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HEAT EXCHANGER SUPPORT BRACKET

DESIGN CALCULATIONS

D-ZERO ENGINEERING NOTE # 3823. 11 5- EN-41 7

January 12, 1995

Russ Rucinski
RD/DeJ Mech.

Revision 5/6/96: Added Independent review questions & answers


Added finite element analysis
Added HX top plate analysis
This engineering note documents the design of the heat exchanger
support brackets. The heat exchanger is roughly 40 feet long, 22
inches in diameter and weighs 6750 pounds. It will be mounted on
two identical support brackets that are anchored to a concrete wall.

The design calculations were done for one bracket supporting the full
weight of the heat exchanger, rounded up to 6800 pounds. The
design follows the American Institute of Steel Construction (AISC)
Manual of steel construction, Eighth edition. All calculated stresses
and loads on welds were below allowables. See the Summary table
on the next page.

5 I 16/96 Reyision:
The hand done analysis was independently reviewed by Bob Wands
of RD/MSD and a memo with his questions and my answers are in
Appendix B. As FEA exercise, I ran a element finite element analysis
using beam elements. The information from this analysis is included
as appendix C. All stresses found in the FEA were below allowables.
Additional hand calculations (See Appendix D) for the top attachment
plate were done after Bob Wands' review. At the time of fabrication
the top plate thickness was increased from 1/4" to 3/8". The
stresses for the 3/8" thick top plate were acceptable.
) ) )
Summary of Support bracKet design analysis

DESIGN ITEM MAX. CALCULATED ALLOWABLE COMBINED


STRESS OR LOAD STRESS OR LOAD fa/Fa + fb/Fb < 1.0

Upper horiz. member 1.1 ksi, tensile 27 ksi, tensile 0.357


{411 x 8" X 114" wall rect. tubing} 2.2 ksi, shear 18.4 ksi, shear
9.6 ksi, bending 30.4 ksi, bending

Vertical member, CASE II 1.2 ksi, compressive 27 ksi, tensile 0.155


{4" x 8" x 114"wall rect. tubing} 2.0 ksi, shear 18.4 kSi, shear
3.4 ksi, bending 30.4 ksi, bending

Vertical member, CASE I 2.0 ksi, shear 18.4 ksi, shear not applicable
{411 x 8" x 114" wall rect. tubing} 8.7 ksi, bending 30.4 ksi, bending

_.

,--.. Lower horiz. member 1.1 ksi, compressive 27 ksi, compressive 0.357
~-'
{411 x 8" X 1/411 wall rect. tubing} 2.2 ksi, shear
9.6 ksi, bending
18.4 ksi, shear
30.4 ksi, bending

Wedge anchors, 1/2" dia. 1820 Ibs, tensile load 2400 Ibs, tensile load ftlFt"2 + fv/Fv"2 < 1.0
{Hilti Kwik bolt II} 850 Ibs, shear load 1960 Ibs, shear load 0.763

Fillet weld, top anchor plate 993 Ibsllinear inch 1909 Ibsllinear inch not applicable
{1/8" intermittent fillet weld}

Weld. upper horiz. to vert. member 4146 Ibs/linear inch 3818 Ibs/inch - 2 short sides not applicable
1/411 fillet, 1/4" groove 5250 Ibs/inch - 2 long sides

Weld, vert. to lower horiz. member 2.4 ksi, compressive 27 kSi, compressive 0.676
{1/8" groove weld} 10.8 ksi. bending 18.4 ksi. shear

Fillet weld. bottom anchor plate 993 Ibs/linear inch 1909 Ibs/linear inch not applicable
{1/8" intermittent fillet weld}

Russ Rucinski, RD/DO Mechanical


SECTION ~RIAL-CATEGORY PAGE
FERMILAB

ENGINEERING NOTE .RD/D 3823 .. 115


SUBJECT NAME
1-\ EAT E.xc,",,~~&E::.R 5 WPpo~-r B~A..c...""e..,..

