**5022.1TA**

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

## Engineering Note Cover Page for MD-ENG-073

Lifting Device Numbers:

  ----------- ------------ ------------- ------------ -------- ------------
  FNAL Site                Div. Specific **154**      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           **Coil Insert Lifting Fixture for SM3
  Description              Disassembly & VM Assembly**

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

+---------+-----------------------------+------------------------------+
| Device  | \[ \] Purchased from a      |                              |
| was     | Commercial Lifting          |                              |
|         |                             |                              |
|         | Device Manufacturer. Mfg    |                              |
|         | Name                        |                              |
+---------+-----------------------------+------------------------------+
| (check  | \[ \] Designed and Built at |                              |
| all     | Fermilab                    |                              |
| appl    |                             |                              |
| icable) |                             |                              |
+---------+-----------------------------+------------------------------+
|         | \[X\] Designed by Fermilab  | **Eng. Drawings: MC-         |
|         | and Built by a              | 407784**                     |
|         |                             |                              |
|         | Vendor. Assy drawing number |                              |
+---------+-----------------------------+------------------------------+
|         | \[ \] Provided by a User or |                              |
|         | other Laboratory            |                              |
+---------+-----------------------------+------------------------------+
|         | \[ \] Other: Describe       |                              |
+---------+-----------------------------+------------------------------+

  ------------------------ --------------------- ------ -------------------
  Engineering Note         **Edward Chi**        Date   **January 28,
  Prepared by                                           2005**

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

Lifting Device Data:

  -------------------- --------------------------------------------------
  Capacity             **6,500 lbs**.

  Fixture Weight       **180 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:

See page 8 for rated load test procedures;

page 9 for rated load test setup layout;

page 10 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- 073 Date: January 28, 2005

Project Internal Reference:

Project: BTeV, SMTF

Title: Coil Insert Lifting Fixture for SM3 Disassembly & VM Assembly

Author(s): Edward Chi

Reviewer(s): David Pushka

Key Words: Coil, insert lifting fixture, tubing, threaded rod, axial
allowable

stresses, critical force, buckling.

Abstract Summary:

The insert lifting fixture is specially designed to lift the sm3 & VM
coil (inner, middle and outer coil) vertically from the limited accessed
space area, and then move to the designated location. The working
stresses of fixture structure; the buckling behavior of the slim tubing
with threaded rod; the welding sizes of the lifting lug have been
presented for discussion and calculation per the related industrial
specifications 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

"Steel structures Design and Behavior" by C. Salmon & J. Johnson, 3^rd^

edition, 1990

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

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

Total design load:

Lifting capacity: P~c1~ = Pc2 =13,000 lbs / 2 = 6,500 lbs.

Fixture weight W~d~ = 180 lbs. (dead weight)

Gross force to the fixture: P~ty~ = 6,500 lbs + 180 lbs. = 6,680 lbs.

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

All tubings: Carbon stl. AISI 1020, F~u~ = 52 ksi, F~y~ = 38 ksi

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

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

*[Reference Drawings]{.underline}*:

LE- 407840, MC-407784, MB-407790, MB-407786, MB-407787, MB-407788

*[The application of the coil insert lifting fixture]{.underline}*:

The coil insert lifting fixture specially designed: lift & move the coil
away from the limited access space area as shown on figure 10 of dwg.
LE-407840; and then move the coil to the designated area for installing
the coil turning fixture as shown on figures 11a to 11c of drawing
LE-407840.

![](media/image2.jpeg){width="4.375in" height="4.031944444444444in"}

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

Figure 1 on page 3 shown the application of the coil insert lifting
fixture: two coil insert

lifting fixtures lifted the coil through the coil lifting spreader bar.
It is assumed that there

is about 6,680 lbs force (P~ty~) applying to each coil insert lifting
fixture.

Figure 2 is the detail engineering drawing of the coil insert lifting
fixture, the coil was supported by upper and bottom decks, there are (4)
tubes with threaded rods connected upper and bottom decks together as
shown on drawing MC-407784.

![](media/image3.jpeg){width="7.0in" height="5.205555555555556in"}

Figure 2. [The detail eng. drawing of the coil insert lifting
fixture.]{.underline}

I. *The discussion of the load condition of the coil insert lifting
fixture.*

When coil is lifted by the coil insert lifting fixture, it is assuming
that the tube with

threaded rod mainly subjected two forces: tension load and compressive
load

a)  Discuss the working tensional load p~tr~ of the threaded rod:

> Conservatively assuming that one rod takes whole load p~t~ = 6,680
> lbs.= p~tr~
>
> The specifications of the threaded rod: grade 5 steel, 5/8" -- 11,
> UNC,

F~u~ = 120 ksi,

F~t~ = 0.33 F~u~ = 39.6 ksi, the allowable tensile stress of the
threaded rod

(per page 4-3, part 4 of ASD, 9^th^ edition)

> P~t~ = Gross area of the threaded rod x allowable tensile stress
>
> = 0.3068 in^2^ x 39.6 ksi
>
> = 12.15 kip \> p~t~= 6.680 kip = p~tr~
>
> where P~t~ is the allowable tensional load for the thread of 5/8"
> nominal diameter.
>
> **The designated threaded rod has enough capacity to take the
> subjected**
>
> **tensional load.**

b). *Discuss the work condition of the tube with threaded rod subject
the axial load*

