KOC-C-002

KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOC RECOMMENDED PRACTICE FOR ENGINEERING DESIGN BASIS OF CIVIL AND STRUCTURAL WORK DOC. NO. KOC-C-002

I

STANDARDS TEAM

1

REV. 1

DOC. NO. KOC-C-002

(9+&)

kh;

KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOC RECOMMENDED PRACTICE FOR ENGINEERING DESIGN BASIS OF CIVIL AND STRUCTURAL WORK DOC. NO. KOC-C-002

STANDARDS TEAM

DOC. NO. KOC-C-002

KOC RECOMMENDED PRACTICE FOR

ENGINEERING DESIGN BASIS OF CIVIL AND STRUCTURAL WORK DOC. NO. KOC-C-002

ISSUING AUTHORITY:

STANDARDS TEAM

1

Rev

10/06/03

Date

Task Force

Issued as KOC Recommended Practice

I TF-c/o4 I

Description

Prepared by

Snr. E&< Te161407

A g Team Leader Sfds. Tel 6 7 8 9 6

DOC. NO. KOC-C-002

TABLE OF CONTENTS Page No. FOREWORD SCOPE APPLICATION TERMINOLOGY 3.1 Definitions 3.2 Abbreviations REFERENCE STANDARDS AND CODES 4.1 Conflicts List of Standards and Codes 4.2 4.3 KOC Standard Drawings ENVIRONMENTAL CONDITIONS HEALTH, SAFETY AND ENVIRONMENT BASIC 7.1 7.2 7.3 7.4 7.5

ENGINEERING INFORMATION General Site and Subsurface Information Site Preparation and Earthwork Site Drainage Basic Design Plinth Levels

GENERAL DESIGN BASIS 8.1 Design Loads 8.2 Design Loads Combinations 8.3 Allowable Functional Limits 8.4 Bearing Pressures and Settlements 8.5 Designated Materials FOUNDATIONS 9.1 General 9.2 Foundation Types 9.3 Shallow Foundations 9.4 Deep Foundations 9.5 Buoyancy Foundations Plant, Pipework and Steelwork Supports 9.6 9.7 Foundation Protection PLANT STRUCTURES 10.1 Dynamic Equipment 10.2 Structures and Overhead Piperacks

DOC. NO. KOC-C-002

10.3 10.4 10.5

Page 4 of 6 9

Fired Heaters Process Tankage Steel Stacks

PLANT AND NON-PLANT BUILDINGS Substation Buildings and Transformers 1 1.I 1 1.2 Control Buildings 1 1.3 Other Plant Buildings 1 1.4 Non-Plant Buildings PAVING AND ACCESSWAYS 12.1 General 12.2 Paving Arrangement 1 2 . 3 Edging and Kerbing 12.4 Widths of Access-ways 12.5 Overhead Clearances 12.6 Live (Imposed) Loads 12.7 Soil Supported Concrete Paving 12.8 Joints 12.9 Unpaved Areas ROADWAYS 13.1 General 13.2 Roadway Construction 13.3 Duty 13.4 Vehicular Loads 13.5 Design Life 13.6 Existing Roads 13.7 Road Bridges 13.8 Road Geometry 13.9 Road Shoulders 13.10 Road Drainage 13.1 1 Crash Barriers & Protection Barriers 13.12 Kerbing 13.13 Road 1 Traffic Markings 13.14 Traffic Signs 13.15 Overhead Clearances MICELLANEOUS CIVIL WORKS FOR SERVICES AND PIPELINES 14.1 Electrical and lnstrument Cable Trenches 14.2 Telephone Cable Trenches 14.3 Pipe Trenches 14.4 Cable Ducts 14.5 Ducts for lnstrument Cables 14.6 Ducts and Cable Trenches at Buildings 14.7 Pipe Sleeves 14.8 Valve Pits

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14.9 14.10 14.11 14.12 14.13

Floodlight Masts Fire Hydrant Pits Earthing Lightning Protection Warning Lights

STEEL STORAGE TANKS 15.1 General 15.2 Foundation Design Criteria 15.3 Foundation Design 15.4 Dikes 15.5 Drainage Within Dikes CONCRETE STORAGE TANKS FENCING 17.1 General 17.2 Type of Fencing 17.3 Chain Link Fencing 17.4 Corrugated Sheet Fencing STRUCTURAL WORK 18.1 General 18.2 Structural Form 18.3 Design Conditions 18.4 Design Stress Levels 18.5 Passive Fire Protection 18.6 Painting 1 Galvanizing 18.7 Connections MISCELLANEOUS METAL WORK 19.1 Platforms 19.2 Steel Flooring 19.3 Stairways 19.4 Spiral Stairways 19.5 Ladders 19.6 Handrails and Toe Plates 19.7 Ramps 19.8 Claddings QUALITY ASSURANCE DOCUMENTATION 21 .I General 21.2 Deliverables ACKNOWLEDGEMENT

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FOREWORD -

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This document " KOC Recommended Practice for Engineering Design Basis of Civil and Structural Work " (KOC-C-002) is intended t o provide consistent and practical guidelines for the design of general civil engineering works including foundations, buildings, and structures made of concrete and structural steel as well as other associated works. This Recommended Practice (RP) complements the families of listed KOC Standards; but refers t o specifically KOC-C-001 "KOC Standard for Basic Civil Engineering Design Data", as a part of general design basis of various civil and structural works. This KOC Recommended Practice (RP) has been approved b y Standards Division in consultation w i t h the Standards Technical Committee for use throughout the corporate engineering and operational functions of Kuwait Oil Company (K.S.C) This RP sets out t o achieve the following objectives: To recommend the general practices t o be adopted in the design specifications of plantlnon-plant buildings and plant structures including equipment foundations, storage tanks, paving and access-ways within KOC plants & facilities, roadways, and other miscellaneous civil and structural works. To establish the practical guidelines on the engineering design basis describing various design aspects w i t h a view t o achieving reasonably safe and economical construction as well as reliable service life. To assist the designers b y giving an access t o the necessary level of documented technical information w i t h a view t o optimizing their design efforts and productivity. To provide general technical guidance for developing project specifications and design I construction drawings in order t o ensure a consistent approach for sound engineering basis, material selection and workmanship in civil and structural work. To set out minimum requirements t o monitor compliance w i t h a contract. Feedback as well as any comments or suggestions from the application of this Standard derived at any stage of conceptual design, engineering, construction, fabrication, erection or maintenance are encouraged and should be directed t o : The Team Leader Standards (Chairman, Standards Technical Committee) Industrial Services Group, KOC P.O. Box 9 7 5 8 , Ahmadi 6 1 0 0 8 State of Kuwait -

I(

REV. 1

DOC. NO. KOC-C-002

Task Force Responsible for this Recommended Practice

--

The preparation of this RP has been entrusted b y the Standards Technical Committee (STCI t o the Task Force No. (TF-C/O41 comprising of the following members: Mr. Mr. Mr. Mr. Mr.

S. Kumar Adel Al-Zaid Khaled Al-Sayed Hisham A.Gharieb Mohd. A. Alam

Standards Team Design Team Gen. Proj. Team Proj. Design Team HSE Team

Task Force Leader Member Member Member Member

Tel. Tel. Tel. Tel. Tel.

No. No. No. No. No.

61407 61835 61613 66575 6641 5

DOC. NO. KOC-C-002

Page 8 of 69

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SCOPE

-

p~

This Recommended Practice (RP) specifies the basic technical requirements and defines the sound engineering design basis of the general civil and structural works including plantinon-plant buildings, plant structures, equipment foundations, paving and access-ways, roadways, storage tanks and other miscellaneous civil and structural works for installations at the KOC onshore plants and facilities within Kuwait. This R P does not cover the design of high rise buildings, pile foundations, foundations for storage tanks containing corrosive, hot or cryogenic fluids, rig foundations, radio structures, and offshore structures including jetties and marine terminals w i t h tanker berths. This RP shall not be applicable t o any structures that construction, pre-stressed concrete and structural aluminum and stainless steel. Any structural work made light gauge steel sections are also excluded from this covered separately under KOC-C-031.

use, as a form of sections such as of cold formed and RP, which shall be

The contents of this RP are intended t o be adopted as a design guide t o meet the minimum KOC requirements. However, the specifications and detailed design shall be provided by the DesigneriContractor for KOC approval.

The design, materials and workmanship of any civil and structural work shall conform t o the requirements of this RP and the reference standards and codes mentioned herein. Any exceptions or deviations from this RP, along w i t h their merits and justifications, shall be brought t o the attention of KOC Controlling Team(s) for their review, consideration and amendment b y Standards Team (if required). Compliance w i t h this RP does not of itself confer immunity from legal or statutory obligations. TERMINOLOGY

For the purposes of this RP, the following definitions shall apply.

Any approved firm or company contracted by KOC, w h o are undertaking the execution of civil and structural work.

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Designer Person or persons from KOC or from Contractor or any consulting firm approved b y KOC, w h o are undertaking the responsibilities of the actual design and detailed specifications of civil and structural work.

NB : For other applicable terminology, refer t o the relevant definitions in the family of KOC Standards mentioned in clause 4.2.2 of this RP. Abbreviations

E PA EPDM FFL FGL HSE KOC NGL OMC

American Association of State Highways and Transportation Officials Environmental Public Authority Epoxy Damp-proof Membrane Finished Floor Level Finished Ground Level Health, Safety and Environment Kuwait Oil Company (K.S.C) Natural Ground Level Optimum Moisture Content

.-REFERENCE

STANDARDS AND CODES

AASHTO

Conflicts In the event of conflicts between this RP and the standards ! codes referenced herein, or other contractual requirements, the most stringent requirement shall apply. In case further clarifications are required, the subject shall be brought t o the attention of KOC Controlling Team. List -

of Standards and Codes

The latest edition o f the following standards, codes and specifications shall apply: National 1 International Standards AASHTO Guide for Design of Pavement Structures ACI 224R

Control of Cracking in Concrete Structures

ACI 3 0 5

Hot Weather Concreting

AC1 3 1 8 M / ACI 3 1 8RM

Building Code Requirements for Structural Concrete

ACI 343R

Analysis and Design of Reinforced Concrete Bridge Structures

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ACI SP-66

ACI Detailing Manual

AlSC

Specification for Structural Steel Buildings Stress Design and Plastic Design

AlSC

Manual of Steel Construction

AlSC

Manual of Steel Construction Factor Design (Vol. I)

AlSC

Manual of Steel Construction (Vol. II)

API RP 7 5 2

Management of Hazards Associated w i t h Location of Process Plant Buildings C M A Manager's Guide

ASCE 7

Minimum Design Loads for Buildings and Other Structures

ASTM A616M

Specification for General Requirements for Rolled Structural Steel Bars, Plates, Shapes and Sheet Piling

-

-

-

Allowable

Working Stress Design Load and Resistance

-

Connections

ASTM A36136M Specification for Carbon Structural Steel ASTM A 5 3

Specification for Pipe, Steel, Black and Hot-Dipped, ZincCoated, Welded and Seamless

ASTM A 1 2 1

Specification for Metallic-Coated Carbon Steel Barbed Wire

ASTM A 3 0 7

Carbon Steel Bolts and Studs, 6 0 0 0 0 PSI Tensile Strength

ASTM A 3 2 5

Specification for Structural Bolts, Steel, Heat Treated, 1 2 0 110 5 ksi Minimum Tensile Strength

ASTM A 3 2 5 M

Specification for Structural Bolts, Steel, Heat Treated, 830MPa Minimum Tensile Strength (Metric)

ASTM A 3 9 2

Specification for Zinc-Coated Steel Chain-Link Fence Fabric

ASTM A 4 4 9

Specification for Quenched and Tempered Steel Bolts and Studs

ASTM A 4 7 5

Specification for Zinc-Coated Steel Wire Strand

ASTM A 4 9 0

Specification for Heat-Treated Steel Structural Bolts, 1 5 0 ksi Minimum Tensile Strength

ASTM A 4 9 0 M

Specification for High-Strength Steel Bolts, Classes 1 0 . 9 and 10.9.3. for Structural Steel Joints (Metric)

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ASTM A 5 8 6

Specification for Zinc-Coated Parallel and Helical Steel Wire Structural Strand

ASTM A 6 0 3

Specification for Zinc-Coated Steel Structural Wire Rope

ASTM A 6 1 5

Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcements

ASTM A 6 5 3

Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

ASTM D l 7 5 1

Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

ASTM E 8 1 4

Standard Test Method for Penetration Fire Stops

ASTM F 1 5 5 4

Specification for Anchor Bolts, Steel, 36, 55, and 1 0 5 ksi Yield Strength

ASTM F 1 6 3 7

Standard Practice for Safe Walking Surfaces

AWS D l . I

Structural Welding Society

BS 4 Part1

Structural Steel Sections: Part 1 : Specification for Hot-Rolled Sections

BS 4 4 9 Part 2

Specification for The Use of Structural Steel in Building: Part 2: Metric Units

BS 4 7 6 Parts 2 0 & 21

Fire Tests on Building Materials and Structures Part 2 0 : Method for Determination of the Fire Resistance of Elements of Construction Part 2 1 : Methods for Determination of the Fire Resistance of Load Bearing Elements of Construction

-

Fire Tests of

Through

Steel

Hot-Dip Zinc Coated and Hot-Dip Aluminum / Zinc Coated Corrugated Steel Sheets for General Purposes I S 0 Metric Precision Hexagon Bolts, Screws and Nuts Specification Specification for Sulfate-Resisting Portland Cement I S 0 Metric Black Hexagon Bolts, Screws and Nuts Specification

-

-

DOC. NO. KOC-C-002

BS 4 3 9 5 Parts 1 & 2

High Strength Friction Grip Bolts and Associated Nuts and Washers for Structural Engineering. Metric Series Part 1 : General Grade Part 2: Higher Grade Bolts and Nuts and General Grade Washers Specification for Carbon Steel Bars for the Reinforcement of Concrete Specification for Steel Fabric for the Reinforcement of Concrete

BS 4 5 9 2 Part

Industrial Type Metal Flooring, Walkways and Stair Treads Part 1: Specification for Open Bar Gratings

BS 4 6 0 4 Part

Use of High Strength Friction Grip Bolts in Structural Steel Work. Metric Series: Part 1: General Grade

BS 5 4 2 7 Part

Code of Practice for the Use of Profiled Sheeting for Roof and Wall Cladding on Buildings Part I : design

BS 5 6 2 8

Code of Practice for Use of Masonry

BS 5 9 5 0 Parts 2 & 8

Structural Use of Steel Work in Building: Part 2: Specification for Materials, Fabrication and Erection: Hot Rolled Sections Part 8 : Code of Practice for Fire Resistant Design

BS 6 3 9 9 Part

Loading for Buildings Imposed Loads

-

Code of Practice for Dead and

Code of Practice for Protection of Structures against Lightning Code of Practice for Earthing Code of Practice for Fatigue Design and Assessment of Steel Structures Code of Practice for Earth Retaining Structures Code of Practice for Foundations Code of Practice for Design of Concrete Structures for Retaining Aqueous Liquids BS 8 1 0 0 Parts 1 & 4

Lattice Towers and Masts Part 1 : Code of Practice for Loading Part 4: Code of Practice for Loading of Guyed Masts

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DOC. NO. KOC-C-002

BS 8 1 0 2

Code of Practice for Protection of Structures against Water from the Ground

BS 8 1 1 0 Part 1

Structural Use of Concrete Design and Construction

-

Part I:Code of Practice for

Specification for Scheduling, Dimensioning, Bending and Cutting of Reinforcements for Concrete BS CP 3 Part 2

Code of Basic Data for the Design of Buildings Chapter V : Loading Part 2: Wind Loads

