Guide Procedure of Piping

THAI OLEFINS PUBLIC COMPANY LIMITED
Corporate Specification
CORPORATE SPECIFICATION
M-001
STRUCTURAL DESIGN LOADS AND CRITERIA
2 1 0 Rev
3/08/05 1/3/00 20/12/99 D/M/Y
Corporate Specification Issue for ITB Issue for review Description of Revision
TWC TPT TPT By
RW SWK SWK Chk
WB JN JN Appr
SPEC. NO. M-001 REV.2
PAGE 1 OF 22
STRUCTURAL DESIGN LOADS AND CRITERIA TABLE OF CONTENTS 1.0 GENERAL 1.1 1.2 2.0 Scope Abbreviations
GOVERNING CODES, REGULATIONS AND REFERENCE DOCUMENTS 2.1 Building Codes, Regulations 2.2 Concrete Design, Materials 2.3 Steel Design, Materials 2.4 Civil Sitework, Underground 2.5 Related Project Specifications
3.0
SITE INFORMATION 3.1 Location 3.2 Weather and Site Data 3.3 Wind Speed 3.4 Seismic 3.5 Geotechnical Data
4.0
CIVIL/STRUCTURAL LOADING CRITERIA 4.1 Design Loads 4.2 Loading Conditions, Combinations 4.3 Stability Against Overturning 4.4 Ultimate Strength 4.5 Allowable Overstress 4.6 Buoyancy
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4.7 Bearing Capacity 5.0 STRUCTURAL MATERIALS 5.1 Structural Steel 5.2 Structural Concrete, Foundations 5.3 Anchor Bolts 5.4 Grout 5.5 Coatings 6.0 STEEL STRUCTURES 6.1 Fabrication and Erection 6.2 Design Details 7.0 CONCRETE STRUCTURES, FOUNDATIONS 7.1 Foundations 7.2 Building Ground Floors 7.3 Trenches and Sewer Boxes 8.0 MISCELLANEOUS STRUCTURES 8.1 Ladders 8.2 Platforms, Walkways, Access-ways
1.0 1.1
GENERAL Scope
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This specification provides criteria governing the design of structures and foundations and shall be used by the Contractor to establish the basis for the structural design. 1.2 Abbreviations Abbreviations as used for Codes and Regulations shall have the following definitions: AASHTO ACI AISC AISI ANSI ASCE ASTM AWS API PCA SJI OSHA UBC TIS 1.3 American Association of Highway Transportation Officials American Concrete Institute American Institute of Steel Construction American Iron and Steel Institute American National Standards Institute American Society of Civil Engineers American Society for Testing and Materials American Welding Society American Petroleum Institute Portland Cement Association Steel Joist Institute Occupational Safety and Health Administration, Department of Labor Uniform Building Code of the International Conference of Building Officials Thai Industrial Standard
The metric system shall be used for all dimensions.
2.0
GOVERNING DOCUMENTS
CODES,
REGULATIONS
AND
REFERENCE
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The following codes, specifications, regulations and industry standards, where applicable, shall cover design and material for structures, site work and other civil related facilities. 2.1 Building Codes, Regulations OSHA Occupational Safety and Health Standards, Title 29 Labor, Parts 15 and 19, 1981. UBC Uniform Building Code of the International Conference of Building Officials, 1982 Edition Local codes and/or regulations of approving Authorities.
LOCAL CODES
The UBC Building Code shall govern except where reference to other codes and regulations is specified herein. Local codes shall also be considered. The more conservative specification shall be used for design purposes after agreement by the Company. 2.2 Concrete Design. Materials, Placing ACI 211.1 ACI 301 ACI 302.lR ACI 304R ACT 305R ACT 311.4R ACI 315 ACI 316R Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete, latest edition. Specification for Structural Concrete for Buildings, latest edition. Guide for Concrete Floor and Slab Construction, latest edition. Guide for measuring, mixing, Transporting, and Placing Concrete, latest edition. Hot Weather Concreting, latest edition. Guide for Concrete Inspection, latest edition. Details and Detailing of Concrete Reinforcement, latest edition. Recommendations for Construction of Concrete Pavements and Concrete Bases, latest edition.
ACI 318&ACI 318RBuilding Code Requirements for Reinforced Concrete, latest edition.
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ACI 347 ACI 531 ASTM A185 ASTM A193 ASTM A194
Recommended Practice for Concrete Formwork, latest edition. Building Code Requirements Structures, 1983. for Concrete Masonry
Specification for Steel Welded Wire, Fabric, Plain, for Concrete Reinforcement, 1997. Standard Specifications for Alloy Steel and Stainless Steel Bolting Materials for High Temperature Sources, 1999. Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service, 1986 Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement, 1996 Standard Specification for Concrete Aggregates, 1999. Standard Specification for Portland Cement, 1999. Specification for Air Entraining Admixtures for Concrete, 1998. Standard Specification for Chemical Admixtures for Concrete, 1999. Welded Steel Tanks for Oil Storage, 1993. Bulletin Design of Concrete Floors on Ground, 1967. Concrete Information Slab Thickness Design for Concrete Floors on Grade. Steel Bar for Reinforced Concrete; Round Bar Steel Bar for Reinforced Concrete; Deformed Bar
ASTM A615 ASTM C33 ASTM C150 ASTM C260 ASTM C494 API 650 PCA PCA TIS TIS 2.3
Steel Design, Materials, Fabrication AISC AISC Specification for the Design, Fabrication and Erection of Structural Steel for Buildings, latest edition. Manual of Steel Construction, Eighth Edition, latest edition.
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AISC AISC
Code of Standard Practice for Steel Building and Bridges, latest edition. Specification for Structural Joints Using ASTM A325 or A490 Bolts, approved by Research Council on Riveted and Bolted Structural Joints of Engineering Foundation, latest edition. Specification for the Design of Light Gauge Cold-Formed Steel Structural Members, latest Edition. Standard Specification for Structural Steel, 1997 ae1. Standard specification for Pipe, Steel, Black and Hot Dipped, Zinc-coated Welded and Seamless, 1999a. Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products, 1997 ae1. Specification for Pipe, Steel, Electric-Fusion (ARC)Welded (sizes NPS16 and over), 1996. Specification for Electric-Fusion (ARC) -Welded (sizes NPS16 and over), 1996 e1. Specification for Zinc-Coating (Hot-Dip) on Iron and Steel Hardware, 1998. Standard Specification for Heat Resisting Chromium and Chromium Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels, 1999. Standard Specification for Stainless and Heat-Resisting Steel Bars and Shapes, 1998b. Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength, 1997. Specification for Alloys-Steel Bolting Materials for LowTemperature Service, 1998. Standard specification for High Strength Bolts for Structural Steel Joints, 1997.
AISI ASTM A36 ASTM A53 ASTM A123 ASTM A134 ASTM 139 ASTM A153 ASTM A240
ASTM A276 ASTM A307 ASTM A320 ASTM A325
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ASTM A490 ASTM A501 ASTM A563 AWS Dl.1 SJI 2.4
Standard Specification for Heat Treated Steel Structural Bolts, 150 ksi Minimum Tensile Strength, 1997. Standard Specification for Hot-Formed Welded Seamless Carbon Steel Structural Tubing, 1999. and
Standard Specification for Carbon and Alloy Steel Nuts, 1997. Structural Welding Code, 1988. Standard Specification for Open Web Steel Joists, DIJ & DLH, IJ & LH, and H & LH Series, latest edition.
Civil, Sitework, Underground AASHTO ASTM A74 ASTM C76 ASTM C361 ASTM C136 ASTM D422 ASTM D4318 ASTM D698 ASTM D1556 ASTM D1557 M36 Corrugated Steel Pipe, 1982. Cast Iron Soil Pipe and Fittings, 1998. Reinforced Concrete Culvert, Storm Drain and Sewer Pipe, 1999. Reinforced Concrete Low Head Pressure Pipe, 1999. Test for Sieve or Screen Analysis of Fine and Coarse Aggregates, 1996a. Particle Size Analysis of Soil, 1998. Test for Plastic Limit and Plasticity Index of Soils, latest edition. Test method for laboratory compaction characteristic of soil using standard effort (12,400 ft-1bf/ft), 1998 Test for Density of Soil in Place by the Sand-Cone Method, latest edition. Tests for Moisture-Density Relations of Soils and SoilAggregate Mixtures Using 10 lb. Rammer and 18 in. Drop, latest edition. Laboratory Determination of Water (Moisture) Content of Soil, Rock, and Soil-Aggregate Mixtures, latest edition.
ASTM D2216
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ASTM D2922 2.5
Tests for Density of Soil and Soil Aggregate in Place by Nuclear Methods (Shallow Depth), latest edition.
Related Project Specifications M-002 M-003 S-001 X-001 Design Basis for Piperacks, Pipeways and Sleepers Design Basis for Structures and Foundations Site Civil Design Criteria Painting and Coatings
3.0 3.1
SITE INFORMATION Location Map Ta Phut Industrial Estate, Rayong, Thailand. Located approximately 205 kilometers southeast of Bangkok on Highway No. 3 (Sukhumvit Highway)
3.2
Weather and Site Data Weather and site data is contained in APPENDIX B ( SECTION 4 )
3.3
Wind Speed Design wind speed for foundation and structural loads shall be based on ANSI A58.1 for a basic wind speed of 38 m/sec, with importance Factor 1.0 and Exposure Category C.
3.4
Seismic Zone Earthquakes are rare in Thailand and no significant earthquake damage has been recorded in the past. Therefore, the earthquake design basis is seismic Zone 0.
3.5
Geotechnical Report General aspects of earthwork and foundation design relating to or derived from geotechnical features shall be based on the evaluation and recommendations contained in the soil report:( Later) The Contractor shall conduct additional geotechnical investigations as required for the design of critical structures and foundations.
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4.0 4.1
CIVIL/STRUCTURAL LOADING CRITERIA Loads and Forces The following loads and forces shall be considered in the design of plant structures: a. b. c. d. e. f. g. h. i. j. k. 1. Dead Load Operating Load Test Load Upset Load Live Load Wind Load Earthquake Load Impact Load Machine Dynamic Load Thermal Expansion Load Erection Load Maintenance Load
4.1.1
Dead Load Shall be considered as the mass of the materials forming a permanent part of the structure unit. It shall be defined as the total mass of all empty vessels and equipment, structures, fireproofing, insulation, piping and electrical conduits. Heavy beams or girders, such as may be required to carry other than platform live loads, shall be given special consideration.
4.1.2
Operating Load
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Shall be defined as the dead load plus the mass of any liquids or solids present within the vessels, equipment or piping during normal operation. Also included in this definition is the mass of all permanently stored materials for operation. 4.1.3 Test Load Shall be defined as either: The dead load plus the mass of any liquid necessary to pressure-test vessels, column, drum equipment or piping. The load due to proof testing of cranes and other lifting equipment.
4.1.4
Upset Load Shall be defined as the short time effects resulting in loads additional to operating loads which occur during start-up, shutting down, or an interruption in the operation of the process, e.g. build-up of catalyst in vessels and piping disrupting normal flow.
4.1.5
Live Load Shall be defined as the mass of all movable loads including personnel, tools, miscellaneous equipment, cranes, hoists, parts of dismantled equipment, and temporarily stored materials. The following live loads shall be used in the design of process and plant buildings:
Area Classification STORAGE AREAS Areas specifically Designated for storing Light loads Areas specifically Designated for storing Heavy loads WORKING AREAS Areas serving tubular Units and vessel manholes
Loads 720 kg/m2 Actual load 350 kg/m2
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ACCESS AREAS
Miscellaneous areas such as connecting walkways and operating platforms (not used as working or storage areas)
250 kg/m2
FLOORING OF PLATFORMS ROOF AREAS Flat or pitched roofs (not used as working or storage area)
490 kg/m2 minimum 150 kg/m2 applied to horizontal projection of roof 490 kg/m2
STAIRWAYS AND LANDINGS
LADDERS HANDRAILS
180 kg concentrated mass 100 kg vertical and horizontal
4.1.6
Wind Loads Wind loads on structures and equipment excepting piperacks shall be computed and applied according to procedures outlined in ANSI A58.1. Wind load on piperacks and sleepers shall conform to the requirements of specification M-002.
4.1.7
Earthquake Loads Earthquake load shall be computed and applied in accordance to procedures outlined in ANSI A58.1.
4.1.8
Impact Loads Shall be computed according to procedures outlined in the AISC specification with the following changes:
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Equipment Load Percentage Increase Jib Cranes and Hoists Monorail Beams Reciprocating or power driven machinery Rotating or motor driven machinery 25 25 200 100
(Load factors, when required, shall be the same as Live Load) 4.1.9 Machine Dynamic Load A dynamic analysis shall be performed for the design of the foundation or structural system for each reciprocating machine, and for each rotary machine having horsepower of 200 or more. The design basis for each major system shall be subject to review by the Company. Included in the Design Basis shall be: a. b. c. d. e. f. 4.1.10 Specifications or requirements as outlined in bid documents. Design static load of machine. Design dynamic loads (forces and couples) in applicable modes of excitation. Dynamic and static soil parameters. Proposed method of dynamic analysis. Tolerable limits of system response to cyclic loading imposed by rotating or reciprocating equipment.
Thermal Expansion Load All equipment support structures and elements shall be designed to accommodate the loads or effects produced by thermal expansion. For friction coefficients relating to support contact surfaces for heat exchangers and horizontal vessels, see Specification M-002 for pipe-racks. For heat exchangers and horizontal vessels, see Specification M-003.
4.1.11
Erection Load
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Shall be defined as temporary forces caused by erection of structures or equipment. 4.1.12 Maintenance Load Shall be defined as temporary forces caused by the dismantling, repair, cleaning or painting of equipment. The supporting structure, anchor bolts and pulling lugs of heat exchangers with removable bundles shall be designed to withstand a longitudinal pulling force equivalent to 1/2 times the tube bundle weight or 1000 kg, whichever is greater, applied at the center line of the tube bundle. 4.2 Loading Conditions, Combinations All structures, vessels and equipment and related foundations, and elements thereof shall be designed for the most severe of any of the following combination of loads and forces: a. Shutdown dead load of equipment (empty, but with all permanent internals, piping, platforms and insulation in place) combined with full wind and maintenance load. Erection weight of vessel (fabricated weight of vessel plus internals, platforms, piping, insulating, etc., to be erected with vessel) combined with full wind. Normal operating loads with all dead and live loads in place, but no wind. Normal operating loads with all dead loads in place, combined with full wind. Vessels and piping under hydrostatic test with all dead loads in place plus 1/3 wind. Emergency upset, normal operating load plus any load resulting from a possible abnormal condition, misoperation, instrument failure, etc.
b.
c. d. e. f. 4.3
Stability Against Overturning Stability Ratio is defined as the stabilizing moment divided by the overturning moment. In the case of structures supported by a single foundation, the stabilizing moment shall be taken about the outside edge of the foundation. Minimum stability ratios shall be as follows:
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Foundation Type Vertical Vessel and Stack Foundations All other foundations loaded per Para. 4.2a, b, c, e, and f above All other foundations loaded per Para. 4.2d above
Stability Ratio 2.0 1.5 1.7
Where a foundation for an integral structural unit consists of two or more footings, as in the case of an elevated heater or a framed structure supporting equipment, the stability ratio of the structure as a whole including related equipment, shall be not less than 1.5 for any condition of loading when the stabilizing moment is taken about the center of outermost footing (s). 4.4 Ultimate Strength For ultimate strength design of the foundation, the operating load and test load factor shall be the same as for dead load. 4.5 Allowable Overstress Allowable stresses for load combinations that include wind or earthquake shall be as stated in AISC and ACI. In addition load combinations that include test may have the allowable stress increased 20%. Allowable stress increase is not allowed for anchor bolts. A 30% increase in drilled shaft capacity is allowed for load combination that includes wind or earthquake. 4.6 Buoyancy A safety factor of not less than 1.20 shall be provided against buoyancy. 4.7 Bearing Capacity The allowable bearing capacity and sliding or lateral resistance of soil and piles shall be in accordance with the soil report. The Contractor shall investigate and verify the bearing capacities and lateral resistances used for design.
5.0
STRUCTURAL MATERIALS
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The following are general guidelines for structural materials. The Contractor is responsible for determining all of the structural material requirements. 5.1 Structural Steel Generally the design shall be based on the use of the following structural steels using the allowable stresses as provided in the AISC Specification for the Design, Fabrication and Erection of Structural Steel for Buildings.
Structural Steel Shades and Plates Structural Tubing Structural Pipe (Steel) Type E or S Grade B Rod and Bar Stock Checker Plate High Strength Bolt Unfinished Bolts Carbon and Alloy Steel Nuts Stainless Steel (Structural Use) ASI Type 304
ASTM A36 ASTM A501 ASTM A53, A134, 139 ASTM A36 ASTM A36 ASTM A325 ASTM A307 ASTM A563 ASTM A240, A276
5.2
Structural Concrete, Foundations Design of concrete structures and foundations shall be in accordance with ACI 318. Minimum compressive strength of concrete at 28 days shall be 210 kg/m2 using the following materials:
Cement (Type 1 unless noted otherwise) Aggregate
ASTM C150 ASTM C33
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Admixtures Reinforcing bars
ASTM C260, C494 ASTM A615 TIS 20-Lastest edition TIS 24-Lastest edition
Welded wire fabric
ASTM A185
Sulfate resistant cement shall be used in concrete for foundations/footings.
5.3
Anchor Bolts All anchor bolt material bolts shall be ASTM A36 steel, hot dip galvanized, excepting reciprocating compressor anchor bolts. Anchor bolts for reciprocating compressors and drivers shall be ASTM A193 grade B-7 steel with ASTM A194 nuts. Welding or bending is not permitted on A193 or A194 material. All anchor bolts consists of double nuts.
5.4
Grout Grouting of non-critical equipment, e.g. small column base plates, very small pumps, small vessels, etc., where high-strength and non-shrink properties are not of prime importance, may be done with a Portland Cement dry-pack mortar. Precision non. shrink grout shall be provide for major mechanical, other critical equipment and heavily loaded/ large column bases with a proprietary product specially formulated for this use and having the following chemical and physical characteristics: a. b. c. d. e. f. Non-rusting or staining No-shrink dimensional stability Compressive strength 630 kg/cm2 at 7 days Flowable placing consistency and fully self leveling characteristics No generation of expansive forces during setting No continuous confinement required during setting period
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g.
Unaffected by exposure to the service temperatures
Grout for base-mounted or skid-mounted reciprocating machinery or critical centrifugal/rotary compressors and pumps including drivers shall be epoxy type, such as Ceilcote 648 CP or the Company approved equivalent grout. Compliance with minimal requirements of equipment vendors regarding grout materials and installation is mandatory. Handling and placement of proprietary grouts shall be in strict accordance with the manufacturers recommended practice.
5.5 5.5.1
Coatings Galvanizing a) The following structural and miscellaneous steel items shall be hot dip galvanized:
All exposed embedded steel in concrete piperacks, sleepers and concrete structures. All ladders, cages, stair members and handrails. ( Shall be painted yellow after galvanized )
Stile framing members. Grating and floor plate. Anchor bolts. Steel roof decking, Bolts, washers and nuts
b) c) d)
Galvanizing, where required, shall be in accordance with ASTM A123 and ASTM A153 as applicable. Members completely encased by fireproofing will not require galvanizing. Cooling tower anchor bolts, embedments and screens shall be stainless steel SUS304
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e) 5.5.2
Field touch-ups of galvanizing shall be thoroughly cleaned and given a heavy touch-up coat of Z.R.C. or equivalent.
Painting a) The following structural and miscellaneous steel items shall be primed and painted:
Structural steel members for piperacks and pipe supports and all other non fireproofed structural steel, Bolts, washers and nuts shall be hot dip galvanized. Structural steel and light gage shapes furnished in enclosed preengineered buildings. Structural steel framing required for masonry buildings. Framing for compressor or equipment operating levels in enclosed buildings.
b) c)
Steel completely encased in concrete or fireproofing shall be primed only. Structural steel requiring priming or priming and painting shall be prepared and painted in accordance with the applicable requirements of Specification X-001. Ladders, cages, stair members and handrail shall be painted yellow after hot dip galvanized.
d)
6.0
STEEL STRUCTURES In general, primary framework for buildings, piperacks and structures supporting equipment or piping above grade shall be constructed of structural steel. For steel structures requiring fireproofing, secondary steel framing consisting of platform supports, monorails, walkways and bracing which do not contribute to vertical support of equipment shall be non-fireproofed.
6.1
Fabrication and Erection Fabrication and erection shall, as a minimum, conform to the requirements of the AISC standards referenced in Section 2.3. The Contractor shall be responsible for
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determining all requirements for steel fabrication and erection and shall prepare detailed specifications. 6.2 Design Details Shop connections shall be welded, Field connections shall be 20-mm diameter ASTM A325 bolts unless noted otherwise. In general, all shear connections shall be designed in accordance with the AISC recommendations and fully supportable by calculations. Bracing connections shall be designed for the computed forces as shown on the drawings. Bracing shall have a minimum of two bolts per connection. Where practical, the bracing forces shall be transmitted to the flanges of the braced members. Shear loads on anchor bolts embedded in concrete shall not exceed allowable shear loads set forth in UBC Section 2624, Table 26G. Shear lugs or similar rationally designed devices shall be provided to resist loads in excess of anchor bolt capacities. Friction of column baseplates on concrete shall not be considered as resisting these loads. Unless the reaction is provided by the design engineer on the design drawing, beam to beam and beam to column connections shall be designed for a reaction equal to half the total uniform load capacity per the given span of a beam shown in the tables, Allowable Loads on Beams, of the AISC Manual of Steel Construction. The connections must also comply with the requirements of Table I and III, Framed Beam Connections, of the above manual. All joints using high strength bolts shall be bearing-type connections. The allowable loads shall be based on all bolts having threads in the shear plane. Moment connections shall be designed to develop the full bending strength of the weakest connected member, unless the moment is noted or connection is detailed on the design drawings.
7.0
CONCRETE STRUCTURES, FOUNDATIONS Concrete structures shall, as a minimum, be constructed in accordance with the ACI codes and standards referenced in Sec. 2.2. The Contractor is responsible for
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determining all of the requirements (forming, mixing, placing, testing, curing, and other related items) for the concrete used in structures, foundations, floors and paving. The Contractor shall prepare detailed concrete specifications. 7.1 Foundations Foundations shall be designed to resist the effects of individual loads or loading combinations including the effect of eccentricity, and shall not exceed the allowable pile design loads or the maximum bearing values of the soil and other design criteria. Foundation details shall be in accordance with Specifications M002 and M-003. 7.2 Building Ground Floors Ground floors shall be reinforced concrete slabs. Floors shall receive a wood float or steel trowel finish as indicated on the drawings. Floor load, i.e. dead loads, live loads and imposed loads shall be transmitted to building foundations. Floors shall not be separated by joints from the building foundations. Elevations of slabs under structures shall match the elevations of adjacent paved areas. Floor slab elevations for enclosed and open-sided buildings shall be 6 inches (150 mm) higher than the surrounding paved and unpaved areas. The edges of paving adjacent to open-sided buildings shall be at the same elevation as the edges of the floor of the building with paving sloping away from the building. 7.3 Trenches and Sewer Boxes Pipe trenches in concrete paved areas shall be of open construction similar to drainage trenches. In unpaved areas they shall be covered with 1/4-inch (6 mm) minimum thick steel floor plate. In inside buildings they shall be covered with 1/4-inch (6 mm) minimum thick steel floor plate with the top set flush with the floor. Drainage trenches in concrete paved areas shall be covered with coating set flush with top of paving with 6 inch (150 mm) thick walls and floor. The floor shall be a slope of 1 inch in 10 feet (1 cm in 1.20 m) and a maximum drop of 6 inches (150 mm). Sewer boxes shall be of concrete pipe or poured in place rectangular box with 6inch (150-mm) minimum thick reinforced concrete walls and floors. Sewer boxes located outside of buildings shall be covered with reinforced concrete slab. The top of slab shall be 2 inches (50 mm) above grade in unpaved area or flush with the top of the pavement. Inside the buildings they shall be covered with
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reinforced concrete slab set flush with the top of the finished floor for sealed construction. Cast iron manhole covers shall be used.
8.0
MISCELLANEOUS STRUCTURES Ladders, handrails, platforms and stairways shall be designed in accordance with OSHA, Subpart D, Section 1910.21-27. Top railing loading strength shall be interpreted to mean a without yielding condition. Every ladder and stairway floor or platform opening shall be in accordance with Para. 1910.23(a)(2). Ladder or stairway entrances shall be provided with a self-closing swinging gate or be so offset that a person cannot walk directly into the opening (a guard chain is not considered adequate). All ladder, handrails and stairway members shall be hot dip galvanized and painted yellow.
8.1
Ladders All ladders for access to platforms, vessels, valves, etc., shall have solid round steel rungs. Ladders serving platforms or landings 3 m to 6 m above grade shall be equipped with hoop guard at top of ladder. Cages shall be provided on all ladders serving platforms more than 6 m above grade. Maximum length of ladder between landings shall be 9m. Elevation of centerline of top ring shall be equal to top of landing elevation. Outside width of ladder shall be 450 mm. Rungs shall consist of minimum 20mm diameter bars spaced at 300-mm maximum centers.
8.2
Platforms, Walkways. Access ways Minimum width of walkways, stairs, landings, stiles or other access ways shall be 750 mm. Platform framing members, including columns and bracing shall clear piping, vessels and/or related insulation by a minimum of 75 mm both vertically and horizontally. Flooring for steel framed platforms, walkways, access ways and stair treads shall be serrated welded galvanized steel bar grating. Grating shall have 32 mm x 5mm minimum bearing bars on 30-mm centers designed for 1250 kg/cm2 stress. Cross bars shall be twisted square or hex bars at 100-mm centers. Grating shall be secured to framing by grate clamps without drilling support members.
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M-002
DESIGN BASIS FOR PIPERACKS, PIPEWAYS AND SLEEPERS
2 1 0 Rev
8/08/05 1/3/00 20/12/99 D/M/Y
Corporate Specification Issue for ITB Issue for review. Description of Revision
TWC TPT TPT By
RW SWK SWK Chk
WB JN JN Appr
PAGE 1 OF 11
DESIGN BASIS FOR PIPERACKS, PIPEWAYS AND SLEEPERS TABLE OF CONTENTS 1.0 GENERAL 1.1 1.2 2.0 3.0 Scope References
TYPES OF CONSTRUCTION PIPERACK FRAMING 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 Concrete Frames Structural Steel Frames Column Base Conditions Braces Beam Struts Transverse Beams Miscellaneous Fireproofing
4.0
DESIGN LOADINGS 4.1 Gravity Loads 4.1.1 4.1.2 4.1.3 4.2 Piping Electrical/Instrument Trays Equipment
Wind Loads 4.2.1 4.2.2 4.2.3 Piping Instrument/Electrical Trays Structural Framing
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4.2.4 4.2.5 4.2.6 4.3 4.4 4.5 5.0
Miscellaneous T-Supports Ladders, Platforms, Stairs, Equipment Longitudinal Load
Friction Loading Anchor Loads Load Combinations
ALLOWABLE STRESSES 5.1 5.2 Superstructure Foundations
6.0
ALLOWABLE DEFLECTIONS 6.1 Lateral Deflection
1.0
GENERAL
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1.1
Scope This design basis covers the general requirements for the design of piperacks, sleepers, and miscellaneous pipe supports. Consideration of pipe-racks carrying electrical and instrument lines and supporting air fin coolers is included.
1.2
References Refer to Project Specification M-001 for a listing of codes, regulations, related project specifications and general criteria applicable to this specification.
2.0
TYPES OF CONSTRUCTION Non-fireproofed piperacks and pipe supports shall be of structural steel. Fireproofed piperacks or pipe supports, if required, shall be either:

