5022.

1TA
BELOW-THE-HOOK LIFTING DEVICE
Engineering Note Cover Page for MD-ENG-112

Lifting Device Numbers:

FNAL Site No/ Div. Specific No. 160 Asset No.

If applicable If applicable If applicable

ASME B30.20 Group: [X ] Group I Structural and Mechanical Lifting Devices
(check one) [ ] Group II Vacuum Lifting Devices
[ ] Group III Magnets, Close Proximity Operated
[ ] Group IV Magnets, Remote Operated

Device Name or Description 38 Ton Lifting Fixture For the SciBooNE Scibar & EC
Detector

Device was [ ] Purchased from a Commercial Lifting

Device Manufacturer. Mfg Name
(check all [ X] Designed and Built at Fermilab Eng. Drawing: ME - 444427
applicable)
[ ] Designed by Fermilab and Built by a
Vendor. Assy drawing number
[ ] Provided by a User or other Laboratory
[ ] Other: Describe

Engineering Note Prepared by Edward Chi Date January 22, 2007

Engineering Note Reviewed by Dave Pushka Date February 8, 2007

Lifting Device Data:

Capacity 76,000 lbs

Fixture Weight 2,740 lbs.

Service: [ X] normal [ ] heavy [ ] severe (refer to B30.20 for definitions)

Duty Cycle _______ 8, 16 or 24 hour rating (applicable to groups III, and IV)
Inspections Frequency

Rated Load Test by FNAL (if applicable) Date Load

[ ] Check if Load Test was by Vendor and attach the certificate

Satisfactory Load Test Witnessed by:

Signature (of Load Test Witness)

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Notes or Special Information:
The load test procedures and the load test also should make as part of the note.

Fermilab

Particle Physics Division

Mechanical Department Engineering Note

Number: MD-ENG- 112 Date: January 22, 2007

Project Internal Reference:

Project: SciBooNE

Title: The 38 Ton Lifting Fixture for the SciBooNE Scibar & EC Detector

Author(s): Edward Chi

Reviewer(s): Dave Pushka 02/08/2007

Key Words: Beam, lifting fixture, bolt, allowable stress, weld, tensile, shear

Abstract Summary: The 38 ton lifting fixture is specially designed for

lifting and moving the Scibar and Electron Catcher
detector of the SciBooNE experiment. The calculated
working stresses of some critical locations, the welding
sizes, the lifting pin and the connecting bolts subject to
the applying loads have been extensively studied and
discussed per the related applicable specifications and
codes.

Applicable Codes:
“Allowable Stress Design”, AISC, 9th edition
“Below-the-Hook Lifting Devices”, ASME B30.20
#5022, ES&H Manual, FermiLab.

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 “Structural Welding Code-Steel”, AWS D1.1-90
“Aluminum Design manual” by The Aluminum
Association, Inc. 6th edition.
Design the lifting fixture (38 tons) for moving the SciBooNE
Scibar and EC detectors

General:

The assembled Scibar and EC detector weights about 35 tons, and it will move from the
CDF assembly hall to the SciBooNE enclosure as one piece. All the materials used for
the lifting fixture are recycled from the existing materials for the cost savings. Though
some configurations of the fixture are awkward due to the availability of the materials,
however, we never compromise the safety and applications of the fixture. The following
calculations and analysis will approve our ultimate principles.

1. Design Criteria, Assumptions and References:

Total design load Py and the loading capacity of the fixture Pyc:

The fixture is designed to lift the SciBooNE Scibar and Electron Catcher detectors from
the CDF assembly hall and move it to the SciBooNE experimental enclosure.

Figure 1.1 is showing the data of the total weight of the detector with the lifting fixture, it
also indicates the coordinated location of the center of the gravity.

Figure 1.1, The data of the load and the location of the center of the gravity.

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It found out that the total weight of the detector and fixture is ~70,279 lbs, where the
fixture weight is about 2, 733 lbs, and the detector weight is about 67,546 lbs. We assume
there is about 12% of the additional accessorial and miscellaneous item weight, that leads
to the total applying capacity load of the lifting fixture Pyc = 1.12 x 67,546 lbs = 75,651
lbs → 76,000 lbs, so:

Pyc = 76,000 lbs = 38 tons (lifting capacity)

Py = 76,000 lbs + 2,740 lbs = 78,740 lbs.
Where Py = 78,740 lbs is the total load applying under the crane hook from
the lifting pin.

