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EPC CPF PHASE 2

AT BADRA OILFIELD, IRAQ

DOCUMENT DETAILS

EMPLOYER CONTRACT NO. : 090-13-BD-205-00

PROJECT : EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ

EMPLOYER : Gazprom Neft Badra B.V.

EMPLOYER JOB NO. : GB090

CONTRACTOR : Samsung Engineering Co. Ltd

CONTRACTOR JOB NO. : SG-2614

DOCUMENT NO. : GB090-2614-250-CS-DB-0001

REVISION NO. : 0 No. of pages (incl. sheet) : 25

DOCUMENT DESCRIPTION : DESIGN BASIS FOR STEEL STRUCTURE

0 Issue for Design 16/07/2013 J.S.Lim S.D.Bae D.M.Ryu JSK / KHS

D Re-Issue for Approval 11/07/2013 J.S.Lim S.D.Bae D.M.Ryu JSK / KHS

C Issue for Approval 27/06/2013 J.S.Lim S.D.Bae D.M.Ryu JSK / KHS

B Re-Issue for Review 30/05/2013 J.S.Lim S.D.Bae D.M.Ryu JSK / KHS

A Issue for Review 15/04/2013 J.S Lim D.M.Ryu KSL / JSK K.H. Song

Rev Description Date Prepared Checked Approved EM / PD

Electronic Filename : GB090-2614-250-CS-DB-0001_0.docx Doc Size : A4


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SUMMARY OF DOCUMENT REVISIONS


Date
Rev. Section Revised Revision Description
Revised
A 15/04/2013 Issue for Review Issue for Employer Review

B 30/05/2013 Re-Issue For Review Incorporated Employers Comments.


Issued for Employers approval
C 27/06/2013 Issue for Approval Revisions are identified in the document and
comment resolution sheet
D 11/07/2013 Re-Issue for Approval Re-Issued for Employers approval

0 16/07/2013 Issue for Design Issued for Design


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TABLE OF CONTENTS
1 INTRODUCTION 6

2 DEFINITIONS AND ABBREVIATIONS 6

2.1 Definitions 6

2.2 List of Abbreviations 6

3 CODES & STANDARDS AND REFERENCE 6

3.1 Order of Precedence 7

3.2 Project Specific Specifications 7

3.3 Codes and Standards 7

4 UNITS OF MEASUREMENT AND LANGUAGE 9

4.1 Units 9

4.2 Language 9

5 METEOROLOGICAL & GEOTECHNICAL DATA 9

5.1 Wind 9

5.2 Air Temperature 9

5.3 Rainfall 9

5.4 Seismicity 9

5.5 Geotechnical Data 10

6 MATERIAL SPECIFICATION 10

7 LOADS 10

7.1 Dead Load (D) 10

7.2 Live Load (L) 12


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7.3 Process Equipment & Vessel Dead Loads (D) 12

7.4 Exchangers Tube Bundle Pull Load 13

7.5 Erection / Maintenance Load 13

7.6 Friction Force (Ff) 14

7.7 Dynamic Load 14

7.8 Impact Load 15

7.9 Thermal Load (T) 15

7.10 Wind Load (W) 16

7.10.1 Design Wind Pressures 16

7.10.2 Wind Load on Shelters and Buildings 17

7.10.3 WIND LOAD on EQUIPMENTS 18

7.10.4 Tributary Area for Piping & Cable Tray 18

7.11 Seismic Load (E) 19

7.11.1 Seismic Parameters 19

7.11.2 Horizontal Component of Seismic Force 19

7.11.3 Vertical Component of Seismic Force 20

7.12 Piping Load 20

7.12.1 Vertical Load 21

7.12.2 Horizontal Load 21

7.12.3 Piping loads on longitudinal beams 22

8 LOAD COMBINATIONS 22

8.1 Pipe rack and Other Steel Structures 22


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8.1.1 Unfactored Load Combination (Service Loads) 23

8.1.2 Factored Load Combination (Strength Design) 23

9 STRUCTURAL CONFIGURATIONS 24

10 ALLOWABLE DEFLECTIONS AND DISPLACEMENTS 24

11 STRUCTURE DESIGN AND LOADS (OTHER THAN FOR PIPE RACKS) 25

12 SOFTWARE USED 25
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1 INTRODUCTION
This design basis establishes the minimum requirements for design engineering of Civil
Works as part of EPC execution of Central Processing Facility Phase 2 at BADRA Oil
Field in the Republic of IRAQ.

2 DEFINITIONS AND ABBREVIATIONS


2.1 Definitions

Throughout this document the following definitions shall apply:

Employer GAZPROM NEFT BADRA B.V.


