RMP2G 0007 SP 001 Structural Design Criteria Rev a 20110412

PETRON BATAAN REFINERY PROCESS INTEGRATION SERVICE FOR REFINERY MASTER PLAN 2 (RMP-2) Job Number 04770H45 PROJECT DOCUMENT NUMBER RMP2G_0007_SP_001

DOCUMENT TITLE:

1 of 30

STRUCTURAL DESIGN CRITERIA

Petron Bataan Refinery Process Integration Service for Refinery Master Plan 2 (RMP-2)

Structural Design Criteria

For Review

A.R.Cortuna

S.S.Chang

I.S.Yoo

K.M.Leem

12-Apr-2011

A

For Review

A.R.Cortuna

S.S.Chang

I.S.Yoo

K.M.Leem

24-Mar-2011

AA

Description

Prepared

Checked

Approved

Authorized

Date

Revision

This document contains confidential proprietary material belonging to Axens and Daelim Consortium which may only be made available to personnel or organizations who have signed appropriate secrecy agreements.


DOCUMENT TITLE:


Page 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

2 of 30

REVISIONS AA X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

A O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O



DOCUMENT TITLE:


3 of 30

Table of contents 1 SCOPE ................................................................................................................................. 4 2 CONFLICTS, DEVIATIONS AND CLARIFICATIONS ................................................. 5 3 REFERENCES .................................................................................................................... 6 4 DEFINITIONS ...................................................................................................................... 8 5 DESIGN LOADS ................................................................................................................. 9 6 LOAD COMBINATIONS .................................................................................................. 15 7 STRUCTURAL DESIGN .................................................................................................. 20 8 AUXILIARY STRUCTURES FOR OPERATION AND MAINTENANCE................. 28 9 PLANT BUILDING FOR OPERATION AND STORAGE .......................................... 29 10 BLAST RESISTANT BUILDINGS ................................................................................. 30



DOCUMENT TITLE:

1


4 of 30

SCOPE This document establishes the mandatory minimum requirements governing the structural design of concrete and steel structures for Petron Bataan Refinery Master Plan-2 (RMP-2) Project located at the existing Petron Bataan Refinery site, west shore of Manila Bay in Limay, Bataan, Philippines. These structures include but are not limited to structures associated with elevated tanks, vessels, and piperacks. This document contains material, design loads, load combinations, and design basis as well as codes, standards and specifications. For items not covered in this document, technical specification, code and standard specified herein shall be followed.



DOCUMENT TITLE:

2


5 of 30

CONFLICTS, DEVIATIONS AND CLARIFICATIONS Any conflicts between this standard and other applicable Company Engineering Standards, Material Specifications, Standard Drawings, Engineering Procedures, Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution. Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern. Where a licensor specification is more stringent than those of this standard, the Licensor’s specific requirement shall apply. Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to attention of Company Representative by Contractor for resolution. Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.



DOCUMENT TITLE:

3


6 of 30

REFERENCES The selection of material and the design of structures and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted. Company References – GP 04-01-01 - Concrete Design and Construction – GP 04-01-02 - Structural Steel Design – GP 04-01-03 - Design Loads for structures – GP 04-01-04 - Surge Vibration Design Loads – GP 04-02-01 - Auxiliary Structures for Operation and Maintenance – GP 04-02-02 - Pipe Supports – GP 04-03-01 - Plant Buildings for Operation and Storage – GP 04-03-02 - Blast Resistant Buildings – GP 04-03-03 - Shelters for Process Analyzers – GP 04-03-04 - Special Category 3 Blast Resistant Buildings – GP 04-06-01 - Reinforced Concrete Foundations, Anchor Bolts and Grout – GP 04-06-01 - Supporting Structures and Foundations for Heavy Machinery – GP 14-03-01 - Fireproofing – GP 18-07-01 - Welding Procedures – GP 19-01-01 - Paint and Protective Coatings

Industry Codes and Standards American Association of State Highway & Transportation Officials (AASHTO) – AASHTO HB16 - Standard Specifications for Highway Bridges American Concrete Institute (ACI) – ACI 318/318R - Building Code Requirements for Structural Concrete and Commentary – ACI 349 - Code Requirements for Nuclear Safety Related Concrete Structures – ACI 207.1R – Mass Concrete American Institute of Steel Construction (AISC) – AISC S335 - Specification for Structural Steel Buildings Allowable Stress Design and Plastic Design with Commentary – AISC M020L - LRFD Manual of Steel Construction – AISC S335 - ASD Manual of Steel Construction