Allowable stresses:

All materials for the lifting fixture are: ASTM A36 ( or better, or unless it specified):
Fu = 58 ksi, Fy = 36 ksi
Fb = Fy /3.0 = 12 ksi = Fv = Fp = Ft
(per section 20-1.2.2.2, ASME B30.20)

All bolt materials: ASTM A325, Fu = 105 ksi

Ft = 44 ksi, Pat = 34.6 kips (for 1” nominal dia.)
Fv = 21 ksi, Pav = 16.5 kips (for 1” nominal dia.)
(per page 4-3, part 4, ASD 9th edition)

All welding metals are E70, where Fu = 70 ksi

Fwv = 0.30 x 70 ksi = 21ksi

References:

Figure 1.2 of page 4 is an isometric view of the 38 tons lifting fixture.

From page 13, there is a listing for the reference drawings which related to this
engineering note.

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 Figure 1.2, The isometric view of the 38 tons lifting fixture
2. Find out the working stresses when the lifting force Pv applying vertically.

Figure 2.1 is simulating the force distribution of the bracket when force applying
vertically through the middle lifting pin.

From figure 2.1 and the engineering drawing ME – 444427, it is found that:

L = 139.75”

P
a
x

R1 R2

Figure 2.1, Force distribution diagram of the lifting fixture as it applies vertically

Py = 76,000 lbs.
R1 = R2 = 38,000 lbs.
*. The distance between the lugs for the lifting pin.

So, Mmax = (Py L) / 4

= (78,740 lbs x 139.75 in) / 4

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 = 2,751,000 in-lbs. @ the center

Assuming R1 = R2 = Py/2 = 39,370 lbs.

2.1 Calculate the working stress at several different locations

2.1a. The working stress in the center of the lifting fixture (x = L/2 = 70”):

Per figure 2.2, the sectional modulus Sxc and the other geometrical properties in the
center of the spreader bar of the strong axis x-x are calculated as following:

Ixx1 = (447 x 2) in4 = 894 in4 for two S15x42.9 I-beams

A1 = 12.6 in2 x 2 = 25.2 in2
y1 = 7.5 + 1 = 8.50 in

Ixx2 =[(14.50 – 6.50) x ( 2.03) /12] in4 = 5.333 in4

A2 = (2.0 x (14.5 – 6.5)) in2 = 16 in2
y2 = 17.0 in

Ixx3 =[(14.50 x 1.03) /12] in4 = 1.208 in4

A3 = 1.0 x 14.5 in2 = 14.5 in2
y3 = 0.50 in

Ixx4 = (2 x 1.0 x 123) ÷ 12) in4 = 288 in4

A4 = ((12.0 x 1.00 x 2) in2 = 24 in2
y4 = 8.50 in

Ixx5 = (2 x 1.44 x 5.1253) ÷ 12) in4 = 32.3 in4

A5 = (5.125 x 1.44 x 2) in2 = 14.76 in2
y5 = 10.50 in

Since y = ∑Aiyi ÷ ∑Ai

= ((25.2 x 8.5 + 16 x 17.0 + 14.50 x 0.5 + 24 x 8.50 –14.76 x 10.5) / 64.94) in
= (542.47 / 64.94) = 8.353 in

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Figure 2.2, The cross section view of the lifting fixture in the center locatio

∆d1 = 0.147 in, ∆d12 = 0.0216 in2

∆d12 A1= 0.544 in4

∆d2 = 8.647 in, ∆d22 = 74.77 in2

∆d22 A2= 1,196 in4

∆d3 = 7.853 in, ∆d32 = 61.67 in2

∆d32 A3= 894 in4

∆d4 = 0.147 in, ∆d22 = 0.0216 in2

∆d22 A2= 0.518 in4

∆d5 = 2.147 in, ∆d22 = 4.6096 in2

∆d22 A2= 68 in4

Also:
∑Ii = Ixx1 + Ixx2 + Ixx3 + Ixx4 - Ixx5
= (894 + 5.33 + 1.208 + 288 – 32.3) in4

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 = 1,156 in4
∑∆di2 Ai = (0.544 + 1,196 + 894 + 0.518 - 68) in4
= 2,023 in4
Itotal =∑Ii +∑∆di2 Ai
= 3,179 in4

Sxc1 = Itotal ÷ 8.353 in = 380 in3

Sxc2 = Itotal ÷ (18- 8.353) in = 329 in3

The max. calculated bending stress fb:

fbc = Mmax / Sxc1 → compressive bending stress
= 2,751,000 lbs-in ÷ 380 in3
= 7.239 ksi < Fb = 12 ksi,

fbc = Mmax / Sxc1 → tensional bending stress

= 2,751,000 lbs-in ÷ 329 in3
= 8.362 ksi < Fb = 12 ksi,

The calculated shear stress fv:

fv = Fy / Atotal = 78,740 lbs / 64.94 in2 = 1.213 ksi < Fv = 12 ksi

2.2a. The working stress at the location where x=19.94” away from the end of the lifting
fixture (x =19.94”):