DE.~'(;a....J At-...JA'-""~'.:s
DATE
12-Z0 -94
I
REVISION DATE

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HEAT EXCHANGER sur PORT

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PROJECT 5ER1Al-cATEGORY, PAGE '
FERMI LAB

ENGINEERING NOTE HEAT e:xC~AtJ6EJ 382'0. 1\:; 3


SUBJECT NAME

He.p.-r EXC.\4~,...10;;'1Z- S UPPo IZ.."" RU5"So RUCI"""sK.\


OATE /REVISION DATE
D~I(;.,..J A ~A'-,,-(SI5 1'2.-20 -94

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SECTION PROJECT SERIAlCATEGORY PAGE
FERMILAB
Ua.T 4
ENGINEERING NOTE Ex ~"'#J6'c;IL
SUBJECT NAME
Russ 'RVGINS t:..1
DATE t"l !REVISION DATE
I "2. 'Z, I -, 't

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FERMILAB SECTION PROJECT SERIAL-CATEGORY PAGE
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ENGINEERING NOTE 5
SUBJECT

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1'2.Z'- '1'1
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FERMILAB SECTION PROJECT SERIAL-CATEGORY PAGE
HIC:~j"
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ENGINEERING NOTE E"e.~ At.J(:;e~
SUBJECT NAME

HE-A.T E,)(CHA.-..l6ER:.. 5UPPOtLl" 8(2..AC.'<..E.-r 'Russ Ruc...,.,J.'S1C..1


DATE !REVISION DATE
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SECTION SERIAL-CATEGORY PAGE
FERMILAB

ENGINEERING NOTE ~D It>r:f;


SUBJECT

, DATE /REVISION DATE


{ I Z-2."2.-<74
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SECTION PROJECT SERIALCATEGORY PAGE
FERMILAB
J..I EI'or-r 3 S 2.3 . " 5
ENGINEERING NOTE C1"-CMA,...J&1O.L
SUBJECT NAME
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SECTION PROJECT SERIAL-CATEGORY PAGE
FERMI LAB

ENGINEERING NOTE . 1\.1:) / b r;I 1-t.~T


e )l.eM A N~"1t,.
382!o.":' Cj
SUBJECT NAME

HE;AI'
D i: ~:"
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SECTION PROJECT SERIALCATEGORY PAGE
FERMILAB
~t;:;.A-r
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ENGINEERING NOTE 3 &2.":5, II S
SUBJECT NAME
H cAT EX.c...\-\A..NG~tL ..$uPPOIL-t B~t::e:;1 Ru~~ QI.Jc..,,.,,,JSt::..'
~--~------~----~------
o e.~lG=t..N A,...., ""\"'-f~\c;. DATE
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ENGINEERING NOTE ,I<DI\:>9 \ \


SUBJECT

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K Dy ~ R6'1 ': "'000 L&S

Me ="By ~o ,w) :::. I 310 1 ObO .,., - 'b 'S' .

'B:slolf:') " (4f ,,.,) -" z...r;.\D~'S" (8,...... fi-") ':" '?::>o. b~ ,tJ. I

Dc:...sffJii,jj).'1't; NG(...I> .Jb,t-lT B -ptt.. pet- F,~ 2.s of= AW5 D\,\-4'U
p .... IZ.., . , ... L. ..l 0 IN "\ Pe t-J -.:.-n,A-t"I O~ 6ftt.,8 () va vJ ~ t./)

,1'8"

- TNE: fi:;I-E:.,-"1?'UJlJe Wl~ MA:1""c.,.j"


I -r,-I-b BA-5i:; M~-r'&~I"""'L
At.-t.. oWA13l-E:;5 "Oll- T;J~ W~,-I) ;4t..E; 'tHE SA.M.E:. AS.
""-t-t E:- -rll~" 1'1' .:{Ouv$.

S tt 'E' A:,L I.a I'r (J


,
\ -V;:::.. (R't>)C -1I"lZ. oy) Cosl45 Q
) r.:zo
Co MPI<.E.SS I or-J
CO' ')
FERMILAB SECTION PROJECT SERIAL-CATEGORY PAGE

H E:A-r 12
ENGINEERING NOTE 1<1) /D<;tS t:.Xc..I-1AAJ(,eJL
SUBJECT

Ex c. l4 A t--1 ~to. S v P P Oil-"T" B il." c. KI;. ,...


