**5022.1TA**

**[BELOW-THE-HOOK LIFTING DEVICE]{.underline}**

## Engineering Note Cover Page of #MD-ENG-066

Lifting Device Numbers:

  ----------- ------------ ------------- ------------ -------- ------------
  FNAL Site                Div. Specific **151**      Asset    
  No/                      No.                        No.      

              If                         If                    If
              applicable                 applicable            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  **Spreader Bar for SM3 Disassembly & VM
                              Assembly**

  --------------------------- -------------------------------------------

+---------+-----------------------------+------------------------------+
| Device  | \[ \] Purchased from a      |                              |
| was     | Commercial Lifting          |                              |
|         |                             |                              |
|         | Device Manufacturer. Mfg    |                              |
|         | Name                        |                              |
+---------+-----------------------------+------------------------------+
| (check  | \[ **X**\] Designed and     | **See eng. drawing ME --     |
| all     | Built at Fermilab           | 407814 for details**.        |
| appl    |                             |                              |
| icable) |                             |                              |
+---------+-----------------------------+------------------------------+
|         | \[ \] Designed by Fermilab  |                              |
|         | and Built by a              |                              |
|         |                             |                              |
|         | Vendor. Assy drawing number |                              |
+---------+-----------------------------+------------------------------+
|         | \[ \] Provided by a User or |                              |
|         | other Laboratory            |                              |
+---------+-----------------------------+------------------------------+
|         | \[ \] Other: Describe       |                              |
+---------+-----------------------------+------------------------------+

  ------------------------ --------------------- ------ -------------------
  Engineering Note         **James Kilmer,       Date   **Dec. 20, 2004**
  Prepared by              Edward Chi**                 

  Engineering Note         **Dave Pushka**       Date   **Dec. 22, 2004**
  Reviewed by                                           
  ------------------------ --------------------- ------ -------------------

Lifting Device Data:

  -------------------- --------------------------------------------------
  Capacity             **16,600 lbs**.

  Fixture Weight       **1,400 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                       Date                Load                      
  FNAL (if                                                                               
  applicable)                                                                            

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

  Satisfactory Load                                                                      
  Test Witnessed by:                                                                     

  Signature (of Load                                                                     
  Test Witness)                                                                          
  ------------------ ---------------- ---- ------ --------- -- ------ --- -------- -- -- --

Notes or Special Information:

1.  **The spreader bar was originally designed for Mino project. It was
    modified to retrofit the applications of the SM3 disassembly and VM
    assembly**.

2\. **See pages 13, 14 & 15 for load tes**t.

  --------------------------------------- ----------------------------------- ------------------------
  ![](media/image1.png){width="0.875in"   **Fermilab**                        
  height="0.8194444444444444in"}                                              

  --------------------------------------- ----------------------------------- ------------------------

**Particle Physics Division**

**Mechanical Department Engineering Note**

# Number: MD-ENG- 066 Date: Dec. 20, 2004

Project Internal Reference:

Project: BTeV, SMTF

Title: Spreader Bar for SM3 Disassembly and Vertex Magnet Assembly

Author(s): James Kilmer, Edward Chi

Reviewer(s): Dave Pushka

Key Words: Spreader Bar, Lifting, Allowable stress, Eccentric, Torsional

Shear, Primary shear, Bolt, Weld size, torque.

Abstract Summary: The spreader bar was originally designed for the

application of the Mino project. It was modified to

retrofit the applications for handling the different coils

in multiple positions. The working stresses, welding

sizes and bolt selections subject the different

applications have been presented for discussion per

related specifications codes.

Applicable Codes:

ASME B30.20, "Below the Hook Lifting Devices"

(#5022, ES&H manual, FermiLab)

"Allowable Stress Design", AISC, 9^th^ edition

ANSI/AWS D1.1-90, "Structural Welding Code-Steel"

**Analysis and Calculations of Spreader Bar for Coil Handling During SM3
disassembly and VM assembly**

*[Background:]{.underline}*

Reuse the existing spreader bar of the Mino project to modified it, to
retrofit the

multiple coil handling applications during SM3 disassembly and VM
assembly

process. It is not only a design approach, but also it is a budgetary
and environmental

approach. Figure 1 shows an isometric view of one of the application of
the spreader

bar.

