Design Calculation for Pipe Supports

ENGINEERING SERVICES FOR MISCELLANEOUS PMRFs, BAB BATCH-4 CONTRACT No. 7359.03 (GES) TASK ORDER No. 92221147

DESIGN CALCULATION OF PIPE SUPPORTS FOR PRODUCED WATER RE-INJECTION UPGRADE AT BAB CL-5, CL-15 & CL-16

THIS DOCUMENT IS INTENDED FOR USE BY ADCO AND IT'S NOMINATED CONSULTANTS, CONTRACTORS, MANUFACTURERS AND SUPPLIERS

ORIGINATOR:

ORIGINATOR DOC No.:

LTWp-JAD1113-XXX-CIV-CAL-XXX-A

ADCO DOC No.:

11-01-83-0602

CONTRACT NO.:

7359.03

PAGE

PROJECT NO.:

P11542

REV.

A

DATE:

1

OF

15

10/8/2012

REVISION RECORD

REV

DATE

ORIGINATOR

REVIEWED

APPROVED

DESCRIPTION

A

10.08.2012

SBU

VBE

AEN

ISSUED FOR COMMENTS

PROJECT:

ENGG. SERVICES FOR MISCELLANEOUS PMRFs BAB BATCH-4

ADCO DOCUMENT NO.

DOC. TITLE:

DESIGN CALCULATION OF PIPE SUPPORTS

11-01-83-0602 PAGE

CONTRACT NO.:

7359.03

PROJECT NO:

P11542

REV.

A

DATE:

2

OF

15

10/8/2012

Table of Contents Pages 1.0 INTRODUCTION……………………..……………………...…………………………………… 4 2.0 SCOPE……..…………….……...…………………………………………………………………..4

3.0 REFERENCE CODES & STANDARDS……………………………………………………………………………… 4 4 4.0 REFERENCE DRAWINGS……………………………………………………………………………….. 5.0 MATERIAL DATA ……………………………………………………………………………….. 4 5 6.0 SOIL DATA ………….…………………...……………………………………………………..

5 7.0 DESIGN LOADS FOR PIPE SUPPORTS …………….………………………………………………………………

8.0 BASIC LOAD CASES AND LOAD COMBINATIONS……………………………………………………………… 7

8 9.0 STEEL STRUCTURE ANALYSIS & DESIGN ………………………………………………………………………

10.0 PIPE SUPPORT FOUNDATIONS …………….……………………………………………………………………… 10 11.0 RESULT ………………………………………………………………….……………………. 10

APPENDIX - I

DRAWINGS (8 sheets)

APPENDIX - II

PIPING INPUT (10 sheets) + ASSUMPTIONS (6 sheets)

APPENDIX - III

STRUCTURAL STEEL STAAD OUTPUT (23 sheets)

APPENDIX - IV

BASE PLATE DESIGN (5 Sheets)

APPENDIX - V

FOUNDATION DESIGN (133 Sheets)

PROJECT:

ENGG. SERVICES FOR MISCELLANEOUS PMRFs BAB BATCH-4

ADCO DOCUMENT NO.

DOC. TITLE:

DESIGN CALCULATION OF PIPE SUPPORTS

11-01-83-0602 PAGE

CONTRACT NO.:

7359.03

PROJECT NO:

P11542

REV.

A

DATE:

3

OF

15

10/8/2012

1.0

INTRODUCTION The Bab field is located in a desert area approximately 160 km southwest of Abu Dhabi city. The field covers an area of approximately 45 km by 25 km. The main processing facilities are located around Habshan. Oil production from Bab field started in the 1960s. Bab field facilities were built in two phases. Phase-1 was commissioned in 1993 and included five processing trains, namely Trains 1 to 5, in the Central Degassing Station (CDS). Phase-1 also included five remote degassing stations, RDS-1, 2, 3, 4, and 5. Phase-2 which included trains 6 and 7 in the CDS and one remote degassing station, RDS-6 was commissioned in 2004. The field is sour, with wells to the northeast exhibiting generally higher H2S content than wells to the southwest. For the purposes of maintaining continuous improvement for the existing Bab facilities, ADCO Intended carrying plant modifications as part of Batch-IV to improve the operability and safety of the existing facilities.

