**5022.1TA**

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

## Engineering Note Cover Page for MD-ENG-070

Lifting Device Numbers:

  ----------- ------------ ------------- ------------ -------- ------------
  FNAL Site                Div. Specific **153**      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  **Coil Lifting Turning Fixture for SM3 & VM
                              Magnets**

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

+---------+-----------------------------+------------------------------+
| Device  | \[ \] Purchased from a      |                              |
| was     | Commercial Lifting          |                              |
|         |                             |                              |
|         | Device Manufacturer. Mfg    |                              |
|         | Name                        |                              |
+---------+-----------------------------+------------------------------+
| (check  | \[ **X**\] Designed and     |                              |
| all     | Built at Fermilab           |                              |
| appl    |                             |                              |
| icable) |                             |                              |
+---------+-----------------------------+------------------------------+
|         | \[X\] Designed by Fermilab  | **Eng. Drawings: ME-121726 & |
|         | and Built by a              | MD - 407803**                |
|         |                             |                              |
|         | Vendor. Assy drawing number |                              |
+---------+-----------------------------+------------------------------+
|         | \[ \] Provided by a User or |                              |
|         | other Laboratory            |                              |
+---------+-----------------------------+------------------------------+
|         | \[ \] Other: Describe       |                              |
+---------+-----------------------------+------------------------------+

  ------------------------ --------------------- ------ -------------------
  Engineering Note         **Edward Chi**        Date   **January 21,
  Prepared by                                           2005**

  Engineering Note                               Date   
  Reviewed by                                           
  ------------------------ --------------------- ------ -------------------

Lifting Device Data:

  -------------------- --------------------------------------------------
  Capacity             **13,000 lbs**. (for 2 sets together)

  Fixture Weight       **3,200 lbs**. (for 2 sets together)
  -------------------- --------------------------------------------------

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:

See pages13 and 14 for rated load test procedures;

page 15 and page 16 for rated load test setup layout;

page 17 for rated load test site pictures if have any.

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

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

**Particle Physics Division**

**Mechanical Department Engineering Note**

# Number: MD-ENG- 070 Date: January 21, 2005

Project Internal Reference:

Project: BTeV, SMTF

Title: Coil Lifting Turning Fixture for SM3 & VM Magnets

Author(s): Edward Chi

Reviewer(s):

Key Words: Coil, turning fixture, threaded rod, allowable stresses,
welding

Sizes, eccentric force.

Abstract Summary:

The turning fixture is specially designed to lift the sm3 & VM coil
(inner, middle and outer coil) vertically, and then turn it lying down
horizontally, lift and move to the designated area. The turning fixture
was originally designed on 1982, the new retrofit modifications enable
the fixture to have multiple functions: turning, lifting and moving. For
several critical areas, the working stresses of fixture structure and
the threaded rod, the welding sizes have been presented for discussion
and calculation per the related industrial specification and codes.

Applicable Codes:

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

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

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

"Hilti North America Product Technical Guide", 2002 edition

**Design the Coil lifting Turning Fixture for SM3 & VM Magnets**

*[Design Criteria and Assumptions]{.underline}*:

Total design load:

Lifting capacity: P~c~ = 13,000 lbs; Fixture weight W~f~ = 3,200 lbs.

All plates: ASTM A36: F~u~ = 58 ksi, F~y~ = 36 ksi

All tubings: A500, Gr. B, F~u~ = 58 ksi, F~y~ = 46 ksi

All bolt materials: Grade 5 steel, F~u~ = 120 ksi

All weld materials: E70, where F~u~ = 70 ksi

Reference Drawings:

LE-407840, ME-121726, MD-407803, ME-407856

The fixture has designed to lift the coil vertically as shown on figure
1, and then turn to lay it down horizontally, lift and move the coil as
shown on figure 2.

![](media/image2.jpeg){width="4.253472222222222in"
height="4.288888888888889in"}

Figure 1. [Using the coil lifting turning fixture to lift the coil
vertically]{.underline}

![](media/image3.jpeg){width="4.211805555555555in"
height="3.6277777777777778in"}

Figure 2. [Using the coil lifting turning fixture to lift the coil
horizontally]{.underline}

The turning fixture was designed on 1982 as shown on figure 3 of page 5.
The modification was done this time as shown on figure 4 for the
multiple usages: turning, lifting and moving.