\-\ E.P-.T
DE; S I t.:J "-' A tv,... '- ""/'$ l S
DATE
\2-Z.Q-'I'f
IREVISION DATE

BE:..~ D, "-1 &

(\At
-= -:r
B f;;N 0 'N(, 3 "='
-- A ..'-OV' A-13 '-E. = '30.

t:..omP /)"1'(/:-1) S-rLc:;.~S~S


I

Ae...e
FO f

". v, If
S.

'- ~S'S 7i-l k""", I'r "'-0 "'-'.A-i3 L-E:. S

iH~Pr;;U:;.. i,...e t,S 6;,<.o01l1Z


II WE; UJ L~J.1( '" H J.s TH(

M I ,.J I M !.1M S I "'Z-c:. A (....L..ow c:. t} fE-I!. A VII S ] IS "N!..


-f4/, 4- -F",~ _ 2 .'"111 10 S/
FCL Fb - ;.;zt . ,. r,l!..Lf -= fo7b (.. I.e
WeI-a A, B,,"""T"o"-"\ PL..A-rt;;. -
-,'II'te. ANA,-Y'SIS IS _,CE.N"1",<:...A-C- -ru 1"" Ht;;:; Af\.J.A,-t.{"SIS

rot<. "T'kS vJe.,-D A"1" -rHE.. -(oP Pc....PtTli:, ... se:& P(;S". 9, roo

AN; SHA~~' 8~-~U;~E~T'~~ F~R~;LAB OR jESTl~C ~A80RATOEv


A'PROVAL. ~HERE REQUIRED. SKEETING AND BRACING SHALL.BE
UTILIZED.
10. tOllECTIOIS FOI OE'AILS lOT SMOMI BUT IECESSARY TO OEVELO'
3. THE SOIL UIDER THE lASE RAT fOUIDATIOI SLUS SKALL HAVE A RERIER OR JOIIT ARE SUBJECT TO FERRILAa APPROVAL.
SAFE IEAIIR' VALUE OF 7.500 PSF fOR THE LOMEI lASE RAT AID
5.000 PSf FOI TME UPPER lASE RAT. 11. AFTER ~EtTIOI. TOUCH-UP ALL AIIAOEO SPOTS AID SPOTS IURIED
I' MELDII' MITM SARE PAIIT AS PIIRE COAT.
_. THE IUILDIIG fOOTIIGS SHALL IE FOUNDED 01 'IAlULAR EIIAIIREIT
MITK A SAFE IEARII' VALUE Of _.000 PSF. SEE SPECIFICATIOI 12. PROVIDE TERPORaRT IRACIIG 'UYS 01 DTHER DEVICES AS I[OUI~
SECTIOI lA. SITE MDRl. PARA&lAPI t.13. TO PIOVIDE-SAFETT AID STAIILITV fOI TME [RECTIOI OF
STRUCTURAL STEEL, LEaVE IRAtll' II PLaCE UITIL ALL 'STEL
5, DEMATER EXCAvaTIOIS I' APPROPRiaTE IEAIS IECESSAIV TO PROVIDE MORI IS II FIIAL POSITIOI AID apPROVED.
A fIRI. DRY SUI..SE fOI COISTIUCTIOI 01 "Clfl~.
13. POITIOIS OF ST[EL TO IE ERIEDDEO II CO",RT SKALL lOT IE
6. ALL UCAVATIOIS SHALL III"'!tTD 9V TRE hllllLU
It PRIRED ORSKOP COATED.
tolSTRUCTIOI toOIlDIIITII IEfORE .UCIII FOBS DR nltlHlltl...

