CALCULATION OF LIFTING (HORIZONTAL POSITION)

PIPERACK MODULE 14A

24TONS TOTAL WEIGHT

General Data

Total weight, W = 24.00 Tons = 52911 lbs

Number of lifting point, NL = 4.00
Safety factor, SF = 2.00 (including WCF, DAF, SKL, CF)
Safety weight load, SWL = W SF = 48.00 Tons = 105822 lbs
Actual weight in each lift point, Wa = W / (NL-1) = 8.00 Tons = 17637 lbs
Safety weight in each lift point, Ws = SWL / (NL-1) = 16.00 Tons = 35274 lbs
Total length, LL = 9500 mm = 374.02 in
Length to CoG, LcgL = 6500 mm = 255.91 in
Angle of lifting, α = 63.2 deg = 1.10 rad
Angle of lifting, β = 62.7 deg = 1.09 rad
Total width, L1 = 9200 mm = 362.20 in
Length to side CoG, Lcg1 = 4550 mm = 179.13 in
Height, H = 9000 mm = 354.33 in
Length of sling 1, Fs1 = 10085 mm = 397.04 in
Length of sling 2, Fs2 = 10130 mm = 398.83 in
Total width, L2 = 9200 mm = 362.20 in
Length to side CoG, Lcg2 = 4550 mm = 179.13 in
Length of sling 3, Fs3 = 10085 mm = 397.04 in
Length of sling 4, Fs4 = 10130 mm = 398.83 in

Sketch :

Fs1 Fs2

Fh2
Z Fh1

R1 COG R2
X Y
L1
Lcg1 W

Fs3 Fs4
H

Z
α Fh3 Fh4 β
X Y
COG R4
R3
L2
W
Lcg2

Page 3
 Fs12 Fs34

COG
R1 & R2 R3 & R4

Z
W

Y X LL
LcgL

Calculation of Actual Lifting Load

R1 = [ (LL - LcgL) / LL ] [ (L1 - Lcg1) / L1 ] W = 5.11 Tons = 11260 lbs

R2 = [ (LL - LcgL) / LL ] (Lcg1 / L1 ) W = 5.00 Tons = 11018 lbs
R3 = ( LcgL / LL ) [ (L2 - Lcg2) / L2 ] W = 11.07 Tons = 24397 lbs
R4 = ( LcgL / LL ) (Lcg2 / L2 ) W = 10.83 Tons = 23872 lbs
Horizontal force 1, Fh1 = R1 / tan (90) = 0.00 Tons = 0 lbs
Horizontal force 2, Fh2 = R2 / tan (90) = 0.00 Tons = 0 lbs
Horizontal force 3, Fs3 = R3 / tan (α) = 5.59 Tons = 12334 lbs
Horizontal force 4, Fs4 = R4 / tan (β) = 5.59 Tons = 12334 lbs
Sling force 1, Fs1 = R1 / sin (α) = 5.72 Tons = 12617 lbs
Sling force 2, Fs2 = R2 / sin (β) = 5.60 Tons = 12346 lbs
Sling force 3, Fs3 = R3 / sin (α) = 12.40 Tons = 27338 lbs
Sling force 4, Fs4 = R4 / sin (β) = 12.13 Tons = 26750 lbs

Calculation of Safety Lifting Load

R1 = [ (LL - LcgL) / LL ] [ (L1 - Lcg1) / L1 ] SWL = 10.22 Tons = 22520 lbs

R2 = [ (LL - LcgL) / LL ] (Lcg1 / L1 ) SWL = 10.00 Tons = 22036 lbs
R3 = ( LcgL / LL ) [ (L2 - Lcg2) / L2 ] SWL = 22.13 Tons = 48794 lbs
R4 = ( LcgL / LL ) (Lcg2 / L2 ) SWL = 21.66 Tons = 47745 lbs
Horizontal force 1, Fh1 = R1 / tan (90) = 0.00 Tons = 0 lbs
Horizontal force 2, Fh2 = R2 / tan (90) = 0.00 Tons = 0 lbs
Horizontal force 3, Fs3 = R3 / tan (α) = 11.19 Tons = 24668 lbs
Horizontal force 4, Fs4 = R4 / tan (β) = 11.19 Tons = 24668 lbs
Sling force 1, Fs1 = R1 / sin (α) = 11.45 Tons = 25235 lbs
Sling force 2, Fs2 = R2 / sin (β) = 11.20 Tons = 24692 lbs
Sling force 3, Fs3 = R3 / sin (α) = 24.80 Tons = 54675 lbs
Sling force 4, Fs4 = R4 / sin (β) = 24.27 Tons = 53500 lbs