The main modifications from the original design (version of 82) are:

1.  Redesign the lifting hole location when it lifts vertically as shown
    on figure 1. In order to create larger eccentric distance in z dir.
    between the center gravity of the coil with accessories and the
    lifting lug, the new lifting lug moved 5.25" in +z dir.

> from the original location. The coil will turn along x axis
> (clockwise) when it is lifted in y dir. as shown on figure 1.

2.  The turning lifting fixture also has capability to lift the coil
    horizontally as shown on figure 2.

3\. The turning fixture can hold the coil vertically with anchoring it
to the heavy blocks

as shown on figure 5.

I. *The discussion of the load condition of the fixture lifting
vertically.*

For simplicity, it is conservatively assumed that the whole weight of
the coil was

supported by coil support plates (2) (see item #3 of drawing ME-121726).
Assuming

beam fixed at one end, simple supported at other end, uniformly
distribution load as

shown on case #12, page 2-299, part 2 of ASD, 9^th^edition.

![](media/image4.jpeg){width="7.248611111111111in"
height="4.878472222222222in"}

Figure 3. [The coil turning fixture drawing of ME -- 121726 dated on
02/04/1982]{.underline}

Where: L = 10" -- 0.5(1.414 x 4") = 7.2"

w = (13000# x 0.5)/7.2" = 903 lbs/inch

P~t~ : Total uniform load, = wL = 6,500 lbs.

R~1~ = (3/8) P~t~= 2,438 lbs.

R~2~ = (5/8) P~t~= 4,063 lbs @ the fixed end

So, M~max~ = (wL^2^) / 8

= (703 lbs/in x 7.2^2^ in^2^) / 8

= 4,555 in-lbs. @ the fixed end.

In order to find the bending and shear stresses @ the most critical
location, it is necessary to find out the geometrical property of the
coil support plate at that location. Per drawing ME -- 121726 (item #3),
it is found that:

A~area:~ in cross section view, see section A-A of drawing ME-121726

= (8.0 x 0.625) in^2^

= 5.0 in^2^

![](media/image5.jpeg){width="5.993055555555555in"
height="4.547916666666667in"}

Figure 4. [The modified coil turning lifting fixture]{.underline}.

I~xx~ = (8 x 0.625^3^) / 12 (in^4^)

= 0.1628 in^4^,

S~xx~ = 0.52 in^3^

The allowable stresses of the coil support plate:

F~b~ = F~y~ /3.0 = 12 ksi = F~v~ = F~t~

(per section 20-1.2.2.2, ASME B30.20)

The computed working stresses:

f~b~ = M~max~ / S~xx~ = 4,555 in-lbs / 0.52 in^3^

= 8.76 ksi \< F~b~ = 12 ksi

f~v~ = R~2~ / A~area~ = 4,063 lbs / 5.0 in^2^

= 0.82 ksi \< F~v~ = 12 ksi

**The working stresses are satisfactory subject to the apply load**.

![](media/image6.jpeg){width="4.625in" height="3.7041666666666666in"}

Figure 5. [The coil turning fixture stands vertically with anchored to
the shielding block B]{.underline}.

II\. a) *Find out the working stresses of the threaded rods for being
subjected the forces*

*when the fixture with coil is lifted vertically first, and then is
gradually turned to*

*horizontally.*

a1). It is assuming that the coil is supported by the coil support plate
as discussed on

part I when coil fixture lifting vertically. The vertical force P~v~
(weight of items #1

& #2 of drawing MD-407803, partial weight of the coil) applying to the
rods

actually is resisted by the friction force F~r~, where F~r~ = P~c~ \* µ

Where P~v~ = 0.5 \[weight of the coil + 0.5(weight of the turning
fixture)\]

= 0.5 (13,000 + 1,600) lbs.

= 7,300 lbs.