Contractor SAMSUNG ENGINEERING Co. Ltd
Project EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
Work The works and / or services entrusted by Contractor
under the contract with Employer
Vendor Once the order is placed, the selected ENTITY / Supplier
shall The word is used where a provision is mandatory
should The word is a strong recommendation
may The word is used where a provision is discretionary

2.2 List of Abbreviations

CODE Description
ACI American Concrete Institute
API American Petroleum Institute
ASCE American Society of Civil Engineers
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
AWS American Welding Society
BS British standards
EN European Standard
EPC Engineering, Procurement & Construction
HPP High Point of surrounding Paving
FGL Finished Grade Level

3 CODES & STANDARDS AND REFERENCE


The design of concrete foundations and structures shall be in accordance with the
standards and codes of practice as mentioned in the clause no.3.1 to 3.3.
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3.1 Order of Precedence

In the event of apparent technical conflict occurring in applying this specification and
reference documents, the Contractor shall notify the Employer of the conflict in writing for
resolution prior to the commencement of work.

The order of precedence shall be:

1. Iraqi Local Regulations.


2. Purchase Requisition of Contractor.
3. Equipment Datasheet.
4. International Codes and Standards as mentioned in the Project Specification.
5. Contractor's Project Specifications.

Note 1 : No technical specification shall be defined herein which conflicts or alters the
Contractor's Project specification

Note 2 : For cases where requirements of Contractor Project specification is superior /


exceed requirements set forth in the codes and standards, the former shall be considered
as mandatory requirement for this Project.

Resolution shall be obtained from the Employer in writing before proceeding with the
design.

3.2 Project Specific Specifications

GB090-2614-250-PR-DB-0001 Design Basis for Process

GB090-2614-250-CS-SP-0001 Engineering Specification for Structural Steel Works

GB090-2614-250-CV-DB-0001 Design Basis for Civil Works

GB090-2614-250-CS-SP-0002 Engineering Specification for Fireproofing

GB090-2614-250-HS-SP-0002 Engineering Specification for Passive Fire Protection

GB090-2614-250-PI-SP-0001 Piping Layout and Design Specification

QRA Report(not yet issued)

3.3 Codes and Standards

ASTM A36 Standard Specification for Carbon Structural Steel

Standard Specification for Steel Welded Wire Fabric, Plain,


ASTM A185
for Concrete Reinforcement
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Standard Specification for Structural Steel bolts, steel, heat


ASTM A325M
treated 830 MPa minimum tensile strength.

Standard Specification for High-Strength Steel Bolts,


ASTM A490M
Classes 10.9 & 10.93 for Structural Steel Joints (Metric)

Standard Specification for Steel Welded Wire


ASTM A497
Reinforcement, Deformed, for Concrete.

ASTM A563 Specification for Carbon Steel & Alloyed Steel Nuts

Standard Specification for Deformed & Plain Steel Bars for


ASTM A615M
Concrete Reinforcement

ASTM F436 Specification for Hardened Steel Washers

AISC 303-05 Code of Standard Practice for Steel Buildings & Bridges

AISC 325-01 LRFD Manual of Steel Construction

AISC 326-02 Detailing for Steel Construction

Specification for Structural Joints Using ASTM A325 & A490


AISC 348-00
Bolts

AISC 360-05 Specification for Structural Steel Buildings

AISC Publication Manual of Steel Construction 13th edition

AASHTO Guide for Design of Pavement Structures

Safety Requirements for Floor & Wall Openings, Railings &


ANSI A12.1
Toe boards

ANSI A14.3 Safety Requirement for Fixed Ladders

ANSI A64.1 Requirements for Fixed Industrial Stairs

API 650 Welded Steel Tanks for Oil Storage

ASCE 07-10 Minimum Design Loads for building and other structures

Design of Blast Resistant Buildings in Petrochemical


ASCE Publication
Facilities

ASME B1.13M Metric Screw Threads : M profile

AWS D1.1 Structural Welding Code

Euro code 1 : Actions on Structures Part1-4 General


BS EN 1991-1-4 2005
Actions-Wind Actions
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UBC-1997 Uniform Building Code

JIS G3101 Rolled steels for general structure

4 UNITS OF MEASUREMENT AND LANGUAGE


4.1 Units

AII documents, calculations and drawings shall be carried out using International System
Units (S. I.).

Length : Kilometer (km), meter (m) or millimeter (mm)


Area : mm2 or m2
Volume : m3
Elevation :m
Time : Hour (Hr) or Second (sec)
Velocity : m/sec
Force and Weight : Kilo Newton (kN) or Newton (N)
Mass : kilogram (kg) or Ton (t)
Stress : kN/m2 (kPa) or N/mm2 (MPa)
Moment : Kilo Newton-meter (kNm)
Frequency : Hertz (Hz) or Rotation Per minute (rpm)

4.2 Language

AII Documents and correspondence shall be written in English language.

5 METEOROLOGICAL & GEOTECHNICAL DATA


5.1 Wind

Extreme Wind Speed : 31.9 m/s

5.2 Air Temperature

The maximum and minimum recorded air temperature is (+) 51.8 and (-) 0.4
respectively.

