Guide Procedure of Piping

THAI OLEFINS PUBLIC COMPANY LIMITED Corporate Specification

CORPORATE SPECIFICATION

M-001

STRUCTURAL DESIGN LOADS AND CRITERIA

2 3/08/05 Corporate Specification TWC RW WB

1 1/3/00 Issue for ITB TPT SWK JN

0 20/12/99 Issue for review TPT SWK JN

Rev D/M/Y Description of Revision By Chk Appr

SPEC. NO. M-001 REV.2 PAGE 1 OF 22


STRUCTURAL DESIGN LOADS AND CRITERIA

TABLE OF CONTENTS

1.0 GENERAL

1.1 Scope

1.2 Abbreviations

2.0 GOVERNING CODES, REGULATIONS AND REFERENCE DOCUMENTS

2.1 Building Codes, Regulations

2.2 Concrete Design, Materials

2.3 Steel Design, Materials

2.4 Civil Sitework, Underground

2.5 Related Project Specifications

3.0 SITE INFORMATION

3.1 Location

3.2 Weather and Site Data

3.3 Wind Speed

3.4 Seismic

3.5 Geotechnical Data

4.0 CIVIL/STRUCTURAL LOADING CRITERIA

4.1 Design Loads

4.2 Loading Conditions, Combinations

4.3 Stability Against Overturning

4.4 Ultimate Strength

4.5 Allowable Overstress

4.6 Buoyancy



4.7 Bearing Capacity

5.0 STRUCTURAL MATERIALS

5.1 Structural Steel

5.2 Structural Concrete, Foundations

5.3 Anchor Bolts

5.4 Grout

5.5 Coatings

6.0 STEEL STRUCTURES

6.1 Fabrication and Erection

6.2 Design Details

7.0 CONCRETE STRUCTURES, FOUNDATIONS

7.1 Foundations

7.2 Building Ground Floors

7.3 Trenches and Sewer Boxes

8.0 MISCELLANEOUS STRUCTURES

8.1 Ladders

8.2 Platforms, Walkways, Access-ways

1.0 GENERAL

1.1 Scope



This specification provides criteria governing the design of structures and foundations and shall be used by the Contractor to establish the basis for the structural design.

1.2 Abbreviations

Abbreviations as used for Codes and Regulations shall have the following definitions:

AASHTO - American Association of Highway Transportation Officials

ACI - American Concrete Institute

AISC - American Institute of Steel Construction

AISI - American Iron and Steel Institute

ANSI - American National Standards Institute

ASCE - American Society of Civil Engineers

ASTM - American Society for Testing and Materials

AWS - American Welding Society

API - American Petroleum Institute

PCA - Portland Cement Association

SJI - Steel Joist Institute

OSHA - Occupational Safety and Health Administration, Department of Labor

UBC - Uniform Building Code of the International Conference of Building Officials

TIS - Thai Industrial Standard

1.3 The metric system shall be used for all dimensions.

2.0 GOVERNING CODES, REGULATIONS AND REFERENCE DOCUMENTS



The following codes, specifications, regulations and industry standards, where applicable, shall cover design and material for structures, site work and other civil related facilities.

2.1 Building Codes, Regulations

OSHA - Occupational Safety and Health Standards, Title 29 Labor,

Parts 15 and 19, 1981.

UBC - Uniform Building Code of the International Conference of Building Officials, 1982 Edition

LOCAL CODES Local codes and/or regulations of approving Authorities.

The UBC Building Code shall govern except where reference to other codes and regulations is specified herein. Local codes shall also be considered. The more conservative specification shall be used for design purposes after agreement by the Company.

2.2 Concrete Design. Materials, Placing

ACI 211.1 Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete, latest edition.

ACI 301 Specification for Structural Concrete for Buildings, latest edition.

ACI 302.lR Guide for Concrete Floor and Slab Construction, latest edition.

ACI 304R Guide for measuring, mixing, Transporting, and Placing Concrete, latest edition.

ACT 305R Hot Weather Concreting, latest edition.

ACT 311.4R Guide for Concrete Inspection, latest edition.

ACI 315 Details and Detailing of Concrete Reinforcement, latest edition.

ACI 316R Recommendations for Construction of Concrete Pavements and Concrete Bases, latest edition.

ACI 318&ACI 318RBuilding Code Requirements for Reinforced Concrete, latest edition.



ACI 347 Recommended Practice for Concrete Formwork, latest edition.

ACI 531 Building Code Requirements for Concrete Masonry Structures, 1983.

ASTM A185 Specification for Steel Welded Wire, Fabric, Plain, for Concrete Reinforcement, 1997.

ASTM A193 Standard Specifications for Alloy Steel and Stainless Steel Bolting Materials for High Temperature Sources, 1999.

ASTM A194 Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service, 1986

ASTM A615 Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement, 1996

ASTM C33 Standard Specification for Concrete Aggregates, 1999.

ASTM C150 Standard Specification for Portland Cement, 1999.

ASTM C260 Specification for Air Entraining Admixtures for Concrete, 1998.

ASTM C494 Standard Specification for Chemical Admixtures for Concrete, 1999.

API 650 Welded Steel Tanks for Oil Storage, 1993.

PCA Bulletin Design of Concrete Floors on Ground, 1967.

PCA Concrete Information Slab Thickness Design for Concrete Floors on Grade.

TIS Steel Bar for Reinforced Concrete; Round Bar

TIS Steel Bar for Reinforced Concrete; Deformed Bar

2.3 Steel Design, Materials, Fabrication

AISC Specification for the Design, Fabrication and Erection of Structural Steel for Buildings, latest edition.

AISC Manual of Steel Construction, Eighth Edition, latest edition.



AISC Code of Standard Practice for Steel Building and Bridges, latest edition.

AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts, approved by Research Council on Riveted and Bolted Structural Joints of Engineering Foundation, latest edition.

AISI Specification for the Design of Light Gauge Cold-Formed Steel Structural Members, latest Edition.

ASTM A36 Standard Specification for Structural Steel, 1997 ae1.

ASTM A53 Standard specification for Pipe, Steel, Black and Hot Dipped, Zinc-coated Welded and Seamless, 1999a.

ASTM A123 Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products, 1997 ae1.

ASTM A134 Specification for Pipe, Steel, Electric-Fusion (ARC)-Welded (sizes NPS16 and over), 1996.

ASTM 139 Specification for Electric-Fusion (ARC) -Welded (sizes NPS16 and over), 1996 e1.

ASTM A153 Specification for Zinc-Coating (Hot-Dip) on Iron and Steel Hardware, 1998.

ASTM A240 Standard Specification for Heat Resisting Chromium and Chromium Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels, 1999.

ASTM A276 Standard Specification for Stainless and Heat-Resisting Steel Bars and Shapes, 1998b.

ASTM A307 Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength, 1997.

ASTM A320 Specification for Alloys-Steel Bolting Materials for Low-Temperature Service, 1998.

ASTM A325 Standard specification for High Strength Bolts for Structural Steel Joints, 1997.



ASTM A490 Standard Specification for Heat Treated Steel Structural Bolts, 150 ksi Minimum Tensile Strength, 1997.

ASTM A501 Standard Specification for Hot-Formed Welded and Seamless Carbon Steel Structural Tubing, 1999.

ASTM A563 Standard Specification for Carbon and Alloy Steel Nuts, 1997.

AWS Dl.1 Structural Welding Code, 1988.

SJI Standard Specification for Open Web Steel Joists, DIJ & DLH, IJ & LH, and H & LH Series, latest edition.

2.4 Civil, Sitework, Underground

AASHTO M36 Corrugated Steel Pipe, 1982.

ASTM A74 Cast Iron Soil Pipe and Fittings, 1998.

ASTM C76 Reinforced Concrete Culvert, Storm Drain and Sewer Pipe, 1999.

ASTM C361 Reinforced Concrete Low Head Pressure Pipe, 1999.

ASTM C136 Test for Sieve or Screen Analysis of Fine and Coarse Aggregates, 1996a.

ASTM D422 Particle Size Analysis of Soil, 1998.

ASTM D4318 Test for Plastic Limit and Plasticity Index of Soils, latest edition.

ASTM D698 Test method for laboratory compaction characteristic of soil using standard effort (12,400 ft-1bf/ft), 1998

ASTM D1556 Test for Density of Soil in Place by the Sand-Cone Method, latest edition.

ASTM D1557 Tests for Moisture-Density Relations of Soils and Soil-Aggregate Mixtures Using 10 lb. Rammer and 18 in. Drop, latest edition.

ASTM D2216 Laboratory Determination of Water (Moisture) Content of Soil, Rock, and Soil-Aggregate Mixtures, latest edition.



ASTM D2922 Tests for Density of Soil and Soil Aggregate in Place by Nuclear Methods (Shallow Depth), latest edition.

