Professional Documents
Culture Documents
DOCUMENT DETAILS
A Issue for Review 15/04/2013 J.S Lim D.M.Ryu KSL / JSK K.H. Song
TABLE OF CONTENTS
1 INTRODUCTION 6
2.1 Definitions 6
4.1 Units 9
4.2 Language 9
5.1 Wind 9
5.3 Rainfall 9
5.4 Seismicity 9
6 MATERIAL SPECIFICATION 10
7 LOADS 10
8 LOAD COMBINATIONS 22
9 STRUCTURAL CONFIGURATIONS 24
12 SOFTWARE USED 25
EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 6 of 25
1 INTRODUCTION
This design basis establishes the minimum requirements for design engineering of Civil
Works as part of EPC execution of Central Processing Facility Phase 2 at BADRA Oil
Field in the Republic of IRAQ.
CODE Description
ACI American Concrete Institute
API American Petroleum Institute
ASCE American Society of Civil Engineers
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
AWS American Welding Society
BS British standards
EN European Standard
EPC Engineering, Procurement & Construction
HPP High Point of surrounding Paving
FGL Finished Grade Level
In the event of apparent technical conflict occurring in applying this specification and
reference documents, the Contractor shall notify the Employer of the conflict in writing for
resolution prior to the commencement of work.
Note 1 : No technical specification shall be defined herein which conflicts or alters the
Contractor's Project specification
Resolution shall be obtained from the Employer in writing before proceeding with the
design.
ASTM A563 Specification for Carbon Steel & Alloyed Steel Nuts
AISC 303-05 Code of Standard Practice for Steel Buildings & Bridges
ASCE 07-10 Minimum Design Loads for building and other structures
AII documents, calculations and drawings shall be carried out using International System
Units (S. I.).
4.2 Language
The maximum and minimum recorded air temperature is (+) 51.8 and (-) 0.4
respectively.
5.3 Rainfall
5.4 Seismicity
6 MATERIAL SPECIFICATION
Unless otherwise noted, all structural calculation shall be carried out based on the
assumption that following materials are used.
7 LOADS
The loads which shall be taken into account in the design of structures, wherever
applicable, are described in this section.
Dead load is defined as the weight of all permanent structural components of building or
structure, such as floors, roofs and non structural components, such as walls, partitions,
fire proofing, insulation, stairways, fixtures, fixed service equipment.
This also include proprietary systems, equipment and machines, including internals, pipes,
valves and accessories; electrical and lighting conduits; switchgear; instrumentation;
fireproofing; insulation; ladders; platforms; and other similar items.
Weight of equipment shall be derived from the MANUFACTURER`s data sheets. Content
load of equipment and piping during operation shall be considered as dead load.
The above load for cable tray shall be taken as 0.7kN/m2 as dead and 1.7 kN/m2 as live
load per tier of tray over the entire width of the support.
If the cable trays tree is having unequal no. of trays on each side or for the end post,
moment shall be added to the beam in addition to vertical load.
The dead loads which are not mentioned above shall be considered as per ASCE 7-10
(e.g. load for waterproofing etc.)
For this Practice, dead loads are designated by the following nomenclature:
Where,
Ds Structure dead load is the weight of the materials forming the structure (not the
empty weight of process equipment, vessels, tanks, piping, nor cable trays),
foundation, soil above the foundation resisting uplift, and all permanently
attached appurtenances (e.g. lighting, instrumentation, HVAC, sprinkler and
deluge systems, fireproofing and insulation, etc.).
De Empty dead load is the empty weight of the equipment or vessels including all
attachments, trays, internals, insulation, fireproofing, agitators, piping, ladders,
platforms, etc. Empty dead load also includes weight of machinery (e.g. pumps,
compressors, turbines, and packaged units)
Do Operating dead load is the empty weight of process equipment, vessels, tanks,
piping, and cable trays plus the maximum weight of contents (fluid load) during
normal operation.
Dt Test dead load is the empty dead load plus the weight of the test medium
contained in the system. The test medium shall be as specified in the contract
documents or as specified by the owner. Unless otherwise specified, a minimum
specific gravity of 1.0 shall be used for the test medium. Equipment and pipes
that may be simultaneously tested shall be included. Cleaning load shall be used
for test dead load if the cleaning fluid is heavier than the test medium.
EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 12 of 25
Live load is defined as the weight superimposed by the use and occupancy of the building
or other structure, but not permanently attached to it. This also includes the load produced
by personnel, moveable equipment, tools and other items placed on the structure, but not
permanently attached to it.
The live loads shall be uniformly distributed over the horizontal projection of the specified
areas, and shall have the following minimum values if not otherwise specified.
The above load for cable tray shall be taken as 0.7kN/m2 as dead and 1.7 kN/m2 as live
load per tier of tray over the entire width of the support. If the cable trays tree is having
unequal no. of trays on each side or for the end post, moment shall be added to the beam
in addition to vertical load.
For other live loads not covered under this section reference is made to ASCE 07- 10.
Load from roof water tanks and mounted equipment including associated concrete plinths
shall be applied as live loads, in addition to the uniformly distributed live loads listed
above.
Loads of all static equipments as well as static load components of rotating equipments
are considered under this category.
All equipment loads shall be increased by 20% to take into account loads from connected
piping and platforms, unless loads from connected piping and platforms have been
determined by detailed calculation.
Erection dead load (Df) for the process equipment and vessels is normally the fabricated
weight of the equipment or vessel and is generally taken from the certified equipment or
vessel drawing.
Empty dead load (De) for the process equipment and vessels is the empty weight of the
equipment or vessels including all attachments, trays, internals, insulation, fireproofing,
agitators, piping, ladders, platforms, etc. Empty dead load also includes weight of
machinery (e.g. pumps, compressors, turbines, and packaged units).
Operating dead load (Do) for the process equipment and vessels is the empty dead load
plus the maximum weight of contents (including packing/catalyst) during normal operation.
Test dead load (Dt) for the process equipment and vessels is the empty dead load plus
the weight of the test medium contained in the system. The test medium shall be as
specified in the contract documents or as specified by the owner. Unless otherwise
specified, a minimum specific gravity of 1.0 shall be used for the test medium. Equipment
and pipes that may be simultaneously tested shall be included. Cleaning load shall be
used for test dead load if the cleaning fluid is heavier than the test medium.
Pull beams and exchanger support beams or foundations shall be designed for a
horizontal force equal to the following values:
Weight of the bundle, for bundles with weight less than 2500 kg.
25 kN when the bundle has a weight between 2500 kg and 5000 kg.
50% of the weight of the bundle when the weight of the bundle is more than 5000 kg.
Fixed end pier Bundle pull minus frictional force on sliding pier.
Sliding end pier Frictional force or half the total bundle pull load, whichever is
less. The remainder of the bundle pull load shall be rested at the
fixed end support.
Bundle pulling force for heat exchangers will be considered as a short-term load during
maintenance for design of equipment supports only and shall not be combined with
seismic/wind load.
Above is not applicable if the bundles are pulled by means of an extractor which acts on
the principle of equilibrium of forces, or if the complete exchanger is being removed from
its foundation and transported to a cleaning area. This should be clearly specified in the
vendor drawing.
Heavy equipment lowered onto a supporting structure can introduce extreme point loads
on structural members, exceeding any operating or test load. After placing of equipment,
EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 14 of 25
the exact positioning (Lining out and leveling) can also introduce extreme point loads.
AII possible loading conditions during erection and maintenance shall be considered and,
for any member of a structure, the most unfavorable condition shall be taken into account.
Maintenance loads are temporary forces caused by the dismantling, repair or painting of
equipment or structures.
7.6 Friction Force (Ff)
Horizontal friction forces, between equipment or single pipes and their supports, as a
result of thermal expansion shall be calculated as,
H =xW
Where,
Each structure shall be designed to withstand the effects of vibration and impact to which
it may be subjected. Each structure or skid supporting a compressor, turbine, pump or
other machinery having significant dynamic unbalance shall be designed to resist the
peak loads specified by the manufacturer. Vibration amplitudes of the supporting structure
or foundation shall be kept within acceptable limits for dynamic forces that occur during
normal machine operation.
