ADDITIONAL AGREEMENT/APPROVAL RECORD · additional agreement/approval record ... design and...

SSG-NG01012401-GEN-CS-7880-00006 Specification for Anchor Bolts

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ADDITIONAL AGREEMENT/APPROVAL RECORD

Party Ref Ind. Name Sign Date

Revision Philosophy

• Revisions for Review - First issue will be issued at R01, with reason of issue description - Issued for Review, (with subsequent R02, R03, etc. as required to be used in dependence of review status received by SPDC). Last issue: A01, A02… with reason of issue description - Issued for approval (Final Issue) (A02 might be reissued in case further modification occurred).

• Revisions for Design Documentation - First issue will be issued at D01, with reason of issue description - Issued for Review, (with subsequent D02, D03, etc as required to be used in dependence of review status received by SPDC). Last issue: C01, with reason of issue description - Issued for Construction (Final Design) (C02 might be reissued in case further modification occurred). When document is considered closed by SPDC, the revision must be increased (with no change on the document itself) and issued , with reason of issue description - Approved for Construction (Final Design).

• Revisions for Purchase - First issue will be issued at P01, with reason of issue description - Issued for Purchase, (P02, etc to be used in dependence of review status received by SPDC). Last issue: P03, with reason of issue description - Approved for Purchase (Final Issue) (P0X might be reissued in case further modification occurred).

• Revisions for Information - First issue will be issued at R01, with reason of issue description - Issued for Information.

• Revisions for As built - Documents or drawings revised as “As built” will be issued as Z01, Z02 Z03 etc as required.

• Narrative sections revised from previous approved issues are to be noted in the table below and/or highlighted in the RH margin (using the appropriate revision status).

• Previous revision highlighting to be removed at subsequent issues.

• Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected areas and by the use of a triangle containing the revision status.

• If a document is cancelled the document will be issued at the next sequential number by adding the suffixed with a X. For example if R02 is the current revision then 03X will be the Cancelled revision

• All revisions to this document must be approved by the relevant Technical authority.

Revision History

Revision No. Date of issue Document ID/Reason for change

C02 04-Feb-2013 Approved for Construction (Final Design)

C01 20-Dec-2012 Issued for construction (Final Design)

