P. DESIGN OF LIFTING AND TAILING LUGS 203Ad, GH, J, K B c D D3 F R t bab N S,P,E 8 t t v w Ww Zz : a oy o os oO % ow Ser Fea LIST OF SYMBOLS shackle dimension width of lug plate = centroidal distance lug plate width at the pin. bolt circle diameter = lift load at each lug = talling lug load vessel wall stress factor dimensions of lug plate number of bolts for the nozzle dimensions of trunnion lug thickness lug plate thickness collar plate thickness thickness of vessel shell weld size weight of vessel section modulus angle of vessel from horizontal stress ratio, o,/o, allowable bending stress allowable bearing stress allowable shear stress, allowable tensile stress vessel stress allowable stress in the weld bending stress in lug plate due to angle e angle of lift cable from vert. 204A. PURPOSE This design guide describes methods of selecting and designing different types of lifting and tailing devices for use in the erection of pressure vessels. B.' CODES AND STANDARDS - Since lifting or tailing lugs are non pressure retaining structural members, vesse! codes or Standards are not applicable in the design of these lugs. Good engineering practice and the recommended procedures given in the AISC Steel Construction Manual are all that are needed. C. TYPES OF LIFTING/TAILING LuGs Besides slings and attachments improvised in the field, lifting lugs for towers, reactors and other pressure vessels can be broadly classified into (1) the ear type, (2) trunnions, and (3) the top nozzle blind type. See Fig. 1. By far the most common are the ear type lifting lugs. These are usually installed at the top of the vessel and can be used for most vessels, especially large towers. Because of their location, interference with vessel appurtenances, such as platforms and ladders below the top head is not very critical. See Section 1. When a tower is unusually tall, so that lifting it will require a large crane and/or a long boom, or will produce excessive bending stress in the vessel as a beam, the trunnion type lifting lugs may be more suitable. ‘These are attached to the vessel shell some distance down from the top head. In using this type of lugs, the interference of the lifting cables with external ladders, platforms, nozzles, etc. attached to the vessel above the lugs, from the tying down to the up-right position of the tower should be carefully checked and avoided. See Section. 2. Most heavy wall vessels have a large and strong nozzle located at the center of their top head. With a special bolted attachment, this nozzle can be used for the erection of the vessel. This type of lifting blind is especially attractive when there are several vessels with the same size and rating top nozzles, so that one such lifting blind can be used on all ofthem. Even if the top nozzles were of different size, a special lifting blind can usually be designed to adapt it to more than one nozzle size. The advantages of the top nozzle liting blind are economy, little interference with vessel appurtenances, and elimination of welding to the vessel which can cause stress risers that are undesirable in some critical vessels. See Section; 3. In uprighting @ vessel from the horizontal to its vertical position, a pivot point, which is also capable of sliding toward the vessel foundation, is needed. This point can be provided simply and relatively inexpensively by a tailing lug. The design of tailing lugs is described in Section © 4, . 