DOCUMENT TITLE:


7 of 30

– AISC 335-89s1 - Supplement No. 1 to the Specification for Structural Steel Buildings, Allowable Stress Design and Plastic Design – AISC S342L - Load and Resistance Factor Design Specification for Structural Steel Buildings American Society of Civil Engineers (ASCE) – ASCE 7 - Minimum Design Loads for Buildings and Other Structures "Wind Loads and Anchor Bolt Design for Petrochemical Facilities." 2002. American Society for Testing and Materials (ASTM) – ASTM A 36/A 36M - Standard Specification for Carbon Structural Steel – ASTM A 193/A 193M - Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service – ASTM A 194/A 194M - Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both – ASTM A 307 - Standard Specification for Carbon Steel Bolts and Studs, 60 000 psi Tensile Strength – ASTM A 325 - Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength – ASTM A 563 - Standard Specification for Carbon and Alloy Steel Nuts – ASTM A 1011/A 1011M - Standard Specification for Steel, Sheet and Strip, HotRolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability Local Codes and Standards Local codes and standards may be substituted for the ones referenced herein provided that the resultant design meets the safety and serviceability criteria attained through the references above and substitution is accepted by the authorities where the facility is to be located and by Owner’s Engineer.



DOCUMENT TITLE:

4


8 of 30

DEFINITIONS Definitions presented in this document have precedence over other definitions. Conflicts between various definitions shall be brought to the attention of Company Representative by the Contractor for resolution. Company : Petron Bataan Refinery. Company Representative : A designated person from the Company or an assigned third party representative. Company Inspector : A designated person or an agency responsible for conducting inspection activities on behalf of the Company.



DOCUMENT TITLE:

5


9 of 30

DESIGN LOADS General

5.1.1 The following basic loads that shall be considered in the structural design include : 5.1.2 Dead Loads 5.1.3 Live loads 5.1.4 Operating loads including fluid, impact, piping restraint, surge vibration, thermal, and vibration loads

5.1.5 Maintenance loads including bundle pull loads 5.1.6 Environmental loads including earthquake, snow, ice, rain, and wind loads 5.1.7 Construction loads including erection forces and transportation loads 5.1.8 Basic loads shall be as defined in ASCE 7 except as clarified and supplemented below:

5.1.9 Live loads include personnel, portable machinery, tools, and equipment; material to be temporarily stored during maintenance, such as exchanger parts, pipe and fittings, valves; material normally stored during operation such as tool, maintenance equipment, catalyst, and chemicals.

5.1.10 Fluid loads are the gravity loads resulting from liquid, solids such as packing, catalyst or inerts, or fluidized solid materials in equipment and piping during operation or hydrotest.

5.1.11 Piping restraint loads are forces on pipe anchors and guides resulting from thermal expansion, surge, or internal pressure of the piping.

5.1.12 Impact loads are loads that account for the dynamic effects from moving equipment such as traveling cranes, elevators, hoists, and vehicular traffic.

5.1.13 Bundle pull load is force resulting from the removal of a tube bundle from a heat exchanger.

5.1.14 Surge vibration loads are lateral inertia forces caused by the surging action of fluidized solids.

5.1.15 Construction loads are temporary loads caused by the erection and construction of structures and equipment, such as loading from guy rigging, shoring, etc.



DOCUMENT TITLE:

10 of 30


5.1.16 Transportation loads are inertial loads caused by the movement of structures and equipment from a fabrication site to the installation site.

5.1.17 Basic loads shall be determined according to the applicable codes and standards listed in Sections 5.1.1 and 5.1.2 as modified or supplemented herein.

5.1.18 Live Loads

5.1.19 Minimum live loads which shall be used to design structural elements and appurtenances shall be per ASCE 7 except as modified below: Minimum Live Loads Component Design

Loaded Area

Minimum Live Load

1. Walkways and Access Platforms

100 psf (4.8 kN/m2)

2. Platforms for Operating Storage or Maintenance Storage Loads

125 psf (6.0 kN/m2)


60 psf (2.9 kN/m2) or a Moving Concentrated Load of 1000 lb (4.4 kN)


125 psf (6.0 kN/m2)


60 psf (2.9 kN/m2) or a Moving Concentrated Load of 1000 lb (4.4 kN)


125 psf (6.0 kN/m2)

Roofs (Sloped or Flat)

--

20 psf (1.0 kN/m2)

Control Room, HVAC Room, Electrical Panel Room, Battery Room

--

100 psf (4.8 kN/m2)

Floor Plate, Grating, and Slabs

Floor Framing and Bracing

Columns and Brackets

Note (1): May be reduced based on influence area per ASCE-7.