Where specifications of dynamic loads are not available from the equipment supplier, the
structure shall be designed for double equipment weight and an additional horizontal load
at the equipments centre of gravity. This horizontal load shall be assumed as 1.5 times
the weight of the moving parts.
Wherever the structure is designed for dynamic loads provided by equipment supplier,
allowable stresses in the supporting members shall be reduced by 20%.
In both the cases the structure shall have a natural frequency outside the frequency range
of the equipment by at least 20%.
In the case of a tall and slender structure, there may be a need to investigate the dynamic
effects of wind gusts.
EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 15 of 25
The following values shall be used in the design of davits, hoist beams and/or trolley
beams and their support:
Load = Lift Load + trolley and hoist + line pull (minimum 500 kg)
Impact = 25% of load
Lateral thrust = 20% of load
Longitudinal force = 10% of load
Only thermal loads due to expansion and contraction of structure shall be considered in
this category.
Thermal loads and displacements shall be calculated on the basis of the difference
between ambient or equipment design temperature and installed temperature.
Temperature in summer is (+) 51.8 and temperature in winter is (-) 0.4 .
The thermal force used for design should be the smaller value resulting from the following
two calculations for equipment foundations.
The force required to overcome static friction between the used surface and the slide
plate.
Ff = (Pop)
Where,
The force required to deflect the pier or column an amount equal to half of the
thermal growth between the supports.
Fd = 3 E I / (2 L3)
Where,
The thermal force should be applied at the top of the piers. The force acts on both the
supports concurrently but in opposite directions.
EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 16 of 25
Wind Load shall be as per the provisions of UBC Vol.2-1997 Chapter 16.
Design wind pressures for buildings, structures and elements shall be determined for any
height as below:
P = Ce Cq qs Iw
Where,
Iw = importance factor as per Table 16-K of UBC Vo1.2-1997 = 1.15 for occupancy
category 2.
qs = wind stagnation pressure at the standard height of 10m as per Table 16-F of
UBC Vo1.2-1997
The maximum wind speed = 31.90 m/sec = 114.84 km/hr = 71.33 mph
From table 16-F of UBC VoI.2-1997,
qs = 13.105 psf = 0.62773 kN/m2
Pressure coefficient Cq for primary frames and method 2 as per Table 16-H of UBC VoI.2-
1997:
(Cq = 1.4)
Height (m) Design Wind Pressure P (kN/m2)
5 1.014
7.5 1.113
8 1.126
10 1.202
15 1.380
20 1.555
30 1.895
EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 17 of 25
Wind load on buildings and shelters shall be computed and applied to the procedures
outlined in UBC-97.
Where,
Method 1 (as per clause 1621.2) shall be used for shelters and Method 2 (as per clause
1621.3) shall be used for buildings.
Structure or
Description Cq Factor
Part Thereof
Primary Method 1 (Normal force method)
frames and Walls : Windward wall 0.8 inward
systems Leeward wall 0.5 outward
Roofs :
Wind perpendicular to ridge
Leeward roof or flat roof 0.7 outward
Windward roof
Less than 2:12(16.7%) 0.7 outward
Slope 2:12(16.7%) to less than 9:12(75%) 0.9 outward or 0.3 inward
Slope 9:12(75%) to less than 12:12(100%) 0.4 inward
Slope > 12:12(100%) 0.7 inward
Wind parallel to ridge and flat roofs 0.7 outward
EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 18 of 25
Structure or
Description Cq Factor
Part Thereof
Wind load on equipments are calculated as per UBC-97 code provisions as per
mechanical design basis. Wind loads mentioned against each equipment by vendor will
be used for the design of foundations. Wind Load not given by vendors shall be calculated
and given for Employers consent before being used in the calculations.
The tributary area for piping or cable trays is calculated as per ASCE Publication Wind
Loads and Anchor Bolt Design for Petrochemical Facilities Chapter 4.
The tributary are for piping should be based on the diameter of the largest pipe plus 10%
of the width of the pipe rack. This sum is multiplied by the length of the pipes (bent
spacing) to determine the tributary area.