Maximum relative humidity : 81 %


Average annual relative humidity : 37 %

5.3 Rainfall

Expected extreme rainfall for return period of 10 years is 41 mm in one hour.

5.4 Seismicity

The project area is classified under seismic Zone-3 of UBC.


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5.5 Geotechnical Data

This shall be confirmed as per the Project Geotechnical Investigation Report.

6 MATERIAL SPECIFICATION
Unless otherwise noted, all structural calculation shall be carried out based on the
assumption that following materials are used.

Structural steel Material: ASTM A36, Shape: JIS G 3101


High strength bolts ASTM A325 Type 1
Ordinary strength bolts ASTM A307 Grade A
(for use in connection of grating, handrails, ladder, purlin and
Girth only)
Anchor bolts ASTM A307, ASTM A36

7 LOADS
The loads which shall be taken into account in the design of structures, wherever
applicable, are described in this section.

7.1 Dead Load (D)

Dead load is defined as the weight of all permanent structural components of building or
structure, such as floors, roofs and non structural components, such as walls, partitions,
fire proofing, insulation, stairways, fixtures, fixed service equipment.

This also include proprietary systems, equipment and machines, including internals, pipes,
valves and accessories; electrical and lighting conduits; switchgear; instrumentation;
fireproofing; insulation; ladders; platforms; and other similar items.

Weight of equipment shall be derived from the MANUFACTURER`s data sheets. Content
load of equipment and piping during operation shall be considered as dead load.

The weight of overburden soil shall be considered as dead load.


Unless otherwise specified, dead weights of structural elements shall be as follows:

Grating = 0.35 kN/m2


Chequered plate (6mm thk.) = 0.55 kN/m2
Handrail = 0.20 kN/m
Ladder without cage
for 70X 10thk post = 0.17 kN/m
for PFC100 post = 0.28 kN/m
Ladder with cage
for 70X 10thk post = 0.30 kN/m
for PFC100 post = 0.38 kN/m
Vermiculite based (Fendolite) fireproofing = 7 kN/ m3
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Unit weight of steel = 78.5 kN/ m3


Cable tray (Erection condition only) = 0.7 kN/ m2

The above load for cable tray shall be taken as 0.7kN/m2 as dead and 1.7 kN/m2 as live
load per tier of tray over the entire width of the support.

Waterproofing load on roof shall be taken at actual weight.

If the cable trays tree is having unequal no. of trays on each side or for the end post,
moment shall be added to the beam in addition to vertical load.

Additional load of 5% of the self-weight of the structure shall be considered towards


connection plates.

The dead loads which are not mentioned above shall be considered as per ASCE 7-10
(e.g. load for waterproofing etc.)

For this Practice, dead loads are designated by the following nomenclature:

Ds, Df, De, Do and Dt,

Where,

Ds Structure dead load is the weight of the materials forming the structure (not the
empty weight of process equipment, vessels, tanks, piping, nor cable trays),
foundation, soil above the foundation resisting uplift, and all permanently
attached appurtenances (e.g. lighting, instrumentation, HVAC, sprinkler and
deluge systems, fireproofing and insulation, etc.).

Df Erection dead load is the fabricated weight of process equipment or vessels.

De Empty dead load is the empty weight of the equipment or vessels including all
attachments, trays, internals, insulation, fireproofing, agitators, piping, ladders,
platforms, etc. Empty dead load also includes weight of machinery (e.g. pumps,
compressors, turbines, and packaged units)

Do Operating dead load is the empty weight of process equipment, vessels, tanks,
piping, and cable trays plus the maximum weight of contents (fluid load) during
normal operation.

Dt Test dead load is the empty dead load plus the weight of the test medium
contained in the system. The test medium shall be as specified in the contract
documents or as specified by the owner. Unless otherwise specified, a minimum
specific gravity of 1.0 shall be used for the test medium. Equipment and pipes
that may be simultaneously tested shall be included. Cleaning load shall be used
for test dead load if the cleaning fluid is heavier than the test medium.
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7.2 Live Load (L)

Live load is defined as the weight superimposed by the use and occupancy of the building
or other structure, but not permanently attached to it. This also includes the load produced
by personnel, moveable equipment, tools and other items placed on the structure, but not
permanently attached to it.

The live loads shall be uniformly distributed over the horizontal projection of the specified
areas, and shall have the following minimum values if not otherwise specified.

Maintenance and operating


platforms / floors 5.00 kN/m2

Walkways 2.50 kN/m2 or 3.00 kN moving load (single load)

Stairways 5.00 kN/m2 or 7.50 kN moving load (single load)

Handrails designed for 1 kN/m applied horizontally at


Railing top rail or a concentrated load of 0.5 kN applied in
any direction at top rail whichever is greater.