7. .0 fOUNDATIOI COItIETE SIALL It PLAtED II tICAV&JIDNS PRECAST CONCRETE


COITAl III' 'IIEE IATtl 01 FROllR lOlL. 1. FURIISH THt.PlECAIT lOOF SLAIS AS SPttlFltD UlDEI
L SrEClflt&TlOII StcnDl 3. PRECAST ClllCRETE.
I. 10 IAClflLL SHALL It f'LACED AIIIIST STRUCTURES UlTIL CDICIETE
HAS CURtD FOI 7 DAVS AID Ittl APPIOVED IY Til FERRILAI METAL DECKING
tolSTIUCTION toOIDINATOR.
1. "tTAL DECIII' SKAL~ IE I~ A~COIIDAICE MITK ASTK A__6 MITM A
t, SEE SpECIfiCATION StCTIDI lA. SITE WORt. PA.a&lA," t.15. fOI III1IRUI YIELD OF 33000 PSI.
TilE PlOYISIOIS AID SPtCIIL SEOUtNtll' IEIUIIED FOR THE
2. ALL D[ClllG SHALLIE GALVAIIUEO III ACCOIoallCE MITM AST~ A525
'ILLII' AID 1&CIFILLII' fOI STRUCTUIES AID IERRS.
MITM TMt COATIIGS A$ SPtCIFIED UlDER SPECIFicaTION SECllOIL
10. SEE SPECifICATION StCTI.. lA. SITE WORt. PAII&IAPK t.16. FOR
st. lETA!. DElliNG.
FILLIII' AND IACIFILLII' '01 SLAIS 011 &RIDE.
3. THt OECI SHALL It THE DEPTH. TYPE lID SAGE SMOMII ON THt
PLANS.
REINFORCING STEEL
1. REIIFORtIN' lARS SIALL COIFORI TO THE ItOUIIElltlTS OF ASTK -. FISTEN DECI PllltLS TO THt STRUCTURAL fRAltMORI IT tllDS IND AT
ADlS. &llDt 60. IITIIIDIATE SUPPOITS IV MELDS SPACED lOT 1I0Rt THIN lZ
ICIOSS THE MIDTH OF THt PAIEl. WELDIIIG SMALL IE I' THE
2. WtLOEO lilt fAIIIC SMALL CONFORR TO ASTK Al15. AIC-IILOIII' "OCESS. USE MELD MASHtRS 01 THE lOaf DEC,.

3. biIFOllttl' OtTAILS IIIALl CDiFORR TO Atl STAl.DARO 315-80. . FERM'LAB FURNISHED MATERIALS
1. THE R'TtIIALS AID StlvIC(S FUIIISlltD IV FEIRllAI IllL IE 'S
-. ALL COII"IIIOUS lARS SIIALL IE LAPPED 36 DllllnE? FOI .6 lARS OUTLINED II SECTIOM _.0 OF.EIIIIIIT A. SCHEDULE AND
AID PALLEI. AID U DllllnERS 'OR 11 URS UD LUGER. IHUE SlJrPWNTAAY TEIUIS AND CDlDlTIIIS. ..""
IPLICES AlE IEIUIIED. VlLEIS OTIERMIIE IOTED.

5. SuPPo.T TIE IIL)ED lIRE "IIIC .. tIIIIIS DR CIIIICRlE kOCIS

.6. WELDED SPLICES SMALL IE USED '"IE IIIOft .. Tilt OIAMIISS.

CONCRETE
1. IlattllAL AID IOI'IAISHIP SIALl IE II acCORDIlltE MnN TilE
'AILS REIUIIEIEITS Of BUIlDII' toOl FOI REIIFORCED to.cltTE Atl
STUDAID 311.

- I 2. "IIIIIUR 21 DAV STREI'TH fOI STRUCTURAL COIICRETE IIClUDII'


PRECAST SLAIS SHALL It -aoo PSI.

3. KII.RUI 21 DI' ITI'I'TII , .. TIE fILL OVEI rK STAIR TIIADS


IIIALL IE 3000 I'll.

4. towe."t COVEl IIIALL IE AI ....... t. IUIIIIIII _ &I


)'T' IUIIIIE IT Atl STUDIID 311-n.

S. SuKwrlacTII UAU. tlOnillATE TIll PLat... " toCIETt " IS


TI ..IVII[ PWVPI.... ADEtUATI CUTlVTS. ILEttlS. IISI.TI....
It IUILT-II I[YICEI '01 U,EClIICII. . . . .C...'CII.
IIU.NIIl All ",p,n UD dCIIlTtCTUUL I[YICEI. -