D01 21-Nov-2012 Issued for review


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CONTENTS

1. INTRODUCTION 4

1.1. PROJECT OVERVIEW 4

1.2. SCOPE 4

1.3. GENERAL DEFINITIONS 5

1.4. ABBREVIATIONS 5

1.5. LANGUAGE 5

2. SPECIFICATIONS, CODES AND STANDARDS 6

2.1. PROJECT SPECIFICATIONS AND STANDARDS 6

2.2. DESIGN AND ENGINEERING PRACTICE (DEP) TECHNICAL SPECIFICATIONS 6

2.3. EUROCODES AND INTERNATIONAL STANDARDS 6

2.4. INTERNATIONAL / EUROPEAN / BRITISH STANDARDS 6

2.5. REFERENCE LITERATURE 7

2.6. UNITS OF MEASUREMENT 7

2.7. ORDER OF PRECEDENCE 7

3. CHARACTERISTIC OF THE ANCHOR BOLTS 8

3.1. SIZING CHARACTERISTICS 8

3.2. MATERIALS AND THREADINGS CHARACTERISTICS 8

3.2.1. THREADED BARS 8

3.2.2. NUTS 8

3.2.3. WASHERS 8

3.2.4. ANCHOR PLATES AND ADJUSTING SLEEVES 8

3.2.5. GALVANISING 8

4. TABLES OF ANCHOR BOLT LOAD CAPACITIES 9

5. VERIFICATION OF BOLT ANCHORAGE IN CONCRETE 10

5.1. SIZING OF THE REBARS PARALLEL TO THE ANCHOR BOLT 10

5.2. SIZING THE REBAR TRANSVERSE TO ANCHOR BOLTS 11

5.3. VERIFICATION OF BOLT ANCHORAGE IN CONCRETE 11

6. ANNEX A: ANCHOR BOLTS STANDARD DRAWINGS 12


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1. INTRODUCTION

1.1. Project Overview

The Southern Swamp area comprises fields within OML 35 and OML 46 in the coastal swamp area, about sixty-five kilometres (65km) south of Warri. There are ten (10) fully appraised, ten partially appraised and four un-appraised fields within the node. All with expectation oil „Ultimate Recovery� (UR) of 1,636 MMstb and 2,138 Bscf of AG, „Gas Initially In Place� GIIP UR of 4 Tscf, 53% Recovery Factor out of which 792 MMstb and 444 Bscf has been produced by end 2010. All existing production in the area is gathered into four flow stations at Tunu, Ogbotobo, Benesede and Opukushi. The produced oil is evacuated via Trans Ramos pipeline to Forcados Terminal whilst the AG is currently flared. The project to end routine flaring and re-develop the fields in the southern swamp catchment area started in 1999 as Southern Swamp Integrated Oil and Gas Project (SIOGP). This project stalled at the Define Phase in 2006 due to among other things funding challenges. In 2009, the project was re-invigorated as an AG Solution project with provision for mini development. The latest project concept now called Southern Swamp AG Solutions (SSAGS) primarily aimed at providing AG solutions to cover „ No further Activity� (NFA) production of 141 MMbbl & 98 Bscf AG while maximising use of existing flowstation assets in order to reduce Capex. It also includes a reduced well scope of 21 oil wells and 2 NAG wells to develop additional 125 MMbbl of oil and 347 Bscf of gas (AG & NAG). NAG development is to support the sustenance of circa 100MMScf/day gas supply to the domestic market for at least 10 years. This development will also provide anchor infrastructure to support future development of significant discovered and undiscovered potentials within the node (presently about 820 MMboe). Gas will be exported to Escravos Lagos Pipeline System (ELPS) via the existing 24” Offshore Gas Gathering System (OGGS) line from EA Riser Platform (RP-A) to Forcados Yokri (reverse flow) and the existing 16”line from Forcados Yokri Integrated Project (FYIP) central processing facility (CPF) to Odidi. A new pipeline will be installed from Tunu to EA RP-A in order to allow gas from Southern Swamp to reverse flow through OGGS to FYIP.

1.2. Scope

This document defines the material characteristics and the load capacities of the steel anchor bolts to be used for the SSAGS project. The bolts defined by this specification shall be used for all the applications such as e.g. anchor bolts for steel structures, equipment, machines, etc., except in case of deviations, if any, concerning equipment and machines for which the suppliers impose the use of their own anchor bolts.


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1.3. General Definitions

For the purpose of this document, the following definitions shall have the meanings stated: SHALL indicates a mandatory requirement. SHOULD indicates a preferred course of action or strongly recommended to comply with the requirements of this specification. MAY indicates an acceptable course of action PRINCIPAL is the party who initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant, authorized to act for, and on behalf of, the principal. The Principal herewith referred to is SHELL PETROLEUM DEVELOPMENT COMPANY OF NIGERIA. CONTRACTOR is the party, which carries out all or part of the engineering, procurement, construction and commissioning or management of a project. The principal may sometimes undertake all or part of the duties of the Contractor. The contractor herewith referred to is SAIPEM CONTRACTING NIGERIA LIMITED. MANUFACTURER/SUPPLIER/VENDOR is the party, which manufactures and/or supplies the equipment and services to perform the duties specified by the Contractor

1.4. Abbreviations

AG Associated Gas AISC American Institute of Steel Construction ANSI American National Standard Institute AWS American Welding Society Bscf Billion Standard Cubic Feet CPF Central Processing Facilities DEP Design and Engineering Practice ELPS Escravos Lagos Pipeline System EN European Norms FLB Field Logistics Base FYIP Forcados Yokri Integrated Project ISO International Standards Organisation MMbbl Million Barrels MMboe Million Barrels of Oil Equivalent MMstb Million Stock Tank Barrel NAG Non-Associated Gas OGGS Offshore Gas Gathering System OML Oil Mining License RF Recovery Factor SIOGP Southern Swamp Integrated Oil and Gas Project SPDC Shell Petroleum Development Company of Nigeria Limited SSAGS Southern Swamps AG Solutions Tscf Trillion Standard Cubic Feet UR Ultimate Recovery

1.5. Language

Unless otherwise agreed in writing, the language of written and spoken communication between the parties to this scope of supply shall be English. Where approval of the principal to obtain documentation in other languages is obtained, the Contractor shall at no extra cost to the Principal, provide translation to English, of such languages.


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2. SPECIFICATIONS, CODES AND STANDARDS

The design shall comply fully with the latest edition of statutory laws and regulations of Nigeria, relevant DEP Standards and Specifications, International Standards & Codes of Practice and industry-published guidelines. Reference to any specification, code or standard shall mean the latest edition of that standard or code, including addenda or supplements or revisions hereto, in being at the time of contract award, unless otherwise noted. Relevant Standards and references are listed as follow:

2.1. Project Specifications and Standards

SSG-NG01012401-GEN-CS-5502-00001 Civil and Structural Engineering Design Philosophy. SSG-NG01012401-GEN-CS-7880-00004 Specification for concrete works. SSG-NG01012401-GEN-CS-7880-00005 Specification for foundation works. SSG-NG01012401-GEN-CS-7880-00002 Structural steel specification.

