element (FE) analysis program COSMOS/M version 1.70
(SRAC 1994) permitted a quick, easy, and detailed stress analysis of the following
components of the 241AZ01A lifting beam: the top lug, the I-beam and gusset plates
and bottom lugs. These analysis are called TOP_LUG02, LBEAM02 and BOTTOM_LUG01
respectively. Each of these analysis used triangular elements to determine the
stresses developed by the 5,442 kg (6 ton) load.
The FE analysis was performed on a Silicon Graphics Incorporated, Indigo
computer. Electronic copies of the input and output files can be found on the
attached tape and on the Common File Storage (CFS) in the directory w81423/241az01a.
IV
WHC-SD-WM-DA-179
Rev. 0
CONTENTS Page
1.0 Introduction 1
3.0 Discussion 2
4.0 Conclusions 3
6.0 References 4
>
v
WHC-SD-WM-DA-179
Rev. 0
1.0 INTRODUCTION
This analysis determines whether the 241AZ01A decant pump lifting beam
design is adequate given the pump weight of 5,442 kg (12,000 lb). The
analysis also determines the adequacy of the redesigned 241AZ01A lifting lugs
given that the existing ones are inadequate due to clearance problems.
The 241AZ01A decant pump lifting beam was separated into two sections
for analysis purposes. The top section was divided into three components,
which are: the top lifting lug, the I-Beam and gusset plates, and the (4)
lower lifting lugs. The lower section is also divided into three components:
the connecting pin, the vertical bar, and the lifting hook. For more
information on the lifting beam, reference drawing H-2-83761 Rev. 0
(WHC 1994a). A finite-element (FE) analysis was completed on the three
components comprising the top section of the lifting beam. Hand calculations
were used to determine the adequacy of the lower section of the lifting beam
and the redesigned 241AZ01A lifting lugs. For more information on the
redesigned 241AZ01A lifting lugs, reference drawing H-2-820775 Rev. 0
(WHC 1994b) and ECN# 704915 (WHC 1994c).
Both the lifting beam and redesigned 241AZ01A lifting lugs are in
accordance with Standard Architectural-Civil Design Criteria, Design loads for
Facilities (DOE-RL 1993) and are safety class 3. The design and fabrication
of each component is in accordance with American Institute of Steel
Construction, Manual of Steel Construction, (AISC 1989) and the Hanford
Hoisting and Rigging Manual (DOE-RL 1993).
top l i f t i n g lug, 26.53 MPa (3,850 lb/in ) for the I-Beam and gusset plates,
2
and 37,90 MPa (5,500 lb/in ) for the lower l i f t i n g lugs. The hand
2
center of the pin connecting the lower l i f t i n g lug and the vertical bar.
1
WHC-SD-WM-DA-179
Rev. 0
Appendix A also contains calculations showing the maximum stress for the
redesigned 241AZ01A lifting lug. The maximum stress for this component was
determined to be 59.21 MPa (8,594 lb/in ) and occurs due to bending in the
2
3.0 DISCUSSION
The lifting beam and the redesigned 241AZ01A lifting lugs analyzed in
this document are to be used for hoisting the 241AZ01A decant pump. The
lifting beam was divided into two sections for analysis purposes. A FE
analysis was performed on the three components comprising the top section.
These components are:
plates, and lower lifting lug are 62.77 MPa (9,110 lb/in ), 26.53 MPa
2
The lower section of the lifting beam was analyzed using hand
calculations. These calculations are shown in Appendix A. The components of
the lower section are:
The remaining components of the lifting beam were analyzed with hand
calculations (Appendix A ) . The maximum stress in the lifting beam, found in
the pin between the lower lug and the vertical bar, is 68.23 MPa
(9,903) lb/in . 2
2
WHC-SD-WM-DA-179
Rev. 0
4.0 CONCLUSIONS
5.0 REQUIREMENTS
Below is a list of requirements that must be met for this lifting beam
to conform to DOE-RL 1992:
With the above requirements met, the lifting beam is adequate for hoisting of
the 241AZ01A decant pump.
The only requirement for the redesigned 241AZ01A lifting lug is that it
must be welded and inspected per AWS 1994. The redesigned 241AZ01A lifting
lug need not be load tested since it is not considered a below the hook
lifting device per DOE-RL 1992. The redesigned 241AZ01A lifting lug, in this
case, is considered to be part of the object to be hoisted.