*[Reference Drawings and Others]{.underline}*:

1\. ME -- 397459, ME -- 397326;

MD -- 397452,

2\. "Steel Structure Design and Behavior" by C. Salmon & J. Johnson,
3^rd^ edition.

3\. "Fastening & Joining", by Robert Parmley, 2^nd^ edition

4\. "Allowable Stress Design", AISC, 9^th^ edition

![](media/image2.jpeg){width="5.621527777777778in"
height="5.291666666666667in"}

Figure 1, [The isometric view of the application of the Spreader
bar]{.underline}

[Allowable Stresses:]{.underline}

The materials of all Plates, channels are:

ASTM A36, where F~y~ = 36 ksi, so F~v~ = F~b~ = 12 ksi

Welds are E70, where F~u~ = 70 ksi, F~wv~ = 0.30 x 70 ksi = 21ksi

Bolts for A490, where F~u~ = 150 ksi, F~t~ = 54 ksi, F~v~ = 21 ksi

[Applying Load P~a~ and Others]{.underline}:

Figure 2 showed the force distribution diagram of the spreader bar,

Where W~inner~ ~coil~ = 13,000 lbs.

W~spre~. ~bar~ = 1,360 lbs.

W~coil~ ~turning~ ~fix.~ = 3,200 lbs

W~coil~ ~lift.\ Fix~. = 370 lbs.

P~at~ = W~inner~ ~coil~ + W~spre~. ~bar~ + W~coil~ ~turning~ ~fix~ +
W~coil~ ~lift.\ Fix~

= 17,930 lbs.

Figure 2. [The force distribution diagram of the spreader
bar]{.underline}

From figure 2 and drawing ME - 407814, it is found that:

L = 201 inch (the span distance for the largest coil -- inner coil)

P = P~at~ =17,930 lbs.

a~c~ = 0.5 L = 100.50 in (@ the center of the spreader bar)

R~1~ = R~2~ =0.5P = 8,965 lbs.

*1. **Calculate the working stresses at different locations***.

1.1. The working stresses in the center of the spreader bar:

The sectional modulus S~xc~ at the center of the spreader bar of the
strong axis x-x

Per Figure 3 on page 4, it was conservatively simplified and calculated
as:

I~xx1~ = (78.9 x 2) in^4^ = 157.80 in^4^ for 2 channels

A~1~ = 5.88 in^2^ x 2 = 11.76 in^2^

I~xx2~ =((0.75 x 10^3^ x 2) ÷ 12) in^4^ = 125 in^4^ for 2 vertical
plates

A~2~ = ( 0.75 x 10 x 2) in^2^ = 15 in^2^

I~xx3~ = ((8.50 -- 2.50) x (11^3^- 10^3^) ÷ 12) in^4^ = 165.5 in^4^

for 2 horizontal plates which assumed that both have 2.50 central cut
out.

A~3~ = ((8.50 -- 2.50) x 0.50 x 2) in^2^ = 6 in^2^

I~total~ = I~xx1~ + I~xx2~ + I~xx3~

= 448.30 in^4^

A~total~ = A~1~ + A~2~ + A~3~ = 32.76 in^2^

S~xc~ = I~total~ ÷ 5.50 in = 81.5 in^3^

![](media/image3.jpeg){width="5.990277777777778in"
height="5.197916666666667in"}

Figure 3. [The cross-section view of the spreader bar in the center
location]{.underline}

The moment at the center location subject to the force application:

M~max~ = PL/4

= (17,930 lbs. x 201 in) ÷ 4

= 900,983 lbs-in

The max. working bending stress f~b~:

f~b~ = M~max~ / S~xc~

= 900,983 lbs-in ÷ 81.5 in^3^

= 11.06 ksi \< F~b~ = 12 ksi,

The working shear stress fv:

