You are on page 1of 14

EMPLOYER

CONTRACTOR

PROJECT

BIOGAS CLEANING SYSTEM AT DOMESTIC SOLID WASTE


MANAGEMENT CENTRE (DSWMC) MESAIEED

DOCUMENT TITLE:

PIPING AND ASSOCIATED STRUCTURAL SUPPORTS DESIGN BASIS

CONSULTANT:

21-03-2018 0 ISSUED FOR COMMENTS DJ PS SS/GB

REV.
DATE REASON FOR REVISION PREPARED REVIEWED APPROVED
NO.

0
DOCUMENT NUMBER: 0220006-099-06-7000-0 REV.
Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

TABLE OF CONTENTS

Item no. Description Page no.

1 Piping 3

1.1 Codes, Standards & References 3

1.2 Piping Layout 4

1.3 Piping material 5

1.4 Piping Tie-in 5

2 Civil / Structural 6

2.1 General 6

2.2 Description of scope 6

2.3 Codes, Standards & References 6

2.4 Loads 7

2.5 Load combination 9

2.6 Pipe support foundation design 9

9
2.7 Concrete grade
2.8 Steel structure design – Pipe bridge 12

© Qatar Design Consortium


Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

1. PIPING
Piping shall conform to the requirements of ASME B31.3

1.1 CODES, STANDARDS & REFERENCES

ASME B31.3 Process Piping

ASME B36.10 Welded & Seamless Wrought Steel Pipe

Ring Joint Gaskets & Grooves for Steel Pipe


ASME B16.20
Flanges.

Square and Hex Bolts and Screws, Inch Series,


ASME B18.2.1
Including Hex Cap Screws and Lag Screws

ASME B18.2.2 Square and Hex Nuts (Inch Series)

NACE MR-0175/ Materials for use in H2S containing environments in


ISO 15156-2009 Oil and Gas production.

ASME B16.5 Pipe Flanges and Flanged fittings

ASME B16.9 Wrought Steel Butt Welding Fittings

ASME B16.10 Dimensions of valves

ASME B16.11 Forged steel fittings, socket welding and threaded

ASME B16.25 Butt Welding Ends

ASME B16.34 Valve-flanged, Threaded and Welding End

Bolted Bonnet Steel Gate Valves for petroleum and


API 600
Natural gas industries.

ASME Section VIII,


ASME un-fired Boiler and Pressure Vessel Codes
Div.1

QCS -2014 Qatar construction specification

API 598 Valve Inspection and Testing

ANSI B36.19 Stainless Steel Pipe

© Qatar Design Consortium


Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

1.2 PIPING LAYOUT

To achieve the most economical arrangement, piping shall be routed to ensure the

shortest practical length with a minimum number of fittings consistent with the

Requirements of the P&IDs and provision of expansion for flexibility.

Piping and structures shall be arranged to allow operation, inspection,

Maintenance and dismantling of equipment. There shall be sufficient access to

Allow mobile lifting devices to approach process equipment and make lifts without

Obstruction and with a minimal removal of pipework.

Piping at grade shall not be located above manholes or drain trenches, nor

Supported from grade above buried lines and cables.

Lines shall be located in as neat and orderly manner (in groups or banks when feasible) as
is consistent with economical design, pressure loss considerations and satisfactory
supporting arrangements. Unit areas shall not be cluttered with scattered pipe support
columns supporting randomly placed overhead lines.

All piping equipment, especially valves, requiring regular attention by the operating and
maintenance personnel shall be accessible from grade or platform.

The minimum clear headroom over main walkways, passageways and working areas at
grade or floor elevations shall be 2.20 m. The minimum clearance over secondary
walkways and elevated platforms, passageways and working areas shall be 2.0 m

The minimum clearance over primary roadways shall be 7.5 m. Secondary roads may have
lower clearance, but not less than 5.0m. Minimum clear head room over areas designated
as main access ways or tracking areas (other than roads) shall be 3.7 m.

Usually bottom most part of any line is provided with a drain line. To facilitate proper
draining and proper supporting arrangement of the pipe the bottom of pipe should
normally be kept at a minimum elevation of 400 mm from finished floor level.

© Qatar Design Consortium


Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

On the basis of frequency and necessity of operation valves shall be suitably located so
that they are accessible and can conveniently be operated from the grade, floor or platform
or from ladder. Where the hand wheel is higher than 2 meter from the operating floor,
chain operating system may be provided.

