Академический Документы
Профессиональный Документы
Культура Документы
revision
date
prepared
checked
approved
changes
09.09.2009
signature
Schiebel
Salvatore
Dr. Roetzer
el.
el.
el.
Page 1 of 40
0 Contents
0 1 2 2.1 2.2 2.3 CONTENTS ................................................................................................................. 2 APPLICABLE DOCUMENTS....................................................................................... 4 DESCRIPTION OF THE TANK SYSTEM..................................................................... 5
TANK SYSTEM ........................................................................................................ 5 TANK DATA.............................................................................................................. 6 DESCRIPTION OF THE CONCRETE TANK STRUCTURE ..................................... 8 2.3.1 GENERAL........................................................................................................ 8 2.3.2 TANK BASE SLAB........................................................................................... 8 2.3.3 WALL ............................................................................................................... 8 2.3.4 RINGBEAM...................................................................................................... 8 2.3.5 ROOF .............................................................................................................. 9 2.3.6 MISCELLANEOUS........................................................................................... 9 2.3.7 TANK TEMPORARY ACCESS OPENINGS....................................................10 2.4 BOTTOM HEATING.................................................................................................10 2.5 TANK SETTLEMENT MONITORING.......................................................................10 2.5.1 REFERENCE POINTS....................................................................................10 2.5.2 INCLINOMETER SYSTEM..............................................................................10 2.6 PRE-STRESSING SYSTEM ....................................................................................11 2.6.1 TENDON LAYOUT..........................................................................................11 2.6.2 PRE-STRESSING OPERATION .....................................................................12 3 3.1 BASIS FOR ANALYSIS..............................................................................................14
DESIGN CRITERIA .................................................................................................14 3.1.1 ULTIMATE LIMIT STATE (ULS)......................................................................15 3.1.2 SERVICEABILITY LIMIT STATE (SLS)...........................................................15 3.2 DESIGN OF PRE-STRESSING ...............................................................................17 3.3 DESIGN CODES .....................................................................................................18 3.3.1 MATERIAL AND LOAD PARTIAL SAFETY FACTORS...................................18 3.3.2 SERVICEABILITY LIMIT STATE (SLS)...........................................................18 3.3.3 ULTIMATE LIMIT STATE (ULS)......................................................................18 3.4 MATERIALS ............................................................................................................19 3.4.1 CONCRETE....................................................................................................19 3.4.2 REINFORCEMENT .........................................................................................19 3.4.2.1 LOW TEMPERATURE (CRYOGENIC) REINFORCEMENT ....................19 3.4.2.2 NON CRYOGENIC REINFORCEMENT ..................................................19 3.4.2.3 PRE-STRESSING REINFORCEMENT ...................................................20 3.4.2.4 USE FOR CRYOGENIC REBAR.............................................................20
Page 2 of 40
APPLICABLE DOCUMENTS ...................................................................................36 GENERAL INFORMATION......................................................................................36 FLAT FOUNDATION CONCEPT .............................................................................37 4.3.1 SETTLEMENTS ..............................................................................................38 4.4 SETTLEMENT REQUIREMENTS............................................................................40
Page 3 of 40
1 Applicable Documents