2l01, _ EAR TYPE LIFTING LUGS. (FIG. 2) 1.1. In designing a lifting lug, the first thing to do is to determine the lift load. Normally a vessel is lifted in the empty state, but in recent years, the trend has been to lift it fully dressed. That means the vessel will have insulation, some piping and all non-interfering ladders and platforms installed on it during lifting. Whatever the méthod of erection, determine the lift weight, W, multiply it by an impact factor, and then divide it by two to obtain the lift load, F, for each lug. The impact factor can vary from 1.25 to 2.0. The commonly used value is 1.50. Thus: 1.50", a) =0.75W When the lift employs a tailing lug, the lift load is reduced in proportion to the relative distances of the lifting and tailing points from the center of gravity of the vessel. However, when the column is nearing its vertical position, the tailing device is going to be removed. Then the lifting load will be as calculated in Eq. (1). 1.2._Iniifting, the field uses standard shackles with safe working load ratings determined Yrom the minimum breaking loads with a safety factor of 5. Based on the lift load from Eq. (1), choose a shackle size from Table 1. _1.3. The dimensions of the shackle selected will determine the lug pin diameter, d, the lug thickness, T, at the pin joint, and the lug projection, L, to provide clearance between the shackle and the vessel. The lug pin diameter can also be determined based on its shearing strength as in (21.6 below. 1.4. Although the lug pin may be conservatively sized so that it can take some bending as well as shearing, it is best to keep the difference between the shackle dimension, G, and the lug thickness, T, to a minimum, usually from 3/32" to 3/16", 4.5 The width of the lug plate, D, at the pin is set equal to 3d minimum. “4.6 Lug Design (See Fig. 3 for different failure modes) 4. Determine lug pin diameter from either the commercial shackle size 1.3) or @ 212. Determine lug plate thickness t from FE . Fr @ ae se? Faq7 3. Find lug thickness. T = t + 2t,, to suit the shackle 1.3) or from (4) F E é Fe Re P 4. “If collar plates are not used, t, = 0, then t = T, and the lug pin may have to be checked for combined shearing and bending loads, especially where T< Bz, tB?/é to, © 1.8 The combined tensile and bending stress in the lug plate should be checked when the vessel is lifted into a position where the axis is at an angle « from the horizontal. (See Fig. 4). If excessive, B should be increased to reduce this stress Fsine , 6Flcosa ©) tbo," e5%0, Ifo, is taken equal to A th, 2% tbo, Combined stress, 22Coop §S @ maximum at a certain angle, ,, Such that d F ~8 FL singe Ge Com) “Fycosa-$ FE sinaso : Thus 62 cine cosa- (75) sina=0 ‘Therefore, stan" (22) If A= 10 chen a, = tan*(2) = 6L (7a) If o,71.50, , 4=1.5, then a,stan*(—2) 4b (7b) 1.9 In calculating the lift load, F, the eccentricity of the tailing load has to be considered. From Fig. 5 W(1,cosa+1,sina) © 2pa—an200Se+h sing) _ T,c0sa+I,cosa+1,sina Fux (Impact factor) 4.10 Stress in the weld for direct load, F, is FE 0.7 (B+2L,) o, 5" 214Centroidal distance, C, of the weld is 2 os 3E8 Moment about the weld centroid = F (L +L, -C) Replacing the U shape weld conservatively with an approximate rectangular shape weld, where L, = 2C, then: Polar moment of inertia = 1.4 t, BC (C+'4B) 2.4t,ac(c+da) VCrB*74 Polar section modulus = Stress due to moment 10) P(Ltly-O VEE TE we) 1. 4BC(C-B/2) b, From the combination of stresses (8) & (10), the weld size t, can be determined. If L, is made equal to B, the above expressions can be simpiiied: B Moment =F (L+8-2) =F(L+0.6678) =1 2) (2s3) en 2 T=2.4(B) (2) (F+3) t-0.3898%t, 0.3895, -647B7t, VB°/S+B*/4 LigF 1 F(L+0.6678) _ 0.7 (B+2B)C, 0.647B?t, Bt, (1.5432+1.5072) Using an allowable stress for the weld ,, = 13500 psi, we have: : 7 (11) tee (0.2242+0.112B) 10~ Table 2 shows weld size, t,, per 1000 Ib. of lift load, F, for various ratios of L/B. TABLE 2 - WELD SIZE t, INCH PER 1000 LB. LIFT LOAD