Note:
Using Shackle 2" - 35 Tons WLL
Not using spreader bar
Using 3 cranes

Page 4
 Calculation of Total Actual Load on Crane

Total Load on Crane 1, R1 = 10.22 Tons = 22520 lbs

Total Load on Crane 2, R2 = 10.00 Tons = 22036 lbs
Total Load on Crane 3, R3 + R4 = 43.79 Tons = 96539 lbs

Page 5
 CALCULATION OF LIFTING LUG (HORIZONTAL POSITION)
PIPERACK MODULE 14A
24TONS TOTAL WEIGHT

Generals Data:
Total empty weight, W = 24000 kg = 52910 lbs
Safety factor, SF = 4.00
Number of lug, NL = 2.00
Total weight include safety factor, WSF = W SF = 48000 kg = 211642 lbs
Max horizontal force, Fx = 0.05 Fz = 1107 kg = 2440 lbs
Max vertical force, Fz = 22133 kg = 48794 lbs
Max lateral force, Fy = 0.05 Fz = 1107 kg = 2440 lbs
Max tension force in sling, Fsl = 24800 kg = 54675 lbs

FX Fsl

R
α
FZ
HT

HH
DH
X

Hw

WL

Lug Dimensions:
Total Height of lift lug, HT = 588 mm = 23.13 in
Height of hole centreline, HH = 150 mm = 5.91 in
Height of slot in, Hw = 300 mm = 11.81 in
Width of lug, WL = 275 mm = 10.83 in
Radius of lug, R = 138 mm = 5.41 in
Diameter of shackle 2" pin, DP = 57 mm = 2.25 in
Diameter of hole, DH = 63 mm = 2.48 in
Width of shackle 2" jaws, WJ = 83 mm = 3.25 in
Thickness of lug, tL = 30 mm = 1.18 in
Thickness of cheek, tC = 15 mm = 0.59 in
Check space of hole and pin = Clear Ratio = 90.71%
Check space of jaws and lug thickness = Clear Ratio = 72.68%

Material, Stress and Properties Data:

Lug material = EH-36
Allowable stress, Fy = 3,515 kg/cm2 = 50,000 psi
Allowable tension stress, 0.6 Fy = 2,109 kg/cm2 = 30,000 psi
Allowable shear stress, 0.4 Fy = 1,406 kg/cm2 = 20,000 psi
DH/2R = 0.23

Page 6
Stress-Concentration factor (near hole), K = 2.45
(for flat plate with centrally located circular hole in tension based on D H/2R value)
Section modulus of lugs, SLz = 41.25 cm3 = 2.52 in3
Section modulus of lugs, SLy = 378.13 cm3 = 23.07 in3

Stresses at Lug:
Tension stress, Stz = Fx /(WL tL)+HH(Fz/SLy+Fy/SLz) = 1,294 kg/cm2 = 18,402 psi
Shear stress z-axis, Ssz = Fz / (WL tL) = 268 kg/cm 2
= 3,816 psi
Shear stress y-axis, Ssy = Fy / (WL tL) = 13 kg/cm 3
= 191 psi
Total stress = 1,321 kg/cm4 = 18,795 psi
Check tension stress = Safe Ratio = 61.34%
Check shear stress z-axis (longitudinal) = Safe Ratio = 19.08%
Check shear stress y-axis (tranversal) = Safe Ratio = 0.95%
Check total stress = Safe Ratio = 62.65%

Stresses near the hole:

Tension stress, Stx = K Fx / [(WL - DH) tL] = 43 kg/cm2 = 606 psi
Tension stress, Stz = K Fz / [(HH + R - DH) tL] = 805 kg/cm 2
= 11,451 psi
Shear stress, Ssy = K Fy / [(WL - DH) tL] = 43 kg/cm 2
= 606 psi
Total stress = 807 kg/cm4 = 11,484 psi
Check tension stress x-axis = Safe Ratio = 2.02%
Check tension stress z-axis = Safe Ratio = 38.17%
Check shear stress y-axis (tranversal) = Safe Ratio = 3.03%
Check total stress = Safe Ratio = 38.28%