3
WHC-SD-WM-DA-179
Rev. 0
6.0 REFERENCES
AWS, 1994, Structural Melding Code, AWS Dl.l, American Welding Society,
Miami, Florida.
DOE-RL, 1992, Hanford Site Hoisting and Rigging Manual, DOE-RL-92-36, U.S.
Department of Energy, Richland Operations Office, Richland, Washington.
4
WHC-SD-WM-DA-179
Rev. 0
Appendix A
Calculations
WHC-SD-WM-DA-179
Rev. 0
Subject: ANALYSIS OF LIFTING BEAM AND REDESIGNED LIFTING LUG FOR 241AZQ1A
DECANT PUMP
Originator: ^ . d . ^ A ^ f r / r /A 3t>~ f4
B. L. Coverdel1, Advanced Engineer Date
A-2
Checker: Date: WHC-SD-WM-DA-179 Rev. 0
From the figure on the previous page and given that the maximum load on the pin will be less than or equal
to 6000 Ibf, the maximum shear and moment can be determined using the following equations. From the
maximum shear and moment calculations the maximum shear bending stresses can be determined. The
interaction of these two stresses must also be checked. The AISC Manual of Steel Construction was used
to determine the allowable stresses. These allowables are shown below.
F := 360002
y
T n e y i e
' d s t r e s s for A 3 6 C S
in
lbf
F =.6F t y F =21600--2
t
lbf
F =F b t F b =21600--^
in
lbf
F =.6F v y F v =21600-J
lbf
F =.9-F b r y F b r = 32400--2
in
Stress calculations for the pin
P = 6000-lbf-1.25 The 1.25 is a 25 percent increase in the load to insure that the lifting
beam will pass the 125 percent of rated load load test.
l=3-in d = 1.5m
a := .25-in b = 2.5-in c =a b is the area the force is distributed over, a and c are the
distance on either side of the distributed force.
P M .. _,-.,_
- - <B = 3000 The distributed force,
b in
7t-d 2
,
A c = j- A = 1.767 -in
c Cross-sectional area of pin.
.3
7t-d J
S =0.331-in 3
V
M := V- a +- ^r M = 3281.25 'lbfin Maximum moment on pin
2-03 K
V lbf
fy--^ f =2122.066^ The pin will support the shear loading. OK
- f =2122.066--^
v
v
c in
M _ lbf
f
b s" := f
b - "7^
_ 9 9 0 2 9 7 4
T h e p i JH support the bending load.
nW
= + p = 0.557 Since the resultant is less than or equal to 1, a 1.375 in. diameter pin is
*" ^v b
adequate. OK
Determine the stresses in the bar given that each bar must support 6000 Ibf. Refer to drawing H-2-83761.
A = R + offset - j -w-2
c A = 6.094-iif
c
lbf
f
v=A: f v = 1230.769- 2
Since the actual shear stress is less than
allowable, the lug is adequate to resist shear
tear out. OK
5.2 BEARING FAILURE
d
A =w-
b r
A b r = 1.953-hr Area under bearing stress.
lbf
f b r = X br f =3840-
br
Since actual bearing is less than the allowable
in bearing, the bar will adequately support the load.
OK
5.3 TENSION FAILURE
This section of calculations determines the remaining stressable area . It then calculates the tensile
stress this area is under. Each side of the bar has a small but significant section of area removed.
y=1.125
y=(x-2 + 2.25)-.5
a = 1.5-in b = .25-in
c := 2-j2-b-R - b 2
c = 1.658-in ^=0.829-in
c
2
,2 .2
x + a - 1.125-in dx Integral defining the area between the two curves.
c
"2
A-4
Checker: Date: WHC-SD-WM-DA-179 Rev. 0
A =0.743-in
s
2
Area due to one removed section (see the sketch above).
A =7t-R -2-A -A
t
2
s h A = 1.676-in
t
2
Total tensile area.
P =447s fifu T h e
stress is less than allowable the
a c t u a l t e n s i i e
Threads must be added to the vertical bar inorder to attach a lifting hook. The reduction in
cross-section area will cause an increase in stress. Determine this stress.
n
2 Cross-sectional area removed due to the
A
thread= 4 ( - 2 2 6 - i n
)
A
thread - = 4 0 1 1
- i n
lifting hook threads.
n 2
bar = 7.069-in
z
Total cross-sectional area of the 3 in.