2.5 Related Project Specifications

M-002 Design Basis for Piperacks, Pipeways and Sleepers

M-003 Design Basis for Structures and Foundations

S-001 Site Civil Design Criteria

X-001 Painting and Coatings

3.0 SITE INFORMATION

3.1 Location

Map Ta Phut Industrial Estate, Rayong, Thailand. Located approximately 205 kilometers southeast of Bangkok on Highway No. 3 (Sukhumvit Highway)

3.2 Weather and Site Data

Weather and site data is contained in APPENDIX B ( SECTION 4 )

3.3 Wind Speed

Design wind speed for foundation and structural loads shall be based on ANSI A58.1 for a basic wind speed of 38 m/sec, with importance Factor 1.0 and Exposure Category C.

3.4 Seismic Zone

Earthquakes are rare in Thailand and no significant earthquake damage has been recorded in the past. Therefore, the earthquake design basis is seismic Zone 0.

3.5 Geotechnical Report

General aspects of earthwork and foundation design relating to or derived from geotechnical features shall be based on the evaluation and recommendations contained in the soil report:( Later)

The Contractor shall conduct additional geotechnical investigations as required for the design of critical structures and foundations.



4.0 CIVIL/STRUCTURAL LOADING CRITERIA

4.1 Loads and Forces

The following loads and forces shall be considered in the design of plant structures:

a. Dead Load

b. Operating Load

c. Test Load

d. Upset Load

e. Live Load

f. Wind Load

g. Earthquake Load

h. Impact Load

i. Machine Dynamic Load

j. Thermal Expansion Load

k. Erection Load

1. Maintenance Load

4.1.1 Dead Load

Shall be considered as the mass of the materials forming a permanent part of the structure unit. It shall be defined as the total mass of all empty vessels and equipment, structures, fireproofing, insulation, piping and electrical conduits.

Heavy beams or girders, such as may be required to carry other than platform live loads, shall be given special consideration.

4.1.2 Operating Load



Shall be defined as the dead load plus the mass of any liquids or solids present within the vessels, equipment or piping during normal operation. Also included in this definition is the mass of all permanently stored materials for operation.

4.1.3 Test Load

Shall be defined as either:

The dead load plus the mass of any liquid necessary to pressure-test vessels, column, drum equipment or piping.

The load due to proof testing of cranes and other lifting equipment.

4.1.4 Upset Load

Shall be defined as the short time effects resulting in loads additional to operating loads which occur during start-up, shutting down, or an interruption in the operation of the process, e.g. build-up of catalyst in vessels and piping disrupting normal flow.

4.1.5 Live Load

Shall be defined as the mass of all movable loads including personnel, tools, miscellaneous equipment, cranes, hoists, parts of dismantled equipment, and temporarily stored materials.

The following live loads shall be used in the design of process and plant buildings:

Area Classification Loads

STORAGE AREAS Areas specifically Designated for storing Light loads

720 kg/m2

Areas specifically Designated for storing Heavy loads

Actual load

WORKING AREAS Areas serving tubular Units and vessel manholes

350 kg/m2



ACCESS AREAS Miscellaneous areas such as connecting walkways and operating platforms (not used as working or storage areas)

250 kg/m2

FLOORING OF PLATFORMS

490 kg/m2 minimum

ROOF AREAS Flat or pitched roofs (not used as working or storage area)

150 kg/m2 applied to horizontal projection of roof

STAIRWAYS AND LANDINGS

490 kg/m2

LADDERS 180 kg concentrated mass

HANDRAILS 100 kg vertical and horizontal

4.1.6 Wind Loads

Wind loads on structures and equipment excepting piperacks shall be computed and applied according to procedures outlined in ANSI A58.1. Wind load on piperacks and sleepers shall conform to the requirements of specification M-002.

4.1.7 Earthquake Loads

Earthquake load shall be computed and applied in accordance to procedures outlined in ANSI A58.1.

4.1.8 Impact Loads

Shall be computed according to procedures outlined in the AISC specification with the following changes:



Equipment Load Percentage Increase

Jib Cranes and Hoists 25

Monorail Beams 25

Reciprocating or power driven machinery

200

Rotating or motor driven machinery 100

(Load factors, when required, shall be the same as Live Load)

4.1.9 Machine Dynamic Load

A dynamic analysis shall be performed for the design of the foundation or structural system for each reciprocating machine, and for each rotary machine having horsepower of 200 or more. The design basis for each major system shall be subject to review by the Company. Included in the Design Basis shall be:

a. Specifications or requirements as outlined in bid documents.

b. Design static load of machine.

c. Design dynamic loads (forces and couples) in applicable modes of excitation.

d. Dynamic and static soil parameters.

e. Proposed method of dynamic analysis.

f. Tolerable limits of system response to cyclic loading imposed by rotating or reciprocating equipment.

4.1.10 Thermal Expansion Load

All equipment support structures and elements shall be designed to accommodate the loads or effects produced by thermal expansion. For friction coefficients relating to support contact surfaces for heat exchangers and horizontal vessels, see Specification M-002 for pipe-racks. For heat exchangers and horizontal vessels, see Specification M-003.

4.1.11 Erection Load



Shall be defined as temporary forces caused by erection of structures or equipment.

4.1.12 Maintenance Load

Shall be defined as temporary forces caused by the dismantling, repair, cleaning or painting of equipment.

The supporting structure, anchor bolts and pulling lugs of heat exchangers with removable bundles shall be designed to withstand a longitudinal pulling force equivalent to 1/2 times the tube bundle weight or 1000 kg, whichever is greater, applied at the center line of the tube bundle.

4.2 Loading Conditions, Combinations

All structures, vessels and equipment and related foundations, and elements thereof shall be designed for the most severe of any of the following combination of loads and forces:

a. Shutdown dead load of equipment (empty, but with all permanent internals, piping, platforms and insulation in place) combined with full wind and maintenance load.

b. Erection weight of vessel (fabricated weight of vessel plus internals, platforms, piping, insulating, etc., to be erected with vessel) combined with full wind.

c. Normal operating loads with all dead and live loads in place, but no wind.

d. Normal operating loads with all dead loads in place, combined with full wind.

e. Vessels and piping under hydrostatic test with all dead loads in place plus 1/3 wind.

f. Emergency upset, normal operating load plus any load resulting from a possible abnormal condition, misoperation, instrument failure, etc.

4.3 Stability Against Overturning

Stability Ratio is defined as the stabilizing moment divided by the overturning moment. In the case of structures supported by a single foundation, the stabilizing moment shall be taken about the outside edge of the foundation. Minimum stability ratios shall be as follows:



Foundation Type Stability Ratio

Vertical Vessel and Stack Foundations 2.0

All other foundations loaded per Para. 4.2a, b, c, e, and f above

1.5

All other foundations loaded per Para. 4.2d above 1.7

Where a foundation for an integral structural unit consists of two or more footings, as in the case of an elevated heater or a framed structure supporting equipment, the stability ratio of the structure as a whole including related equipment, shall be not less than 1.5 for any condition of loading when the stabilizing moment is taken about the center of outermost footing (s).

4.4 Ultimate Strength

For ultimate strength design of the foundation, the operating load and test load factor shall be the same as for dead load.

4.5 Allowable Overstress

Allowable stresses for load combinations that include wind or earthquake shall be as stated in AISC and ACI. In addition load combinations that include test may have the allowable stress increased 20%. Allowable stress increase is not allowed for anchor bolts. A 30% increase in drilled shaft capacity is allowed for load combination that includes wind or earthquake.

4.6 Buoyancy

A safety factor of not less than 1.20 shall be provided against buoyancy.

4.7 Bearing Capacity

The allowable bearing capacity and sliding or lateral resistance of soil and piles shall be in accordance with the soil report. The Contractor shall investigate and verify the bearing capacities and lateral resistances used for design.

5.0 STRUCTURAL MATERIALS



The following are general guidelines for structural materials. The Contractor is responsible for determining all of the structural material requirements.

5.1 Structural Steel

Generally the design shall be based on the use of the following structural steels using the allowable stresses as provided in the AISC Specification for the Design, Fabrication and Erection of Structural Steel for Buildings.

Structural Steel Shades and Plates ASTM A36

Structural Tubing ASTM A501

Structural Pipe (Steel) Type E or S Grade B ASTM A53, A134, 139

Rod and Bar Stock ASTM A36

Checker Plate ASTM A36

High Strength Bolt ASTM A325

Unfinished Bolts ASTM A307

Carbon and Alloy Steel Nuts ASTM A563

Stainless Steel (Structural Use) ASI Type 304 ASTM A240, A276

5.2 Structural Concrete, Foundations

Design of concrete structures and foundations shall be in accordance with ACI 318. Minimum compressive strength of concrete at 28 days shall be 210 kg/m2 using the following materials:

Cement (Type 1 unless noted otherwise) ASTM C150

Aggregate ASTM C33



Admixtures ASTM C260, C494

Reinforcing bars ASTM A615

TIS 20-Lastest edition

TIS 24-Lastest edition

Welded wire fabric ASTM A185

Sulfate resistant cement shall be used in concrete for foundations/footings.