Page 7
 WELD CALCULATION ON THE LIFT LUG (HORIZONTAL POSITION)
PIPERACK MODULE 14A
24TONS TOTAL WEIGHT

General Data:
Total weight, W = 24000 kg = 52911 lbs
Number of lug, NL = 4.00
Safety factor, SF = 2.00
Horizontal force x-axis, Fx = 1107 kg = 2440 lbs
Vertical force z-axis, Fz = 22133 kg = 48794 lbs
Lateral force y-axis, Fy = 1107 kg = 2440 lbs

FZ Fsl

R
α
FY
HT

HH
DH
Z

Hw

WL

Weld length (assume only top and bottom side welded -conservative method)
Length of weld around, Aw = 2 Hw + 2 WL = 1150 mm = 45.28 in
Fillet weld dimension, w = 10 mm = 0.39 in
Allowable weld stress, Sw = 675 kg/cm2 = 9600 psi

Load on Fillet Weld per linear inch of weld:

Tension stress of weld, St = Fx / Aw = 4 kg/cm2 = 54 lbs/in
Shear stress of weld, Ss = Fz / Aw = 76 kg/cm2 = 1078 lbs/in
Lateral stress of weld, Sl = Fy / Aw = 4 kg/cm3 = 54 lbs/in

Load on weld:
Tension stress of weld, ft = St / (0.707w) = 14 kg/cm2 = 194 psi
Shear stress of weld, fs = Ss / (0.707w) = 272 kg/cm2 = 3872 psi
Lateral stress of weld, fl = Sl / (0.707w) = 14 kg/cm3 = 194 psi
Total stress of weld, f = 273 kg/cm2 = 3882 psi

Check tension stress = OK Ratio = 2.02%

Check shear stress = OK Ratio = 40.33%
Check shear stress = OK Ratio = 2.02%
Check total stress = OK Ratio = 40.43%

Page 8
Book Reference : Eugene F.Megyesy, "Pressure Vessel Handbook-Eleventh Edition", page : 459.

Page 9
 CALCULATION OF LIFTING (VERTICAL POSITION)
PIPERACK MODULE 14A
24TONS TOTAL WEIGHT

General Data

Total weight, W = 24.00 Tons = 52911 lbs

Number of lifting point, NL = 4.00
Safety factor, SF = 2.00
Safety weight load, SWL = W SF = 48.00 Tons = 105822 lbs
Actual weight per lifting point, Wa = W / (NL-1) = 8.00 Tons = 17637 lbs
Safety weight per lifting point, Ws = SWL / (NL-1) = 16.00 Tons = 35274 lbs
Total length, LL = 9230 mm = 363.39 in
Length to CoG, LcgL = 4615 mm = 181.69 in
Angle of lifting, α = 75.0 deg = 1.31 rad
Angle of lifting, β = 75.0 deg = 1.31 rad
Total width, L1 = 3212 mm = 126.46 in
Length to side CoG, Lcg1 = 1606 mm = 63.23 in
Height, H = 6000 mm = 236.22 in
Length of sling 1, Fs1 = 6211 mm = 244.54 in
Length of sling 2, Fs2 = 6211 mm = 244.54 in
Total width, L2 = 3212 mm = 126.46 in
Length to side CoG, Lcg2 = 1606 mm = 63.23 in
Length of sling 3, Fs3 = 6211 mm = 244.54 in
Length of sling 4, Fs4 = 6211 mm = 244.54 in

Sketch :