ue as lie s 12" 15° 18" aig 24" 0.75__| 0.066_| 0.033 _| 0.022 | 0.016 | 0.013 | 0.011 | 0.009 | 0.008 1.0 0.075 _| 0.038 | 0.025 | 0.019 | 0.015 | 0.013 | 0.011 | 0.009 1.25 {0.085 | 0.042 | 0.028 | 0.021 | 0.017 | 0.014 [0.012 |-0.011 1.5 0.094 _| 0.047_|'0.031_| 0.024 | 0.019 [0.016 | 0.013 | 0.012 1.75__| 0.104 | 0.052 | 0.035 | 0.026 | 0.021 | 0.017 | 0.015 2.0 0.113 | 0.057_| 0.038 _| 0.028 | 0.023 | 0.019 | 0.016 2.25 | 0.123 | 0.061 | 0.041 | 0.031 | 0.025 | 0.020 | 0.018 25 0.132 _| 0,066 _| 0.044 | 0.033 | 0.026 | 0.022 | 0.019 | 0.017 2.75 0.142 | 0.071_| 0.047 | 0.035 | 0.028 | 0.024 | 0.020 | 0.018 3.0 0.151 _| 0.076 | 0.050 | 0.038 | 0.030 | 0.025 | 0.022 | 0.019 411 In order to keep the lifting cable vertical, 2 spreader bar is used. When the ‘spreader bar is not available or not to be used, then the cables will make an angle with the axis of the vessel. This will produce out-of-plane bending of the lug plate. If the cable angle is 8°, the corresponding bending stress in the lug plate is 6FisinO1 ee (12) ‘The maximum allowable angle to ensure og, < 0, is 1, Bt?a, (ae 7 13) ee ar) (43) eS zeTo reduce this bending stress, a bracing plate may be used tying the lug plate to the vessel head at a distance L, from the lug pin. The reduced bending stress is now 00, () a9, (14) The load on this bracing plate, F sine, is rather small for small angles, 8. Therefore its thickness, t,, and the weld sizes usually are minimal. For very large angles of, this plate should be properly designed. 2, TRUNNIONS (Fig. 6) ‘Trunnions are used to erect vessels that are too tall to be lifted by lugs located at the top head. There are generally 3 different types of trunnions. The most common is the fixed pipe, fixed plate type. Sometimes, for clearance purposes, the lug plate has to be made very long. In order to prevent the high twisting moment at the pipe-vessel attachment, the lug plate is allowed to turn over the lug pipe. When the lug pipe projection has to be large, again for clearance purposes, the bending moment at the vessel attachment may be very high. This will produce excessive stress and distortion in the shell, especially in large diameter, thin wall vessels. In this case, a turning axle type trunnion can be used. 2.1 _As for the ear type lifting lug in Sectior_.1, determine the lift load, shackle size, pin diameter and lug plate thickness. 2.2 For the tuming plate trunnion, the dimension, s, is determined by (15) F F i Zst <7 or "Fro, 2.3. The trunnion pipe size is determined by either its bending strength: (16) or its torsional resistance: (17) FL ge or its shear resistance: P (18) ae where A, = cross-sectional area of the lug pipe 14 Ze(19) In addition: FLLP az ast 2.4 For the rotating axle type trunnion, the pipe diameter, P, is determined from: 7 EF Fa 20) 2.5 Weld size, t,, is determined from FE 455705 @) O.7xPt,” Pe, *°* or from 0.91FE ., (22) o.7e(n et) PPty 2 or from 1.82FE Pe “TPE oY x(2)(0.78,) ™ 7 (23) 2.6 Except in the case of the turning axle trunnion, the lift load on the trunnion produces local stresses in the vessel shell. These need to be evaluated using WRC Bulletin 107 or other similar methods. A simplified way to check the vessel stresses is: (Fig. 7 Solid Lines). (24) £,(42) <0, In checking the stress of the vessel in the vertical position, when the load F represents the entire vessel weight not reduced by any tailing load, use the stress factor given by the dashed lines in Fig. 7. When the vessel wall stress is excessive, use a reinforcing pad. The stress is dependent on the combined vessel and pad thicknesses at the edge of the trunnion pipe and on the vessel thickness at the edge of the pad. 272.7. After a vessel has been erected, the trunnion lifting lugs are usually cut off. In the case of the tuming axle type, the lug is cut apart and the axle withdrawn. The openings in the vessel are covered by welded plates or bolted flanges. 