Roofs 1.0 kN/m2 or 2.00 kN moving load (single load)

Roofs with access


Without parapet 1.5 kN/m2
With parapet 2.5 kN/m2

Impact loads (F) on traffic Trucks F = 100 kN h = 1.20m


ways at height h (not to be Cars F = 10 kN h = 0.50m
considered for foundations) Fork lift F= 5 x total weight h = 0.75m
Windblown sand accumulation 0.1 kN/m2
Cable Tray
1.7 kN/m2
(Erection condition only)

The above load for cable tray shall be taken as 0.7kN/m2 as dead and 1.7 kN/m2 as live
load per tier of tray over the entire width of the support. If the cable trays tree is having
unequal no. of trays on each side or for the end post, moment shall be added to the beam
in addition to vertical load.

For other live loads not covered under this section reference is made to ASCE 07- 10.
Load from roof water tanks and mounted equipment including associated concrete plinths
shall be applied as live loads, in addition to the uniformly distributed live loads listed
above.

7.3 Process Equipment & Vessel Dead Loads (D)

Loads of all static equipments as well as static load components of rotating equipments
are considered under this category.

Equipment loads shall be according to mechanical data sheets/vendor drawings.


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All equipment loads shall be increased by 20% to take into account loads from connected
piping and platforms, unless loads from connected piping and platforms have been
determined by detailed calculation.

Erection dead load (Df) for the process equipment and vessels is normally the fabricated
weight of the equipment or vessel and is generally taken from the certified equipment or
vessel drawing.

Empty dead load (De) for the process equipment and vessels is the empty weight of the
equipment or vessels including all attachments, trays, internals, insulation, fireproofing,
agitators, piping, ladders, platforms, etc. Empty dead load also includes weight of
machinery (e.g. pumps, compressors, turbines, and packaged units).

Operating dead load (Do) for the process equipment and vessels is the empty dead load
plus the maximum weight of contents (including packing/catalyst) during normal operation.

Test dead load (Dt) for the process equipment and vessels is the empty dead load plus
the weight of the test medium contained in the system. The test medium shall be as
specified in the contract documents or as specified by the owner. Unless otherwise
specified, a minimum specific gravity of 1.0 shall be used for the test medium. Equipment
and pipes that may be simultaneously tested shall be included. Cleaning load shall be
used for test dead load if the cleaning fluid is heavier than the test medium.

7.4 Exchangers Tube Bundle Pull Load

Pull beams and exchanger support beams or foundations shall be designed for a
horizontal force equal to the following values:

Weight of the bundle, for bundles with weight less than 2500 kg.
25 kN when the bundle has a weight between 2500 kg and 5000 kg.
50% of the weight of the bundle when the weight of the bundle is more than 5000 kg.

Exchanger supports shall be designed as follows:

Fixed end pier Bundle pull minus frictional force on sliding pier.
Sliding end pier Frictional force or half the total bundle pull load, whichever is
less. The remainder of the bundle pull load shall be rested at the
fixed end support.

Bundle pulling force for heat exchangers will be considered as a short-term load during
maintenance for design of equipment supports only and shall not be combined with
seismic/wind load.
Above is not applicable if the bundles are pulled by means of an extractor which acts on
the principle of equilibrium of forces, or if the complete exchanger is being removed from
its foundation and transported to a cleaning area. This should be clearly specified in the
vendor drawing.

7.5 Erection / Maintenance Load

Heavy equipment lowered onto a supporting structure can introduce extreme point loads
on structural members, exceeding any operating or test load. After placing of equipment,
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the exact positioning (Lining out and leveling) can also introduce extreme point loads.

AII possible loading conditions during erection and maintenance shall be considered and,
for any member of a structure, the most unfavorable condition shall be taken into account.

Maintenance loads are temporary forces caused by the dismantling, repair or painting of
equipment or structures.
7.6 Friction Force (Ff)

Horizontal friction forces, between equipment or single pipes and their supports, as a
result of thermal expansion shall be calculated as,

H =xW

Where,

= Friction coefficient as per table below


W = Operating load on support.

Surface Friction coefficient,


Steel to steel 0.30
Stainless Steel to Teflon 0.10
Teflon to Teflon 0.10
Steel to concrete or grout 0.50

7.7 Dynamic Load

Each structure shall be designed to withstand the effects of vibration and impact to which
it may be subjected. Each structure or skid supporting a compressor, turbine, pump or
other machinery having significant dynamic unbalance shall be designed to resist the
peak loads specified by the manufacturer. Vibration amplitudes of the supporting structure
or foundation shall be kept within acceptable limits for dynamic forces that occur during
normal machine operation.

Where specifications of dynamic loads are not available from the equipment supplier, the
structure shall be designed for double equipment weight and an additional horizontal load
at the equipments centre of gravity. This horizontal load shall be assumed as 1.5 times
the weight of the moving parts.

Wherever the structure is designed for dynamic loads provided by equipment supplier,
allowable stresses in the supporting members shall be reduced by 20%.
In both the cases the structure shall have a natural frequency outside the frequency range
of the equipment by at least 20%.