DOCUMENT TITLE:


11 of 30

Wind Loads

5.1.20 Wind loads shall be calculated based on procedures provided in ASCE 7 with the following additions/clarifications.

5.1.21 Basic Wind Speed (V) and Importance Factor (I) shall be 232 km/h (64.4 m/s) and 1.15, respectively.

5.1.22 Exposure Category C shall be used unless the terrain condition of the site justifies a different exposure category subject to the approval of the Owner.

5.1.23 Gust effect factors for flexible building and structures may be calculated by alternate methods acceptable to the Owner. A building or structure shall be considered flexible only if it has a fundamental natural frequency less than 1Hz.

5.1.24 Force coefficients (Cf) for typical petrochemical facilities not specifically covered by ASCE 7, such as multiple-bay open-frame structures containing equipment, pipe racks, vessel with appurtenances, etc., shall be determined based on guidelines provided in ASCE report "Wind Loads and Anchor Bolt Design of Petrochemical Facilities."

5.1.25 The total wind force on equipment support structures may be determined as the sum of the forces on each component in the structure. Components shall include: equipment and supports (without considering shielding), piping, structural framing, ladders, stairs, and other miscellaneous objects attached to the structure. However, the total force due to wind for an ordinary structure need not exceed that of an enclosed structure that would completely envelope the structure and attachments.

Earthquake Loads

5.1.26 Earthquake loads for structures shall be calculated and applied in accordance with UBC-97 with the following values:

5.1.27 Seismic Importance Factor ‘I’ = 1.0 and Seismic Zone Factor ‘Z’ = 0.4 shall be applied for all structures and buildings. Other factors shall be as per UBC-97.

5.1.28 Load factors applied to earthquake loads shall be consistent with the strength (limit states) design or allowable stress design method, as appropriate.

5.1.29 When a dynamic analysis is required by the applicable code, it shall be based on the seismic response spectrum method to determine the earthquake forces and structural response.



DOCUMENT TITLE:


12 of 30

Process Loads

5.1.30 The operating contents of vessels including liquid, catalyst, inert balls, packing, etc. shall be treated as Fluid loads per ASCE 7 and shall be based on the maximum level that may occur during operation.

5.1.31 Vibration loads shall be based on process design or equipment specifications, or manufacturer data, whichever is governing. They shall be considered as live loads in the selection of load factors or safety factors in the applicable load combinations.

5.1.32 Surge forces vibration loads for support structures and vessels for fluid-solids shall be per GP 04-01-04. Load factors and combinations shall be subject to Owner's approval.

5.1.33 Impact loads for hoist and equipment handling facilities shall be as follows: 5.1.34 Impact load shall be considered a variable load, similar to live load in the selection of load factors, safety factors, and load reduction factors in the applicable load combinations.

5.1.35 Vertical, lateral, and longitudinal impact loads on the supports for moving bridge cranes, trolleys and davits, and monorail cranes shall be per ASCE 7 or the AISC specification, as applicable.

5.1.36 Davits (exclusive of manhole davits) shall be designed for the weight (mass) of the heaviest piece of equipment that they may be required to lift, plus the weight of rigging equipment, plus the impact load, but not less than a total load of 1000 lb (4.4 kN). Design shall be based on use of a single sheave pulley block. All davits shall be legibly marked with the safe working load (SWL).

5.1.37 Impact loads for other moving equipment shall be determined in conjunction with the equipment manufacturer.

5.1.38 Thermal loads shall be considered for support structures, foundations, and elements thereof based on the effects of differential temperature, and shall reflect the following:

5.1.39 Thermal loads shall be considered as a self-straining force per ASCE 7 in the selection of load factors or safety factors in the applicable load combinations.

5.1.40 Thermal effects shall be based on the difference between ambient or equipment design temperature and the installed temperature, whichever is more severe.



DOCUMENT TITLE:


13 of 30

5.1.41 Forces due to sliding friction shall be considered as a self-straining force per ASCE 7 and shall be based on the following coefficients of static friction:

5.1.42 Teflon on Teflon: 0.10 5.1.43 Steel on Steel: 0.40 5.1.44 Steel on Concrete: 0.45 5.1.45 Concrete on Soil: 0.50 5.1.46 The coefficient of static friction for use on proprietary sliding surfaces and coatings shall be per the manufacturer's specification and is subject to Owner's approval.