Fs1 Fs2
H

Fh1 Fh2
Z α β

R1 COG R2
X Y
L1
Lcg1 W

Fs3 Fs4
H

Z
α Fh3 Fh4 β
X Y
COG R4
R3
L2
W

Page 9
 Lcg2

Fs12 Fs34

COG
R1 & R2 R3 & R4

Z
W

Y X LL
LcgL

Calculation of Actual Lifting Load

R1 = [ (LL - LcgL) / LL ] [ (L1 - Lcg1) / L1 ] W = 8.00 Tons = 17637 lbs

R2 = [ (LL - LcgL) / LL ] (Lcg1 / L1 ) W = 8.00 Tons = 17637 lbs
R3 = ( LcgL / LL ) [ (L2 - Lcg2) / L2 ] W = 8.00 Tons = 17637 lbs
R4 = ( LcgL / LL ) (Lcg2 / L2 ) W = 8.00 Tons = 17637 lbs
Horizontal force 1, Fh1 = R1 / tan (α) = 2.14 Tons = 4721 lbs
Horizontal force 2, Fh2 = R2 / tan (β) = 2.14 Tons = 4721 lbs
Horizontal force 3, Fs3 = R3 / tan (α) = 2.14 Tons = 4721 lbs
Horizontal force 4, Fs4 = R4 / tan (β) = 2.14 Tons = 4721 lbs
Sling force 1, Fs1 = R1 / sin (α) = 8.28 Tons = 18258 lbs
Sling force 2, Fs2 = R2 / sin (β) = 8.28 Tons = 18258 lbs
Sling force 3, Fs3 = R3 / sin (α) = 8.28 Tons = 18258 lbs
Sling force 4, Fs4 = R4 / sin (β) = 8.28 Tons = 18258 lbs

Calculation of Safety Lifting Load

R1 = [ (LL - LcgL) / LL ] [ (L1 - Lcg1) / L1 ] Ws = 16.00 Tons = 35274 lbs

R2 = [ (LL - LcgL) / LL ] (Lcg1 / L1 ) Ws = 16.00 Tons = 35274 lbs
R3 = ( LcgL / LL ) [ (L2 - Lcg2) / L2 ] Ws = 16.00 Tons = 35274 lbs
R4 = ( LcgL / LL ) (Lcg2 / L2 ) Ws = 16.00 Tons = 35274 lbs
Horizontal force 1, Fh1 = R1 / tan (α) = 4.28 Tons = 9442 lbs
Horizontal force 2, Fh2 = R2 / tan (β) = 4.28 Tons = 9442 lbs
Horizontal force 3, Fs3 = R3 / tan (α) = 4.28 Tons = 9442 lbs
Horizontal force 4, Fs4 = R4 / tan (β) = 4.28 Tons = 9442 lbs
Sling force 1, Fs1 = R1 / sin (α) = 16.56 Tons = 36516 lbs
Sling force 2, Fs2 = R2 / sin (β) = 16.56 Tons = 36516 lbs
Sling force 3, Fs3 = R3 / sin (α) = 16.56 Tons = 36516 lbs
Sling force 4, Fs4 = R4 / sin (β) = 16.56 Tons = 36516 lbs

Note:
Using Shackle 2" - 35 Tons WLL
Not using spreader bar

Page 10
Using 2 cranes

Calculation of Total Actual Load on Crane

Total Load on Crane 1, R1 + R2 = 16.00 Tons = 35274 lbs

Total Load on Crane 2, R3 + R4 = 16.00 Tons = 35274 lbs

Page 11
 CALCULATION OF LIFTING LUG (VERTICAL POSITION)
PIPERACK MODULE 14A
24TONS TOTAL WEIGHT

Generals Data:
Total empty weight, W = 24000 kg = 52910 lbs
Safety factor, SF = 4.00
Number of lug, NL = 2.00
Total weight include safety factor, WSF = W SF = 48000 kg = 211642 lbs
Max vertical force, Fz = 16000 kg = 35274 lbs
Max horizontal force, Fy = 4283 kg = 9442 lbs
Max lateral force, Fx = 0.05 Fz = 800 kg = 1764 lbs
Max tension force in sling, Fsl = 16563 kg = 36515 lbs

FZ Fsl

R
α
FY
HT

HH
DH
Z

Hw

WL

Lug Dimensions:
Total Height of lift lug, HT = 588 mm = 23.13 in
Height of hole centreline, HH = 150 mm = 5.91 in
Height of slot in, Hw = 300 mm = 11.81 in
Width of lug, WL = 275 mm = 10.83 in
Radius of lug, R = 138 mm = 5.41 in
Diameter of shackle 2" pin, DP = 57 mm = 2.25 in
Diameter of hole, DH = 63 mm = 2.48 in
Width of shackle 2" jaws, WJ = 83 mm = 3.25 in
Thickness of lug, tL = 30 mm = 1.18 in
Thickness of cheek, tC = 15 mm = 0.59 in
Check space of hole and pin = Clear Ratio = 90.71%
Check space of jaws and lug thickness = Clear Ratio = 72.68%