I. tDlSTlucTIOI JOIIITS IIIALL It LOCATED as I. . . . . TIt


OIAMII". AaT JOlin lor 111011 IUT _tCESSARY'. .
COiSTIUCTION SHALL It APPRDvED It Tilt FERRIW Entlul. A
~ PEIIDD Of -. NOURS IHILL U,&I'IE itT'" ADJAaJIT CllllClt".,:
... PLACER EllS
Specification Table
Anchor Size
Setting Details HKB HKB HKB HKB HKB HKB
V4" %" 112" 54" 3/4" 1"
BD = 0 drill bit size::::; anchor diameter 14" %" Ik" %" 314" 1"
depth of embedment 214 "/31k" 2314"/4" 41k"/6"
E 11A1"/2" 1%"/21k" 314"1434"
(minimum/standard)
HD hole depth (E + 1 0) min.!std.
1%"
I 214"
2"
I 2~" 2314" I 4"
3%" I 4%"
4"
I 51k"
51k" I 7"
DC wedge clearance hole 5/16" 7/16" 9/16" 11/16" 13/16" 11A1"
1314" 21f4 " 2314" 3314" 4314" 6"
L anchor length min.!max.
41k" 7" 7" 10" 12" 12"
thread length std.! 314" ~"/11A1" 114" 11k" 11k" 214"
TL 3" 4" 4" 31k"/41k" 31k"/41k" 41k"
extra thread length
M Installation Stainless min.E 4 20 40 85 150 235
torque (ft. lb.) Steel std. E 7 30 75 110 200 450
guide values Carbon min. E 4 20 40 85 150 250
Steel std. E 7 25 65 110 235 450
BMT Min. Base Material
3" or 1.3E whichever number is greater
Thickness (inches)
.
Listings
Conforms to the description in Federal Specification FF-S-325, Group II, Type 4, Class 1 for concrete expansion anchors.

UL listed, "Pipe Hangers" (%" - 314" diameters). International Conference of Buildings Officials, ICBO Evaluation Report #4627.

Factory Mutual listed "Pipe Hangers" % KB II wlrod coupler.

Southern Building Code Congress International, SBCCI Report #8913

City of Los Angeles Research Report #24946

Anchor Program .

Standard Kwik Bolt II Sizes

~ ~, ~~
Hole Anchor Min. Hilti Std. Allowable Working Loads
Item Dia. Length Embed. Thread Drill Qty. Per Emb. 4000 psi Concrete
Number Description (In.) (In.) Depth (In.) Length Bit BoxtCtn. (In.) Tension (Ibs.) Shear (lbs.)
000453597 KB 14-134 1f4 13/4 100/900
000453605 KB 14-214 1f4 21f4 11A1 314" TE-C+ 14-6 100/900 2" 630 530
000453613 KB 14-314 1f4 314 100/400
000453621 KB 38-214 % 21f4 1% ~" TE-C+ 3.41-6 100/500 1%" 750 1470
000453639 KB 38-3 % 3 100/400
000453647 KB 38-334 % 3314 1% 11fs" TE-C+ %-6 100/400 21f2" 1370 1470
000453654 KB 38-5 % 5 50/200
000453662 KB 12-234 Ik 2314 50/20C
.. 000453670
000453688
KB 1112-334
KB 12-412
Ik
Ik
If.!
3314
41k
21f4 11f4 "
TE-C+1f2-6

TE-C+ 1f2-12
50/200
501200
31k" 2400 2450 ~
000453696 KB 12-512 51k 25/125
000453704 KB 58-334 % 3314 25/10C
TE-C+%-6
000453712 KB 58-434 % 434 25/75
2314 11k" 4" 3290 3840
000453720 KB 58-6 % 6 25/75
% TE-C+ %-12
000453738 KB 58-7 7 25/75
000453746 KB 34-434 34 434 20/80
TE-C+3f4-8
000453753 KB 34-512 34 51k 20/80
31f4 11k" 4314" 4800 5120
000453761 KB 34-7 314 7 10/40
TE-C+ 3/4-12

,
000453779 KB 34-8 314 8 10/40
000454124 KB 1-6 1 6 5/25
41k 21f4" TE-FY1-13 6" 7070 9200
000454132 KB 1-9 1 9 5/20
Values shown are for shear plane acting through the anchor bolt shank. When the shear plane is acting through the anchor bolt
threads, reduce shear values by 20%
Values shown are for a shear plane acting through the anchor bolt shank. When the shear plane is acting through the anchor bolt
threads, reduce the shear value by 12%.
All other valves shown are for shear plane acting through either body or threads.