3. TOP LIFTING BLINDS Heavy wall vessels have sturdy nozzles. if there is a large central nozzle in the top head, it can usually be utilized to lift the vessel into place. A specially designed liting blind is bolted to the top nozzle, and lug plates are welded to the biind for attachment of the lifting shackle, When there are several vessels with the same size top nozzles, one lifting blind can be made to lift all of them. Even if the top nozzles are of different size and/or rating, the lifting blind can be designed with different sets of bolt holes to fit more than one size of nozzles. 3.1. In lifting, usually not all the bolts for the top nozzle are used. if only half of the nolts are used, the load on each bolt due to a moment is approximately 22% more than if all the bolts are utilized. In checking the adequacy of the botis, the following concitions have to be satisfied: ML Bolt capacity in tension’ (25) 2F, - +s Bolt capacity in shear (28) 2F, apa Fs Bott capacity in tension (27) Where —_F, = max. load on the lug when iting angle a = 0 (vessel in horizontal position) lifting load when vessel is in the vertical position = W. impact factor. E = distance from lug pin center line to biind flange back face. See Fig8. 4, = thickness of blind flange. N. = total number of bolts for the nozzle. 3.2. Design of the lug plate, that is to be welded to the blind, follows the same procedure as for the ear type lug.3.3 A conservative way to determine the thickness of the blind is to design it for the pressure equivalent to the max. moment acting on it at the initial lifting condition. This moment equals F,(E+t) and the equivalent design pressure 16F, (E+ty) RGp 5 where G, = gasket diameter of the flange. and the blind thickness is: e (232#)-< 4.8F, (E+) ° oS “ =Gpa, By assuming an initial value of 2" for t, and using the bolt circle diameter D; as G,, we have (28) ifthe calculated t, is much different from 2", another iteration may be done. In any case, do not use t, less than the lug plate thickness determined in 3.3.2 above. The equivalent Pressure due to the force F, on the lug is relatively insignificant. 3.4 Examples of one lifting biind fitting two sizes of nozzles are shown in Fig. 9. 4, TAILING LuGs In iting a tall vessel, whether by lifting lugs attached near the top head, or by trunnions located lower down the shell, a tailing lug is usually required to lift the entire column off the ground in order to facilitate the uprighting of the vessel. Since most vertical vessels have skirt supports, the tailing lug is usually attached to the bottom of the vessel to take advantage of the stiffness of the base ring there, Unless the tailing load is unusually large, only one lug is required. See Fig. 10. 4.1 Design of the lug plate again follows the same procedure as for the ear type. 4.2 Check stresses in the base ring-skirt section Max. moment = .2887 FR where F, = load on the tailing lug. LGGenerally the skirt plate is welded approximately to the midgle of the base ring. It does not therefore contribute much to the section modulus of the section. Thus the bending stress in the base ring during the lift is w44F, , one where t, and B, = thickness and width of the base ring. 2 (Bo, - When this stress is too high, a strut can be welded diametrally between the tailing lug and the other side of the skirt, The force on the strut is approximately haff the tailing load, and the moment in the base ring section will be reduced to about a third of that without the strut. See the derivation