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Shell Petroleum Development Company of Nigeria

Classification Status: Restricted

May 2018 DOCUMENT NUMBER :

SSG-NG01017365-GEN-CS-8180-00007

SOUTHERN SWAMP SALES GAS EVACUATION PIPELINE


(SSSGEP) PROJECT

PIG LAUNCHER PLATFORM LIFT ANALYSIS &


DESIGN REPORT (MODULE 1,2,3)

Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced
without prior written permission from Shell Petroleum Development Company
Revision Date Status Originator Checker Approver

C01 07/05/2018 Approved For Construction


A. Ajuya C. Ekweozor D. Nnanna

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ADDITIONAL AGREEMENT/APPROVAL RECORD

Party Ref Ind. Name Sign Date

Revision Philosophy
 Revisions for review will be issued at R01, with subsequent R02, R03, etc. as required for FEED.
 Revisions for review will be issued at D01, with subsequent D02, D03, etc. as required for DED
Deliverables
 All revisions approved for issue or design will be issued at A01, with subsequent A02, A03, etc as
required.
 Documents approved for Construction will be issued at C01, C02, C03, etc as required
 Documents or drawings revised as “As built” will be issued as Z01, Z02 Z03 etc as required
 Narrative sections revised from previous approved issues are to be noted in the table below and/or
highlighted in the RH margin (using the appropriate revision status) thus: A02
 Previous revision highlighting to be removed at subsequent issues.
 Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected
areas and by the use of a triangle containing the revision status.
 If a document is cancelled the document will be issued at the next sequential number and suffixed with
a X. For example if 02R is the current revision then 03X will be the Cancelled revision.

Revision History

Revision No. Date of issue Document ID/Reason for change

D01 01/03/2018 D01 Comment

D02 10/04/2018 No Comment

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CONTENTS
1.0  PROJECT DESCRIPTION ................................................................................. 4 
1.1  Scope of Work .................................................................................................... 4 
1.2  Design Methodology ........................................................................................... 5 
1.3  Codes, Specifications and References............................................................... 5 
1.3.1  Nigerian National Standards ................................................................... 6 
2.0  STRUCTURAL MODEL ...................................................................................... 7 
2.1  General ............................................................................................................... 7 
2.2  Global Axis System............................................................................................. 7 
2.3  Material Properties.............................................................................................. 7 
2.4  Effective Length Factor (K – Value).................................................................... 8 
2.5  Boundary Conditions .......................................................................................... 8 
2.6  Lifting Sling Height Computation ........................................................................ 9 
3.0  APPLIED LOADS ............................................................................................. 15 
3.1  Basis Load Cases ............................................................................................. 15 
3.2  Load Combination Cases ................................................................................. 16 
4.0  ANALYSIS RESULTS....................................................................................... 17 
4.1  Sling Forces ...................................................................................................... 17 
4.2  Stress Unity Check Results .............................................................................. 18 
5.0  LIFTING EYE DESIGN CALCULATION........................................................... 20 
5.1  Module 1 Lifting-eye design calculation............................................................ 20 
5.2  Module 2 Lifting-eye design calculation............................................................ 25 
5.3  Module 3 Lifting-eye design calculation............................................................ 30 
6.0  CONCLUSION. ................................................................................................. 34 
7.0  APPENDIX: STAAD.PRO INPUT/OUTPUT FILE (MODULE 1) ...................... 35 
8.0  APPENDIX: STAAD.PRO INPUT/OUTPUT FILE (MODULE 2) ...................... 42 
9.0  APPENDIX: STAAD.PRO INPUT/OUTPUT FILE (MODULE 3) ...................... 49 

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1.0 PROJECT DESCRIPTION

The project scope includes all works necessary for, arising out of and incidental to the
Engineering, Procurement, Installation and Commissioning of 16” x 34km Southern Swamp
Sales Gas Evacuation Pipeline from the Tunu Central Processing Facility (CPF) in Ekeremou
Local Government Area of Bayelsa State to the EA Riser Platform – A (EARP-A) Offshore
Nigeria. This Pipeline provides the only evacuation route for processed Gas from Tunu CPF in
order to meet COMPANY’s domestic gas supply and flares down obligations on the Southern
Swamp Sales Gas Evacuation Pipeline (SSSGEP) Projects.