Fv = P~at~ / A~total~ = 548 psi \< F~v~ = 12 ksi

***The design in this location is satisfactory***.

![](media/image4.jpeg){width="4.872222222222222in"
height="4.167361111111111in"}

Figure 4, [The cross-section view of the spreader bar in the location of
12" away from the]{.underline}

[center.]{.underline}

1.2. The working stresses in the location 12 inches away from the center
of the spreader

bar:

Find out the sectional modulus S~x12~ in the location of 12" away from
the center of

spreader bar about the strong axis x-x:

Per Figure 4 on page 5, it was found that:

I~xx1~ = (78.9 x 2) in^4^ = 157.80 in^4^ for 2 channels

A~1~ = 5.88 in^2^ x 2 = 11.76 in^2^

I~xx2~ = (8.50 x (11^3^- 10^3^) ÷ 12) in^4^ = 234.45 in^4^ for 2
horizontal plates

A~2~ = (8.50 x 0.50 x 2) in^2^ = 8.50 in^2^

I~total~ = I~xx1~ + I~xx2~

= 392.25 in^4^

A~total~ = A~1~ + A~2~ = 20.26 in^2^

S~x12~ = I~total~ ÷ 5.50 in = 71.31 in^3^

The applying moment in this location subject to the force application:

M~12~ = R~2~ x (100.5 -12) lbs.-in

= 8,965 lbs. x 88.5 in

= 793,403 lbs-in

The max. work bending stress f~b~:

f~b~ = M~12~ / S~x12~

= 793,403 lbs-in ÷ 71.31 in^3^

= 11.13 ksi \< F~b~ = 12 ksi,

The max. work shear stress fv:

Fv = R~2~ / A~total~ = 443 psi \< F~v~ = 12 ksi

***The design in this location is satisfactory***.

1.3. The working stresses in the location of 60 inches away from the
center of the the

spreader bar:

Find out the sectional modulus S~x60~ in the location of 60" away from
the center of

spreader bar about the strong axis x-x:

Per Figure 5 on page 7, it was found that:

I~xx1~ = ((1 x 9.94^3^) ÷12)in^4^ = 81.84 in^4^ for one vertical central
plate

A~1~ = (1 x 9.94) in^2^ = 9.94 in^2^

I~xx2~ = (1 x 8.50^3^ x 2) ÷ 12) in^4^ = 102.35 in^4^ for 2 vertical
side plates

A~2~ = (8.50 x 1.0 x 2) in^2^ = 17 in^2^

I~total~ = I~xx1~ + I~xx2~

= 184.19 in^4^

A~total~ = A~1~ + A~2~ = 26.94 in^2^

S~x12~ = I~total~ ÷ 4.97 in = 37.06 in^3^

The applying moment in the location subject to the force application:

M~12~ = R~2~ x (100.5 -60) lbs.-in

= 8,965 lbs. x 40.5 in

= 363,083 lbs-in

The max. work bending stress f~b~:

f~b~ = M~12~ / S~x12~

= 363,083 lbs-in ÷ 37.06 in^3^

= 9.80 ksi \< F~b~ = 12 ksi,

The max. work shear stress fv:

Fv = R~2~ / A~total~ = 333 psi \< F~v~ = 12 ksi

***The design in this location is satisfactory***

![](media/image5.jpeg){width="4.124305555555556in"
height="3.970833333333333in"}

Figure 5. [The cross-section view of the spreader bar in the location of
12" away from the]{.underline}

[center.]{.underline}

***2. The Calculation and discussion of the fastener group of the
spreader bar:***

*[Background]{.underline}*:

Try to re-use (or to modify) the existing Mino project spreader bar for
the SM3

disassembly project. the capacity of the spreader bar for the SM3
project is:

Overall load P~at~ = 17,930 lbs = 9 tons with max. span distance L~s~ =
201 in

[Assumptions]{.underline}:

Slip critical connection, single shear

2.1 [The selection of the fastening group and the others]{.underline}

Figure 6 is showing that when the applying load P is eccentric to the
centroid of the bolt group. This physical configuration is represented
by the design of the spread bar using for the SM3 project, which is also
shown pictorially in figure 1 on page 3.