Following documents are applicable or will be referred to: /1.1/ Geotechnical Investigation for Ruwais Refinery Expansion Project, NO.5578 Agreement NO.07-5578-F-1 Ruwais, Abu Dhabi, UAE S08000288 Factual Report Revision 2 /1.2/ Geotechnical Investigation for Ruwais Refinery Expansion Project, NO.5578 Agreement NO.07-5578-F-1 Ruwais, Abu Dhabi, UAE S08000288 Recommendation Report Revision 3 /1.3/ Ruwais Refinery Expansion Project Project Specification Addendum Design General Specification - Rotating Equipment-Minimum General Requirements Bechtel Document Number 25418-1000-3PS-M000-M0004 Rev. 1 /1.4/ Ruwais Refinery Expansion Project Project Specification Earthworks and Reclamation Bechtel Document Number 5418-1000-3PS-CG00-C0002 Rev. 3
Page 4 of 40
The tank consists of the following main components: a flat foundation a monolithic concrete outer tank, comprising a reinforced concrete base slab and a pre-stressed circular wall and a spherical concrete roof. The wall has a constant thickness. a ring beam on top of the wall a steel frame roof platform a self supporting, open top steel inner tank a suspended ceiling fastened to the roof insulation system mainly comprising of foamglas blocks on top of the base slab, perlite within the annular space between inner and outer tank together with a resilient blanket at the outer surface of the inner steel tank and fiberglass blankets on top of the suspended ceiling steel liner (vapor barrier) at the inner surface of the concrete tank a corner and bottom protection system (TPS) connected to the outer tank wall and extended between the foamglas layers of the tank bottom a settlement monitoring system a bottom heating system
Page 5 of 40
Page 6 of 40
Page 7 of 40
2.3.3 Wall
The outer cylindrical tank wall is made of pre-stressed concrete. The wall has a constant thickness of 0,80 m. The ring beam above the wall has a constant thickness of 1,20 m and a height of 2,50 m. The inner diameter of the cylindrical concrete tank is 67,00 m. The wall and ring beam are pre-stressed in vertical- and horizontal direction, see section 2.6.
2.3.4 Ringbeam
A roof ring beam of 2,50 m height and a thickness of 1.20 m completes the wall. The ring beam is made of pre-stressed concrete and of the same concrete quality as the wall. The function of the roof ring beam is to pick up the membrane forces of the domed roof structure. Therefore, the roof ring beam is horizontally pre-stressed. A walkway is located on top of the ring beam.
Page 8 of 40
2.3.5 Roof
The spherical roof is a concrete dome with an inner sphere radius of 67,00 m. Due to the given diameter of the cylindrical wall of 67,00 m the inner height of the sphere segment will be approx. 9,0m. All loads hanging above the inner steel tank - resulting e.g. from the suspended deck and its insulation - have to be supported by the roof structure. In addition, the pump wells will be suspended from the roof. The piping and pump platform consists of a steel frame structure with a steel grating floor on top. The platform is arranged on the outer part of the roof and supported by the roof shell and roof ring beam.
2.3.6 Miscellaneous
An inner pressure of maximum 105 mbarg will be applied during service of the tank (= design pressure). Between the concrete wall and the inner steel tank there is an annular space of 1,00 m. The reinforcement at the inner surface of the wall above the corner protection system, which is affected by cryogenic design temperatures of -48 C, shall be suitable for the applied temperature. The reinforcement at the outer surface of the wall, as well as for the base slab and ringbeam will be normal hot rolled high yield steel. The reinforced and pre-stressed concrete elements of the outer tank will be made of concrete with a minimum required 28 day characteristic strength acc. to section 3.4
Page 9 of 40
Page 10 of 40
Page 11 of 40
Page 12 of 40
Page 13 of 40
Page 14 of 40
Stability
- Earthquake SSE
Stability
Stability
Stability
Stability
No perforation
Page 15 of 40
Serviceability Limit State Performance Criteria - Construction phases Durability Stage Design Criteria maximum crack width: - overall structure: wlim = 0.30 mm - consideration of the reduced stiffness due to crack formation maximum crack width: - prestressed concrete wall sections: wlim = 0.20 mm - reinforced concrete sections of base slab and roof: wlim = 0.30 mm - consideration of the reduced stiffness due to crack formation pre-stressed concrete wall: remaining compression zone: - 10% of wall thickness, 100 mm - average compressive stress of 1 MPa within the residual compression zone - consideration of the reduced stiffness due to crack formation
- Hydrotest and pneu- Durability matic test pressure - Operation - Earthquake OBE
- Liquid spill
Liquid tightness (liquid tightness of the base slab and lower part of the wall by means of a corner protection system)
In case of a liquid spill it can be demonstrated that a residual compression zone in the wall of at least 100 mm and an average concrete compressive stress of about 1 N/mm2 within the compression zone can generally be maintained in the principle direction of pre-stress above the corner protection system. The crack width limitation and the residual compressive zone requirements are considered not to be applied to the worst-case consideration of inner tank spill in addition to OBE.
