FW Pipe Rack Document

CONTRACT NO:

1-14-3040/59

CLIENT: SHELL EASTERN PETROLEUM (PTE) Ltd., PROJECT TITLE:

SEPC-MEG

DISCIPLINE:

Civil Engineering

CALCULATION NO: 3041-8310-CA-0130 SAFETY CALCULATION: COMPUTER PROGRAM: EXCEL

CALCULATION CLASS: 1

YES DSN: 9317 Page 1 of 28

SUBJECT MAIN PIPE RACK SUBSTRUCTURE DESIGN

DRAWING NO'S. 3041-8310-43-0015 3041-8310-43-0016 3041-8310-43-0017

RA AREA MAIN E-W PIPE RACK FOUNDATION LAYOUT. RB AREA MAIN E-W PIPE RACK FOUNDATION LAYOUT. RC AREA MAIN E-W PIPE RACK FOUNDATION LAYOUT.

REFERENCE DATA

DESIGN BASIS SS CP 65 : Part 1 : 1999 BS 6399- Part-2 : 1997 3041-8310-SP-3002 2721-8310-RP-0002 DEP 34.00.01.30

Code of practice for structural use of concrete (Incorporating Erratum No.1, September 2000) Loading for Buildings - Part 2 Code of practice for wind loads Civil/Structural Engineering Guide Preliminary Interpretative Report for Shell Houdini Project -Rev. 1 Gen. Technical specification - Minimum specification for Design and Engineering

REMARKS

REV A1

DATE 2-Apr-07

DESCRIPTION Issued for Authority Approval

ORIGINATOR

CHECKER

S.L. NARAYANA

V. PREMA

APPROVER

CONTRACT NO: 1-14-3040/59

CALCULATION NO.: 3041-8310-CA-0130

PAGE 2 OF 28

CALCULATION AMENDMENT SHEET

SECTION NO.

PAGE NO.

AMENDMENT NO.

REMARKS

SECTION NO.

PAGE NO.

REV: A1

AMENDMENT NO.

REMARKS

FOSTER WHEELER SUBJECT :

MAIN PIPE RACK SUBSTRUCTURE DESIGN

PROJECT:

SEPC-MEG

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Date

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A1

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SAFETY CALC.

YES

CALC. NO

3041-8310-CA-0130

Sheet No :

4

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CONTENTS Cl. No

Sheet No.

Items COVER SHEET

1

AMENDMENT SHEET

2

ENGINEER'S & CHECKER'S STANDARD CERTIFICATION

3

CONTENTS

4

1.0

SCOPE

5

2.0

DESCRIPTION

5

3.0

DESIGN INFORMATION

5

4.0

ANALYSIS METHODOLOGY

9

5.0

PILE CAPACITY

9

6.0

DESIGN PHILOSOPHY

9

7.0

POCKET DESIGN

10

8.0

GROUND BEAM -1, DESIGN

18

9.0

ANCHOR BOLT DESIGN

20

10.0

BASE PLATE DESIGN

21

11.0

PLINTH DESIGN

23

12.0

GROUND BEAM - 6, DESIGN

26

ENGINEER'S & CHECKER'S STANDARD CERTIFICATION

28

APPENDIX - A

POKCET DESIGN FOR ERECTION MOMENTS

A1 TO A3

APPENDIX - B

DRAWINGS

B1 TO B4

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FOSTER WHEELER SUBJECT :

MAIN PIPE RACK SUBSTRUCTURE DESIGN

PROJECT:

SEPC-MEG

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1.0

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5

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SCOPE This document covers the substructure design for main pipe rack (excluding standard pile caps). Design of standard pile caps are covered in Doc. No. 3041-8310-CA-3001.

2.0

DESCRIPTION Main pipe rack columns are precast concrete members except stair case columns. Stair case columns are steel members and which are supported on plinth with base plate and anchor bolts. Stair case column pile caps are connected with ground beams for sharing of lateral forces. Ground beams are also provided along longitudinal(E-W) direction of pipe rack at braced bay locations for sharing of longitudinal forces from superstructure.