In the case of a tall and slender structure, there may be a need to investigate the dynamic
effects of wind gusts.
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7.8 Impact Load

The following values shall be used in the design of davits, hoist beams and/or trolley
beams and their support:

Load = Lift Load + trolley and hoist + line pull (minimum 500 kg)
Impact = 25% of load
Lateral thrust = 20% of load
Longitudinal force = 10% of load

7.9 Thermal Load (T)

Only thermal loads due to expansion and contraction of structure shall be considered in
this category.
Thermal loads and displacements shall be calculated on the basis of the difference
between ambient or equipment design temperature and installed temperature.
Temperature in summer is (+) 51.8 and temperature in winter is (-) 0.4 .

Average stress free temperature/construction temperature is 25 ,


Difference temperature (rise) = (51.8-25) = +26.80C
Difference temperature (fall) = (-0.4-25) = -25.40C
Hence structures shall be designed for the temperature difference of 27

The thermal force used for design should be the smaller value resulting from the following
two calculations for equipment foundations.

The force required to overcome static friction between the used surface and the slide
plate.

Ff = (Pop)

Where,

Ff = Static friction force


= coefficient of friction refer to section 6.5 of this document
Pop = Operating vertical load on slide plate

The force required to deflect the pier or column an amount equal to half of the
thermal growth between the supports.

Fd = 3 E I / (2 L3)
Where,

Fd = Pier deflection force


= Total deflection between pier
E = Modulus of elasticity
I = Pier moment of inertia
L = Pier height

The thermal force should be applied at the top of the piers. The force acts on both the
supports concurrently but in opposite directions.
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7.10 Wind Load (W)

Wind Load shall be as per the provisions of UBC Vol.2-1997 Chapter 16.

7.10.1 Design Wind Pressures

Design wind pressures for buildings, structures and elements shall be determined for any
height as below:
P = Ce Cq qs Iw

Where,

Ce = combined height, exposure and gust factor coefficient for Exposure C


as per Table 16-G of UBC Vo1.2-1997

Cq = pressure coefficient for the structure or portion of structure under consideration


as per Table 16-H of UBC Vo1.2-1997

Iw = importance factor as per Table 16-K of UBC Vo1.2-1997 = 1.15 for occupancy
category 2.

P = design wind pressure

qs = wind stagnation pressure at the standard height of 10m as per Table 16-F of
UBC Vo1.2-1997

The maximum wind speed = 31.90 m/sec = 114.84 km/hr = 71.33 mph
From table 16-F of UBC VoI.2-1997,
qs = 13.105 psf = 0.62773 kN/m2

Pressure coefficient Cq for primary frames and method 2 as per Table 16-H of UBC VoI.2-
1997:

Cq = 1.3 for structure height 12m.


Cq = 1.4 for structure height > 12m.
Design wind pressure for open frame structures like pipe racks, technological structures,
grade platforms and pipe supports etc.

(Cq = 1.4)
Height (m) Design Wind Pressure P (kN/m2)
5 1.014
7.5 1.113
8 1.126
10 1.202
15 1.380
20 1.555
30 1.895
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Height (m) Design Wind Pressure P (kN/m2)


35 1.938
45 2.014
50 2.050
75 2.183
100 2.285

7.10.2 Wind Load on Shelters and Buildings

Wind load on buildings and shelters shall be computed and applied to the procedures
outlined in UBC-97.

Design Wind Pressure = CeCqqslw (Section 1616 from UBC-97)

Where,

Ce = combined height, exposure and gust factor coefficient


(Table 16-G from UBC-97)

Cq = Pressure coefficient for the structure or portion of structure under consideration


(Table 16-H from UBC-97)

Method 1 (as per clause 1621.2) shall be used for shelters and Method 2 (as per clause
1621.3) shall be used for buildings.

The value of Cq as mentioned below:

Structure or
Description Cq Factor
Part Thereof
Primary Method 1 (Normal force method)
frames and Walls : Windward wall 0.8 inward
systems Leeward wall 0.5 outward
Roofs :
Wind perpendicular to ridge
Leeward roof or flat roof 0.7 outward
Windward roof
Less than 2:12(16.7%) 0.7 outward
Slope 2:12(16.7%) to less than 9:12(75%) 0.9 outward or 0.3 inward
Slope 9:12(75%) to less than 12:12(100%) 0.4 inward
Slope > 12:12(100%) 0.7 inward
Wind parallel to ridge and flat roofs 0.7 outward
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Structure or
Description Cq Factor
Part Thereof

Method 2 (Projected area method)


On vertical projected area
Structure < 12m height 1.3 horizontal on windward
side only
Structure > 12m height 1.4 horizontal on windward
side only
On horizontal projected area i.e. roofs 0.7 upward

Iw = Importance Factor (Table 16-K from UBC-97)


qs = Wind stagnation pressure at the standard height of 33 feet
(Table 16-F from UBC-97)

7.10.3 WIND LOAD on EQUIPMENTS

Wind load on equipments are calculated as per UBC-97 code provisions as per
mechanical design basis. Wind loads mentioned against each equipment by vendor will
be used for the design of foundations. Wind Load not given by vendors shall be calculated
and given for Employers consent before being used in the calculations.