2.0

SCOPE The scope of this calculation note is to design the Pipe support structures & foundations as per piping requirements. There are 4 types of pipe supports: - Cantilever on existing structure (PS-01) - "T" post type steel supports (PS-04). - "T" post type steel supports (PS-02 & PS-03) connected with tie-beams and horizontal bracings - Concrete supports with embedded steel plates and supporting steel beams on top: - PS-05, PS-06, PS-07, PS-08, PS-09, PS-10, PS-29, PS-30, PS-31 & PS-32 - all in BAB CDS Area - PS-33, PS-34, PS-35 - all in Cluster (5, 15, 16) Area.

3.0

REFERENCE CODES & STANDARDS BS 8110: 1997 Part-1

-

Structural Use Of Concrete (Code of practice for design & construction)

ASCE/SEI 7-05

-

Minimum Design Loads for Buildings and Other Structures

BS 5950

-

Structural Use of Steelwork in Building

UBC 1997

-

Uniform Building Code

Company specifications

4.0

30.99.75.0067

-

Structural Design Basis

34.19.20.31

-

Reinforced Concrete Structures

REFERENCE DRAWINGS P11542-11-01-76-0602

5.0

-

Pipe Supports

11-01-79-1706 rev. 3

-

GA Civil Section V BCDS Area (NPCC Drawing Project no. P11500)

11-01-76-2630 rev. 2 (sht.3/6)

-

Layout for paving and pipe supports - Water treatment area BCDS (NPCC Drawing Project no. P11500)

11-20-79-0215

-

GA Civil Pipe Support Foundation - WSW Cluster 16

MATERIAL DATA a.

Grade of structural steel BS En 10025: Yield strenght

=

250

N/mm2

b.

Grade of blinding concrete

=

20

N/mm2

c.

Grade of reinforced concrete

=

40

N/mm2

d. e.

Unit weight of concrete, γc

= =

24 460

KN/m3

Grade of reinforcement (BS 4449), fy

N/mm2

PROJECT:

ENGG. SERVICES FOR MISCELLANEOUS PMRFs BAB BATCH-4

ADCO DOCUMENT NO.

DOC. TITLE:

DESIGN CALCULATION OF PIPE SUPPORTS

11-01-83-0602 PAGE

CONTRACT NO.:

7359.03

PROJECT NO:

P11542

REV.

A

DATE:

4

OF 15 10/8/2012

6.0

SOIL DATA Soil parameters according to Geo-technical investigation for EPC for BAB THAMAMA G & HABSHAN 2, 1.8/MMBOPD PHASE-I DEVELOPMENT ADCO PROJECT No. P11500, doc. No.S10000066, Part 3 - BCDS AREA, Final Report. a. b.

Net allowable Bearing Pressure Unit weight of soil (γs1)

150

KN/m

=

18

KN/m

c.

Water Table level

=

d.

3 Modulus of Subgrade Reaction (ks = 3 kg/cm )

=

e.

Co-efficient of friction between concrete and soil

=

0.30

f.

Co-efficient of friction between concrete and polythene sheet

=

0.30

7.0

DESIGN LOADS FOR PIPE SUPPORTS

7.1

DEAD LOADS (DL)

2

=

3

N/A 29421 kN/m3

For the pipe supports, the selfweight of the members are included in the structural analysis using STAAD Pro. 7.2

PIPING LOADS Refer Appendix II for Piping Input.

7.3

WIND LOADS Wind Loads in X and Z directions are considered for the analysis of pipe supports as follows: Wind loads are calculated based on ASCE/SEI 7-05. Wind load is calculated across the direction of Piping. Basic wind speed

Vb

=

44.7

Importance factor

I

=

1.15

Exposure category

=

C

Wind Directionality Factor, Kd (Table 6-4 of ASCE 7-05)

=

0.85

Topographic Factor, Kzt (Structural design criteria)

=

1

2

Velocity pressure

qz=0.613*Kz*Kzt*Kd*V *I

Height above G.L.