5.3 Anchor Bolts

All anchor bolt material bolts shall be ASTM A36 steel, hot dip galvanized, excepting reciprocating compressor anchor bolts. Anchor bolts for reciprocating compressors and drivers shall be ASTM A193 grade B-7 steel with ASTM A194 nuts. Welding or bending is not permitted on A193 or A194 material.

All anchor bolts consists of double nuts.

5.4 Grout

Grouting of non-critical equipment, e.g. small column base plates, very small pumps, small vessels, etc., where high-strength and non-shrink properties are not of prime importance, may be done with a Portland Cement dry-pack mortar.

Precision non. shrink grout shall be provide for major mechanical, other critical equipment and heavily loaded/ large column bases with a proprietary product specially formulated for this use and having the following chemical and physical characteristics:

a. Non-rusting or staining

b. No-shrink dimensional stability

c. Compressive strength 630 kg/cm2 at 7 days

d. Flowable placing consistency and fully self leveling characteristics

e. No generation of expansive forces during setting

f. No continuous confinement required during setting period



g. Unaffected by exposure to the service temperatures

Grout for base-mounted or skid-mounted reciprocating machinery or critical centrifugal/rotary compressors and pumps including drivers shall be epoxy type, such as Ceilcote 648 CP or the Company approved equivalent grout.

Compliance with minimal requirements of equipment vendors regarding grout materials and installation is mandatory. Handling and placement of proprietary grouts shall be in strict accordance with the manufacturers recommended practice.

5.5 Coatings

5.5.1 Galvanizing

a) The following structural and miscellaneous steel items shall be hot dip galvanized:

All exposed embedded steel in concrete piperacks, sleepers and concrete structures.

All ladders, cages, stair members and handrails.

( Shall be painted yellow after galvanized )

Stile framing members.

Grating and floor plate.

Anchor bolts.

Steel roof decking,

Bolts, washers and nuts

b) Galvanizing, where required, shall be in accordance with ASTM A123 and ASTM A153 as applicable.

c) Members completely encased by fireproofing will not require galvanizing.

d) Cooling tower anchor bolts, embedments and screens shall be stainless steel SUS304



e) Field touch-ups of galvanizing shall be thoroughly cleaned and given a heavy touch-up coat of Z.R.C. or equivalent.

5.5.2 Painting

a) The following structural and miscellaneous steel items shall be primed and painted:

Structural steel members for piperacks and pipe supports and all other non fireproofed structural steel, Bolts, washers and nuts shall be hot dip galvanized.

Structural steel and light gage shapes furnished in enclosed pre-engineered buildings.

Structural steel framing required for masonry buildings.

Framing for compressor or equipment operating levels in enclosed buildings.

b) Steel completely encased in concrete or fireproofing shall be primed only.

c) Structural steel requiring priming or priming and painting shall be prepared and painted in accordance with the applicable requirements of Specification X-001.

d) Ladders, cages, stair members and handrail shall be painted yellow after hot dip galvanized.

6.0 STEEL STRUCTURES

In general, primary framework for buildings, piperacks and structures supporting equipment or piping above grade shall be constructed of structural steel.

For steel structures requiring fireproofing, secondary steel framing consisting of platform supports, monorails, walkways and bracing which do not contribute to vertical support of equipment shall be non-fireproofed.

6.1 Fabrication and Erection

Fabrication and erection shall, as a minimum, conform to the requirements of the AISC standards referenced in Section 2.3. The Contractor shall be responsible for



determining all requirements for steel fabrication and erection and shall prepare detailed specifications.

6.2 Design Details

Shop connections shall be welded, Field connections shall be 20-mm diameter ASTM A325 bolts unless noted otherwise.

In general, all shear connections shall be designed in accordance with the AISC recommendations and fully supportable by calculations.

Bracing connections shall be designed for the computed forces as shown on the drawings. Bracing shall have a minimum of two bolts per connection. Where practical, the bracing forces shall be transmitted to the flanges of the braced members.

Shear loads on anchor bolts embedded in concrete shall not exceed allowable shear loads set forth in UBC Section 2624, Table 26G. Shear lugs or similar rationally designed devices shall be provided to resist loads in excess of anchor bolt capacities. Friction of column baseplates on concrete shall not be considered as resisting these loads.

Unless the reaction is provided by the design engineer on the design drawing, beam to beam and beam to column connections shall be designed for a reaction equal to half the total uniform load capacity per the given span of a beam shown in the tables, Allowable Loads on Beams, of the AISC Manual of Steel Construction. The connections must also comply with the requirements of Table I and III, Framed Beam Connections, of the above manual. All joints using high strength bolts shall be bearing-type connections. The allowable loads shall be based on all bolts having threads in the shear plane.

Moment connections shall be designed to develop the full bending strength of the weakest connected member, unless the moment is noted or connection is detailed on the design drawings.

7.0 CONCRETE STRUCTURES, FOUNDATIONS

Concrete structures shall, as a minimum, be constructed in accordance with the ACI codes and standards referenced in Sec. 2.2. The Contractor is responsible for



determining all of the requirements (forming, mixing, placing, testing, curing, and other related items) for the concrete used in structures, foundations, floors and paving. The Contractor shall prepare detailed concrete specifications.

7.1 Foundations

Foundations shall be designed to resist the effects of individual loads or loading combinations including the effect of eccentricity, and shall not exceed the allowable pile design loads or the maximum bearing values of the soil and other design criteria. Foundation details shall be in accordance with Specifications M-002 and M-003.

7.2 Building Ground Floors

Ground floors shall be reinforced concrete slabs. Floors shall receive a wood float or steel trowel finish as indicated on the drawings.

Floor load, i.e. dead loads, live loads and imposed loads shall be transmitted to building foundations. Floors shall not be separated by joints from the building foundations. Elevations of slabs under structures shall match the elevations of adjacent paved areas. Floor slab elevations for enclosed and open-sided buildings shall be 6 inches (150 mm) higher than the surrounding paved and unpaved areas. The edges of paving adjacent to open-sided buildings shall be at the same elevation as the edges of the floor of the building with paving sloping away from the building.

7.3 Trenches and Sewer Boxes

Pipe trenches in concrete paved areas shall be of open construction similar to drainage trenches. In unpaved areas they shall be covered with 1/4-inch (6 mm) minimum thick steel floor plate. In inside buildings they shall be covered with 1/4-inch (6 mm) minimum thick steel floor plate with the top set flush with the floor.

Drainage trenches in concrete paved areas shall be covered with coating set flush with top of paving with 6 inch (150 mm) thick walls and floor. The floor shall be a slope of 1 inch in 10 feet (1 cm in 1.20 m) and a maximum drop of 6 inches (150 mm).

Sewer boxes shall be of concrete pipe or poured in place rectangular box with 6-inch (150-mm) minimum thick reinforced concrete walls and floors. Sewer boxes located outside of buildings shall be covered with reinforced concrete slab. The top of slab shall be 2 inches (50 mm) above grade in unpaved area or flush with the top of the pavement. Inside the buildings they shall be covered with



reinforced concrete slab set flush with the top of the finished floor for sealed construction. Cast iron manhole covers shall be used.

8.0 MISCELLANEOUS STRUCTURES

Ladders, handrails, platforms and stairways shall be designed in accordance with OSHA, Subpart D, Section 1910.21-27. Top railing loading strength shall be interpreted to mean a without yielding condition. Every ladder and stairway floor or platform opening shall be in accordance with Para. 1910.23(a)(2). Ladder or stairway entrances shall be provided with a self-closing swinging gate or be so offset that a person cannot walk directly into the opening (a guard chain is not considered adequate). All ladder, handrails and stairway members shall be hot dip galvanized and painted yellow.

8.1 Ladders

All ladders for access to platforms, vessels, valves, etc., shall have solid round steel rungs. Ladders serving platforms or landings 3 m to 6 m above grade shall be equipped with hoop guard at top of ladder. Cages shall be provided on all ladders serving platforms more than 6 m above grade.

Maximum length of ladder between landings shall be 9m. Elevation of centerline of top ring shall be equal to top of landing elevation.

Outside width of ladder shall be 450 mm. Rungs shall consist of minimum 20-mm diameter bars spaced at 300-mm maximum centers.

8.2 Platforms, Walkways. Access ways

Minimum width of walkways, stairs, landings, stiles or other access ways shall be 750 mm.

Platform framing members, including columns and bracing shall clear piping, vessels and/or related insulation by a minimum of 75 mm both vertically and horizontally.