7.10.4 Tributary Area for Piping & Cable Tray

The tributary area for piping or cable trays is calculated as per ASCE Publication Wind
Loads and Anchor Bolt Design for Petrochemical Facilities Chapter 4.

Tributary Area for Piping

The tributary are for piping should be based on the diameter of the largest pipe plus 10%
of the width of the pipe rack. This sum is multiplied by the length of the pipes (bent
spacing) to determine the tributary area.

A = L (D + 0.1 W)

Where,

D = Largest pipe diameter in bent (including insulation)


W = Width of the pipe rack
L = Bent spacing
A = Tributary area for piping

Wind load on pipes


Wp = P X A X Cf
Cf = 0.8 (Force coefficient)

Tributary Area for Cable Trays

The tributary area for cable trays should be based on the height of the largest tray plus 10%
of the width of the pipe rack. This sum is multiplied by the length of the trays (bent
spacing) to determine the tributary area.
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DESIGN BASIS FOR STEEL STRUCTURE
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Pressure at the highest cable tray elevation shall be considered in the calculation.

Ac = L (h X N + 0.1 W)

Where,

h = Height of each cable tray


N = Number of cable tray tiers
W = Width of the pipe rack
L = Bent spacing
Ac = Tributary area for cable trays

Wind load on cable trays


Wc = P X Ac X Cf
Cf = 2.0 (Force coefficient)

7.11 Seismic Load (E)

Seismic Load shall be as per the provisions of UBC Vo1.2-1997 Chapter 16. The seismic
zone for the project site shall be Zone 3 with Importance Factor (I) of 1.25.

7.11.1 Seismic Parameters

UBC reference Factor Coefficients


Table 16-I Zone Factor Z = 0.3
Sc (to be verified with
Table 16-J Soil Type
Geotechnical report)
Table 16-Q Seismic Coefficient, Ca Ca = 0.33
Table 16-R Seismic Coefficient, Cv Cv = 0.45

7.11.2 Horizontal Component of Seismic Force

The total design base shear in given direction as per equation 30-4 of UBC Vol 2-1997 is

V = (Cv I / R T) W

The total design base shear shall not exceed the following equation 30-5 of UBC VoI2-
1997 is
V = (2.5 Ca I / R) W

The total design base shear shall not be less than the following equation 30-6 of UBC Vol
2-1997:
V = 0.11 Ca I W
Where,

Ca = Seismic coefficient
Cv = Seismic coefficient
I = Importance factor
W = Total seismic dead load
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DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 20 of 25

Time period is calculated as per clause 1630.2.2 of UBC-97


Time period from method A ,
Ta = Ct(hn)3/4
Where:
hn = Height of structure above base
Ct = 0.0853 for steel moment resisting steel frames
Ct = 0.0731 for RC moment resisting frames & steel braced frames
Ct = 0.0488 for other buildings

R = numerical co-efficient (per Table 16-N of UBC 1997)


= 2.2 for ordinary steel moment resisting frame system
(for isolated pipe support & pipe portal design only)
= 3.5 for Ordinary moment resisting concrete frame
(For design of buildings only)
= 5.6 for Ordinary Steel Braced Building Frame System
(For shelters and pipe/bridge rack design along the ordinary braced frame only)
= 4.5 for Ordinary Steel Moment Resisting Frame System
(for shelters and pipe/bridge rack design along the moment resisting frame only)

The factor for non building structures shall be as per the table 16-P of UBC-97

TA obtained as per above calculation is compared with time period obtained from STAAD
analysis TB.

User defined Time periods PX & PZ (to be given as input in STAAD Pro) are calculated as
follows:

if TB > 1.4 TA user defined time period in STAAD = 1.4TA


if TB < TA user defined time period in STAAD = TA
if TB > TA but < 1.4 TA, user defined time period in STAAD = TB

For non-building structure earthquake load shall be as defined in chapter 16, section 1634
of UBC 1997. Rigid structures, i.e. foundations for Horizontal/vertical vessels /tanks (with
time period T less than 0.06s), and their anchorages shall be designed for lateral force as
per section 1634.3 of UBC 1997.

Base shear
V=0.7 Ca I W

7.11.3 Vertical Component of Seismic Force

The load effect resulting from the vertical component of the earthquake ground motion
and is equal to an addition of 0.5CaID to the dead load effect, D, as pre Clause No.
1630.1.1 UBC 1997 for Strength Design, and may be taken as zero for Allowable Stress
Design.

7.12 Piping Load


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DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 21 of 25

Where applicable the forces produced by piping, pipe anchors and guides shall be taken
into consideration for the design of the whole structure as well as for its components and
foundations.