The Sales Gas Evacuation Pipeline shall convey hydrocarbon and water dew pointed gas from
Tunu CPF to the domestic gas market using existing pipeline infrastructure downstream of
EARP-A and thus the 16” x 34km Sales Gas Evacuation Pipeline must meet stringent export
gas specifications for the Escravos Lagos Pipeline System (ELPS). The offshore section of the
16” x 34km Tunu to EA Riser Platform A is approximately 18.4km of the total pipeline length
inclusive of the shore approach area. The remaining onshore section (swamp and river
crossings) is estimated as 15.6km.

The 16” x 34km Southern Swamp Sales Gas Evacuation Pipeline shall be installed from the pig
launcher platform around 354,367mE 97,144mN at Tunu Central Processing Facilities (CPF) in
Ekeremo Local Government Area of Bayelsa State and will hook up to a pre-installed riser
flange around 325,789.86mE 84,099.51mN at EA Riser Platform - A (EARP-A) Offshore
Nigeria.

1.1 Scope of Work


The objective of this design calculation is to:

 Develop a lift model for the Pig Launcher Platform (Module 1, 2) and Hoist Structure
(Module 3).

 Ensure that all structural elements satisfy code check requirements in accordance with
Eurocodes, Shell’s DEPs as well international codes and standards and are adequate
for Ultimate Limit State and Serviceability Limit State conditions during lifting.

 Provide Sling Reactions and details for installation purpose.

 Design appropriate lifting pad – eyes for respective module.

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1.2 Design Methodology
The Pig Launcher platform (with the hoist structure included) was designed to be lifted in three
parts and was therefore split into three modules for lift analysis. The Pig launcher platform was
separated into two parts of 12m each (module 1 & 2) while the hoist structure formed module 3.

Lifting analysis was performed using STAAD.pro for each of the modules in line with factors,
loads and parameters defined in the relevant sections of Eurocodes, Shell’s DEP, DNV codes
and Civil/Structural Design Basis.

The resulting sling forces shall be used for the design of lifting pad-eyes and to select
appropriate sling and shackle materials.

1.3 Codes, Specifications and References


CODES
EN 1990 Eurocode: Basis of structural design.

EN 1991 Eurocode 1: Actions on structures.

EN 1993 Eurocode 3: Design of steel structures.

DNV 2.7.3: Portable Offshore Unit, May 2011.

DNV 2.7.1; Offshore Containers, April 2006.

SPECIFICATION

DEP 34.00.01.30 Gen-: Structural Design and Engineering of Onshore Structures. Feb 2015.

DEP 34.28.00.31 Gen -: Onshore Steel Structures. February 2015.

PROJECT DOCUMENTS

 Piping Arrangement Drawing Plan – Tunu CPF Export Gas Pig Launcher (A – 2309) - (SSG-
NG0107365-TUNG1-MP-4018-00001_D02 Sheet 1/1).

 Civil Plot Plan _SSG-NG01017365-GEN-CX-4024-00003_C01.

 Datasheet For Pig Traps (16”) _ SSG-NG01017365-GEN-MS-2105-00001_D03.

 Tunu CPF – Pig Launcher Structural Steel Platform (Framing Plan) _ SSG-NG01017365-
GEN-CX-2386-00001_C02.

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PROJECT SPECIFICATIONS

 SSG-NG01017365-GEN-CX-7880-00003_C01_Specification for Structural Steel Works.

 SSG-NG01017365-GEN-CX-7880-00005_C01_Specification for Structural Engineering


Design.

 SSG-NG01017365-GEN-CX-7880-00001_C01_Civil and Structural Engineering Design


Philosophy.

1.3.1 Nigerian National Standards

S/N Document Title

1 The Mineral Oils (Safety) Regulations of the Federal Republic of Nigeria

2 The Oil Pipelines Act (CAP 338 LFN 1990)

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2.0 STRUCTURAL MODEL

2.1 General

The pig launcher platform lift models were derived from the platform inplace model. The lift
models for modules 1, 2 & 3 were developed in STAAD.Pro V8i (select series 5) and
configured as a 4-point single hook lift with minimum sling angle of 60 deg to the horizontal.
For respective modules, the centre of gravity was generated by the software and the hook
point was positioned directly above it. The sling height was computed and the result used to
position the hook point.

2.2 Global Axis System

The model global axis system is as follows:

 X – axis in the transverse direction.

 Y – axis in the vertical direction.

 Z – axis in the longitudinal direction.