Flooring for steel framed platforms, walkways, access ways and stair treads shall be serrated welded galvanized steel bar grating. Grating shall have 32 mm x 5-mm minimum bearing bars on 30-mm centers designed for 1250 kg/cm2 stress. Cross bars shall be twisted square or hex bars at 100-mm centers. Grating shall be secured to framing by grate clamps without drilling support members.




M-002

DESIGN BASIS FOR PIPERACKS, PIPEWAYS AND SLEEPERS



0 20/12/99 Issue for review. TPT SWK JN




DESIGN BASIS FOR PIPERACKS, PIPEWAYS AND SLEEPERS

TABLE OF CONTENTS

1.0 GENERAL

1.1 Scope

1.2 References

2.0 TYPES OF CONSTRUCTION

3.0 PIPERACK FRAMING

3.1 Concrete Frames

3.2 Structural Steel Frames

3.3 Column Base Conditions

3.4 Braces

3.5 Beam Struts

3.6 Transverse Beams

3.7 Miscellaneous

3.8 Fireproofing

4.0 DESIGN LOADINGS

4.1 Gravity Loads

4.1.1 Piping

4.1.2 Electrical/Instrument Trays

4.1.3 Equipment

4.2 Wind Loads

4.2.1 Piping

4.2.2 Instrument/Electrical Trays

4.2.3 Structural Framing



4.2.4 Miscellaneous T-Supports

4.2.5 Ladders, Platforms, Stairs, Equipment

4.2.6 Longitudinal Load

4.3 Friction Loading

4.4 Anchor Loads

4.5 Load Combinations

5.0 ALLOWABLE STRESSES

5.1 Superstructure

5.2 Foundations

6.0 ALLOWABLE DEFLECTIONS

6.1 Lateral Deflection

1.0 GENERAL



1.1 Scope

This design basis covers the general requirements for the design of piperacks, sleepers, and miscellaneous pipe supports. Consideration of pipe-racks carrying electrical and instrument lines and supporting air fin coolers is included.

1.2 References

Refer to Project Specification M-001 for a listing of codes, regulations, related project specifications and general criteria applicable to this specification.

2.0 TYPES OF CONSTRUCTION

Non-fireproofed piperacks and pipe supports shall be of structural steel.

Fireproofed piperacks or pipe supports, if required, shall be either:

Precast reinforced concrete, or

Poured in place reinforced concrete, or,

Application of the Company approved proprietary fireproofing systems applied to structural steel framing.

Where concrete support beams or sleepers are utilized, steel bearing plates consisting of flat bars, inverted channels, or structural tees adequately anchored, shall be provided as bearing surfaces for pipe or pipe shoes. Bearing plates shall project 3-mm minimum above concrete surface. Where fireproofing of steel support beams is employed, the top flange of steel support beams shall project 3-mm minimum above fireproofed surface.

In all areas, low pipe sleepers (1. 0 m or less above grade) shall be either:

Poured in place concrete stem-wall and footings, or

Precast concrete beams supported on poured in place concrete foundations, or

Structural steel beams supported on poured in place concrete foundations, if fireproofing is not required.

Sleepers greater than 1.0 m above grade shall be either precast concrete beams or structural steel beams, (if fireproofing not required) supported in concrete piers and footings.



3.0 PIPERACK_FRAMING

3.1 Concrete Frames

Single or multi-level precast or cast-in-place concrete piperack bents or frames shall be designed and detailed as rigid frames.

3.2 Structural Steel Frames

Single or multi-level steel frames may be designed as rigid frames or a braced frame utilizing knee bracing between the lower support level and columns. Where knee bracing is employed, minimum clearances as required by job criteria must be provided.

For multi-level frames, connections between columns and first transverse beam shall be either moment connections or simple connections with knee bracing. Connections between column and transverse beams other than the first beam may be either moment or simple connections.

3.3 Column Base Conditions

Column Base Conditions shall normally be as follows:

Precast concrete frames - pinned, both directions.

Cast-in-place concrete frames - 100% fixed, both directions.

Structural steel frames Fixed or pinned transverse ; pinned, longitudinal.

Miscellaneous independent frames - 100% fixed, longitudinal; pinned, transverse.

T-Supports (cantilever, columns) - 100% fixed, both directions.

Where the application of lateral loads results in excessive deflection of piperack from support pinned conditions, partial fixity in the range of 30% to 50% may be used provided partial fixity can be substantiated by analysis.

3.4 Braces



Vertically braced bays shall be provided as required to handle calculated pipe anchor loads. Longitudinal bracing may be either cross bracing or K-bracing. Maximum spacing of longitudinally braced bays shall be 60 m.

3.5 Beam Struts

Longitudinal beam struts shall be provided to transmit pipe anchor loads to braced bays; to support piping and tray turnouts; and to provide stability for pinned base design of frames.

In addition to axial forces, beam struts should be designed for 50% of the most heavily loaded transverse pipe support beam unless unusual loading is encountered. This loading should not normally be added to the design load for columns or foundations. Concentrated loads from large pipes may be treated as in Section 4.1.

Longitudinal expansion shall be controlled by providing an expansion joint in a set of beam struts located preferably midway between adjacent braced bays. Spacing of braced bays shall be 60m maximum. Braced bays shall not be located opposite equipment such as pumps requiring maintenance access from within the piperack.

3.6 Transverse Beams

The beam must be capable of resisting all loads, moments and shears produced by the load combinations.

For the design of steel beams, the unbraced length of the compression flange should be between points of inflection. For axial loads, however, the total span of the beam should be used, modified by the appropriate effective length factor for each direction. No consideration of lateral support of beam by piping shall be permitted.

In the design of the beam, consideration should be given to large lines that are hydro-tested.

In analyzing effects at Friction Loading on beams, the top flange of beam only shall be assumed to resist Friction Loads. The effects of torsion should be considered on an individual basis when unusually large loads (such as large anchor forces) are applied to the beam flange.

Where longitudinal forces from pipe anchors are very large, compression or tension members placed in the horizontal plan of pipe deck to relieve beam of torsional loading may be utilized.



3.7 Miscellaneous Supports

Miscellaneous pipe supports shall be either cantilever T-Supports or frames. Frames shall be either rigid or braced in the transverse direction and cantilevered columns in the longitudinal direction of pipe-way. Single T-Supports shall normally be cantilevered in both directions.

3.8 Fireproofing

For requirement , see TS. N-002 Fireproofing

4.0 DESIGN LOADINGS

4.1 Gravity Loads

4.1.1 Piping

The summation of all individual lines including contents on each level shall be converted into an equivalent uniform load as follows:

A minimum uniform pipe deck load of 170 kg/m2 shall be used for major pipe-racks. This corresponds to an equivalent load of 150-mm lines full of water covered with 50-mm thick insulation and spaced on 300-mm centers.

A concentrated load shall be added for pipes which are 300 mm diameter and larger. The concentrated load P = S*(w p*d) where S = pipe support spacing, w = large pipe weight (including weight of contents if liquid), plf., p = uniform loading used, d = large pipe diameter, including insulation.

A minimum uniform pipe load of 120 kg/m2 shall be used for miscellaneous pipe supports.

4.1.2 Electrical/Instrument Trays

The uniform load from electrical and instrument trays should be determined from the loaded weight of trays and/or separate conduit. A minimum uniform load of 100 kg/m2 shall be used for single trays and 200 kg/m2 for double level trays.



4.13. Equipment

If plant layout and equipment arrangement requires installation of air coolers on upper pipe-rack levels, design and analysis of the supporting pipe-rack substructure shall include adequate support for equipment loads. Design shall provide for minimal transmittal of vibrations from fans to piperack. Fabreeda or equal isolation pads of effective thickness shall be provided where equipment base plates are mounted on piperack.

4.2 Wind Loads

Transverse wind loads shall be calculated and applied to piping, trays, structural shapes and equipment in accordance with M-001, ANSI A58.1 and with the following:

F = qzGhCfAf (refer to Table 4 page 27 of ANSI A58.1)

Interpretation of values for Cf and Af shall be:

4.2.1 Piping

Af shall equal projected area of the largest pipe of given level including insulation, if any. If pipe diameters are unknown or cannot be estimated, assume an 450 mm diameter pipe plus 75 mm inches of insulation; i.e., projected area of 600 mm x length.

For the following combinations of piping on any one level, Cf shall equal:

0.7 for a single pipe

1.1 for two pipes

2.0 for more than two pipes

4.2.2 Instrument/Electrical Trays

Af shall equal projected area of deepest tray x length. If tray dimensions are unknown or cannot be estimated, use 150-mm tray height.

For the following combination of trays on any one level, Cf shall equal:



2.0 for a single tray

2.5 for two trays

3.0 for three or more trays

4.2.3 Structural Framing

Af shall equal projected area of structural elements exposed on windward side.