P~c~ = 0.75 A~s~ F~p~ Clamp load

A~s~ = 0.7854 \[D~n~ -- 0.9743/n\]^2^ stress area

= 0.7854 x (1 -- 0.9743/8 )^2^

= 0.6057 in^2^

D~n;~ nominal diameter of the rod, 1.0 in

n: number of threads per inch, 8

F~p~ = 70% of the tensile strength

= 0.70 x 120 ksi (for grade 5 screw)

= 84 ksi

P~c~ = 0.75 x 0.6057 in^2^ x 84 ksi

= 38 kip

µ: The coefficient of friction between the coil contact surface and the

mating surface from the turning fixture, conservatively assume that

µ = 0.1

So: F~r~ = P~c~ \* µ = 38,000 lbs x 0.1

= 3,800 lbs per threaded rod

Per figure 4 or drawing MD-407803, it is found that there are 8 threaded
rods, so the

total friction force F~rt~ to support the applying vertical load P~v~
is:

F~rt~ = 8 F~r~ = 8 x 3,800 lbs = 30,400 lbs \> P~v~ = 7,300 lbs.

**Applying only \~25% of the threaded rod's clamping force will hold the
coil and**

**the fixture vertically with coefficient of friction µ = 0.1.**

a2). Compute the working load vs. the allowable load of the threaded rod
when the

turning fixture lifting horizontally as shown on figure 2.

There are (16) 1"-8, UNC, grade 5 threaded rods to support the weight of
the coil

and the lower half of the turning fixture (see dwg. MD-407803 for
reference), per

page 4-3, part 4 of ASD, 9^th^ edition, the allowable tensional load of
the rod P~tr~:

P~tr~ = 0.33F~u~A~n~

= 0.33 x 120 ksi x 0.7854 in^2^

= 31 kip, for the each thread rod

The total applying load P~ay~ = 2P~y~ = 14,600 lbs (for 16 threaded rod)

p~tr~ = P~ay~ / n

= 14,600 lbs / 16

= .92 kip \< P~tr~ = 31 kip

Consider such big safety of factor, for simplicity, ignore some
tensional

and compressive loads caused by the unsymmetrical loading.

**The** **threaded rods are satisfactory to the subjected load**.

b). *Find the working stresses subject the axial load as shown on figure
5.*

b1). Find out the critical force P~cr~ to cause the column to buckling:

P~cr~ = (Π^2^E) A~g~/ (KL/r)^2^

= 479 kip \> P~v~ = 7.3 kip

(see section 6.3, Steel Structures Design & Behavior, 3^rd^ edition)

**So there is no buckling under the current load condition**.\*

where: E = 29 x 10^6^ ksi, modulus of elasticity of the subjected member

A~g~= 14.4 in^2^, for 8" x 8" x 0.5" tubing gross cross-section area

L = 133.75 in, the length of the subjected member

K = 2.10, assuming effective length factor

r = 3.03 in, radius of gyration

\*: Since the big value difference between P~cr~ and P~y~, it ignores
the

eccentric loading condition for simplicity, however, the calculation of
f~b~ in

section I has included such eccentric load case.

b2). Find out the allowable stresses vs. the computed working stresses:

F~a~ = F~y~ \[1- (KL/r)^2^ / (2C~c~^2^)\] ÷ \[5/3 + (3/8) x (KL/r)/
C~c~ - (KL/r)^3^/ 8C~c~^3^\]

= 16.63 ksi

(see eq. E2-1, Charter E, Part 5, ASD, 9^th^ edition)

where: F~a~: the allowable axial stress for the compressive member

KL/r = 92.7, the largest effective slenderness ratio

Cc = \[(2Π^2^E) / F~y~\]^1/2^ = 111.55 \> KL/r = 92.7

F~y~ = 46 ksi, yielding stress for tubing with ASTM A500, Gr. B

However, per section 20-1.2.2.2, ASME B30.20

F~b~ = F~y~ /3.0 = 15.33 ksi = F~v~ = F~a~

Pick the less value one as allowable stress, so F~a~ = 15.33 ksi.

f~a~ = P~y~ / A~g~ = 7,300 lbs / 14.4 in^2^

= 0.51 ksi \< F~a~ = 15.33 ksi,

**The computed axial working stress is satisfactory subjecting the axial
applying**

**force.**

III\. *Computer the anchor bolt force f~anchor~ subjected the eccentric
force*.

![](media/image7.jpeg){width="3.4680555555555554in"
height="3.8722222222222222in"}

Figure 6. [Coil and turning fixture stand vertically, and anchored with
B block]{.underline}.

