PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

INDEX
SR.NO. TITLE PAGE NO.

1 INTRODUCTION 3

2 SCOPE 3

3 GENERAL STRUCTURE DESCRIPTION 3

4 REFERENCE DRAWINGS & DOCUMENTS 4

5 DESCRIPTION OF STRUCTURE MODEL 4

6 DESIGN INPUT DETAILS 5

7 LOADS & LOAD COMBINATIONS 13

ANNEXURE-1 PILE FOUNDATION DESIGN

ANNEXURE-2 ANCHOR BOLT AND SHEAR KEY DESIGN

ANNEXURE-3 FOUNDATION DRAWINGS

ANNEXURE-4 PIPING LOAD INPUT

ANNEXURE-5 SOLIDITY RATIO CALCULATION FOR WIND

ANNEXURE-6 STAAD INPUT AS PER IS 1893 RESPONSE SPECTRUM

ANNEXURE-7 STAAD OUTPUT AS PER IS 1893 RESPONSE SPECTRUM

 PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

1 INTRODUCTION

Mangalore Refinery and Petrochemicals Limited (MRPL), a subsidiary of Oil and Natural Gas Corporation Limited has set up Petrochemical
Fluidized Catalytic Cracking Unit (PFCC) .
PFCC flue gas handling system is designed for recovering the catalyst fines in flue gas and to meet suspended particle matter emission limit
of 50mg/Nm3 at stack.
MRPL intends to install Flue gas wet scrubbing system (WSS) to reduce suspended particulate matter in flue gas to 20 mg/Nm3 dry basis or
less with provision to further reduce the SPM level upto 10mg/Nm3.

2 SCROPE

This document is in continuation with Document no. 5083-CVS-WSS-ED0001. Scope of this documents is to provide Pile Foundation Design
of Duct supporting platform near Disengaging drum. For Pile foundation design refer Annexure-01

3 GENERAL STRUCTURE DESCRIPTION

Duct supporting platform near Disengaging Drum is a 7.1 meter hight structure, above FGL. Pile foundation of 1.0m Thick Pile Cap is
provided at 2.5 m depth from HPP EL 100.000. RCC Pedestals size 1.0m x 1.0m , provided upto 2.5 m above HPP, to take care of the
Fireproofing requirements. Tie beam is provided at top of pedestal in both direction
 PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

4 REFERENCE DRAWINGS AND DOCUMENTS

4.1 REFERENCE DOCUMENTS :

Documents No. Discriptions

IS: 800 2007 General Construction in Steel - Code of Practice

IS: 456 Plain & Reinforced Concrete - Code of Practice
IS 1875 part3 Code of Practice for Design Loads (other than earthquake) for Buildings & Structures
IS 1893 part1 Criteria for Earthquake Resistance Design of Structures
IS 1893 part4 Criteria for Earthquake Resistance Design of Structures (Industrial Structure)
IS 13920-2016 Ductile Design and Detailing of Reinforced Concrete Structures Subjected to Seismic Forces
IS 2911 part2 Design and Construction of Pile Foundations_Code of Practise
6723-CVC-331-EC-0005 General Engineering Specifications: Civil
EDB-002 Engineering Design Basis (Civil, Structural, Architectural)

4.3 UNITS OF MEASUREMENT

SI units are used in this document unless otherwise noted.

5 DESCRIPTION OF STRUCTURAL MODEL

Structure modelled in staad pro with steel buitup sections for main column and main beam and Indian standard sections for other
beams and bracings. Rcc pedestals and Rcc beams modelled and designed in staad pro as per IS 13920. To design Pile
foundation,Pile cap modelled in staad pro as a plate element, thickness of pile cap assinged is 1. meter. Pile assiged as a spring at
each pile locations in model.