Cf shall equal:

2.0 for first column row

3.0 for two rows of columns

4.0 for three rows of columns

4.2.4 Miscellaneous T-Supports

Af for piping shall equal projected area of largest pipe at given level of support.

Cf for structural shapes shall equal 2.0. Cf for piping shall be as 4.2.1 above.

4.2.5 Ladders, Platforms, Stairs, Equipment

Af for these items supported by piperacks or pipe supports shall be equal to the net projected area exposed to windward side.

Cf shall equal 2.0.

4.2.6 Longitudinal Load

Longitudinal wind shall be considered negligible compared to other longitudinal forces and can be disregarded except for air coolers or other unusual configurations.

4.3 Friction Loading



Friction forces caused by hot lines sliding across the pipe support during start-up and shutdown shall be assumed partially resisted by adjacent cold lines. Therefore, in order to provide for a nominal unbalance of friction forces acting on a pipe support, a resultant longitudinal friction force equal to 7 % of the total pipe weight or 30% of any one or more lines known to act simultaneously in the same direction, whichever is larger shall be assumed for piperack design.

4.4 Anchor Loads

Pipeway shall be checked for anchor loads as determined from Stress Analysis. It may be necessary to use horizontal bracing if large anchor forces are encountered. It is normally preferred if either have the anchors staggered along the pipeway so that each support has only one or two anchors, or to anchor most pipes on one braced support.

When applying ultimate strength load factors for concrete design, anchor forces should be considered as dead loads.

4.5 Load Combinations

Pipe supports shall normally be designed to resist the following load combinations:

Gravity Load

Gravity Load + Transverse Wind + Anchor Load + Friction Load

Gravity Load + Friction Load

Gravity Load + Friction Load + Anchor Load

Gravity Load + Anchor Load + Longitudinal Wind (if applicable) + Friction Load

5.0 ALLOWABLE STRESSES

5.1 Superstructure

Allowable stresses may be increased one-third for all load combinations with wind.

5.2 Foundations



When vertical load, shear and moment of the column bases are used for design of reinforced concrete foundations, the following should apply:

If working stress method is used for superstructure, the load factor for concrete strength method as per ACI 318 shall be added to the loads.

The allowable soil pressures shall be as stated in the Project Soils Report. Allowable soil pressures may be increased 1/3 for wind load -combinations. With confirmation by soil report.

6.0 ALLOWABLE DEFLECTIONS

6.1 Lateral Deflection

Permissible lateral deflection of frames due to applied transverse loads shall be h/150 for thermal loading due to pipe guides or anchors, or for a combination of guide/anchor load and wind load.




M-003

DESIGN BASIS FOR STRUCTURES AND FOUNDATIONS



0 31/3/00 Issue for review TPT SWK JN




DESIGN BASIS FOR STRUCTURES AND FOUNDATIONS

TABLE OF CONTENTS

1.0 GENERAL

1.1 Scope

1.2 References

1.3 Types of Construction

2.0 LOADING CRITERIA

2.1 Wind Loads

2.2 Building Loading

3.0 FRAME SYSTEMS

3.1 Steel Framed Structures

3.2 Concrete Framed Structures

3.3 Steel Buildings

3.4 Masonry Building Frames

3.5 Stairways and Ladders

4.0 VIBRATION CONTROL

5.0 GENERAL FOUNDATION REQUIREMENTS

5.1 General Design

5.2 Allowable Settlement

5.3 Foundation Elevations

5.4 Anchor Bolts

5.5 Sleeves

5.6 Slide Plates

6.0 VERTICAL VESSEL FOUNDATION DESIGN



6.1 Anchor Bolts

6.2 Pedestal Design

6.3 Footings

7.0 HORIZONTAL VESSEL AND EXCHANGER FOUNDATION DESIGN

7.1 Load Distribution for Exchangers

7.2 Slide Plates

7.3 Pier Design

7.4 Column Design

7.5 Spread Footings

8.0 STORAGE TANK FOUNDATIONS

8.1 Large Tanks

8.2 Small Tanks

8.3 Earthwork

9.0 BUILDING FOUNDATIONS

9.1 Foundation Types

9.2 Joints

9.3 Floor Slabs

9.4 Grade Beams

10.0 DRILLED SHAFT FOUNDATIONS

11.0 GROUTING AND FINISHING

11.1 Grouting



11.2 Finishing

11.3 Scoring and Edging

12.0 TRENCH DRAINS

13.0 CONCRETE WATER CONTAINMENT BASINS

1.0 GENERAL

1.1 Scope



This Design Basis covers the general requirements for the design of superstructures and substructures for equipment support structures, access and maintenance structures and structural elements of buildings. Requirements for design of equipment foundations and of building and structure foundations are included.

1.2 References

Refer to Project Specification M-001 for a listing of codes, regulations, related project specifications and general criteria applicable to structures and foundation design.

1.3 Types of Construction

Non-fireproofed equipment support structures shall be designed of structural steel. Structures or equipment supports which require fireproofing may be constructed of reinforced concrete.

Fireproofing of structures, if required, shall be accomplished by utilization of reinforced concrete superstructures, (pre-cast or poured-in-place) or by application of the Company approved proprietary fireproofing systems applied to structural steel framing.

Fireproofing of structural steel columns and of compression or tension members shall totally encase the steel. The top flange of horizontal steel beams, shall be exposed to support piping, equipment or flooring, top of steel shall be 3-mm minimum above fireproofing.

2.0 LOADING CRITERIA

Refer to Section 4.0, Specification M-001 for design load definitions, loading conditions, load combinations and stability requirements. Criteria shown therein shall apply to design of structures and foundations.

2.1 Wind Loads



Wind loads shall be calculated and applied to vessels, equipment, structures, ladders, platforms and stairs in accordance with M-001, ASCE 7-88 and with the following:

F = qzGhCfAf (refer to Table 4, page 27 of ASCE 7-88)

Interpretation of values for Cf and Af shall be:

2.1.1 Vessels, Cylindrical Equipment & Piping

Af shall equal projected area of vessel or similar equipment and piping, plus insulation, exposed to wind. Cf shall be derived from Table 12, ASCE 7-88 round shapes for applicable D /qz value.

2.1.2 Open Structures

Af shall equal projected area of windward frame exposed to wind plus area of any additional members in successive bays, i.e., AA + AB + AC etc. Assume no shielding for AB, AC, etc.

Cf shall be determined from ASCE 7-88, Tables 10 through 15.

2.1.3 Ladders, Handrails, Stairs, Miscellaneous Equipment

For circular platforms on vertical vessels, Af shall be based on the maximum projected area of platform, handrail, etc., up to 180 of platform size. Af on rectangular platforms, stairs, handrails, ladders and miscellaneous equipment shall equal the net projected area of elements exposed to wind.

Cf shall equal 2.0 for all of the above.

3.0 FRAME SYSTEMS

3.1 Steel Framed Structures

Steel framed single or multilevel equipment structures shall be designed to provide adequate support for equipment and to provide necessary access for service and maintenance.

Frames transverse to centerlines of exchangers and horizontal vessels shall normally be either rigid frame with moment connections or a knee-braced design



using simple connections. Frames in the longitudinal direction should utilize either knee bracing, K-bracing or cross bracing.

Permissible lateral deflection of frames due to combined wind, thermal and operation-related loads shall be h/180.

3.2 Concrete Framed Structures

Concrete framed structures for support of equipment shall be open rigid frame, having 100% fixed column base conditions.

3.3 Steel Buildings

Metal covered buildings shall be either engineered type or pre-engineered. Engineered steel buildings shall be clear span, rigid frame type. Column base conditions shall be pinned in both directions.

3.4 Masonry Building Frames

Masonry buildings shall be one of the two following types:

Load bearing exterior masonry walls. Joists and flat metal roof deck supported by exterior walls and interior columns as required.

Non-load bearing exterior masonry walls. Joists and flat metal roof deck supported by steel column and beam frame system.

Lateral bracing shall be accomplished by means of one of the two following systems.

Exterior masonry walls parallel to wind direction to act as shear walls resisting total horizontal force of wind. Roof deck to act as a diaphragm transmitting horizontal force of wind to shear walls.

Where a steel column and beam frame system is employed for support of roof deck, braced frames or rigid frames may be utilized to resist total horizontal wind force.

Design of concrete masonry walls shall be in accordance with ACI 531.

3.5 Stairways and Ladders



Ladders required to have cages shall be side step-off in all cases where access and layouts permit.

Stairways shall have a minimum width of 750 mm, a minimum tread width of 250 mm, a maximum riser of 200 mm and the maximum vertical distance between landings (for open equipment structures) shall be 5.5 m. treads shall have non. Slip or abrasive nosing.

Stairway runs on the same structure shall have, if possible, the same slope.

4.0 VIBRATION CONTROL

Vibration isolation pads shall be installed at support points for noise and vibration attenuation for any steel supporting structures subject to vibration. Specifically, design shall require furnishing of effective isolation pads:

Between base plates of air fin cooler support points and steel substructure.