3.0

DESIGN INFORMATION

3.1

DESIGN CODES & SPECIFICATIONS a) SS CP 4 : 2003

:

Code of practice for foundations

b) SS CP 65 : Part 1: 1999

:

Code of practice for structural use of concrete (Incorporating Erratum No.1, September 2000)

c) BS 8110 -1: 1997

:

Part 1:Code of practice for design and construction (Incorporating Amendments Nos: 1, 2 and 3)

d) BS 6399 -1: 1996

: :

Loading for buildings Part 1 : Code of practice for Dead & Imposed Loads

e) BS 6399 -2 : 1997

: :

Loading for buildings Part 2 : Code of practice for Wind Loads

f) BS 5950-1 : 2000

:

Structural use of Steelwork in building. Part 1: Code of practice for design Rolled and welded sections(incorporating corrigendum No:1)

g) SS CP 73 : 1998

:

Code of practice for Design of concrete structures for retaining aqueous liquids

h) Singapore Building Control Regulations (S 148/1989, Fourth, fifth & Sixth) i) Singapore Civil Defence Force 3.2

:

Code of Practice for Fire Precautions in Buildings, 1997 - (Fire Safety Bureau)

MATERIALS a) Structural Steel (i)

Steel Section (Grade S275 JR)

-

BS EN 10210 for Hollow Section (hot-finished) BS EN 10025 for other non-alloy steel

(ii)

Chequered floor plate

-

Grade S275 JR

FOSTER WHEELER SUBJECT :

MAIN PIPE RACK SUBSTRUCTURE DESIGN

PROJECT:

SEPC-MEG

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(iii)

High Tensile Bolts

-

Grade 8.8

(iv)

Anchor Bolts

-

Grade 4.6

(v)

Ordinary Bolts

-

BS 4190 for grade 4.6 and 8.8 bolts

b) Reinforced Concrete 2

(i)

Concrete grade (below grade level)

-

fcu = 40 N/mm

(ii)

Concrete grade (above grade level)

-

fcu = 40 N/mm

(iii)

High tensile re-bar

-

fy = 460 N/mm

(iv)

Mild steel re-bar

-

fy = 250 N/mm2

-

fcu = 60 N/mm2

2

2

c) Precast Reinforced Concrete Piles Concrete grade (piles) 3.3

6

GENERAL LOADING CONDITION a) Dead loads (i)

Fireproofing concrete

-

24 kN/m3

(ii)

Steel

-

77 kN/m3

(iii)

Water

-

10 kN/m3

(iv)

Platform

-

1.0 kN/m2

(v)

Soil

-

18 kN/m3

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b) Imposed Loads Unless otherwise stated in the calculation, imposed loads shall be based on the following. Item Floor Area Usage Imposed Load 2 1 1 Operating and service areas 5.0 kN/m (See Note ) or single point load of 7.5 2 2 Access platforms, walkways and tower 2.0 kN/m or single point load of 3.0 kN 2 platforms 3 Roof areas accessible for inspection and 1.5 kN/m or single point load of 2.0 kN 2 repairstairs 4 Plant 3.0 kN/m 2 5 Exit or public stairs 5.0 kN/m 2 6 Storage areas, light 5.0 kN/m 2 7 Storage areas, heavy 10.0 kN/m (To be determined considering the intended 2 1 of the area) 8 use Compressor/generator platforms 10.0 kN/m (See Note ) 2 1 9 Exchanger head platform areas or similar 5.0 kN/m (See Note ) 10 equipment Hand railing, horizontal 1 kN point load at any one point 11 Ladder, moving concentrated load 2.5 kN 12 Piping load(excluding empty weight of pipe) a) Piping less than 300 mm diameter 0.7 kN/m2 (Operating condition) 2

b) Pipes larger than 300 mm diameter

1.5 kN/m (Test condition) Concentrated loads in their actual locations.