2.3 Material Properties

The basic material properties used in the structural analysis and design are as follows:

Steel
 Steel grade S275
 Yield strength 275 N/mm2
 Young modulus of steel 210000 N/mm2
 Poison ratio 0.3
 Steel Density 7850 Kg/m3
 Shear Modulus, G 0.81 x 105 N/mm2

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2.4 Effective Length Factor (K – Value)

The effective length coefficients for STAAD.Pro analysis models are as follows:

Member Type Effective Length coefficient

Ky Kz

Beams 1.0 1.0

Columns 1.0 1.0

Braces 1.0 1.0

Cantilevers Beams 2.0 2.0

UNL shall be taken as 1.0 for all members.

2.5 Boundary Conditions

The structural frame for each of the pig launcher platform modules were fixed at the hook
points. At the assumed support points, a restraint in the x and z direction with a spring
constant of 100 N/mm (100 kN/m) was applied.

Also, the module for hoist structure was fixed at the hook point. At the support points, a
restraint in the x and z direction with a spring constant of 100 N/mm (100 kN/m) was applied.

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2.6 Lifting Sling Height Computation

REFERENCE CALCULATION OUTPUT


LIFTTING SLING HEIGHT COMPUTATION (MODULE 1)

Hook Point

Hook Point

X = 0.00 Hsling
Y = 0.00
Z = 0.00 60 Deg.
9.600
R
CoG
Z
X = 2.684
X Y = 0.00
Z = 4.849

3.555

Figure 1: Schematic Isometric view of module 1 showing coordinates and dimensions


Distance Z = 4.849 - 0.00 = 4.849 m
Distance X = 2.684 - 0.00 = 2.684 m
2 2
Diagonal length of the base dimension, R = Sqrt (X + Z ) = 5.542 m
The base angle of the sling to the horizontal is 60 degrees.
Sling angle = 60 Deg.
Vertical Height of sling, Hsling = R * Tan 600 = 9.60 m

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REFERENCE CALCULATION OUTPUT
LIFTTING SLING HEIGHT COMPUTATION (MODULE 2)
Hook Point

Hook Point

Hsling
X = 0.00
Y = 0.00 60 Deg.
7.884
Z = 0.00
R
Z CoG

X = 2.698
X
Y = 0.00
Z = 5.108

3.555

Figure 2: Schematic Isometric view of module 2 showing coordinates and dimensions


Distance Z = 5.108 - 0.00 = 5.108 m
Distance X = 2.698 - 0.00 = 2.698 m
Diagonal length of the base dimension, R = Sqrt (X2 + Z2) = 5.777 m
The base angle of the sling to the horizontal is 60 degrees.
Sling angle = 60 Deg.
Vertical Height of sling, Hsling = R * Tan 600 = 10.01 m

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REFERENCE CALCULATION OUTPUT
LIFTTING SLING HEIGHT COMPUTATION (MODULE 3)

Hook Point

Hook Point

Hsling
X = 0.00
Y = 0.00 60 Deg.
2.500
Z = 0.00
R
Z CoG

X X = 2.337
Y = 0.000
Z = 1.208

2.900

Figure 3: Schematic Isometric view of module 3 showing coordinates and dimensions (y = 5.000)
Distance Z = 1.208 - 0.00 = 1.208 m
Distance X = 2.337 - 0.00 = 2.337 m
Diagonal length of the base dimension, R = Sqrt (X2 + Z2) = 2.631 m
The base angle of the sling to the horizontal is 60 degrees.
Sling angle = 60 Deg.
Vertical Height of sling, Hsling = R * Tan 600 = 4.56 m

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The boundary conditions for each of the model are as shown below:

Hook Point (Fixed Support)

Lifting Sling

Restrained Point (Typical)

Pig Launcher
Platform (Module 1)

Figure 4: Isometric view of Pig Launcher Platform (Module 1) frame showing boundary
conditions.

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Hook Point (Fixed Support)

Lifting Sling

Restrained
Point (Typical)

Pig Launcher
Platform (Module 2)

Figure 5: Isometric view of Pig Launcher Platform (Module 2) frame showing boundary
conditions.

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Hook Point (Fixed Support)

Lifting Sling

Crane Hoist Structure


Platform (Module 3)

Restrained
Point (Typical)

Figure 6: Isometric view of Hoist Structure (Module 3) frame showing boundary conditions.

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3.0 APPLIED LOADS
The applied dead load for each of the lifting analysis model for the Pig Launcher Platform
consist of the self-weight of the structures, the grating loads, handrail load and the stair dead
load.

Similarly, the applied dead loads for the hoist structure consist of the self-weight of the
structure, grating and drip pan dead loads.