![](media/image6.jpeg){width="6.625in" height="3.7576388888888888in"}

Figure 6. Eccentric load P and the group of bolt (6 bolts) of the
spreader bar

Where:

P = R1 = R2 = 8,965 lbs, applying load

L = 47.625 in

Location A is the geometrical centroid of the bolt group, 6 bolts are
located as

showing in Figure 6. currently, the spec. of bolt is assuming:

A490, 1 1/4 - 7, UNC

n = 6 (number of bolts)

Per Table I --D, part 4 of ASD, it is found that:

R~av~ = 25.8 kip (allowable shear load for the bolt)

Find out the local properties of the fastener group:

∑x^2^ = 4 (4)^2^ = 64 in^2^

∑y^2^ = 6 (2)^2^ = 24 in^2^

∑x^2^ + ∑y^2^ = 88 in^2^

The primary shear load f~v1~ of each bolt subject to the applying load
P:

R~v1~ = P/n = 8,965 lbs / 6

= 1,494 lbs ↓

The secondary torsional shear load of the bolt is subjected to the
moment PL:

Pick the bolt of the most right top one as shown in figure 1,

(which is subjected by the largest 2^nd^ shear force)

Where: R~vx~ = PLy ÷ (∑x^2^ + ∑y^2^)

= (8,965 lbs) x (47.625 in) x (2 in) ÷ 88 in^2^

= 9,704 lbs. →

R~vy~ = PLx ÷ (∑x^2^ + ∑y^2^)

= (8,965 lbs) x (47.625 in) x (4 in) ÷ 88 in^2^

= 19,407 lbs ↓

The resultant force applying to the most right top bolt:

R = \[(R~v~ + R~y~)^2^ + R~x~^2^ \]^1/2^

= \[(1,494 + 19,407)^2^ + (9,704)^2^ \]^1/2^ lbs

= [23.044 kip]{.underline} \< R~av~ = 25.8 kip

**Using (6) A490 (or grade 8) high strength structural bolts with
specification of 1 ¼ -7, UNC -- 2B can be meet the current
applications.**

2.2***.*** [The Assembly Torque Value for Two Arms of the Spreader
Bar]{.underline}

There are (12) A490 structural bolts for connecting the center piece to
the arms (2) of the spreader bar as shown on drawing ME -- 407814 and on
figure 6.

The suggested tightening torque value T can be calculated as:

F~t~ = 150 ksi Min. tensile strength of A490 bolt.

F~p~ = 120 ksi, proof strength of A490 bolt.

P~c~ = 0.75 As F~p~ Clamp load, where

A~s~ = 0.969 in^2^, stress area for 1 ¼ -7, UNC bolt

P~c~ = 0.75 x 0.969 x 120 ksi

= 87,210 lbs

T = K D~b~ P~c~ where K = 0.2, torque coefficient,

D~b~ = 1.25 in, nominal bolt diameter

T = 0.2 x 1.25 in x 87,210 lbs

= 21,803 lbs--in = 1,817 lbs-ft

(Per table 4.1.1, page 107 of ref. 2, also table 1-2, Page 1-25 of
ref.3)

***3. Weld Calculations and Discussions***:

Per figure 1 on page 3, design drawings of ME -- 407814 and MD --
407915, it is found that the welds on 3 plates (MD-397452, MD-407815)
are subjected:

Stress due to direct load P~y~

Stress due to torsional moment T

Figure 7 is based on the design weld configuration to treat it as line
with unit thickness.