Page 16 of 40
Page 17 of 40
Page 18 of 40
3.4 Materials
3.4.1 Concrete
The following concrete qualities are proposed in accordance with project specifications. The characteristic strength is defined as 28-day concrete strength acc. to BS 8110
cube strength (BS 8110) 20,0 40,0 40,0 40,0 N/mm2 N/mm2 N/mm2 N/mm2
3.4.2 Reinforcement
3.4.2.1 Low temperature (cryogenic) reinforcement Reinforcement at the inner face of the wall, which is subject to cryogenic temperatures, shall be suitable for use at design temperature according to BS 7777-3:1993 6.3.4 at -50.0 C (Krybar -50 C). Characteristic strength (yield strength): 500 MN/m - Krybar -50 C (500 B acc. to BS 4449) 3.4.2.2 Non cryogenic reinforcement All other reinforcement is made of hot rolled high yield steel bars according to BS 4449 Characteristic strength (yield strength): Grade 500 (acc. to BS 4449 - 2005)
Page 19 of 40
3.4.2.3 Pre-stressing reinforcement Bundled strand tendons made of 7-wire super strands (0.6) according to DYWIDAG Prestressing System and ETAG 013 (European Technical Approval Guideline) with low relaxation shall be used. The system incl. strands and anchorages shall be suitable for cryogenic applications acc. to FIP reports 904/128:1982 and SR 88/2, June 1988. The steel for posttensioning tendons shall comply with ASTM A 416. Characteristic strength (yield strength): Nominal size: 3.4.2.4 Use for Cryogenic Rebar The tank is equipped with a corner protection system. The corner protection system made of steel is located at the inner face of the lower part of the concrete tank wall min. 5,0 m above the secondary base slab and further within the foam glass blocks of the bottom insulation. It ensures the liquid-tightness during the emergency situations of liquid spill and thus protects the outer tank concrete wall from direct contact with LPG in these areas. However, the inner face of the concrete wall above the corner protection is unprotected, thus in the case of liquid spill in direct contact with LPG. In order to ensure the structural integrity of the tank in this case, special precautions are required. 1860 MN/m 140 mm
Page 20 of 40
3.5.1 Calculations
In Fig. 3.5 a brief overview is given of the software to be used and of the results that will be obtained. Most of this software has been developed to analyze large and sophisticated structures and has been used for the design of LNG/LPG tanks constructed by DYWIDAG, e.g. LNG Tanks Brunei, LNG Tanks Inchon South Korea, LPG Tanks Abu Dhabi, LNG Tanks Oman, LNG Tanks Tongyoung South Korea, ALNG Train 4 Trinidad, LNG Tanks Sagunto Spain, LNG Tanks Bal Haf Yemen, Tombak LNG Project and LNG Tank Nynshamn Sweden. The software SOFISTIK will be applied for the design calculations, which have been used for previous LNG projects. NAFEMS benchmark tests have been carried out for the SOFISTIK software and are available.