Vents or blind flanged vents for equipments shall be provided at high points of lines and
equipment required to be hydrostatically tested. However if this vent isolation is used
during normal operation from process consideration, valve will be provided.

Valved or plugged drains shall be provided at trapped low points of piping or equipment to
drain water, condensate or process liquids that must be drained during normal plant
operations. Drains at low points of lines and equipment required to be used only for
hydrostatic testing shall not be provided with valves. Instead threaded plugs (to be seal
welded after testing) or blind flanges will be used.

Pipe spans shall be evaluated such that the pipe stress does not exceeded 28N/mm 2
and the pipe shall not deflect more than 12.5mm, in either design or hydro test
conditions.

1.3 PIPING MATERIAL


The below mentioned piping material shall be followed,

Bio-Gas piping – Stainless steel, A312-TP316L

Hot water piping – Carbon steel, A 106-B

Portable water piping – Carbon steel, A 106-B

The minimum corrosion allowance for piping shall be as follows:

Carbon steel piping-1mm

Alloy steel – Nil

© Qatar Design Consortium


Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

1.4 PIPING TIE-IN


5nos of pipe tie-in identified during site visit observation along with Technochem/Keppel.

1. Bio gas supply to ERG system.

2. Bio gas return from ERG system.

3. Hot water supply to ERG system.

4. Hot water return from ERG system.

5. Portable water to ERG system.

2. CIVIL/STRUCTRUAL

2.1 GENERAL
This document defines the design criteria for Pipe Bridges/Pipe supports of the project
Biogas cleaning system at Domestic Solid Waste Management Centre (DSWMC) at
Mesaieed.

2.2 DESCRIPTION OF SCOPE


Steel Pipe Bridge shall be provided to support the piping crossing over roads. These shall
be taken into account all the dead and imposed loads and shall provide access underneath
in accordance with the Plant and Equipment layout specification.
Civil/structural engineering scope for the pipe bridges & associated pipe supports is as
follows:
 Design of pipe supports
New tie in point shall be from the existing piping network system. The new
pipelines shall be supported over a new pipe bridge system which shall be laid
parallel to the existing pipe racks so that proposed pipe rack foundation should
not disturb the existing one as well.
 Design of foundation for Pipe Bridge

© Qatar Design Consortium


Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

Foundation for the Pipe Bridge shall be block type foundation with its top level
matching with the surrounding concrete paving. It shall be sized and designed for
all strength and stability requirements.

2.3 CODES, STANDARDS & REFERENCES


The design standard and code of practices adopted in the design is as follows.
 BS EN 1990 : Basis of Structural Design
 BS EN 1991 : Euro code 1 – Action on Structures
 BS EN 1991-1-4 : Part 1-4: General actions – Wind actions
 BS EN 1992-1-1 : Euro code 2-Design of concrete structures
 BS EN 1993-1-1 : Design of steel structures

2.4 LOADS
Loads on the pipe bridge, pipe support structures and their components shall be calculated
with reference to the codes & standards specified in earlier sections. The following actions
shall be considered for the steel structure & concrete foundation design,
 Dead Load
 Live load / Imposed load
 Wind load

2.4.1 DEAD LOADS


All structural materials, floors and various permanent elements forming part of the
structure/building shall be considered as dead loads. The unit weights of materials and
components shall be as defined in BS 648 "Schedule of Weights for Building Materials" or
information from the product supplier giving installed weights of materials or
components. Suitable contingencies for material tolerances shall be included. Actions on
structures. The density of materials used in design shall be as follows.
Self-weight of reinforced Concrete = 25 kN/m3
Self-weight of plain Concrete = 24kN/m3
Structural Steel = 78.50 kN/m3

2.4.2 LIVE LOAD

© Qatar Design Consortium


Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

Variable action on different facilities shall comply with BS EN 1991-1. Imposed action
shall be applied as a combined arrangement for the most severe effect.

2.4.3 PIPING LOADS

Piping loads (including self-weight of piping) will be considered as live loads.


The following piping load conditions will be considered:
 Hydro test
 Operating
 Pipe empty
Vertical loads from piping in empty, operating and testing conditions will be used for the
design of supports. Horizontal loads due to thermal expansion will be considered as
operating loads. Loadings on pipe supports will be calculated based on the output from a
detailed pipe stress analysis utilizing the actual data for individual pipes and pipe
contents. However, a minimum design vertical load applied to each pipe support beam
will be 2.0 kPa and for erection condition 0.5 kPa.
Hydrotest on pipe support structures will be taken as the total weight of water in all pipes
in addition to pipes dead load. Beams supporting piping will be designed to withstand the
30% of the operating pipe loads.