Fig: Raft layout with column position

 PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

6 DESIGN INPUT DETAILS

6.1 MATERIAL DATA :

Concrete
Design Comp. Strength Fck = 30 N/mm2

Unit Weight of Concrete γc = 25 KN/m3

Unit Weight of Water γW = 10 KN/m3

Concrete Cover for Found. Cf = 75 mm

Concrete Cover for Column. Cc = 75 mm

Concrete Cover for Beam. Cb = 50 mm

Reinforcement Steel
Yield Strength of Steel Fy = 500 N/mm2

Unit Weight of Steel = 78.5 KN/m3

Structural Steel
Ultimate Strength of Steel Fu = 410 N/mm2

Yield Strength of Steel Fy = 250 N/mm2 ( As per Design Basis )

Unit Weight of Steel = 78.5 KN/m3

6.2 SECTIONAL PROPERTY:

R.C.C Column Section Size = 800mm x 800mm

R.C.C Beam Section Size = 400mm x 400mm

Section modifier factor fok column crack section = 0.7 Ig ( As per IS 1893 )

Section modifier factor fok beam crack section = 0.35 Ig ( As per IS 1893 )
 PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

Figure: STAAD Model with R.C.C. Column 0.8m x 0.8m

Figure: STAAD Model with R.C.C. Beam 0.4m x 0.4m

 PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

Figure: STAAD Model Node Numbers

 PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

6.3 LOADING DATA

6.3.1 Dead Loads (DL)

Dead load case shall cover the self weight of steel structure, Rcc structure (Rcc beam, column, bracing and raft), grating load, handrail load
staircase dead load and Electrical and Instrumentation load. The software automatically calculates the self weight of each modelled components
as per density and sectional properties. Factor 1.1 used for weight of gusset plates, anchor bolt, conncetion bolts etc.

(Grating load applied as u.d.l on supporting

Grating load = 0.5 Kn/m2 ( As per Design Basis )
beam)
9) Grating span 1.050 = 0.525 Kn/m
13) Grating span 0.5 = 0.25 Kn/m
14) Grating span 1 = 0.5 Kn/m

Handrail load = 0.2 Kn/m ( As per Design Basis )

Electrical & Instrumentation Load

Lamp post load = 10 Kg ( As per Electrical input )
Electrical cable tray load = 30 Kg/m

6.3.2 Live Load (IL)

Live Load on Platform = 5 Kn/m2 ( As per Design Basis ) (Live load applied as u.d.l on supporting
beam)

9) Slab span 1.050 = 5.25 Kn/m

13) Slab span 0.5 = 2.5 Kn/m
14) Slab span 1 = 5 Kn/m
Live Load on Paving = 10 Kn/m2 ( As per Design Basis )

6.3.4 Pipe Loads (PE, PO & PT ) (As per piping input)

Piping load taken from Stress analysis report, Stress report as attached in Annexure-5

6.3.5 Thermal Load (TL)

Thermal Load applied, 30% of pipe operating load in longitudinal and transverse direction and 10% for pipe which support on spring with teflon
pad.

6.3.6 Thermal Anchor Guide load (TA)

The anchor and guide forces in longitudinal and transverse directions shall be as per piping inputs.

6.3.7 WIND LOAD

Basic wind speed Vb = 39 m/s

Risk factor k1 = 1

Terrian category factor k2 = 1 for upto 10m height

Terrian category factor k2 = 1.05 for upto 15m height
Terrian category factor k2 = 1.07 for upto 20m height
Terrian category factor k2 = 1.12 for upto 30m height
Terrian category factor k2 = 1.17 for upto 50m height
Topography factor k3 = 1

Cyclonic factor k4 = 1

Design wind speed Vd = 39 m/s for upto 10m height

Design wind speed Vd = 40.95 m/s for upto 15m height
Design wind speed Vd = 41.73 m/s for upto 20m height
 PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

Design wind speed Vd = 43.68 m/s for upto 30m height

Design wind speed Vd = 45.63 m/s for upto 50m height

Wind pressure at z height Pz = 912.6 N/m2 for upto 10m height

Wind pressure at z height Pz = 1006.1415 N/m2 for upto 15m height
Wind pressure at z height Pz = 1044.83574 N/m2 for upto 20m height
Wind pressure at z height Pz = 1144.76544 N/m2 for upto 30m height
Wind pressure at z height Pz = 1249.25814 N/m2 for upto 50m height

Wind directionality factor Kd = 0.9 for triangular, square , rectangular structure

Area averaging factor Ka = 1 being open strucure, value assigned as 1
Combination factor Kc = 1 no external internal pressure, value assigned as 1

Design wind pressure Pd = 821.34 N/m2 for upto 10m height

Design wind pressure Pd = 905.52735 N/m2 for upto 15m height
Design wind pressure Pd = 940.352166 N/m2 for upto 20m height
Design wind pressure Pd = 1030.288896 N/m2 for upto 30m height
Design wind pressure Pd = 1124.332326 N/m2 for upto 50m height