A
bar 4-( ' ) : = 3 i n
diameter bar.
t bar ~ thread t - 3.057 -iri
A : = A A
M
f =2453.318-^
t OK
in
5.5 THREAD STRESS CALCULATIONS
Threads matching the hook design from drawing H-2-99569 Rev. 4 are used on the vertical
bar, therefore, the threads on the vertical bar are adequate.
The 15 ton lifting hook design was obtained from a Westinghouse Hanford drawing (H-2-99569).
Therefore, the hook is adequate for use in this design.
The welds connecting the top lug and bottom lugs to the I-beam are a prequalified complete penetration
welds per AISC 1992, page 4-164. OK.
A-5
Checker: Date: WHC-SD-WM-DA-179 Rev. 0
2 PLACES
lbf
F y = 36000- Yield stress for A36 CS.
m
lbf
F = 12000 ^
t
in 2
lbf
F = 12000 ^
t
in
lbf
Fb=Ft F =12000
b 2
fa?
F lbf
F = 12000
v
in
lbf
F r=-9F,
b F b r = 32400--^ AISC Manual of Steel Constructions
in
A-6
Checker: Date: WHC-SD-WM-DA-179 Rev. 0
8.1 SHEAR TEAROUT
Determine if the lifting lug will fail due to shear tearout as shown in the sketch below. Since there are two lugs
assume that one lug can carry 2/3 of ie load to be conservative.
P := 12000-lbf p
Iug = 2 lug = 9000-lbf
3
Each lug is constructed of two plates, assume that one plate can carry 2/3 of the lug load
p
lug
p
plate = - -
:
P pIate =675<Hbf
3
A :=2-l-iiT
v
A =2in v
The minimum area in shear.
plate
lbf
f =3375- This calculation shows that shear tearout is not a
factor in this design. OK
v 1
in
A := 2.0625-int
b r
Projected area of hole in bearing.
p
plate
c
br The actual bearing stress is less than the allowable bearing stress. OK
br
A-7
Checker: Date: WHC-SD-WM-DA-179 Rev. 0
8 3 TENSION FAILURE
Given the tension failure shown below and the sketch on the previous page, determine the tension stress.
A =2-lint
t
A = l-int
2
Area under tensile loading.
plate
f
t= A
lbf
f = 6750
t 5
The actual tensile loading is less
in than the allowable. OK
Given the 2" diameter pin shown in the sketch on page A-1, determine if it is adequate to support the load on the lug.
1 = 3-in d := 2-in Obtained from the sketch on page A-1 and the drawing H-2-820775.
*-<T i
A = 3.142-in
c
:
Cross-sectional area of the pin.
S = 0.785-in 3
Section modulus of the pin.
~32~
Pjug
V:= V ==4500 -lbf Maximum shear load on the pin.
2
Plug 1
lbf
fy = 1432.394' The actual shear load is less than the allowable. OK
M lbf
fb = 8594.367 The actual moment is less than the allowable. OK
A-8
Checker: Date: WHC-SD-WM-DA-179 Rev. 0
Check interaction of the shear and moment stresses.
fb f
v
= + p 0.836 =
Since the interaction, of the two stresses is less than or equal to 1 the pin is adequate per
*b F v
AISC. OK
A w := Ji-d
r
'" A
lbf
f = 1432.394-^-
rr Linear force on
in
weld.
Ibf
f := 360002
a
Allowable
in
force on weld.
fr
W r
~.707-f a
A-9
Checker: Date: WHC-SD-WM-DA-179 Rev. 0
Determine the stress in the rectangular weld shown below if it is treated as a line.
w
plate = n 8 i
A
w 2* * plate
= + w
plate
I A
f
r
w
'" A
= 17-in
P
lug
Linear area of the weld.
lbf
f = 529.412
r Linear force on weld,
in
i
lbf
f, = 36000-^r ... ...
a
2 in Allowable force on weld.
size.
w = .1875-in
a w =0.187'in
a
The actual weld size.
FS FS =9.014 The actual weld size is less than the required weld
size. OK
A-10
WHC-SD-WM-DA-179
Rev. 0
Appendix B
B-l
Rev. O
0 a e 0 0 R
</5 3 Oi
CO
8 B
ii
u
CD
CO
UJ
on
J
t
CO
a-E
WHC-Sb-WAA-bA-n ! 6
Rev. O
o R
I
5
00
o
> CO .o CD
85 J
J
u
in
c
-J-
3-3
WUC-Sb-WMrbfl-nCi
fW. o
in
f
Hal
^
to
BrM