NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES Q.10

REINFORCED CONCRETE STACKS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES Q.10
REINFORCED CONCRETE STACKS Page 2 of 13
Rev 0 1999

INDEX
SECTION TITLE PAGE

1.0 SCOPE OF SPECIFICATION 3

1.1 Introduction 3
1.2 Other NOC Specifications 3

2.0 DEFINITIONS 3

2.1 Technical 3
2.2 Contractual 4

3.0 DESIGN 5

3.1 Codes and Standards 5

3.2 Design Considerations 6
3.3 Electrical Design 7
3.4 Structural Design 7
3.5 Access Facilities/Ancillaries 9
3.6 Foundation Design 9

4.0 MATERIALS 9

4.1 General 9
4.2 Reinforced Concrete 9
4.3 Access Facilities/Ancillaries 10
4.4 Corrosion Allowance 10

5.0 FABRICATION AND CONSTRUCTION 10

6.0 CURING 10

6.1 General 10
6.2 Hot Weather Concreting 10
6.3 Temperature Records 10
6.4 Propping 10

7.0 INSPECTION AND TESTING 11

7.1 Responsibility 11
7.2 Owner Access 11
7.3 Testing 11
7.4 Rejection 11
7.5 Notification 11

8.0 DOCUMENTATION 11

8.1 Introduction 11
8.2 Schedule and Reports 12
8.3 Data and Calculations 12
8.4 Drawings 12
8.5 Final Records, Documents and Manuals 13
8.6 Warranty 13
1.0 SCOPE OF SPECIFICATION
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1.1 Introduction

1.1.1 This specification covers the minimum requirements for the structural design, detailing, material supply and
construction of freestanding reinforced concrete single and multiflue stacks (chimneys).

1.1.2 This specification applies to refineries, onshore oil and gas installations and processing facilities.

1.1.3 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner.

1.1.4 In the event of any conflict between this specification and the applicable codes and standards, the
Vendor/Contractor shall inform the Owner in writing and receive written clarification before proceeding
with the work.

1.1.5 This General Engineering Specification will form part of the Purchase Order/Contract.

1.2 Other NOC Specifications

The following NOC Specifications form an integral part of this specification and any exceptions shall be
approved in advance by the Owner.

GES C.03 Safety Procedures on Construction Sites

GES F.05 Linings for Fired Equipment and Stacks

GES L.25 Grounding and Overvoltage Protection

GES L.26 Plant Lighting

GES Q.03 Foundations (inc. Piling)

GES Q.04 Concrete Structures

GES Q.14 Design Loads for Structures

GES S.01 Steelwork Structures

GES S.02 Structures for Operation and Maintenance

GES X.01 Surface Preparation and Painting Application

GES X.02 Colour Coding of Equipment and Piping

GES X.03 External Protective Coatings

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Single Wall Stacks (Chimney)

A single reinforced concrete shell or wind shield utilised as the primary structural support system.
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Multiflue Stacks

Multiple gas passage elements contained within one exterior reinforced concrete shell.

Design Loadings

The various components of applied loads which shall be taken into account in the structural design and
which shall be as defined in GES Q.14 together with the requirements of ACI 307.

Design Drawings

These are the conceptual design drawings that form part of the Purchase Order/Contract and may be
produced by the Owner, his appointed consultant or the Vendor/Contractor.

Detailed Engineering Drawings

These are detailed working drawings prepared by the Vendor/Contractor which must be submitted to the
Owner for approval and marked "Issued for Construction" prior to the commencement of construction.
During preparation of these drawings, the Vendor/Contractor is required to verify the accuracy of the
Design Drawings.

Substitutions

The Vendor/Contractor shall submit in writing to the Owner, for approval, any proposals for substitutions
due to non-availability of materials or changes to the proposed design, prior to the commencement of work.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.
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Inspection Authority

The organisation representing the Owner or Vednor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification, the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

The following codes and standards, together with the references therein, shall be deemed to form part of
this specification. All recommendations shall apply, unless specifically modified herein.