Per figure 2.3, as it indicating, there is no top connecting plate. However, an 8”x4”x1/4”
rectangular tube locates in the middle. The sectional modulus Sxc and the other
geometrical properties at the location of x = 19.94” of the lifting fixture with respect the
strong axis x-x are calculated as following:

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Figure 2.3, The cross section view of the lifting fixture at the x = 19.94” location

Ixx1 = (447 x 2) in4 = 894 in4 for two S15 x 42.9 I-beams
A1 = 12.6 in2 x 2 = 25.2 in2
y1 = 7.5 + 1 = 8.50 in

Ixx2 =(14.50 x 13) / 12 in4 = 1.2083 in4

A2 = 1.0 x 14.50 in2 = 14.50 in2
y2 = 0.50 in

Ixx3 = (10.56 x (8.03- 7.503) ÷ 12) in4 = 79.31 in4

A3 = 0.25 x 10.56 x 2 in2 = 5.28 in2
y3 = (4.50 + 4.00) in = 8.50 in

Since y = ∑Aiyi ÷ ∑Ai

= ((25.2 x 8.5 + 14.5 x 0.5 + 5.28 x 8.5) / 44.98 ) in
= 5.921 in

∆d1 = 2.579 in, ∆d12 = 6.651 in2

∆d12 A1= 167.605 in4
∆d2 = 5.421 in, ∆d22 = 29.387 in2
∆d22 A2= 426.111 in4

∆d3 = 2.579 in, ∆d32 = 6.651 in2

∆d32 A3= 35.117 in4

Itotal =∑Ii +∑∆di2 Ai = ((894 + 1.208 + 79.31) + (167.605 + 426.111 +35.117)) in4
= (974 + 628) in4

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 = 1,602 in4
Atotal = A1 + A2 + A3 = 44.98 in2
Sxc = Itotal ÷(16 – 5.921) in = 158.9 in3

The moment @ this location when the fixture is lifted:

M@ x=19.94” = 19.94 in x 39,370 lbs = 785,038 lbs- in

The calculated bending stress fb:

fb = M@ x=19.94” / Sxc
= 785,038 lbs-in ÷ 158.9 in3
= 4.94 ksi < Fb = 12 ksi,

The calculated shear stress fv:

fv = Ri / Atotal = 39,370 lbs / 44.98 in2 = 0.876 ksi < Fv = 12 ksi

The working stresses of the lifting fixture are satisfactory when it is subjected 38
tons lifting force vertically.

I don’t think the deflection is an issue for this application regarding the values of the
calculated working stresses. To this end, I omit the calculations of the fixture deflection.

3, The discussions of the lifting pin and the others:

3.1, The size of the pin and the material:

As showing from figure 1.2, there is on lifting pin locates in the center (axial dir. of the
fixture) of the fixture. Per figures 2.1 and 2.2, it can assume the following force
distribution data:

Load case: simple beam with concentrated load at the center

L = 10.0” (See figure 2.2)

Py = 78,740 lbs.
R1 = R2 = 39,370 lbs.

Mmax = (Py L) / 4 (@ the center of the span L)

= (78,740 lbs x 10 in) / 4
= 196,8500 in-lbs.

Assuming use a cold finished round steel (C1018, ASTM 108) with dia. 5.0 in,
where:
Fu = 64 ksi, Fy = 54 ksi
The allowable stresses:
Fb = Fy /3.0 = 18 ksi = Fv = Ft
(per section 20-1.2.2.2, ASME B30.20)

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 then:
Ixx = Iyy = (π d4) / 64 = 30.68 in4
Sxx= I ÷ r = 12.272 in3
Apin = (π d2) / 4 = 19.63 in2

fb = Mmax / Sxx = 196,850 in-lbs / 12.272 in3

= 16.041 ksi < Fb = 18 ksi
fv = Ri / Apin= 39,370 lbs / 19.63 in2
= 2.006 ksi < Fv = 18 ksi

3.2, Bearing stresses of the pin hole area:

Abearing = (1.4375 x 5.00) in2

= 7.1875 in2 → the bearing area of the hole, see fig. 2.2 for more details
fp = Ri / Abearing = 39,370 lbs / 7.1875 in2
= 5.478 ksi < Fp = 12 ksi

The design of the pin and the pin hole area are satisfactory.