Design wind pressure Pd = 0.82134 kn/m2 for upto 10m height

Design wind pressure Pd = 0.90552735 kn/m2 for upto 15m height
Design wind pressure Pd = 0.940352166 kn/m2 for upto 20m height
Design wind pressure Pd = 1.030288896 kn/m2 for upto 30m height
Design wind pressure Pd = 1.124332326 kn/m2 for upto 50m height

Shape factor for wind = 1.7 (for star column as per IS875 Part3 Table-32)

Calculation of Shielding factor for Wind Load

(For Solidity ratio calculations Refer Annexure-5 )

8.5 / 8.5 = 1

Solidty ratio of Main Structure in X-dir 0.36

Solidty ratio of Main Structure in -X-dir 0.29

Solidty ratio of Main Structure in Z-dir 0.39

 PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

Solidty ratio of Box Bridge in X-dir 0.46

Solidty ratio of Box Bridge in Z-dir 0.42

Solidty ratio of Truss in X-dir 0.45

Frame width in X & -X -direction = 8.5 m

Frame spacing in X & -X-direction = 8.5 m

Frame Widht in Z & -Z-direction = 11.5 m

Frame spacing in Z & -Z -direction = 8.5 m

Length of Bridge in X-direction = 2 m

Frame spacing of Bridge in X-direction = 2 m

Depth of Bridge in Z-direction = 2 m

Frame spacing of Bridge in Z-direction = 2.5 m

Depth of Truss in X-direction = 1 m

Frame spacing of Truss in X-direction = 1.85 m

Frame spacing ratio of main structure in X = 1.00

& -X -direction

Frame spacing ratio of main structure in Z = 0.74

& -Z-direction

Frame spacing ratio of Bridge in X & -X - = 1.00

direction

Frame spacing ratio of Bridge in Z & -Z - = 1.25

direction

Frame spacing ratio of Truss in X & -X - = 1.85

direction

As per Table 32 IS875 part3 2015

Shielding factor for main structure in X - = 0.75

direction
 PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

Shielding factor for main structure in -X - = 0.70

direction

Shielding factor in Z & -Z -direction = 0.70

Shielding factor of Bridge in X & -X - = 0.64

direction

Shielding factor of Bridge in Z & -Z - = 0.78

direction

Shielding factor of Truss in X & -X - = 0.95

direction

Cf factor for main structure in X-dir = 1.70 (for star column as per IS875 Part3 Table-29)

Cf factor for main structure in X-direction = 1.28

with shielding effect

Cf factor for main structure in -X -dir = 1.70 (for star column as per IS875 Part3 Table-29)

Cf factor for main structure in -X -direction = 1.19

with shielding effect

Cf factor for main structure in Z & -Z-dir = 1.70 (for star column as per IS875 Part3 Table-29)

Cf factor for main structure in Z-direction = 1.19

with shielding effect

Cf factor for Bridge in X and -X-direction = 1.64

Cf factor for Bridge in X and -X-directionn = 1.05
with shielding effect

Cf factor for Bridge in Z and -Z-direction = 1.68

Cf factor for Bridge in Z and -X-directionn = 1.30
with shielding effect

Cf factor for Truss in X and -X-direction = 1.65

Cf factor for Truss in X and -X-directionn = 1.57
with shielding effect

6.3.8 Seismic Load

The site is located in Zone – III of seismic zoning map of india as per IS 1893 for which parameter are as follows:

Zone Factor (Z) = 0.16

Response reduction factor ( R) = 4

Importance factor = 1.75 ( For category 2 Structure, as per IS 1893 Part4 )

Damping = 0.02

Soil Type = Medium Soil

 PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

Rock and Soil Site Factor = 2

Scale Factor for IS code response = 0.035

spectrum ( Z/2 x I/R ) in X and Z-dir

Scale Factor for IS code response = 0.02

spectrum ( 2/3 x Z/2 x I/R ) in Y-dir

Scale Factor for Site response spectrum ( = 0.4375

I/R ) in X and Z-dir

Scale Factor for Site response spectrum ( = 0.29

2/3 x I/R ) in Y-dir

Comparision between IS Code Response Spectrum v/s Site Response Spectrum Seismic Results
IS Code Response Spectrum
Dynamic Weight = 25499.18 kn
Base Shear = 1491.37 kn

Site Response Spectrum

Dynamic Weight = 25499.18 kn
Base Shear = 1458.52 kn

Note: For seismic analysis , Site specific spectrum and IS code response spectrum used, in both case , IS code response spectrum
shows higher seismic base shear, hence IS 1893 response spectrum used for design purpose.