5.1.47 Pipe anchor and guide loads produced from thermal movement, internal pressure, and surge shall be considered as a self-straining force per ASCE 7 for determining applicable load combinations and allowable stresses or load factors, as appropriate.

5.1.48 Maintenance Loads

5.1.49 Bundle pull loads shall be considered for structures and foundations supporting heat exchangers subjected to bundle pulling during maintenance based on the following:

5.1.50 Bundle pull load shall be a longitudinal force equal to 100 percent of the tube bundle weight, but not less than 2000 lb (8.9 kN), applied at the centroid of the tube bundle.

5.1.51 Bundle pull load shall be considered as a live load. 5.1.52 Bundle pull force (shear) shall be assumed transmitted by only one (either) shell support, unless specified otherwise.

5.1.53 Construction Loads

5.1.54 Construction loads shall be determined in conjunction with the erection contractor and equipment manufacturer

5.1.55 Transportation loads for structures and equipment shall be as follows: 5.1.56 Transportation loads for sea going transport shall be based on the most extreme conditions from a minimum 10-year seasonal storm for the worst part of the route. Roll, pitch, and heave motion response of the barge/ship shall be developed in conjunction



DOCUMENT TITLE:


14 of 30

with the transportation contractor.

5.1.57 Transportation loads shall be considered as a variable load per ASCE 7 for the selection of load factors or safety factors in the applicable load combinations.

5.1.58 Other Loads

5.1.59 Vehicular loads shall be determined as follows: 5.1.60 For tired-vehicles (moving equipment) that operate on paved areas according to the AASHTO specification.

5.1.61 For railway equipment that operates on tracks-according to the applicable industry standards.

5.1.62 Hydrostatic Loads and Buoyancy shall be considered when a structure or equipment extends below water level, either temporarily or long-term as follows:

5.1.63 Structure or equipment shall be considered as empty when evaluating impact of buoyancy.

5.1.64 Water table level shall be assumed to be at grade unless otherwise approved by the Owner's Engineer.

5.1.65 Treatment of external hydrostatic pressure and buoyancy loads shall be the same as ground water load in ASCE 7.



DOCUMENT TITLE:

6

15 of 30


LOAD COMBINATIONS Loading conditions for buildings, structures, equipment, and foundations shall be according to ASCE 7, qualified local/national codes, and standards plus the load combinations shown in Table 2. Applicable Loads for Loading Conditions

Operation Loads

Erection

Testing

Empty (Shutdown) Normal

Abnormal (Upset)

Dead (Fixed) Loads X

X

X

X

X

X

X

X

X

X

X

X

plus internals, insulation

X

X

X

X

Dead Load of Piping plus insulation

X

X

X

X

Platform and walkway loads

X

X

X

X

Material storage

X

X

X

X

Dead Load of Structure

X

plus fireproofing Dead Load of Equipment

X

Construction Loads Forces caused by erection

X

Live (Moveable) Loads

Process Loads Normal fluid loads

X

Shutdown fluid loads

X

Thermal forces

X

X

Vibrating equipment forces

X

X

Impact forces

X

X

Normal surge forces Abnormal surge forces

X(4) X(4)



DOCUMENT TITLE:

16 of 30


Maintenance Loads X

Test fluid loads Bundle pull force

X(3)

Environmental Loads Snow, ice or rain

X

X

Earthquake (1) Wind, 3 second gust (1)

80% of full wind

X(2)

X

X

X

X

X

X

X

X(2)

Notes: (1) Wind and Earthquake are not considered to act simultaneously. (2) 1/3 full wind load or wind at 20 m/s, whichever is greater. (3) Bundle Pull shall not be combined with Wind or Earthquake. (4) Normal and abnormal surge loads shall be treated as variable loads. Load factors and combinations shall be subject to Owner's approval.

