EMPLOYER

WEST AFRICAN ENERGY SA SENEGAL NATIONAL ELECTRICITY AGENCY

EPC CONTRACTOR

ÇALIK ENERJİ SAN. VE TİC. A.Ş

CAP DES BICHES COMBINED CYCLE POWER STATION PROJECT

(300MW)

REVISION HISTORY

A 27.08.2021 FOR APPROVAL G.A S.K A.P

REV. DATE DESCRITPION PREPARED CHECKED APPROVED
DOCUMENT TITLE/SUBJECT:

SPREADER BEAM CALCULATION

PROJECT DOCUMENT NO:

Type
Doc.
Disc

Project Unit System Orig. Serial No Rev. A

Detailed Information

SNC 36 HNE MC RME 007 Size A-4

VENDOR DOCUMENT NO: 2109 EC 07
Lang. Eng.

Total Sheet 14

This document is the property of ÇALIK Enerji Sanayi ve Ticaret A.Ş and may not be copied, used, reprinted or distributed by others.
 ROTA Job No 2109 Page 1 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

SPREADER BEAM CALCULATION

for

BY-PASS SYSTEM

Client:
ÇALIK ENERJİ

Project No:
ROTA: 2109 / CAP DES BICHES CCPP (300 MW)

0 27.08.21 For Approval G.A S.K A.P

Revision Date Description-Reference Prepared Reviewed Approved
 ROTA Job No 2109 Page 2 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

TABLE OF CONTENT
1 OBJECTIVES .................................................................................................................. 3
2 SPREADER BEAM .......................................................................................................... 3
3 DESIGN PRINCIPLES ...................................................................................................... 4
4 CALCULATION OF BEAM ............................................................................................... 5
5 CALCULATIONS OF LIFTING LUGS ................................................................................ 12
6 SCHAKLE CALCULATION .............................................................................................. 14
 ROTA Job No 2109 Page 3 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

1 OBJECTIVES

The aim of this calculation note is to show the basic lifting operation of the exhaust stack system
equipments and show the static calculations of spreading beam that used for lifting operations.

2 SPREADER BEAM

Spreader beam is designed to be used for lifting equipments as below.

Figure-1: Spreader beam

• LL lugs will be used for connection to the crane.

• L1, L2, L3, L4,L5,L6 lugs will be used for lifting equipments with proper lug couples
according to lug distance on the equipments.

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 ROTA Job No 2109 Page 4 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

3 DESIGN PRINCIPLES

Spreader beam calculations done according to EN 13155 section Annex A.1 “Verification of
mechanical strength without static tests”

This method is applicable to non-alloy structural steel in accordance with EN 10025.

The following load case is considered.

𝐿𝐶 = 𝑆𝐷𝐿 + 2𝑆𝑊𝐿𝐿
SDL : Loads due to dead weight of the attachment (self weight of beam)
SWLL : Loads due to the working load limit

The factor 2 considers the dynamic effect due to lifting.

Table-1: Admissible stress(EN13155)

Table-2: Admissible stress in the weld(EN13155)

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 ROTA Job No 2109 Page 5 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

Admissible stress for normal stress of welding is α * fy / ɣ for shear stress is αs * fy / ɣ (ɣ = 1,1)

fy of S275JR weld material is SG2 fy: 420 MPa

Admissible stress for normal stress;

𝛼𝑡 . 𝑓𝑦 0,7 . 420
= = 267𝑀𝑃𝑎
𝛾 1,1

Admissible stress for shear stress;

1
𝛼𝑠 . 𝑓𝑦 √3 . 420
= = 220𝑀𝑃𝑎
𝛾 1,1

4 CALCULATION OF BEAM

The worst case is used for beam calculation. Worst case is the case that using lug couples L1 and
L6 as shown in the next sections. Static calculation of beam is made by SAP 2000 program.
Analysis model is defined as below.