Between column base plates and corresponding piers for platform framing installed on compressor foundations or mats.

Isolation pads are to be omitted where pad temperatures will continuously exceed 65C or rigidity of support is critical. Anchor bolts at support points requiring isolation pads shall have isolating washers and bushings.

5.0 GENERAL FOUNDATION REOUIREMENTS

5.1 General Design

5.1.1 Load Conditions, Combinations

Design of foundations shall include all applicable considerations regarding design loads, loading conditions, loading combinations and stability as outlined in Section 4.0, Specification M-001.

5.1.2 Required Strengths



Footings and piers shall be proportioned for required strength in accordance with provisions of ACI 318, using load factors as specified in Chapter 9, except as modified herein. Provisions of Chapter 15 shall apply for design of footings.

The required strength, U, for test load shall be, U = 0.83 (1.4 x test load).

The following soil loading conditions shall apply:

Allowable soil bearing pressure may be increased 33% for wind or seismic loading.

The allowable soil bearing pressure may not be increased for test loading.

5.2 Allowable Settlement

5.2.1 Settlement Sensitive Equipment

Foundations or piers for closely connected equipment sensitive to differential settlement shall be placed on common mats to limit differential settlement between the connected equipment. This requirement shall apply to foundations for:

Directly connected recoilers to vessels

Drivers to rotating machines

Bottle supports near compressor cylinder discharge or suction connection

Heater support columns

Combinations of equipment and piping where differential settlement will cause excessive piping, nozzle or flange stress.

5.2.2 Differential Settlement

Design of foundations of soil bearing type where differential settlement can be tolerated in structures and piping shall limit differential settlement as follows:

Equipment structure: 7 mm for concrete frame; 13 mm for steel frame.

Between pipe rack columns; 7 mm for concrete frames; 13 mm for steel frame.

Between vessels, exchangers and pumps connected with moderately flexible piping: 13 mm.



Masonry building foundations: 7 mm.

Metal building foundations: 13 mm.

5.2.3 Total Settlement

Design of foundations shall limit total settlement as follows:

Equipment structures, Pipe racks individual equipment, buildings; 20 mm.

Storage tanks: 20 mm consolidation settlement after pre-loading at water-test: 75 mm total.

5.3 Foundation Elevations

The depth of soil bearing foundations must extend to a minimum of 450 mm below finished grade level or per recommendation by soil report.

The elevation of the top of grout shall be a minimum of 300 mm above high point of paving or of finish grade.

5.4 Anchor Bolts

ASTM A-36 steel anchor bolts shall be anchored either by means of an L or by an anchor plate welded to bottom of bolt. Maximum allowable tensile stress shall be 0.6 times the yield strength on tensile stress area.

ASTM A-193 steel anchor bolts shall be anchored by means of an anchor plate secured to bottom of bolt between two nuts of a threaded section of lower end of bolt.

Coupled bolts may by utilized to facilitate equipment installation.

The adequacy of bolt anchor devices must be substantiated by analysis. Corrosion allowance is not required on anchor bolts. Anchor bolts shall be provided with two nuts, one of which will serve as a lock nut.

All anchor bolts and accessories shall be hot dip galvanized.

The minimum distance from the edge of the concrete to the centerline of the bolt shall be 100 mm or 4 bolt diameters, whichever is greater, unless each anchor bolt is tied back with the equivalent of the 90 corner of a tile, as follows:

Minimum Size of



Bolt Diameter Reinforced Bar Tie

Up to 25 mm 10 mm diameter

Over 25 mm to 40 mm 12 mm

Over 40 mm 16 mm

5.5 Sleeves

Anchor bolt sleeves, where utilized, shall be either made from 28 gauge galvanized sheet metal or of the manufactured PVC type.

Provide 75-mm minimum clearance between the edge of the foundation and face of anchor bolt sleeves.

Special care shall be taken to assure that sleeves around anchor bolts are, in all cases, completely filled with grout before grouting under base and ring plates.

Sleeves of anchor bolts for compressor foundations shall be filled with elastic material or styro foam.

5.6 Slide Plates

Slide plates shall be required for use between top of foundations or pier and equipment base plate for equipment operating subject to movement from thermal expansion or contraction. Specific applications are horizontal exchangers and vessels, heaters and furnaces. Slide plates shall be A-36 smooth plates, Hot-dip galvanized.

6.0 VERTICAL VESSEL FOUNDATION DESIGN

Vertical vessels are assumed self-supporting. Maximum anchor bolt tension and foundation size shall be determined from the maximum of anyone of the several design conditions.

6.1 Anchor Bolts

Maximum tension force for sizing anchor bolts shall be at least equal to the following:



Tension (kg) = 4M/ N*BC W/N

Where: M = Maximum overturning moment at base of vessel m-kg

N = Number of anchor bolts

BC = Diameter of bolt circle m

W = Weight of Vessel kg

Frictional resistance to shear between vessel base plate and concrete or grouted bearing surface shall be neglected. Adequate mechanical means shall be provided to resist horizontal shear either through anchor bolts or through a combination of anchor bolts, shear lugs or other devices.

Unit shear per bolt shall be:

Shear/bolt = Maximum shear at vessel baseNumber of anchor bolts

6.2 Pedestal Design

6.2.1 Sizing

Concrete pedestals supporting vertical vessels shall be sized in 50-mm increments according to the following criteria:

Face-to-face pedestal size shall be no less than the larger of:

Bolt circle + 180 mm

Bolt circle + 8 bolt diameters

Bolt circle + sleeve diameter + 150 mm

Diameter of base-plate + 100 mm

Pedestals 1.2 m and over in diameter shall be octagonal in shape; less than 1.2 m uses a square shape. For ease of forming, use multiples of 50 mm for each octagonal side.

Provide 50 mm. minimum between face of pedestal and edge of equipment base or slide plates.

6.2.2 Reinforcing


OLEFINS PLANT EXPANSION PROJECT PROJECT SPECIFICATION

The pedestal shall be tied to the footing with sufficient dowels around the pedestal perimeter to prevent separation of the pedestal and footing. Use a class C splice for dowels, in accordance with ACI 318.

Dowels are sized by computing the maximum tension existing at the pedestal perimeter due to overturning moments.

Minimum pedestal reinforcement shall be as follows:

Octagon 1.2 m to 1.8 m: 8-12 mm vertical with 12 mm ties at 380 mm maximum

Octagons over 1.8 m to 2.7 m: 16-16 mm vertical with 16 mm at 380 mm maximum

Octagons over 2.7 m to 3.7 m: 24-19 mm vertical with 20 mm ties at 300 mm maximum

Octagons larger than 3.7 m: 32-19 mm vertical with 20 mm at 300 mm maximum

Pedestals over 1.8 m in diameter shall have a mat of reinforcing steel or mesh in top.

6.3 Footings

Footings for vertical vessels shall normally be octagonal in shape and sized 50-mm increments for each octagonal side. Offsets and combined footings shall be avoided where possible. Footings less than 2.1 m face to face dimension, shall be square.

The footing thickness shall be 300-mm minimum and thickened in 50-mm increments. The thickness of the footing should be adequate for the embedment length of the dowels or anchor bolt hooks, if anchor bolts are extended into footing.

The maximum bottom footing reinforcing shall be a 16-mm diameter bar at 300-mm center to center.

7.0 HORIZONTAL VESSEL AND EXCHANGER FOUNDATION DESIGN

7.1 Load Distribution for Exchangers



Vertical loads from exchanger reactions should be derived from the location of the center of gravity. Where impractical to obtain definite location of the C.G., distribution of the exchanger loads may be distributed in the proportion of 0. 6 to the channel end support and 0.4 to shell end support.

Bundle pull force shall be applied at center of bundle or of top bundle in stacked arrangement and shall be resisted by fixed pier only. If exchanger is designed to use a Bundle Puller to remove bundle by jacking against exchanger shell, then bundle pull load should be zero.

7.2 Slide Plates

Slide plates shall be used on both piers. The coefficient of friction shall be considered 0.3, and per manufacturer s recommendation for low friction slide plates.

7.3 Pier Design

Sizing - Unless controlled by other factors, normal pier dimensions shall approximate support base plate size plus 100 mm. Pier thickness should be approximately 10% of pier height with a minimum thickness of 250 mm. Overall pier dimensions shall be in 50-mm increments.

If foundation design employs drilled shaft footings, consideration must be given to center to center spacing of drilled shaft and to spacing of vertical bars projecting from drilled shaft in determination of final thickness and width.

Both piers shall normally be alike as to size, reinforcement, anchor bolts and slide plates.

Minimum vertical pier reinforcement shall conform to requirements of ACI 318 Section 10.5. Minimum horizontal reinforcement shall not be less than 0.0025 times gross cross sectional area of pier.