3.1.1 American Standards

This specification references American Standards (Metric Editions) within the text, mainly because of their
comprehensive coverage of seismic loading and hot weather requirements. Equivalent European Codes
may also be acceptable, provided that seismic and hot weather requirements are included.

ACI 305R - Hot Weather Concreting

ACI 307 - Standard Practice for the Design and Construction of Reinforced Concrete
Chimneys

ACI 308 - Practice for Curing Concrete

ACI 318M - Building Code Requirements for Structural Concrete and Commentary
(Metric)

ASCE 7 - Minimum Design Loads for Buildings and Other Structures

ASME STS-1 - Steel Stacks ((Referred parts only)

ASTM A123/A123M - Specification for Zinc (Hot Dip Galvanised) Coatings on Iron and Steel
Products

ASTM C39 - Test Method for Comprehensive Strength of Cylindrical Concrete

Specimens

NFPA 780 - Lightning Protection Code

3.1.2 British and International Standards

The use of the following equivalent British and International standards and their references is deemed
equally acceptable, subject to their consistent application throughout the works (design and construction)
and with the addition of seismic and hot weather requirements.

BS 3572 - Specification for Access Fittings for Chimneys and other High Structures in
Concrete.
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BS 4211 - Specification for Ladders for Permanent Access to Chimneys, other High
Structures, Silos and Bins.

BS 7668 - Specification for Weldable Structural Steels

BS 8110:1 - Structural use of Concrete - Codes of Practice for Design and

Construction

BS CP3 (Chapter V, Part 2) Code of Practice for the Design of Buildings - Loading - Wind Loads

International Standard

International Committee for Industrial Chimneys and Stacks

CICIND - Model Code for Concrete Chimneys

Parts A, B & C

3.1.3 Other Standards

The use of National Standards of other countries shall be subject to approval by the Owner. The
intermixing of National Standards from various countries is not acceptable. In the event of a conflict
occurring between codes, standards and this specification, the requirement leading to the safer design shall
be used as determined by the Owner.

3.1.4 Edition of Standards

Unless specified otherwise in the Purchase Order/Contract, the editions of the above codes and standards
shall be those prevailing at the effective date of Purchase Order/Contract.

3.1.5 Units

SI derived metric units shall be used for all measurements, except nominal pipe sizes (NPS diameters)
which shall be in inches.

3.2 Design Considerations

The stack structure design shall ensure that adequate insulation is incorporated to maintain the temperature
below 300°C even during upset conditions, and to ensure that the foundation temperature does not affect
the soil bearing capacity and settlement due to ground shrinkage.

Design draught capacity and the type of internal lining, shall be dependent on the equipment, the stack is
designed for and in accordance with GES F.05.

Due consideration shall be given to at least the following aspects for effect on the structural design:

(a) Sizing of diameter and height to achieve the required draft and flue gas dispersion.

(b) Design of stack insulation to conserve heat to prevent condensation and meet the emission criteria.

(c) Differential expansion between the following stack components:

- external/internal shells of single or multiflues;

- breechings/openings;
- test/instrument ports;
- platform/ladder brackets;
- building braces and guides;
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- roof flashings;
- top stack/truncated cone.

(d) Appurtenances which may include attachments for:

- access doors at base and other locations;

- false bottoms below lower stack inlet;
- drains in false bottoms and/or foundations;
- test/instrument ports;
- inspection ports;
- access ladders and platforms;
- maintenance trolley track;
- rain caps or truncated cone caps;
- spark arresting screens;
- internal or cap dampers;
- internal vanes or splitter baffles;
- davits;
- stack roofs for multiple flues and flashings;
- lining supports;
- external fixings.

(e) Discontinuities in the shell for:

- breechings/openings;
- inspection ports;
- access doors;
- corbel rings/floors for lining support.