Material, Stress and Properties Data:

Lug material = EH-36
Allowable stress, Fy = 3,515 kg/cm2 = 50,000 psi
Allowable tension stress, 0.6 Fy = 2,109 kg/cm2 = 30,000 psi
Allowable shear stress, 0.4 Fy = 1,406 kg/cm 2
= 20,000 psi
DH/2R = 0.23

Page 12
Stress-Concentration factor (near hole), K = 2.45
(for flat plate with centrally located circular hole in tension based on D H/2R value)
Section modulus of lugs, SLy = 41.25 cm3 = 2.52 in3
Section modulus of lugs, SLx = 378.13 cm3 = 23.07 in3

Stresses at Lug:
Tension stress, Stz = Fz /(WL tL)+HH(Fx/SLy+Fy/SLx) = 655 kg/cm2 = 9,312 psi
Shear stress y-axis, Ssy = Fy / (WL tL) = 52 kg/cm 2
= 738 psi
Shear stress x-axis, Ssx = Fx / (WL tL) = 10 kg/cm 3
= 138 psi
Total stress = 657 kg/cm4 = 9,343 psi
Check tension stress = Safe Ratio = 31.04%
Check shear stress y-axis (longitudinal) = Safe Ratio = 3.69%
Check shear stress x-axis (tranversal) = Safe Ratio = 0.69%
Check total stress = Safe Ratio = 31.14%

Stresses near the hole:

Tension stress, Stz = K Fz / [(WL - DH) tL] = 616 kg/cm2 = 8,766 psi
Tension stress, Sty = K Fy / [(HH + R - DH) tL] = 156 kg/cm 2
= 2,216 psi
Shear stress, Ssx = K Fx / [(WL - DH) tL] = 31 kg/cm 2
= 438 psi
Total stress = 636 kg/cm4 = 9,053 psi
Check tension stress z-axis = Safe Ratio = 29.22%
Check tension stress y-axis = Safe Ratio = 7.39%
Check shear stress x-axis (tranversal) = Safe Ratio = 2.19%
Check total stress = Safe Ratio = 30.18%

Page 13
 WELD CALCULATION ON THE LIFT LUG (VERTICAL POSITION)
PIPERACK MODULE 14A
24TONS TOTAL WEIGHT

General Data:
Total weight, W = 24000 kg = 52911 lbs
Number of lug, NL = 4.00
Safety factor, SF = 2.00
Vertical force z-axis, Fz = 16000 kg = 35274 lbs
Horizontal force y-axis, Fy = 4283 kg = 9442 lbs
Lateral force x-axis, Fx = 800 kg = 1764 lbs

FZ Fsl

R
α
FY
HT

HH
DH
Z

Hw

WL

Weld length (assume only top and bottom side welded -conservative method)
Length of weld around, Aw = 2 Hw + 2 WL = 1150 mm = 45.28 in
Fillet weld dimension, w = 10 mm = 0.39 in
Allowable weld stress, Sw = 675 kg/cm2 = 9600 psi

Load on Fillet Weld per linear inch of weld:

Tension stress of weld, St = Fz / Aw = 55 kg/cm2 = 779 lbs/in
Shear stress of weld, Ss = Fy / WL = 61 kg/cm2 = 872 lbs/in
Lateral stress of weld, Sl = Fx / Aw = 3 kg/cm3 = 39 lbs/in

Load on weld:
Tension stress of weld, ft = St / (0.707w) = 197 kg/cm2 = 2799 psi
Shear stress of weld, fs = Ss / (0.707w) = 220 kg/cm2 = 3133 psi
Lateral stress of weld, fl = Sl / (0.707w) = 10 kg/cm3 = 140 psi
Total stress of weld, f = 296 kg/cm2 = 4204 psi

Check tension stress = OK Ratio = 29.16%

Check shear stress = OK Ratio = 32.64%
Check shear stress = OK Ratio = 1.46%
Check total stress = OK Ratio = 43.79%

Page 14
Book Reference : Eugene F.Megyesy, "Pressure Vessel Handbook-Eleventh Edition", page : 459.

Page 15