7 LOADS & LOAD COMBINATION

7.1 LOADS

DL Dead Load ( Grating load, Handrail load, Cable load etc )

IL Imposed / Live Load
EE Equipment Loads for Empty / Erection
EO Equipment Loads for Operation
ET Equipment Loads for Testing
WL Wind Load
SL Seismic / Earthquake Load
PE Piping Loads for Empty / Erection
PO Piping Loads for Operation
PT Piping Loads for Testing
TL Thermal Load/ Friction Load
TA Thermal Anchor Load
NL Notional Load ( 0.5% of factored dead load plus imposed )

7.2 LOAD COMBINATION

Load combination for check of soil bearing pressure & stability of foundation and Serviceability check

Load Condition Load Combination

DL + EE + PE
Erection
DL + EE + PE + WL
 PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

Load Condition Load Combination

DL + EE + PE
DL + EE + PE + BP
DL + EE + PE + ML + OL
Empty
DL + EE + PE + RL
DL + EE + PE + RL + WL
DL + EE + PE + SL
DL + EO + PO + TA + TL
DL + IL + EO + PO + TA + TL
DL + IL + EO + PO + BP + TA + TL
DL + EO + PO + RL + TA + TL
Operating DL + IL + EO + PO + ML + OL + TA + TL
DL + EO + PO + RL + TA + WL
DL + IL + EO + PO + TA + WL
DL + EO + PO + TA + SL
DL + IL + EO + PO + TA + SL
DL + ET + PT
DL + ET + PT + ML + OL
Test DL + ET + PT + IL
DL + ET + PT + 0.25 WL
DL + ET + PT + IL + (0.25 WL)

Load combination for Foundation Reinforcement Design & R.C.C. / Steel Structure Member Design

Load Condition Load Combination

1.5 (DL + EE + PE )
Erection 1.5 (DL + EE + PE) + 1.5 WL
0.9 (DL + EE + PE) + 1.5 WL
1.5 (DL + EE + PE )
1.5 (DL + EE + PE + BP )
1.5 (DL + EE + PE + ML + OL )
1.5 (DL + EE + PE + RL )
Empty 1.5 (DL + EE + PE) + 1.5 WL
0.9 (DL + EE + PE) + 1.5 WL
1.5 (DL + EE + PE) + 1.5 SL
0.9 (DL + EE + PE) + 1.5 SL
DL + IL + EE + PE + NL
1.5 (DL + IL + EO + PO + TA + TL)
1.5 (DL + IL + EO + PO + RL + TA + TL)
1.5 (DL + IL + EO + PO + ML + OL + TA + TL)
1.2 (DL + IL + EO + PO + TA) + 1.2WL
Operating 1.5 (DL + EO + PO + TA) + 1.5WL
0.9 (DL + EO + PO ) + 1.5TA + 1.5WL
1.2 (DL + 0.5IL + EO + PO + TA) + 1.2SL
1.5 (DL + EO + PO + TA) + 1.5SL
0.9 (DL + EO + PO ) + 1.5TA + 1.5SL

1.5 (DL + ET + PT + IL)

Test
1.5 (DL + ET + PT + ML + OL)
 PFCC UNIT FLUE GAS WET SCRUBBER SYSTEM

DOCUMENT NO. : 5083-CVC-WSS-ED-0022 REV. NO. : 0

DOCUMENT TITLE : PILE FOUNDATION DESIGN FOR DUCT SUPPORTING PLATFORM NEAR DISENGAGING DRUM

1.2 (DL + ET + PT + IL) + 1.2 (0.25 WL)

Test 1.5 (DL + ET + PT ) + 1.5 (0.25 WL)
0.9 (DL + ET + PT ) + 1.5 (0.25 WL)

Load combination for Connection Design

1.2 (DL + EO+ PO ) + 0.5IL + 2.5SL

0.9 (DL + EO+ PO ) + 2.5SL