Note1 :- This live load applies only to platforms and floor slabs in areas where the possibility exists of the flooring or slab being subjected to a concentrated load from either equipment parts or heavy tools.

c) Wind Loading Wind loading shall be in accordance with BS 6399-2: 1997 & Shell DEP 34.00.01.30 GEN Ground roughness category: Country.  As per cl. 8.3.7 of 3041-8310-SP-3002 The site wind speed to be taken equals basic wind speed as specified in Cl. 8.3.7 of 3041-8310-SP-3002 Wind loads for Buildings and Structures Design wind pressure shall be determined for an hourly wind speed of 65Km/hr (18.06 m/s) for terrain category 3. Structure is designed for 10 second gust factor. All structures shall be designed for 10 second gust. 3.4

GROUND WATER TABLE The ground water level is approximately 1.5m below 5.4m ACD

 As per cl. 3.14.4 of 3041-8820-SP-0001

3.5

STRUCTURAL SUMMARY The scope of this submission consists of main pipe rack substructure design .

FOSTER WHEELER SUBJECT :

MAIN PIPE RACK SUBSTRUCTURE DESIGN

PROJECT:

SEPC-MEG

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A1

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SAFETY CALC.

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3041-8310-CA-0130

3.6

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COMPUTER PROGRAM USED Analysis STAAD. Pro is capable of performing two and three dimensional analysis of structures consisting of beam, truss, and thin Plate/shell elements. Specific applications include trusses, frames with or without shear wall stiffening, plate and shell systems, elastically supported beams and plates, as well as a broad range of other types of structures. Bandwidth Reduction The time of execution for a given STAAD.Pro run is dependent upon the bandwidth of the stiffness matrix as determined by the joint and member numbering scheme used in the input file. STAAD.Pro has the capability of rearranging this numbering system internally so as to minimize the time and disk space required for execution, while maintaining a level of ease and flexibility for the user in generation of these data. Structural Steel Sections STAAD.Pro contains a complete listing of standard sections. This enables the program internally to pick up properties for analysis and design based on a simple designation in the member property portion of input. Generation of Joints & Members Joints and members may be easily generated in a linear or set fashion to minimize the amount of required input. Offset Connections Members, not directly connected at the geometric point of incidence, can be designated as such so that secondary forces due to these eccentricities will be taken into account during analysis. Spring Supports Supports having a spring constant in any translational or rotational direction may be specified. Loads A variety of load types may be specified including joint, member (uniform, concentrated or linearly varying), temperature, support displacement, area, prestressing and moving loads. In addition, the program has the capability of calculating the self weight

Load Combination Factored load combinations of primary loads facilitate data input and implementation of code requirements. Parameters for Steel Design A variety of different design parameters such as K, F Y and Cb are available for design purposes. These parameters have standard default values which may be changed by the user as desired. Code Checking Complete code checking of members may be performed according to the AISC, (Working Strength & LRFD), AASHTO or British Codes of Practice. Member Selection Member selection, based on least weight criteria or design parameters such as member depth or section profile, may be made from STAAD.Pro's internal tables or user created tables. This capability can significantly reduce the amount of time and expense in design work.

FOSTER WHEELER SUBJECT :

MAIN PIPE RACK SUBSTRUCTURE DESIGN

PROJECT:

SEPC-MEG

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A1

2-Apr-07

SAFETY CALC.

YES

CALC. NO

3041-8310-CA-0130

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Save/Restore Feature STAAD.Pro can save the latest stiffness matrix from a run in a designated file to be reactivated at a later point of time for additional analysis. 3.7

REFERENCE a) Pile Design and Construction Practice. Fourth edition; By: M.J.Tomlinson b) Foundation Analysis and Design. Fourth edition; By: Joseph E. Bowles.