The applied dead loads were derived from the load computaion in the Pig Launcher Platform
Calculation Report SSG-NG01017365-GEN-CS-8180-00001_D02. See table below for load
summary.

Design Load Summary

Modelled Load Unmodelled Load


S/No. Description
(kN) (kN)
1 Module 1 78.634 42.585
2 Module 2 79.992 37.698
3 Module 3 31.106 15.948

3.1 Basis Load Cases

Basic Load Cases


S/No Load Description Abbreviation
Module 1
1 Self-weight SW
2 Grating Dead Load GD
3 Handrail Dead Load HD
4 Stair Dead Load SD

Module 2
1 Self-weight SW
2 Grating Dead Load GD
3 Handrail Dead Load HD
4 Stair Dead Load SD

Module 3
1 Self-weight SW
2 Grating/Drip pan Dead Load GD/DP

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3.2 Load Combination Cases

The basic loads state above were combined in accordance to Design Approach 1 (DA 1)
and DEP 34.00.01.30 clause 2.3.2 – to give the onerous loading combination for the lifting
analysis of each of the models. From the above stated DEP, the impact factor (DAF) for
lifting/ jack lugs/padeye is 2.0 while the impact factor (DAF) for other members is 1.3. See
the table below for combination summary

Module 1
Combination Number Load Combination
SW GD HD
101 1.00 1.00 1.00
201 1.30 1.30 1.30
301 2.00 2.00 2.00
Module 2
Combination Number Load Combination
SW GD HD
101 1.00 1.00 1.00
201 1.30 1.30 1.30
301 2.00 2.00 2.00
Module 3
Combination Number Load Combination
SW GD/DP
101 1.00 1.00
201 1.30 1.30
301 2.00 2.00

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4.0 ANALYSIS RESULTS

4.1 Sling Forces

The resulting sling forces shall be used for design of pad-eyes and selection of sling material
for respective modules.
SLING FORCE SUMMARY (MODULE 1)
Maximum Axial Force
S/No. Description Load Cases
(kN)
1 Sling 1 (Beam 357) 301 64.098
2 Sling 2 (Beam 358) 301 70.315
3 Sling 3 (Beam 359) 301 64.974
4 Sling 4 (Beam 360) 301 74.744

SLING FORCE SUMMARY (MODULE 2)


Maximum Axial Force
S/No. Description Load Cases
(kN)
1 Sling 1 (Beam 355) 301 61.364
2 Sling 2 (Beam 356) 301 63.567
3 Sling 3 (Beam 357) 301 74.443
4 Sling 4 (Beam 358) 301 68.243

SLING FORCE SUMMARY (MODULE 3)


Maximum Axial Force
S/No. Description Load Cases
(kN)
1 Sling 1 (Beam 148) 301 31.808
2 Sling 2 (Beam 149) 301 26.312
3 Sling 3 (Beam 150) 301 21.315
4 Sling 4 (Beam 151) 301 29.991

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4.2 Stress Unity Check Results

MODULE 1

Section Beam No. Maximum Ratio Load Case Remark

PRIMARY BEAMS

HE300B 65 0.170 301 OK

SECONDARY BEAMS

IPE300 323 0.231 301 OK

UPN200 214 0.042 301 OK

PIPE SUPPORTS

HE160A 351 0.001 301 OK

MODULE 2

Section Beam No. Maximum Ratio Load Case Remark

PRIMARY BEAMS

HE300B 98 0.232 301 OK

SECONDARY BEAMS

IPE300 330 0.484 301 OK

UPN200 263 0.042 301 OK

PIPE SUPPORTS

HE160A 183 0.018 301 OK

HE160B 333 0.002 301 OK

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MODULE 3

Section Beam No. Maximum Ratio Load Case Remark

COLUMNS

HE200A 15 0.468 301 OK

BEAMS

IPE270 122 0.415 301 OK

HE140B 127 0.038 301 OK

UPN200 82 0.004 301 OK

U60 X 60 X 6 103 0.360 301 OK

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5.0 LIFTING EYE DESIGN CALCULATION.