Dead loads for piping on pipe racks shall be estimated as follows, unless actual load
information is available and requires otherwise on receipt of actual piping loads, the same
shall be verified with the UDL loads given below and the worst case shall be considered.

7.12.1 Vertical Load

(1) Operating dead load (Do) : A uniformly distributed load of 1.9 kN/m2 for piping,
product, and insulation

(2) Empty dead load (De) : For checking uplift and components controlled by minimum
loading, 40% of the estimated piping operating loads shall be used unless the actual
conditions.

(3) Test dead load (Dt) is the empty weight of the pipe plus the weight of test medium
contained in a set of simultaneously tested piping systems. The test medium shall be
as specified in the contract documents or as specified by the owner. Unless
otherwise specified, a minimum specific gravity of1.0 shall be used for the test
medium. In absence of concrete data, 60% of estimated piping operating loads shall
be taken.

For any pipe larger than 12-inch (304-mm) nominal diameter, a concentrated load,
including the weight of piping, product, valves, fittings, and insulation shall be used in lieu
of the 1.9 kN/m2. This load shall be uniformly distributed over the pipes associated area.

Pipe racks and their foundations shall be designed to support loads associated with full
utilization of the available rack space and future expansion.

7.12.2 Horizontal Load

Horizontal loads are generated due to change in the temperature of piping. For pipe rack
design, both friction forces and anchor forces shall be considered.

Friction Load (Ff) :

Friction forces caused by hot lines sliding over pipe support are considered to be
partially supported by adjacent cold lines. A longitudinal horizontal force is
For pipe racks supporting 4 or more pipes, 10% of the pipe operating weight
(Empty pipes+ pipe contents).
For pipe racks supporting less than 4 pipes, 20% of the pipe operating weight
(Empty pipes + pipe contents).
For standalone pipe support 30% of the pipe operating weight
(Empty pipes + pipe contents).

These loads shall be applied on each pipe only to local supporting beam of the pipe
rack. For small bore lines (Less than or equal to 12 inch dia.) above loads shall be
taken as uniformly distributed.
Longitudinal friction loads shall be considered to be temporary and shall not be
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DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 22 of 25

combined with wind or seismic loads.

For pipe racks, 10% of the total piping weight shall be used as an estimated
horizontal friction load applied only to local supporting beams. However, an
estimated friction load equal to 5% of the total piping weight shall be accumulated
and carried into pipe rack struts, columns, braced anchor frames, and foundations.

Anchor / Stop / Guide Forces (Af) :

(1) The horizontal longitudinal anchor/stop load shall be the greatest of :


Anchor forces defined by piping stress calculation.
5% of piping vertical loads per pipe rack per tier.

(2) The horizontal transverse anchor/guide load shall be the greatest of :


Anchor forces defined by piping stress calculation.
5 kN.

Anchor loads shall be combined with wind or seismic loads. These forces shall be
transferred by the longitudinal beams to the braced bays and the foundations.

7.12.3 Piping loads on longitudinal beams

Vertical loads :
Longitudinal beams shall be designed for the reaction forces of intermediate cross beams
or a provisional vertical load of 20 kN at mid span whichever is greater.

Horizontal loads :
A transversal horizontal load of 7.5 kN shall be set on longitudinal beams at mid span.

These vertical and horizontal loads allow piping turn offs and shall be considered
combined and in addition to other loading as described in clause 10.2 for local design
check of these longitudinal beams.

8 LOAD COMBINATIONS
Load combinations for concrete foundations shall be determined considering their
applicability, safety and economy. Piles, structures and member of structures as well as
their support and fixing points shall be designed for the various loading combinations
given in clause 7.1 ~ 7.5.

8.1 Pipe rack and Other Steel Structures

Ds Dead Weight of Structure (Section 7.1)


Do Operating weight of pipes/Equipment (Section 7.1)
De Empty weight of pipes/Equipment (Section 7.1)
Ff Friction Force (Section 7.5 & 7.13.2)
Dt Test Load (Section 7.1)
Af Anchor Force
W Wind (Section 7.10)
L Live Load in case of platforms (Section 7.2)
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DESIGN BASIS FOR STEEL STRUCTURE
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T Self straining forces caused by the thermal expansion of structural steel (Section 7.9)
Ee Earthquake load considering the unfactored empty dead load and the applicable
portion of the unfactored structure dead load (Section 7.11)
Eo Earthquake load considering the unfactored operating dead load and the applicable
portion of the unfactored structure dead load (Section 7.11)

a) Thermal loads (Expansion & Contraction) shall be considered in operation.


b) Live Load shall be considered to provide unfavorable load combinations.
c) When live load and Wind or earthquake is combined together 0.75(LL + W or 0.7E) is
considered in stability checks. No increase in soil bearing capacity is allowed.
d) Full DS + DO value shall be considered for the calculation of EO in load combination 4
of service loads.
e) 50% of live load shall be considered for Earthquake load cases.
f) Live load shall be a separate load case and as required in case of platforms.