4.0

ANALYSIS METHODOLOGY

4.1

ASSUMPTIONS The following points are assumed for the strength design of pile caps. 1. One typical cast in situ pocket is designed by considering maximum reactions from all areas of the pipe rack. 2. Top of pocket is 400mm below the H.P.P.

5.0

PILE CAPACITY The following pile capacities are considered for the design of foundations under working conditions. Pile Diameter (mm) 500

6.0

Vertical Load Capacity (kN) 1000

Uplift Capacity (kN) 200

Lateral Load Capacity(kN) 50

DESIGN PHILOSOPHY Main pipe rack sub structure is designed by considering maximum forces from all the areas of the pipe rack. The pile caps, ground beams, column pockets and plinths are designed by using SS CP 65 : part1: 1999. BS 5950 : part 1 is used for designing stair case. Pocket plinth for precast column is designed for maximum support reactions from the super structure and also pocket design is checked for erection moments which is covered in Appendix-A.

FOSTER WHEELER SUBJECT :

MAIN PIPE RACK SUBSTRUCTURE DESIGN

PROJECT:

SEPC-MEG

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A1

2-Apr-07

SAFETY CALC.

YES

CALC. NO

3041-8310-CA-0130

7.0 POCKET DESIGN INPUT DATA: Characteristic strength of concrete Characteristic strength of steel

Sheet No :

Bc Dc Cb Ct H D c

REACTIONS: Maximum reaction

100

800

SLN

541.66 kN 85.963 kN

100

 Ref. Node No: 11, L/C 267, RB area staad Model

300

1000

Z

50

50

ELEVATION ALONG Z - DIRECTION

300

100

500

100

300

1000

X

50

Approver

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= 500 mm = 800 mm 50 mm = = 100 mm = 1000 mm = 300 mm 75 mm =

Fx = Fz = 300

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40 N/mm2 460 N/mm2

fcu = fy =

Pre cast column width Pre cast column depth Clearance at bottom Clearance at top Depth of pocket Width of pocket at top Clear cover to the reinforcement

10

50

ELEVATION ALONG X - DIRECTION

FOSTER WHEELER SUBJECT :

MAIN PIPE RACK SUBSTRUCTURE DESIGN

PROJECT:

SEPC-MEG

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A1

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SAFETY CALC.

YES

CALC. NO

3041-8310-CA-0130

Sheet No :

W1 = = = W2 = = =

Uniform force along Z direction due to Fx

Uniform force along X direction due to Fz

11

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Fx/(Dc+2Ct) 541.664/((800+2*100)/1000) 541.66 kN/m Fz/(Bc+2Ct) 85.963/((500+2*100)/1000) 122.80 kN/m

BENDING MOMENT CALCULATIONS:  with reference to the Reinforced Concrete Designer's hand book (Reynolds & Steedman) the bending moment in the " beam" b/w the side walls can be assessed, treating the pocket as a Box culvert.

X- DIRECTION: hs

A

X

B Z

hw

hw kN/m

h

541.664

q1

C

hs

D l

Center to center distance B/W walls along X- direction

l

Center to center distance B/W walls along Z- direction

h

k

k1 k3 k5 q1

Bending moment at B & D

= = = = = = = = = = = = = = = = = = = =

Bc+Ct+Ct+D/2+D/2 500+100+100+300/2+300/2 1000 mm Dc+Ct+Ct+D/2+D/2 800+100+100+300/2+300/2 1300 mm (l/h)(hs/hw)3 (1000/1300)*(300/300)^3 0.77 k+1 1.77 k+3 3.77 2k+3 4.54 W 1(Dc+2Ct)/h+D 541.664*(800+2*100)/(1300+300) 338.54 kN/m q1h2k/12k1k3 338.54*(1.3)^2*0.77/(12*1.77*3.77)

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SAFETY CALC.