A double tie shall be placed at top of piers spaced 50 mm at 125 mm below top of concrete or below bottom of grout to protect top of pier against cracking.

7.4 Column Design

Sizing - the columns for T-type supports may be round or rectangular. However, it is desirable to standardize column dimensions and shapes as much as possible in order to simplify forming. Column dimensions shall be in 50-mm increments.



Both columns and T-head beams shall normally be alike as to size and reinforcement.

7.5 Spread Footings

Common Mat - Consider uses of common or combined footing when pier spacing is 3.7 m or less.

Two Spread Footings - Recommended when pier spacing is greater than 3.7 m.

Footing dimensions shall be in 50 mm multiples. Minimum footing dimensions shall normally be pier dimension plus 300 mm. Minimum footing thickness shall be 300 mm.

8.0 STORAGE TANK FOUNDATION

8.1 Large Tanks

Foundations for tanks larger than 4.6-m diameter shall be earth foundations with a concrete ring wall. Recommendations contained in API 650 Appendix B shall apply.

Ring wall top of concrete shall be 300-mm minimum above adjacent finished grade. Bottom of ring wall shall extend 450-mm minimum below finished grade. Ring wall width shall be proportioned in accordance with Section B.4.3.2 API 650.

Lateral pressure against the ring wall due to the confined fill with surcharge shall be calculated in accordance with parameters provided in Project Soils Report. Minimum reinforcement in ring wall shall be no less than recommended in Section B.4.4.4 of API 650.

Cutouts in ring wall required for bolted doors, clean outs or bottom piping connections shall be in compliance with recommended details per API 650.

8.2 Small Tanks

Foundations for steel tanks 4.6 m diameter or smaller and for fiberglass tanks shall be concrete slab type. Top of concrete shall be 300-mm minimum above finished grade. Foundation may consist of a 150-mm minimum center slab with perimeter thickened to a depth of 300 mm below grade. Reinforcement for temperature, shrinkage and continuity shall be provided.



8.3 Earthwork

Earth fills material, compaction of earth and preparation of sub-grade shall comply with recommendations in the Project Soils Report. Earthwork must be adequate to support tank without exceeding allowable soil pressure and to hold settlement within recommended limits under hydrotest or operating loads. The specified density for tank pads shall apply to all earth material within the confines of full height of ring wall.

9.0 BUILDING FOUNDATIONS

9.1 Foundation Types

The following general foundation types shall be furnished:

Masonry Buildings - continuous strip footing. Where perimeter columns or pilasters require additional support, footings shall be combined with strip footing. Slab-on-grade shall be isolated from foundations.

Enclosed Steel Framed Metal Buildings - Continuous grade beams supported on spread footings with column pedestals. Slab-on-grade shall be isolated from foundations.

Open Steel Framed Buildings (Compressor Buildings) - Individual spread footings with column pedestals. Slab-on-grade shall be isolated from foundations.

Small Self-Framing Buildings - Floating slab-on-grade with stiffening beams around perimeter and through interior as required.

9.2 Joints

The following types of joints shall be provided in building slabs, wall and foundations:

Isolation Joints - Required where floor slabs must be isolated structurally from other building elements to avoid differential horizontal and vertical movements caused by vibrating equipment. Isolation joints shall be placed at junctions with walls, columns, machine foundations, or points of restraint, such as drainpipes and piers projecting through the slab. These joints shall consist of a 12 mm thick



strip of asphalt impregnated fiber sheet and extend the full depth of the joint. Reinforcement bars should not go through any isolation joints.

Control or Contraction Joints - Shall be used to control slab or structure cracking by providing a plane of weakness in the concrete element at 4.6 to 6.1.m centers.

9.3 Floor Slabs

Floor slabs-on-grade shall be adequate to support applicable concentrated and/or wheel loads. A ratio of slab reinforcement of 0.0018 (reinforcement area to gross concrete area) shall be provided. Control joints shall be provided as noted above.

100-mm minimum compacted sand fill shall be placed on sub-grade beneath all building floor slabs.

0.15 mm polyethylene film shall be provided beneath floor slabs to assist in the control of curing.

9.4 Grade Beams

Grade beams shall be designed as flexural members of ACI 318 based on lateral and vertical loading conditions. Bottom of beam must be a minimum of 300 mm below finished grade. Grade beams shall normally be loaded to span from footing to footing assuming no support by the ground. Minimum reinforcement shall be as controlled by ACI 318 Section 10.5.1.

10.0 DRILLED SHAFT FOUNDATIONS

Drilled shaft footings may be used in lieu of spread footings in most applications where practical, with the exception of compressor foundations and tall vertical vessel foundations.

In utilizing drilled shaft footings for pier support, generally two or more drilled shafts shall be located beneath each support and pier. If equipment or structural support is very small, consideration may be given to placing each pier on a single



drilled shaft. Each application of drilled shaft footings which resist overturning as well as vertical loads must be justified by an acceptable method of calculation.

Design Criteria for Embedment of Piers by E. Czerniak presents an acceptable method for determining the capacity of drilled shafts to resist applied lateral forces and moments. Recommendations concerning Drilled Pier Foundations contained in the Project Geotechnical Report shall also apply to drilled shaft design.

Drilled shaft design shall provide adequate reinforcing steel for compressive, tensile and bending loads.

Minimum shaft embedment in concrete cap or foundation shall be 75 mm. Drilled shafts designed for tension or for single shaft applications or for support of reciprocating equipment shall be embedded 300-mm minimum into foundation. For tension loading, tension ties or anchors shall be provided.

11.0 GROUTING AND FINISHING

11.1 Grouting

A minimum of one inch of Portland Cement grout shall be used on foundations for small vessels, small equipment and small column base plates.

Dry-pack motor may be used if grouting can be achieved without void.

Non-shrink grout or epoxy grout shall be employed for mechanical equipment vessels and large column base plates as covered in Section 5.4, Specification M-001.

11.2 Finishing

Required finishes for concrete are as follows:

Exposed surfaces of formed foundations and structures - concrete to be left with surface finish imparted by forms objectional irregularities shall be removed and voids pointed up.

Exposed top surface of foundations - Wood float surface to depress coarse aggregate and steel trowel to smooth even surface free from defects.

Exposed grout surfaces - Steel trowel to smooth even surface.



Interior floor slabs - Wood float surface to depress course aggregate and steel trowel to smooth even surface free from defects.

Exterior slab, walks, building stoops - Wood float surface to depress course aggregate. When surface is true and even use broom to produce a uniform texture.

11.3 Scoring and Edging

Required edgings are:

Exposed edges or salient corners of above grade foundations and structures - 25-mm chambers formed by beveled wood strip in internal angles of form.

Slabs - Use round tooled edge on corners and scored or sawed groove for control joints.

12.0 TRENCH DRAINS

Slab trenches where required for drainage of water or combinations of wastewater shall be modular type, pre-cast, interlocking polymer concrete channels. Matching grates shall be cast iron, ductile iron, stainless steel or fiberglass as required for adequate corrosion resistance.

13.0 CONCRETE WATER CONTAINMENT BASINS

Joint design, use of sealant and use of water stops, shall comply with recommendations contained in ACI 504 R-77, Guide to Joint Sealant in Concrete Structures. PVC water-stops shall be used for all construction joints subject to a containment of water as follows:

225-mm minimum, serrated with center bulb where joint is subject to movement.

225-mm minimum, serrated without center bulb where joint will not be subjected to movement.




N-002

FIREPROOFING


1 28/04/00 Issue for ITB PM SWK JN

0 02/02/00 Issue for review PM SWK JN


SPEC. NO. N-002 REV.2 PAGE 1 OF 19


FIREPROOFING

TABLE OF CONTENTS

1.0 SCOPE

2.0 DRAWINGS, CODES AND STANDARDS

3.0 FIREPROOFING REQUIREMENTS

4.0 MATERIALS

5.0 APPLICATION

1.0 SCOPE



This Specification defines the basic requirements for design, materials, and application of fireproofing for structures, equipment, and supporting elements of piping and equipment, cable trays, and conduit banks located in fire potential areas of process plants.

No variations from this specification are permitted unless approved in writing by the Company.

Contractors shall define scope of fireproofing and agreed by company at early stage of the project.

2.0 DRAWINGS, CODES AND STANDARDS

The following reference documents are the minimum standards required for the project.

NFPA No. 321-87 - Standards of Basic Classification of Flammable and Combustible Liquids.

UL-1709 (P) Proposed First Edition of the Standard for Rapid Rise. Fire Tests of Protection Materials for Structural Steel.

Underwriters Laboratories, Inc. Fire Resistive Directory American Welding Society (AWS) ASTM Joint Specifications for

Welding Electrodes.