![](media/image7.jpeg){width="4.750694444444444in"
height="3.9256944444444444in"}

Figure 7. The weld configuration of the connect plate to treat as lines

Find the geometric properties of the welds (treated as lines):

Length l = 2b = 16.50 in where b = 8.25 in, d = 7 in

I~p~ = b(3d^2^ + b^2^) ÷ 6 (Per table 5.18.1, section 5.18 of reference
2)

= (8.25 x (3 x 7^2^ + 8.25^2^) ÷ 6) in^3^

= 295.7 in^3^ Where I~p~ is the polar moment of inertia about C.G.

Compute the components of the force on the weld at the maximum area:

Per figure 7, the locations to subject the maximum force are 4 corners .

T = P~y~ \*L Where T is torsional moment,

P~y~ = 0.5 R~1~ =0.5 R~2~ = 4,483 lbs, assuming 2 plates (conservative)

L = 36.56 in

= 4,483 lbs x 36.56 in

= 163,899 lbs-in

The primary shear R~v1~:

R~v1~ = Py ÷ weld length

= 4,483 lbs ÷ 16.50 in

= 272 lbs/in ↓

The secondary torsional shear about the centroid of the welds:

R~vx~ = (T y)/ I~p~

= ((163,899 x 3.50) ÷ 295.7) lbs/in

= 1,940 lbs/in →

R~vx~ = (T x)/ I~p~

= ((163,899 x 4.125) ÷ 295.7) lbs/in

= 2,287 lbs/in ↓

The resultant force R~t~

R~t~ = \[(R~v1~ + R~vy~)^2^ + R~vx~^2^ \]^1/2^

= ((272 + 2,287)^2^ + 1,940^2^)^1/2^ lbs/in

= 3,212 lbs/in

Find the fillet weld size C, assuming all are fillet welds with E70 weld
metal:

Allowable stress of the weld metal F~wv~:

F~wv~ = 0.30 x 70 ksi = 21ksi, for E70 weld metal

C = R~t~ / (0.707 x F~wv~ ) ( Per section 5.18, reference 2)

= 3,212 lbs/in ÷ (0.707 x 21,000) lbs/in^2^

= 0.217 in

Per drawing MD-407815, it was found that the weld sizes are 0.25", so
the design is satisfactory.

***Conclusions:***

The engineering note was presented by discussing and analyzing several
of the most critical structural areas and locations. The calculations
have been shown that the modified reused spreader bar has been designed
per the related applicable codes.

**[Rated Load Test Layout and Procedures]{.underline}**

Step 1. Review the test setup layout as shown on figure 8.

Step 2. Move B blocks (2) and E blocks (4) to the designated area, lay
them out per

figure 8 (the center line of E block should be lined up the ctr. line of
the B block

on top view). The distance of the two B blocks will depend on the
distance

between AA, BB, CC & DD lifting lugs respectively.

Step 3. Select designated rated slings, anchor shackles (1" dia.
alloy/carbon steel) and

scale, install them per figure 8.

Step 4. Gradually, slowly apply load through crane until the scale
reading reaches

22,150 lbs, sustain the load up to 10 minutes, take pictures if it is
possible.

Step 5. Release the loads and relocate the bottom 2 slings and anchor
shackles to the

next 2 lifting lugs.

Step 6. Repeat steps 4 & 5 until all lifting lugs (AA, BB, CC & DD) are
been tested.

Step 7. Fill out and sign form 5022.1TA (page 1) as Load Test Witness.

Step 8. Mark the spreader bar as:

Number 151

Lifting Capacity: 16,600 lbs.

Fixture Weight: 1,400 lbs.

Step 9. Remove every item back in order. Thanks for finish the project
safely and

Successfully!

![](media/image8.jpeg){width="7.254861111111111in"
height="5.214583333333334in"}

Figure 8. [SM3 Coil Spreader Bar Load Test Setup]{.underline}

![](media/image9.jpeg){width="5.511111111111111in"
height="4.133333333333334in"}~Ll~

![](media/image10.jpeg){width="5.511111111111111in"
height="4.133333333333334in"}

Figure 9. [The Load Test for SM3 Coil Spreader @ MAB
Building]{.underline}