2.2. Design and Engineering Practice (DEP) Technical Specifications

DEP 34.19.20.31 – Gen Reinforced Concrete Structures. DEP 34.24.00.31 – Gen Steel Structures

2.3. Eurocodes and International Standards

In the project we use last edition of BS Structural Eurocode with National Annexes UK.

BS EN 1990 Eurocode 0. Basis of Structural Design BS EN 1991 Eurocode 1. Actions on Structures BS EN 1992 Eurocode 2. Design of Concrete Structures. BS EN 1993 Eurocode 3. Design of Steel Structures. BS EN 1997 Eurocode 7. Geotechnical Design

2.4. International / European / British Standards

• BS-EN 10025: Hot rolled products of non-alloys structural steel • BS-EN ISO 898-1: Mechanical properties of fasteners made of carbon steel and alloy steel – Part

1: Bolts, screws and studs with specified property classes – Coarse thread and fine pitch thread; • BS-EN ISO 7091: Plain washers – Normal series – Product grade C • BS-ISO 68: General purpose metric screw threads – Basic profile • BS-ISO 261: General purpose metric screw threads – General plan • BS-ISO 965: General purpose metric screw threads – Tolerances • BS-EN ISO 4034: Hexagon nuts – Product grade C • BS-EN ISO 1461: Hot dip galvanised coatings on fabricated iron and steel articles – Specifications

and test methods •


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2.5. Reference Literature

ASCE Petroc. Committee Wind loads and anchor bolt design for Petrochemical Facilities

2.6. Units of Measurement

The SI units will be used, in particular:

Length m, mm Mass kg Concentrated force, weight N, kN Linear distributed force kN/m Surface distributed force kN/m2 Specific weight kN/m3 Pressure, stress N/mm2

2.7. Order of Precedence

The regulations, codes and standards listed shall be applied in the following order of priority:

• Nigerian National Standards • Specifications from FEED including Vendor Data Sheets • Shell DEPs' • International Codes and Standards • Industry Standards.

Should there be any conflict between the above standards and the project Scope of Work/ Project Specifications, the project Scope of Work/Specifications shall take precedence as specified in Section §1.10 section VI [Scope of work] of the Signed Contract


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3. CHARACTERISTIC OF THE ANCHOR BOLTS

3.1. Sizing characteristics

Anchor bolts shall comply with the types and dimensions as set on the standard reported in Annex A

3.2. Materials and threadings characteristics

3.2.1. Threaded bars

The material shall comply with BS EN 10025 code, type S275JR. The bars shall be theaded with metric coarse thread according to BS - ISO 68-1 and tolerance degree 8g according to BS - ISO 965/1 and BS - ISO 965/2 codes.

3.2.2. Nuts

Nuts shall comply with BS EN ISO 4034 code, category C, with the following classes: as to d ≤ M16: class 5 as to d > M16: class 4,5.

Nuts shall be threaded with tolerance degree 7H according to BS - ISO 261, BS - ISO 965/1 and BS - ISO 965/2 codes.

3.2.3. Washers

The material shall comply with BS EN 10025 code, type S275JR. Washer sizes shall comply with BS EN ISO 7091 code, with the exception of thickness that shall comply with the following limitations:

5 mm for diameters ≤ 36 mm 9 mm for diameters > 36 mm.

3.2.4. Anchor plates and adjusting sleeves

Anchor plates and adjusting sleeves shall be in BS EN 10025 steel, type S275JR. Sizes shall comply with dimensional standard mentioned under Annex A.

3.2.5. Galvanising

Hot-dip galvanising shall comply with BS EN ISO 1461 code.


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4. TABLES OF ANCHOR BOLT LOAD CAPACITIES

The tables below indicate maximum value of tension (Ft,Rd) and shear (Fv,Rd) resistance of anchor bolts for ultimate limit state design evaluated considering a distance between bolt centres equal to 6 diameters. Shear and tension resistance of anchor bolts is calculated according to BS-EN1993-1-8. Acting shear and tension loads are indicated as Ft,Ed and Fv,Ed. Concrete failure under tension and shear loads are avoided providing vertical or horizontal rebar as per par. 5 of this job specification. The tension capacity take into account also the maximum tension load supported by the development length of anchor bolt into the concrete structure as per BS-EN 1992-1-1. Anchor bolts shall comply with the types and dimensions as set on the standard reported in Annex A. In case of tension and shear interaction the following equation from BS-EN1993-1-8 shall be respected:

0.14.1 ,

,

,

, ≤⋅

+Rdt

Edt

Rdv

Edv

FF

FF

For shear loads Fv,Ed ≤ Fv,Rd 30%, as indicated in following tables, Ft,Ed max = Ft,Rd For shear loads Fv,Ed > Fv,Rd 30% bolt capacity shall be in accordance to the interaction formula mentioned above.