BS CP 1 4 3 Part 1 0

Code of Practice for Sheet Roof and Wall Coverings Part 1 0 : Galvanized Corrugated Steel. Metric Units

BS CP 2 0 1 2 Part 1

Code of Practice for Foundations for Machinery Part 1 Foundations for Reciprocating Machines

BS EN 1 0 0 2 5

Hot Rolled Products of Non-Alloy Structural Steels Technical Delivery Conditions

BS EN 1 0 0 5 6 Parts 1& 2

Specification for Structural Steel Equal and Unequal Leg Angles Part 1 : Dimensions Part 2: Tolerances on Shape and Dimensions

BS EN 1 0 2 1 0 Parts 1& 2

Hot Finished Structural Hollow Sections of Non-Alloy and Fine Grain Structural Steels Part 1 : Technical Delivery Requirements Part 2: Tolerances, Dimensions and Sectional Properties

BS EN I S 0 1 4 6 1

Hot Dip Galvanized Coatings on Fabricated lron and Steel Articles

DIN 4 0 2 4 Part 2 Machine Foundations: Part 2: Rigid Foundations for Machinery w i t h Periodic Excitation IEC 6 1 0 2 4 - 1 Part 1

Protection of Structures against Lightning Part 1 : General Principles

I S 0 12 9 4 4 Part 1

Paints and Varnishes - Corrosion Protection of Steel Structures by Protective Paint Systems Part 1: General Introduction Protection Against Corrosion of lron and Steel in Structures Zinc and Aluminum Coating -

NACE RPO 1 8 7

Design Considerations for Corrosion Control of Reinforcing Steel in Concrete

DOC. NO. KOC-C-002

NFPA 2 5 1

Standard Methods of Tests of Fire Endurance of Building Construction and Materials

NFPA 7 8 0

Standard for the lnstallation of Lightning Protection Systems

SSPC SP 6

The Society for Protective Coating - Commercial Blast Cleaning NACE No. 3 - 2 0 0 0 (Steel Structures Painting Manual, Ch. 2 Surface Preparation Specifications) -

UBC (Vol. 1 - 3 )

Uniform Building Code Vol. 1 - Administrative Fire and Life Safety, and Field Inspection Provisions Vol. 2 - Structural Engineering Design Provisions Vol. 3 Material, Testing and lnstallation standards -

UFC 4.2.2

Uniform Fire Code

KOC Standards KOC-C-00 I

KOC Standard for Basic Civil Engineering Design Data

KOC-(-003

KOC Standard for Geotechnical Investigation (Onshore)

KOC-(-005

KOC Standard for Materials and Workmanship Preparation and Earthwork KOC Standard for Concrete Work Construction

-

-

Site

Materials and

KOC Standard for Structural Steel Work Fabrication and Erection

-

Materials,

KOC-(-024 Part 1

KOC Standard for Materials and Workmanship Roadways, Paving and Hard Standing : Flexible Pavement

KOC-C-024 Part 2

KOC Standard for Materials and Workmanship Roadways, Paving and Hard Standing : Miscellaneous Works & Rigid Pavement

-

KOC Recommended Practice for Drainage Systems KOC Standard for Storage Tank Foundations KOC Standard for Materials and Workmanship Proofing of Structural Steel Work

-

Fire

KOC Recommended Practice for Pre-Engineered Buildings

Page 15 of 69

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KOC-(-033

KOC Standard for Materials and Workmanship for Storage Tanks

KOC-E-024

KOC Recommended Practice for Earthing and Bonding

KOC-G-002

KOC Standard for Hazardous Area Classification

KOC-G-007

KOC Standard for Basic Design Data

KOC-L-002

KOC Recommended Practice for the Protection of KOC Services: Spacing Between Pipelines, Piping, Cables and Buildings 1 Housing Projects

KOC-L-006

KOC Standard for Fire and Gas Detection Equipment

KOC-L-009

KOC Standard for Fire Protection and Safety Equipment

KOC-L-026

KOC Recommended Practice for External Protection of New Steel Tank Bottoms

KOC-L-027

KOC Standard for Layout, Spacing Aboveground Petroleum Storage Tanks

KOC-P-001

KOC Standard for Painting and Coating of Metal Surfaces N e w Construction

-

and

Bund Wall

Cathodic

Diking

of

-

3 8 1 11 3 Part 1

Standard Requirements and Regulations for the Protection of KOC Services Part 1: Crossing of Roads and Motorways under Construction

3 8 11020

General Specification of Electrical Engineering (March, 1983)

381/022

General Specification for Civil Engineering and Building Works (Feb. 1 9 8 3 )

KOC Fire & Safety Regulations 4.3

KOC Standard D r a w i n s -

Chain Link Fencing & General Details

-

Shallow Foundation for Fencing and

15-2-6

Standard Security Fence

1 5-2-7

Standard Security Fence Details

15-5-75

Chain Link Fence and Gate Details ( 1 . 8 m High)

15-5-77

Galvanized Corrugated Iron Sheet Fence (1.8 m High)

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15-5-79

Fence Details

15-5-80

Security Chain Link Fence Details ( 2 . 4 m High)

15-5-82

Galvanized Corrugated lron Sheet Fence (2.4 m High)

15-5-83

Galvanized Corrugated lron Sheet Gate ( 2 . 4 m High)

1 5-1 4-1 3

Standard P i ~ e Sleeves

15-30-1 1 1 Standard Platforms and Crossovers Details 1 5 - 3 0 1 2 0 Standard Steel Anchor Bolts 15-34-1 9

Pipe Crash Barrier Detail

15-39-53

Standard Steel Ladder Detail

15-39-54

Standard Handrail Details

15-39-55

Standard Circular and Rectangular Platforms

15-39-56

Standard Steel Stair Details

15-39-57

Standard Stiles and Walkways

ENVIRONMENTAL CONDITIONS The environmental conditions in Kuwait are severe. Due regard should be given t o the consistently high levels of solar radiation experienced in Kuwait, which may develop surface temperatures of over 80°C (176°F) in exposed metals. Refer t o KOC-G-007 "KOC Standard for Basic Design Data" which provides the detailed design information regarding the environmental, site and utility supply conditions prevailing throughout the KOC facilities. HEALTH, SAFETY AND ENVIRONMENT The engineering design should meet all the applicable Kuwaiti EPA Regulations and should conform t o the relevant KOC Health and Environment (H&E) Guidelines w i t h a view t o protecting personnel and surrounding environment. All relevant safety requirements of KOC Fire & Safety Regulations and KOC Health, Safety & Environment Management System (HSEMS) shall be adhered to, b y the designer 1 contractor, while designing the plant building, structures and foundations t o be installed within KOC areas.

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3 ENGINEERING INFORMATION

Prior t o commencement of any preliminary design activities of civil and structural work, the Site should be established b y KOC; and the layout of plant and facility including equipment, utilities and necessary infrastructure should be finalized t o meet the basic requirements of the project(s) in accordance w i t h the State regulations and all relevant International I National and KOC Standards as appropriate. As all the technical information about the major equipment(s) may not be available at the initial design stage, some adjustments should be envisaged in the layout, which shall not affect the planned progress of design. _Site and Subsurface Information

Where available, a summary of the ground conditions, site topography and subsurface data shall be provided b y KOC through the latest topographical survey and geo-technical investigation reports. Where the information is insufficient, the survey shall be further carried out t o (Northing & Easting) and Site formation Standard for Basic Civil Engineering Design

necessary detailed topographical establish the Site co-ordinates levels as per KOC-C-001"KOC Data".

If necessary, detailed soil exploration program shall be conducted t o determine the general subsurface characteristics of the ground at different locations in accordance w i t h K O C - ( - 0 0 3 "KOC Standard for Geo-technical Investigation (Onshore)". The final report shall, as minimum, provide the soil parameters, ground water table, recommended bearing capacity and settlement criteria at the locations/sites of major structures in order t o establish the reliable and sound engineering design basis for any civil and structural work. For climatic conditions, refer t o KOC-G-007 "KOC Standard for Basic Design Data". Permanent monuments or survey points shall be established at all sites and their locations shall be indicated on a record drawing, together w i t h their grid references and elevations. The Site "Grade Datum Level" shall be decided considering groundwater level and drainage requirements, and shall generally be derived from the high point of plant paving or roadways. The relationship between this level and the Mina Ahmadi Construction Datum (MACD) shall be shown on all major drawings.

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Site Preparation and Earthwork The site preparation and earthwork shall be carried out at the proposed Site(s) as described in KOC-C-005 "KOC Standard for Materials and Workmanship - Site Preparation and Earthwork" in accordance w i t h the grid lines, grades and levels decided by the designer Icontractor in line w i t h the recommended basic design plinth levels in Table I of this RP or as per actual site conditions. Grading shall be carried out as per the approved grading plans. In case of filling either "Gatch" or locally available materials, suitable as site fill, shall be used on the basis of soil properties as laid d o w n in the relevant clauses of KOC-C-005. Placement of these materials in successive layers of 1 5 0 m m t o 2 0 0 m m maximum and compaction t o at least 9 5 % of the maximum dry density at O M C by equipment suitable for that purpose, shall comply w i t h the requirements of KOC-C-005. Spread foundations including storage tanks and plant paving, road subgrades and any other settlement sensitive equipment supported on fill material shall be designed t o ensure that any settlement that may occur should be within tolerable limits, as given in the relevant clause of this RP and Ior as specified by the equipment manufacturer. Site Drainaqe Natural topography of Site and surrounding areas should be considered as practicable as possible in the planning of overall drainage of the plant 1 facilities b y gravity flow; and shall be graded accordingly t o collect all surface f l o w s and effluents generated in the plant. Drainage systems for the plant and facilities should be planned adequately w i t h provisions for future extension; and shall be provided t o collect and direct all the surface f l o w s and effluents t o the segregated systems as detailed in KOC-C-025 "KOC Recommended Practice for Drainage Systems". Adequate slopes as required shall be provided across the grids of the plant or facilities site in order t o prevent accumulation of any liquids such as rainwater and or leaked I spilled products and ensure quick disposal without ponding. Basic Desiqn Plinth Levels The Site Grade Level shall be established for the entire works, where such works should be constructed on a site of graded level ground b y cutting and or filling.

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DOC. NO. KOC-C-002

7.5.2

Basic design plinth levels relative to the appropriate Finished Grade Level (FGL) of the various work(s) should be followed as a minimum as per the recommendation in the Table I of this RP. Table I: k c o m m e n d e d Basic Desiqn Plinth Levels

SI. No.

1

9

1

I

Grade

Hlgh Points o f Plant Paving (HPP) Unpaved

Areas

within

Basic Design Plinth Level (Minimum)

Plant

Plot

Limits.

+

P a v ~ n gThickness

Grade

75 m m

-

(Maximum) Buildings General Plinth Level IFFL) Elevated

S u b s t a t ~ o n and

Grade

Switchgear

+

450 mm

Preferably Grade + Clear Headroom 2 1 0 0 mrn

Buildings

+

iFFLlTOCi

Beam Depth Grade

Normal Substation and General Control Buildings Control Buildings w i t h Mezzanine type floors i spaces for Cables (FFLITOC)

+

450 mm

A s decided, b u t preferably Grade 21 0 0 m m +

+

Floor Thickness

+

Paving Level

Concrete Bases for Columns, Towers, Major Vessels, Static I Dynamic Equipment Supports, Storage Tanks, Structural Base Plates o f Plant

Grade

Structures, Pipe Racks, Steelworks etc. (TOC)

+

150 mm

400 mm

(Unpaved area)

Concrete Bases for Minor Equipment like small Pumps, Tanks, Miscellaneous Electrical I

+

Paving Level

150mm

Instrument Items supported o n Paving Slab (TOC) Low

Points of

Compressor

Floors t o

Shelters

Open-sided Pump I

adjacent

to

Grade

+

2 0 0 rnm

surrounding

Paving ITOC) Stairway and Ladder Bases in Plant Paving ITOCI Stairway and Ladder Bases in Unpaved Areas

Paving Level

I

ITOCI Cable Trenches w i t h Covers i n Paved Areas (TOC)

Grade

ITOC) Covers over Pipe TrenchesIDrainage Manholes, T o p o f Hydrant Pits & Sumps and Screeds e t c , as

1

Grade

+

50 mm

150 mm

Paving Level I

Cable Trenches w i t h Covers in Unpaved Areas

+

+

+

50 mm

150 mm

I

a. W i t h i n Paved Areas (TOCI

Flush w i t h Paving

b. In Unpaved Areas (TOC)

Grade

+

150 mm

DOC. NO. KOC-C-002 GENERAL DESIGN B

!

Desiqn Loads

-

Engineering design basis of any civil and structural work shall be established t o consider all possible types of appropriate loads and combinations thereof that will act on the structure(s) within its service life. All categories of applicable design loads, such as static loads (dead & live), wind loads, seismic loads, dynamic loads (impact & machine induced), pipeway loads (on elevated pipe racks and or on grade pipe-ways sleepers), friction loads, temperature loads, vehicular loads and fire loads including any unusual loads, shall be accounted as specified in KOC-C-001 "KOC Standard for Basic Civil Engineering Design Data". Desiqn Load C o m b i n a m The designerlcontractor shall comply w i t h all the relevant load combinations as specified in KOC-C-001, applicable t o the design of specific buildings and structures supporting cranes 1 monorails I hoists etc.; and shall also be responsible t o determine any other load combination which may cause the worst condition t o the structure for a particular application or situation. Design of structures supporting equipment as well as vertical vessels shall consider the worst effects on structures, generated out of several load combinations under different conditions such as erection, test and operating condition(s) in compliance w i t h KOC-C-001. Design of elevated pipe racks and grade pipe-way supports as well as horizontal vessels including exchanger supports shall take into account the specified load combinations as per KOC-C-001. In addition t o the above, the governing load combination for each structure should be established t o give the most critical criteria in the design. Allowable Functional Limits Structures shall be designed t o behave within the allowable functional limits (stability, contact pressure, deflection, noise, corrosion, fire rating etc.) as appropriate and as stipulated in the relevant clauses of KOC-C-001 in order t o achieve reliability of good performance and reasonable safety. Any foundation designed for dynamic loads resulting from reciprocating and rotary machines shall comply w i t h the allowable frequency and amplitude limits as specified in KOC-C-001 or as recommended b y the manufacturer in order t o avoid resonance conditions. In case of difference, the most stringent shall apply.

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Bearinq Pressures and Settlements Bearing pressure and settlement are the t w o most critical factors in the design considerations for foundations, and a professionally conducted soil investigation t o assess them should be the essential part of the engineering design basis. The soil report should recommend the foundation types and allowable bearing pressures for design at suitable depths, considering appropriate factors of safety. Following are the recommended ranges of factors of safety against ultimate bearing capacity failure: a. From 2.0 t o 3 . 0 based on the type of structure and the reliability of the soil condition for normal operating loads. b.

From 1.5 t o 2 . 2 5 for normal operating loads plus the maximum wind or seismic (if applicable) loads as well as for hydrostatic tests where applicable.