*P~ca~.*

P~ca~ = P~ty~ / n, compressive axial load per tubing column

= 6,680 lbs / 4 =1.67 kip,

n: number of the tubing columns per insert lifting fixture

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

P~cr~ = (Π^2^E) A~g~/ (KL/r)^2^

= \[(Π^2^ x 29 x 10^6^ ksi) x 1.215 in^2^\] ÷ (2.0 x 72.0 in / 0.732
in)^2^

= 8.986 kip \> P~ca~= 1.67 kip

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

**So there is no buckling under the current load conditions**.

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

A~g~= 1.215 in^2^, for gross cross-section area of the tubing with 2.25"
od. and

3/16" wall thickness (see drawing MB-407790 for ref.)

L = 72.0 in, the length of the subjected member conservatively assumed.

K = 2.0, assuming effective length factor

I = 0.651 in^4^, geometrical inertia of the tubing.

r = 0.732 in, radius of gyration

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

F~a1~ = 12 Π^2^E ÷ 23(KL/r)^2^

= (12 Π^2^ x 29,000 ksi) ÷ 23 x 196.7^2^

= 3.86 ksi

(see eq. E2-2, Charter E, Part 5, ASD, 9^th^ edition)

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

KL/r = 2.0 x 72 in/0.732 in = 196.7, the largest effective slenderness
ratio

C~c~ = \[(2Π^2^E) / F~y~\]^1/2^ = 122.73 \< KL/r = 196.7

F~y~ = 38 ksi, yielding stress for tubing with AISI 1020, carbon stl.

per section 20-1.2.2.2, ASME B30.20

F~b~ = F~y~ /3.0 = 12.67 ksi = F~v~ = F~a2~

Pick the less value one as allowable stress,

so F~a~ = 3.86 ksi.

f~a~ = P~c~ / A~g~ = 1,670 lbs / 1.215 in^2^

= 1.375 ksi \< F~a~ = 3.86 ksi,

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

**force.**

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

The figure 3 is the weld configuration for the lifting lug of the coil
insert lifting fixture,

See drawings MB-407788, MB-407786 and MC-407784 for the reference.

Find the geometrical properties of the welds as shown on figure 3:

Where: d = 1.25 inch,

b = 5.0 inch

L = 2b = 10 in, length of the welds

I~xx~ = bd^2^ / 2

= 3.9 in^3^

S~xx~ = bd

= 6.255 in^2^

![](media/image4.jpeg){width="3.998611111111111in" height="3.575in"}

Figure 3. [The weld configuration for the lifting lug]{.underline} [of
the coil insert lifting]{.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~v~ = P~ty~ / L

= 6.680 lbs ÷ 10 in

= 668 lbs/in

Per figure 1 for the application of the insert lifting fixture, it can
be assumed that there is no significant moment to be produced from the
subjected applying load.

So: f~r~ = f~v~

= 668 lbs/in

where: f~r~ is the combined working load per unit length

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

= (668 lbs/in) ÷ (0.707 x 21 ksi)

= 0.045 in \< 0.31 in (the designated weld size in the area per drawing
MB-407786)

**The designated weld sizes are satisfactory**.

***Conclusions:***

The coil insert lifting fixture has been designed per the related
engineering codes after the discussions from several different areas,
such discussions were presented by computing the working structural
stresses; allowable axial stresses of the slim tubing column; and
finally the weld sizes in terms the different applications.

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

1.  Review the load test setup on figure 4 of page 9 and the lifting
    fixture engineering

> drawing MC-407784, call Edward Chi \@x2879 for the questions.

2.  Prepare and move the items to the designated area:

> 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). Two timber blocks:
>
> One with one sizes of 8" x 8" x 24"
>
> Another one with sizes of 10" x 8" x24"
>
> 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 figure 4.

g). Hoist scale

f). One 1" dia, alloy steel anchor shackle

3.  Assemble all items per load test set up as shown on figure 4 of page
    9 (per right side view), uniformly apply the clamping force to the
    tubes and blocks through the threaded rods, the tight torque to the
    nut is about 75 ft-lbs. Cross--check the position per the test setup
    layout and drawing MC-407784.

4.  Lift up the assembled test fixture slowly, apply the slings per the
    test setup on figure 4 (see the front view), make sure that both
    slings stay on the distance of 30" and 60" as shown on the front
    view of figure 4.

5.  Gradually, slowly apply load through crane until the scale reading
    reaches 8,350 lbs, sustain such load up to 10 minutes, observe the
    fixture to see if there is any irregular mechanical behavior.

6.  Take the pictures for the load test setup.

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

8.  Remove every item back in order.

9.  Mark the fixture as:

Number 154

Lifting Capacity: 6,500 lbs.

Fixture weight: 180 lbs.

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

![](media/image5.jpeg){width="6.329861111111111in"
height="7.739583333333333in"}

Figure 4. [SM3 Coil Insert Lifting Fixture Load Test Setup]{.underline}

![](media/image6.jpeg){width="5.875in" height="4.396527777777778in"}

![](media/image7.jpeg){width="5.875in" height="4.396527777777778in"}