8.1.1 Unfactored Load Combination (Service Loads)

Load
Loading Condition Load Combinations
comb
Operating Weight+ Friction Force+
DS + DO + Ff + Af + T +
1 Thermal Expansion + Anchor Force
L(separate Load case)
without Wind/Earthquake
Ds + Do + Af + L(separate Operation Weight + Anchor +Wind or
2
Load case) + (W) or (0.7Eo) Earthquake

3 Ds + De + W Empty Weight +Wind (Wind Uplift case)

Operating Weight + Earthquake


4 0.9(Ds + 0.4Do) + 0.7Eo
(Earthquake uplift case)
Empty Weight + Earthquake (Earthquake
5 0.9(Ds + De ) + 0.7 Ee
uplift case)

6 Ds + Dt + Wp Test Load + Partial Wind

8.1.2 Factored Load Combination (Strength Design)

Load
Loading Condition Load Combinations
comb
Operating Weight + Friction Force +
1 1.4 (Ds + Do + Ff + T + Af) Thermal Expansion + Anchor
Operating Weight + Friction Force
1.2 (Ds + Do + Ff + T + Af) + 1.6
2 +Thermal Expansion + Anchor Force
L(Separate Load Case)
without wind/earthquake
1.2 (Ds + Do + Af) + L(separate Operating Weight + Anchor + Wind or
3
load case )+(1.3 W or 1.0 Eo) Earthquake
Empty Weight + Wind
4 0.9 (Ds + De) + 1.3 W
(Wind Uplift Case)
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DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 24 of 25

Load
Loading Condition Load Combinations
comb
Operating weight + Earthquake
5 0.9 Ds + 0.4 Do + 1.0 Eo
(Earthquake Uplift Case)
Empty weight + Earthquake
6 0.9 (Ds + De) + 1.0 Ee
(Earthquake Uplift Case)
7 1.4 (Ds + Dt) Test Weight
8 1.2 (Ds + Dt) + 1.3 Wp Test Weight + Partial Wind
9 STRUCTURAL CONFIGURATIONS
All structural configurations shall be as per Employer approved layout and piping
drawings. Pipe rack shall be designed as per Employer approved pipe rack study, unless
otherwise difficult due to clashing. Bay width (Center to Center of columns in longitudinal
direction) shall be equidistance whether in case of main, interconnecting, sub rack or
continuous pipe supports or sleepers. All spacing shall be in multiplies of 1000mm, and
should be equidistance as stated above.

Cable tray and critical cable will be fireproofed as per GB090-2614-250-HS-SP-0002,


Engineering specification for passive fire protection.

The lowest tier in a pipe rack should be placed so as to provide 4m X 4m clear access
way in both transverse and longitudinal directions. Further the bracing shall be placed so
as to provide clear access of 4m X 4m.

No platforms or ladders shall be placed near to road.

Horizontal clearance between road (from outer edge of road) and pipe rack column shall
be 3.0 m as per GB090-2614-250-CV-SP-0006, Specification for Road, Access and
Parking lots, otherwise contractor shall provide bollards.

Cable tray dropping arrangement should be made so as to facilitate erection and


maintenance.

Live cables dropping from pipe rack to substation or at any other locations shall be
protected using fencing to prevent workers from accidental shocks.

All future access and tie in configuration shall be given.

10 ALLOWABLE DEFLECTIONS AND DISPLACEMENTS


The maximum total deflection related to span shall not exceed the following values:

a) Operating floors, platforms and walkways L/300


b) Static equipment support beams L/400
c) Pipe rack main beams L/400
d) Pipe rack intermediate beams L/300
e) Cantilevers L/200
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DESIGN BASIS FOR STEEL STRUCTURE
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f) Crane beams/hoisting beams L/600


g) Wall posts and sheeting rail (horizontal) L/300 and < 20mm

The total maximum horizontal displacement related to height shall not exceed the
following values:

a) Equipment supporting structures H /200


b) Pipe racks H /200
c) Structures and buildings carrying travelling cranes H /500
d) Miscellaneous vertical pipe supports H /200
e) Conveyor supporting structures (due to wind) H /500

11 STRUCTURE DESIGN AND LOADS (OTHER THAN FOR PIPE


RACKS)
Steel structures shall be designed considering applicable loads and load combinations as
described in clause no. 8.0 of this design basis and in accordance with the configuration

12 SOFTWARE USED
Following software shall be used:

For analysis and design of


STAAD Pro V8i
steel and concrete structures
Employer validated excel spreadsheets
Design of Steel Connections
(Calculation for Standard drawings)
Anchor Bolts, Base Employer validated MS-Excel
Plates for static loads. Spread sheets/Mathcad sheets
All structural GA drawings shall be extracted from
Preparation of Drawings
PDMS using PDMS draft.

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