Figure-2: Spreader beam analysis model

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 ROTA Job No 2109 Page 6 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

Designation of beam = HEA 500 S275 JR

Figure-3: Section size of beam

Figure-4: Section properties of beam

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 ROTA Job No 2109 Page 7 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

Stability criteria of frame;

𝑑 235
≤ 69 . √
𝑡𝑤 𝑓𝑦

444 235
≤ 69 . √ ⇒ 37 ≤ 68,78 ⇒ 𝑂𝐾
12 275

SWLL is determined as 50.000 kgs according to heaviest equipment to be lifted.

As per loads case defined above, each lifting lug will lift 50.000 kgs.

Figure-5: Load case-1 for lugs L1 (kg)

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ROTA Job No 2109 Page 8 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

Figure-6: Load case-2 for lugs L2 (kg)

Figure-7: Load case-3 for lugs L3 (kg)

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ROTA Job No 2109 Page 9 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

Figure-8: Load case-4 for lugs L4 (kg)

Figure-9: Load case-5 for lugs L5 (kg)

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 ROTA Job No 2109 Page 10 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

Figure-10: Load case-6 for lugs L6 (kg)

Table-3: Design moments and forces

case-1 case-2 case-3 case-4 case-5 case-6
maximum
6,70E+08 3,10E+08 6,10E+07 1,90E+08 4,30E+08 6,70E+08
moment(Nmm)
maximum shear
5,00E+05 5,00E+05 5,00E+05 5,00E+05 5,00E+05 5,00E+05
force (N)

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 ROTA Job No 2109 Page 11 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

Figure-11: Design shear force diagram (N,mm)

Figure-12: Design bending moment diagram(N,mm)

Shear Stress;

500000
𝜏= = 85,1 𝑀𝑃𝑎 ≤ 153𝑀𝑃𝑎 ⇒ 𝑂𝐾
5880

Bending Stress;

670000000
𝜏= = 188,8 𝑀𝑃𝑎 ≤ 265𝑀𝑃𝑎 ⇒ 𝑂𝐾
3549796

Combined Stress;

2 2
𝜎𝑏 𝜏 188,8 2 85,1 2
( ) + 3. ( ) = ( ) + 3. ( ) = 0,81 ⇒ 1 ⇒ 𝑂𝐾
𝑓𝑦 𝑓𝑦 265 265

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 ROTA Job No 2109 Page 12 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Project No Date 27.08.2021
2109
Prepared By G.A
SPREADER BEAM CALCULATION Approved By S.K
5 CALCULATIONS OF LIFTING LUGS
Date 27.08.2021

UPPER LUG CALCULATION

Dimensions
a 90 mm
b 90 mm
d 75 mm
e 150 mm
t1 20 mm
t2 20 mm
tf 23 mm
L 130 mm
Lw 400 mm
αmax 30 °
Loads Material
Equipment Dead Load 𝑆𝑊𝐿𝐿 50000 kg Plate Material Quality S235JR
Lifting Beam D. Load 𝑆𝐷𝐿 2000 kg fy 235 MPa
Lug Quantity n 2 Admissible Stress for Plate
Safety Factor SF 2 Tension/Compression 235 MPa
Loads on Lug Shear 136 MPa
𝑆𝐷𝐿 + 𝑆 𝑆𝑊𝐿𝐿 Weld Material Quality SG2
𝑃𝑦 = 500310 N
fy 420 MPa
𝑃𝑦 Admissible Stress for Weld
𝑃 = 577708 N
𝛼 Tension/Compression 267 MPa
Shear 220 MPa
𝑃 =𝑃 𝛼 288854 N