Page 21 of 40
Page 22 of 40
SOFISTIK
dynamic analyses - earthquake
SOFISTIK
linear structural analysis of single load cases
Results (due to single load cases): axis- and non-axis-symmetrical settlement, deflections and linear sectional forces (based on axis-symmetrical geometry
SOFISTIK
superposition of linear sectional forces
Results (due to load combinations): superposed axis- and non-axis-symmetrical, settlement, deflections and linear sectional forces (based on axis-symmetrical geometry)
SOFISTIK
design of concrete sections
Constructiondrawings
SOFISTIK
non linear analysis
Results: axis-symmetrical deflections and sectional forces due to reduced stiffness, crack width, check of reinforcement temperature progress, strain, stress
CALCULATION BY FORMULA
Local impact by a flying valve
Page 23 of 40
Page 24 of 40
3.5.2.3 Non-Linear Analyses In operation and emergency cases in which the concrete is exposed to high tensile stresses e.g. due to extreme temperatures due to liquid spill or in emergency cases, non-linear effects of the concrete behavior caused by the reduced stiffness due to crack formation have to be taken into account. Contrarily to the linear elastic analysis, where the individual single load cases can be superposed, a non-linear analysis must be carried out for load combinations determined before. For non-linear calculations the reinforcement is an input and will be determined by the results of the linear calculation. If this quantity isnt sufficient to fulfill the requirements (stress, strain, crack width etc.), it has to be adjusted. The calculation of non-linear sectional forces is an iteration process, which will be performed by the selected computer program SOFISTIK. The FE-model corresponds to the one used for the linear elastic calculation.
Page 25 of 40
3.5.2.4 Seismic Analysis The model for the seismic analysis consists of an axis-symmetrical lumped mass system using acceleration response spectra as excitation input. The whole system is required to remain within the elastic range, no physical or geometrical non-linearity shall occur. The system considering the interaction of the outer concrete tank, the inner steel tank and the liquid will be modeled using a FE-model, called tuning-fork-system, consisting of beam elements and lumped masses. For this analysis also the software SOFISTK is used. The liquid will be assigned as lumped masses to the nodes of the inner tank. The distribution of the liquid masses will be done in a parabolic form. The impulsive and sloshing portions of the liquid mass are calculated according to API 620, Appendix L. The results of a response analysis are not depending on time, because overall results (i.e. maximum sectional forces) will be calculated using the SRSS (square root of the sum of the squares) combination method. Superposition with other (statical) loadings: The dynamic models provide global bending moments, shear and normal forces of twodimensional beams or one-dimensional springs. These sectional forces will be expanded to the three-dimensional shell model for superimposing with the statical loadings. The overall bending moments (due to horizontal excitation) are distributed acc. to a costype shape along the tank wall. From the overall shear forces (due to horizontal excitation) and normal forces (due to vertical excitation) individual accelerations for base slab, wall and dome are calculated corresponding to their ideal unit weights. The modal analyses are performed for the horizontal and vertical directions separately. The superposition of the maximum values shall be done by considering the more unfavourable of the following two combinations:
(1) 1.0 Fx + 0.3 Fz (2) 0.3 Fx + 1.0 Fz Fx (horizontal direction), Fz (vertical direction)
Page 26 of 40
Fig. 3.7 Tuning fork system (lumped mass model) for horizontal excitation
Page 27 of 40
Period
SSE [g]
0,038 0,041 0,070 0,094 0,094 0,094 0,094 0,083 0,055 0,041 0,021 0,009 0,005 0,003
2006 IBC
[sec]
0,00 0,01 0,10 0,18 0,20 0,30 0,88 1,00 1,50 2,00 4,00 6,00 8,00 10,00
Fig. 3.9 Spectrum acc. to 2006 IBC for site class D and return period of 2475 years
The shown spectrum is assumed to correspond with SSE. The OBE spectrum is scaled down by a factor of 1,5. Consequently, the horizontal PGA values are considered with 0,038 g for SSE and 0,025 g for OBE. The vertical PGA values are defined by project specification as 2/3*0,038 = 0,025 g for SSE and 2/3*0,025 = 0,017 g for OBE. For the preliminary design the following percentages of the critical damping are considered. The values are based on previous design experience and literature. OBE sloshing mass outer tank soil
Fig. 3.10 Critical damping
Note: Uplift during OBE/SSE is permitted if further performance and acceptance requirements specified for the project are met and provided that the foundation can withstand the resultant actions.