Exposure

Velocity Pressure

(m)

Kz

0-4.6

0.85

(kN/m2) 1.018

6.1

0.9

1.078

m/s

2

(N/m )

G - Gust effect factor for all structural members

=

0.85

Cf - for circular members, Diam. > 50mm

=

0.80

Cf - for Flat sided members

=

2

=

1.0

Cs - Shielling coefficient (shielding effect neglected)

PROJECT:

ENGG. SERVICES FOR MISCELLANEOUS PMRFs BAB BATCH-4

ADCO DOCUMENT NO.

DOC. TITLE:

DESIGN CALCULATION OF PIPE SUPPORTS

11-01-83-0602 PAGE

CONTRACT NO.:

7359.03

PROJECT NO:

P11542

REV.

A

DATE:

5

OF 15 10/8/2012

(a) Wind force on Structual Members

F=(qz*G*Cf*Cs)*Af

kN

where Af = Projected Area (m2) F=(1.078 * 0.85 * 2 * 1) * Af F=

1.8326

*Af

UB203x133x25

0.203

Wind Load (kN/m) 0.37

UB254x146x31

0.251

0.46

PS-02 & PS-03

UC254x254x89

0.263

0.48

PS-04

UC254x254x89

0.263

0.48

Sl.No.

Member

PS-01

Width

(b) Wind force on Pipes

F=(qz*G*Cf*Cs)*D

kN/m

where D = Average Diameter of Pipe (m) F=(1.078 * 0.85 * 0.8 * 1) * D

7.4

D [m]

D[in]

F [kn/m]

0.273

10.00

0.201

0.350

14.00

0.257

SEISMIC LOAD CALCULATION: Seismic loads are calculated based on UBC 1997 UBC load generation is capable to calculate the natural period of vibration, base shear and distribute the lateral forces for each level automatically. Time period Time period of the structure is calculated based on clause 1630.2.2.1 (Method A). Ta = Ct*(hn)^0.75 Ct = hn =

0.085 4.82 m Ta=

0.277

Design base shear As per clause 1630.2.1, the total design base shear need not exceed the following: V = (2.5 * Ca * I / R) * W , where: Ca – seismic coefficient, as set forth in Table 16-Q 0.12 (considering Z = seismic zone '1', factor = 0.075, soil profile type: Sd = stiff soil profile) Ca= I = importance factor given in table 16-K 1.25 (occupancy category = 2 "Nonbuilding structures housing, supporting or containing quantities of I= toxic or explosive substances that, if contained within a building, would cause that building to be classified as a Group H, Division 1, 2 or 7 Occupancy") R= numerical coefficient representative of the inherent overstrength and global ductility capacity of lateral force-resisting systems, as set forth in Table 16-N Rx=

2.2

Rz=

2.2

(Table 16-P UBC-97 - Factors for cantilevered column type structures)

W= Total dead load as per Clause 1630.1.1 of UBC-97

PROJECT:

ENGG. SERVICES FOR MISCELLANEOUS PMRFs BAB BATCH-4

ADCO DOCUMENT NO.

DOC. TITLE:

DESIGN CALCULATION OF PIPE SUPPORTS

11-01-83-0602 PAGE

CONTRACT NO.:

7359.03

PROJECT NO:

P11542

REV.

A

DATE:

6

OF 15 10/8/2012

8.0

BASIC LOAD CASES AND LOAD COMBINATIONS The Following are the Basic loads & Load combinations adopted for the analysis of Pipe Supports using STAAD Pro. V.8i Basic Loads: Load 1

DL

-

Structure selfweight

Load 2

LL

-

Live Load - Instrument cable trays weight considered

Load 3

PE

-

Piping Empty Loads

Load 4

PO

-

Piping Operating loads

Load 5

PT

-

Piping Test Loads

Load 6

FLT

-

Frication loads - Transvers

Load 7

FLL

-

Frication loads - Longitudinal.