Settlements at different points and depths shall be derived from the field tests, and should then be predicted for the buildings and structures under normal load conditions. Uniform settlements shall generally be limited t o 2 5 m m maximum and differential settlement to 18 m m maximum so that t h e buildings and structures can absorb the effects without cracks or undue deformations. However, for storage tank foundations the permissible range of settlements is considered more than the above, and should comply w i t h K O C - ( - 0 2 6 "KOC Standard for Storage Tank Foundation". The maximum pressure under a foundation shall be computed from the sum of all possible loads such as dead load including the self weight of foundation, live (or imposed) load on the plant, equipment or structure, and wind loads or seismic loads (both not acting together) and the moments transferred from the structural frames t o the base of foundation. The net maximum pressure after deducting the displaced weight of soil by the foundation shall not exceed the recommended allowable bearing pressure at the foundation level. The net maximum pressure under eccentric loading on foundations shall not exceed the allowable bearing pressure. However, where the soil pressure under foundations due t o dead and wind loads are more than 2 5 % of that due t o dead and live loads, the foundations shall be so proportioned that the maximum net bearing pressure due t o combined dead, live and w i n d loads shall not exceed the allowable bearing pressure b y more than 2 5 % .

DOC. NO. KOC-C-002 In case of tall structures (stacks I columns) and towers, due t o the effects of possible sway, the maximum applied bearing pressure under eccentric loading due t o w i n d shall not exceed the allowable bearing pressure. Desiqnated Materials All superstructures shall be normally made of either structural concrete or structural steel as specified by the designer in accordance w i t h the clause 1 0 . 0 of KOC-C-001 and as described elsewhere in this RP; while all foundations including other substructures shall be generally constructed in concrete in accordance w i t h KOC-C-006. All concrete structures and foundations should be designed and constructed w i t h the applicable National I International codes given in clause 4.2 of this RP. However, the design of concrete structures shall comply in particular w i t h all the requirements as specified in BS 8 1 10, BS CP 3 or ACI 3 1 8 . All concrete structures for retaining aqueous liquids shall be designed and constructed as per the provisions made in BS 8 0 0 7 , w i t h l o w water cement ratio t o make dense concrete in order t o minimize cracks and ensure water tightness. All materials, workmanship and construction of reinforced, plain and mass concrete shall be in accordance w i t h KOC-C-006. For concreting in hot weather like Kuwait, the provisions of ACI 3 0 5 and K O C - C - 0 0 6 shall be followed particularly during construction. All structural steelwork shall be designed in compliance w i t h BS 449, AlSC or equivalent and should be fabricated as per KOC-C-007. Welding should comply w i t h the procedures as laid d o w n in A W S D l . I and KOC-C-007.

The design of foundations shall include all specified functional and testing requirements for the structures supported thereon. The responses of structures vary widely in their capacity t o accommodate movement of their foundations, and the design of both the structure and the foundation shall be considered interrelated. The design should take account of the following: a. all possible relative movements between different parts of a foundation if supported o n compressible and weak soil; b. movement of the supporting ground or soils due t o seasonal effects, erosion, natural consolidation or compaction due t o vibration; and c. relative movements between adjacent structures particularly when there are interconnecting pipes or utilities or equipment.

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A t sites where the immediate subsoil is found t o be highly compressible, foundations shall be taken d o w n t o deeper depth at a soil stratum of lower compressibility in order t o minimize the long term settlement problems. As an alternative t o the deeper construction, special measure of ground improvement techniques should be considered. Specialist companies in this field should be consulted t o select a simple, cost effective and appropriate ground improvement technique. Foundation Types

General Considerations a. Foundation types (shallow or deep) should be selected after analyzing all the applicable loads on the structures and their worst combinations, on the basis of recommended allowable soil bearing capacity and permissible settlement at the founding level.

b. Except those for minor structures, building foundations shall not be laid generally in areas of soft and or compressible subsoil t o avoid possible cracks on their load bearing frames and infill masonry walls due t o excessive and non-uniform (differential) settlements. c. Building, structure and equipment shall not be placed partly on rigid or deep foundations and partly on shallow foundations or partly on compacted fill. d. Any adjacent building or heavy structure may be founded on different type of foundations and at different soil strata, provided differential settlements are not harmful and are within acceptable limits; and sufficient flexibility should be provided into the design for all interconnecting structures, plant piping, drainage and service trenches. e. The foundation of any building subject t o blast loading shall be designed t o withstand the dynamic loads and moments resulting from the blast overpressure, which should be computed as per the current recommended design models. Other Considerations Foundation types (shallow or deep) should also be selected from the following requirements as below: a.

Speed of construction

b.

Cost of construction.

c.

Problems associated w i t h construction (high water table, unstable soil).

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REV.l

Shallow Foundations Normally, single storied buildings (residential, public, office, amenity and the like), store and laboratory buildings shall be founded on shallow foundations within a minimum depth of 1.0 m t o 1.5 m from the natural ground level or as recommended in the soil investigation report, if the reasonably hard strata of soil is encountered within that depth. Multistoried buildings such as administrative and control buildings, industrial buildings (workshops & factories), warehouses and utility buildings shall be laid on firm and hard strata generally within a minimum depth of 1 . 5 m t o 2.5 m from the natural ground level (NGL) or as recommended in the soil investigation report. Plant structures having heavy equipment should be decided for the appropriate foundation types, which shall be laid at the subsoil levels in compliance w i t h the recommendations, allowable bearing capacity and sound judgment of the designer. Shallow foundations are generally preferred t o transfer loads from one or more columns in the form of isolated footings such as spread, combined or strap footings. But wherever the individual footings overlap or their total area exceeds 7 5 % of the structure or building plan area due t o a l o w permissible soil bearing pressure, raft or m a t foundation should be generally recommended for economv and faster construction. Raft foundations shall be used also in areas where high and non-uniform settlements are expected due t o subsoil conditions and / or due t o nonuniform distribution of heavy loads on the structures. In that case, the foundation level shall be carefully set t o leave sufficient room above for running cable trenches and service lines above the raft. The remaining space between raft and paving shall be sand filled. The design of spread foundations in the vicinity of existing units or in the place of any dismantled units, should allow for the possible soil contamination b y oil or chemicals, which may have percolated d o w n through loose or porous surface soils t o the bearing stratum. In that case, foundations should be of such depth as t o ensure safe bearing below any oil softened subsurface or chemically contaminated subsoil. If a n e w foundation be constructed near an existing foundation, the bottom of both the foundations should be preferably at the same level. Otherwise, slope between the bottom edges of t w o adjacent footings should be maintained at least equal t o 4 5 " ( 1 : 1 ) , but shall not be less than 30" w i t h the horizontal. Where foundations are expected t o settle due t o the presence of underlying layers of soft subsoil, the initial construction levels should be fixed above

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REV. 1

their final required levels so that the drainage of roads or paving surrounding the foundations shall not be adversely affected b y such settlements, nor cause surface water t o f l o w into or pond around the foundation slabs or floors. Deep Foundations Deep foundations should be provided where shallow foundations are neither feasible due t o weak subsoil conditions, resulting l o w bearing capacity and / or unacceptable high settlements, nor due t o high loadings giving rise t o various design problems such as stability of structures or overlapping of several foundations at shallow depths. Deep foundations should be selected after carefully considering the economy, type of foundation required and method of construction t o be adopted. These may be in the form of raft foundations at deeper depths, pile foundations, piers, caissons or retaining walls. The designer I contractor shall comply w i t h the general principles of design for the type of deep foundation as mentioned above t o transfer all the vertical & lateral forces and moments from the superstructures as well as the subsoil forces from the underlying soils (dry, saturated or submerged) and ground water acting on the substructures t o the most reliable foundation depths, in accordance w i t h relevant BS and I or ACI codes and standards mentioned in clause 4 . 2 of this RP. Retaining walls if required, shall be provided for the underground structures and basements t o withstand all the pressures from the surrounding soils including any surcharge as well as from the ground water for stability of the structures in accordance w i t h BS 8 0 0 2 . Retaining walls should also be provided as necessary t o protect any filled-up elevated areas inside the plants like elevated roads that are subject t o heavy loads or frequent erosion. Pile foundations should only be considered as an exceptional case, where they are essential t o transfer either the heavy vertical loads t o a very deep strata or large amount of lateral forces t o the surrounding soils in order t o avoid very deep open cut excavations and massive foundations. Pile foundations should be selected for the appropriate pile type (friction 1 gravity), based on the recommended length & diameter t o achieve the required pile load bearing capacity as per the soil report; and should also consider the cost effective modes of pile installations (short I long, bored I driven, insitu I precast) for economy and speed of construction. Note: Details of design and installation method of pile foundations are excluded from this RP and are subject t o the proprietary contractor's exoertise.

Buoyancy Foundations In some cases, underground structures like basements, tanks and pits may become unstable and buoyant due t o high ground water table. The total weight of structure shall be provided under this condition t o neutralize the uplift pressure from the ground water, especially during empty condition. The minimum factor of safety against uplift shall be not less than 1.5 at empty condition. The design of foundations under buoyancy condition shall consider the possibility of ingress of surface and ground water, and provision shall be made for pumping out water, which may collect through the voids of concrete in the foundation. The design shall also consider t o avoid the possibility of flammable gases and / or liquids t o be collected in the foundation. However, all below ground concrete structures including tanks and pits etc. shall be designed and constructed in compliance w i t h BS 8 0 0 7 or equivalent ACI t o make t h e m watertight in order t o prevent any entry of ground and / or rain water through the bottom slabs and side walls. Plant. Pipework and Steelwork Supports Concrete columns, pedestals and sub-grade or grade tie beams shall be adequately anchored into the supporting foundations or t o the underlying foundation slabs, especially where they may be subject t o horizontal loads, overturning or vibrating forces. Reinforcements sufficiently embedded in the substructures, or sufficiently long holding d o w n bolts, shall be provided t o ensure their integral action. Reinforcements from concrete pedestals where supported on the paving, shall be adequately anchored into the slab t o assure the full transfer of the applied forces. Concrete bases, plinths and pedestals should extend not less than 5 0 m m beyond the edges of plant or equipment rings, fixed base plates, or slide plates. Sufficient clearance shall be kept between the side of concrete, or the reinforcements, and holding d o w n bolt pockets, sleeves or anchor plates. High or slender concrete pedestals I piers shall be designed as load bearing concrete columns or walls (where applicable) w i t h due allowance for horizontal loads due t o thermal forces, and for tube bundle removal or replacement. Major structural bases and all plant and equipment base plates and rings shall be grouted w i t h a flowable non-shrink non-metallic grout.

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REV.l

Concrete sleepers for grade pipe-ways shall be minimum 6 0 0 m m above the ground. However, the final levels shall be decided t o satisfy all the piping requirements (available clear height for drain valves, flange connections w i t h 90" bend from the bottom, operability of valves etc.) and shall be made as specified in the approved piping drawings. Sleepers shall be provided w i t h plain round steel bars of 2 0 m m I 2 5 m m diameter, welded t o a minimum 1 2 m m thick steel plate flushed w i t h concrete top. The t o p surface of the sleeper should slope away from the steel flat plate. FoundatiBn Protection Concrete surfaces below ground level that will be in contact w i t h soil except blinding concrete for foundations shall be protected b y three ( 3 ) coats of cold applied modified bituminous paint of total thickness of 1 0 0 0 microns ( 1 . 0 m m ) . Each coat of paint shall be left t o dry before the next coat is applied and backfilling shall commence only after the paint is completely dry. Foundations shall be placed over a layer of polyethylene sheet, 1 0 0 0 gauge thick, laid over blinding concrete. All sides of foundations and column necks shall be permanently covered w i t h impervious polyethylene sheet of 1 0 0 0 gauge w i t h minimum 1 5 0 m m overlap of the sheeting. Exposed external surfaces of concrete columns up t o 1 5 0 m m below ground level and concrete pedestals 1 piers up t o 3 0 0 m m above ground level shall be protected w i t h one ( 1 ) coat of l o w viscosity primer and then coated w i t h t w o ( 2 ) coats of light grey-colour epoxy paint of approved quality w i t h a minimum 1 2 5 microns dry film thickness (DFT) per coat.

PLANT STRUCTURES DynamicEquipment Dynamic equipment (reciprocatinglrotating) such as pumps, compressors, turbines and similar machines shall be designed for t h e ~ r bases and foundations taking into consideration of all appropriate static and dynamic loads as recommended b y the Manufactureds) and in accordance w i t h BS CP 2 0 1 2 Part 1 and I or DIN 4 0 2 4 Part 2. The base and foundation sizes of these equipment(s) shall be proportioned t o distribute their masses in such a w a y that the vibration and amplitude limits shall be achieved in compliance w i t h KOC-C-001 and 1 or as recommended b y the Manufacturer(s). Large machines or any machine which may have large out of-balance forces should be supported on structures and foundations in order t o minimize:

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DOC. NO. KOC-C-002

a. Vibration of the machine; b. Transmission buildings.

of

vibration

to

adjacent foundations,

equipment

and

Large pumps or compressors shall have individual foundations. But in case of series of smaller machines in a group, combined foundation(s) should preferably be provided due t o process layout considerations or due t o underlying soft soil areas. In that case, each machine on the combined foundation shall be separated by an upstand kerbing w i t h a drain t o prevent drifting of spilled liquid onto the other part of foundation. Drivers and driven units should be supported on a common base block adequately stiff t o limit distortion within the tolerance permitted by the Manufacturers. With independent pump blocks or bases, anchor supports t o the pump suction and discharge lines should, whenever possible, be integral and monolithic w i t h the pump base. Bases should extend not less than 5 0 m m beyond the edges of fixed bedplates or sliding plates. Adequate clearance should be provided between any projecting bolt lugs, holding d o w n pockets, sleeves or anchor plates and the concrete edge or the reinforcement. Holding d o w n bolts shall be designed t o adequately resist all horizontal forces, in addition t o the vertical forces, originating from the machine. The distance from a pocket or bolt t o the edge of the block should be at least 1 0 0 m m in order t o allow for reinforcement. Pump and compressor bases shall be adequately reinforced in all surfaces, vertical and horizontal. Where bases of small pumps are integral w i t h floors or paving slabs, the designer should ensure that slabs are sufficiently thick at those locations and adequate reinforcements are provided t o prevent the propagation of cracks from the surface due t o vibration. 10.1 . 1 0 Holding d o w n bolt pockets and the space under the bedplates shall be completely filled w i t h grout and all air expelled. Grout thickness should be within the range of 25 m m t o 5 0 m m . 10.1.1 1 However, large machines or any machines w i t h large out-of-balance forces should be grouted in accordance w i t h Manufacturer's requirements, using a flowable non-metallic non-shrink grout. Special grouts shall be placed in compliance w i t h the Manufacturer's instructions. If necessary, placing should be supervised b y a qualified representative of the Manufacturer. 10.1 . I 2 Some large machines, particularly those having out-of balance forces, i.e. reciprocating compressors, may require alternative means of mounting such as channels set in the foundation block or as recommended b y the manufacturer.

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REV.l

10.1 . I 3 Seoaration ioints of minimum 20 m m w i d t h shall be provided between the equipment foundations and surrounding floor or paving slabs. The joints shall be filled w i t h preformed compressible mineral fibre board and nonshrink grout. Structures and Overhead Pipe Ra& Generally structures supporting equipment, process pipes, heat exchangers, vessels, air coolers and electrical I instrument cable racks & cable trays, should preferably be designed in structural steel t o transfer the loads by means of either moment resisting frames or braced frames in compliance w i t h BS 449, AlSC or equivalent as specified in clause 18.0 of this RP. However if necessary, the designer may choose t o support the above on the structures made of concrete, which shall comply w i t h the requirements as per BS 81 10, ACI 31 8M / 31 8RM or equivalent. Structures shall be designed t o resist all the appropriate loads, considering various load combinations thereof and design limits as specified in K O C - C ~ 001. Overhead pipe racks shall be wide enough t o include all the proposed pipes at one or t w o levels; and should also consider additional 25% space for future extension. For multilevel pipe rack generally, the t o p tier should be catered for utility lines and cable trays t o run the electrical and telecom cables separately. Pipe racks shall be provided w i t h pipe shoes or plain steel round bars below the pipes t o reduce the friction forces at the various levels. Pipe racks shall be designed as the moment resisting frames in the transverse direction perpendicular t o the run of pipes and as the braced frames in the longitudinal direction of pipes. The horizontal spacing of moment resisting frames, composed of steel columns (stanchions) and main beams, and restrained b y longitudinal struts or tie beams, shall be determined by the sizes of pipelines t o be supported and plant layout in the adjoining areas. For acceptable piping spans w i t h full loads, the column spacing is recommended in the ranges of 6.0 m t o 7.5 m t o achieve reasonably economical pipe racks; but in no case shall exceed 12.0 m for any special design condition, as i t leads t o heavier pipe racks. However, minimum column spacing shall be limited t o 4.5 m for smaller pipelines of diameters including and up t o 76 m m (3"). Spacing less than 6.0 m is not generally preferred t o accommodate the lesser allowable spans of smaller pipelines and conduits, which then should be supported by intermediate crossbeams.