ASTM-C-150 - Portland Cement Specification (Dense Type Fireproofing) ASTM-E-119 - Fire Tests of Building Construction and Materials. American Concrete Institutes Building Code Requirements (ACI-318). National, State, and Local Laws and Codes shall apply when they contain

more stringent requirements than contained herein.

IRI-IM 2.5.1 June 1, 1998 fireproofing for hydrocarbon fire exposures.

3.0 FIREPROOFING REQUIREMENTS



3.1 Definitions

Fire Potential Equipment: Vessels, pumps, compressors, piping, heat exchangers, fired heaters/furnace and other equipment containing flammable or combustible liquids or vapors, or both, which are potential fire sources, shall be considered fire potential equipment. Classification of flammable and combustible liquids shall be in accordance with NFPA No.321.

Fire Potential Areas:

Inside Process Battery Limits a. Areas containing fire potential equipment

b. Areas containing nonflammable but potentially hazardous materials within 15 m. of fire potential equipment.

c. Areas containing nonflammable materials where failure of equipment support could endanger personnel or cause severe damage to the unit or other fire potential equipment thereby increasing the severity or prolonging the duration of the fire.

Outside Process Battery Limits a. Areas within 15 m. of fire potential equipment.

b. Areas containing pressure storage spheres.

3.2 General

3.2.1 Structural elements supporting fire potential equipment shall have minimum 3-hour hydrocarbon fire protection.

3.2.2 Structural elements supporting not fire potential equipment in a fire hazardous area shall be fireproofed only if the following conditions exist:

a. The equipment is essential for controlled shutdown of the plan.

b. Failure of the equipment would damage fire potential equipment, or other equipment essential to controlled shutdown of the plant.

3.2.3 Terminations of fireproofing on steel shall be sloped to shed water and sealed with mastic to prevent moisture from entering between fireproofing material and the steel surface. Typical examples are top edges of fireproofing on beams whose



top flanges are not fireproofed, and top edges of fireproofing on columns, vessel legs and vessel skirts of non-insulated vessels.

3.2.4 Fireproofed members resting on foundations shall have their base plates and anchor bolting fireproofed unless otherwise noted on drawings.

3.2.5 Ratings of fireproofing materials, in hours of protection, shall be as listed by Underwriters Laboratories Inc. or other acceptable testing laboratory, using test procedures described in ASTM El19.

3.3 Extent of Fireproofing

3.3.1 Structures

When supporting fire potential equipment within the battery limits, columns, beams and horizontal strut bracing of structural steel shall be fireproofed from grade to an elevation where the highest important equipment load is applied to the structure.

All bracing which contributes to the support of vertical loads or stability of columns shall be fireproofed when part of a fireproofed supporting system with the following additions or exceptions:

a. On structures over 9 m. in height, wind bracing shall be fireproofed.

b. On structures less than 9 m. in height, bracing used only for wind loading need not be fireproofed. When bracing is not subject to vertical loads.

Platforms, runways, stairways, and their supports need not be fireproofed.

The top flange of structural steel that supports floor plate need not be fireproofed. See Figure 4.

3.3.2 Pipe Racks/ Pipe Supports

Process area pipe racks and interconnecting pipe ways, which support piping only, shall be fireproofed from their bases up to and including the pipe support beam leaving the upper most surface of the top flange exposed.

Structural steel supports of main pipe racks outside process areas shall be fireproofed from their bases up to and including the pipe supporting cross beams.

Pipe rack bents supporting fire potential equipment in addition to piping shall be fireproofed up to the point of support of the equipment.



Fireproofing of pipe supports shall include vertical and horizontal load-bearing members and load-bearing bracing.

Both the vertical and horizontal members of the first transverse level of pipe racks located within 15 m. of fire potential equipment shall be fireproofed, struts below such first level shall be fireproofed. Fireproofing in this area shall have a 3-hour rating. Pipe rack structures supporting Non-Hydrocarbon and more than 15 m. from any fire potential equipment normally would not need fireproofing unless unusual conditions of exposure or loading exist.

If air-coolers are installed above pipe racks, the pipe racks shall be protected with fireproofing from grade up to the level supporting air-coolers. All horizontal structural members supporting air-coolers, including those cantilevered beyond the vertical supports shall be fireproofed.

Pipe rack supports above the first level need not be protected, unless unusual conditions of exposure or loading exist.

For fire potential areas, miscellaneous supports for pipes which contain hydrocarbon shall be fireproofed.

The top flange of pipe bearing beams need not be fireproofed. See Figure 4.

3.3.3 Equipment Supports

All lugs, brackets, skirts, and legs supporting fire potential equipment located within the fire potential area and below a minimum height of 10 m. shall be fireproofed.

Saddles supporting equipment and measuring more than 300 mm in height at their lowest points shall be fireproofed within the fire potential area

On supports of vessels and exchangers having slots in their base plates for thermal expansion, fireproofing shall not interfere with the sliding motion of these supports.

3.3.3.1 Vessel Skirts

On insulated vessels, fireproofing shall extend from the foundation up to the insulation.

On vessels having no insulation, fireproofing shall extend from the foundation to the top of the skirt.

The outside of skirts supporting process vessels shall be fireproofed.



The inside of skirts over 1 m. in diameter and the bottom heads of noninsulated vessels on skirts over 1 m. in diameter shall be fireproofed.

Skirts less than 1 m. in diameter shall be fireproofed as follows:

1. Skirts with one access opening which is 400-mm diameter or smaller, and only welded connections within the skirt, shall be fireproofed on the outside only.

2. Skirts with an access opening larger than 400 mm in diameter or more than one access opening, or skirt with flanged or screwed connections within the skirt, shall be fireproofed inside and outside.

3. Where the inside of skirt is required to be fireproofed, bottom heads of uninsulated vessels shall be fireproofed, whereas insulation on bottom head shall be covered with stainless steel or galvanised steel jacket.

Skirts, which require insulation, shall be fireproofed on the non-insulated portions only. See Figure 2.

3.3.3.2 Air Coolers

Structural members supporting air-coolers shall be fireproofed as follows:

a. All members of supports for exchangers handling flammable liquids.

b. Only those structural members that are within fire potential areas, for exchangers handling non-flammable liquids.

3.3.3.3 Heaters

Main supports and all bracing, with the exception of wind bracing, shall be fireproofed up to the firing floor level.

3.3.4 Conduit Banks and Cable Trays

Conduit banks and cable trays vital to the emergency shutdown system of the plant and located within normal fire protection areas shall be provided with a minimum of a 30 minute fire protection system based upon testing in accordance with ASTM E119 fire test as a minimum standard fire test.

When utilizing a fire protective system for electrical power cables, special consideration should be given to the effects on high amperage cables caused by the heat retaining capacity of the fire protection system.



3.4 Method of Fireproofing

Methods of fireproofing resulting in a 3-hour rating are as follows:

a. Concrete: Seventy-five (75) mm

b. Lightweight Concrete: Fifty (50) mm

c. Lightweight Cementitious Products:

Thickness shall be the manufacturers specified thickness listed by the Underwriters Laboratories Inc. Fire Resistive Directory for an exterior use three (3) hour minimum fire resistance rating based upon testing in accordance with ASTM E119 fire test as a minimum standard fire test. Thickness shall be determined by probed measurements in accordance with the recommended procedure of ASTM E605 or other method approved by the Company.

4.0 MATERIALS

4.1 Concrete or Lightweight Concrete: Form Placed method and pneumatically applied.

Components for concrete fireproofing shall be as follows:

Concrete for both manual and pneumatic placement shall be mixed in the proportion as determined by the applicator in accordance with manufacturers recommendation so as to obtain a minimum compressive strength of 140 kg/cm2 at 28 days. Water/cement ratio shall not exceed 0.50. Ready mixed concrete in accordance with ASTM Specification C94 may be used

a.

b.

c.

d.

Cement shall be Type 1 Portland Cement conforming to ASTM C 150. Other cements may be used if required for special reasons, such as early strength or sulphate resistance.

Sand shall be commercial, high silica sand with clean, sharp, hard, durable particles conforming to ASTM C33.

For general purposes, aggregate shall be sharp and angular in nature and range in size from 6 mm to 12 mm and shall conform to ASTM C 33.



Where lightweight is essential, insulating type aggregates, such as perlite, vermiculite, expanded shale, or slag may be used.

Welded galvanised steel wire mesh, 50 mm x 50 mm x 3 mm shall be used for reinforcement.

e.

f.

g.

h.

i.

Lacing wire shall be 1.6 mm galvanised wire.

Carbon steel rectangular welding studs, Nelson RGP or equal, shall be used for securing wire mesh reinforcement to steel. Length of studs shall provide for 19 mm to 25-mm space between steel and the wire mesh. Carbon steel square or hexagonal nuts are also ac

Date post:	30-Oct-2015
Category:	Documents
Upload:	thai-woo-re
View:	236 times
Download:	15 times

Guide Procedure of Piping

Documents