BOLTS TYPE AA – BB – GG (according to Annex A)

Diameter Ft,Rd Fv,Rd Fv,Rd 30%

[mm] [kN] [kN] [kN]16 47,0 21,9 6,620 73,3 34,2 10,322 90,6 42,3 12,724 105,6 49,3 14,827 137,3 64,1 19,230 167,8 78,4 23,533 207,5 97,0 29,136 244,3 114,2 34,339 291,9 136,4 40,942 319,4 156,5 47,045 373,5 183,1 54,948 419,2 205,4 61,652 501,8 246,0 73,856 578,8 283,7 85,160 672,9 329,8 98,964 764,2 374,5 112,4

BOLTS TYPE CC – DD – EE - FF (according to Annex A)

Diameter Ft,Rd Fv,Rd Fv,Rd 30%

[mm] [kN] [kN] [kN]12 20,0 11,8 3,514 27,8 16,1 4,816 32,3 21,9 6,620 41,6 34,2 10,322 45,7 42,3 12,724 57,7 49,3 14,827 72,9 64,1 19,230 81,9 78,4 23,533 91,1 97,0 29,136 111,2 114,2 34,339 121,6 136,4 40,9


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5. VERIFICATION OF BOLT ANCHORAGE IN CONCRETE

In order for the anchor bolt to be able to transmit the design tensile and shear actions to the foundation, it is necessary to:

- arrange a sufficient number of rebars parallel to the anchor bolt, capable of absorbing the tensile force

- arrange a sufficient number of horizontal rebars (stirrups) near the upper surface of the foundation,

capable of absorbing the shear force

5.1. Sizing of the rebars parallel to the anchor bolt

The required area of reinforcing bars (Arb) for each anchor bolt can be evaluated as follows: Arb = (Ab x fb) / fy where: Ab is the anchor bolt net area; fb is the stress of the anchor bolt steel; fy = 410 MPa is the yield stress of the reinforcing bars. The minimum development length of the reinforcing bars can be evaluated as follows: ld = Hef – c – [(X+Wh / 2) / 1.5 Where: Hef is the embdment depth of the anchor bolt c is the concrete cover over the top of reinforcing bars to the finished surface X is the clear distance from the anchr nut to the reinforcing bars (maximum Hef /3) Wh is defined as follows (with reference to Annex A): - For anchor bolts type AA-BB is the anchor plate external diameter (De) - For anchor bolts type CC-DD-EE-FF is the anchor bolt diameter (D)

The reinforcing bar development length may be reduced by the ratio of the reinforcing bar area required to the reinforcing bar area provided: ld,req = ld x (Arb,req / Arb,prov) ≤ lbd

Where: lbd is the reinforcing bar anchorage length


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5.2. Sizing the rebar transverse to anchor bolts

The shear force transmitted by the anchor bolt must be transferred to the concrete pedestal by horizontal stirrups having the following area:

Ast = VEd / fy

Where VEd is the shear force transmitted by the anchor bolt fy = 410 MPa is the yield stress of reinforcing steel

To be considered effective, the stirrups must be inserted inside the horizontal rupture cone that is represented in the following sketch (cmin is the minimum required cover of reinforcement):

5.3. VERIFICATION OF BOLT ANCHORAGE IN CONCRETE

Shear stress between base plate and concrete may be transmitted by friction and bolts shear resistance, or carried by shear lugs (normal steel shapes) welded below the base plate and contained in pockets provided in the concrete foundation. When the Shear force is transmitted by friction between base plate and grout, it shall be checked that the design shear resistance Ft,Rd indicated below is greater than the design factored shear load.

Fv,Rd = Ff,Rd + n Fvb,Rd where n is the number of anchor bolts, Fvb,Rd is the shear resistance of the anchor bolt (see § 1.0), and Ff,Rd is the resistance provided by friction calculated as:

Ff,Rd = Cf,d x Nc,Ed where Cf,d is the friction coefficient between grout and base plate, equal to 0.2 for cement grout, and Nc,Ed is the axial compressive load. The uniform pressure, due to factored load combination, based on ultimate stress design will be 8 N/mm2, in compliance with DEP 34.24.00.31 § 2.2.4.


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6. ANNEX A: ANCHOR BOLTS STANDARD DRAWINGS


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