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REV.l

For multilevel pipe racks, the clear vertical distance between the first and second tiers should be decided on the basis of average and maximum pipeline sizes t o be installed. Adequate clearance should be provided for lines t o lay the pipe-way and for reasonable accessibility for completing field welds, insulation and painting, as well as for fittings and elbows. Generally, a clear distance of 1.2 m t o 1.8 m should be considered from t o p of the first tier beam t o the underside of the second tier beam for the average lines. The first tier of multilevel pipe rack for overhead transfer pipelines shall be fixed at 6 . 5 m clear above the plant roads for heavy cranes movement or 5 . 0 m clear above the process paving level for the smooth passage of major mobile equipment and vehicles without any hindrance. The first level of load bearing structures and general pipe racks having equipment and process piping shall be above 4 . 0 m clear from the process paved floor in general plant areas, which are accessible t o mobile equipment for the ease of maintenance. Where steel structures support plant and equipment handling flammable materials, fire proofing shall be provided for the specified fire rating in accordance w i t h KOC-C-027 "KOC Standard for Materials and Workmanship Fireproofing of Structural Steel Works" t o satisfy the passive fire protection requirements. -

Overhead pipe racks having pipes conveying flammable material like gas shall be fire proofed up t o t w o ( 2 ) levels. 1 0 . 2 . 1 0 All the supporting columns for heavy structures shall be suitably tied together at the foundation levels b y means of grade or sub grade tie beams. However, tie beams connecting supports for light structures may be omitted, if they are adequately embedded in the concrete paving where sufficient lateral restraint is provided by the concrete slab. 1 0 . 2 . 1 1 The area should have proper draining facility connected t o the plant drainage system t o prevent accumulation of flammable liquid in case of spillage.

10.3

Fired Heateys

10.3.1

Foundations for heaters should provide ample natural ventilation between the underside of the firing floor and the concrete foundations. Heater foundations and grade level flue gas ducts should not be placed on such subsoil, which is prone t o drying and shrinkage due t o heat, without adequate air gap and sufficient depth of footings.

1 0 . 3 . 2 The design shall consider the horizontal movements and thrusts t o the columns or piers supporting heaters due t o thermal expansion of the heater.

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REV. 1

In soft soil areas, foundations for the flue gas trunking should be arranged to prevent harmful differential settlements between the trunking and the heater stack. Process Tankaqe Process tanks shall generally comprise of vertical or horizontal cylindrical steel tanks or vessels, including items like b l o w d o w n tanks and coolers, which primarily form part of process units located within plant plot limits. Foundations for process tankage should be provided at or near grade levels; and shall be any of the following: a. Concrete bases or rafts bearing on the surface of the ground b. Earth foundations w i t h concrete ring walls under the tank perimeter. c.

Steel or concrete cradles for horizontal cylindrical tanks

d. Concrete sleeper walls t o support a vertical steel tank b o t t o m clear of the ground. The t o p surface of tank foundations as per item (a) or (b) above should be finished w i t h 5 0 m m clean sand cushion as a bearing surface and sand layer shall be protected b y an upstand curbing around the periphery from overflowing. Cradles for horizontal cylindrical tanks should normally be of steel saddles, welded t o the tank shell and saddle supports bearing o n low, flat topped concrete foundation plinths generally described as in clause 9.6 of this RP. In cases where tank shells are thin and thermal forces are high, overstressing of tank shells due t o excessive rigidity of the foundations should be avoided. The saddle base plates may have fixed connection w i t h oversized holes at one end and sliding connection w i t h slotted holes a t the other end t o minimize this rigidity. Cradles of concrete should be designed t o take the full thrusts at their horns (top) and the tank shells should be insulated from any anticipated corrosion on the saddle by means of pads of filler board t o prevent moisture absorption. For tanks containing flammable materials, the passive fireproofing shall be provided in accordance w i t h KOC-C-027; and the cradle frames shall have provision of drain holes t o avoid accumulation of any liquids. Only t w o supports should be provided for horizonral cylindrical tanks, when founded on weak soils. In the case of such tanks containing hazardous materials, a rigid slab and multiple supports may be used as an alternative foundation.

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Steel Stacks Steel stacks (flares, vent stacks etc.) and process columns are generally thin walled tall cylindrical structures; and should be designed as self supporting wherever possible; or supported by guys t o provide structural stability. Stacks shall be welded, and shall be embedded into the ground w i t h rigid foundations on the hard bearing stratum at founding levels, that may be selected deeper than the normal founding depths, for stability due t o wind loads. The factor of safety against overturning shall be considered not less than 2.0 as minimum. Steel stacks and tall cylindrical structures are susceptible t o large amplitude oscillations during steady winds of moderate velocity giving rise t o resonance conditions and ovalling vibrations, if not properly taken care in the design. Mass and geometry o f stacks w i t h respect t o heights shall be chosen in such a w a y that the critical w i n d velocity should normally be more than the design w i n d velocity at the t o p of the stacks in order t o avoid susceptibility of oscillation. Otherwise, the structure shall be critically damped not t o exceed the acceptable limits of amplitudes due t o wind-induced vibrations. Thin-wall stacks are also susceptible t o ovalling vibrations i.e., oscillations where the stack cross-section vibrates as a ring. Whenever applicable, additional circumferential stiffeners shall be provided t o the stack in the helical forms (spoilerslstrakes) at the t o p one-third height t o prevent ovalling. If guys are t o be used t o support the steel stacks, they shall be made of galvanized steel structural strands or steel wire ropes as required. Structural strands shall conform t o the requirements as specified in A S T M A 4 7 5 for sizes up t o 518 inches and ASTM A 5 8 6 for sizes over 518 inches; whereas structural wire ropes shall be as per ASTM A 6 0 3 . Guys when placed should be fixed at an angle of inclination of 4 5 " for most efficient use, but when not possible due t o any constraints, they should be connected at multi-levels t o the stack. However, guys shall not be fixed t o the stack at slopes lesser than 30" from the horizontal. Guys shall be anchored in the concrete blocks that shall be designed for the tensile forces from the guys and shall be adequately embedded into the ground. Guys shall be orientated t o avoid crossing of any roads and access-ways

DOC. NO. KOC-C-002

PLANT -

Page 33 of 69

AND NON-PLANT BUILDINGS

Substation Buildinqs and Transformers Substation buildings generally comprising of switchgear rooms, control rooms, battery rooms and transformer bays should be sized adequately t o accommodate all the electrical equipments w i t h the necessary safety clearances from the walls and the adjacent equipment in compliance w i t h IEC regulations and KOC Standard (3811020). Substation buildings shall be located in the unclassified (safe) areas. These buildings shall normally be single storied on the ground for small substations; or elevated type t o suit the project requirements for bigger substations w i t h the basic plinth levels as per Table I of this RP. The sizing of substation building should include also additional space for any future addition. For elevated substations, the minimum head clearance between equipment floor beams and ground level shall be maintained at 2 1 0 0 m m above the finished grade, which should be made of compacted gatch. Adequate openings / cutouts shall be provided in the equipment floor slab for cable entry w i t h future openings. These openings for future cables should be sealed w i t h checker plate or removable slab panels. One or more access ramps of non-slip type shall be provided from the surrounding area w i t h a slope not exceeding 1 in 1 5 t o all equipment rooms. Cable trenches, wherever provided, should not be left open, and shall be covered w i t h galvanized steel checker plates or sand filled and covered w i t h removable concrete slabs. The entry and exit points of cables in the trenches shall be through the sleeves embedded into the walls, which shall be sealed properly w i t h nonsetting, non-flammable and non-toxic liquid-tight sealant to prevent ingress of any water or flammable liquids during spillage. Empty sleeves if provided in walls for future requirements, shall be flanged type and shall be blanked o f f w i t h blind flanges. Room ceiling heights shall be determined by overall panel I equipment height, installation, maintenance and requirements for light fittings I HVAC ducts and roof beam depths etc., and w i t h due regard for the use of any lifting equipment that may be required. However in any case, the ceiling height shall be not less than 3 0 0 0 m m . Substation buildings shall be adequately protected against ingress of dust, sand and rain w i t h double air sealed doors. Concrete plinth protection c u m walkway of at least 1 0 0 0 m m wide shall be provided all around the building.

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REV.l

1 1 . I .8

Floors shall be made of reinforced concrete t o support heavy electrical equipment and shall be smooth trowel finished self-leveling screed w i t h floor hardener. The finished floor shall be painted w i t h light grey colour epoxy paint. If required, steel rolled sections (joists or channels) should be embedded flush w i t h the floor t o roll out the equipment.

1 1 . I .9

Roofs shall be made water leak proof w i t h the necessary treatments and watertight membranes such as EPDM or equal as specified b y the designer and approved by KOC. Roofs shall be protected w i t h steel hand railings w i t h the toe board 1 plate or concrete parapet walls of similar height w i t h access facility for maintenance of electro-mechanical equipment t o be installed thereon.

1 1 . I . I 0 Electrical control panel room wherever specified in the substation building, shall have raised access flooring consisting of 6 0 0 m m x 600 m m removable type non-slip anti-static vinyl finished noncombustible panels. These floor panels shall be mounted on removable telescopic type electrozinc plated steel pipe supports w i t h threaded studs t o allow for level adjustments. When finally assembled, the floor shall be rigid and free from vibration rocking, rattling and squeaking. 1 If rooms like office 1 storage 1 filing etc. are t o be constructed attached t o the substation building, they shall be provided w i t h independent entrance door from outside; and shall be completely isolated from the substation building b y fire rated walls and doors. These walls and doors shall have the fire rating of minimum t w o ( 2 ) hours, or as appropriate as per KOC-C-001; and the openings for cables (power, lighting, telephone etc.) and for H V A C ducts shall be provided w i t h UL approved through-penetration fire stops t o achieve this rating as per A S T M E 814.

1 1 .I. I 2 For elevated type substation buildings, the open space between the ground beams and equipment floor beams shall be closed w i t h chain link fence panels and minimum t w o ( 2 ) Nos. of 1 0 0 0 m m wide personnel entry gates shall be provided all along the periphery of substation building. Chain link fabric shall be of 2 5 m m x 2 5 m m mesh, hot dip galvanized w i t h PVC coating. 1 1 . I . 1 3 Battery rooms shall be independently ventilated and the floors shall be finished w i t h approved acid resistant tiles of anti-slip type. Tiles should be bedded and jointed in chemical resistant mortar. Drain(s) shall be provided in the battery room(s) w i t h floor sloping from all directions towards the drain points, which should be connected t o chemical drain network.

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1 1 . 1 . 1 4 Transformers should be located in separate covered bays adjoining but outside the substation buildings, and shall be supported on independent concrete foundations. I n case more than one transformer (oil filled type) are t o be installed adjacent t o each other, fire walls made of minimum 230 m m thick brick or concrete block work should be provided t o minimize the degree of fire risk. Roof covering may be of either pre-engineered steel structure or reinforced concrete canopy slab extended from the building.

11.1 . I 5 The space surrounding the foundation block and within the enclosure walls shall be filled w i t h open graded gravel or stone chippings so that the volume of the voids provided should not be less than the volume of oil contained in each transformer. A sump should be provided consisting of a trapped gully set within brick walls w i t h porous openings, t o allow rainwater t o drain o f f while keeping the chippings clear of the gully. The outlet from the trapped gully should be connected t o the oily water drainage system if available, or provision should be made for pumping out.

11 . I . I 6 All transformers shall be protected by enclosures and roof including fences w i t h gates for access in compliance w i t h clause 1 7 . 0 of this RP.

1 1 . 2 . 1 Control buildings shall be planned independently, depending o n available plot size, as the single storied or double storied building, catering t o all the requirements for operations of the plants (GCIBS). Adequate spaces shall be provided t o the operators and other essential personnel w i t h facilities for 24 hours operation every day and for the necessary equipment t o be located within the building.

11.2.2

Control buildings should include as a minimum, but shall not be limited t o the following facilities only: a. b. c. d. e. f g. h. i. j. k. I. m. n.

Control room Auxiliary 1 Marshalling rooms Telecom I LAN room Conference & Training rooms Rest rooms Toilets, shower and locker rooms Prayer room Pantry Offices Instrument room Electrical room Mechanical room (HVAC) Store room(s1 Other if any.

11 . 2 . 3

The design of control buildings should consider the under-floor space 1 basement t o serve as air return and passage for routing electrical 1 instrument cables. Suitable vapour barriers and seals shall be used; and absolute minimum openings shall be allowed t o assure dryness. Conduit bank entrance shall have the provision t o eliminate the possibility of any liquid (water or oil) entry.

1 1 . 2 . 4 If control building is required t o be blast resistant, i t should be designed safe considering the dynamic forces generated out of overpressures due t o any blast loads, its anticipated direction and distance of the source. Current models of dynamic analysis should be used t o derive the forces acting on the building w i t h minimum openings. Alternately, independent blast resistant walls should be considered outside exterior doors t o reduce blast pressures acting on the doors. These walls shall be constructed w i t h concrete of suitable thickness, and shall be fully reinforced on both sides vertically and horizontally as per the actual design. 11 .2.5

Control building(s) should be located in the unclassified (safe) area; but if happens t o be within hazardous area, it shall be designed t o maintain a positive internal pressure t o prevent ingress of hazardous vapour 1 fumes inside the building. In such case, air lock shall be provided at the main entrance of control building. Many times, the control buildings in safe areas are also preferred t o be pressurized t o ensure that the wind b l o w n dust and harmful gases should not enter into them.

11.2.6

Control buildings should preferably be comprised of concrete load bearing structural frames w i t h infill materials for cavity walls. The cavity walls shall generally be made of 2 3 0 m m thick recast concrete blocks, 5 0 m m air gap, 4 0 m m rigid insulation and 1 1 5 m m thick sand lime bricks, totaling t o 4 3 5 m m thickness.

11.2.7

Room heights shall be made adequate by taking proper allowances for light fittings, HVAC ducts etc. and a lightweight suspended acoustic ceiling of approved quality and make shall be provided at not less than minimum 3 0 0 0 m m above the finished floor level.

11 . 2 . 8

Control buildings should have floors w i t h smooth finishes as specified b y the designer as per the facility requirements. However, raised access flooring shall be provided in the control room, auxiliary room, marshalling room and telecom 1 LAN room for running large number of cables. The flooring system shall be of approved type and make, t o satisfy the following: a. The floor shall be made of 6 0 0 m m x 6 0 0 m m removable type non-slip anti-static vinyl finished noncombustible panels. These panels shall be mounted on removable telescopic type electro-zinc plated steel pipe supports w i t h threaded studs t o allow for level adjustments, and shall be

DOC. NO. KOC-C-002

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REV. 1

installed over the reinforced concrete sunken slab as per the installation requirements. b. The floor shall be rigid when finally assembled; and shall be free from any rocking and squeaking.