A = L (D + 0.1 W)
Where,
The tributary area for cable trays should be based on the height of the largest tray plus 10%
of the width of the pipe rack. This sum is multiplied by the length of the trays (bent
spacing) to determine the tributary area.
EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 19 of 25
Pressure at the highest cable tray elevation shall be considered in the calculation.
Ac = L (h X N + 0.1 W)
Where,
Seismic Load shall be as per the provisions of UBC Vo1.2-1997 Chapter 16. The seismic
zone for the project site shall be Zone 3 with Importance Factor (I) of 1.25.
The total design base shear in given direction as per equation 30-4 of UBC Vol 2-1997 is
V = (Cv I / R T) W
The total design base shear shall not exceed the following equation 30-5 of UBC VoI2-
1997 is
V = (2.5 Ca I / R) W
The total design base shear shall not be less than the following equation 30-6 of UBC Vol
2-1997:
V = 0.11 Ca I W
Where,
Ca = Seismic coefficient
Cv = Seismic coefficient
I = Importance factor
W = Total seismic dead load
EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 20 of 25
The factor for non building structures shall be as per the table 16-P of UBC-97
TA obtained as per above calculation is compared with time period obtained from STAAD
analysis TB.
User defined Time periods PX & PZ (to be given as input in STAAD Pro) are calculated as
follows:
For non-building structure earthquake load shall be as defined in chapter 16, section 1634
of UBC 1997. Rigid structures, i.e. foundations for Horizontal/vertical vessels /tanks (with
time period T less than 0.06s), and their anchorages shall be designed for lateral force as
per section 1634.3 of UBC 1997.
Base shear
V=0.7 Ca I W
The load effect resulting from the vertical component of the earthquake ground motion
and is equal to an addition of 0.5CaID to the dead load effect, D, as pre Clause No.
1630.1.1 UBC 1997 for Strength Design, and may be taken as zero for Allowable Stress
Design.
Where applicable the forces produced by piping, pipe anchors and guides shall be taken
into consideration for the design of the whole structure as well as for its components and
foundations.
Dead loads for piping on pipe racks shall be estimated as follows, unless actual load
information is available and requires otherwise on receipt of actual piping loads, the same
shall be verified with the UDL loads given below and the worst case shall be considered.
(1) Operating dead load (Do) : A uniformly distributed load of 1.9 kN/m2 for piping,
product, and insulation
(2) Empty dead load (De) : For checking uplift and components controlled by minimum
loading, 40% of the estimated piping operating loads shall be used unless the actual
conditions.
(3) Test dead load (Dt) is the empty weight of the pipe plus the weight of test medium
contained in a set of simultaneously tested piping systems. The test medium shall be
as specified in the contract documents or as specified by the owner. Unless
otherwise specified, a minimum specific gravity of1.0 shall be used for the test
medium. In absence of concrete data, 60% of estimated piping operating loads shall
be taken.
For any pipe larger than 12-inch (304-mm) nominal diameter, a concentrated load,
including the weight of piping, product, valves, fittings, and insulation shall be used in lieu
of the 1.9 kN/m2. This load shall be uniformly distributed over the pipes associated area.
Pipe racks and their foundations shall be designed to support loads associated with full
utilization of the available rack space and future expansion.
Horizontal loads are generated due to change in the temperature of piping. For pipe rack
design, both friction forces and anchor forces shall be considered.
Friction forces caused by hot lines sliding over pipe support are considered to be
partially supported by adjacent cold lines. A longitudinal horizontal force is
For pipe racks supporting 4 or more pipes, 10% of the pipe operating weight
(Empty pipes+ pipe contents).
For pipe racks supporting less than 4 pipes, 20% of the pipe operating weight
(Empty pipes + pipe contents).
For standalone pipe support 30% of the pipe operating weight
(Empty pipes + pipe contents).
These loads shall be applied on each pipe only to local supporting beam of the pipe
rack. For small bore lines (Less than or equal to 12 inch dia.) above loads shall be
taken as uniformly distributed.