100
44/ Design of Welded Connections

Flare-bevel-groove weld (10)


Butt joint (B)
T-joint (T)
Comer jOint (C) L.______ dr
(V; /
(E) : '

~:'~

r'------- --
-'

,!
?
lTl

1?
T3

~-.--1
1 ~R .
lAv
j LT2

Base Metal Groove preparation


Thickness
Root Opening Tolerances Permitted Weld
(U = unlimited)
Welding Joint Root Face As Detailed As Fit Up Welding Size
Process Designation T1 T2 T3 Bend Radius (see 2.10.2) (see 3.3) Positions (E) Notes
R=O +1116.-0 +1/8.-1/16
J2.
BTC-Pl0 T 1min '.3116 min +U.-O +U.-1/16
SMAW 3116 min U All 5I8T 1 02.
C.,3T,min -O.+Not -O.+Not- Z
2 Umited Umited
R.O +1/16.-0 +1/8.-1/16 A
GMAW 3116 min T,min 1-3116 min +U.-O +U.-1I16 J2.
BTC-Pl0-GF U All 51ST 1
FCAW C-3T,min -O.+Not -O.+Not 02.
2 Limited Umited Z
R=O to + 1/16.-0
J2.
1/2 1..112 min +U.-O +U.-1/16
SAW T-P10-S 112 min NtA F 51ST 1 02.
min C-3T,min -O.+Not -O.+Not- Z
2 Limited Limited !
Note A: Not prequalified for gas metal arc welding using short circuiting transfer. Refer to Appendix A.
Note J2: If fillet welds are used in statically loaded structures to reinforce groove welds in corner and T -jOints. they shall be equal to
1/4 T 1 but need not exceed 3/8 in.
Note Q2: The member orientation may be changed provided that the groove dimensions are maintained as specified.
Note Z: Weld size (E) is based on joints welded flush
For cold formed (A500) rectangular tubes. C dimension is not limited (see commentary).

Figure 2.5 (continued)- Prequalified Partial Joint Penetration Groove Welded Joints (see 2.10.1)
-,

Design of Welded Connections/35

Square-groove weld (1)


Butt joint (B) I ~(EJi~ I
-It ')L
T11..

,<i REINFORCEMENT 1/32 TO 1/8.


R NO TOLERANCE

Base Metal Groove preparation


Thickness
Tolerances Permitted Weld
(U .. unlimited)
Welding Joint As Detailed As Fit Up Welding Size
Process Designation Tl T2 Root Opening (see 2.10.2) (see 3.3) Positions (E) Notes
B-Pla 118 max - R..O10 1/16 +1116,-0 1/16 All Tl-1132 B
SMAW T1 Tl
B-P1c 1/4 max - R= min +1/16.-0 1/16 All
2
B
2

Square-groove weld (1)


Butt joint (B)

BeseMelal Groove preparation


Thickness
Tolerances Permitted Weld
(U .. unlimited)
Welding Joint As Detailed As Fit Up Welding Size
Process Designation Root Opening (see 2.10.2) (see 3.3) Positions (E) Notes

3T
SMAW B-Plb 1/4 max +1/16,0 1/16 All - 41

Note B: Joint is welded from one side only.

Figure 2.5 - PrequaHfied Partial Joint Penetration Groove Welded Joints (see 2.10.1)
.. APP''''''' , ')C AS
.
. r.,~=._________________________ ~~L~"'I5Ii:.D s/,.,/'.4
I
i
I
II
I
Ii
f
...
,It
e
i;
!

.. u,a ~
i; 1.
~Q
LU
~ !
i
~


Ii
Il!
;I...
~~ :;;;
~
~~
u
",t ...
~
. . G.l
.a
...
!!
...
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=
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...
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...
November 7, 1995
FERMILAB
RDlMSDlEngineering Analysis Group

To: Russ Rucinski


From: Bob Wands ~'J~
Subject: Review of Heat Exchanger Support Bracket Design Calculations

I have reviewed you design calculations and believe that the basic frame design is sound. In
theory design safety factors will exceed three on the yield of the frame material, due to the
criteria of a single support carrying the entire heat exchanger weight, and the application of AISC
safety factors.