11.2.9

c.

The under floor area shall be sealed w i t h a suitable paint t o suppress dust.

d.

Proper ventilation shall be provided t o the under floor space,

Roofs shall be made water leak proof w i t h the necessary treatments and w i t h watertight membranes such as EPDM or equal as specified b y the designer and approved by KOC. Roofs shall be protected w i t h steel hand railings w i t h the toe board 1 plate or concrete parapet walls of similar height w i t h access facility for maintenance of equipment(s) t o be installed thereon.

1 1 . 2 . 1 0 Control buildings except blast resistant type shall have normal size windows as necessary, w i t h splinter proof, non-spalling type glasses. However, control room w i n d o w s should be kept t o the optimum area for adequate daylight illumination without excessive glare or heat loss. 1 1 . 2 . 1 1 Where control building is more than single storied, emergency / fire escape stairways shall be provided. 1 1 . 2 . 1 2 Control buildings shall be furnished w i t h the fire and gas alarms in accordance w i t h KOC-L-006 "KOC Standard for Fire and Gas Detection Equipment" and shall be equipped w i t h fire fighting facility as per KOC-L0 0 9 "KOC Standard for Fire Protection and Safety Equipment". 1 1 . 2 . 1 3 Control buildings shall be provided w i t h 1 5 0 0 m m wide concrete plinth protection c u m walkway around the buildings Other Plant Buildings Other plant buildings such as compressor house, pump house, chemical storage building should be made either of structural steel in framed structures w i t h sheet claddings or of reinforced concrete in load bearing frames w i t h block walls, as decided by the designer w i t h KOC approval. Building layout, sizes and equipment clearances shall be subject t o KOC review prior t o detail design that should meet all the functional and safety requirements as envisaged or specified by KOC. The design shall be carried out w i t h the appropriate loads in accordance w i t h the relevant provisions specified in KOC-C-001, and shall comply w i t h applicable codes and standards of BS, AlSC or ACI given in clause 4.2 of this RP.

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All other requirements of rooflwall coverings, ceilings, doorslwindows and finishes etc. shall be assessed and developed in the detailed specifications by the designer/contractor as appropriate subject to KOC approval. Non-Plant Buildings Non-plant buildings such as administrative offices, workshops, warehouses, stores, laboratory, amenity and residential buildings should be planned as per the KOC requirements; and should be designed in accordance w i t h the relevant clauses of KOC-C-001 for the appropriate loads as well as w i t h applicable design codes and standards of BS, AlSC or ACI given in clause 4 . 2 of this RP. The buildings should be constructed w i t h the materials, either concrete or steel or combination of both, as specified by either KOC or the designer; and should be finished good t o suit the general aesthetic and construction requirements w i t h KOC approval. P A V I N G AND ACCESSWAYS

The designer should determine the need for paving areas and their extent within each site. All intended uses and loading requirements for paving including culverts, suspended and removable paving slabs, should be considered in the design. In general, paved surface areas should be kept t o a minimum consistent w i t h following general requirements listed below. Process Plot Areas a. Concrete paving should be provided within plot limits only where necessary for vehicular and pedestrian access t o process plant, equipment buildings and maintenance areas, and as a drainage surface in areas which may be subject t o oil or chemical spillage during operations or maintenance. b. Paved areas, other than meeting the requirements for collection of surface water, oil or chemical spillage, should also consider in the design the following conditions and additional requirements: i) ii) iii)

Flammable liquid spills do not collect under process equipment. Firewater should not spread t o process or plant areas unaffected by fire incident. Specific catchment areas for drainage within a process or plant unit should be defined in relation t o the layout of the individual parts of the unit and applicable fire fighting methods.

c. Catchments should be generally defined b y high points of the paving or in particular cases by upstand kerbs. However, trip hazards or obstruction of access-ways shall be avoided.

d. If a specific potential fire risk has been identified within a plant, additional paving may also be needed t o allow efficient drainage of the high volume of firewater flows. e. Additional paving may be required in some areas of the plant as a protective layer against erosion of certain soil types. f.

Concrete paving should generally be provided for:i) ii) iii) iv)

v)

vi)

Vehicular access-ways from process plot limits t o the paved areas. Walkways. Maintenance access comprising of 1 2 0 0 m m wide paving around any individual equipment isolated from main paved areas. Tube pulling areas for heat exchangers, where oil may be spilt during extraction and removal of tube bundles, even where such areas are outside plot limits. All groups of pumps and compressors, continuously around and piping manifolds, associated w i t h pump stations as well as generally under all structures supporting process plant overhead. Access ramps for maintenance vehicles, trolleys etc.

g. Concrete access-ways should be provided from t w o opposite direction t o all critical equipment such as Fire Water Pump, Instrument Air Compressor etc. t o cater for operation and maintenance in case of emergency situation. h. Concrete paving should not normally be provided for walkway access t o isolated floodlight towers and manholes. 12.1.2

Offsite Areas There are no general requirements for paving in offsite areas. However, paving may be required at particular locations such as pump areas, metering areas and manifold areas where hydrocarbon and c h e m ~ c a l leakage or spillage could occur.

1 2 . 1 . 3 Tankage Areas For paving details in tankage areas, refer t o clause 1 5 . 0 of this RP

12.2

Pavinq Arranqernent

12.2.1

Concrete paving should be laid t o falls sloping w i t h a gradient 1 in 1 0 0 t o drainage points. The perimeter of the paving should be at Grade Level. Bituminous paving wherever provided, should have minimum slopes not less than I in 6 0 t o ensure adequate drainage without ponding.

DOC. NO. KOC-C-002

Page 4 0 of 69

1 2 . 2 . 2 Drain points and valley lines should be located t o ensure an unhindered f l o w past all bases, plinths, columns and other obstructions. High points should be located along cable trenches, expansion joints and over sub-grade beams, and the valleys along any pipe trenches. 1 2 . 2 . 3 Paving layout drawings should show all bases, plinths, columns and other obstructions, w i t h paving valley lines and ridges indicated and all falls shown w i t h arrows in order t o eliminate any dead areas that could cause ponding 12.2.4

Surface drainage collection points should be provided w i t h their t o p level set 2 5 m m below the paving surface, pipe trench b o t t o m or other surface t o be drained.

12.2.5

Paving should be kept as free as possible from all obstructions liable t o cause a trip hazard. Covers for cable and pipe trenches, manholes, sockets and the like should be graded flush w i t h the paving w i t h hand grips sunk below. Open pits and sumps should be protected by railings.

12.2.6

Pipe trenches within the paved areas should be avoided wherever possible. Pipe trenches below paving level where unavoidable, should comply w i t h the clause 1 4 . 3 of this RP.

12.2.7

Where permanent access-ways from the plant t o the surrounding roads are ramped, the slope should not exceed 1 in 1 5 .

12.3

Edqinq a n d - K e r n

12.3.1

Protection should generally be provided t o the paving formation at the perimeter or edge of all paving. The pavement edging may be formed either by inverted kerbs or downstand edge beams of minimum dimensions 1 5 0 m m w i d t h x 3 0 0 m m depth where:a. offsite fill or natural ground beyond the plot limit is more than 1 0 0 m m below the edge of the plot paving. b. offsite pipetracks, cable trenches or draw pits, manholes or valve pits are at lower levels immediately adjacent t o the plot paving limit.

12.3.2

Inverted kerbs or downstand edge beams are not required for the edges of concrete paving and access-ways where they terminate at unpaved areas within the plot limits or directly adjoin offsite roads or paving.

12.3.3 Where concrete paved access-ways from the plot meet bituminous pavlng of offsite roads, a flush edge kerb should be provided. Where such accessways adjoin surrounding roads, a minimum internal radius of 9 . 0 m should be provided at the junction of paved access-ways.

Page 41 of 6 9

DOC. NO. KOC-C-002

REV. 1

Fully supported upstand kerbing t o a height of 1 5 0 m m should be provided around the bend and for 1 0 0 0 m m beyond the tangent points. The top surface of the 1 0 0 0 m m beyond the tangent point should slope d o w n t o road and access-way level. 12.3.4 Where paved and unpaved plot limits adjoin offsite fill or natural ground more than 1 0 0 m m below the edge of the plot paving, provision should be made for fill t o be graded d o w n from plot limits t o the lower offsite levels.

Widths of access-ways should be such that they serve the intended purpose without any inconvenience, and should be neither t o o narrow nor too wide. As a guidance, the minimum widths should conform t o the following as given in Table II: Table II : Recommended Widths of Access-ways G o .

11

Description

..

..

Minimum Width

1

Access-ways for vehicles within Plant Plot limits

6.0 m

2

Access-ways for Pedestrian

1.0 m

3

Elevated walkways within Plant Plot Limits

1.0 m

4

Clear Access for Maintenance around individual

1.0 m

equipment and its appurtenances isolated from the main paved areas 5

12.5

Stairways i n Tankage areas

1.0 m

m e a d Clearances Minimum clear vertical distance for all overhead structures, platforms, piping supports and equipment should be maintained over the plant paving surface as recommended below in Table Ill of this RP. Table Ill : Recommended Overhead Clearances

1

Over Plant roads for heavy cranes

6.5 m

2

Over Plant access-ways for major mobile equipment

5.0 m

3

Over Plant general paved areas accessible t o mobile

4.0 m

4

Over pumps and turbines from h ~ g hpoint of paving

2.5 m

5

Over walkways, passageways and platforms

2.1 m

equipment

- :

12.6

Live (Imposed) Loads Culverts, suspended paving slabs and removable cover slabs for service trenches should consider in the design the following live loads (imposed loads) t o serve the intended purpose as given in Table IV of this RP.

Page 4 2 of 69

DOC. NO. KOC-C-002

Table I V : Recommended Live (Imposed) Loads Description 1

Culverts

and suspended

paving slabs

Live (Imposed) Loads (LL) AASHTO or H A loading as per BS

in

5400

vehicle access-ways 2

1 0 k N point load o n area 3 0 0 mrn2

Suspended paving n o t accessible t o vehicles

and 5 kN/rn2distributed load 3

i

Removable cover slabs t o service trenches

1 i n paved areas accessible t o vehicles

(

5 0 k N wheel loads ( 4 0 k N + 2 5 % m p a c t ) at 9 0 0 m m c i c w i t h 4 wheels m a x i m u m per axle

4

5

Removable cover slabs t o service trenches i n paved areas n o t accessible t o vehicles

l O k N point load o n area 3 0 0 m m 2 placed t o produce w o r s t effect

Removable cover slabs t o service trenches

5 k N / m 2 distributed loads

I i n unpaved areas w i t h no vehicle access.

(1

Soil Supported Concrete Paving Concrete paving should be designed for the appropriate thickness w ~ t h adequate reinforcements for the loads, arising out of the above intended usage of the paving within the plant plot limits, offsite and remote places; and shall be laid on compacted soil t o have uniform support. Sometimes, minor static equipment, l o w level manifolds, small diameter pipes, platforms and stairs are supported on the concrete paving in place of separate footings. In that case, the supporting areas of the paving should be thickened over the normal thickness and should be strengthened w i t h additional reinforcements. Access-ways and paving accessible t o vehicleslmobile equipment, and drop out areas where heavy loads may be placed or handled during maintenance, should have a minimum thickness of 1 5 0 m m , adequately reinforced in t o p and b o t t o m t o suit loading and ground conditions. Paving not accessible t o vehicles should be reinforced and should have a minimum thickness of 1 0 0 m m . Permanent ladders from paved / ground level should be connected, wherever possible, directly t o its supporting structure and should be kept clear of the paving t o avoid effects of any settlement and corrosion at ground level. Paving t o cable trenches not subject t o vehicular loading and supported on compacted sand fill should be 75 m m thick concrete screed of characteristic strength 1 0 N/mm2, generally without reinforcement. Where cable trenches are subject t o vehicular loads, removable type cover slabs should be installed in place of in-situ paving.

DOC. NO. KOC-C-002 12.7.7

Paved walkways of the main paved areas should be of 5 0 m m thick precast concrete paving tiles of approved quality and colour.

12.8

Joints

12.8.1 Paving slabs shall be provided w i t h movement joints (contraction/expansion) t o minimize the potential cracks in concrete due t o the high temperature variation in Kuwait. Hydrocarbon resistant mastic sealing compounds should be used for joint sealants. Steel reinforcements should be either made continuous through contraction joints or curtailed at joints as specified b y the designer t o suit the requirements. 12.8.2 Paving shall be discontinued around equipment bases, pedestals, columns, grade beams and manholes unless otherwise specified. A clear gap of suitable w i d t h ranging from 1 2 m m t o 25 m m shall be provided all around. The joint should be filled w i t h preformed compressible mineral fibre board and should be sealed w i t h approved sealing materials t o prevent ingress of water, soil, chemicals and other foreign materials. 12.8.3 However screeds should be poured in-situ against the adjacent paving edges without jointing or sealing, and for a maximum length of 5 m at one time. 12.9

Unpaved Areas

12.9.1

Unpaved areas adjacent t o buildings and structures shall be sloped t o direct surface water and rainwater from roofs away from the buildings and structures at a minimum slope of 1 in 2 0 for the first 3000 m m .

12.9.2 Unpaved areas not occupied by equipment, buildings or any structures should be graded t o have adequate continuous slopes t o drain towards drainage swales, storm water inlets, roadways or natural water courses. The surface runoff shall be carried under walkways and roadways in pipes of sufficient sizes t o avoid clogging by debris an other materials.

General Roadways, which provide smooth vehicular movement and access t o the KOC plants and facilities within KOC areas, within plot perimeter of KOC plants and facilities, offsite areas and Ahmadi residential areas, should be designed in accordance w i t h the appropriate national or local regulations and practices and shall comply w i t h the following requirements as listed below. Roadway Construc_tion

13.2.1 All main facility access and primary roads, offsite (secondary/service) and plot perimeter roads of KOC facilities should of bituminous construction and shall be made in compliance w i t h KOC-C-024 Part 1 "KOC Standard for Materials and Workmanship - Roadways, Paving and Hard Standing: Flexible Pavement".

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REV. 1

13.2.2

Paved areas adjoining roadways within KOC facilities should be of bituminous construction, if not subject t o contamination b y spillage or leakage of hydrocarbons, or alternatively of concrete.

13.2.3

However, access-ways and paving inside the plants shall be of concrete construction as described in clause 1 2 . 0 of this RP.

Permanent roads should be sealed and surfaced smooth w i t h the class of wearing coat as per KOC-C-024 Part 1 , unless required solely for fire access or infrequent maintenance access. Temporary roads should be made of "Gatch" as per KOC-C-005 and may remain unsurfaced depending on the degree of maintenance. Vehicular Loads

-

The roadways should be designed for the maximum vehicle loads expected. These loads should conform t o the standard classes of loading as specified in "AASHTO Guide for Design of Pavement" or BS 5 4 0 0 . The standard classes generally considered in the design are designated as H 2 0 - 4 4 for t w o ( 2 ) axle truck or H S 2 0 - 4 4 for tractor truck w i t h semi-trailer as per AASHTO.

NB: The Number "20" indicates the gross weight of truck in tons

The design life of roads should be compatible w i t h that used for plant or works, but shall not be less than 2 0 years as minimum. However, b y means of regular maintenance and resurfacing, this life can be further extended, until and unless the g r o w t h of vehicular traffic and heavy vehicles exceeds far the anticipated numbers of vehicles within its design life.