Design should be based on the load combination causing the most unfavorable effect. When excluding loads other than dead loads results in a more critical loading condition, then such exclusion shall be considered. Loads Factors and load combinations below shall be used for design of all structures and buildings:



DOCUMENT TITLE:


17 of 30

For Allowable Stress Design (Unfactored Combination) Case Erection

Load Combinations DLS + EQEP + CL + 0.8WL

Normal Operation

Abnormal Oepration

Empty Shutdown

Normal

DLSF + EQOP + PLOP + LL + FF + TF + AF

Wind

DLSF + EQOP + PLOP + 0.75LL + FF + TF + AF + 0.75WL

Earthquake

DLSF + EQOP + PLOP + 0.75LL + FF + TF + AF + 0.75(0.7EL)

Abnormal

(DLSF + EQOP + PLOP + LL + FF + TF + SF ) /1.2

Wind

(DLSF + EQOP + PLOP + 0.75LL + FF + TF + SF + 0.75WL) / 1.2

Bundle

DLSF + EQEP + PLEP + LL + BF

Wind

DLSF + EQEP + PLEP + 0.75LL + 0.75WL

Earthquake

DLSF + EQEP + PLEP + 0.75LL + 0.75(0.7EL)

Normal

(DLSF + EQTL + PLTL + LL) / 1.2

Wind (Note1)

[DLSF + EQTL + PLTL + 0.75LL + 0.75(WL/3)] / 1.2

Test

DLS : DLSF : EQEP : EQOP : EQTL : PLEP : PLOP : PLTL : CL : LL : FF : TF : AF : SF : BF : WL : EL :

Dead Load of Structrure Dead Load of Structure plus fireproofing Equipment Empty Weight Equipment Operating Weight Equipment Test Weight (If equipment test is done at shop, it can be ignored.) Piping Empty Weight (Note2) Piping Operating Weight Piping Test Weight Construction Load Live Load Friction Force Thermal Force Anchor Force Surge Force Bundle Force Wind Load Earthquake Load

Notes (1) (WL/3) shall be1/3 full wind load or wind at 20m/s, whichever is greater. (2) 0.6 PLOP is used as a good approximation of the empty pipe.



DOCUMENT TITLE:


18 of 30

For Strength Design (Factored Combination) Case Erection

Load Combinations 0.9(DLS + EQEP + CL) + 1.6(0.8WL) 1.4(DLSF + EQOP + PLOP + FF + TF + AF)

Normal Normal Operation

Abnormal Oepration

Empty Shutdown

1.2(DLSF + EQOP + PLOP + FF + TF + AF) + 1.6LL Wind

1.2(DLSF + EQOP + PLOP + FF + TF + AF) + LL + 1.6WL

Earthquake

1.2(DLSF + EQOP + PLOP + FF + TF + AF ) + LL + EL

Abnormal

[1.2(DLSF + EQOP + PLOP + FF + TF + SF) + 1.6LL] / 1.2

Wind

[1.2(DLSF + EQOP + PLOP + FF + TF + SF) + LL+ 1.6WL] / 1.2

Bundle

1.2(DLSF + EQEP + PLEP) + 1.6LL + 1.6BF

Wind

0.9(DLSF + EQEP + PLEP + LL) + 1.6WL

Earthquake

0.9(DLSF + EQEP + PLEP + LL) + EL

Normal

[1.2(DLSF + EQTL + PLTL) + 1.6LL] / 1.2

Wind (Note1)

[1.2(DLSF + EQTL + PLTL) + LL + 1.6(WL/3)] / 1.2

Test

DLS : DLSF : EQEP : EQOP : EQTL : PLEP : PLOP : PLTL : CL : LL : FF : TF : AF : SF : BF : WL : EL :

Dead Load of Structrure Dead Load of Structure plus fireproofing Equipment Empty Weight Equipment Operating Weight Equipment Test Weight (If equipment test is done at shop, it can be ignored.) Piping Empty Weight (Note2) Piping Operating Weight Piping Test Weight Construction Load Live Load Friction Force Thermal Force Anchor Force Surge Force Bundle Force Wind Load Earthquake Load

Notes (1) (WL/3) shall be1/3 full wind load or wind at 20m/s, whichever is greater. (2) 0.6 PLOP is used as a good approximation of the empty pipe.



DOCUMENT TITLE:


19 of 30

For modifications or additions to existing structures, reduced load factors or higher allowable stresses may be used with the approval of the Owner.



DOCUMENT TITLE:

7


20 of 30

STRUCTURAL DESIGN Steel

7.1.1 Material 7.1.2 Structural steel shall be of grades 36, 50, dual certified, and/or equivalent materials. Grade substitutions shall not be made without approval from the Owner's Engineer. Structural steel for roll shape and plate shall be in accordance with ASTM A36/A36M, ASTM A992/A992M, JIS SM490YA, JIS SM490A, JIS SS400, KS SS400 or equivalent.

7.1.3 Special materials, coating protection or increased material thickness shall be used where structural elements are subject to severe corrosion or wear. Corrosion protection shall be in accordance with GP 19-01-01, except that galvanizing is acceptable for both Category I and II exposures.

7.1.4 All field connections to coated or galvanized structural steel shall be bolted. However, field welding may be allowed with approval from the Owner's Engineer.

7.1.5 Where connecting dissimilar metals will cause galvanic corrosion, a suitable insulation material shall be provided between the metals.

7.1.6 Use of high-strength and micro-alloy steel for structures at service temperatures less than 32 F (0 C) shall be approved by Owner.

7.1.7 Only galvanized fasteners shall be used to connect galvanized structural members. 7.1.8 Coated fasteners shall be used for painted structural members. 7.1.9 Where structural members, having a thickness > 1/2 in. (12 mm), are subjected to tensile stresses from dynamic or impact operating loads, the material impact property requirements shall be reviewed and approved by the Owner's Engineer, when the minimum service temperature can reach below 0 F (-18 C).

7.1.10 High strength bolt material shall be ASTM A325/A325M Type-1 or ASTM A490/A490M Type-1, painted or galvanized. Washer material shall be ASTM F436/F436M. Heavy Hex Nut material shall be ASTM A563 Grade DH or ASTM A563M Grade 10s.

7.1.11 Common bolt material shall be ASTM A307/A307M Grade A, painted or galvanized. Washer material shall be ASTM F436/F436M. Heavy Hex Nut material shall be ASTM A563/A563M Grade A.

7.1.12 Anchor Bolt shall be referred to Section 7.3.1 in this specification.



DOCUMENT TITLE:

21 of 30


7.1.13 Design 7.1.14 Certain structures are subject to sustained vibration or stress reversal caused by operating equipment. The plastic design method shall not be used in the design of such structures, unless approved by the Owner's Engineer.

7.1.15 For structural elements subject to prolonged exposure to heat above 200 F (93 C), allowable design stress shall be reduced in proportion to reductions in yield strength of the steel at the design temperature. The modulus of elasticity shall also be reduced to account for the effect of elevated temperature.

7.1.16 Bolts shall be designed on the basis that the threads will be included in the shear plane. That is, type N bolts per AISC shall be used for bearing connections.

7.1.17 Pipe Supports shall be designed for piping loads resulting from changes in line temperature due to normal and abnormal conditions.

7.1.18 Top of concrete piers for pipe supports shall be a minimum of 8 in. (200 mm) above finished grade or high point of paving.

7.1.19 Piping anchor structures (or supports) shall be designed for the forces developed under normal and abnormal conditions. The design of structures anchoring more than one line shall accommodate the most stringent combination of forces due to abnormal conditions on the following basis:

7.1.20 Total No. of Lines resisted by the structure that could have abnormal conditions

Percent of lines under abnormal conditions to be used in design (1)

1

100%

2-4

50%

Over 4

25%

Note (1): Round up fractions of lines to the next whole number of lines. Generally select largest lines, providing thrust loads are in the same direction.

7.1.21 Longitudinal struts and bracing members shall be designed to resist the cumulative friction forces from piping thermal growth, equal to 2.5 percent of the total pipe weight plus the load from any pipe anchors. For the purpose of design of individual piping supports, longitudinal forces due to thermal growth shall be equal to 7.5 percent of the weight of the supported pipe and are additive to piping anchor forces.



DOCUMENT TITLE:

22 of 30


7.1.22 The minimum vertical clearances between finished grade, paving or top of floor plate, and the bottom of the piping, insulation or support beam (whichever controls) are shown below:

7.1.23 Minimum Vertical Clearances Minimum Clearance, See Note 1 Location Ft

mm

20

6100

16

4880

12 10

3660 3050

c. Above walkways and elevated platforms

6 ft 9 in

2060

d. Under any low level piping in paved or unpaved areas

1 ft (1)

305

a. Above major roads open to unrestricted traffic (such as periphery of process unit area limits) b. Within process unit areas: Above internal roadways provided for access of maintenance and fire fighting equipment Under pipeways where access is: 1. Required for vehicular equipment 2. Required only for portable (temporary service equipment)

Note (1): Measured to bottom of pipe disregarding flanges and insulation.

7.1.24 A fireproofed "catch" beam shall be installed beneath the piping containing flammable material where such piping is hung by rods or spring type supports from a fireproofed pipe support cross beam.