4. The connecting bolt and the welds of the lifting fixture:

4.1, The connecting bolts:

The lifting fixture is designed to use 8 bolts (4 bolts at each end of the fixture) to connect
with the Scibar & EC detector or other connecting partner (see figures 1.1 & 1.2)

The spec. of the bolt: ASTM A325, 1”- 8 UNC, 31/2” length
Ft = 44 ksi (allowable tensile stress)
Pt = 34.6 kip (allowable tensional load for nominal 1” dia. bolt)
(per page 4-3, part 4, ASD 9th edition)

Total allowable tensional load for eight 1” dia. A325 bolts:

8 x 34.6 kip = 276.8 kip > 78.74 kip.

The computed pull out force Pout from the base metal:
Per eq. 5.3.2.1-1, section 5.3.2.1, part I-A of “Aluminum Design Manual” 6th edition,
Pout = 0.85 tb D Ftb
= 0.85 x 1.25 in x 1.00 in x 58 ksi
= 61.62 kip (per bolt bearing area) > 78.74 kip/8 = 9.85 kip
Where: tb the thread bearing length on base metal (see drawing ME - 435903)
D.the nominal dia. of the bolt
Ftb. The tensile strength of the base metal (see drawing ME - 435903)

So the bolt selection is satisfactory subject to the applying loads.

4.2, The welding calculations:

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The welds at the end bottom bearing plate area with subject to the lifting force:

Per figure 1.1, figure 1.2 and drawing of ME – 444427, it is found that all the welds do
not subject any significant moments along the major axis. However, we still present some
welding calculations to make sure that all welding sizes are satisfactory.

Figure 4.1, The welds at the bottom bearing plate of the lifting fixture

Figure 4.1 is the welding configuration for the bottom bearing plate (omitting the gussets
conservatively). Treating the welds as a line, then:

L = (5.5 x 4 + 8.5 x 2 + (8.5 -1.5) x 2) = 53 in *

R1 = R2 = 39,370 lbs.
fv = R1 / L = 39,370 lbs / 53 in
= 743 lbs/in
*: Where 1.50” is the free of weld zone for the bolt washer access.

C = working load per unit length ÷ (effective factor × allowable stress)

= (743 lbs/in) ÷ (0.707 x 21 ksi) (See page 4 for Fv value)
= 0.05 in < 0.375 in (designated weld size in the area)
Where: C is the size of the weld.

The welds subject to the minor axis (assuming the z axis of the lifting fixture) moment:

When the lifting fixture is lifting through the bottom bearing plate, we have discussed the
primary and secondary stresses subject the major axis moment in section 2 of page 5 to
page 9. Here are the discussions of the welds subject to the minor axis moment:

Per drawing of ME – 444427, there is an 8”x4”x1/4” tube to connect two beams together
at each end of the fixture. Let’s conservatively assume that the tube will take all the loads

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and moment at this location as showing from figure 4.2. By referring to figure 2.1, it is
found that:

L = 21.25 in,
R1 = R2 = 39,370 lbs/2 = 19,685 lbs.
The moment @ x = 5.34” (where the tube welds to the beam)
Mx=5.34 = 19,685 lbs x 5.34 in
= 105,118 lbs-in

Figure 4.2, The end connecting tube and the welds of the lifting fixture.

Per figure 4.2, treating the welds as a line, it is found that:

( per page 276, table 5.16.1, part 5, “Steel Structures” by C. Salmon & J.
Johnson, 3rd edition)

d = 8.0 inch, b = 4.0 inch

Lw = 2 ( 6+3) = 18 in length of the welds
Ixx = d2 (3b + d)/ 6
= 213.33 in3
Sxx = d (3b+d) / 3
= 53.33 in2

fv = R1 / Lw = 19,685 lbs / 18 in
= 1,094 lbs/in
fb = Mx=5.34 / Ixx = 105,118 lbs-in / 53.33 in2
= 1,971 lbs/in

fr = ( fb2 + fv2 )½ = (1,0942 + 1,9712 )½

= 2,255 lbs/in

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 C = combined working load per unit length÷ (effective factor × allowable
stress)
= (2,255 lbs/in) ÷ (0.707 x 21 ksi)
= 0.152 in < 0.187 in (designated weld size in the area)
Where: C is the size of the weld

The designated weld sizes are satisfactory.

Conclusions:

The lifting fixture has been designed per the related engineering codes after the
calculations and discussions from several the most critical areas, such discussions were
approached by computing the working structural stresses, bolt stresses and weld sizes in
terms of the different applications.

Reference drawings related to this engineering note:

3954.330- ME – 444427
MC – 444423
MC – 444425
MC – 444426
MC – 444449
MC – 444439
ME – 444071 -1
ME – 435903 -1

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