Existing Roads The performance and requirements of maintenance for existing roads should be evaluated based on their conditions, frequency of heavy vehicles, daily traffic volumes and number of traffic lanes required. Existing roads should be periodically resurfaced w i t h n e w asphalt and repaired for the cracks, depressions and potholes. When necessary, existing roads should be widened, dug out and reconstructed w i t h n e w bituminous materials and traffic markings as per KOC-C-024 Part 2 t o give a n e w lease of life and meet the present I future requirements

1 3 . 7 . 1 Where road bridgeslculverts are required t o cross over pipe tracks and water channels or streams, the w i d t h between parapets, alignment of centre line

DOC. NO. KOC-C-002

1

1

Page 45 of 69

REV.l

and profile of the flexible surface layer should be fully compatible w i t h the adjoining roads. 13.7.2

Gentle ramps w i t h maximum slope 1 in 1 5 may be provided from top of road t o t o p of bridge level, but not at road junctions. Crash barriers are recommended, where any accidental loss of vehicular control may damage the adjacent facilities.

13.7.3

All the road bridges / culverts should be designed t o withstand the appropriate vertical loading described in clause 13.4 of this RP.

13.7.4

Hand railing should be installed on the bridge parapet.

13.8

Road Geom-

13.8.1

Proper care should be taken from the initial planning stage, particularly where large plant items or pre-assembled units require special considerations for safe movement. Attention should be paid t o the proper geometry of road w i t h the location of plants and facilities t o have the maximum clear visibility w i t h the natural surrounds during driving, and should avoid abruptly sharp turns and blinds.

1 3 . 8 . 2 Road junctions or bends shall provide for the safe movement of traffic without undue restrictions. The design should allow for the type of vehicles t o be used and the limitations of space at such locations, generally the internal radius t o the kerbing should not be less than 1 0 m. Crash barriers are recommended for all junctions where there exists the potential risks for damage t o the adjoining facilities 13.8.3

Permanently surfaced roads, as classified in K O C - ( - 0 2 4 Part 1 according t o traffic density, should conform t o the minimum widths w i t h the types of shoulders on each side, as recommended in Table V of this RP. Table V: Recommended Widths o f Roadwavs

(Minimum) 1

Main Facility Access and Primary

2

Secondary

/

Shoulder

7.0 m t o 8.0 m

2.5 m

6.0 m

2.0 m 1.5 m

Roads w i t h hard shoulders

1 shoulders

Roads

with

hard

3

Service Roads w i t h s o f t shoulders

5.0 m

4

Service Roads w i t h o u t shoulders 1 Lane

3.5 m

5

1 Temporary Roads w i t h Gatch

6.0 m t o 7.0 m

I i

REV.l

DOC. NO. KOC-C-002

13.8.4

General gradients of roads should be chosen taking into account the natural slopes of the surrounding areas for drainage and ease of driving. The sustained gradients should be neither t o o steep nor t o o flat and should be limited t o the following recommended values as per Table VI below. Table VI: Recommended Gradients Designated Areas (Maximum) 1

M a i n Facility Access and Primary

(Minimum)

1 in 3 0

13%)

1 in 1 0 0 (1%)

1 in 2 0

(5%)

1 in 1 0 0 i l % )

(5%) 16.5%)

1 in 5 0

(2%)

1 in 25

(4%)

(5%)

1 i n 100 (1 %)

13°/ni

1 in 5 0 1 in 5 0

Roads -

2

Secondary Roads

p~

3

Service Roads

4

Ramps

1 in 2 0 1 in 1 5

5

Parking Areas

1 in 2 0

6 7

Cross-fall o n each w a y for all roads C r o - f a l l on shnoldnrs

1 i n 30

(2%) (2%)

13.9

Road Shorn

13.9.1

Shoulders (hard/soft) should be laid and finished as specified in clause 1 2 . 0 of K O C - ( - 0 2 4 Part 1.

1 3 . 9 . 2 Shoulders at roads without kerbing should be generally free from anything protruding above its grade; otherwise a minimum 1 0 0 0 m m clearance shall be maintained between the shoulder edge and any structure thereon. However, lighting poles, guardrails and traffic signs may be located at a distance not less than minimum 6 0 0 m m from the edge. 13.10

Road Drainaqe

1 3 . 1 0 . 1 The maximum level of the ground water table should be established t o determine whether subsoil drainage is required t o maintain a stable condition during the rainy period. 1 3 . 1 0 . 2 The road surface should be crowned t o drain surface water away from both sides on t o the adjoining grade, and then b y percolation into adjacent ground where natural ground is below the grade level. However, if the natural ground is above the c r o w n of road, surface water should be drained t o run o f f t o drainage channels, which are generally open ditches and I or lined swales. Where this is not feasible due t o ground impermeability or where such practice would contravene the local regulations, drainage should be provided via an open ditch and piped system.

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REV. 1

1 3 . 1 0 . 3 Open ditches may be unlined w i t h general side slopes 4 : l (horizontal t o vertical) or flatter w i t h b o t t o m graded t o a longitudinal gradient 1 in 2 5 0 . Swales should be trapezoidal in section w i t h side slopes asphalt lined only. Refer t o KOC-C-024 Part 2 for more details related t o road drainage. 1 3 . 11

Crash Barriers & Protection Bollards

13.1 1.1 Crash barriers and protection bollards are not generally required. However, where the horizontal alignment of any type o f road changes abruptly, and potentially any out-of-control vehicle could cause damage t o pipework, cabling or items of installation, a safety barrier shall be provided. If for any reason, pipework or an item of the installation is located immediately adjacent t o a road, a protective barrier shall be erected for safety 13.1 1.2 Where required, protective barriers should generally be located at the outel edge of the hard shoulder and not less than 1 0 0 0 m m from the road edge. 13.12

Kerbing

13.12.1 Kerbing shall be provided generally at the plot perimeter roads inside the plants and facilities as well as at the road network inside Ahmadi residential areas t o protect the surrounding areas from any flooding of water and hydrocarbon spillage and shall be provided in accordance w i t h KOC-C-024 Part 1 . 13.1 2.2 Kerbing shall also be provided at road 1 vehicle access-way junctions, where there is a specific requirement t o contain contaminated runoff or spillages. Road I Traffic Markinqs Traffic markings for all roads in the offsite areas shall be provided in accordance w i t h KOC-C-024 Part 1 . Traffic S& Traffic signs for all major roads outside the plant areas within KOC jurisdiction shall be provided in accordance w i t h KOC-C-024 Part 2. Overhead Clearances The minimum overhead clearances from the c r o w n level of roads should be maintained for the vehicular traffic as 6.5 m for the main facility access road and primary road; and 4 . 0 m over the other secondary roads.

I

REV. 1

14.0

W C E L L A N E O U S CIVIL WORKS FOR SERVICES A N D PIPELINES

14.1

Electrical and Instrument Cable Trenches

14.I . 1

Paved Areas a. Cable trenches for electrical and instrument cables, where required t o be provided through the plant paved areas, should generally be constructed w i t h a reinforced concrete base w i t h walls made of either reinforced concrete or precast concrete block work. b. Trench filling should be carried out after cable being installed and then filled w i t h sand as specified in KOC Standard 381 1020. c.

Paving should be provided over cable trenches as per clauses 12.6 and 12.7 of this RP.

d. Partition walls should be provided in a multipurpose cable trench extending the full depth of the trench. Instrument and telecommunication cables should be separated from power cables. e.

Weep holes of nominal sizes 100 m m x 100 m m at 5.0 m centre t o centre should be provided at the junction of the base slab and walls for the passage of moisture.

f.

Cable entry through the trench walls should be via built in ducts.

g.

Such trenches should be designed taking into consideration the effects of the following: i. ii. iii. iv. v.

Soil conditions and loads. Vehicular loads. Wall heights. Cover slab spans or trench surfacing. Other requirements like cable laying etc.

14.1.2 Unpaved Areas a. Electrical and instrument cables in unpaved areas, which may be located within, adjacent to, or remote from plant plot limits, should be buried direct in accordance w i t h KOC Standard 381 1020. b. Where cables are buried direct, they should be laid over a 75 m m thick compacted bed of uncontaminated sand at a minimum depth of 750 m m for l o w voltage cables and 1000 m m for 3.3 kV / I I kV cables below the unpaved surface in compliance w i t h KOC Standard 3811020. They shall be protected b y cable tiles and identified w i t h non-corrodible tags as appropriate.

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Concrete Cable Trenches A t road crossings cable ducts should be provided; but where large numbers of ducts are required, reinforced concrete in-situ trenches may be used as an alternative w i t h removable cover slabs, which should be designed t o carry the appropriate vehicular loads. The t o p level of covers t o trenches abutting or within paved areas should be 5 0 m m above the plot paving level. In unpaved areas adjacent t o plot paving, covers should generally be 1 5 0 m m above adjacent graded level, but suitable transition levels shall be provided, where they connect w i t h trenches within paved areas. Lifting slots should be provided in every f i f t h removable type cover for ease o f maintenance. Trenches shall be supported directly on the subsoil, which shall be levelled and compacted. Telephone Cable Trenches Normally, telephone cables should be run directly buried within plot limits; and within paved area in trenches w i t h minimum separation distances from power cables as recommended in KOC-L-002.

Trenches for plant piping should generally be avoided, unless otherwise necessary. However, if provided, they should conform t o the minimum requirements of clearance t o pipe work, gradients for drainage, spacing of firebreaks, trench flooring and provision of trapped gullies. Trenches in plot paved areas should have bases and walls made of in-situ reinforced concrete. As an alternative, walls may be of precast concrete block w o r k on a minimum 1 5 0 m m high concrete upstand cast monolithically w i t h the trench base slab. The base slab shall be sloped t o pass any surface water below pipe supports. Trench covers should be either galvanized open steel gratings or concrete wherever practical: a. Inside plant buildings, 8 m m thick checker plate covers may be considered. b.

In open pattern, kerbing that the

areas within plot limits, open grating should be of rectangular galvanized or suitably protected against corrosion. Angle is t o be connected t o the reinforced concrete and will ensure covers are flush fitting.

DOC. NO. KOC-C-002

Page 50 of 69

Trench firebreaks should be provided as required. Large pipes and all pipes subject t o thermal movement should be sleeved, and the annulus plugged and then sealed w i t h a hydrocarbon resistant mastic seal. All pipes or sleeves in contact w i t h the fill material contained within firebreak should be protected against corrosion. The filling t o firebreaks between concrete work should be of sandy soil, compacted around the pipes in as dry a state as practicable. In paved areas, trench firebreaks should be topped w i t h a 5 0 m m concrete screed. Cable Ducts Cable crossings, under offsite roads and vehicular access-ways not part of the plot paving, should be formed of ducts encased in reinforced concrete. Ducting should extend a sufficient distance beyond the road or hard shoulder edge t o ensure that there will be no damage or undermining of the road or hard shoulder during any subsequent excavation t o d u c t invert level. Spare ducting should be included for possible future requirements. The design of such ducts, their bedding, concrete surround and reinforcement shall withstand the appropriate traffic loading as given in clause 1 3 . 4 of this RP. The t o p level of duct shall be maintained at a minimum depth of 1 2 0 0 m m below the c r o w n level of the road or the access-way. If cables enter at the end of the duct into a trench, a suitable transition pit should be provided w i t h floor sloping at an angle not greater than 3 0 degrees and w i t h removable concrete covers and sand filling above the cables. Ducts for Instrument Cables Ducts for instrument cables crossing under roads or access-ways from process units t o adjoining or centralized control building should be formed in accordance w i t h clause 1 4 . 4 above. Instrument cables after installation in the ducts should be surrounded w i t h mastic sealant. D u ~ n Cable d Trenches a t B u i l d i n s Provision should be made t o prevent any accumulation of flammable liquids and gases in buildings, due t o entry via service ducts, cable trenches or drains. The b o t t o m levels of cable trenches required within control room, substation and s w i t c h gear buildings and invert level of any entry holes or ducts thereto, should be specified t o suit as necessary.

DOC. NO. KOC-C-002

REV. 1

Sleeves

14.7

14.7.1

Page 51 of 69

Road Crossings a. Load bearing sleeves should be provided t o pipes crossing under KOC field roads and all vehicular access-ways, where provision of a culvert would be uneconomical due t o f e w numbers of pipelines, and where: the strength of the pipe is inadequate for the anticipated loading. the pipe is subject t o excessive thermal movement. the pipe is t o be more protected from any accidental damage due t o transfer of any loads. iv) for operational convenience or safety, the pipe is t o be replaced w i t h o u t excavation. i) ii) iii)

b. Flexible end seals, resistant t o hydrocarbons where appropriate, should be fitted between pipes and sleeves at both sides of the crossing. c. Pipe sleeves shall be provided in accordance w i t h Drawing 1 5 - 14-1 3 for "Standard Pipe Sleeves". 14.7.2

KOC Standard

Pipes Through Structures a. Large diameter pipes and all pipes subject t o thermal movement should be sleeved, when passing through walls or other structural elements or firebreaks. Such sleeves should generally be of steel, except that in any exposed condition above grade, they should be of non-corroding material in order t o obviate rusting and spalling of t h e surrounding concrete or mortar. b. Where necessary, flexible end seals resistant t o hydrocarbon and of nonflammable, non-setting and non-toxic type should be fitted between the pipe and its sleeve.

14.7.3

Pipes Through Earthen Dikes a.

Piping or conduits should not generally pass through earthen dike walls in compliance w i t h KOC-L-027. However, if necessary t o penetrate through the dike walls, they shall be adequately protected from external corrosion b y use of coatings and pipe sleeves. Where pipe sleeves penetrates through the dike walls, the surrounding area shall be filled w i t h concrete t o prevent dike erosion and collapse.

b. The annular space between the pipe and its sleeve should be fitted w i t h the appropriate liquid tight end seals. Such seals should be hydrocarbon resistant, non-flammable, non-setting and non-toxic type, and should be capable t o withstand the hydrostatic pressure appropriate for the height of the dike.

DOC. NO. KOC-C-002

Pits for small underground lines should be constructed w i t h precast concrete block work, where there is no need t o anchor the pipes in the walls. Where there is potential risk of hydrocarbon contamination of the pit, the block work should be laid on a concrete upstand of minimum of 1 5 0 m m high, cast monolithically w i t h the pit base slab, the t o p of this upstand being horizontal. For pipelines where restraint is needed against thermal movement, and for large size deeper pits where earth and hydrostatic pressures from the ground water become the governing design criteria, construction shall be of reinforced concrete in accordance w i t h the requirements of liquid retaining structures as specified in BS 8 0 0 7 or ACI equivalent; and shall also comply w i t h the requirements as given in KOC-L-002. The pits shall be made watertight t o prevent any ingress of ground or rainwater through the sidewalls and b o t t o m slabs. Where pipes penetrate walls at a level below the highest expected water table, the pipes should be fitted w i t h puddle flanges located in the centre of the wall and the walls near t o the pipe should be at least 2 5 0 m m thick. Valve pits should be finished 1 5 0 m m above adjacent paving or ground level. They may be either left open but protected w i t h handrails or covered w i t h 6 m m thick removable chequer plate. Pit floors should be sloped t o a shallow sump, t o allow for pumping out of liquids, and where necessary the pit walls should be provided w i t h step irons. Floodliqht Masts Floodlights, when they are not mounted on plant structures, should be mounted o n masts w i t h foundations either spread or integral w i t h the plot paving, thickened and reinforced as required. Masts shall be guyed for stability against winds and wind-excited vibrations; and shall be designed in accordance w i t h BS 8 1 0 0 Part 4 . Floodlights, when required t o be installed at great heights above the ground, are generally mounted on t o p of the tall freestanding towers in either triangular or quadrilateral shapes. Towers should be of lattice type structures, which shall be designed in compliance w i t h BS 81 0 0 Part 1 . -Hy&ant

Pits

The use of fire hydrants pits should be discouraged

Earthing for buildings and steel structures shall be provided in accordance KOC Recommended Practice for Earthing and Bonding" w i t h KOC-E-024 and BS 7 4 3 0 . "

DOC. NO. KOC-C-002

14.12

REV. 1

Liqhtninq Protection

14.12.1 Appropriate lightning protection systems for buildings and tall structures shall be selected as per the electrical requirements and shall be provided in compliance w i t h BS 6651, IEC 61 024, NFPA 780 and KOC-E-024. 14.12.2 Earthing requirements of lightning on buildings less than 20 m high, as a good engineering practice, should also be considered especially where explosive hazards exist, in accordance w i t h BS 6651. Warninq Liqhts Aviation warning lights shall be installed on tall structures for obstruction as per the Federal Aviation Regulations for safety. STEEL STORAGE TANKS

The layout and spacing of several numbers of aboveground vertical steel storage tanks, which are basically meant for storing crude petroleum and flammable liquids within KOC facilities (plantsltank farms), shall be decided in accordance w i t h KOC-L-027 "KOC Standard for Layout, Spacing and Diking of Aboveground Petroleum Storage Tanks". The layout of these above tanks should, from the preliminary stage of design, take into consideration several factors as below:a. Topography w i t h good and flat surface. b. Subsurface having not too deep load bearing hard soil strata. c. Safe distances from the nearest road(s) and adjoining publiciprivate properties. d. Level of risks associated w i t h any major fire incident. e. Acceptable level of safety and protective measures t o be provided f.