7.1.25 Fabrication 7.1.26 For structural members with full penetration corner or T-joints between plates both thicker than 3/4 in. (18 mm), procedures to minimize the risk of lamellar tearing shall be provided for approval by the Owner's Engineer.

7.1.27 Fabrication requiring welding of structural steel shall be in accordance with ‘Welding Procedures GP 18-07-01.’

7.1.28 Closed structural shapes, such as tubes, pipes and box members, are not permitted unless otherwise approved by the Owner's Engineer. When such shapes are approved for use, special precautions to prevent internal corrosion shall be taken.



DOCUMENT TITLE:


23 of 30

7.1.29 Selection and application of exterior paint and protective coating systems for structures shall be in accordance with ‘Paint and Protective Coating GP 19-01-01.’

7.1.30 Fireproofing of structural support members installation shall be in accordance with ‘Fireproofing GP 14-03-01.’

Concrete

7.1.31 Material 7.1.32 Concrete shall be per ‘RMP2G-0006-SP-002 Civil Design Criteria’ 7.1.33 All reinforcing bars shall be as per ‘RMP2G-0006-SP-002 Civil Design Criteria’. 7.1.34 Concrete cover for cast-in-situ shall be referred to ‘RMP2G-0006-SP-002 Civil Design Criteria’.

7.1.35 Design 7.1.36 Concrete design shall be as per ‘RMP2G-0006-SP-002 Civil Design Criteria’. 7.1.37 Safety factor flotation shall be as per ‘RMP2G-0006-SP-002 Civil Design Criteria’. 7.1.38 Construction 7.1.39 Concrete construction shall be per ACI 301 and ACI 318M/318RM. 7.1.40 Foundation

7.1.41 Material Foundations shall be of reinforced concrete with a 28-day compressive strength of not less than 3000 psi. Concrete and steel reinforcement materials shall be per ACI 318/318R. Anchor bolt materials shall be as follows: Material for carbon steel anchor bolts shall be per ASTM A36/A36M or ASTM A 307, unless otherwise specified. The nuts for carbon steel anchor bolts and headed bolts shall be per ASTM A 563, Grade A, heavy hex. ASTM A 36/A 36M or ASTM A 307 anchor bolts can be hot dip galvanized.



DOCUMENT TITLE:


24 of 30

Material for alloy steel anchor bolts shall be per ASTM A 354, Grade BC, unless otherwise specified. The nuts for A354 bolts shall be per ASTM A 563, Grade DH, heavy hex. ASTM A 354 Grade BC anchor bolts can be hot dip galvanized. When anchor bolts will be subjected to elevated temperatures significantly above normal atmospheric temperatures, the alloy bolting material shall be per ASTM A 193/A 193M, Grade B7, and the nuts shall be per ASTM A 194/A 194M, Grade 2H, heavy hex. ASTM A 193/A 193M Grade B7 anchor bolts cannot be hot dip galvanized. Anchor bolts for heavy machinery that are pre-tensioned shall conform to ASTM A 193/A 193M, Grade B7, unless otherwise specified.

Grout for the base of static structures, vessels and equipment shall be cementitious type comprised of 1 part water to 2 parts sand with minimum amount of ware to produce a workable mix.

7.1.42 Design 7.1.43 Footings 7.1.44 Footing design shall be as per ‘RMP2G-0006-SP-002 Civil Design Criteria’. 7.1.45 Piers and Pedestals 7.1.46 Pedestals are supports having a ratio of height to least width dimension of not more than three (3). Piers are supports with a ratio of height to least width dimension of three (3) or more.

7.1.47 The top of concrete shall be a minimum of 8 in. (200 mm) above finished grade or high point of paving for foundations under the following equipment:

7.1.48 Steel column bases of open structural framing 7.1.49 Pipe supports 7.1.50 Pumps, fans, compressors, and legs or skirts of towers, drums, and exchangers 7.1.51 Piers under base plates and pedestals supporting vessels with skirts shall extend 11/2 in. (38 mm) minimum beyond the base plates, or skirt base rings and lugs, in all directions.



DOCUMENT TITLE:


25 of 30

7.1.52 Piers and pedestals shall be reinforced to resist thermal stresses due to expansion of base plates, soleplates, rails, skirt base rings and lugs, anchor bolts, and concrete. As a minimum, vertical reinforcing shall be tied as follows:

7.1.53 In piers, vertical reinforcing shall be enclosed in lateral ties per ACI 318/318R requirements for tie reinforcement for compression members.