Precast reinforced concrete, or Poured in place reinforced concrete, or, Application of the Company approved proprietary fireproofing systems applied to structural steel framing.
Where concrete support beams or sleepers are utilized, steel bearing plates consisting of flat bars, inverted channels, or structural tees adequately anchored, shall be provided as bearing surfaces for pipe or pipe shoes. Bearing plates shall project 3-mm minimum above concrete surface. Where fireproofing of steel support beams is employed, the top flange of steel support beams shall project 3mm minimum above fireproofed surface. In all areas, low pipe sleepers (1. 0 m or less above grade) shall be either:

Poured in place concrete stem-wall and footings, or Precast concrete beams supported on poured in place concrete foundations, or Structural steel beams supported on poured in place concrete foundations, if fireproofing is not required.
Sleepers greater than 1.0 m above grade shall be either precast concrete beams or structural steel beams, (if fireproofing not required) supported in concrete piers and footings.
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3.0 3.1
PIPERACK_FRAMING Concrete Frames Single or multi-level precast or cast-in-place concrete piperack bents or frames shall be designed and detailed as rigid frames.
3.2
Structural Steel Frames Single or multi-level steel frames may be designed as rigid frames or a braced frame utilizing knee bracing between the lower support level and columns. Where knee bracing is employed, minimum clearances as required by job criteria must be provided. For multi-level frames, connections between columns and first transverse beam shall be either moment connections or simple connections with knee bracing. Connections between column and transverse beams other than the first beam may be either moment or simple connections.
3.3
Column Base Conditions Column Base Conditions shall normally be as follows:

Precast concrete frames - pinned, both directions. Cast-in-place concrete frames - 100% fixed, both directions. Structural steel frames Fixed or pinned transverse ; pinned, longitudinal. Miscellaneous independent frames - 100% fixed, longitudinal; transverse. T-Supports (cantilever, columns) - 100% fixed, both directions. pinned,
Where the application of lateral loads results in excessive deflection of piperack from support pinned conditions, partial fixity in the range of 30% to 50% may be used provided partial fixity can be substantiated by analysis.
3.4
Braces
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Vertically braced bays shall be provided as required to handle calculated pipe anchor loads. Longitudinal bracing may be either cross bracing or K-bracing. Maximum spacing of longitudinally braced bays shall be 60 m. 3.5 Beam Struts Longitudinal beam struts shall be provided to transmit pipe anchor loads to braced bays; to support piping and tray turnouts; and to provide stability for pinned base design of frames. In addition to axial forces, beam struts should be designed for 50% of the most heavily loaded transverse pipe support beam unless unusual loading is encountered. This loading should not normally be added to the design load for columns or foundations. Concentrated loads from large pipes may be treated as in Section 4.1. Longitudinal expansion shall be controlled by providing an expansion joint in a set of beam struts located preferably midway between adjacent braced bays. Spacing of braced bays shall be 60m maximum. Braced bays shall not be located opposite equipment such as pumps requiring maintenance access from within the piperack. 3.6 Transverse Beams The beam must be capable of resisting all loads, moments and shears produced by the load combinations. For the design of steel beams, the unbraced length of the compression flange should be between points of inflection. For axial loads, however, the total span of the beam should be used, modified by the appropriate effective length factor for each direction. No consideration of lateral support of beam by piping shall be permitted. In the design of the beam, consideration should be given to large lines that are hydro-tested. In analyzing effects at Friction Loading on beams, the top flange of beam only shall be assumed to resist Friction Loads. The effects of torsion should be considered on an individual basis when unusually large loads (such as large anchor forces) are applied to the beam flange. Where longitudinal forces from pipe anchors are very large, compression or tension members placed in the horizontal plan of pipe deck to relieve beam of torsional loading may be utilized.
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3.7
Miscellaneous Supports Miscellaneous pipe supports shall be either cantilever T-Supports or frames. Frames shall be either rigid or braced in the transverse direction and cantilevered columns in the longitudinal direction of pipe-way. Single T-Supports shall normally be cantilevered in both directions.
3.8
Fireproofing For requirement , see TS. N-002 Fireproofing
4.0 4.1
DESIGN LOADINGS Gravity Loads 4.1.1 Piping The summation of all individual lines including contents on each level shall be converted into an equivalent uniform load as follows:
A minimum uniform pipe deck load of 170 kg/m2 shall be used for major pipe-racks. This corresponds to an equivalent load of 150-mm lines full of water covered with 50-mm thick insulation and spaced on 300-mm centers. A concentrated load shall be added for pipes which are 300 mm diameter and larger. The concentrated load P = S*(w p*d) where S = pipe support spacing, w = large pipe weight (including weight of contents if liquid), plf., p = uniform loading used, d = large pipe diameter, including insulation. A minimum uniform pipe load of 120 kg/m2 shall be used for miscellaneous pipe supports.
4.1.2 Electrical/Instrument Trays The uniform load from electrical and instrument trays should be determined from the loaded weight of trays and/or separate conduit. A minimum uniform load of 100 kg/m2 shall be used for single trays and 200 kg/m2 for double level trays.
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4.13. Equipment If plant layout and equipment arrangement requires installation of air coolers on upper pipe-rack levels, design and analysis of the supporting pipe-rack substructure shall include adequate support for equipment loads. Design shall provide for minimal transmittal of vibrations from fans to piperack. Fabreeda or equal isolation pads of effective thickness shall be provided where equipment base plates are mounted on piperack. 4.2 Wind Loads Transverse wind loads shall be calculated and applied to piping, trays, structural shapes and equipment in accordance with M-001, ANSI A58.1 and with the following: F = qzGhCfAf (refer to Table 4 page 27 of ANSI A58.1) Interpretation of values for Cf and Af shall be: 4.2.1 Piping Af shall equal projected area of the largest pipe of given level including insulation, if any. If pipe diameters are unknown or cannot be estimated, assume an 450 mm diameter pipe plus 75 mm inches of insulation; i.e., projected area of 600 mm x length. For the following combinations of piping on any one level, Cf shall equal: 0.7 1.1 2.0 for a single pipe for two pipes for more than two pipes
4.2.2 Instrument/Electrical Trays Af shall equal projected area of deepest tray x length. If tray dimensions are unknown or cannot be estimated, use 150-mm tray height.
For the following combination of trays on any one level, Cf shall equal:
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2.0 2.5 3.0 4.2.3 Structural Framing
for a single tray for two trays for three or more trays
Af shall equal projected area of structural elements exposed on windward side. Cf shall equal: 2.0 3.0 4.0 for first column row for two rows of columns for three rows of columns
4.2.4 Miscellaneous T-Supports Af for piping shall equal projected area of largest pipe at given level of support. Cf for structural shapes shall equal 2.0. Cf for piping shall be as 4.2.1 above. 4.2.5 Ladders, Platforms, Stairs, Equipment Af for these items supported by piperacks or pipe supports shall be equal to the net projected area exposed to windward side. Cf shall equal 2.0. 4.2.6 Longitudinal Load Longitudinal wind shall be considered negligible compared to other longitudinal forces and can be disregarded except for air coolers or other unusual configurations.
4.3
Friction Loading
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Friction forces caused by hot lines sliding across the pipe support during start-up and shutdown shall be assumed partially resisted by adjacent cold lines. Therefore, in order to provide for a nominal unbalance of friction forces acting on a pipe support, a resultant longitudinal friction force equal to 7 % of the total pipe weight or 30% of any one or more lines known to act simultaneously in the same direction, whichever is larger shall be assumed for piperack design. 4.4 Anchor Loads Pipeway shall be checked for anchor loads as determined from Stress Analysis. It may be necessary to use horizontal bracing if large anchor forces are encountered. It is normally preferred if either have the anchors staggered along the pipeway so that each support has only one or two anchors, or to anchor most pipes on one braced support. When applying ultimate strength load factors for concrete design, anchor forces should be considered as dead loads. 4.5 Load Combinations Pipe supports shall normally be designed to resist the following load combinations:

Gravity Load Gravity Load + Transverse Wind + Anchor Load + Friction Load Gravity Load + Friction Load Gravity Load + Friction Load + Anchor Load Gravity Load + Anchor Load + Longitudinal Wind (if applicable) + Friction Load
5.0 5.1
ALLOWABLE STRESSES Superstructure Allowable stresses may be increased one-third for all load combinations with wind.
5.2
Foundations
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When vertical load, shear and moment of the column bases are used for design of reinforced concrete foundations, the following should apply:
If working stress method is used for superstructure, the load factor for concrete strength method as per ACI 318 shall be added to the loads. The allowable soil pressures shall be as stated in the Project Soils Report. Allowable soil pressures may be increased 1/3 for wind load -combinations. With confirmation by soil report.
6.0 6.1
ALLOWABLE DEFLECTIONS Lateral Deflection Permissible lateral deflection of frames due to applied transverse loads shall be h/150 for thermal loading due to pipe guides or anchors, or for a combination of guide/anchor load and wind load.
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M-003
DESIGN BASIS FOR STRUCTURES AND FOUNDATIONS
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TWC TPT TPT By
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DESIGN BASIS FOR STRUCTURES AND FOUNDATIONS TABLE OF CONTENTS 1.0 GENERAL 1.1 1.2 1.3 2.0 Scope References Types of Construction
LOADING CRITERIA 2.1 2.2 Wind Loads Building Loading
3.0
FRAME SYSTEMS 3.1 3.2 3.3 3.4 3.5 Steel Framed Structures Concrete Framed Structures Steel Buildings Masonry Building Frames Stairways and Ladders
4.0 5.0
VIBRATION CONTROL GENERAL FOUNDATION REQUIREMENTS 5.1 5.2 5.3 5.4 5.5 5.6 General Design Allowable Settlement Foundation Elevations Anchor Bolts Sleeves Slide Plates
6.0
VERTICAL VESSEL FOUNDATION DESIGN
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6.1 6.2 6.3 7.0
Anchor Bolts Pedestal Design Footings
HORIZONTAL VESSEL AND EXCHANGER FOUNDATION DESIGN 7.1 7.2 7.3 7.4 7.5 Load Distribution for Exchangers Slide Plates Pier Design Column Design Spread Footings
8.0
STORAGE TANK FOUNDATIONS 8.1 8.2 8.3 Large Tanks Small Tanks Earthwork
9.0
BUILDING FOUNDATIONS 9.1 9.2 9.3 9.4 Foundation Types Joints Floor Slabs Grade Beams
10.0
DRILLED SHAFT FOUNDATIONS
11.0
GROUTING AND FINISHING 11.1 Grouting
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11.2 11.3 12.0 13.0
Finishing Scoring and Edging
TRENCH DRAINS CONCRETE WATER CONTAINMENT BASINS
1.0 1.1
GENERAL Scope
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This Design Basis covers the general requirements for the design of superstructures and substructures for equipment support structures, access and maintenance structures and structural elements of buildings. Requirements for design of equipment foundations and of building and structure foundations are included. 1.2 References Refer to Project Specification M-001 for a listing of codes, regulations, related project specifications and general criteria applicable to structures and foundation design. 1.3 Types of Construction Non-fireproofed equipment support structures shall be designed of structural steel. Structures or equipment supports which require fireproofing may be constructed of reinforced concrete. Fireproofing of structures, if required, shall be accomplished by utilization of reinforced concrete superstructures, (pre-cast or poured-in-place) or by application of the Company approved proprietary fireproofing systems applied to structural steel framing. Fireproofing of structural steel columns and of compression or tension members shall totally encase the steel. The top flange of horizontal steel beams, shall be exposed to support piping, equipment or flooring, top of steel shall be 3-mm minimum above fireproofing.
2.0
LOADING CRITERIA Refer to Section 4.0, Specification M-001 for design load definitions, loading conditions, load combinations and stability requirements. Criteria shown therein shall apply to design of structures and foundations.
2.1
Wind Loads
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Wind loads shall be calculated and applied to vessels, equipment, structures, ladders, platforms and stairs in accordance with M-001, ASCE 7-88 and with the following: F = qzGhCfAf (refer to Table 4, page 27 of ASCE 7-88) Interpretation of values for Cf and Af shall be: 2.1.1 Vessels, Cylindrical Equipment & Piping Af shall equal projected area of vessel or similar equipment and piping, plus insulation, exposed to wind. Cf shall be derived from Table 12, ASCE 7-88 round shapes for applicable D /qz value. 2.1.2 Open Structures Af shall equal projected area of windward frame exposed to wind plus area of any additional members in successive bays, i.e., AA + AB + AC etc. Assume no shielding for AB, AC, etc. Cf shall be determined from ASCE 7-88, Tables 10 through 15. 2.1.3 Ladders, Handrails, Stairs, Miscellaneous Equipment For circular platforms on vertical vessels, Af shall be based on the maximum projected area of platform, handrail, etc., up to 180 of platform size. Af on rectangular platforms, stairs, handrails, ladders and miscellaneous equipment shall equal the net projected area of elements exposed to wind. Cf shall equal 2.0 for all of the above.
3.0 3.1
FRAME SYSTEMS Steel Framed Structures Steel framed single or multilevel equipment structures shall be designed to provide adequate support for equipment and to provide necessary access for service and maintenance. Frames transverse to centerlines of exchangers and horizontal vessels shall normally be either rigid frame with moment connections or a knee-braced design
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using simple connections. Frames in the longitudinal direction should utilize either knee bracing, K-bracing or cross bracing. Permissible lateral deflection of frames due to combined wind, thermal and operation-related loads shall be h/180. 3.2 Concrete Framed Structures Concrete framed structures for support of equipment shall be open rigid frame, having 100% fixed column base conditions. 3.3 Steel Buildings Metal covered buildings shall be either engineered type or pre-engineered. Engineered steel buildings shall be clear span, rigid frame type. Column base conditions shall be pinned in both directions. 3.4 Masonry Building Frames Masonry buildings shall be one of the two following types:
Load bearing exterior masonry walls. Joists and flat metal roof deck supported by exterior walls and interior columns as required. Non-load bearing exterior masonry walls. Joists and flat metal roof deck supported by steel column and beam frame system.
Lateral bracing shall be accomplished by means of one of the two following systems.
Exterior masonry walls parallel to wind direction to act as shear walls resisting total horizontal force of wind. Roof deck to act as a diaphragm transmitting horizontal force of wind to shear walls. Where a steel column and beam frame system is employed for support of roof deck, braced frames or rigid frames may be utilized to resist total horizontal wind force.
Design of concrete masonry walls shall be in accordance with ACI 531.
3.5
Stairways and Ladders
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Ladders required to have cages shall be side step-off in all cases where access and layouts permit. Stairways shall have a minimum width of 750 mm, a minimum tread width of 250 mm, a maximum riser of 200 mm and the maximum vertical distance between landings (for open equipment structures) shall be 5.5 m. treads shall have non. Slip or abrasive nosing. Stairway runs on the same structure shall have, if possible, the same slope.
4.0
VIBRATION CONTROL Vibration isolation pads shall be installed at support points for noise and vibration attenuation for any steel supporting structures subject to vibration. Specifically, design shall require furnishing of effective isolation pads:

Between base plates of air fin cooler support points and steel substructure. Between column base plates and corresponding piers for platform framing installed on compressor foundations or mats.
Isolation pads are to be omitted where pad temperatures will continuously exceed 65C or rigidity of support is critical. Anchor bolts at support points requiring isolation pads shall have isolating washers and bushings.
5.0 5.1 5.1.1
GENERAL FOUNDATION REOUIREMENTS General Design Load Conditions, Combinations Design of foundations shall include all applicable considerations regarding design loads, loading conditions, loading combinations and stability as outlined in Section 4.0, Specification M-001.
5.1.2
Required Strengths
PAGE 8 OF 19
Footings and piers shall be proportioned for required strength in accordance with provisions of ACI 318, using load factors as specified in Chapter 9, except as modified herein. Provisions of Chapter 15 shall apply for design of footings. The required strength, U, for test load shall be, U = 0.83 (1.4 x test load). The following soil loading conditions shall apply:
Allowable soil bearing pressure may be increased 33% for wind or seismic loading. The allowable soil bearing pressure may not be increased for test loading.
5.2 5.2.1
Allowable Settlement Settlement Sensitive Equipment Foundations or piers for closely connected equipment sensitive to differential settlement shall be placed on common mats to limit differential settlement between the connected equipment. This requirement shall apply to foundations for:

Directly connected recoilers to vessels Drivers to rotating machines Bottle supports near compressor cylinder discharge or suction connection Heater support columns Combinations of equipment and piping where differential settlement will cause excessive piping, nozzle or flange stress.
5.2.2
Differential Settlement Design of foundations of soil bearing type where differential settlement can be tolerated in structures and piping shall limit differential settlement as follows:

Equipment structure: 7 mm for concrete frame; 13 mm for steel frame. Between pipe rack columns; 7 mm for concrete frames; 13 mm for steel frame. Between vessels, exchangers and pumps connected with moderately flexible piping: 13 mm.
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Masonry building foundations: 7 mm. Metal building foundations: 13 mm.
5.2.3
Total Settlement Design of foundations shall limit total settlement as follows:

Equipment structures, Pipe racks individual equipment, buildings; 20 mm. Storage tanks: 20 mm consolidation settlement after pre-loading at watertest: 75 mm total.
5.3
Foundation Elevations The depth of soil bearing foundations must extend to a minimum of 450 mm below finished grade level or per recommendation by soil report. The elevation of the top of grout shall be a minimum of 300 mm above high point of paving or of finish grade.
5.4
Anchor Bolts ASTM A-36 steel anchor bolts shall be anchored either by means of an L or by an anchor plate welded to bottom of bolt. Maximum allowable tensile stress shall be 0.6 times the yield strength on tensile stress area. ASTM A-193 steel anchor bolts shall be anchored by means of an anchor plate secured to bottom of bolt between two nuts of a threaded section of lower end of bolt. Coupled bolts may by utilized to facilitate equipment installation. The adequacy of bolt anchor devices must be substantiated by analysis. Corrosion allowance is not required on anchor bolts. Anchor bolts shall be provided with two nuts, one of which will serve as a lock nut. All anchor bolts and accessories shall be hot dip galvanized. The minimum distance from the edge of the concrete to the centerline of the bolt shall be 100 mm or 4 bolt diameters, whichever is greater, unless each anchor bolt is tied back with the equivalent of the 90 corner of a tile, as follows:
Minimum Size of
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Bolt Diameter Up to 25 mm Over 25 mm to 40 mm Over 40 mm 5.5 Sleeves
Reinforced Bar Tie 10 mm diameter 12 mm 16 mm
Anchor bolt sleeves, where utilized, shall be either made from 28 gauge galvanized sheet metal or of the manufactured PVC type. Provide 75-mm minimum clearance between the edge of the foundation and face of anchor bolt sleeves. Special care shall be taken to assure that sleeves around anchor bolts are, in all cases, completely filled with grout before grouting under base and ring plates. Sleeves of anchor bolts for compressor foundations shall be filled with elastic material or styro foam. 5.6 Slide Plates Slide plates shall be required for use between top of foundations or pier and equipment base plate for equipment operating subject to movement from thermal expansion or contraction. Specific applications are horizontal exchangers and vessels, heaters and furnaces. Slide plates shall be A-36 smooth plates, Hot-dip galvanized.
6.0
VERTICAL VESSEL FOUNDATION DESIGN Vertical vessels are assumed self-supporting. Maximum anchor bolt tension and foundation size shall be determined from the maximum of anyone of the several design conditions.
6.1
Anchor Bolts Maximum tension force for sizing anchor bolts shall be at least equal to the following:
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Tension (kg) = 4M/ N*BC W/N Where: M N = Maximum overturning moment at base of vessel m-kg = Number of anchor bolts
BC = Diameter of bolt circle m W = Weight of Vessel kg
Frictional resistance to shear between vessel base plate and concrete or grouted bearing surface shall be neglected. Adequate mechanical means shall be provided to resist horizontal shear either through anchor bolts or through a combination of anchor bolts, shear lugs or other devices. Unit shear per bolt shall be: Shear/bolt 6.2 6.2.1 Pedestal Design Sizing Concrete pedestals supporting vertical vessels shall be sized in 50-mm increments according to the following criteria: Face-to-face pedestal size shall be no less than the larger of: Bolt circle Bolt circle Bolt circle + 180 mm + 8 bolt diameters + sleeve diameter + 150 mm = Maximum shear at vessel base Number of anchor bolts
Diameter of base-plate + 100 mm Pedestals 1.2 m and over in diameter shall be octagonal in shape; less than 1.2 m uses a square shape. For ease of forming, use multiples of 50 mm for each octagonal side. Provide 50 mm. minimum between face of pedestal and edge of equipment base or slide plates.
6.2.2
Reinforcing
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OLEFINS PLANT EXPANSION PROJECT
PROJECT SPECIFICATION
The pedestal shall be tied to the footing with sufficient dowels around the pedestal perimeter to prevent separation of the pedestal and footing. Use a class C splice for dowels, in accordance with ACI 318. Dowels are sized by computing the maximum tension existing at the pedestal perimeter due to overturning moments. Minimum pedestal reinforcement shall be as follows: Octagon 1.2 m to 1.8 m: Octagons over 1.8 m to 2.7 m: Octagons over 2.7 m to 3.7 m: Octagons larger than 3.7 m: 8-12 mm vertical with 12 mm ties at 380 mm maximum 16-16 mm vertical with 16 mm at 380 mm maximum 24-19 mm vertical with 20 mm ties at 300 mm maximum 32-19 mm vertical with 20 mm at 300 mm maximum
Pedestals over 1.8 m in diameter shall have a mat of reinforcing steel or mesh in top. 6.3 Footings Footings for vertical vessels shall normally be octagonal in shape and sized 50mm increments for each octagonal side. Offsets and combined footings shall be avoided where possible. Footings less than 2.1 m face to face dimension, shall be square. The footing thickness shall be 300-mm minimum and thickened in 50-mm increments. The thickness of the footing should be adequate for the embedment length of the dowels or anchor bolt hooks, if anchor bolts are extended into footing. The maximum bottom footing reinforcing shall be a 16-mm diameter bar at 300mm center to center.
7.0 7.1
HORIZONTAL VESSEL AND EXCHANGER FOUNDATION DESIGN Load Distribution for Exchangers
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Vertical loads from exchanger reactions should be derived from the location of the center of gravity. Where impractical to obtain definite location of the C.G., distribution of the exchanger loads may be distributed in the proportion of 0. 6 to the channel end support and 0.4 to shell end support. Bundle pull force shall be applied at center of bundle or of top bundle in stacked arrangement and shall be resisted by fixed pier only. If exchanger is designed to use a Bundle Puller to remove bundle by jacking against exchanger shell, then bundle pull load should be zero. 7.2 Slide Plates Slide plates shall be used on both piers. The coefficient of friction shall be considered 0.3, and per manufacturer s recommendation for low friction slide plates. 7.3 Pier Design Sizing - Unless controlled by other factors, normal pier dimensions shall approximate support base plate size plus 100 mm. Pier thickness should be approximately 10% of pier height with a minimum thickness of 250 mm. Overall pier dimensions shall be in 50-mm increments. If foundation design employs drilled shaft footings, consideration must be given to center to center spacing of drilled shaft and to spacing of vertical bars projecting from drilled shaft in determination of final thickness and width. Both piers shall normally be alike as to size, reinforcement, anchor bolts and slide plates. Minimum vertical pier reinforcement shall conform to requirements of ACI 318 Section 10.5. Minimum horizontal reinforcement shall not be less than 0.0025 times gross cross sectional area of pier. A double tie shall be placed at top of piers spaced 50 mm at 125 mm below top of concrete or below bottom of grout to protect top of pier against cracking.
7.4
Column Design Sizing - the columns for T-type supports may be round or rectangular. However, it is desirable to standardize column dimensions and shapes as much as possible in order to simplify forming. Column dimensions shall be in 50-mm increments.
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Both columns and T-head beams shall normally be alike as to size and reinforcement. 7.5 Spread Footings Common Mat - Consider uses of common or combined footing when pier spacing is 3.7 m or less. Two Spread Footings - Recommended when pier spacing is greater than 3.7 m. Footing dimensions shall be in 50 mm multiples. Minimum footing dimensions shall normally be pier dimension plus 300 mm. Minimum footing thickness shall be 300 mm.
8.0 8.1
STORAGE TANK FOUNDATION Large Tanks Foundations for tanks larger than 4.6-m diameter shall be earth foundations with a concrete ring wall. Recommendations contained in API 650 Appendix B shall apply. Ring wall top of concrete shall be 300-mm minimum above adjacent finished grade. Bottom of ring wall shall extend 450-mm minimum below finished grade. Ring wall width shall be proportioned in accordance with Section B.4.3.2 API 650. Lateral pressure against the ring wall due to the confined fill with surcharge shall be calculated in accordance with parameters provided in Project Soils Report. Minimum reinforcement in ring wall shall be no less than recommended in Section B.4.4.4 of API 650. Cutouts in ring wall required for bolted doors, clean outs or bottom piping connections shall be in compliance with recommended details per API 650.
8.2
Small Tanks Foundations for steel tanks 4.6 m diameter or smaller and for fiberglass tanks shall be concrete slab type. Top of concrete shall be 300-mm minimum above finished grade. Foundation may consist of a 150-mm minimum center slab with perimeter thickened to a depth of 300 mm below grade. Reinforcement for temperature, shrinkage and continuity shall be provided.
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8.3
Earthwork Earth fills material, compaction of earth and preparation of sub-grade shall comply with recommendations in the Project Soils Report. Earthwork must be adequate to support tank without exceeding allowable soil pressure and to hold settlement within recommended limits under hydrotest or operating loads. The specified density for tank pads shall apply to all earth material within the confines of full height of ring wall.
9.0 9.1
BUILDING FOUNDATIONS Foundation Types The following general foundation types shall be furnished: Masonry Buildings - continuous strip footing. Where perimeter columns or pilasters require additional support, footings shall be combined with strip footing. Slab-on-grade shall be isolated from foundations. Enclosed Steel Framed Metal Buildings - Continuous grade beams supported on spread footings with column pedestals. Slab-on-grade shall be isolated from foundations. Open Steel Framed Buildings (Compressor Buildings) - Individual spread footings with column pedestals. Slab-on-grade shall be isolated from foundations. Small Self-Framing Buildings - Floating slab-on-grade with stiffening beams around perimeter and through interior as required.
9.2
Joints The following types of joints shall be provided in building slabs, wall and foundations: Isolation Joints - Required where floor slabs must be isolated structurally from other building elements to avoid differential horizontal and vertical movements caused by vibrating equipment. Isolation joints shall be placed at junctions with walls, columns, machine foundations, or points of restraint, such as drainpipes and piers projecting through the slab. These joints shall consist of a 12 mm thick
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strip of asphalt impregnated fiber sheet and extend the full depth of the joint. Reinforcement bars should not go through any isolation joints. Control or Contraction Joints - Shall be used to control slab or structure cracking by providing a plane of weakness in the concrete element at 4.6 to 6.1.m centers.
9.3
Floor Slabs Floor slabs-on-grade shall be adequate to support applicable concentrated and/or wheel loads. A ratio of slab reinforcement of 0.0018 (reinforcement area to gross concrete area) shall be provided. Control joints shall be provided as noted above. 100-mm minimum compacted sand fill shall be placed on sub-grade beneath all building floor slabs. 0.15 mm polyethylene film shall be provided beneath floor slabs to assist in the control of curing.
9.4
Grade Beams Grade beams shall be designed as flexural members of ACI 318 based on lateral and vertical loading conditions. Bottom of beam must be a minimum of 300 mm below finished grade. Grade beams shall normally be loaded to span from footing to footing assuming no support by the ground. Minimum reinforcement shall be as controlled by ACI 318 Section 10.5.1.
10.0
DRILLED SHAFT FOUNDATIONS Drilled shaft footings may be used in lieu of spread footings in most applications where practical, with the exception of compressor foundations and tall vertical vessel foundations. In utilizing drilled shaft footings for pier support, generally two or more drilled shafts shall be located beneath each support and pier. If equipment or structural support is very small, consideration may be given to placing each pier on a single
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drilled shaft. Each application of drilled shaft footings which resist overturning as well as vertical loads must be justified by an acceptable method of calculation. Design Criteria for Embedment of Piers by E. Czerniak presents an acceptable method for determining the capacity of drilled shafts to resist applied lateral forces and moments. Recommendations concerning Drilled Pier Foundations contained in the Project Geotechnical Report shall also apply to drilled shaft design. Drilled shaft design shall provide adequate reinforcing steel for compressive, tensile and bending loads. Minimum shaft embedment in concrete cap or foundation shall be 75 mm. Drilled shafts designed for tension or for single shaft applications or for support of reciprocating equipment shall be embedded 300-mm minimum into foundation. For tension loading, tension ties or anchors shall be provided.
11.0 11.1
GROUTING AND FINISHING Grouting A minimum of one inch of Portland Cement grout shall be used on foundations for small vessels, small equipment and small column base plates. Dry-pack motor may be used if grouting can be achieved without void. Non-shrink grout or epoxy grout shall be employed for mechanical equipment vessels and large column base plates as covered in Section 5.4, Specification M001.
11.2
Finishing Required finishes for concrete are as follows:
Exposed surfaces of formed foundations and structures - concrete to be left with surface finish imparted by forms objectional irregularities shall be removed and voids pointed up. Exposed top surface of foundations - Wood float surface to depress coarse aggregate and steel trowel to smooth even surface free from defects. Exposed grout surfaces - Steel trowel to smooth even surface.
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Interior floor slabs - Wood float surface to depress course aggregate and steel trowel to smooth even surface free from defects. Exterior slab, walks, building stoops - Wood float surface to depress course aggregate. When surface is true and even use broom to produce a uniform texture.
11.3
Scoring and Edging Required edgings are:
Exposed edges or salient corners of above grade foundations and structures 25-mm chambers formed by beveled wood strip in internal angles of form. Slabs - Use round tooled edge on corners and scored or sawed groove for control joints.
12.0
TRENCH DRAINS Slab trenches where required for drainage of water or combinations of wastewater shall be modular type, pre-cast, interlocking polymer concrete channels. Matching grates shall be cast iron, ductile iron, stainless steel or fiberglass as required for adequate corrosion resistance.
13.0
CONCRETE WATER CONTAINMENT BASINS Joint design, use of sealant and use of water stops, shall comply with recommendations contained in ACI 504 R-77, Guide to Joint Sealant in Concrete Structures. PVC water-stops shall be used for all construction joints subject to a containment of water as follows:
225-mm minimum, serrated with center bulb where joint is subject to movement. 225-mm minimum, serrated without center bulb where joint will not be subjected to movement.
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N-002
FIREPROOFING
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SPEC. NO. N-002 REV.2
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FIREPROOFING TABLE OF CONTENTS 1.0 2.0 3.0 4.0 5.0 SCOPE DRAWINGS, CODES AND STANDARDS FIREPROOFING REQUIREMENTS MATERIALS APPLICATION
1.0
SCOPE
PAGE 2 OF 19
This Specification defines the basic requirements for design, materials, and application of fireproofing for structures, equipment, and supporting elements of piping and equipment, cable trays, and conduit banks located in fire potential areas of process plants. No variations from this specification are permitted unless approved in writing by the Company. Contractors shall define scope of fireproofing and agreed by company at early stage of the project.
2.0
DRAWINGS, CODES AND STANDARDS The following reference documents are the minimum standards required for the project. NFPA No. 321-87 - Standards of Basic Classification of Flammable and Combustible Liquids. UL-1709 (P) Proposed First Edition of the Standard for Rapid Rise. Fire Tests of Protection Materials for Structural Steel. Underwriters Laboratories, Inc. Fire Resistive Directory American Welding Society Welding Electrodes. (AWS) ASTM Joint Specifications for
ASTM-C-150 - Portland Cement Specification (Dense Type Fireproofing) ASTM-E-119 - Fire Tests of Building Construction and Materials. American Concrete Institutes Building Code Requirements (ACI-318). National, State, and Local Laws and Codes shall apply when they contain more stringent requirements than contained herein. IRI-IM 2.5.1 June 1, 1998 fireproofing for hydrocarbon fire exposures.
3.0
FIREPROOFING REQUIREMENTS
PAGE 3 OF 19
3.1
Definitions Fire Potential Equipment: Vessels, pumps, compressors, piping, heat exchangers, fired heaters/furnace and other equipment containing flammable or combustible liquids or vapors, or both, which are potential fire sources, shall be considered fire potential equipment. Classification of flammable and combustible liquids shall be in accordance with NFPA No.321. Fire Potential Areas: Inside Process Battery Limits a. b. c. Areas containing fire potential equipment Areas containing nonflammable but potentially hazardous materials within 15 m. of fire potential equipment. Areas containing nonflammable materials where failure of equipment support could endanger personnel or cause severe damage to the unit or other fire potential equipment thereby increasing the severity or prolonging the duration of the fire.
Outside Process Battery Limits a. b. Areas within 15 m. of fire potential equipment. Areas containing pressure storage spheres.
3.2 3.2.1 3.2.2
General Structural elements supporting fire potential equipment shall have minimum 3hour hydrocarbon fire protection. Structural elements supporting not fire potential equipment in a fire hazardous area shall be fireproofed only if the following conditions exist: a. b. The equipment is essential for controlled shutdown of the plan. Failure of the equipment would damage fire potential equipment, or other equipment essential to controlled shutdown of the plant.
3.2.3
Terminations of fireproofing on steel shall be sloped to shed water and sealed with mastic to prevent moisture from entering between fireproofing material and the steel surface. Typical examples are top edges of fireproofing on beams whose
PAGE 4 OF 19
top flanges are not fireproofed, and top edges of fireproofing on columns, vessel legs and vessel skirts of non-insulated vessels. 3.2.4 3.2.5 Fireproofed members resting on foundations shall have their base plates and anchor bolting fireproofed unless otherwise noted on drawings. Ratings of fireproofing materials, in hours of protection, shall be as listed by Underwriters Laboratories Inc. or other acceptable testing laboratory, using test procedures described in ASTM El19. Extent of Fireproofing Structures When supporting fire potential equipment within the battery limits, columns, beams and horizontal strut bracing of structural steel shall be fireproofed from grade to an elevation where the highest important equipment load is applied to the structure. All bracing which contributes to the support of vertical loads or stability of columns shall be fireproofed when part of a fireproofed supporting system with the following additions or exceptions: a. b. On structures over 9 m. in height, wind bracing shall be fireproofed. On structures less than 9 m. in height, bracing used only for wind loading need not be fireproofed. When bracing is not subject to vertical loads.
3.3 3.3.1
Platforms, runways, stairways, and their supports need not be fireproofed. The top flange of structural steel that supports floor plate need not be fireproofed. See Figure 4. 3.3.2 Pipe Racks/ Pipe Supports Process area pipe racks and interconnecting pipe ways, which support piping only, shall be fireproofed from their bases up to and including the pipe support beam leaving the upper most surface of the top flange exposed. Structural steel supports of main pipe racks outside process areas shall be fireproofed from their bases up to and including the pipe supporting cross beams. Pipe rack bents supporting fire potential equipment in addition to piping shall be fireproofed up to the point of support of the equipment.
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Fireproofing of pipe supports shall include vertical and horizontal load-bearing members and load-bearing bracing. Both the vertical and horizontal members of the first transverse level of pipe racks located within 15 m. of fire potential equipment shall be fireproofed, struts below such first level shall be fireproofed. Fireproofing in this area shall have a 3-hour rating. Pipe rack structures supporting Non-Hydrocarbon and more than 15 m. from any fire potential equipment normally would not need fireproofing unless unusual conditions of exposure or loading exist. If air-coolers are installed above pipe racks, the pipe racks shall be protected with fireproofing from grade up to the level supporting air-coolers. All horizontal structural members supporting air-coolers, including those cantilevered beyond the vertical supports shall be fireproofed. Pipe rack supports above the first level need not be protected, unless unusual conditions of exposure or loading exist. For fire potential areas, miscellaneous supports for pipes which contain hydrocarbon shall be fireproofed. The top flange of pipe bearing beams need not be fireproofed. See Figure 4. 3.3.3 Equipment Supports All lugs, brackets, skirts, and legs supporting fire potential equipment located within the fire potential area and below a minimum height of 10 m. shall be fireproofed. Saddles supporting equipment and measuring more than 300 mm in height at their lowest points shall be fireproofed within the fire potential area On supports of vessels and exchangers having slots in their base plates for thermal expansion, fireproofing shall not interfere with the sliding motion of these supports. 3.3.3.1 Vessel Skirts On insulated vessels, fireproofing shall extend from the foundation up to the insulation. On vessels having no insulation, fireproofing shall extend from the foundation to the top of the skirt. The outside of skirts supporting process vessels shall be fireproofed.
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The inside of skirts over 1 m. in diameter and the bottom heads of noninsulated vessels on skirts over 1 m. in diameter shall be fireproofed. Skirts less than 1 m. in diameter shall be fireproofed as follows: 1. Skirts with one access opening which is 400-mm diameter or smaller, and only welded connections within the skirt, shall be fireproofed on the outside only. Skirts with an access opening larger than 400 mm in diameter or more than one access opening, or skirt with flanged or screwed connections within the skirt, shall be fireproofed inside and outside. Where the inside of skirt is required to be fireproofed, bottom heads of uninsulated vessels shall be fireproofed, whereas insulation on bottom head shall be covered with stainless steel or galvanised steel jacket.
2.
3.
Skirts, which require insulation, shall be fireproofed on the non-insulated portions only. See Figure 2. 3.3.3.2 Air Coolers Structural members supporting air-coolers shall be fireproofed as follows: a. b. All members of supports for exchangers handling flammable liquids. Only those structural members that are within fire potential areas, for exchangers handling non-flammable liquids.
3.3.3.3 Heaters Main supports and all bracing, with the exception of wind bracing, shall be fireproofed up to the firing floor level. 3.3.4 Conduit Banks and Cable Trays Conduit banks and cable trays vital to the emergency shutdown system of the plant and located within normal fire protection areas shall be provided with a minimum of a 30 minute fire protection system based upon testing in accordance with ASTM E119 fire test as a minimum standard fire test. When utilizing a fire protective system for electrical power cables, special consideration should be given to the effects on high amperage cables caused by the heat retaining capacity of the fire protection system.
PAGE 7 OF 19
3.4
Method of Fireproofing Methods of fireproofing resulting in a 3-hour rating are as follows: a. b. c. Concrete: Seventy-five (75) mm Lightweight Concrete: Fifty (50) mm Lightweight Cementitious Products:
Thickness shall be the manufacturers specified thickness listed by the Underwriters Laboratories Inc. Fire Resistive Directory for an exterior use three (3) hour minimum fire resistance rating based upon testing in accordance with ASTM E119 fire test as a minimum standard fire test. Thickness shall be determined by probed measurements in accordance with the recommended procedure of ASTM E605 or other method approved by the Company.
4.0 4.1
MATERIALS Concrete or Lightweight Concrete: Form Placed method and pneumatically applied. Components for concrete fireproofing shall be as follows:
a.
Concrete for both manual and pneumatic placement shall be mixed in the proportion as determined by the applicator in accordance with manufacturers recommendation so as to obtain a minimum compressive strength of 140 kg/cm2 at 28 days. Water/cement ratio shall not exceed 0.50. Ready mixed concrete in accordance with ASTM Specification C94 may be used Cement shall be Type 1 Portland Cement conforming to ASTM C 150. Other cements may be used if required for special reasons, such as early strength or sulphate resistance. Sand shall be commercial, high silica sand with clean, sharp, hard, durable particles conforming to ASTM C33. For general purposes, aggregate shall be sharp and angular in nature and range in size from 6 mm to 12 mm and shall conform to ASTM C 33.
b.
c.
d.
PAGE 8 OF 19
Where lightweight is essential, insulating type aggregates, such as perlite, vermiculite, expanded shale, or slag may be used.
e.
Welded galvanised steel wire mesh, 50 mm x 50 mm x 3 mm shall be used for reinforcement. Lacing wire shall be 1.6 mm galvanised wire. Carbon steel rectangular welding studs, Nelson RGP or equal, shall be used for securing wire mesh reinforcement to steel. Length of studs shall provide for 19 mm to 25-mm space between steel and the wire mesh. Carbon steel square or hexagonal nuts are also acceptable anchors for attachment of wire mesh. Mastic material for fireproofing terminations shall be waterproof, nonflammable when dry, durable under weather conditions, and able to withstand temperatures to 250F (120C). Water shall be clean and free of oils, acids, salts or other substances injurious to the concrete. Water of drinkable quality is acceptable.
f. g.
h.
i.
4.2
Light Weight Cementitious Products Commercial lightweight cementitious products are acceptable only when in compliance with the following quality criteria. Intumescent, subliming, or ablative coatings, gypsum, and magnesium oxychlorides are not acceptable. 1. The Underwriters Laboratories Inc must list product. Fire Resistive Directory for exterior use based upon testing in accordance with ASTM E119 Fire test as a minimum standard fire test Fireproofing material shall contain no asbestos, toxic, or red label solvents. Properties (as defined by ASTM E-84) Ratings for: Flame Spread: 0-20 Fuel Contribution: 0-5 4. Fireproofing manufacturer shall furnish a list of current installations utilizing the product in question. The list shall contain the locations, type and years of service.
2. 3.
PAGE 9 OF 19
4.3
Ceramic Wool a. b. c. d. Ceramic wool 38 mm thick, 128 kg/cu density, may be used for fireproofing of instrument runs. Wire for holding ceramic wool in place shall be annealed Series 300 stainless steel 1.6 mm wire. Jacket for ceramic wool shall be 0.25-mm thick Series 300 stainless steel sheet. Bands for securing the jacket on ceramic wool shall be 12mm wide, 3.8 mm thick stainless steel.
4.4
Intumescent Coatings Acceptable intumescent fireproofing materials are Albiclad 890, manufactured by Albi Manufacturing, Rockville, Connecticut, Cherteck 59, manufactured by Avco System, Lowell, Massachusetts.
4.5
Mastic Flashing Mastic Flashing shall consist of a fibrated mastic material in ready mixed form nonflammable when cured, durable under extreme weather conditions and suitable for temperatures to 120 C
4.6 4.6.1
Anchorage Concrete and Lightweight Concrete 1. Materials Materials for anchorage and reinforcement shall be as specified in Figure 1 through 4. 2. Preparation a. All steel surfaces to be in contact with the fireproofing shall be cleaned of all oil, loose rust, or mill scale and other foreign matter by wire brushing or by sandblasting. All steel surfaces shall be prime coated in accordance with the fireproofing applicators recommendations.
b.
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3.
Installation a. Attach the wrapper firmly in place on vessel skirts as shown in Figure 1 Detail A. The wrapper shall be tied to the nuts so that it is held 19 mm to 25 mm from the face of support. Attach the wrapper firmly in place on structural steel members as show in Figures 3 and 4. Exposed ends of members shall also be covered with the wrapper securely tied.
b.
4.6.2
Lightweight Cementitious Products 1. Material Material shall be as specified by the fireproofing supplier and shall conform to designs which will provide the specified fire ratings per Underwriters Laboratories Fire Resistive Directory. 2. Preparation a. All steel surfaces to be in contact with the fireproofing shall be cleaned of all oil, loose rust, or mill scale and other foreign matter by wire brushing or by sandblasting. All steel must be primed as specified by the fireproofing supplier.
b. 3.
Installation Installation details shall conform to design which will provide the specified fire ratings per Underwriters Laboratories Fire Resistive Directory.
5.0 5.1 5.1.1 5.1.2
APPLICATION Concrete and Lightweight Concrete Exposed concrete corners shall be chamfered or rounded. Reinforcement for Concrete Fireproofing Wire mesh shall be used for reinforcement and shall be supported on the member being fireproofed by means of welded studs or nuts on edge. Clearance between the mesh and the structural member shall be a minimum of 19 mm. Edges of
PAGE 11 OF 19
adjacent sheets of mesh shall lap minimum distance of 50mm and shall be secured with lacing wire spaced 450mm apart. 5.1.3 Precautions a. During operation, the application equipment should be properly grounded to prevent static electricity especially in areas where there is a possibility of flammable vapours occurring. Surfaces and equipment adjacent to the member being fireproofed should be shielded by screens, taurpaulins, or heavy paper covering to shield them from spatters and prevent excessive clean up.
b.
5.1.4. 5.1.5
The strength of concrete after 28 days shall be 140-kg/cm2 minimum. Placing Before proceeding with the project, the Contractor shall install a section for final approval by the Company as to the texture and thickness of the finished project. Thickness will be determined by probed measurements in accordance with the recommended procedure by ASTM Specification E605 or other method approved by the Company. Concrete shall not be mixed and placed at temperatures below 5C or when temperatures may be expected to drop below freezing within the first 5 days or curing unless proper cold weather methods are followed. During warm weather concrete mix shall be below 32C Form Placed Method: Concrete shall be placed into forms wetted or oiled and made to correct dimensions to give the specified minimum coverage. Vibration shall be employed as necessary to insure that the fireproofing shall have a smooth surface free from voids or irregularities.
Pneumatic Application: Only competent and experienced personnel shall be employed for this work. Nozzle shall be held perpendicular to the surface except where reinforcement is encountered; in which case the concrete should be shot around the reinforcement from both sides. The nozzle shall be held a distance of 900 to 1200 mm from the fireproofing area.
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The water content shall be adjusted so that concrete adheres properly and does not sag and slide upon application. Water/cement ratio shall not exceed 0.50. For vessels skirts the concrete shall be applied in horizontal bands working upward from the bottom of the skirt. The full-specified thickness shall be developed in one band before proceeding with the next band. It is important that the bottom of each successive band is securely bonded to the top of the proceeding one before the latter has developed its initial set. Therefore, the height of the bands will be governed by the diameter of the skirt and by atmospheric conditions. Forms and accessories shall be incorporated to insure that lines and corners and proper thickness of fireproofing is obtained. Once the application has started, it shall proceed continuously, without interruption, until the entire skirt surface or structural steel member surface is completed. If the application is interrupted before completion of the entire member, the concrete shall be cut back immediately to the substrate with a steel trowel. This cut back shall be made at a right angle to the substrate and shall be made at locations where the full thickness has already been applied. All concrete beyond the cut shall be discarded. Immediately prior to resuming application, the exposed surface of the concrete to which a bond must be made shall be thoroughly wetted. Areas adjacent to pneumatic application should be shielded to prevent splatters and excessive cleanup. Under no circumstances shall any rebound material be used.
5.1.6
Curing and Finishing Keeping it in a damp condition for a period of 5 days shall cure concrete. Spraying when employed, shell is with a fine mist to prevent the washing out of the cement. When membrane curing is used, the membrane curing compound shall be a solution of resin and hydrocarbon base, which has low permeability, compatibility with aluminous cements, ease of application, short drying time and long storage life. A one-coat application of membrane compound shall be used, with contrasting color and of sufficient thickness to completely cover lining. The membrane shell is allowed to dry tack free before lining is
PAGE 13 OF 19
installed in adjoining area. Adequate ventilation shall be provided during the membrane compound application and curing period. Immediately after initial set-up, while the concrete is still moist, all the necessary pointing-up shall be done and all surfaces shall be finished with a brush coat. The desired finish texture shall be sprayed (rough, stuccolike), rolled, or trowelled (smooth, flat with finished corners) as specified by the Company. The top edges of the fireproofing shall be flashed with a mastic weatherproof coating when not otherwise shielded. Painting of concrete is not recommended, as this tends to hide surface evidence of defects.
5.1.7
Caulking Apply caulking at all exposed steel and fireproofing intersections. Slope or slant fireproofing downward from intersection to facilitate drainage. When fireproofing terminates on a column provide a cap plate in addition to caulking to prevent the intrusion of moisture.
5.2 5.2.1
Other Materials General Required thickness of other fireproofing materials than concrete for a 3-hour rating shall be obtained from the UL Listing of Fire Resistance Directory. Materials shall be applied over reinforcement such as expanded metal lath, as recommended by the manufacturer.
5.2.2
Intumescent Coatings These materials are generally applied by spray method. Preparation of steel surfaces, application and finishing shall be in accordance with manufacturers instructions. The applicator shall be experienced in handling these materials and shall be recommended by the coating manufacturer. Priming of steel surfaces and painting the finished work is required.
5.2.3
Light Weight Cementitious Materials
PAGE 14 OF 19
These materials can be sprayed or trowelled on. However, a sprayed-on surface is very rough therefore if smooth surfaces are required, sprayed-on material may be smoothed with a trowel, or trowelled application used. Metal surface preparation, reinforcement, application, and finishing shall be in accordance with manufacturers recommendations. Application details and thickness shall conform to designs, which will provide the specified fire ratings per Underwriters Laboratories Inc. Fire Resistive Directory. Detailed application procedures should be obtained from the manufacturer. Before proceeding with the project, the Contractor shall install a section for final approval by the Company as the texture and thickness of the finished project. Thickness will be determined by probed measurements in accordance with the recommended procedure of ASTM specification E605 or other method approved by the Company. Application shall be made only under the supervision of a trained and qualified applicator in accordance with the manufacturers most recent instruction manual. When a box configuration is selected, install fire-stops at 2.5 meters maximum centers in boxed columns. The desired finish texture shall be sprayed (rough, stucco like), rolled, or trowelled (smooth, flat with finished corners) as specified by the Company. A finishing topcoat as recommended by the fireproofing supplier shall be provided. Proprietary materials described in this specification shall be acceptable only if installed using the manufacturers approved primers, topcoats, reinforcing materials, and details as described in the qualifying Underwriters Laboratories Fire Resistive Directory.
PAGE 15 OF 19
Unit = Millimeters
PAGE 16 OF 19
Unit = Millimeters
PAGE 17 OF 19
Unit = Millimeters
PAGE 18 OF 19
Unit = Millimeters
PAGE 19 OF 19
Spec No.: PS-C-511-1 Page No.: 1 of 9
THAI OLEFINS CO., LTD.
PROJECT SPECIFICATION FOR UNDERGROUND INSTALLATION OF EXTERNAL POLYETHYLENE COATED PIPING AND POLYETHYLENE TAPE WRAPPING
THE FOLLOWING DOCUMENTS FORM PART OF THIS SPECIFICATION : SPECIFICATION PS-C-510 EXTERNAL POLYETHYLENE(PE) COATING FOR UNDERGROUND PIPE
REVISION DATE PREPARER LEAD ENGINEER PROJ. MANAGER
Spec No.: PS-C-511-1 Page No.: 2 of 9 TABLE OF CONTENTS =============================================================================== Page Section Title =============================================================================== 1 GENERAL 1.1 Scope 3 1.2 Bids 3 1.3 Drawings, Data and Records 3 1.4 Application Code and Specification 3 2 APPLICATION 2.1 General 2.2 Surface Preparation 2.3 Priming 2.4 Tape application 2.5 Wrapping tape materials INSTALLATION 3.1 General 3.2 Handling of coated pipe 3.3 Backfilling 3.4 Inspection 3.5 Repair of damaged PE pipe coating 3.6 Repair of damaged tape wrapping 3.7 Rejection
4 4 5 5 6
6 7 7 8 8 9 9
Spec No.: PS-C-511-1 Page No.: 3 of 9 1 1.1 1.1.1 GENERAL Scope This Specification together with the purchase order, purchasing specification supplement sheets and data sheets covers the minimum requirements forth field of coating construction joints and damaged areas at external polyethylene coated piping as well as the requirements to be observed in installing such piping components underground. All conflicts between the requirements of this specification and the purchase order shall be referred to the purchaser for clarification before proceeding with the installation. Bids The bidder shall specification A. submit one quotation in accordance with this
1.1.2
1.2 1.2.1
Alternate bids may also be submitted provided all divergences are indicated.
1.2.2
The bidder shall furnish with the bid a complete description of the materials to be furnished. Drawings, Data and Records The purchaser will supply all of the necessary drawings and data required by the installation contractor to enable him to accurately assess the scope of work. Records of material specifications, dates of application, physical tests, application and repair procedures and an affidavit of compliance with American Federal Specification FS-L-C-530B and French standard NF A-705 for shop coated pipe and fitting shall be kept available for examination by the purchaser. Application Code and Specification FS-L-C-530B : Coating, Pipe, Thermoplastic Resin or Thermosetting Epoxy NF A49-705 : Steel tube external polyethylene coating application by powder fusion. : External polyethylene coating for underground pipe.
1.3 1.3.1
1.3.2
1.4
PS-C-510
Spec No.: PS-C-511-1 Page No.: 4 of 9 2 2.1 2.1.1 APPLICATION General The extent and the type of coating will be shown on the data sheets or drawings. Field welded joints and small fittings shall be wrapped polyethylene tape in accordance with this specification. Tape wrapping system consists of tape, outerwraps and accessaries. compatible primers, with
2.1.2
2.1.3
adhesives
2.1.4
The primary coating tape shall be included such properties as resistance to extreme heat and cold, low shrinkage, high dielectric strength, chemical inertness, corrosion resistance and toughness under pressure and abrasive conditions. The outerwraps shall be composed of a tough durable polyethylene that is made to take the punishment of backfilling, saddle weight installation, rocks or any other threat to the continuity of the primary coating. All welded joints that have not been previously leak tested shall be leak tested as required by the piping specifications before commencing any of the application operations. Surface Preparation Prior to application of the tapes, the surfaces to be coated shall be cleaned and primed with a fast drying primer recommended by the tape manufacturer. Bare pipe shall be considered clean when, immediately before coating applications, all paint, old coating, oil and grease, mill scale, rust, knurls, burrs, dirt, mud, moisture, weeds, and other foreign matter shall be removed. Where tape wrapping is to be applied to or to be overlapped existing polyethylene pipe coating the polyethylene surface is shall be dried and freed from dirt, oil, grease, etc. Priming The primer shall be applied to a clean pipe surface in a uniform thin film at a rate in accordance with manufacturer's recommendations. Primer shall be made a strong permanent bond with the highly conformable adhesive coated wrapping tape. The prime coat shall be uniform and free from floods, runs, sags, drips, or bare spots.
2.1.5
2.1.6
2.2 2.2.1
2.2.2
2.3 2.3.1
2.3.2
2.3.3
Spec No.: PS-C-511-1 Page No.: 5 of 9 2.4 2.4.1 Tape Application Tape width for pipe diameters up to 150 mm shall be 100 mm. For pipe diameters above 150 mm tape width shall be 150 mm. Under no circumstance shall the tape width exceed 150 mm. Use of other tape width shall be subject to the approval of DEC. 2.4.2 Where the area to be wrapped adjoins pipe with existing PE coated, wrapping shall start and finish, so as to provide a 100 mm minimum overlap on pipes up to 200 mm diameter and 150 mm overlap on pipes in excess of 200 mm diameter. Tape may be applied by hand or machine at the contractors options. The tape shall be applied in an even spiral with an overlap of 50% to ensure a minimum of two tape thickness at all points. Tensioning of the tape during application shall be such as to ensure conformity at weld areas and at the overlap with any existing polyethylene coating, but shall not be excessive. The finished application shall be free from all wrinkles, air traps, etc. 2.4.5 The first and last turns of tape shall be straight around the pipe. If a new roll of tape is started, the ends shall be overlapped at least 150 mm. The overlap of the outer-layer tape shall not be coincide with the overlay of the inner-layer. Both the inner and outer tape wrap will be applied to assure a double thickness of tape. The total resultant thickness of tape wrap should be a minimum of 1.4 mm. Wrapping Tape Materials The materials of polyethylene tape shall be listed as below:
2.4.3 2.4.4
2.4.6
2.4.7
2.4.8
2.5 2.5.1
Manufacturer
Primer Pipe
Interwrap Joint & Fitting 930-35
Outerwrap
Polyken
927 or 929
900-12
954-15
Use of alternative product to those listed above shall be subject to the approval of DEC.
Spec No.: PS-C-511-1 Page No.: 6 of 9 3 3.1 3.1.1 INSTALLATION General Coated pipe shall be handled with equipment such as wide belt slings and wide padded skids selected to prevent damage to the coating. Bare cables, chains, hooks, metal bars, or narrow skids shall not be permitted in contact with coating. When moved by truck, the pipe shall be supported in wide cradles of suitably padded timers hollowed out on the supporting surface to fit the curvature of pipe and all chains, cables or other equipment used for fastening the load shall be carefully padded. For smaller diameter pipe, sand or sawdust-filled bags may be used instead of hollowed-out timbers. During installation of the pipe, every precaution shall be taken to prevent damage to the protective coating. Contact between the finished coating and metal tools or heavy objects shall be avoided as much as practicable. Any damage to the pipe or the protective coating from any cause during the installation of the pipe shall be repaired. Handling of Coated Pipe Pipe shall be stored along the trench side, supported on wooden timbers placed under the uncoated ends to hold the pipe off the ground. During this operation it shall not be dropped, rolled, impacted against or with any solid objects with a force capable of damaging the coating. 3.2.2 Pipe shall be hoisted from the trench side to the trench by means of wide belt slings. Chains, cables, tongs, or other equipment likely to cause damage to the coating shall not be used and dragging or skidding the pipe shall not be permitted. The coating on the underside of the pipe shall be inspected by the inspector while suspended from the sling. Any damage shall be repaired before lowering the pipe into the trench. The alignment of the coated pipe shall be adjusted y the sand bags. When the trench traverses rocky ground or ground containing hard objects that expect to penetrate the protective coating, then the selected fill material, screened earth, or sand at least 80mm depth layer shall be placed at the bottom of the trench before laying the pipe in the trench. When lowering the pipe into the trench, the pipe shall be prevented from swinging or rubbing against the sides of the
3.1.2
3.1.3
3.1.4
3.2 3.2.1
3.2.3
3.2.4
3.2.5
Spec No.: PS-C-511-1 Page No.: 7 of 9 trench. 3.2.6 If held in open storage in excess of two months, the contractor shall protect the pipe from exposure to sunlight by black polyethylene sheet, canvas or other means approved by the DEC. Backfilling Backfilling shall be conducted in a manner that will prevent damage and abrasion to the polyethylene coating. After placing and aligning the pipe in the trench and then before completing the joint, loose backfill shall be placed around the pipe except at field joints, to a depth of about 200 mm above the pipe. This backfill shall consist only of fine soil, sand, or other selected material. 3.3.3 If rocks or other hard objects occur in the backfill along any section of the pipeline, such backfill shall be screened before being placed about the pipe, or suitable waste backfill from other areas may be placed about the pipe in such sections. The exposed coating shall be inspected by the inspector before completing the backfilling operation and any damaged areas shall be repaired. The backfilling work is subject to inspection and approval by TOC. Inspection All stages of preparation, materials, workmanship, application and inspection by the inspector shall be subject to inspection by the TOC. Inspection of the PE coated pipe shall include the witness of tape application and the passage of a spark holiday detector over the pipe immediately after completing the wrapping of the pipe. Generally, a voltage of approximately 10,000 volts is required. 3.4.3 The travel rate of the holiday detector shall not exceed 18m/min and it shall not be allowed to remain stationary with the circuit open i.e. with the detector switched on. Defective locations shall be clearly in dated by a circular chalk mark immediately upon the discovery by visual examination or by the holiday detector, Marked areas shall be subsequently repaired as in Section 3.5 and 3.6 and inspected as in Section 3.4 above. The complete underground coating inspection and approval by TOC. system shall be subject to
3.3 3.3.1
3.3.2
3.3.4 3.4 3.4.1
3.4.2
3.4.4
3.4.5
3.4.6
Any flaws or holidays found in the coating during final inspection
Spec No.: PS-C-511-1 Page No.: 8 of 9 shall be repaired at no additional cost to DEC. 3.5 3.5.1 3.5.2 Repair of Damaged PE Pipe Coating Repair shall be applied to the all detecting point. The damaged area shall be trimmed and the surface prepared as in section 2.2 and primed as necessary in accordance with section 2.3. Apply a spiral wrap of tape as in section 2.4, so as to ensure a minimum extension of tape beyond the damaged area of 50mm. Repair of Damaged Tape Wrapping Where damage is to elbows, bends and fittings, then remove the whole section of tape completely and re-apply using fresh tape. Re-prime as necessary before tape application. 50% into adjoining tape wrapping. 3.6.2 Ensure overlap of
3.5.3
3.6 3.6.1
Where damage is on a long pipe section remove only a section of tape extending 100 mm on either side of the damaged area and apply fresh tape as in 3.6.1. Rejection Coatings or materials used for coatings, which contain injurious defects or excessive repairs, indicate improper application, or are not in accordance with the requirements of specification shall be rejected.
3.7 3.7.1
S-001
SITE CIVIL DESIGN CRITERIA
2 1 0 Rev
4/08/05 9/06/00 31/3/00 D/M/Y
TWC TPT TPT By
RW SWK SWK Chk
WB JN JN Appr
SPEC. NO. S-001 REV.2
PAGE 1 OF 11
SITE CIVIL DESIGN CRITERIA TABLE OF CONTENTS 1.O 2.0 SCOPE RELATED CODES, SPECIFICATIONS AND DOCUMENTS 2.1 2.2 3.0 Codes and Regulations Related Project Specifications
EARTHWORK 3.1 3.2 3.3 3.4 Clearing and Grubbing Compaction of Fill Quality Assurance Erosion Control
4.0
SURFACE DRAINAGE 4.1 4.2 4.3 4.4 4.5 4.6 Rainfall Rate Firewater Quantities Runoff Calculations Storm Sewer Design Ditch Design Tankage Areas
5.0
FINISHED GRADING AND AREA SURFACING 5.1 5.2 5.3 5.4 Grade Limitations Area Paving Sidewalks Graveled Areas
PAGE 2 OF 11
6.0 7.0
SANITARY WASTE TREATMENT RELATED DRAINAGE STRUCTURES 7.1 7.2 7.3 Sumps and Pits Sewage Lift Stations Sewage Manholes
PAGE 3 OF 11
1.0
SCOPE This specification provides criteria for civil work and general site development. Requirements for surface drainage, grading, surfacing, and miscellaneous civil related items are included. This document shall be utilized to establish the civil design requirements and is not intended for use as a construction specification.
2.0
RELATED CODE, SPECIFICATIONS AND DOCUMENTS 2.1 Codes and Regulations Refer to Project Specification M-001 for a listing of codes and regulations. Applicable portions of listed codes and regulations shall apply to work specified herein. M-001 also contains references to weather and site data and the Project Geotechnical Report. Civil work and general site development shall be in compliance with all local codes, laws and regulations. 2.2 Related Project Specifications M-001 - Structural Design Loads and Criteria S-002 - Fencing S-003 - Roads and Paving
3.0
EARTHWORK General earthwork design and construction procedures shall conform to the recommendations of the Project Geotechnical Report, and with requirements outlined herein. 3.1 Clearing and Grubbing Designated areas of the plant site shall be cleared of trees, brush, rubbish and vegetation. All grass and weeds including roots shall be stripped and removed. The areas shall also be grubbed of stumps, large roots and other undesirable buried material. Any soils loosened by removal of stumps, roots, existing man-made fill, etc., shall be removed and replaced with structural fill. Debris from stripping, clearing and grubbing operations shall be removed from the site. Method of disposal
PAGE 4 OF 11
and location of disposal site shall be subject to approval of the Company. 3.2 Compaction of Fill Soil embankments and fill shall be compacted to the following percent of maximum dry density obtainable at optimum moisture content as determined by a Standard Proctor test, per ASTM D698. (*) Percent of maximum dry density for roads, parking areas and pavement shall be determined by a Modified Proctor Test, per ASTM D 1557.
Buildings and Process Areas Tank Pads Tank Firewalls Dikes around Ponds/Basins (*)Roads, Parking Areas, Pavements Non-building areas
95 95 90 95 95 90
percent percent percent percent percent percent
The above fill compaction requirements shall apply to the backfill of utility trenches, foundations, retaining walls and other excavations in areas subject to subsequent placement of shallow foundations, slabs, sidewalks or roadways. Backfill for the excavations located in areas not subject to subsequent placement of the above items shall be compacted to a minimum density equivalent to the undisturbed soil density. Compacted thickness of fill material shall not exceed 200 mm per lift. No permanently exposed cut or fill including Tank Firewalls shall be steeper than 2 horizontal to 1 vertical. 3.3 Quality Assurance Grading work will be inspected by the Companys geotechnical specialist to determine compliance of the Contractors work with the specified requirements. The representative will evaluate and approve all stripping and foundation preparation measures in advance of placing
PAGE 5 OF 11
compacted fill and direct any necessary undercutting and special stabilization measures which are required. Tests will be performed on fill. Lifts failing to comply with the specified requirements shall be adjusted in natural water content as required, compacted and retest to establish compliance of the total embankment with the requirements. For construction control, field density tests should be performed as often as possible. As a guideline, a minimum of one field density test should be performed for an area of 2000 square meters per each layer for general fill, and for an area of 500 square meters per each layer for structural fill. 3.4 Erosion Control Drainage ditches, culverts and other surfaces composed of erodible materials shall be provided with slope protection. Generally, the protection will form an impervious layer constructed in or on designated surfaces and may have at its bottom and ends anti-scour devices, such as toe walls. Where above grade earth firewalls or dikes are required, slopes shall be protected against erosion upon completion of finish grading by sodding or other controlled growth low vegetation or by applying a coat of liquid asphalt to the surface, as indicated below:
Tightly bonded surfaces: Loosely bonded fine-grained surfaces:
1.4 liter/square meter of MC-30 2.3 liter/square meter of MC-70 or SC-70
Loosely bonded coarse-grained surfaces: 3.6 liter/square meter of MC-250 or SC-250
4.0
SURFACE DRAINAGE This section covers the handling of uncontaminated water generated from rainfall, firewater and uncontaminated process drains. Site design shall provide for removal of storm water by surface and ditch methods. Underground storm sewers shall be avoided unless equipment and building arrangement make ditching impractical.
PAGE 6 OF 11
4.1
Rainfall Rate The design rainfall rate shall be based on the weather and site data report referenced in Specification M-001, Section 3.2 and on local studies. Minimum design concentration time shall be 10 minutes.
4.2
Firewater Quantities
For sewers or ditches subject to firewater loads, the following design quantities shall be used: 2,000 liter/min to the first inlet 1,000 liter/min to each subsequent inlet on the same lateral 4,000 liter/min maximum to a lateral 12,000 liter/min maximum to a main 12,000 liter/min shall be considered as the maximum firewater load to the sewer or ditch system at any time.
4.3
Runoff Calculations Surface runoff from rainfall shall be calculated by Rational Formula Q=CIA in which C = 1.0 for paving and roots, 0.50 for graveled areas. Other areas shall have C determined by their characteristics. Capacity of ditches and head loss in sewer pipes shall be calculated by Manning Formula: Q = A* (1.486/n)*R2/3 S1/2, where, n = 0.013 for sewer pipe, 0.018 for lined ditches and 0.025 for unlined maintained ditches.
4.4
Storm Sewer Design Storm sewers system shall be designed for the rain fall or firewater, whichever is greater. Storm sewers shall be sized as flowing full with future requirements to be included in design quantities. Minimum size for sewers leaving catch basins or area drains shall be 150 mm. Minimum storm sewer size shall be 200 mm.
PAGE 7 OF 11
Minimum allowable velocity at design flow shall be 0.6 m/sec. for storm sewers. Maximum allowable velocity at design flow shall be 2.4 m/sec. Where large quantities of sediment or sludge are expected, minimum allowable velocity at design flow shall be increased to minimize deposition. Minimum cover for sewers shall be 600 mm. Culverts shall be provided for drainage under roads, cover shall be as required for AASHTO H-20 loading. The culverts shall be provided with headwalls. 4.5 Ditch Design Ditches shall normally be trapezoidal in cross section with a minimum bottom width of 600 mm. The side slope shall normally be 2-l/2, horizontal to 1 vertical, but may be 1-1/2 horizontal to 1 vertical if space is limited and soil conditions permit. Vee ditches may be used for laterals not exceeding 60 m in length. The side slope shall normally be 1-1/2 horizontal to 1 vertical. Minimum gradient shall be .005 m/m. Minimum depth shall be 150 mm and maximum depth shall be 600 mm. Shallow swales may be used within or adjacent to process units. Minimum gradient shall be 0.01 m/m for unlined, 0.003 m/m for lined gutters. Minimum depth shall be 75 mm; maximum depth shall be 300 mm. Maximum velocity in unlined ditches of low capacity shall be as indicated in the soil report. In the absence of this information, velocity should not exceed the following:

Fine sand or silt Coarse sand to sandy loam Sandy clay Clay
.75 m/sec .75 m/sec 1.0 m/sec 1.5 m/sec
4.6
Tankage Areas Storm water from areas within tankage firewalls shall be collected in one or more catch basins located near the firewalls. Discharge flow
PAGE 8 OF 11
shall be controlled with a normally closed valve located outside the firewall. Water draw off shall be to an underground sewer system. Minimum size water draw off sewer shall be 150 mm.
5.0
FINISHED GRADING AND AREA SURFACING 5.1 Grade Limitations Nominal slope of finished grade shall be 1%, within the limits of process area. Surface of areas beyond the process area, i.e., flare, storage tank, office and switchgear areas may slope 3% maximum. In general, the normal grade shall slope gently in all directions away from buildings and equipment to provide adequate surface runoff without erosion of the Plant site. Grade conditions permitting surface runoff water to pond or stand around foundations are not acceptable. 5.2 Area Paving Concrete paving shall be provided in the following locations:
Where paved surfaces are required around equipment to control hydrocarbon or chemical spills. With curb and valve box. Underground piping shall be connected to the proper system. Areas adjacent to buildings comprising vehicular and personnel entrance. Lay down areas for equipment maintenance at grade. Areas on congested piping and controls where numerous dummy legs support can extend to a common slab, thus eliminating numerous individual foundations. Areas where small parallel pumps or equipment may be installed directly on common slabs instead of on closely spaced individual foundations. Project requirements regarding settlement and soil bearing must be satisfied.
For general design requirements for area paving see Project Specification S-003, Roads and Paving Criteria.
PAGE 9 OF 11
5.3
Sidewalks Walkways and pedestrian paths at grade shall be concrete, constructed 100 mm thick reinforced with welded wire fabric. Where walkways cross-unpaved vehicle access ways, minimum thickness shall be 150 mm reinforced with two layers of the wire fabric. Walkways shall be a minimum 1-m width. Where walkways cross minor swales or shallow drainage ways, surface of slab shall be depressed equal to ground surface to create a low water crossing. Drainage pipes or trenches across walkways shall not be used unless necessary because of layout and space limitations.
5.4
Graveled Areas Upon completion of underground and major above grade construction, a 50-mm layer of crushed gravel (12 mm to 25-mm size) shall be distributed and compacted in non-paved areas. Gravel shall not be spread until final grading has been completed. It is intended that gravel be installed continuously from sidewalks to the outside limits of specified areas.
6.0
SANITARY WASTE TREATMENT There is no central waste treatment plant provided for heavy industries at the plant site. A wastewater treatment plant will have to be provided. Sanitary sewers shall transport waste from toilet facilities, lavatories, building floor drains, etc., to the treatment plant. Waste effluent after treatment may be discharged into a drainage canal running parallel to the site. Acids, caustics, hydrocarbons or similar contaminants shall not discharge to this system the sanitary system design shall comply with all local laws and building codes.
7.0
RELATED DRAINAGE STRUCTURES 7.1 Sumps and Pits Below grade pump sumps or pits shall be constructed of either pre-cast or poured-in-place concrete. Bottom and floor of concrete sumps or pits shall be designed and constructed liquid tight free of cold joints that will prevent underground leakage with water stop.
PAGE 10 OF 11
Pipe penetrations through sump walls shall be either cast-in-place or grouted using epoxy grout. Sump covers shall be either pre-cast concrete or poured-in-place concrete with appropriate manhole access. 7.2 Sewage Lift Station Sewage lift stations of suitable sizes shall be constructed at appropriate intervals. Each lift station shall be equipped with at least 2 submersible sewage pumps; each pump shall have full capacity of sewage flow. Pipes, fittings, valves and controls shall be provided for automatic operation. Controls shall be arranged to have each pump operated in alternating sequence. 7.3 Sewage Manholes Sewage manholes of suitable size shall be constructed at ever 15-m interval, at every change of pipe direction, and at the connection point of two or more sewer pipes.
PAGE 11 OF 11
S-002
FENCING
2 1 0 Rev
4/08/05 27/3/00 20/01/00 D/M/Y
TWC TPT TPT By
RW SWK SWK Chk
WB JN JN Appr
PAGE 1 OF 7
FENCING TABLE OF CONTENTS 1.0 2.0 3.0 4.0 5.0 SCOPE CODES AND SPECIFICATIONS GENERAL FABRICATION INSTALLATION
PAGE 2 OF 7
1.0
SCOPE This specification establishes the materials and construction for fencing and gates.
2.0
CODES AND SPECIFICATIONS ASTM A90 A120 American Society for Testing and Materials (Latest Editions): Test Method for Weight of Coating on ZincCoated (Galvanized) Iron or Steel Articles Specification for Pipe, Steel, Black and Hot-Dipped Zinc-Coated (Galvanized) Welded and seamless, for Ordinary Uses. A121 A123 A153 A239 Specification for Zinc-Coated (Galvanized) Steel Barbed Wire Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products Specification for Zinc Coating (hot-Dip) on Iron and Steel Hardware Test Method for Locating the Thinnest Spot in a Zinc (Galvanized) Coating on Iron or Steel Articles by the Preece Test (Copper Sulfate Dip) A392
Specification for Zinc-Coated Steel Chain Link Fence Fabric
Plot Plan, Olefins Plant Fencing-Chain Link Type, Elevation and Details. Drawing 20715-FS-001, Rev. B
3.0 3.1
GENERAL Description This fencing shall be used for perimeter fencing and interior fencing for selected areas, such as substations and storage yards. The fence shall be a galvanized
PAGE 3 OF 7
chain link fence type A or B per Drawing FS-001, Rev. B. The fence shall be topped with four strands of barbed wire with two outriggers. 3.2 General Design There are two (2) styles of fences for the Project. These are as follows: (1) (2) Type A - Combination chain-Link/Barbed Wire. Concrete Block with Concrete Posts and Rails Type B - Chain Link and Barbed Wire with Concrete Posts and Rails.
The two types of fencing are depicted on Drawing FS001, a part of this specification. The combination concrete block and chain link fence, Type A, shall be used on the perimeter fence around the entire unit. The chain link barbed wire fence shall be used for the fencing separating the process area from the utility area.
4.0 4.1
FABRICATION General All steel material shall be hot-dipped galvanized steel. All top rails, bottom rails, brace rails, and gate frames shall be galvanized Schedule 40 carbon steel pipes as specified in ASTM A120. Caps shall be furnished for all posts. End rails and corner connections shall be provided at posts for the connection of rails. Zinc coating shall be smooth and relatively free of lumps, globs, or points. Miscellaneous material shall be galvanized as specified in ASTM A123 and A153. Weight of coating shall be tested as specified in ASTM A90 and A239.
4.2
Fabric Fabric shall be made from No.10 gauge, basic open-hearth steel. Steel wire shall have minimum silicon content of 0.10%. Fabric shall be woven in a 5-centimeter chain link diamond mesh. Top and bottom salvages shall be twisted and barbed. Galvanizing shall be done after
PAGE 4 OF 7
weaving as specified in ASTM A392, Class I. The final coating of the fencing shall be paint in colors that shall be specified by the Company. 4. 3 Posts Column 150-mm square shall be used for line posts. Column 150-mm square shall be used for end, corner, angle and intermediate braced posts. The following shall be used for gateposts:

Use 150-mm square columns for openings up to 2 meters. Use 200-mm square columns for openings up to 4 meters. Use 250-mm square columns for openings up to 5.5 meters.
4.4
Gates Nominal 1-1/2 OD pipe shall be used for gate frames. Nominal 1-1/2 OD pipe shall be used for diagonal bracing. Full height vertical members at 3 meters maximum spacing shall be provided with bracing between the vertical members. Gate frames shall be of all-welded construction and shall be welded before galvanizing. All vertical members shall be extended 0.3 meters above the top rail and shall be provided with 3 strands of barbed wire.
4.5
Braces 1-1/2 OD pipe shall be used for horizontal brace rails and bottom rails at posts requiring bracing.
4.6
Tension Wire No. 7 gauge galvanized spring coil steel wire of good commercial quality shall be used for tension wires at the bottom of all fence fabric.
4.7
Barbed Wire Barbed wire made from two strands of galvanized, twisted; Number 12-gauge carbon steel wire shall be used. It shall be galvanized as specified in ASTM A121, Class 1.
4.8
Extension Arms
PAGE 5 OF 7
Extension arms shall be dual-type for four (4) strands of barbed wire. The topmost strand shall be 0.3 meters above the top of the fabric and 0.3 meters out at a 60-degree angle. 4.9 Miscellaneous Materials Galvanized malleable wrought iron or pressed steel shall be used for fittings and miscellaneous materials. 4.10 Concrete Blocks Concrete block shall be used for the style of fence as shown on the Fencing Drawing 20715-FS-001 in this document. The type of block used shall be architectural grade block for industrial use. Specifications shall be made by the Contractor and submitted to the Company for approval for the materials and fabrication of the concrete blocks. The type of block used on the project is a solid design with no holes. The size of the concrete blocks and number of courses and width of sections shall be as shown on the Fencing Drawing.
5.0
INSTALLATION The fence shall be erected so that it is plumb, taut, true to line and grade, and complete in all detail. It shall be staked down where required. The outside face of fabric shall be located 0.5 meters inside of the property line where the fence runs along the property boundary. In ungraded areas, the fence shall follow the existing ground line. Minor irregularities shall be removed or filled by grading 0.6 meters on each side of the fence. Bottom of fence shall be within 5 centimeters of finished grade line. Changes in line where the angle of deflection is 20 degrees or more shall be considered as corners, and corner posts shall be installed. All end, corner, angle, and gateposts shall be braced. Line posts shall be braced in both directions at intervals not to exceed 100 meters. Maximum spacing of line posts shall be 3.0 meters. All posts shall be made of reinforced concrete. Concrete columns shall be plastered and painted. Reinforcement shall be steel 1-1/2 OD pipe for the Type B.- Chain Link and Barbed Wire.
PAGE 6 OF 7
Line, end, pull, corner, angle and 75 mm gateposts shall have 750 mm square concrete spread footings. Rails, bracing, and couplings shall be installed before the fabric is installed. The tension wire shall be installed before stretching the fabric.
PAGE 7 OF 7
S-003
ROADS AND PAVING CRITERIA
2 1 0 Rev
4/08/05 9/06/00 31/3/00 D/M/Y
TWC TPT TPT By
RW SWK SWK Chk
WB JN JN Appr
PAGE 1 OF 8
ROADS AND PAVING CRITERIA TABLE OF CONTENTS 1.0 2.0 SCOPE RELATED CODES, STANDARDS AND SPECIFICATIONS 2.1 2.2 3.0 Standards and Specifications Related Project Specifications
GEOMETRIC DESIGN INFORMATION 3.1 3.2 3.3 3.4 3.5 3.6 Road Classification Design Speed Grade Limitation Minimum Radii Horizontal and Vertical Clearances Lane and Shoulder Widths
4.0 5.0 6.0 7.0 8.0 9.0 10.0
PRIMARY ROADS SECONDARY ROADS SERVICE ROADS ACCESSWAYS PARKING AREAS AREA PAVING DESIGN DETAILS 10.1 10.2 10.3 Subgrade Flexible Pavements Rigid Pavements
1.0
SCOPE
PAGE 2 OF 8
This specification establishes general design requirements for roads and paving. Extent of work shall be covered by project Design Criteria, Design Basis and as reflected by the project drawings. This document is not intended for use as a construction specification.
2.0
RELATED CODES, STANDARDS AND SPECIFICATION 2.1 Standards and Specifications Structural design of pavements shall be in accordance with applicable sections of the following documents: Specification for Highway Construction, Department of Highways, Ministry of Communication Thickness Design for Concrete Pavement, Portland Cement Association. Joint Design for Concrete Highway and Street Pavement, Portland Cement Association Thickness Design, Asphalt Pavement Structures for Streets and Highways, The Asphalt Institute Construction Specifications for Asphalt Concrete (SS-1), The Asphalt Institute Standard Specifications for Highway Bridges. The American Association of State Highway Official (AASHTO), Current edition. 2.2 Related Project Specifications M-001 - Structural Design Loads and Criteria S-001 - Site Civil Design Criteria
3.0
GEOMETRIC DESIGN INFORMATION 3.1 Road Classification
PAGE 3 OF 8
The following road classifications shall be used for the design of roads within the plant site. Primary Road - A main traffic arterial or a tanker truck or semi-trailer truck route. Secondary Road - A road subjects to regular operational or maintenance traffics but not subjects to high traffic volume. Service Roads - A road which serves remote areas or provides access for fire-fighting equipment. Access ways - A road or distinctly delineated traveled way which provides access to equipment in congested areas. 3.2 Design Speed Geometric design of roads within plant limits shall be based on the following design speeds. Primary Roads for semi-trailer truck traffic - 50 km/h Other Primary Roads - 40 km/h Secondary Roads - 30 km/h Service Roads - 25 km/h Passing sight distance shall not be used as a limiting design criterion.
3.3
Grade Limitations
Maximum
Minimum
PAGE 4 OF 8
OLEFINS PLANT I & II EXPANSION PROJECT
Primary Roads Secondary Road Service Roads Access ways (Ramps) Parking Areas Area Paving
5.0% 7.5% 10.0% 10.0% 5.0% 3.0%
flat 1.0%
3.4
Minimum Radii Minimum radii to edge of paving or surfacing for 90 intersection. Primary roads for semi-trailer truck traffic - 12 m Other primary roads and secondary roads - 4.6 m Service roads and access ways - 3.1 m
3.5
Horizontal and Vertical Clearances At roads without raised curbs a horizontal clearance of 1 m shall be maintained between the edge of paving, or traveled way in the absence of paving, and any structure projecting above shoulder grade. However, for guard rails and traffic signs the minimum horizontal clearance shall be 0.6 m from edge of paving or traveled way. At roads with raised curbs the minimum horizontal clearance shall be 0.6 m from the face of curb. Required vertical clearances for the applicable road classification shall be maintained for the roadway width plus 0.6 m from edge of paving or traveled way. Minimum vertical clearance over primary roads shall be 4.6 m; over other roads it shall be 3.7 m.
3.6
Lane and Shoulder Widths
PAGE 5 OF 8
Minimum lane and shoulder widths shall be as listed below. Shoulder and/or gutter widths shall be added to the lane widths to obtain minimum roadway widths. All roads are two lanes.
Classification Entrance Road In-Plant Road
Lane Width 5.8 m 3.4 m
Shoulder 1.2 m 0.9 m
4.0
ROADS 4.1 Roads shall be designed for AASHTO H20-Sl6 wheel loading. All roads shall be paved using either concrete or hot-laid plant mixed asphalt surfacing. As specified on project contract. Structural design of pavement shall be based on stabilometer R value and expansion pressures, CBR values, or local practice.
4.2
5.0
PARKING AREAS 5.1 5.2 Parking areas serving cars or light trucks only shall be surfaced with 150 mm of gravel road base material. Parking areas serving H10 or heavier trucks shall have a pavement structure equal to the road(s) serving the parking area. Concrete paving shall be used in areas subject to excessive hydrocarbon spillage. Automobile parking lot layout shall be based on the following minimum dimensions. Parking stall: width = 2.7 m and length = 5.8 m. Driveway widths for various angles of parking shall be 90 = 7.3 m; 60 = 5.5 m; 45 = 4.0 m.
5.3
6.0
AREA PAVING
PAGE 6 OF 8
Area paving is provided around or beneath equipment as specified in Project Specification S-001. 6.1 Flexible pavement shall be used in open areas and concrete paving shall be used in congested areas or areas subject to drips or spills harmful to asphalt. Areas used by mobile equipment shall be designated as access ways. In operating areas paving shall be divided into areas of 25m x 25m maximum size and sloped to catch basins set 150 mm. below high point of finish grade. Operating areas shall not drain into areas beneath pipe ways. Graveled or unsurfaced areas shall not drain across paving in operating areas. For reinforced concrete pavement not subject to wheel loads 100mm. thick pavement reinforced with welded wire fabric shall be used. Concrete pavement shall be provided at shell and tube exchangers or pumps, etc where hydrocarbon spillage occurs during maintenance operations is expected. Pavement shall extend a minimum of 1.8 m into the bundle pulling areas as measured from the center of channel. Parallel pumps or exchangers may have common curbed area with valve box, drained to oily water sewer system. Graded areas not indicated as being paved on the drawings, and not required by the specifications to be paved, shall be constructed as indicated on the drawing, but shall receive not further surface treatment. Contraction joint spacing in concrete paving shall not exceed 6.0 m unless otherwise noted on the drawing.
6.2
6.3 6.4
6.5
6. 6
7.0
DESIGN DETAILS 7.1 Subgrade General guidelines for subgrade preparation are given in project specification S-001. Final construction of subgrade shall be based on the project geotechnical report.
PAGE 7 OF 8
7.2
Flexible Pavements Construction of flexible pavements shall consist of hot-laid asphaltic concrete, crushed rock base and soil aggregate over compacted subgrade. The design thickness is dependent upon load requirements. However, as a minimum, the pavement thickness should consist of the following:

150 mm thick asphaltic concrete 150 mm thick crushed rock aggregate base 150 mm thick soil aggregate subbase
Materials and construction shall be in accordance with the codes and standards referenced in section 2.0 and in project specification M-001. 7.3 Rigid Pavements Rigid pavements are recommended over flexible pavements where possible due to site climatic conditions. Rigid pavements shall be constructed from concrete with a minimum 28 day compressive strength of 210 kg/cm2 reinforced with 12-mm diameter rebar (minimum). The design thickness is dependent upon load requirements. Materials and construction of reinforced concrete pavement shall be in accordance with the codes and standards referenced in section 2.0 and in project specification M-001.
PAGE 8 OF 8
W-001
WELDING
2 1 0 Rev
8/08/05 9/06/00 30/03/00 D/M/Y
Corporate Specification Issue for ITB Issue for review Description of Revision PM PM By
RW SWK SWK Chk
WB JN JN Appr
SPEC. NO. W-001 REV.2
PAGE 1 OF 9
WELDING TABLE OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 SCOPE CODES AND STANDARDS WELDING PROCESSES RESTRICTIONS WELDING ELECTRODES PREHEAT AND INTERPASS TEMPERATURE POSTWELD HEAT TREATMENT WORKMANSHIP, VISUAL QUALITY EXAMINATION AND INSPECTION WELDING PROCEDURES NONDESTRUCTIVE EXAMINATION
1.0
SCOPE
PAGE 2 OF 9
This specification covers welding, nondestructive examination and other fabrication requirements.
2.0
CODES AND STANDARDS 2.1 All welding and other criteria covered by this specification shall be in accordance with the following Codes and/or Standards.
2.1.1
ASME Boiler and Pressure Vessel Code Section I, II, IX and VIII, Division 1 and 2. ASME Code Section V, Non-Destructive Examination. ASME Code for Pressure Piping B31.1 and B31.3. API 620 Recommended Rules for Design and Construction of Large Welded, Low Pressure Storage Tanks. API 650 Welded Steel Tanks for Oil Storage. AWS D1.1 Structural Steel Welding Code. API 653 Tank Inspection, Repair, Alteration, and Reconstruction
2.1.2 2.1.3 2.1.4
2.1.5 2.1.6
2.1.7 3.0
WELDING PROCESSES 3.1 The following welding processes are permitted, provided satisfactory evidence is submitted that the procedure is qualified in accordance with all applicable Codes, Standards and job specifications: 3.1.1 3.1.2 3.1.3 Manual Shielded Metal-Arc (SMAW), with covered electrodes. Gas Tungsten-Arc (GTAW), manual, machine, and automatic. Automatic Submerged-Arc.( SAW )
3.2 Other welding processes may be considered providing: 3.2.1 3.2.2 The process effectiveness can be proven and prior Company approval is obtained. The required quality control program and post-weld heat treatment are approved by the Company. Information submitted shall include
PAGE 3 OF 9
the extent of nondestructive examination and all inspection techniques employed throughout production
4.0
RESTRICTIONS 4.1 All welding processes shall be protected from wind, rain and other harmful weather conditions which may affect weld quality. 4.2 Welding techniques shall be selected to ensure specified tolerances for straightness and out-of-roundness are not exceeded. 4.3 Permanently installed backing rings or strips shall not be used without the Companys prior written approval. 4.4 Peening shall not be used without the Companys prior written approval. The use of pneumatic tools for slag removal is not considered peening and is acceptable. An argon or helium internal purge shall be used for Gas Tungsten-Arc root pass welding of P-5 and higher alloys except that nitrogen may also be used for austenitic stainless steels, copper and copper based alloys. P-1, P-3 and P-4 steels may be welded with or without an internal argon purge. For aluminum or titanium butt joints welded from one side only, the root pass shall be made by the Gas Tungsten-Arc or Gas Metal-Arc process. Low interstitial ferritic stainless steels shall be welded by the Gas TungstenArc process, except when the filler material is austenitic stainless steel or a nickel base alloy, then the SMAW process may be used. For clad steels, the following limitations apply: 4.7.1 Cladding shall be stripped back a minimum of 6.5 mm from the edge of base material bevels by machining or grinding, not flame or arc-gouging. Removal of the cladding shall not reduce the base materials thickness below the design thickness. A minimum radius of 1.60 mm shall be used at the limit of cladding removal unless the clad material is beveled at least 30 degrees.
4.5
4.6
4.7
4.7.2 4.7.3
PAGE 4 OF 9
4.7.4
Preparation of local repair cavities in overlay welds that penetrate into the base material more than 10% of its thickness shall have the base material re-welded with the proper welding procedure consistent with the base metal before completing the overlay repair.
4.8
All completed weld joints shall be within the mechanical property limits specified for the materials to be joined unless otherwise approved in writing for special applications. Weld bevel preparations for P-5 and higher alloys shall be machined or ground back to bright and sound metal if flame or arc cut. At least 1.6 mm shall be removed.
4.9
4.10 All surfaces to be welded shall be free of scale, oil, grease, dirt, and other harmful agents. 4.11 Welded joints shall be made by completing each weld layer before succeeding layers are deposited. Block welding is prohibited unless prior written approval is obtained. 4.12 For ASME Section VIII, Process Vessels, all vertical welding shall be done vertical up. 4.13 If protective coating is to be used on surfaces to be welded, they shall be included in the welding procedure. Qualification tests for the brand formulation and maximum thickness of coating to be applied.
5.0
WELDING ELECTRODES 5.1 Unless specifically waived by the Company, all Shielded Metal-Arc welding, on ASME Section VIII Pressure Vessels, shall be done using low-Hydrogen type electrodes. E6010 electrodes may be used for the root pass only on ASME B31.3 Code piping, and API-650 atmospheric tanks, provided that: 5.1.1 Use is for P-1 material only. 5.1.2 The second pass, using Low Hydrogen filler, is started no less than 3 minutes after completion of the root pass. 5.2 Electrode classifications E6012, E6013, E7014 and E7024 shall not be used for welding of pressure-retaining parts of Pressure vessels and
PAGE 5 OF 9
piping. E6012 may be used on atmospheric tanks for fillet welding of bottom plate lap joints, and shell to bottom plate connections, provided the material thickness is 12.7 mm maximum and the material is Group I, II or III per API-650 requirements. 5.3 For Gas Tungsten-Arc Welding of P-1 steels, the filler metal shall meet the chemical and physical test requirements of ASME SFA-5.18, Classification ER70S-2, ER70S-3 or ER70S-6. For Flux Cored-Arc Welding of P-1 steels, the electrodes shall conform to ASME SFA 5.20, Classification E70T-1 or E70T-5 and shall be used with an external shielding gas. The receipt, use, disbursal and retrieval of all welding filler metals shall be maintained under strict control. The storage, baking and drying of Low Hydrogen, shall be per AWS D.1.1, paragraph 4.5.2, Low Hydrogen Electrode Storage Conditions, and paragraph 4.5.4, redrying Electrodes, Table 4.6 Stainless Steel coated electrodes shall receive the same treatment as Low Hydrogen Electrodes. Cellulosic and rutile coated electrodes shall be held at ambient temperatures, protected from dampness. All others should be handled as recommended by the manufacturer.
5.4
5.5
6.0
PREHEAT AND INTERPASS TEMPERATURE (P&IPT) 6.1 P&IPT shall be in accordance with the applicable codes and their latest addenda except those recommended minimums preheat temperatures shall be considered mandatory under this specification. In addition to governing code requirements, P-1 steels shall have a Preheat of 93C minimum for material over 38 mm thickness. The maximum interpass temperature for austenitic stainless steels and nickel alloys shall be 177C.
6.2 6.3
7.0
POSTWELD HEAT TREATMENT (PWHT) 7.1 PWHT for pressure vessels shall be in accordance with the ASME Code (Paragraphs UCS-56, UCS-85, UHA-32 and UW-40 of Section VIII, Division 1) with the following exceptions:
PAGE 6 OF 9
7.1.1 7.1.2
A minimum of 680C on P-4 and P-5 materials is required. For P-6 materials, the nominal PWHT temperature used shall be not more than 780 and the material shall be checked to assure Brinell Hardness does not exceed 241. Exothermic heat treatment is prohibited.
7.2 7.3 7.4
PWHT of pressure piping and furnace tubes shall be in accordance with Paragraph 331.3 of ASME B31.3 and applicable code cases. PWHT of power piping shall be in accordance with Paragraph 131.3 or 133 as applicable of ASME B31.1. For P-1 material, When the Code specifies only a minimum PWHT temperature, the maximum PWHT temperature shall not exceed the specified minimum by more than 650C. Sufficient thermocouples shall be properly attached so as to accurately indicate metal temperature in all areas of vessels and piping during PWHT. Direct impingement by torch or furnace burner heating is not permitted for PWHT.
7.5
7.6
8.0
WORKMANSHIP, INSPECTION 8.1
VISUAL
QUALITY
EXAMINATION
AND
Each weld shall be uniform in width and size throughout its full length. Each layer of welding shall be smooth and free of slag, inclusions, cracks, porosity, lack of fusion and undercut; except to the extent permitted in the referenced Codes. In addition, the cover pass shall be free of coarse ripples, irregular surface, non-uniform bead patterns, high crown and deep ridges or valleys between beads. Butt welds shall be slightly convex, of uniform height and have full penetration, unless otherwise specified and permitted in the applicable Codes. For piping, limitations on weld reinforcement shall apply to the internal surface as well as the external. Fillet welds shall be of the specified size with full throat and legs of uniform size.
8.2
8.3
PAGE 7 OF 9
8.4
Repair of welds by chipping, grinding or gouging shall be done in such a manner as not to gouge, groove or reduce the adjacent base-material thickness. For P-3, P-4 and P-5 alloy steel, Removal of defects shall be verified by NDE before repair is started. Repair welding shall be done only by qualified welders using qualified procedures. All vessel and heat exchanger overlay welds and tube-to-tube-sheet welds shall be liquid-penetrant examined. For overlay welds, this shall be done after final machining and postweld heat treatment when machining and/or postweld heat treatment is required. Tube-to-tube sheet welding shall meet the requirements of specification. Clad vessels and heat exchangers shall have the inside surface of openings examined by an approved method, not deleterious to the cladding or overlay. All aluminum, titanium P-3, P-4 and P-5 alloy steel butt joints shall have the root side inspected by PT when possible. All arc strikes, starts and stops shall be confined to the welding groove. All groove welds shall be full penetration except as specifically allowed in the applicable code. All partial penetration weld joints shall be identified. The use of temporary welded attachments shall not be allowed any pressure vessels or piping unless approved by the company. Undercut shall not exceed the lesser of 0.8 mm or Code allowable on P-3, P-4, P-5 or other crack sensitive material.
8.5
8.6
8.7 8.8 8.9
8.10 8.11
9.0
WELDING PROCEDURES 9.1 Only Company approved welding procedure specifications (with welding procedure qualification records) in accordance with this specification shall be used for welding. Separate or inclusive procedures shall be submitted to the Company for repair welding. Weld maps are required from Manufacturer for review and approval by the Company.
9.2
PAGE 8 OF 9
10.0
NONDESTRUCTIVE EXAMINATION 10.1 NDE procedures shall be submitted by the Contractor to the Company for review and approval. These shall meet the requirements of ASME Section V.
PAGE 9 OF 9
THAI OLEFINS PUBLIC COMPANY LIMITED Corporate Specification
X-002
EQUIPMENT PRESERVATION
2 1 0 Rev
29/07/05 9/06/00 31/3/00 D/M/Y
CHM TS TS By
RW SWK SWK Chk
WB JN JN Appr
SPEC. NO. X-002 REV.2
PAGE 1 OF 11
EQUIPMENT PRESERVATION TABLE OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 SCOPE CODES AND STANDARDS APPLICATION PRESERVATIVES CORROSION PROTECTION MEASURES BEFORE SHIPPING CORROSION PROTECTION AT THE SITE STORE MEASURES AFTER TRANSPORT TO THE PLANT TRANSPORT PROTECTION OF MACHINES PROTECTIVE COVERS
1.0
SCOPE
PAGE 2 OF 11
This specification shall be applicable to the preservation of machinery and machine parts for the period of shipment, storage on the site and installation through startup. It applies to the types of machinery usually employed in process plants. This standard is intended to avoid damage to machines and machine parts by corrosion. It describes a minimum scope of protective measures but does not relieve the Contractors responsibility for proper preservation.
2.0
CODES AND STANDARDS There are no applicable national or engineering society standards referenced for this specification. This document refers only to practices followed during design, fabrication, and shipment to the plant. More detailed equipment specific requirements are to be included in project specifications to be developed by Contractor.
3.0 3.1
APPLICATION This standard shall be applicable to: Pumps Centrifugal compressors Reciprocating compressors Rotary compressors Steam turbines Gas turbines Centrifugal fans Gears Lube and seal oil units Combustion gas turbines Diesel engines
PAGE 3 OF 11
Hydraulic systems Machine elements Vessels Piping Instruments Valves and Fittings 3.2 This standard shall also apply to other machinery as stated in project specifications. If a supplier has special preservation requirements exceeding this standard, they shall be approved for application. They shall then be included in the shipping instructions and installation, operating and maintenance instruction manuals. The corrosion protection measures described in this standard are based on a period of 12 months between delivery and installation.
4.0
PRESERVATIVES Preservatives shall protect machinery and other items from corrosion by weather, perspiration and/or atmospheric vapors. Before application, check and consider the particular environmental conditions prevailing during transport and at the place of installation. Types of preservatives are described and examples of products given below. The preservatives listed in Table 1 and their application are examples. This shall not relieve the Contractor from any responsibility for proper preservation for the contractually agreed period.
5.0 5.1
CORROSION PROTECTION MEASURES BEFORE SHIPMENT General
PAGE 4 OF 11
All exchangers and vessels shall be shipped under inert gas pressure. Stainless steel shall be protected to prevent chloride attack during shipping by sea. The following measures shall be taken for all types of machines and other items as far as applicable. After all testing is completed, and before any preservation efforts are begun, all equipment shall be thoroughly dried. To be certain that all water is removed, the following steps shall be taken: a. b. c. d. Open all vent and drain valves. Remove pressure gauges, thermowells and other instrumentation. Open all in line valves; open and block all control valves. Blow all interior areas thoroughly dry with either instrument air or nitrogen (preferably heated). The inspector shall determine when the equipment is adequately dried.
Machine casing surfaces exposed to the product and all internals shall be preserved using a water-repellent preservative such as Type A. Before using the preservative, clarify whether this agent is compatible with certain process gases or steam. The following possibilities shall be checked:
The machine is temporarily operated with air for cleaning purposes, after using preservative Type A. Another preservative is more compatible with the process gas.
If preservative Type A cannot be used, this shall be stated by the Contractor in that machinery specification. If for process reasons machine internals cannot be preserved using preservatives Type A to C other measures shall be taken such as:
Filling with nitrogen under slight pressure and providing a check gauge. Insert a desiccant (e.g. Silica gel).
PAGE 5 OF 11
A procedure to remove the preservatives from the machine casing and all internals and other product-exposed parts shall be clearly described in the installation, operating and maintenance instruction manuals. Separately shipped rotors shall be treated with preservative Type B. Then they shall be welded airtight in plastic sheeting with a desiccant inside (e.g. Silica gel). All threaded holes in the machine casing shall be closed with threaded steel plugs. The flange faces are to be preserved with preservative Type B. Then the flange opening shall be closed as described in section 9 of this specification. Bare shaft parts outside the machine casing shall be protected by preservative Type C and additionally wrapped with aluminum-coated wax paper Type E. Mechanical seal casings with installed mechanical seal shall be preserved using preservative Type A. The above paragraph is also applicable to valves if the operating packing contains graphite. Stuffing-box packing shall be removed and shipped separately. In their stead graphite-free soft packing rings soaked in preservative Type A are to be inserted in the stuffing box. Casings of oil-lubricated bearings shall have the seal rings or sealing chambers sealed by water-repellent grease. 5.2 Oxygen Compressors For oxygen compressors of any type, preservation requirements of the machinery shall apply. 5.3 Reciprocating Compressors Piston and piston rods shall be shipped and stored separately. Exceptions to this (such as very small compressors) shall be approved by the Company before this work starts. Pistons shall be treated with preservative Type B and then made airtight in plastic sheeting together with a desiccant (e.g. Silica gel). Piston rods and crankshafts shall be protected with preservative Type C and, additionally, wrapped in aluminum coated wax paper Type E.
PAGE 6 OF 11
Piston-rod packing shall be shipped and stored separately. Cylinders and valve chambers shall be protected using preservative Type B. Openings shall be closed airtight by steel covers. Fixing by wire and plastic covers is not permitted. Pulsation dampers for lubricated compressors shall be sprayed with preservative Type A and closed airtight by a steel cover. Pulsation dampers for non-lubricated machines shall be filled with nitrogen under slight pressure, provided with a desiccant (e.g. Silica gel) and closed airtight. A pressure gauge shall be provided to control the over pressure. Pulsation dampers for oxygen compressors must be treated in accordance with paragraph 5.2. 5.4 Displacement pumps The plungers of plunger pumps with graphite-containing packing shall be removed and shall be protected with agent Type B or C. If internals are removed, they shall be protected by preservative Type B or C and wrapped in aluminum-coated wax paper Type E. The gear housings of proportioning pumps shall be filled with preservative Type A up to the crankshaft, if possible. Cylinders and valve chambers shall be protected using preservative Type B. 5.5 Combustion engines and gas turbines These machines shall be preserved in accordance with the requirements of the manufacturer. 5.6 Lube and seal-oil systems Oil systems are normally supplied as package units. The following measures shall be taken:
All connection flanges and holes shall be closed as per section 5.1 of this specification after the piping has been flushed with preservative Type A. Machines and accessories included in the oil system shall be treated in accordance with the machine-specific sections of this specification.
PAGE 7 OF 11
Oil tanks shall be treated with preservative Type B. After flushing the machines with nitrogen, bags with desiccant (Silica gel) shall be inserted and all openings closed airtight as described under section 5.1 in this specification. The manufacturer shall ensure that the preservative is compatible with the lube-oil and seal oil used later.
Lube and seal oil coolers shall be handled as follows: 5.7 Air Coolers At the completion of testing, all header plugs shall be removed. Header boxes and tubes shall be thoroughly cleaned with either hot, high-pressure water or steam and dried. After preservative is introduced, header plugs shall be reinstalled using new gaskets. All screwed openings shall be plugged using steel plugs and thread dope or tape. Flanges shall be covered with blind flanges using proper gaskets and full bolt sets properly tightened. The blind flange on one top nozzle shall be fitted with a 1-inch pipe coupling. The coupling will be fitted with a pressure gauge and pressurizing valve (with plugs). The cooler shall be pressurized to 100 kPa (or more) with dry nitrogen. The gauge shall be marked to show the pressure. All fittings shall be checked with soap solution to ensure that they are not leaking. 5.8 Shell and Tube Coolers Shell and tube lube and seal oil coolers shall be treated as above if the cooling medium is on the shell side. If the oil is on the shell side, the following steps shall be taken.
Before final assembly of the exchanger, the outside of the tubes and the inside of the shell shall be cleaned with either hot, high pressure water or steam. Special care shall be taken to remove any debris trapped around baffles. Shell side hydrotest water shall be filtered (20 microns). After hydrotest, the shell side shall be blown dry with warm air or nitrogen. After preservative has been introduced, the shell side shall be closed and pressurized as described under air cooler above.
5.9
Hydraulic systems
PAGE 8 OF 11
Hydraulic systems shall be protected as described under section 5.6 in this standard. Ensure that the preservative is compatible with the hydraulic fluid used later.
6.0 6.1 6.2 6.3
CORROSION PROTECTION AT THE SITE STORE The packing and preservation shall be checked for damage. Any damage to packing and/or preservation shall be repaired without delay. Machine interiors and bearing casings shall be checked for the presence of water (rain or condensation water). If water is noticed at drains, the protective covers shall be removed from the flanges and the interior shall be inspected. If necessary, the corrosion protection shall be renewed. Bearing casings shall be filled with appropriate preservative up to the bottom of the shafts if possible, and the rotors shall be turned over every 2 weeks if possible. Centrifugal pump casings shall be filled with preservative Type A as far as possible (bottom of suction nozzle).
6.4
6.5
7.0 7.1 7.2
MEASURES AFTER TRANSPORT TO THE PLANT After placing the machines on the foundations, the corrosion protection shall be regularly checked/renewed. Machine rotors shall be turned over weekly to redistribute the oil in the casing and bearing and prevent damage to the bearings due to standing (oxidation and friction corrosion). The interior of reciprocating compressor frames and of gears shall be checked monthly for condensation water and sprayed with preservative if necessary. Reciprocating compressor cylinders shall be inspected monthly through the openings in the valve chambers. Suction and discharge valves shall be kept in preserved condition in the site store until startup.
7.3 7.4
PAGE 9 OF 11
7.5
In addition to the measures stated above, the protection of machinery which is opened partially during installation (e.g. steam turbines, turbocompressors, reciprocating compressors, etc.) shall be decided on site. The protective covers on the flanges shall not be removed until startup. As the machines are particularly endangered during the pressure test of vessels and piping, blank slides shall be placed in front of the protective covers.
7.6 7. 7
8.0 8.1
TRANSPORT PROTECTION OF MACHINES Compressors and steam turbines If the machines are shipped with the rotors in place, clearance-free retaining bearings shall be installed instead of the original bearings. If rotor sagging and thus labyrinth damage may be expected, the rotor shall be shipped separately.
8.2
Pumps Care shall be taken to see that anti-friction bearings are protected against friction corrosion during ocean and rail transport. The pump rotors and drives shall be secured by radial bracing against micromovement of the anti-friction bearings. Axial bracing and securing the rotors against turning only is not sufficient.
8.3
Lube- and seal-oil systems The piping of these systems is particularly susceptible to fatigue fractures caused by transport vibrations. Therefore, attachments and internals (such as heating coils) must be especially well secured for transport. Oil pump rotors and drives shall be secured by radial bracing for ocean and rail transport (see section 8.2 of this standard).
PAGE 10 OF 11
9.0 9.1
PROTECTIVE COVERS General The protective covers described below shall be used to close flange openings of machinery, equipment and accessories such as coolers, filters, pulsation dampeners and piping. The protective covers shall prevent dirt and foreign matter from entering the engineered object after fabrication until connection of the piping on the site. This specification in no way restricts the responsibility for proper delivery. After test run and preservation, all flange openings of the equipment to be supplied shall be closed with protective covers and gaskets in accordance with this specification.
9.2
Flange cover design and installation Design A. B. Flange covers shall be made from steel plate. Minimum thicknesses are as follows:

To 4 6 through 12 above 12
4 mm 6 mm 8 mm
C.
Covers shall have the same diameter as a blind flange for the particular pipe size.
Installation A. B. Flange covers shall be bolted to flanges using a minimum of 4 bolts for sizes through 12 inch. Above 12 inch, 6 bolts shall be used. An elastomer gasket shall be installed between the flange and the flange cover. The material shall be compatible with the preservative used.
PAGE 11 OF 11

Guide Procedure of Piping

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Guide Procedure of Piping

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THAI OLEFINS PUBLIC COMPANY LIMITED

STRUCTURAL DESIGN LOADS AND CRITERIA

3/08/05 1/3/00 20/12/99 D/M/Y

TWC TPT TPT By

RW SWK SWK Chk

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

The metric system shall be used for all dimensions.

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

ASTM A276 ASTM A307 ASTM A320 ASTM A325

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

ASTM D2922 2.5

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

Loads 720 kg/m2 Actual load 350 kg/m2

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

STAIRWAYS AND LANDINGS

180 kg concentrated mass 100 kg vertical and horizontal

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

Stability Ratio 2.0 1.5 1.7

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

Cement (Type 1 unless noted otherwise) Aggregate

ASTM C150 ASTM C33

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

Admixtures Reinforcing bars

Welded wire fabric

Sulfate resistant cement shall be used in concrete for foundations/footings.

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

Unaffected by exposure to the service temperatures

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

SPEC. NO. M-001 REV.2

THAI OLEFINS PUBLIC COMPANY LIMITED

DESIGN BASIS FOR PIPERACKS, PIPEWAYS AND SLEEPERS