Good accessibility in the tankage area and smooth movement of the fire fighting equipment, in case of any fire incident.

The layout and spacing of other aboveground vertical steel storage tanks, which are needed for storing non-petroleum liquids (brackishlpotable water) within KOC facilities (plants I tank farms etc.), may be established in conformity w i t h relevant design features as laid d o w n in KOC-L-027 and in line w i t h applicable items (a-c) and ( f ) of clause 15.1 .2 above.

DOC. NO. KOC-C-002

Page 54 of 69

REV. 1

The design grade levels of tanks other than pumping requirements and tie-in points, should take account of subsoil conditions, drainage, ground water table and earthwork requirements on the site. Normally grade level on which a tank bottom rests, should be kept 300 m m above the finished ground level (FGL) or as specified by the designer. If anode grid type cathodic protection t o be installed under the tank foundation, the design level should be checked for the adequate space required for embedding the system below the tank b o t t o m and may be increased t o minimum 750 mm, if necessary t o accommodate it. Grade levels, wherever possible, should be determined t o balance the cut and fill earthwork requirements in the storage area w i t h the associated levels of tank pads and roads. Foundation Desiqn Criteria A geotechnical investigation shall be conducted t o establish the ground conditions at any tank site and its suitability for the proposed tank sizes in relation t o the allowable bearing capacity and settlement criteria. The sub-grade shall be capable enough t o support the load of tank w i t h its content; and should be assessed for the immediate (short) and long term conditions whether tank foundations will encounter any appreciably high settlements that may strain the connecting piping or produce gauging inaccuracies and may cause the deformations of the tank shell and bottom within its acceptable limits. The ultimate bearing capacity of the tank foundation should be determined by a comprehensive stability analysis, and an adequate factor of safety against failure under the worst loading conditions shall be applied as specified in the relevant clause of KOC-C-026 "KOC Standard for Storage Tank Foundation". Settlement criteria for the immediate and long-term conditions should be established at an early stage in the design in relation t o : a. Total settlement b. Edge t o center differential settlement and localized rotation of the floor plates. c. Peripheral differential settlement. Settlement criteria should be defined t o ensure that excessive settlements will not result in the tank and its fittings being overstressed, and in the case of floating roof tanks, t o limit deformation of the shell so that the roof remains free t o move and the seals retain their integrity.

DOC. NO. KOC-C-002

Page 55 of 69

REV. 1

As the settlement calculations are of limited accuracy even w i t h detailed investigation and analysis, tanks shall not be designed t o depend for their integrity on precise settlement predictions. However as a guidance, the permissible ranges of predicted settlements for tank foundations should be considered in accordance w i t h the relevant clauses of KOC-C-026 for floating and fixed roof tanks. The maximum recommended uniform (total) settlement should not exceed 1 5 0 m m for long term condition. A t tank sites where subsoil conditions indicate the presence of weak and poor sub-grade w i t h high compressibility and fail t o satisfy the above criteria, ground improvement may be necessary and should be considered as outlined in KOC-C-026. Foundation Desiqn Types of Foundation Depending on the tank sizes (diameter & height), types of foundations for aboveground vertical steel storage tanks should be considered as given below unless otherwise specified:. a. Earth foundation w i t h concrete ring wall for tanks (Diameter > 3 5 m & Height 2 1 5 m ) b. Earth foundation without concrete ring wall for tanks (Diameter < 3 5 m & Height < 1 5 m ) The earth foundations for any aboveground steel storage tanks shall be constructed w i t h or without concrete ring walls in compliance w i t h all the design, materials and construction requirements as specified in KOC-C-026 "KOC Standard for Storage Tank Foundation". In the first type, a reinforced concrete (RC) ring wall is provided t o support directly the tank shell, whereas in the other type i t IS being supported b y a compacted crushed stone ring wall composed of 2 5 m m graded crushed stone or gravel w i t h screenings and clean sand. In both types, the tank bottom is rested on a compacted earth pad as inner core finished w i t h several layers of stable permeable materials as described below and shown in the appendices of KOC-C-026. The core of the earth pad shall be constructed from highly compactable, chemically inert, locally available material like "Gatch", which is generally non-corrosive and having l o w compressibility but sufficient strength. It should satisfy the specific soil properties in accordance w i t h KOC-C-005 and shall be compacted t o at least 9 5 % dry density up t o the tank grade level.

DOC. NO. KOC-(2-002

Page 56 of 69

On t o p of the core, layers of free draining permeable material shall be provided t o prevent tank base corrosion by capillary action of soil; and they shall be made of graded sand-gravel mix of minimum 1 0 0 m m thick w i t h a final layer of minimum 1 0 0 m m t o 1 5 0 m m thick graded clean washed sand cushion as the bearing surface of tank bottom. The area of earth pad outside the tank shell shall be sloped for drainage, and shall be finished w i t h a 7 5 m m thick protective layer of asphalt concrete including the side slopes t o form a firm shoulder around the tank. The shoulder around the tank shell should be minimum 9 0 0 m m wide for ease of maintenance. Environmental Protection For tanks storing crude and petroleum products, potential environmental damages t o subsoil and ground water etc. in the event of any leakages should be studied in detail. API 6 5 0 recommends a non-mandatory provision of laying secondary containment barrier such as flexible impermeable membrane liner or other suitable system below the earth pad. The effectiveness of these membrane liners should be judged in relation t o the presence of ground water (generally deep except coastal areas in Kuwait) and other maintenance problems; and decision should be taken in consultation w i t h the specialists whether liners below the tank base should be provided or not in the design. However in view of increasing global consciousness regarding environment, the final design should satisfy the regulations of Kuwait EPA and KOC HSE requirements in this regard. Dikes

--

Dikes shall be provided around tanks storing crude and flammable petroleum products t o safeguard important facilities, nearby surroundings, waterways and properties from any accidental discharge. Dikes shall be liquid-tight, impervious t o the liquid and shall be designed t o withstand a full hydrostatic height. Dikes shall be sized t o contain the volume of liquid equal t o 1 1 5 % of tank rated capacity and accordingly, dike height shall be decided in the tank layout. Generally, the dike height should be limited t o not more than 1 8 0 0 m m above the interior grade level for the convenience of approach, proper ventilation within diked areas and ease of fire fighting, but more height may be permitted if special provisions are provided as described in KOC-L-027.

DOC. NO. KOC-C-002

1

Page 57 of 69

REV. I

15.4.4

Dikes shall normally be of earth construction w i t h KOC approved locally available suitable fill materials in accordance w i t h KOC-C-033 "KOC Standard for Materials and Workmanship - Bund Wall for Storage Tanks".

15.4.5

Dikes should have stable side slopes consistent w i t h the angle of repose of soil; and the crest and sloping sides should be stabilized and protected from erosion by one of the following protective lining(s) as per KOC-C-033 :a. Asphalt lining (short life but inexpensive). b. Bitumen sand lining (medium life and medium cost) c. Concrete lining (long life but high cost). Depending on the dike areas, life cycles and costs involved for protective linings, the appropriate material should be decided case b y case basis.

15.4.6

Earthen dikes should have minimum flat t o p w i d t h of 9 0 0 m m for heights above 1 2 0 0 m m t o provide a walkway on top, and should be accessed inside the dike area by stairways from at least one convenient location of each side from the surrounding roads. Stairways should be at least 1 0 0 0 m m wide w i t h steps not less than 3 0 0 mm, and should be provided w i t h handrails for safety. Proper access ramps should be provided for entry of vacuum trucks and maintenance vehicles inside the dikes. Drainaqe within Dikes Areas inside the dikes shall be graded for surface drainage w i t h a minimum slope not less than 1 in 1 0 0 ( 1 %) from the edges of the tank foundations towards drain pit(s) or sump(s) or any impounding basin as appropriate. The drainage from the dikes should meet the requirements as given in KOCL - 0 2 7 and shall be connected t o the disposal system as provided. Concrete Storaqe Tanks Concrete tanks, storing mainly potable water, are generally overhead tanks of various shapes t o serve the functional and aesthetic purposes. Based on the tank sizes required, the shapes should be decided as follows: a. rectangular I trapezoidal for smaller capacity; b. cylindrical w i t h domed roof & b o t t o m for medium and large capacity; c. hyperbolic or spheroids for large capacity. The height of tank(s) above ground should be decided according t o the specific requirements of plantslfacilities, residential localities t o be served and their distances from the tank location in order t o maintain the necessary supply pressures.

DOC. NO. KOC-'2-002

The storage capacity should be estimated in excess t o those required t o meet the daily consumption criteria and future projected demands in compliance w i t h the local practices and regulations. Concrete tanks shall be designed as liquid retaining structures t o make them watertight and leak proof b y controlling the crack widths in the concrete w i t h the appropriate construction details for joints in compliance w i t h BS 8 0 0 7 , BS 8 1 1 0 or ACI as applicable. Concrete columns should be adequately tied for lateral restraint and shall be capable t o transfer all the design loads t o the foundations. Foundations shall be checked for stability and soil weight not more than 5 0 % on the foundations shall be accounted in the stability calculation.

17.1.1

Fencing should be provided for security around plant and facilities t o restrict unauthorized access, and t o protect equipment at isolated places as well as in remote and desert locations for safety.

17.1 .2

Fencing including all accessories w i t h openable gates and locks should be erected at KOC approved locations t o the specified height for i t s purpose as given below.

1

Fencing may be of permanent or temporary type depending o n its purpose, duty and durability.

17.2.2

The permanent fencing should be made from the following chainlink types: a. General purpose fencing b. Transformer compound fencing c. Industrial security fencing

: 1 8 0 0 m m high : 1 8 0 0 m m high : 2 4 0 0 m m high

17.2.3

In transformer compounds, adequate provision of frame mounted and bolted type removable sections of fencing should be provided t o ensure maximum access for, and removal of, transformers. In addition, an outward opening lockable access gate should be provided t o each separate transformer com~ound.

17.2.4

Temporary fencing should provide the safety and security conforming t o its duty, although i t need not have the same durability of permanent fencing. If this duty is met, some departures may be acceptable for the materials and workmanship requirements of permanent fencing.

DOC. NO. KOC-C-002

1

Page 59 of 69

REV. 1

17.3.1

Generally, fence shall be comprised of galvanized chain link fabric and fittings t o the specified height, w i t h tension wires at t o p and b o t t o m and several r o w s of barbed strands at top. If the fence height is more than 1 8 0 0 mm, one r o w of concertina barbed wire should be installed on top supported b y extension arms and a continuous t o p and b o t t o m rail.

17.3.2

The fence fabric shall be fastened t o the side of line posts (pipes or angles) at 3 0 0 0 m m apart, which shall be embedded into concrete blocks of suitable sizes. The fence shall be adequately braced at panels adjacent t o gates and removable panels.

17.3.3

The fence fabric shall be as per ASTM A392, and shall be made of uniform square or diamond wire mesh of 5 0 m m from helically interwoven steel wires. The wires should be not less than 4 m m diameter, having class 2 zinc coating of minimum 6 1 0 g/m2. The t o p and bottom edges of mesh should be twisted and barbed

17.3.4

Galvanized barbed wire (barbed strands) shall conform t o A S T M A 1 2 1 . Strand wire should be not less than 2.5 m m diameter w i t h minimum zinc coating weight of 2 4 5 g/m2; and barbed wires should be 2.0 m m diameter w i t h 2 0 0 g/m2 minimum zinc coating.

17.3.5

Concertina barbed wire, if provided, shall have 3 . 0 m m diameter high tensile line wire w i t h 2 . 0 m m diameter l o w carbon mild steel barbed wire and shall be galvanized. Coil diameter shall be of approximately 1 0 0 0 m m .

17.3.6

Tension wires shall be of not less than 4 . 0 m m diameter and shall be galvanized w i t h zinc coating of minimum 6 1 0 g/m2.

17.3.7

All line posts, braces, fittings and frames shall be hot dip galvanized and shall conform t o A S T M A53, schedule 4 0 for pipes or t o A S T M A 3 6 for angle sections.

17.3.8

For all other details, refer t o KOC Standard drawing 1 5 - 2 - 6 or 1 5 - 5 - 8 0 for chain link fencing.

17.4

Qrruqated

17.4.1

Corrugated iron sheets, as fencing up t o 2.4 m high are t o be provided In some places like manifold areas and houses in the residential areas t o prevent ingress of sands and accumulation thereof.

17.4.2

Corrugated sheets shall be minimum 2 2 gauge steel, galvanized w i t h coating type 3 5 0 as per BS 3 0 8 3 ; and shall be installed in accordance w i t h KOC Standard drawing 15-5-77 for 1 . 8 m high or 1 5 - 5 - 8 2 for 2.4 m high fences. Gates shall be made as per KOC Standard drawing 1 5 - 5 - 8 3 .

Sheet Fencing

1

DOC. NO. KOC-C-002

Page 6 0 of 69

REV. 1

18.0

STRUCTURAL W O M

18.1

General

18.1 . I

Structural steelwork should be used for multilevel plant structures, overhead pipe racks, heavy girders, large span frames and for industrial buildings covering large areas by trusses or portal frames and miscellaneous metal works like platforms, stairs, ladders etc. as well as for equipment supports and supporting structures, if not located at grade level.

18.1 . 2 Normally, the structural work made of weldable non-alloy, hot rolled steel sections is preferred over the other materials of construction due t o the several factors as follows: a. Ease o f construction. b. Speed of construction. c. Ease of modifications and strengthening in future. d. Ease of periodic maintenance. e. Reliability of good structural strength and long life, i. Highly cost effective and economical. Structural Form 1

Structural steelwork shall be made in the simpler forms of construction for ease of fabrication and erection; as well as for ease of general maintenance and painting.

18.2.2

As far as practicable, complex structural forms should be avoided; and lattice type structures other than towers and roof trusses should preferably not t o be used.

18.2.3

Structural steelwork shall be generally shop fabricated by welding, and field assembled and erected b y bolting at Site. Or, they may be fabricated in pieces and / or pre-assembled in a fabrication yard remote from the Site.