3.3 Electrical Design

The design must take account of any appurtenances such as lighting etc and consideration shall be given to
at least the following items:

- aviation obstruction marking light systems shall be provided in accordance with International Civil
Aviation Organisation (ICAO) requirements;

- plant lighting shall be provided in accordance with GES L.26;

- earthing (grounding) shall be provided in accordance with GES L.25;

- lightning protection shall be provided in accordance with NFPA 780.

3.4 Structural Design

3.4.1 Scope

The following structural design requirements apply only to freestanding stacks with circular cross-section
of the following forms of construction:

- single flue and shell where the shell is the primary structure;
- multiflue where several liners are contained in one load bearing shell.

Stacks other than circular in cross-section or in pairs, rows or groups closer than 15 diameter apart, and
those near other structures of comparable height, may be subject to exceptional wind force and particularly
wind-induced oscillation greater than that allowed for in this specification. Appropriate expert advice
should therefore be obtained in these cases.
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3.4.2 Loadings

The stacks shall be designed to resist the wind and seismic loads and combinations in accordance with GES
Q.14 and ACI 307.

Thermal load due to unequal distribution of heat, and due to differential movement of components, shall be
given adequate consideration as shall other loads such as duct weight, expansion joint thrusts and pressure
loads. Thermal stresses shall be determined for the flue shell using the largest temperature differential that
could occur at the start-up, shut-down or normal operation.

3.4.3 Allowable Stresses

Allowable stresses shall be in accordance with GES Q.14 and ACI 307.

Discontinuities in the shell shall be designed as follows to withstand all applied loads:

- the top and bottom of breeching openings shall be reinforced to transfer the longitudinal shell
loads across the opening;
- the sides of breeching openings shall act as columns or tension members to withstand the end
reactions of the assumed horizontal girders indicated above. The section modulus of a plane cut
through the opening shall be adequate to withstand all applied loads at the permitted allowable
stress;
- the entire breeching opening shall perform as a Vierendeel frame to withstand the applied
longitudinal tension or compression, the summation of tangential shear, circumferential tension or
compression and radial shear;
- the top and bottom of the breeching opening shall be adequately reinforced to transfer the
discontinuities of shell stress back to the full circumference;
- the breeching opening reinforcement may also serve as a means of connecting the breeching to the
flue.

3.4.4 Deflections

The maximum deflection under equivalent static design loading shall be calculated, and the foundation
rotation or movement shall be considered in evaluating deflection. The calculated static deflection shall be
considered in evaluating the suitability of any mechanical equipment on the stack. The maximum vibration
amplitude shall be evaluated.

Deflection under lateral loads, sun effect or non-uniform gas temperature across the flue will displace the
stack centreline and produce a secondary moment equal to the summation of the stack element weights
times the displacements and these secondary moments shall be analyzed.

For analysis during the construction condition, the allowable static deflections may be increased by 20%.
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3.4.5 Vibration

The stack shall be designed to limit dynamic response stresses and deflections under both wind and seismic
loading in accordance with ACI 307.

Stacks shall be designed to avoid excessive oscillation due to wind vortex shedding but shall also be made
strong enough to allow the future addition of shrouds or strakes, should actual wind oscillations prove
significant in service.

3.5 Access Facilities/Ancillaries

Structure for access and ancillaries shall be designed in accordance with the minimum requirements of GES
S.02 and ACI 307. Should conflicts of criteria occur between the documents, the more conservative shall
form the design basis. All proposals shall be subject to the Owner's approval.

Maintenance ring and trolley, and drain system shall be in accordance with ASME STS-1 Sections 2.2.8(e)
and (h).

3.6 Foundation Design

3.6.1 General

The foundations shall be designed in accordance with GES Q.03 to transfer all applied loads to the
supporting soil or piles. Static and dynamic loads in accordance with Section 3.4.2 above shall be
considered.

The shell base shall be capable of transferring all longitudinal, tangential and radial loads to the foundation.

For cylindrical base rings an approximate analysis similar to the procedures indicated in ACI 307 shall be
used to estimate the neutral axis location and thereby the starter bar tensions and shell pressure on the
concrete base.