The following question, however, do arise:

1. What was the source of information on the heat exchanger weight?

2. Is there the possibility of a horizontal load parallel to the long axis of the heat exchanger,
and how large can such a load be?

3. Is there the possibility of incidental vertical loads (personnel or equipment)?

4. No estimation of the effects of prying action were presented, and given the relatively thin
plate through which the Hiltis anchor the bracket to the wall, this effect could be
significant.

5. The bracket is of unusual shape; a simple truss would be more efficient. Was this shape
driven by the need to avoid certain volumes due to cable trays, etc?

6. The calculation of vertical force on the vertical member assumes that force can be a
maximum of the heat exchanger weight. However, one simplified analysis can show that,
if the upper bracket is assumed to be pinned to the wall (simply supported) and the upper
horizontal member is loaded, there is a mechanical advantage that tends to multiply the
vertical load on the vertical member. For consistency this load should be examined as the
highest load the member will see.

7. No calculation is presented for stability of the vertical member. As this design will
transfer most of its shear to the bottom bracket via this member, (see 6 above) some
check of stability should be made.

8. Are there any plans to load test the platform to some reasonable margin over it's true
operational load?

9. No factor was included for dynamic loading during installation. Did you intend the
doubling of design load to accommodate this effect?

Overall the note was very complete, well written, and easy to follow. I doubt that answering any
of the questions above will result in a modification to the design, and as soon as I receive your
reply and we get these issues resolved the note will be approved.
November 11, 1995

C~ Fermilab
TO: Bob Wands

FROM: Russ Rucinski

SUBJECT: Reply to comments on review of Heat Exchanger Support Bracket Design Calcs.

Thank you for your review of the calculations. I will address your questions and comments in
this memo. To document the information, a copy of your memo and this memo will be appended
to D-Zero engineering note 3823.115-EN417 as a revision.

ANSWERS:

I. The heat exchanger weight of 6700 lbs was obtained by weighing the heat exchanger
with a below the hook scale when the heat exchanger was initially moved into the D-Zero
assembly building. The heat exchanger was recently weighed at 7100 lbs. The weight change
was due to piping modification work. The center of gravity of the heat exchanger is
approximately 24" towards the bayonet can end. So in the final installation the support closest to
",.-. the bayonet can will see a static load of 3960 lbs. and the other will see 3140 lbs.

2. The possibility of a horizontal load parallel to the axis is only present during installation.
A calculation was done in which I estimated that each support could safely withstand a load of
1835 lbs in this direction, acting at a point 34" away from the wall mounting connection. Even
though the expected horizontal load is an order of magnitude less than this, a temporary member
is attached to one of the brackets to strengthen it in this direction during installation. Due to the
nature of the installation, the other bracket does not have a possibility of horizontal loading.

3. Some additional vertical loading will be applied to the bracket furthest from the bayonet
can end from piping being supported off of the vertical member. It is estimated that the
additional weight will be less than 500 lbs. There will probably be veIY little if any piping
supported off of the bracket nearest the bayonet can of the heat exchanger.

4. The plate through which the Hilti anchors act was increased to 3/8" thickness at the time
of fabrication. In addition, the weld attaching this plate to the rectangular tubing was made
continuous rather than intermittent. Since these changes only increased the strength of the
design, I never revised the calculations. In hindsight, I agree that an analysis of the attachment
plate should have been made. The effects of PlYing are not easily analyzed, and simple
conservative models do indicate that it may have been a concern if the plate thickness was not
increased.

5. The shape of the bracket was chosen by the installation location. The outeIlllost surface
of the vertical member matches the surfaces of concrete support columns in D-Zero.

"........ 6. The simplified analysis that you propose models the connection of the vertical member to
the upper horizontal member as pinned. I think that model is interesting and conservative. I
chose to consider that connection to be rather rigid considering the full around welding at the
joint. If I consider the mechanical advantage model. the stresses in the member are still below
allowable. I prefer not to revise the calculations for a pinned model.
2

7. The vertical member was not analyzed for buckling because it is a very short, stout
~ member with relatively low stresses.
8. We have no plan to load test the supports.