The discussion of the anchor bolt doesn't belong the scope of the
lifting fixture,

however, the process of the computation will help us further understand
the nature of

the design.

Per side and top views of the drawing ME- 407856, it is found that the
coil is

supported by (4) 8"x 8" tubing columns (i.e: the (2) outer columns (E)
and (2) inner

columns (F)); the distance between the ctr. gravity to the central line
between E

column and F column L~z1~ = 8" + 10.24"/2 = 13.12"; the distance between
top and

bottom drop-in anchor bolt L~ab~ = 78.0" (see figure 6 as reference),
the distance

between the anchor bolt A to location C of the bottom of the column
L~ac~ = 84.0".

The over-turn moment M~ov~ due to the eccentric force P~yt~ can be write
as:

M~ov~ = L~z1~ x P~yt~

= 13.12 in x 16,200 lbs = 212,544 in-lbs.

The moment M~re~ to resist the over-turn moment M~ov~ will be:

M~re~ = L~ac~ x f~ant~ = M~ov~

So: f~ant~ = \[(L~z1~ x P~yt~) ÷ L~ac~\]/ n

= \[(212,544 in-lbs) ÷ 84.0 in\]/ 4

= 633 lbs \< F~at~ = 1,135 lbs.

where: n = 4, number of the anchor bolt on the top surface of two B
blocks.

F~at~ = 1,135 lbs, the allowable tensional load for ½" -13, UNC drop-in

HDI anchor bolt (per page 171, section 4.3.5, "Hilti

North America Product Technical Guide, 02 edition)

f~ant:~ the computed tension working load for drop-in anchor bolt.

For simplicity, the discussion has ignored the computation the anchoring
force from

the 4 bottom bolts (@ B location) as shown on drawing ME-407856 and
figure 6.

**The current anchor bolts will generate enough resistant force to
counter balance**

**the overturning eccentric force.**

3\. [Weld Calculations:]{.underline}

The part (I) and part (II) of Figure 7 are the weld configuration for
the two different welding places of the turning fixture respectively.

Part (I) is the welds of the coil support plate (see item #3 of drawing
ME-121726 ), find the geometrical properties of the welds as shown on
part (I) of figure 7:

where d = 0.625 inch, b = 8.0 inch

L = 2b = 16 in, length of the welds

I~xx~ = bd^2^ / 2

= 1.5625 in^3^

S~xx~ = bd

= 5 in^2^

![](media/image8.jpeg){width="2.7465277777777777in"
height="2.6972222222222224in"}![](media/image9.jpeg){width="3.123611111111111in"
height="2.6145833333333335in"}

\(I\) (II)

Figure 7. [The weld configuration for the two different welding
location]{.underline} [of the turning]{.underline}

[fixture (treat as line with unit thickness).]{.underline}

The working load per unit length of the weld subject to the applying
load can be found:

f~b~ = M~max~ / S~xx~ (see page 5, section I for the value M~max~ and
R~2~)

= 4,555 in-lbs ÷ 5 in^2^

= 911 lbs/in

f~v~ = R~2~ / L

= 4,063 lbs ÷ 16 in

= 254 lbs/in

f~r~ = ( f~b~^2^ + f~v~^2^ )^½^

= 946 lbs/in

To find the required weld size C~I~:

All weld metals are E70,

Where: F~u~ = 70 ksi

The allowable stresses for the weld metals:

F~t~ = F~v~ = 0.30 F~u~ = 21 ksi

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

= (946 lbs/in) ÷ (0.707 x 21 ksi)

= 0.064 in \< 0.5 in (the designated weld size in the area per drawing
ME-121726)

Part (II) are the welds of the hoist flange (see item #11 of drawing
MD-407803 ), find the geometrical properties of the welds as shown on
part (II) of the figure 7:

where d = 4 inch, b = 6.0 inch

L = 2(b+d) = 20 in, length of the welds

The working load per unit length of the weld subject to the applying
load can be found:

f~v~ = P~yt~ / L

= 8,100 lbs ÷ 20 in

= 405 lbs/in

where P~yt~ is the total applying load to the one hoist ring:

P~yt~ = 0.5(weight of the coil + weight of the turning fixture)

= 0.5 x (13,000 + 3,200) lbs.

= 8,100 lbs.