5.1 Module 1 Lifting-eye design calculation.

REFERENCE CALCULATIONS OUTPUT


LIFTING AIDS/PADEYE DESIGN (MODULE 1)
DESIGN INFORMATION:

9.60 m

Figure 7: Isometric view showing four (4) lifting positions and sling vertical height of Module 1

Maximum axial force in kN (Module 1) = 74.74 kN


Maximum axial force in Tons = 7.62 Tons
Resulting Sling Load, RSF = 7.62 Tons

Table 8-1, DNV 2.7-1 Minimum working Load Limit, WLLmin = 13.07 Tons

Required norminal shackles working load limit at a single point, = WLLmin 13.070 Tons

where

β = angle of sling legs to the vertical 30 Deg

Adopt a 17 Tons padeye - [EN 13889]


F
y

R
S
F
6
0
°

F
x
T
o
p
o
f
P
l
a
t
f
o
r
m

Figure 8: Schematic drawing showing details of 17 Ton Padeye.

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REFERENCE CALCULATIONS OUTPUT

17 Tons Padeye Details

Table D1, DNV 2.7-1 Diameter of shackle pin, DP =


42.00 mm
Considering 3mm allowance for shackle pin and hole,

Padeye hole diameter, DH , = Dp + 3 = 45.00 mm


Adopt Padeye hole diameter for 17 tons padeye, = 44.00 mm
Resulting Sling Load, RSF = 7.62 Tons
Minimum distance from center hole to edge of plate, Rpl = 75.00 mm
Radius of cheek plate, Rch = 55.00 mm

Thickness of cheek plate, tch = 10.00 mm


Thickness of padeye plate, tpl = 30.00 mm
Thickness of padeye at hole position, t = 50.00 mm
DNV 2.7-3 Appendix A.2 From, Rpad = ((Rpl * t pl) + (2 * Rch * tch))/t - 67.00 mm

Check for Padeye Strength

Check for Tear out Stress

[DNV 2.7-3 Appendix A, section


From, Tear out stress, σt = (2 * RSF)/ ((2 * Rpad - DH ) * t)
A.4

Resulting Sling Load, RSF = 7.62 Tons


Resulting Sling Load, RSF in Newton = 74744.00 N
Tear out stress, σt = (2 * RSF)/ ((2 * Rpad - DH ) * t) = 33.22 N/mm2
For S275 material and thickness of plate greater than 40mm,

EN1993-1-1, Table 3.1 Allowable strength of material, py = 255.00 N/mm2


Allowable stress, σe = 0.85 * py = 216.75 N/mm2
Unity ratio, = 0.15 < 1.0
Padeye is okay in Tear out stress.

Check for Bearing Stress


DNV 2.7-3 Appendix A, section From, σb= 0.045 * √((RSF * E)/ (DH * t)), where Dp > 0.94*DH
A.3
0.94*DH = 41.36 mm
Diameter of shackle pin, DP = 42.00 mm
Dp > 0.94*DH (Satisfied)

EN1993-1-1, Section 3.2.6 E = Elastic Modulus of steel materials = 210000.00 N/mm2


2
Bearing stress, σb = 120.20 N/mm
EN1993-1-1, Table 3.1 Allowable strength of material, py = 255.00 N/mm2
Allowable stress, σe = 0.85 * py = 216.75 N/mm2
Unity ratio, = 0.55 < 1
Padeye is okay in Bearing stress.

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REFERENCE CALCULATIONS OUTPUT

Check for Cheek plate weld


DNV 2.7-3 Appendix A, section From, Cheek plate weld stress, σcw= (RSF * tch)/(t * Dch * a)
A.5
RSF = Resulting Sling Load, = 74744.00 N
Dch = Diameter of cheek plate = 2* Rch = 110.00 mm

Thickness of weld, s = 6.00 mm


a = throat of fillet weld = 0.7*s = 4.20 mm

Stress on cheek plate weld, σcw = 32.36 N/mm2


Stress on cheek plate weld in N/mm, σch = σcw * a 135.90 N/mm
[EN1993-1-8:2005, section Design shear strength of weld, Fww.d = (F u/(√3))/(βw*γ M2)
4.5.3.3(3)]
2
Ultimate tensile strength of weaker part, F u = 430.00 N/mm
EN1993-1-8:2005, Table 4.1 Correlation factor, βw = 0.85

Partial factor of resistance of plate in bearing, γ m2 = 1.25


Fww,d = (F u/(3)^(1/2))/(βw*γ M2) 233.66 N/mm2
Design resistance of weld per unit length, F w,Rd = F ww.d*a

a = throat thickness of weld = 4.20 mm

Design resistance of weld per unit length, F w,Rd = F ww.d*a = 981.36 N/mm

Unity ratio = σch/Fw,Rd = 0.14

Cheek plate weld is okay

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REFERENCE CALCULATIONS OUTPUT

Shackles

Design Sling Force, RSF = 7.62 Tons

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REFERENCE CALCULATIONS OUTPUT

Table 8-1, DNV 2.7-1 Minimum working Load Limit, WLLmin = 13.07 Tons

Required norminal shackles working load limit at a single point, = WLLmin = 13.070 Tons

where

β = angle of sling legs to the vertical 30 Deg

0.45*RSF = 3.43

Section 7.3.3, DNV 2.7-3 WLLmin > 0.45*RSF, OK

Adopt a shackle working load limit of 13-1/2 Tons.