For ancillary bases direct analysis complying with the AISC manual requirements for anchor bolts shall be
used as guidance.

Soil bearing pressure shall be taken as GES Q.03, Section 3.8.

Stability ratio for overturning shall be as GES Q.03, Section 3.4.1 with the additional requirement that, for
all load cases, at least 60% of the foundation length in the direction of overturning shall provide positive
soil pressure.

4.0 MATERIALS

4.1 General

The basic material categories are summarised below, however, the Owner may approve the use of
alternative grades to suit individual applications and availability, subject to compliance with the
requirement of ACI 307.

4.2 Reinforced Concrete

All materials shall be strictly in accordance with GES Q.03 Section 4.0 and GES Q.04 Section 4.0
requirements unless modified by ACI 307 and approved by the Owner.

The minimum design strengths of the concrete shall comply with the requirements of GES Q.04 Section
5.6.
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4.3 Access Facilities/Ancillaries

Materials for structures for operation and maintenance, such as ladders, stairs, platforms and handrails shall
generally be in accordance with GES S.02. The possibility of corrosion and bimetallic corrosion shall be
considered in the design.

Insulation, jacketing, strapping and corrosion protection shall be as referenced in GES F.05, GES X.01,
GES X.02 or GES X.03 as applicable.

4.4 Corrosion Allowance

A corrosion allowance of 1.5 mm shall be provided for ancillary equipment and accessory structures, unless
approved otherwise by the Owner.

5.0 FABRICATION AND CONSTRUCTION

Fabrication and construction of stack shall be in accordance with GES Q.04 subject also to compliance with
ACI 307.

Foundation construction shall be strictly in accordance with GES Q.03.

6.0 CURING

6.1 General

The curing of all concrete work shall be strictly in accordance with ACI 308 and GES Q.04.

No concreting will be allowed until all curing materials are on site and have been approved by the Owner.
Concrete curing shall be continuous until the compressive strength has reached 70% of the specified
strength, but not less than 7 days minimum.

6.2 Hot Weather Concreting

The recommendations of GES Q.04 Section 6.2 and ACI 305R, shall be strictly followed for the
manufacture, placing and curing of concrete.

6.3 Temperature Records

The requirements of GES Q.04 Section 6.3 shall apply.

6.4 Propping

Propping shall be as per GES Q.04 Section 6.4.

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7.0 INSPECTION AND TESTING

7.1 Responsibility

The Vendor/Contractor shall be fully responsible for the provision of adequate supervision to ensure that
the works are executed as indicated on the design and detailed design drawings, to the standards in this
specification and the Purchase Order/Contract. The Vendor/Contractor shall submit his inspection and
testing programme for approval of the Owner, prior to commencement of work. Before use, samples of all
materials shall be subject to appropriate testing and no material shall be used until it has been approved.

Release for shipment by the Owner or representative does not relieve the Vendor/Contractor of any
responsibility or any guarantee.

7.2 Owner Access

All design works and construction covered by this specification are subject to inspection by the Owner or
his Inspector. The Vendor/Contractor shall allow free access to the design office, fabrication yard and
construction site for inspection by the Owner's representative, however, such inspection shall not relieve
the Vendor/Contractor of his responsibility for the correct execution of the works.

7.3 Testing

Testing of cylindrical concrete specimens shall be as per ASTM C39.

7.4 Rejection

Works or parts thereof and material included therein, indicating irremediable or injurious defects, improper
construction, excessive repair or not in accordance with this specification, shall be subject to rejection.
They shall also be subject to rejection even if such conditions are discovered after previous acceptance. All
liability associated with rejection shall be borne by the Vendor/Contractor.

7.5 Notification

Adequate notification shall be given by the Vendor/Contractor, prior to the commencement of any stage of
the work, in order to allow inspection by the Owner.

8.0 DOCUMENTATION

8.1 Introduction

8.1.1 This section covers the documentation required for the design, material, selection, fabrication, construction,
inspection and testing for reinforced concrete stacks to be provided against this specification.