Load 8

WLX

-

Wind load in X-DIR

Load 9

WLZ

-

Wind load in Z-DIR

Load 10

EQX

-

Earthquake load in X-DIR

Load 11

EQZ

-

Earthquake load in Z-DIR

Combinations for Bearing capacity and stability check. (STAAD Combinations 201-247) (For bearing capacity and stability check) 1 - 1.0DL+1.0 Emp 2 - 1.0DL+1.0 Emp ± 1.0 WL 3 - 1.0 DL + 1.0 Live+1.0 Oper 4 - 1.0 DL + 1.0 Live+1.0 Oper ± 1.0 FLT ± 1.0 FLL 5 - 1.0 DL + 1.0 Live+1.0 Oper ± 1.0 FLT ± 1.0 FLL ± 1.0 WL 6 - 1.0 DL + 1.0 Live+1.0 Oper ± 1.0 FLT ± 1.0 FLL ± 0.715 EQ 7 - 1.0 Test + 1.0 DL 8 - 1.0 DL + 1.0 Test ± 0.60 WL

Combinations for Strength Design. (STAAD Combinations 101-147) 1 - 1.4 DL+1.4 Emp 2 - 1.4 DL+1.4 Emp ± 1.4 WL 3 - 1.4 DL + 1.6 Live+1.4 Oper 4 - 1.4 DL + 1.6 Live+1.4 Oper ± 1.6 FLT ± 1.6 FLL 5 - 1.2 DL + 1.2 Live+1.2 Oper ± 1.2 FLT ± 1.2 FLL ± 1.2 WL 6 - 1.2DL + 1.0 Live+1.2 Oper ± 1.2 FLT ± 1.2 FLL ± 1.0EQ 7 - 1.4 Test + 1.4 DL 8 - 1.2 DL + 1.2 Test ± 0.72WL

PROJECT:

ENGG. SERVICES FOR MISCELLANEOUS PMRFs BAB BATCH-4

ADCO DOCUMENT NO.

DOC. TITLE:

DESIGN CALCULATION OF PIPE SUPPORTS

11-01-83-0602 PAGE

CONTRACT NO.:

7359.03

PROJECT NO:

P11542

REV.

A

DATE:

7

OF 15 10/8/2012

9.0

STEEL STRUCTURE ANALYSIS & DESIGN Analysis and checking of pipe supports is carried out using Staad Pro.V8i , based on BS 5950. The STAAD output is given in Appendix III Pipe support PS-01

Dimensions

3D view

Beams

Nodes

Beams

Nodes

Pipe support PS-02 & PS-03

Dimensions

3D view

PROJECT:

ENGG. SERVICES FOR MISCELLANEOUS PMRFs BAB BATCH-4

DOC. TITLE:

DESIGN CALCULATION OF PIPE SUPPORTS

ADCO DOCUMENT NO. 11-01-83-0602 PAGE

CONTRACT NO.:

7359.03

PROJECT NO:

P11542

REV.

A

DATE:

8

OF 15 10/8/2012

Pipe support PS-04

Dimensions

3D view

Nodes

Beams

DEFLECTION CHECK Sway check Deflection calculation is being done using STAAD PRO v.8i at top of Pipe Supports with all unfactored load combinations (201-247) Allowable Load Combo deflection H/200

Pipe supports

Maximum deflection (x)

Load Combo

Maximum deflection (z)

PS-01

2.390 mm

211

9.088 mm

220

24.10 mm

Safe

PS-02 & PS-03

8.196 mm

211

12.075 mm

223

24.10 mm

Safe

PS-04

5.336 mm

218

10.119 mm

219

24.10 mm

Safe

Remarks

As shown in the table above, the maximum displacements are less than the allowable deflection H/200. Vertical deflection check Vertical deflection of beams has been checked as per Structural Design Basis (30-99-75-0067). Pipe supports

Maximum vertical deflection (y)

Load Combination

Allowable deflection L/180

Remarks

PS-01

1.394 mm

211

4.17 mm

Safe

PS-02 & PS-03

3.376 mm

211

6.94 mm

Safe

PS-04

0.417 mm

218

1.39 mm

Safe

PS-01

Maximum utility Ratio 0.192