The details of the adopted shackle are as highlighted in red colour above.

Pin diameter = 38.10 mm

Diameter of padeye hole = 44.00 mm

Pin diameter < Diameter of padeye hole, OK

Sling

Design Sling Force, RSF = 7.62 Tons


Table 8-1, DNV 2.7-1 Minimum working Load Limit, WLLmin = 13.07 Tons

For the above stated WLL, the require sling diamter is 24 mm as highlighted above for four leg sling.

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5.2 Module 2 Lifting-eye design calculation.

REFERENCE CALCULATIONS OUTPUT


LIFTING AIDS/PADEYE DESIGN (MODULE 2)
DESIGN INFORMATION:

10.01 m

Figure 9: Isometric view showing four (4) lifting positions and sling vertical height of Module 2

Maximum axial force in kN (Module 2) = 74.44 kN


Maximum axial force in Tons = 7.59 Tons
Resulting Sling Load, RSF = 7.59 Tons

Table 8-1, DNV 2.7-1 Minimum working Load Limit, WLLmin = 13.07 Tons

Required norminal shackles working load limit at a single point, = WLLmin 13.070 Tons

where

β = angle of sling legs to the vertical 30 Deg

Adopt a 17 Tons padeye - [EN 13889]


F
y

R
S
F
6
0
°

F
x
T
o
p
o
f
P
l
a
t
f
o
r
m

Figure 10: Schematic drawing showing details of 17 Ton Padeye.

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REFERENCE CALCULATIONS OUTPUT

17 Tons Padeye Details

Table D1, DNV 2.7-1 Diameter of shackle pin, DP =


42.00 mm
Considering 3mm allowance for shackle pin and hole,

Padeye hole diameter, DH , = Dp + 3 = 45.00 mm


Adopt Padeye hole diameter for 17 tons padeye, = 44.00 mm
Resulting Sling Load, RSF = 7.59 Tons
Minimum distance from center hole to edge of plate, Rpl = 75.00 mm
Radius of cheek plate, Rch = 55.00 mm

Thickness of cheek plate, tch = 10.00 mm


Thickness of padeye plate, tpl = 30.00 mm
Thickness of padeye at hole position, t = 50.00 mm
DNV 2.7-3 Appendix A.2 From, Rpad = ((Rpl * t pl) + (2 * Rch * tch))/t - 67.00 mm

Check for Padeye Strength

Check for Tear out Stress

[DNV 2.7-3 Appendix A, section


From, Tear out stress, σt = (2 * RSF)/ ((2 * Rpad - DH ) * t)
A.4

Resulting Sling Load, RSF = 7.59 Tons


Resulting Sling Load, RSF in Newton = 74443.00 N
Tear out stress, σt = (2 * RSF)/ ((2 * Rpad - DH ) * t) = 33.09 N/mm2
For S275 material and thickness of plate greater than 40mm,

EN1993-1-1, Table 3.1 Allowable strength of material, py = 255.00 N/mm2


Allowable stress, σe = 0.85 * py = 216.75 N/mm2
Unity ratio, = 0.15 < 1.0
Padeye is okay in Tear out stress.

Check for Bearing Stress


DNV 2.7-3 Appendix A, section From, σb= 0.045 * √((RSF * E)/ (DH * t)), where Dp > 0.94*DH
A.3
0.94*DH = 41.36 mm
Diameter of shackle pin, DP = 42.00 mm
Dp > 0.94*DH (Satisfied)

EN1993-1-1, Section 3.2.6 E = Elastic Modulus of steel materials = 210000.00 N/mm2


2
Bearing stress, σb = 119.96 N/mm
EN1993-1-1, Table 3.1 Allowable strength of material, py = 255.00 N/mm2
Allowable stress, σe = 0.85 * py = 216.75 N/mm2
Unity ratio, = 0.55 < 1
Padeye is okay in Bearing stress.