in Appendix A. In the case when the skirt plate is not centrally located on the base ring, a portion of the skirt plate will act to resist the bending moment in the ring section, will increase the section modulus of the base ring appreciably, and should therefore be taken into consideration. If a second ring also exists, then the section modulus will be further substantially increased. The length of the skirt plate that can be included in the base ring section, varies with the skirt diameter and its thickness, but for simplicity, use conservatively a length equal to 12 times its thickness. If a second ring exists, then this length shall be taken beyond the second ring. D. MATERIALS Lifting and tailing lugs are structural elements that are used only for a short time during the erection of vessels. For this reason, the most common structural steel A-36 is adequate. However, parts of the lugs that are welded directly to vessels which are constructed of alloy metals, such es Cr.Mo. steel, stainless steel, no-ferrous metal, etc., should preferably be of the same type of material as the vessel. -105 and A-53-B respectively, except as Forgings and pipes will also be carbon steel: noted above. E, ALLOWABLE STRESSES Unless otherwise specified, use the following allowable stresses 38 Tensile - 20,000 psi A-105 Bearing - 30,000 psi A-53 Shear- 13,500 Bending - 22,000 psi C.S. Welds: Full penetration - 20,000 psi Shear - 43,500 psi Vessel Stress: Membrane - 1.28 Bending - 1.5S where S = code allowable tensile design stress. ZLoF. RECOMMENDED PROCEDURE 1_ Determine from Construction, the type of lifting to be used: from the top of the vessel or lower down the shell; whether the vessel will be bare or insulated with platforms and ladders installed; whether a’spreader beam will be used; whether a large sturdy nozzle will be available on the top head for lifting, etc. Then choose the appropriate lugs to be designed. 2 Calculate the lift load at each lifting lug, and if tailing lug is going to be used, calculate the lift and tailing loads. See paragraph “1.1. 3 Design the lugs per sections 2. Sor 4. 4 Forward the lug design to the fabricator of the vessel on which the lugs are to be installed. 5 When design of the lifting and tailing lugs is the responsibility of the vessel fabricator, use this Design Guide to check the latter's calculations. 6 _ After erection, remove the lugs from the vessel as necessary, and patch up the openings where the rotating axle type trunnion has been used. G. REFERENCES Formulas for Stress and Strain by R. J. Roark Local Stresses in Spherical and Cylindrical Shells due to External Loadings, WRC Bulletin 107, by K. R. Wichman, A. G. Hopper and J. L. Mershon ZuANCHOR SHACK OROP FORGED STEEL. WELOLESS. BRIGHT. HEAT TREATED) ss Tew osTRUNNION FIGURE _1——LIFTING LuGs.FIGURE 2——EAR TYPE LIFTING LUG ezdFIGURE 3——LIFTING LUG DESIGN LUG PIN SHEARING LUG PLATE TENSILE LUG PIN BEARING LUG TENSILE LUG SHEARING aia) ga: EG sary * GF F ame eGR) + ¢ Grey) a ara oe array FE marae EG) Tevsaramy © o THeaHy ZurGUI EA eee ANG Ee Ohm el nul REGULAR TAILING LUG TANGENTIAL, NO_TAILING LUG (ly 1S POSITIVE) TAILING LUG (ly IS NEGATIVE) (1y=0) FIGURE 5——LOCATION OF TAILING LUG 226FIGURE 6——TRUNNIONS| 2271 fyF vesset stress 45% a { TE 4 STRESS FACTOR. VESSEL WALL +08 +06 +04 -02| 0.02.04 .06 -08 -10 -12.14 .16 18.20.22 .24 26.28.30 TRUNNION DIAMTER VESSEL DIAMETER FIGURE 7——VESSEL STRESS FACTOR 2Z2LIFTING BLIND FIGURE 8 229(16) 1h" HOLES ON 39/478.C. FOR 30” 300% FLANGE (12) 1%" HOLES ON 32°8.C. FOR 24* 3008 FLANGE (16) 24" HOLES ON 40'4°8.C. FOR 30° 600% FLANGE (12) 27HOLES ON 33°8.C. FOR 24° 600# FLANGE FIGURE 9——LIFTING BLIND BOLT PATTERNS 240CHAIR OR RING FIGURE 10——TAILING LUG Z4alDesivatian of 4ing Moment (D Increase in diameter due ro lead Wi-Ws 15+ 2 yf, 5 = o 3 Dy FEB [3183 (s00e)- Z] = 2 eel WIR UL) Decrease in hhameter due 7 load We 1s: Dy= = 0784 WR? (Fa (DB) Elongation of Stret due 10 load We is =2HR 4f1-~6 20788 (We-Ws JR? O74 Ws RF = 24R él ZI AE 20372 WiR* _ Ws , .07¢AWsR? z = The tirst term en the cight sie us small compared %o the second term, and can be neglected. 