Page 28 of 40
3.5.2.5 Thermal models In principle two situations will be taken into account for the temperature analysis of the concrete tank: operation respectively spill situations and fire scenarios. Maximum and minimum ambient temperature profiles are considered as basis for the design for both situations. Besides the area of the base slab to wall connection onedimensional heat transfer dominates in wall as well as in base slab sections. In other areas than the corner protection system, a conventional calculation will therefore be performed using formulas published in the literature. In the wall to base slab connection area and on top of the corner protection system the influence of the two-dimensional heat transfer will be analyzed under spill condition using thermal finite element analysis in order to study the transition of the one-dimensional temperature gradient from the base slab to the wall sections and from the corner protection system to the unprotected wall. The structure is axis-symmetric. It is therefore sufficient to study the temperature distribution of a segment of the structure. The resulting temperature profiles will afterwards be transformed to the design models used for the operation and spill design calculations. The concrete outer tank and all insulation material layers located between the outer tank and the inner tank are considered for the determination of the temperature profiles. The steel plates (inner tank, secondary bottom and liners at the inner face of the concrete tank), however, will be neglected due to their high thermal conductivity. A constant LPG design temperature is considered at the inner face of the steel tank wall and of the steel tank bottom for the operations situations. In case of an LPG spill the LPG penetrates the perlite in the annular space and the cellular glass and sand layers above the secondary bottom plates. A constant LPG temperature is therefore taken into account at the inner face of the concrete wall, at the inner face of the corner protection system and on top of the secondary bottom plates for various spill conditions. Convection film coefficients are used to model the convective heat transfer between the outer face of the concrete wall and the surrounding air. The film coefficient depends on the air movement at the concrete surface. A film coefficient will be therefore not applied between the base slab and the soil. It will be assumed that an air movement will not occur there.
Page 29 of 40
3.5.2.6 Crack width calculation Control of cracking in flexural/tension members will be carried out acc. to BS 8110, part 2, section 3.8. Early age cracking is considered also acc. to BS 8110, part 2, section 3.8.
Page 30 of 40
Page 31 of 40
dc, de
Operation and Test Situation: dead weight of the tank structure concrete (density 2500 kg/m), inner steel tank, steel liners, suspended ceiling, steel roof and platform, insulation etc. horizontal pressure due to perlite fill temporary loads during construction phases and stress history where appropriate effects of predicted differential centre to edge soil settlements will be considered by the soil-structure interaction (spring elements in the static model) pre-stressing incl. losses due to creep, shrinkage and relaxation ambient temperature operation : max. ambient temperature min. ambient temperature Basic Wind Speed for use with ASCE 7 live load on roof: uniform distributed load live load on platform and access ways : hydro test of inner tank with water, test level: 16,0 m pneumatic test pressure: 1,25 x 105 mbarg according to API 620, app G LPG filling inner tank: H = 16,0 m design density minimum design temperature design max. internal pressure: +105 mbarg
lcons
ss
lpre
top