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REFERENCE CALCULATIONS OUTPUT

Check for Cheek plate weld


DNV 2.7-3 Appendix A, section From, Cheek plate weld stress, σcw= (RSF * tch)/(t * Dch * a)
A.5
RSF = Resulting Sling Load, = 74443.00 N
Dch = Diameter of cheek plate = 2* Rch = 110.00 mm

Thickness of weld, s = 6.00 mm


a = throat of fillet weld = 0.7*s = 4.20 mm

Stress on cheek plate weld, σcw = 32.23 N/mm2


Stress on cheek plate weld in N/mm, σch = σcw * a 135.35 N/mm
[EN1993-1-8:2005, section Design shear strength of weld, Fww.d = (F u/(√3))/(βw*γ M2)
4.5.3.3(3)]
2
Ultimate tensile strength of weaker part, F u = 430.00 N/mm
EN1993-1-8:2005, Table 4.1 Correlation factor, βw = 0.85

Partial factor of resistance of plate in bearing, γ m2 = 1.25


Fww,d = (F u/(3)^(1/2))/(βw*γ M2) 233.66 N/mm2
Design resistance of weld per unit length, F w,Rd = F ww.d*a

a = throat thickness of weld = 4.20 mm

Design resistance of weld per unit length, F w,Rd = F ww.d*a = 981.36 N/mm

Unity ratio = σch/Fw,Rd = 0.14

Cheek plate weld is okay

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REFERENCE CALCULATIONS OUTPUT

Shackles

Design Sling Force, RSF = 7.59 Tons

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REFERENCE CALCULATIONS OUTPUT

Table 8-1, DNV 2.7-1 Minimum working Load Limit, WLLmin = 13.07 Tons

Required norminal shackles working load limit at a single point, = WLLmin = 13.070 Tons

where

β = angle of sling legs to the vertical 30 Deg

0.45*RSF = 3.41

Section 7.3.3, DNV 2.7-3 WLLmin > 0.45*RSF, OK

Adopt a shackle working load limit of 13-1/2 Tons.

The details of the adopted shackle are as highlighted in red colour above.

Pin diameter = 38.10 mm

Diameter of padeye hole = 44.00 mm

Pin diameter < Diameter of padeye hole, OK

Sling

Design Sling Force, RSF = 7.59 Tons


Table 8-1, DNV 2.7-1 Minimum working Load Limit, WLLmin = 13.07 Tons

For the above stated WLL, the require sling diamter is 24 mm as highlighted above for four leg sling.

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5.3 Module 3 Lifting-eye design calculation.

REFERENCE CALCULATIONS OUTPUT

LIFTING AIDS/PADEYE DESIGN (MODULE 3)


DESIGN INFORMATION:

4.63 m

Figure 11: Isometric view showing four (4) lifting positions and sling vertical height of Module 3

Maximum axial force in kN (Module 3) = 31.81 kN


Maximum axial force in Tons = 3.24 Tons

Resulting Sling Load, RSF = 3.24 Tons

Table 8-1, DNV 2.7-1 Minimum working Load Limit, WLLmin = 8.41 Tons

Required norminal shackles working load limit at a single point, = WLLmin 8.41 Tons

where

β = angle of sling legs to the vertical 30 Deg

Adopt a 9.5 Tons padeye - [EN 13889]


F
y

R
S
F
6
0
°

F
x
T
o
p
o
f
P
l
a
t
f
o
r
m

Figure 12: Schematic drawing showing details of 9.5 Ton Padeye.

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REFERENCE CALCULATIONS OUTPUT

9.5 Tons Padeye Details

Table D1, DNV 2.7-1 Diameter of shackle pin, DP =


32.00 mm
Considering 3mm allowance for shackle pin and hole,

Padeye hole diameter, DH , = Dp + 3 = 35.00 mm


Adopt Padeye hole diameter for 9.5 tons padeye, = 44.00 mm
Resulting Sling Load, RSF = 3.24 Tons
Minimum distance from center hole to edge of plate, Rpl = 75.00 mm
Radius of cheek plate, Rch = 55.00 mm

Thickness of cheek plate, tch = 10.00 mm


Thickness of padeye plate, tpl = 30.00 mm
Thickness of padeye at hole position, t = 50.00 mm
DNV 2.7-3 Appendix A.2 From, Rpad = ((Rpl * t pl) + (2 * Rch * tch))/t - 67.00 mm

Check for Padeye Strength

Check for Tear out Stress

[DNV 2.7-3 Appendix A, section


From, Tear out stress, σt = (2 * RSF)/ ((2 * Rpad - DH ) * t)
A.4

Resulting Sling Load, RSF = 3.24 Tons


Resulting Sling Load, RSF in Newton = 31808.00 N
Tear out stress, σt = (2 * RSF)/ ((2 * Rpad - DH ) * t) = 14.14 N/mm2
For S275 material and thickness of plate greater than 40mm,

EN1993-1-1, Table 3.1 Allowable strength of material, py = 255.00 N/mm2


Allowable stress, σe = 0.85 * py = 216.75 N/mm2
Unity ratio, = 0.07 < 1.0
Padeye is okay in Tear out stress.