2 M=2Ws or We=FmM ZarFrom Keoark , Mament in the ring due ty outward oad 13. My =(Wi-WS)RU. 2387 cos x~.S 0X 44892 (Asin ¥4/-Cosx)) Moment due to inward /oad 1s: Maz WSR L 2387 cos (0-4) -.5 sin (I-A) P1892 [STH +/- Cos or-ay) = WR (-.2387 cosX- Son b.iste fir-asing t/t ccs) No Strut Strut | Mi Ma Ma 2M | M=NMitM2 OC |t. 1/94 WAR |-.0398 WR |4.2388 WR |40796 WR Ye__|+.0099 WR |-.0243 WR \9.0198 WR \-.0188 WR | Ys \-0449 WR |4.0124 WHR |-0898 WR |-.0325 WR Te__|-0ase wR |4.045¢W:R 0908 WR) 6 12% | -.0128 wR | 4.0449 Wik 0248 Wer! #0525 WR! [°% _|7.0243 wir |-.0099 WR | 4.0886 WR|-.0184 WER W_|4.0398 WR \-.1194 WiR | 4.0796 WR\|-.0796 WR W 29?Sample Problem Gwen: Clumn 60°08 1000 T/T ples 11 A shirt We with trays, nsulaten and platforms =F Aips Center op gravity : 50% from base Vessel phichness: Le top third , Fb miildle third, and Ya" bette phird, Shirt 28. LA poem (A) pear rhe Sop head. (8) $5-60' fromm base. Required: Lifting (ug design Ya" we 0" A) Ear Type Lifting Lug Mex. tit load (vecrical, failing load =0) FF Xs3sx1s = ot ead, 0 a Yens/ lug) Horiz. htt load = Ca Fx/3$x/ Sx ZS = 45 Kips / hig From Table 1, a size 3" anchor shackle /s reguueds S* 344" (pin) GOgrp)= 8). Use lug thick. 7 = 478 From on 8), ig plate thickness | 421 — ag.s2" Use 14" plate eee SAG “373. 25420 24¢Gller plate rhich. t= £0913 U4) 21.81". Use Veo Assume dimension L =/2" Thea xoom Eg.(5), a Width of bug plote 8 2) GE = 10.9 Use 12° Since Bis tihen rs be 22 ksi, ane! Op+ 204s) A= Woz 7 - Max. combined stress rn the 1g plate occurs at = typ Ab 2 4 NB2 . m= ten BE = fan GF = 10.4 e . BS8D104 | & E412 cos od <. Combined stress = Tiga tg SSS = 0.54 416,09 = 16.6 ksi < 20 ksi we OX. Assume a weld heagth £3714" and a weld size Ly= fe" trom Eg09), for vessel in the foriz pater, shear stress in lug atachmen? weld = *Yorii242:14)10.5) = 3.2 ksi 7 Ceatrerdal distance CIEE 4AT oo Moment about weld centroid ¢ = 4S (12t/4-4.9)= 950 ink.” 2 , Blar mers. of mertia of weld eet = [OSE a o.50/4 (7-09) }tOS8/244.9° 2 : + 210.5014 xb*4 PFE2* = ye/Q jn,* solo . Polar sechen modulus * TE897 = 92:7 in? 1 Tonsvoral stress due to mement = 980/927 =/0.2 ke! tasCombned shear stress tor vessel in heriz. position = F2Zt102 = 13.4 hs! OK. Shear stress in weld tor vesse/ i vert pest Teele = 0lffa7 20 28)xa5] = 72 ksi OK. wey i fl A 3 & of pa B) Truanien Type lug (assume tied pipe) (55 tem base) Max. lift load! (vertee!)= Jol k. May. litt load Uhoriz.)= 00511521354 22 = 92 As in example (A), 3" shackle 13 reguired: A344 t= Ble Assume dimensions E and L fo meet Clearance requirements: E=8° , L/S From Ep. Ub), Z of trunnion PRS + 9248/02 * 33.5 in 0G), Z of frunmen pipe ~ INS (2313.5) “S11 sir? From €.8), Xsechenal area of pype = 103.5 = 725 mae TS ,— es 22. : $2u/S 92 : ee ———— SS = This stress exceeds 2/35 hss - be HEKS pipes 22715 m2, Azbh2 tn, Ceomb=18 kes heck vesse/ stress using fiz. 7. ihe True Diem 1h Toes 976 | FRR Re aig OAs 0.083 Vessel Stress « BPS gg ps; & “sng 2 Lh" rhyck Pad » Ce2078 10.8252 1.375" Stress around pipe =(O0s3r $28 1378°= 1S ksi Stress around rhe pad (assume reasonchle size) wll stl be excessive. +. @ turning axle Frumnion /'s recommended. Bearing svress at shell pening = HOE =VSksi OK. Ff size of weld between 1g plate anil pype end . = fol (3 18, then weld shress =Wilinieg 6-6 ksi Ck 227