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CALC. NO

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Sheet No :

Mbd = Mca = = = Mx = = =

Bending moment at A & C

Free span moment

5.50

12

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kN.m

Mbdk5/k 5.50*4.54/0.77 32.45 kN.m q1h2/8 338.54*(1.3)^2/8 71.52 kN.m

Z - DIRECTION: q2 hs A

X

B Z 122.80

kN/m

hw h

hw

C

Bending moment at C & D

Bending moment at A & B

Free span moment

hs

D l

k = = = k1 = = k3 = = k5 = = q2 = = = Mcd = = = Mab = = = Mz = = =

(h/l)(hw/hs)3 (1300/1000)*(300/300)^3 1.3 k+1 2.30 k+3 4.3 2k+3 5.6 W 2(Bc+2Ct)/h+D (122.80*(500+2*100))/(1000+300) 66.13 kN/m q2*l2*k/12*k1*k3 66.13*(1)^2*1.30/(12*2.30*4.30) 0.72 kN.m Mcdk5/k 0.72*5.60/1.30 3.12 kN.m q2*l2/8 66.13*(1)^2/8 8.27 kN.m

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PROJECT:

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SAFETY CALC.

YES

CALC. NO

3041-8310-CA-0130

Sheet No :

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COMBINED BENDING MOMENTS ( X & Z DIRECTIONS): 1.Bending moment at A

2.Bending moment at B

3.Bending moment at C

4.Bending moment at D

5.Span moment mid span AB

6.Span moment mid span AC

Maximum design moment Effective depth of wall

Breadth of wall considered

MA = = = MB = = = MC = = = MD = = = MAB = = = MAC = = = M = d = = = b = = = k =

Mca+Mab 32.45+3.12 35.57 kN.m Mbd+Mab 5.50+3.12 8.62 kN.m Mca+Mcd 32.45+0.72 33.17 kN.m Mbd+Mcd 5.50+0.72 6.22 kN.m Mz-(MA+MB)/2 8.27-(35.57+8.62)/2 -13.83 kN.m Mx-(MA+MC)/2 71.52-(35.57+33.17)/2 37.15 kN.m 37.15 kN.m D-c-f/2 300-75-20/2 215 mm 0.45H 0.45*1000 450 mm M/bd2fcu  As per SS CP 65: Part 1: 1999 cl. 3.4.4.4.

= 37.15*10^6/(450*215^2*40) = 0.045 k' ( Redistribution not exceed 10%) = 0.156 k Hence Safe.

604.17

kN

CHECKING FOR SELF WEIGHT & SOIL WEIGHT: Length of member Unit weight of concrete Self weight of member Moment due to self weight

Depth of soil above ground beam

l = 7.0 m wc = 24 kN/m3 W 1 = 0.4*0.6*24 = 5.76 kN/m M1 = W 1l2/8 = 5.76*7^2/8 = 35.28 kN.m Ds = 1.45 m  H.P.P - Top of pile cap-50mm, 100.000-98.600-0.050

Unit weight of soil Weight on member due to soil Moment due to soil weight

Total moment

g = 18 kN/m3 W 2 = 0.4*1.45*18 = 10.4 kN/m M2 = W 2l2/8 = 10.44*7^2/8 = 63.9 kN.m M = M1+M2 = 35.28+63.95 = 99.2 kN.m

FOSTER WHEELER SUBJECT :

MAIN PIPE RACK SUBSTRUCTURE DESIGN

PROJECT:

SEPC-MEG

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CONTRACT NO :

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A1

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SAFETY CALC.

YES

CALC. NO

3041-8310-CA-0130

Sheet No :

19

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Reinforcement required to resist moment: 99.23 kN.m M = d = D-c-f/2 = 600-75-32/2 = 509 mm b = 400 mm k = M/bd2fcu

Maximum design moment Effective depth of member

Breadth of beam considered

 As per SS CP 65: Part 1: 1999 cl. 3.4.4.4.

= 99.23*10^6/(400*509^2*40) = 0.024 k' ( Redistribution not exceed 10%) = 0.156 k