18.3.1

The structure or a part of the structure shall be designed t o resist all applicable loads and worst load combinations within the deflection limits as specified in KOC-C-001 "KOC Standard for Basic Civil Engineering Design Data".

1 8 . 3 . 2 The steel structures shall be designed in accordance w i t h the current practices as established in AlSC or BS 4 4 9 or BS 5 9 5 0 along w i t h other applicable British standards; and shall be fabricated w i t h all the materials in compliance w i t h the relevant technical specifications as specified in KOC-C0 0 7 " KOC Standard for Structural Steel Work - Materials, Fabrication and Erection ".

DOC. NO. KOC-C-002

18.4

m

n Stress Levels

Allowable design stresses for the selected structural steel sections (rolled ! hollow) conforming t o BS EN 1 0 0 2 5 Grade S275JR I S 2 7 5 JOH or ASTM A 3 6 or equivalent shall be used in accordance w i t h the applicable National codes and standards given in clause 4 . 2 of this RP. However, reduction in the allowable design stresses may be considered necessary as safety measures for the following conditions. 18.4.1

Fatigue a. Special structures, such as gantry girders w i t h heavy moving loads from the crane(s), tall free-standing towers and guyed masts which are prone t o fatigue due t o cyclic loading, should consider in design, the appropriate safety factors and reduced stress levels in order t o limit the allowable material stresses. b. Structural details, which may give rise t o high local stress in these fatigue prone structures, should be avoided.

18.4.2

Fire Structural steel can withstand temperature up t o 200°C (392°F) without any significant reduction in the allowable stresses and can retain its integrity without change in its strain levels. But its loss of strength starts then at an increasingly faster rate, up t o a temperature of about 750°C (1382°F) w i t h increased strain levels causing serious inelastic deformations as per BS 8 1 1 0 Part 8 . If the critical temperature for structural steel is intended t o describe the steel temperature at which its strength reduces t o such an extent that collapse is impending, this temperature may be judged w i t h reasonable approximation in the range of 538°C ( 1000°F). Where the structure supports equipment containing or handling flammable materials and where high risk of potential fire exists, suitable reduction in the allowable stresses should be considered in design as an additional protective measure other than encasing the structure w i t h selected fire proofing material.

18.5

Passive Fire Protection

1 8 . 5 . 1 The passive fire protection of steel structures as needed shall be established for the requisite fire rating, wherever fireproofing requirements are specified by KOC or b y the designerlcontractor; and shall be provided in accordance w i t h KOC-C-027 "KOC Standard for Materials and Workmanship Fireproofing of Structural Steel Work".

DOC. NO. KOC-C-002

Page 6 2 of 6 9

The materials shall be fire rated t o maintain the temperature of 538°C (1000°F) on the steel substrate t o a specified period of fire resistance, which may in general vary from minimum one ( 1 ) hour t o maximum four ( 4 ) hours t o provide the breathing time for the required fire fighting response. Accordingly, the material properties and thickness should be selected and verified b y the fire tests certificates for suitability as per BS 4 7 6 Parts 2 0 and 2 1 . However, materials w i t h t w o (2) hours of fire rating should be good enough as passive fire resistance in the form of in-situ dense concrete, lightweight vermiculite concrete or epoxy intumescent coating as specified in KOC-C027. Paintinq I Galvanizing All metal surfaces shall be prepared as per SSPC SP6 and shall be pamted, unless galvanized or otherwise specified, in accordance w i t h KOC-P-001 "KOC Standard for Painting and Coating of Metal Surfaces - New Construction". All steelwork for miscellaneous metal work such as platforms, walkways (open grid flooring I checker plates), handrails, stair treads, ladders, cages and safety guards including bolts, nuts and washers shall be hot dip galvanized in accordance w i t h BS EN I S 0 1 4 6 1 . Connections Welded connections shall be carried out using the manual metallic arc process as per A W S D l . I . Welding procedure specification (WPS) for each class of work and procedure qualification records (POR) as per A W S D l .1 requirements shall be submitted for KOC approval prior t o commencement of work. Bolted connections shall be made w i t h high strength friction grip (HSFG) bolts or grade 8.8 high tensile structural bolts, except in the following minor connections where ordinary black bolts may be used: a. Purlins, sheeting rails and light bracings. b. Platforms and walkways attached t o vessels. c.

Removable floor assemblies.

plates,

removable hand railings and ladder cage

The use of HSFG bolts for structural steelwork shall be in accordance w i t h AlSC or BS 4 6 0 4 .

DOC. NO. KOC-C-002

Page 63 of 69

REV. 1

All bolted connections shall be made w i t h minimum t w o ( 2 ) bolts w i t h bolt sizes per connections as below: a. M 2 0 high strength bolts for main connections. b. M 16 ordinary bolts for secondary connections. As far as practicable, various forms of connections should be minimized and complicated details should be preferably avoided for fabrication as a good engineering practice. MISCELLANEOUS METAL WORK Platforms Platform(s) shall be provided at locations for access t o equipment and their appurtenances for regular attention t o operations or servicing and maintenance, when they are in operation and are placed more than 2 0 0 0 m m above the grade level. Minimum w i d t h shall be not less than 1 0 0 0 m m for operating platforms and access around equipment(s). Platforms should therefore be provided especially for access to: a.

elevated man-ways on process equipment,

b. manifold locations, C. instrument locations, d.

high level fixed fire monitors.

Platforms, if provided at various levels and around different items, shall be interconnected b y walkways, stairways or ladders w i t h specific attention t o escaae routes in the event of fires. Headroom clearance at all platforms shall not be less than 2 1 5 0 m m considering the presence of electrical fittings and all other obstructions thereon. Platforms shall be installed in the form of either open grid or solid checker plate steel flooring w i t h stairways and ladders for access and exit; and shall be protected w i t h handrails and toe plates. Walkways shall be of open grid type and shall be provided w i t h handrails and toe plates. Walkways shall not be less than minimum 7 5 0 m m in width. Self closing gates should be provided at platform exits t o all vertical ladders, which should open inwards towards the platform. Self closing safety bars may be used in lieu of gates.

DOC. NO. KOC-C-002

Page

64 of 69

REV.l

19.2

Steel F l o o r m

19.2.1

Normally, steel flooring should be of open grid type and should be hot dip galvanized. However, checker plate flooring should be considered for safety where any chance of spillage exists from upper level t o lower platforms or equipment.

1 9 . 2 . 2 Open grid type metal flooring in rectangular pattern is normally preferred w i t h load bearing bars having anti-slip serrated t o p surface. The load bearing main bars shall be 3 0 m m deep x 5 m m thick @ 3 0 m m centers w i t h 1 0 m m t w i s t e d cross bars @ 1 0 0 m m centres in transverse direction. Checker floor plates shall have raised pattern t o provide a non-slip surface and shall be minimum 6 m m thick excluding the pattern. Floor panel shall be limited t o span (L) having deflections not more than LIZ00 or 1 0 mm, whichever is smaller.

Stairways shall be provided for access t o platforms serving equipment which requires regular and frequent operational attendance or rapid escape or access in the event of an emergency. Stairways shall be arranged w i t h the angle of slope between 3 0 " t o 3 8 " t o the horizontal. In some special cases, up t o 45' may be provided subject t o KOC approval. Generally, stairs shall be provided w i t h at least 7 5 0 m m minimum clear w i d t h between stringers. Stairs shall have minimum 2 4 0 m m tread w i d t h and maximum 1 9 0 m m riser height. However, main access and escape stairs shall have at least minimum clear widths of 1 0 0 0 m m and 1 2 0 0 m m respectively between stringers. The maximum rise in a single flight of stairs shall be limited t o 3 0 4 0 m m or 1 6 risers without landing. The minimum length of landing shall be 1 2 0 0 mm. Headroom clearance over stairs shall be minimum 2 1 5 0 m m measured at the nose of a tread. Treads for all stairs and landings shall be galvanized open grid flooring w i t h full w i d t h anti-skid checker plate nosing and shall be made in accordance w i t h clause 1 9 . 2 . 2 of this RP. However, for stairs having 7 5 0 m m width, main bearing bars should be 2 5 m m in place of 3 0 m m deep.

DOC. NO. KOC-C-002

Page 65 of 69

Spiral stairways shall be generally provided t o the circular structures like vessels and tanks for access t o platforms. Stair widths shall be at least minimum 1 0 0 0 m m between stringers and slope shall be decided on the basis of number of landings, depending on the diameter and height of the structures. Stairs and landings of stairways shall be galvanized open grid flooring. Treads of stairs and landings shall have full w i d t h anti-skid checker plate nosing and shall be made in accordance w i t h clause 1 9 . 2 . 2 of this RP.

Fixed ladders shall be provided for: a. Access t o all platforms not served by a stairway. b. An emergency escape from a platform which is already served b y a stairway. c.

Access t o locations where no platforms are provided

All ladders shall be generally vertical. If inclined ladders are t o be provided, the sloue shall be not more than 15" t o the vertical. Changes in inclination of ladders shall not be allowed. Intermediate platforms shall be provided t o avoid change of inclination within a flight. Side access ladders shall be preferred t o front access. Safety bars shall be provided where ladders start close t o the edge of an elevated platform. Ladder shall be provided w i t h safety cage, when ladder height is 5 . 0 m or more above ground or platform level. Safety cage shall start in that case from a height of 2.1 m minimum but not exceeding 2.4 m maximum from the ground or platform level. Safety cage shall be circular shape in plan w i t h a radius ranging from minimum 3 4 0 m m t o maximum 3 8 0 rnm as applicable. Ladder rungs shall be fitted into holes in the stringers and secured b y welding. Ladder w i d t h shall be not less than minimum 3 8 0 m m but not more than 4 6 0 m m for ease of climb. For more details, refer t o KOC drawings 1 5 - 3 9 - 5 3 for steel ladder.

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Handrails and Toe Plates Handrails shall be provided for safety around edges of all platforms and walkways which are 5 0 0 m m or more above ground or any operating level. Handrails shall be provided for stairways and all landings. Toe plates shall be provided along all edges protected b y handrails, at openings in flooring around equipment, but not across the entrance t o platforms by stairs and ladders. Toe plate upstand shall be not less than 100 mm. Refer t o KOC Standard drawing 1 5 - 3 9 - 5 4 for all structural details,

Ramps, if made of steel, shall be provided w i t h adequate w i d t h at emergency escapes in hospitals and buildings; and shall be of solid checker plates w i t h raised anti-skid patterns. Checker plate shall be minimum 8 m m thick excluding the raised patterns. Ramps or inclines shall have slopes not more than 1 5 " and should never exceed 2 0 " from the horizontal; and shall be laid over a smooth surface of thoroughly compacted base.

Roof and side claddings should be selected from hot dip galvanized steel profiled sheets w i t h lightly bonded plastic finish both sides as per relevant BS 3 0 8 3 , BS 5 4 2 7 and BS CP 1 4 3 Part 1 0 or ASTM A653M or equivalent. QUALITY ASSURANCE The designer I contractor shall operate a quality system preferably based on I S 0 9 0 0 0 series of standards t o ensure that the requirements of this Standard are achieved. The designer 1 contractor shall demonstrate compliance by providing a copy of the accredited certificate or its quality manual. Verification of the designerlcontractor quality system is normally part of the pre-qualification procedure and is, therefore, not detailed in the core t e x t of this Standard. DOCUMENTATION General All correspondence, instructions, data sheets, drawings or any other written information shall be in English language. In case of dual languages, one language shall be English.

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21 . I .2 All dimensions, units of measurement, physical constants etc. shall be in SI units unless otherwise specified. (Nominal bore pipe sizes t o be generally mentioned in inches). 21 . I .3

All documents (text, data sheets, specifications etc.) shall be provided w i t h electronic files in the approved and widely used software ( M S Word, Excel, Auto Cad etc.). All calculations shall be submitted in approved and widely used software(s) agreed upon by KOC.

Designer I Contractor shall submit the necessary documents as a minimum t o KOC for review and acceptance as given below, but is not limited t o the following only: a. b. c. d. e. f. g. h. i. j. k.

I. m. n. o. p.

q. r.

s. t. u.

Geo-technical Investigation Report Topographical Survey Contour Maps Plot Layout Block Diagrams Area Drawings Grading Plans Drainage Plans Location Plans Architectural Plans, Elevations and Sectional Drawings for Buildings Architectural Plans for roofs, reflected ceilings, doors, windows, toilets & W C w i t h internal plumbing, finishes & colour schedules and furniture etc. including all details for Buildings Structural Plans, Elevations and Sectional Drawings for various Units Structural Plans, Elevations and Sectional Drawings for Piperacks Paving Layout Drawings Structural Analysis and Design Calculations Desjgn Drawings showing plans, elevations and details w i t h dimensions, sizes, materials, reinforcements and connections Bar Bending Schedules and / or Fabrication Drawings (by Contractor) Master List of all Submittals Master List of Schedules for Planned Progress Work Breakdown Schedules (WBS) Any other as required.

DOC. NO. KOC-C-002 ACKNOWLEDGEMENT

This Standard has been approved by the Standards Technical Committee (STC) consisting of the following: Mr. Mohammad Emam Mr. S. Kumar Dr. Mohammad llyas Mr. Khalid S. AI-Ali Mr. Henry S. Hill Mrs. Amina Rajab Mr. Khalaf Hamada Mr. N. Ramanathan Mr. Anwar Al-Sayer Mr. Faris Al-Mansouri Dr. M . Araghi M r . Abdul Aziz Akbar Mr. Moataz Khalaf

(Insp.& Corr. Team-S&E) (Standards Team) (Standards Tearn) (Gen. Proj. Team) (Opns. Tech. Svcs.) (Design Tearn) (Design Team) (Major Projects-EFP) (Utilities Team) (HSE Tearn) (Insp. & Corr Team-N&W) (Proj. Mgmt. Team-N) (Information System Tearn)

Deputy Chairman Secretaryi Member Member Member Member Member Member Member Member Member Member Member Member

The draft of this Standard has been circulated t o the KOC User Teams for their review and responses were received from the following: =NEERING

GROUP

A H M A D I SERVICES GROUP

Team Leader D e s ~ g n Team Leader Construction Team Leader General Projects

Team Leader Project Design Team Leader Bldg. Maintenance Team Leader Utilities

MAJOR PROJECTS GROUP

OPE-RATIONS GROUP (NKJ

Team Leader Project Support Team Leader Export Faclllt~es

Team Leader Opns. Tech. Svcs. Team Leader Maintenance

-

OPERATIONS GROUP (EK)

OPERATIONS GROUP (SKI

Team Leader Opns Tech Svcs. Team Leader Mamtenance

Team Leader Gas Opns. Team Leader Maintenance

=RATIONS

HSE GROUP

G R O U P 0

Team Leader Opns. Tech Svcs

Ag. Team Leader Safety

N U S T R I A L SERVICES GROUP

DIVIDED ZONE GROUP

Team Leader Flre

Team Leader Proj. Engg.& Facilities

E X P O R T M A R I N E OPNS. GROUP

DRILLING 0 v S . GROUP

Team Leader Export Svcs

Team Leader Drilling Svcs.

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The preparation of this RP has been entrusted by the Standards Technical Committee (STC) t o the Task Force No. (TF-C/O41 comprising of the following members: Mr. Mr. Mr. Mr. Mr.

S. Kumar Adel Al-Zaid Khaled Al-Sayed Hisham A.Gharieb Mohd. A. Alam

Standards Team Design Team Gen. Proj. Team Proj. Design Team HSE Team

Task Force Leader Member Member Member Member

Tel. Tel. Tel. Tel. Tel.

No. 6 1 4 0 7 No. 6 1 8 3 5 No. 6 1 6 1 3 No. 6 6 5 7 5 No. 6 6 4 1 5