7.1.54 In pedestals, vertical reinforcing shall be enclosed by closed ties meeting the size and spacing requirements per ACI 318/318R for tie reinforcement for compression members.

7.1.55 The spacing between the top two ties in piers and pedestals shall not be more than 4 in. (100 mm).

7.1.56 Concrete in piers and pedestals, and grout shall not extend above the bottom face of base plates, soleplates, rails, skirt base rings and lugs.

7.1.57 Pedestals for vessels with skirts shall have the area within the skirt sloped for drainage and a suitable embedded pipe or opening in the grout for discharge to the pavement outside the skirt.

7.1.58 Anchor Bolts Anchor bolts shall be sized using allowable stresses given in the AISC S335 except as follows: Anchor bolts that have not been galvanized or coated with inorganic zinc or fluorocarbon shall have their diameters increased by 1/8 in. (3 mm) as a corrosion allowance. Anchor bolts shall be developed as ductile connections with all anchor loads transferred to reinforcing steel per ACI 318/318R for hooked bolts, or be designed per ACI 349 Appendix B for bolts with an anchor head, nut, plate, or similar device. Anchor bolts shall be set by using templates placed at the approximate elevation of base plate or equipment bases or frames. Anchor bolts shall be carefully plumbed and checked for location and elevation. They shall be held in position rigidly to prevent displacement while concrete is being placed. Threads on anchor bolts shall be protected at all times against damage and corrosion. Minimum protection shall be provided by greasing and wrapping of the threads. Expansion type anchors shall not be used to attach rotating equipment to existing concrete and in any other application where the anchor bolts will be subjected to vibratory loads.



DOCUMENT TITLE:


26 of 30

Grout Grout for static structures and equipment shall be field or factory prepared cementitious types as follows: Field-prepared cementitious grout shall be as follows: Air-entrainment shall be kept to a minimum. Mixing time shall not exceed 5 minutes. Non-shrink grout shall be per the manufacturer's specification. Non-shrink grout shall be used for tall vessels and towers. Grout material storage before use shall be as follows: Materials shall be stored in a dry weatherproof area. Material stored outside shall be placed on pallets off the ground surface and completely covered with adequate weatherproof covering. Surface preparation for grouting shall include the removal of all laitance and debris, light chipping of concrete, and wetting surfaces before placing grout. Forms for grout shall be thoroughly braced and be tight. Grout shall extend not extend less than 2 in. (50 mm) or more than 4 in. (100 mm) beyond base plate edges. Shims and wedges used as temporary supports for structural components and equipment shall be removed after grout cures and the pockets filled with similar grout. Grout for major equipment shall not be poured until after alignment are checked and mixing and pouring procedures are verified. Curing for field-prepared grout shall be at least 7 days and according to manufacturer's specification for factory-prepared non-shrink cementitious grout. Design and testing of supporting structures and foundations for heavy machinery shall be in accordance with ‘Supporting Structures and Foundations for Heavy Machinery GP 0406-02.’



DOCUMENT TITLE:


27 of 30

Design Drawings

7.1.59 Specifications for the materials of construction of all structural elements shall be indicated on the design drawings.

7.1.60 All "slip-critical" joints shall be clearly identified on the design and erection drawings. 7.1.61 All steel grades shall be identified on the drawings.



DOCUMENT TITLE:

8


28 of 30

AUXILIARY STRUCTURES FOR OPERATION AND MAINTENANCE Use, design, and layout of auxiliary structures and facilities provided for access and maintenance of plant equipment shall be in accordance with ‘Auxiliary Structures for Operation and Maintenance GP 04-02-01.’



DOCUMENT TITLE:

9


29 of 30

PLANT BUILDING FOR OPERATION AND STORAGE Materials, design, and erection of buildings and shelters for processing plants, building buildings housing process or manufacturing equipment, control or service rooms, in-plant sample laboratories, in-plant sanitary facilities, power station equipment, and material receiving, handling and storage facilities shall be in accordance with ‘Plant Building for Operation and Storage GP 04-03-01.’



DOCUMENT TITLE:


30 of 30

10 BLAST RESISTANT BUILDINGS Design of blast resistant buildings shall be in accordance with ‘Blast resistant Buildings GP 04-03-02’ and ‘Special Category 3 Blast Resistant Buildings GP 04-03-04.’


RMP2G 0007 SP 001 Structural Design Criteria Rev a 20110412

Recommend Documents