To find the required weld size C~II~:

All weld metals are E70,

Where: F~u~ = 70 ksi

The allowable stresses for the weld metals:

F~t~ = F~v~ = 0.30 F~u~ = 21 ksi

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

= (405 lbs/in) ÷ (0.707 x 21 ksi)

= 0.028 in \< 0.25 in (the designated weld size in the area per drawing
MD-407803)

**The designated weld sizes are satisfactory**.

***Conclusions:***

The coil turning 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; threaded rod
and anchor bolt forces; and finally the weld sizes in terms the
different applications.

**[Rated Load Test Procedures for SM3 Coil Turning Lifting
Fixture]{.underline}**

1.  Review the load test setups on figures 8 & 9 and the lifting fixture
    engineering

drawing MD-407803, call Edward Chi \@x2879 for the questions.

2\. Prepare and move the items to the designated area for the test:

> a). Three B shield blocks
>
> b). Two existing steel tubes:

One with sizes of 10" x 12" x ½" with 10' in length,

Another one with sizes of 10" x 10" x ½" x 120".

> c). One timber block with sizes of 8" x 8" x 24"
>
> d). 8 pieces of garden hose (\~19" in length) -- or equivalent, for
> threaded rod

protections.

e). 8 pieces of steel angles or equivalent parts for restricting the
sling contact

area

f). Slings with spec. as shown on figures 8 & 9.

g).One hoist scale and (4) 1 ¼" -7, hoist rings.

f). (4) \~ 12" x 12" x 24" blocks as shown on figure 9.

I. *[For the vertical rated load test as shown on figure
8]{.underline}:*

> I1. Assemble all items per load test set up as shown on figure 8 of
> page 15, cross--
>
> check the position per the test setup layout figure 8 and drawing
> MD-407803.
>
> Gradually, uniformly tight (8) threaded rods, suggested torque value
> is about 190
>
> ft-lbs.
>
> I2. Lift up the assembled test fixture slowly, apply the slings per
> the test setup on
>
> figure 8, make sure that both slings stay on the distance of 30" and
> 60" as shown
>
> on the front view of figure 8.
>
> I3. Gradually, slowly apply load through crane until the scale reading
> reaches 9,850
>
> lbs, sustain such load up to 10 minutes, observe the fixture to see if
> there is any
>
> irregular mechanical behavior.
>
> I4. Take the pictures for the load test setup.

II\. [*For the horizontal rated load test as shown on figure
9*:]{.underline}

II1. Move the assembled turning fixture with 2 tubes to the designated
location,

cross-check the position per the test setup layout of figure 9. Please
pays special

attention to the location of 4 blocks underneath of the turning fixture.

II2. Lays down the turning fixture horizontally on the top of 4 blocks,
adjust to the

position as shown on figure 9.

II3.Move 2 B blocks to the top of the (2) test tubs (10" x 10" x ½" &
10" x 12" x

½"), adjust to the position as shown on figure 9.

II4. Install (2) 1-1/4" -- 7, hoist rings to the location as shown on
drawing MD-

407803\.

II5. Install rated slings between hoist rings and hoist scale per figure
9.

II6.Gradually, slowly apply load through crane until the scale reading
reaches 9,850

> lbs, sustain such load up to 10 minutes, observe the fixture to see if
> there is any
>
> irregular mechanical behavior.

II7.Take the pictures for the load test setup.

3\. Repeat the rated load test for another set of coil turning lifting
fixture.

4\. Fill out and sign the form 5022.1TA (page 1) as Load Test Witness

5.  Remove every item back in order one by one.

6.  Mark each set of the fixture as:

Number 153

Lifting Capacity: 6,500 lbs.

Fixture weight: 1,600 lbs.

7\. Thanks for finish the project safely and successfully.

![](media/image10.jpeg){width="5.9944444444444445in" height="8.125in"}

Figure 8. [Vertical setup of the load test for the coil turning lifting
fixture]{.underline}.

![](media/image11.jpeg){width="5.833333333333333in"
height="8.253472222222221in"}

Figure 9. [The horizontal setup of the load test for the coil turning
lifting fixture]{.underline}.

![](media/image12.jpeg){width="6.105555555555555in"
height="4.2972222222222225in"}

![](media/image13.jpeg){width="6.126388888888889in"
height="4.374305555555556in"}