50,0 C 5,0 C 160 km/h 1,5 kN/m2 2,4 kN/m2 = 1000 kg/m3 13,125 kN/m2
A A D
lw lr
C C
lp ftest ptest
fLPG
B A B
pmax
Page 32 of 40
Emergency Situations eOBE operating base earthquake, pending depending on detailed site survey safe shut down earthquake, pending depending on detailed site survey leakage of inner tank at intermediate levels fsp liquid spill of inner tank, density tsp temperature liquid spill psp internal pressure due to liquid spill 125% missile impact (local effect): mass velocity impact diameter PGA: 0,025 g (hor.) PGA: 0,017 g (vert.) PGA: 0,038 g (hor.) PGA: 0,025 g (vert.) E E E E B 6,074 kN/m -48 C 13,125 kN/m2 50 kg 45,0 m/sec 100 mm 32,0 kW/m2 1 hour*
eSSE
fsp
limp
lvf
PRV- fire (acting on roof) maximum incident heat flux (concrete part) duration Fig. 3.11 Main loading values A B C D E
According to Project Specification, Doc. No. 25418-1000-3PS-MT00-M0004 According to Datasheet No. 25418-1041-MTD-MTD0-B0065 REV1 According to EN 14620-1 According to STRUCTURAL ENGINEERING DESIGN CRITERIA, 25418-1000-3PS-S000-C0001 Development of Preliminary 2006 IBC Design Ground Motion Estimates for the Takreer Refinery Project, Ruwais, Abu Dhabi
Page 33 of 40
LPG Spill lcons fLPG pma ftest ptes lp, l PE PR PE PE PE V V V V V d lpre lshr ss
3) 2)
lw V V
tvf E
taf E
1,4 0,9 1,4 Hydro test and pneumatic test 0,9 Operation phases + imposed load + wind Operation + OBE Operation + SSE Inner tank liquid spill Spill + OBE Blast wave Pressure relief fire Adjacent fire Impact of projectiles Only local effect 1) 2) 3) 1,4 0,9 1,4 0,9 1,05 1,0 1,05 1,0 1,0 1,0 1,05 1,0 1,05 1,0 1,05 1,0
1,2 1,0 1,2 1,0 1,2 1,0 1,2 1,0 1,05 1,0 1,05 1,0 1,0 1,0 1,05 1,0 1,05 1,0 1,05 1,0 1,2 0,0 1,2 0,0 1,05 0,0 1,05 0,0 1,0 0,0 1,05 0,0 1,05 0,0 1,05 0,0
1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0
1,6 0,0
1,2 0,0
1,6 0,0 1,6 0,0 1,6 0,0 1,6 0,0 1,05 0,0 1,05 0,0 1,0 0,0 1,05 0,0 1,05 0,0 1,05 0,0 1,6 0,0 1,2 0,0 1,2 1,3 0,0 1,05 0,0
1,0 1,05
1,0
1,0
1,0
PE = Permanent Load, V = Live Load, E = Emergency Load the soil settlements will be considered by the interaction of the structure and the soil (spring elements in the static model) Ptso and Pts will be applied
Page 34 of 40
ULS Abnormal
1,05
LPG Spill lcons fLPG pma ftest ptes lp, l PE PR PE PE PE V V V V V d lpre lshr ss
3) 2)
lw V V
1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0
tvf E
taf E
1,0
1,0 1,0 1,0 1,0 1,0 0,0 1,0 0,0 1,0 0,0
Hydro test and pneumatic test 1,0 Operation phases + imposed load + wind Operation + OBE 1,0 1,0
1,0 0,0
1,0 0,0
1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1) 2) 3)
PE = Permanent Load, V = Live Load, E = Emergency Load the soil settlements will be considered by the interaction of the structure and the soil (spring elements in the static model) Ptso and Pts will be applied
Page 35 of 40
ULS Abnormal
/1.3/
A factual geotechnical report describing the project area is available. An engineering geotechnical report is not available at present stage. A final engineering report for the tank area is required to finalize the foundation concept, especially a soil data report and a recommendation for the foundation by the geotechnical expert.
Page 36 of 40
Page 37 of 40
Page 38 of 40
thickness [m]
Es [kN/m]
70000
Page 39 of 40
Differential Settlement Limits 1 : 500 1 : 300 1 : 500 but not exceeding the maximum settlement limit calculated for tilt of the tank
The final design will be adjusted to the final engineering geotechnical report, which may lead to changes. If the above mentioned is confirmed by the final, still outstanding engineering report for tank area, the subsoil for the Tank foundation will be suitable for a flat foundation supported on engineering fill (tank pad) and keep the settlement requirements.
Page 40 of 40