Horizontal loads at the anchor support will be designed to carry anchor loads from pipe
stress analysis or the above mentioned friction load, whichever is more.

2.4.4 WIND LOAD


Wind load calculation is determined as per CP3 Chapter 5.
Wind speed as specified – V = 45 m/s
Design wind Speed - VS = V* S1*S2*S3
S1 = 1.0 (Table 2);
S2 = As per Class B, Table 3, open country with no obstruction;
S3 = 1.0
Design Wind Speed – Vs = 45 * 1*S2*1
= 45 *S2 m/s
Dynamic Wind Pressure – q = 0.613* Vs²
= 0.613 * (45 * S2)²

© Qatar Design Consortium


Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

2.5 LOAD COMBINATION

Types of loads and load combinations shall be in accordance with BS EN 1990: Basis of
structural design, BS EN 1991: Action on structures and any other relevant standards
listed in section: 4.

Design loads shall be arranged such that the combined loads produce the most severe
effect on the elements and structure as a whole.

Load combinations involving minimum dead load and maximum overturning loads shall
be included in the civil / structural analysis and design.

Appropriate load factors within all load combinations shall be applied in accordance with
the design code(s) being used.

2.6 PIPE SUPPORT FOUNDATION DESIGN


Design and details of structural concrete for pipe support foundation shall be in
accordance with BS EN 1992; Euro code 2 – Design of concrete structures.

Maximum allowable settlement in foundations shall be 25 mm. General design of


foundations shall be in accordance with BS 8004.
The minimum factors of safety for stability checks shall be as follow:
Overturning - 1.5 (erection condition)

- 2.0 (operating condition)


Sliding - 1.5
Uplift - 2.0
Geotechnical parameters such as safe bearing capacity of soil, densities, angle of internal
friction, lateral earth pressure coefficients, recommended friction coefficients etc. which
are used in foundation design shall be referred from the available geotechnical
investigation report.
In case of static plus dynamic loads, soil pressure below the foundation shall not exceed
75% of allowable soil bearing capacity.

© Qatar Design Consortium


Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

2.7 CONCRETE GRADE


Concrete work shall be designed using the following minimum grades:

(kg/m3)Minimum cement content


(N/mm2)Nominal 28 day strength

ratioMaximum water/ cement


Strength classCompression

(mm)SizeAggregate
ClassExposure
Cement type
Concrete

CEM I:
Structural Ordinary
C40 XS1 40 20 350 0.45
Concrete Portland
cement
Lean CEM I+:
C20 Sulphate XA2 20 20 310 0.55
Concrete Resistant
Plain
Concrete CEM I+:
C15 Sulphate XA2 15 20 280 0.55
(for Resistant
Blinding)

In case of static plus dynamic loads, soil pressure below the foundation shall not exceed
75% of allowable soil bearing capacity.

2.7.1 CEMENT
Cement for structural reinforced concrete and paving shall be Ordinary Portland Cement
to BS EN 197 or Client Approved equivalent. Sulphate Resisting Portland Cement (SRC)
complying with BS 4027 shall be used for blinding concrete, mass concrete and other
unreinforced concrete.

© Qatar Design Consortium


Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

2.7.2 REINFORCEMENT STEEL


Reinforcing steel shall be uncoated high yield deformed bars of minimum strength of 500
N/mm2 (GRB500B) as supplied by Qatar Steel Company (QASCO), in accordance with
BS 4449. No welding, including tack-welding, will be permitted on GRB500B deformed
bar reinforcement. High yield deformed bars of minimum strength of 500 N/mm2 shall be
designated as grade B500B using the notation ‘H’.

2.7.3 CONCRETE COVER


Minimum clear concrete cover to all steel reinforcement including links cover to any
reinforcement shall be as follows:
 Cover for all concrete works in contact with soil including Foundations up to base
plate level - 70mm
 Cover for all above concrete exposed to weather - 50mm
Minimum thickness of blinding layer shall be 75 mm.