Check for Bearing Stress


DNV 2.7-3 Appendix A, section From, σb= 0.045 * √((RSF * E)/ (DH * t)), where Dp > 0.94*DH
A.3
0.94*DH = 41.36 mm
Diameter of shackle pin, DP = 32.00 mm
Dp > 0.94*DH (Satisfied)

EN1993-1-1, Section 3.2.6 E = Elastic Modulus of steel materials = 210000.00 N/mm2


2
Bearing stress, σb = 78.41 N/mm
EN1993-1-1, Table 3.1 Allowable strength of material, py = 255.00 N/mm2
Allowable stress, σe = 0.85 * py = 216.75 N/mm2
Unity ratio, = 0.36 < 1
Padeye is okay in Bearing stress.

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REFERENCE CALCULATIONS OUTPUT

Check for Cheek plate weld


DNV 2.7-3 Appendix A, section From, Cheek plate weld stress, σcw= (RSF * tch)/(t * Dch * a)
A.5
RSF = Resulting Sling Load, = 31808.00 N
Dch = Diameter of cheek plate = 2* Rch = 110.00 mm

Thickness of weld, s = 6.00 mm


a = throat of fillet weld = 0.7*s = 4.20 mm

Stress on cheek plate weld, σcw = 13.77 N/mm2


Stress on cheek plate weld in N/mm, σch = σcw * a 57.83 N/mm
[EN1993-1-8:2005, section Design shear strength of weld, Fww.d = (F u/(√3))/(βw*γ M2)
4.5.3.3(3)]
2
Ultimate tensile strength of weaker part, F u = 430.00 N/mm
EN1993-1-8:2005, Table 4.1 Correlation factor, βw = 0.85

Partial factor of resistance of plate in bearing, γ m2 = 1.25


Fww,d = (F u/(3)^(1/2))/(βw*γ M2) 233.66 N/mm2
Design resistance of weld per unit length, F w,Rd = F ww.d*a

a = throat thickness of weld = 4.20 mm

Design resistance of weld per unit length, F w,Rd = F ww.d*a = 981.36 N/mm

Unity ratio = σch/Fw,Rd = 0.06

Cheek plate weld is okay

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REFERENCE CALCULATIONS OUTPUT

Shackles

Design Sling Force, RSF = 3.24 Tons

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REFERENCE CALCULATIONS OUTPUT

Table 8-1, DNV 2.7-1 Minimum working Load Limit, WLLmin = 8.41 Tons

Required norminal shackles working load limit at a single point, = WLLmin = 8.410 Tons

where

β = angle of sling legs to the vertical 30 Deg

0.45*RSF = 1.46

Section 7.3.3, DNV 2.7-3 WLLmin > 0.45*RSF, OK

Adopt a shackle working load limit of 9-1/2 Tons.

The details of the adopted shackle are as highlighted in red colour above.

Pin diameter = 31.80 mm

Diameter of padeye hole = 44.00 mm

Pin diameter < Diameter of padeye hole, OK

Sling

Design Sling Force, RSF = 3.24 Tons


Table 8-1, DNV 2.7-1 Minimum working Load Limit, WLLmin = 8.41 Tons

For the above stated WLL, the require sling diamter is 20 mm as highlighted above for four leg sling.

6.0 CONCLUSION.
The lifting analysis results for modules 1, 2, 3 show that the general lifting configuration
satisfy code check requirement and are therefore adequate to withstand the lifting stresses
Also, appropriate lifting-eyes, shackles and slings were selected in accordance with reference
Eurocode, DNV codes and DEP standards.

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7.0 APPENDIX: STAAD.PRO INPUT/OUTPUT FILE (MODULE 1)

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8.0 APPENDIX: STAAD.PRO INPUT/OUTPUT FILE (MODULE 2)

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9.0 APPENDIX: STAAD.PRO INPUT/OUTPUT FILE (MODULE 3)

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