9. Yes, doubling of the design load did give me a margin to take care of any dynamic
loading during installation.
) ) )

/dks'd3s7/ms_rucioski/
RESULTS: 6-RESULTS6
STRESS COMPONENT - MAG MIN: '.8'E-ll MAX: 1.16E+O' VALUE OPTIOH:ACTUAL

1.16E+O'

1.0'E+O'

9.28E+03

8.12E+03

6.96E+03

5.80E+03

'-6'E+03

))
3.'82+03
-0
\J
~
2.32E+03 ...o

1.16E+03
Y

'&11
Page 1
I-DEAS Master Series 2.1: Simulation 02-Jan-96 10:44:39
/dks4d3s7/ms_rucinski/HXbracket2.mf1
Gr~ ID None
Re_ ....t Set 7 - RESULTS7
Report Type contour units IN
Result Type STRESS COMPONENT

Node Stress
1 4.838E-11
2 4.645E+03
3 7.603E-11
4 1.156E-10
5 2.019E-10
6 3.682E-10
7 3.553E-10
8 1.767E+03
9 3.533E+03
10 3.616E+03
11 4. 314E+03
12 5.546E+03
13 6.779E+03
14 5.786E+03
15 2. 950E+03
16 2.710E+03
17 2. 471E+03
18 2.231E+03
19 1. 991E+03
20 1.752E+03
21 1.512E+03
.;--
22 1.273E+03
23 1.033E+03
24 8.732E+02
25 4.805E+03
26 4.327E+03
27 3.850E+03
28 3.372E+03
29 2.895E+03
30 2.417E+03
31 2.087E+03
32 2.079E+03
33 2.400E+03
34 2.877E+03
35 3.355E+03
36 3.832E+03
37 4.310E+03
38 4.787E+03
39 5.265E+03
40 S.742E+03
41 6.220E+03
42 6.698E+03
43 6. 915E+03
44 4.247E+03
45 4.247E+03
46 4.247E+03
47 4.247E+03
48 4. 980E+03
Page 2
I-DEAS Master Series 2.1: Simulation 02-Jan-96 10:44:39
/dks4d3s7/ms_rucinski/HXbracket2.mf1 AP P fCt-.U::;)\ X
C.3
Node Stress
49 6.450E+03

50 7.922E+03

51 9.395E+03

52 1.087E+04

53 1.160E+04

159 8.332E+02

53
Maximum 1.160E+04
1
Minimum 4.838E-11

Average 3.742E+03

--
,eat Exchanger Bracket Results LIsting
elected 566 entities. Use "Highlight_Selection" to see all A,PPE:..ND \ 'f..
:'umber of data items : 0
:umber of data items : 0
'ata component: VON MISES STRESS
c4
~
Maximum Von Mises Stress

deam Location Point Loadset Stress

555 1.0 7 1 11602.9


17 1.0 7 1 10130.7

554 1.0 7 1 8658.4863

545 1.0 5 1 7395.2891

16 1.0 7 1 7186.2974

564 1.0 8 1 6936.2935

565 0.0 8 1 6893.2378

27 1.0 8 1 6458.7412
7 1.0 5 1 6162.7417

563 1.0 8 1 5981.1885

553 1.0 7 1 5714.1079

26 1.0 8 1 5503.6357
18 0.0 6 1 5043.6450

562 1.0 8 1 5026.0825

546 1.0 5 1 4930.1924

556 0.0 6 1 4566.0928

25 1.0 8 1 4548.5283
13 0.0 6 1 4246.6167
14 0.0 6 1 4246.6152
15 0.0 6 1 4246.6152
'hese beams stored in in the processed group
'orces on beam 555 at X - 1.999998 for analysis dataset 5
Axial force - -2634.67
Y shear force 8122.105
Z shear force 0.0002531347
~7que 0.007400619
+ moment - -0.06526328

~ending
Z bending moment - -122825.2

'orces on beam 566 at X- 1.5 for analysis dataset 5


Axial force - 2634.833
Y shear force - -1322.106
Z shear force - -0.0002531347
Torque 0.0261942
Y bending moment - 0.4854327
Z bending moment - -246.9303

--
- l-\X ToP PL.A.TE.. A I-JA I....'-f SIS

l17~ ~4~ -----1' I


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