Calculations of Plate Calculations of Weld

Shear Stress in A-A section(𝛾 = 1,1 Weld Area

𝑃𝑦 .𝛾 = 𝐿𝑤
𝑤 𝑡 8000 mm2
𝜏 = 101,92 MPa OK Bending Moment
2. 𝑎. 𝑡 + 𝑡2
𝑀=𝑃 43328117 Nmm
Tensile Stress in B-B section 𝛾 = 1,1 Moment of Inertia
(acc. to EN13001-3-1) k 3,50 𝑡 𝐿𝑤 106666666,7 mm4
𝑤 =
12
0,95.1,38. 𝑓𝑦
𝛾𝑠 𝑡 = 0,48 Bending Stress
.𝑓
𝑀 𝐿
𝜎𝑏 = 52,8 MPa
𝑃𝑦 . . 𝛾 . 𝛾𝑠 𝑡 𝑤
𝜎 = 172,77 MPa OK Tension Stress
2. . 𝑡 + 𝑡2
𝑃𝑦
𝜎𝑡 = 62,5 MPa
𝑤
Normal Stress
𝜎 = 𝜎𝑏 + 𝜎𝑡 115,3 ≤ 267 MPa OK
Shear Stress
𝑃
𝜏= 36,1 ≤ 220 MPa OK
𝑤
Combined Stress
2 2
𝜎𝑏 𝜏
+3 0,27 ≤1 OK
𝑓𝑦 𝑓𝑦
Conclusion : Desing is adequate for lifting the equipment according to given data.
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 ROTA Job No 2109 Page 13 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

LOWER LUG CALCULATION

Dimensions
a 82,5 mm
b 82,5 mm
d 75 mm
e 150 mm
t1 20 mm
t2 20 mm
tf 23 mm
L 120 mm
Lw 240 mm
αmax 5 °
Loads Material
Equipment Dead Load 𝑆𝑊𝐿𝐿 50000 kg Plate Material Quality S235JR
Lifting Beam D. Load 𝑆𝐷𝐿 3500 kg fy 235 MPa
Lug Quantity n 2 Admissible Stress for Plate
Safety Factor SF 2 Tension/Compression 235 MPa
Loads on Lug Shear 136 MPa
𝑆 𝑆𝑊𝐿𝐿 Weld Material Quality SG2
𝑃𝑦 = 490500 N
fy 420 MPa
𝑃𝑦 Admissible Stress for Weld
𝑃 = 492374 N
𝛼 Tension/Compression 267 MPa
Shear 220 MPa
𝑃 =𝑃 𝛼 42913 N

Calculations of Plate Calculations of Weld

Shear Stress in A-A section 𝛾 = 1,1 Weld Area
= 𝐿𝑤
𝑤 𝑡 4800 mm2
𝑃𝑦 .𝛾
𝜏 = 109,0 MPa OK Bending Moment
2. 𝑎. 𝑡 + 𝑡2
𝑀=𝑃 6436978 Nmm
Tensile Stress in B-B section 𝛾 = 1,1 Moment of Inertia

(acc. to EN13001-3-1) k 3,50 𝑡 𝐿𝑤 23040000 mm4

𝑤 =
12
0,95.1,38. 𝑓𝑦
𝛾𝑠 𝑡 = 0,48 Bending Stress
.𝑓 𝑀 𝐿
𝜎𝑏 = 33,5 MPa
𝑤
𝑃𝑦 . . 𝛾 . 𝛾𝑠 𝑡
𝜎 = 184,78 MPa OK Tension Stress
2. . 𝑡 + 𝑡2
𝑃𝑦
𝜎𝑡 = 102,2 MPa
𝑤
Normal Stress
𝜎 = 𝜎𝑏 + 𝜎𝑡 135,7 ≤ 267 MPa OK
Shear Stress
𝑃
𝜏= 8,9 ≤ 220 MPa OK
𝑤
Combined Stress
2 2
𝜎𝑏 𝜏
+3 0,26 ≤1 OK
𝑓𝑦 𝑓𝑦
Conclusion : Desing is adequate for lifting the equipment according to given data.

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 ROTA Job No 2109 Page 14 / 14 Rev. 0
Document Name Spreader Beam Calculation
Rota Doc. No 2109 EC 07
Customer Doc. No SNC-36-HNE-MC-RME-007
Design GA Check SK Date 27.08.2021

6 SCHAKLE CALCULATION

Recommended schakle for design load 50.000 kgs is defined as below. Schakles works %100
working rate according to spreader beam design.

Figure-13: Working rates of the schakle

Figure-14: Size definition of schakle

Figure-15: Schakle properties

*Recommended schakle is G2130 1-3/4 25t as indicated in the table.

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