2.7.4 SURFACE PROTECTION


All concrete foundations in contact with soil shall be coated in accordance with
requirements of QCS. Concrete surfaces where acid spillage is expected shall have acid
resistance tiles/ acid resistance coating, as appropriate. Appropriate concrete protection
system shall be designed as per the soil / environmental condition to which the structural
elements are exposed. Underground concrete protections system shall be provided based
on the soil report.
Hydrocarbon resistant epoxy based coating shall be provided to all exposed concrete
structures and surfaces above ground.

2.7.5 GROUTING

© Qatar Design Consortium


Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

Cement-based proprietary non-shrink grout shall be used for filling space under base
plates of steel columns and static equipment, and in sleeves around anchor bolts unless
noted otherwise.

2.7.6 ANCHOR BOLT


Anchor bolts and nuts shall be grade 4.6 conforming to BS 4190. Washers shall conform
to BS 4320. Lock nuts shall be provided for anchor bolts to vibrating equipment. Anchor
bolts, nuts and washers shall be hot dip galvanized in accordance with BS EN ISO 1461.
All other structural steel items cast-in to concrete shall be hot dip galvanized accordance
with BS EN ISO 1461 unless noted otherwise in the project documents. Each anchor bolt
shall be adequately anchored into concrete.
The minimum distance from centerline of anchor bolt to edge of concrete plinth shall be as
follows:
a) 100mm for bolts < 20 mm Ø
b) 150mm for bolts > 22 mm Ø
The minimum distance from base plate grout to edge of concrete plinth shall be 75mm.
Adequate reinforcement shall be provided in concrete plinths to transfer the design tension
and shear from anchor bolts to the foundation. Vertical reinforcement in concrete plinths
shall be provided with sufficient anchorage length above and below the bottom of anchor
bolts.

2.8 STEEL STRUCTURE DESIGN – PIPE BRIDGE


Structural steelwork shall be designed and constructed in accordance with BS EN 1993,
BS 5950 and Qatar National Construction Standards. This specification shall apply to all
structural steelwork including secondary steelwork such as platform & walkway joists,
purlins & girts, stair stringers, ladders, handrails and the like.
2.8.1 MATERIAL
All structural steel shall be of Grade S275 JR to BS EN 10025 or equivalent as a
minimum. All structural steel hollow sections shall be grade S275JOH to BS EN 10210 or
equivalent as a minimum.
Minimum thickness of structural members and connections shall be as follows:

© Qatar Design Consortium


Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

 Except for the webs of rolled steel beams and channels, the minimum thickness of
structural members shall be 6mm.
 Minimum thickness for plates in structural connections shall be 10 mm.

2.8.2 DEFLECTION CRITERIA


The allowable deflections for some of the members are given below. For other
members, BS 5950 shall be followed.
Deflection Type Deflection Limit
Beam Vertical Deflection L / 200
Cantilever Beam Vertical
L/180
Deflection
Column Horizontal Deflection H/300

‘H’ = Height of Column


‘L’ = Span of beams

2.8.3 CONNECTIONS
BOLTING
All structural connections at field shall be made using galvanized bolts of grade 8.8
conforming to BS 3692 in normal tolerance holes using a minimum of 2 x M20 bolts. The
reduced strength due to holes shall be computed. Connection designs shall be based upon
field bolting and shop welding.

WELDING
Design strength of fillet welds shall be in accordance with Table 37 of BS 5950
Part-I. For steel sections fabricated from plate, connection between flange and
web of section shall have fillet weld both sides of web. The minimum leg
length of any stressed weld shall be minimum 6mm or in accordance with the
following:
Thickest part to be connected
Leg Size (mm)
(mm)
Up to and including 20 6
Above 20 and up to 35 8

© Qatar Design Consortium


Project: Biogas cleaning Doc: Piping and associated structural
system at domestic solid supports Rev Date
waste management centre
(dswmc) 21-03-
Doc No: 0220006-099-06-7000-0 0
18

Size of fillet welds shall refer to the leg length. The effective length of the fillet welds
shall be the length excluding the first and last 25mm of the weld.
2.8.4 BASE PLATES
Shear resistance shall be developed by shear in the anchor bolts or other mechanical
means. Base plates shall be proportioned so that the maximum bearing stress on grout and
foundation concrete shall not exceed allowable limits.

2.8.5 STEEL PROTECTIVE COATING


All materials, consumables, labour and equipment necessary for application of protective
coatings shall be in accordance with standard specification and the coating manufacturer
instructions.

© Qatar Design Consortium