8.1.2 The detailed list of documents that are required is included in the Purchaser Order/Contract. However, as a
minimum the following listed documents will be provided by the Vendor/Contractor:-

- list of key engineers and skilled operators with their resumés;

- details of similar work undertaken;

- list of proposed construction plant;

- methodology statement for the implementation of the work;

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- survey and site investigation proposals;

- proposals for testing of materials.

8.1.3 The documents as listed may be considered as a minimum requirement; all details to confirm compliance
with the relevant specifications and to allow a full and continued appraisal to be made of the
Vendor/Contractor's proposals and interpretations of the awarded Purchase Order/Contract.

8.1.4 Any purchase or procurement undertaken by the Vendor/Contractor, which is prior to the relevant
documentation being submitted and reviewed by the Owner, is at the Vendor/Contractor's risk.

8.1.5 On all documentation the Purchase Order/Contract number, equipment title, tag number and project name
shall be quoted.

8.1.6 All documentation shall be checked and signed by the checker before submission.

8.2 Schedule and Reports

8.2.1 The Vendor/Contractor shall submit with his tender a preliminary Quality Control Plan.

8.2.2 The Vendor/Contractor shall include with his tender documentation a statement of proposed Sub-
Contractors/sub-vendors, a document submission schedule for all documents based on a review cycle of 3
weeks and outline programme for procurement and construction activities.

8.2.3 The Vendor/Contractor shall incorporate any revisions agreed with the Owner during the enquiry review
stage and submit revised tender documentation for approval.

8.2.4 Monthly reports shall be submitted by the Vendor/Contractor, detailing design, procurement, production
and documentation activities, the format of which shall be agreed with the Owner.

8.3 Data and Calculations

8.3.1 Project specific instructions shall be issued to the Vendor/Contractor with the Purchase Order/Contract,
which describes the data and calculations to be submitted and the methods of submission.

8.3.2 The Vendor/Contractor shall be responsible for obtaining approvals from the Inspection Authority, if any.

8.3.3 All calculations shall be carried out in a clear and logical manner. Where conditions involve the use of
formulae or methods not specified in the Design Code, the source of these formulae or methods shall be
clearly referenced.

8.3.4 Computer calculations will only be acceptable if all the input is shown, together with calculated values of
intermediate terms and factors and options chosen, as well as final calculated dimensions, stress or other
values and the computer programme has been validated to the satisfaction of the Owner.

8.3.5 Calculations and drawings that are interdependent, i.e. foundation loading and equipment footprint, shall be
presented for appraisal together.

8.4 Drawings

8.4.1 The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to the Owner
for review and approval.

8.4.2 General arrangement drawings shall be to scale and show the relative location and main dimensions of all
components, including elevations.

8.4.4 As-built drawings shall include the general arrangement drawings marked-up with the actual as-built
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dimensions.

8.5 Final Records, Documents and Manuals

8.5.1 Two copies of the Data Dossier shall be supplied and shall be a record of the construction process. Where
stated in the Purchase Order/Contract it shall contain the following:-

- general arrangement drawings and bill of materials;

- the Quality Control Plan;
- material certificates;
- chemical analysis certificates;
- positive material identification certificates;
- weld procedures;
- welder qualifications;
- NDT procedures and records;
- non-conformity records;
- approvals by the Independent Inspection Authority;
- Certificate of Conformity;
- Owner's Release Certificates.

8.5.2 The Vendor/Contractor shall produce as built documents, revised to indicate field changes.

8.5.3 The Vendor/Contractor shall provide one set of mylar original drawings.

8.6 Warranty

8.6.1 The Vendor/Contractor shall warrant all materials and workmanship incorporated into the facilities against
any defect for a minimum of twelve months after Owner certified completion of the works, or for the
period stipulated in the Purchase Order/Contract.

8.6.2 Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring it to the standard specified in the Purchase Order/Contract.