Longitudinal friction loads shall be considered to be temporary and shall not be
EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 22 of 25
For pipe racks, 10% of the total piping weight shall be used as an estimated
horizontal friction load applied only to local supporting beams. However, an
estimated friction load equal to 5% of the total piping weight shall be accumulated
and carried into pipe rack struts, columns, braced anchor frames, and foundations.
Anchor loads shall be combined with wind or seismic loads. These forces shall be
transferred by the longitudinal beams to the braced bays and the foundations.
Vertical loads :
Longitudinal beams shall be designed for the reaction forces of intermediate cross beams
or a provisional vertical load of 20 kN at mid span whichever is greater.
Horizontal loads :
A transversal horizontal load of 7.5 kN shall be set on longitudinal beams at mid span.
These vertical and horizontal loads allow piping turn offs and shall be considered
combined and in addition to other loading as described in clause 10.2 for local design
check of these longitudinal beams.
8 LOAD COMBINATIONS
Load combinations for concrete foundations shall be determined considering their
applicability, safety and economy. Piles, structures and member of structures as well as
their support and fixing points shall be designed for the various loading combinations
given in clause 7.1 ~ 7.5.
T Self straining forces caused by the thermal expansion of structural steel (Section 7.9)
Ee Earthquake load considering the unfactored empty dead load and the applicable
portion of the unfactored structure dead load (Section 7.11)
Eo Earthquake load considering the unfactored operating dead load and the applicable
portion of the unfactored structure dead load (Section 7.11)
Load
Loading Condition Load Combinations
comb
Operating Weight+ Friction Force+
DS + DO + Ff + Af + T +
1 Thermal Expansion + Anchor Force
L(separate Load case)
without Wind/Earthquake
Ds + Do + Af + L(separate Operation Weight + Anchor +Wind or
2
Load case) + (W) or (0.7Eo) Earthquake
Load
Loading Condition Load Combinations
comb
Operating Weight + Friction Force +
1 1.4 (Ds + Do + Ff + T + Af) Thermal Expansion + Anchor
Operating Weight + Friction Force
1.2 (Ds + Do + Ff + T + Af) + 1.6
2 +Thermal Expansion + Anchor Force
L(Separate Load Case)
without wind/earthquake
1.2 (Ds + Do + Af) + L(separate Operating Weight + Anchor + Wind or
3
load case )+(1.3 W or 1.0 Eo) Earthquake
Empty Weight + Wind
4 0.9 (Ds + De) + 1.3 W
(Wind Uplift Case)
EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
DESIGN BASIS FOR STEEL STRUCTURE
Doc No.: GB090-2614-250-CS-DB-0001 Rev. : 0 Page : 24 of 25
Load
Loading Condition Load Combinations
comb
Operating weight + Earthquake
5 0.9 Ds + 0.4 Do + 1.0 Eo
(Earthquake Uplift Case)
Empty weight + Earthquake
6 0.9 (Ds + De) + 1.0 Ee
(Earthquake Uplift Case)
7 1.4 (Ds + Dt) Test Weight
8 1.2 (Ds + Dt) + 1.3 Wp Test Weight + Partial Wind
9 STRUCTURAL CONFIGURATIONS
All structural configurations shall be as per Employer approved layout and piping
drawings. Pipe rack shall be designed as per Employer approved pipe rack study, unless
otherwise difficult due to clashing. Bay width (Center to Center of columns in longitudinal
direction) shall be equidistance whether in case of main, interconnecting, sub rack or
continuous pipe supports or sleepers. All spacing shall be in multiplies of 1000mm, and
should be equidistance as stated above.
The lowest tier in a pipe rack should be placed so as to provide 4m X 4m clear access
way in both transverse and longitudinal directions. Further the bracing shall be placed so
as to provide clear access of 4m X 4m.
Horizontal clearance between road (from outer edge of road) and pipe rack column shall
be 3.0 m as per GB090-2614-250-CV-SP-0006, Specification for Road, Access and
Parking lots, otherwise contractor shall provide bollards.
Live cables dropping from pipe rack to substation or at any other locations shall be
protected using fencing to prevent workers from accidental shocks.
The total maximum horizontal displacement related to height shall not exceed the
following values:
12 SOFTWARE USED
Following software shall be used: