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April 2002
PIP STC01015
Structural Design Criteria
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES
In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
Practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these Practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.
This Practice is subject to revision at any time by the responsible Function Team and
will be reviewed every 5 years. This Practice will be revised, reaffirmed, or withdrawn.
Information on whether this Practice has been revised may be found at www.pip.org.
PIP will not consider requests for interpretations (inquiries) for this Practice.
PRINTING HISTORY
December 1998 Issued February 2002 Technical Revision
February 2002 Technical Revision April 2002 Editorial Revision
PIP STC01015
Structural Design Criteria
Table of Contents
5.1 Steel................................................. 10
1. Introduction .................................. 2 5.2 Concrete .......................................... 11
1.1 Purpose ............................................. 2 5.3 Masonry ........................................... 11
1.2 Scope................................................. 2 5.4 Elevator Supports ............................ 11
5.5 Crane Supports................................ 12
2. References .................................. 2 5.6 Allowable Drift Limits ....................... 12
2.1 Process Industry Practices ................ 2 5.7 Foundations ..................................... 13
2.2 Industry Codes and Standards .......... 2 5.8 Vibrating Machinery Supports.......... 13
2.3 Government Regulations ................... 4 5.9 Anchor Bolts .................................... 14
1. Introduction
1.1 Purpose
This Practice provides the structural engineer with engineering design criteria that
harmonize the structural design requirements of process industry companies and
engineering/construction firms into a single document.
1.2 Scope
These general criteria define the minimum requirements for the structural design of
process industry facilities at onshore U.S. sites. This Practice is intended to be used
in conjunction with PIP ARC01015, PIP CVC01015, PIP CVC01016,
PIP CVC01017, PIP CVC01018, and PIP ARC01016, as applicable.
2. References
When adopted in these criteria, the latest edition of the following applicable codes,
standards, specifications, and references in effect on the date of contract award shall be used,
except as otherwise specified. Short titles will be used herein when appropriate.
3. Design Loads
New facilities, buildings, and other structures, including floor slabs and foundations, shall be
designed to resist the minimum loads defined in ASCE 7, local building codes, and this
section. In addition to the loads in this section, other loads shall be considered as appropriate.
These loads shall include, but are not limited to, snow, ice, rain, hydrostatic, dynamic, upset
conditions, earth pressure, vehicles, buoyancy, and erection. Future loads shall be considered
when specified by the owner.
For existing facilities, actual loads may be used in lieu of the minimum specified loads.
3.2.4 Uniform and concentrated live loads listed in the table in Section 3.2.3 shall
not be applied simultaneously.
3.2.5 According to ASCE 7, concentrated loads equal to or greater than
1,000 pounds (4.5 kN) may be assumed to be uniformly distributed over an
area of 2.5 feet (762 mm) by 2.5 feet (762 mm) and shall be located to
produce the maximum load effects in the structural members. However, stair
treads shall be designed according to OSHA regulations or building code as
applicable.
3.2.6 Live load reductions shall be as permitted in ASCE 7. In addition, for process
manufacturing floor areas not used for storage, the live load reduction
permitted by ASCE 7 for lower live loads may be used.
3.2.7 The loadings on handrail and guardrail for process equipment structures
shall be according to OSHA 1910. The loadings on handrail and guardrail for
buildings and structures under the jurisdiction of a building code shall be
according to the building code.
agitators, piping, ladders, platforms, etc. Empty load also includes weight of
machinery (e.g., pumps, compressors, turbines, and packaged units).
3.3.2 Operating load (Po) is considered empty load plus the maximum weight of
contents during normal operation.
3.3.3 Test load (Pt) is empty load plus the weight of test medium contained in the
system. Test medium shall be as specified in the contract documents or by
the owner. Equipment and pipes that may be simultaneously tested shall be
included. Cleaning load may be higher than hydrotest load (e.g., cleaning
fluid is heavier than water).
3.3.4 Process equipment empty, operating, and test loads shall have the same load
factor as dead loads.
3.8.5 Friction loads shall be considered temporary and shall not be combined with
wind or earthquake loads. However, anchor and guide loads (excluding their
friction component) shall be combined with wind or earthquake loads.
3.8.6 For pipe racks supporting multiple pipes, 10 percent of the total piping
weight shall be taken as an estimated horizontal friction load applied only to
local supporting beams. However, an estimated friction load equal to
5 percent of the total piping weight shall be accumulated and carried into
pipe rack struts, columns, braced anchor frames, and foundations. Under
normal loading conditions with multiple pipes, torsional effects on the local
beam need not be considered since the pipes supported by the beam limit the
rotation of the beam to the extent that the torsional stresses are minimal.
Under certain circumstances, engineering judgement shall be applied to
determine whether a higher friction load and/or torsional effects should be
considered.
3.8.7 Pipe anchor and guide loads shall have the same load factor as dead loads.
Beams, struts, columns, braced anchor frames, and foundations shall be
designed to resist actual pipe anchor and guide loads. For local beam design,
consider only the top flange effective for horizontal bending unless the pipe
anchor engages both flanges of the beam. Internal pressure and surge shall
also be considered for pipe anchor and guide loads.
3.8.8 Estimated pipe friction loads (see Section 3.8.5) shall not be combined with
wind or seismic loads for the design of pipe rack struts, columns, braced
anchor frames, and foundations where there are multiple frames. However,
anchor and guide loads (excluding their friction component) shall be
combined with wind or seismic loads.
considered where applicable. Truck or crane loads shall have the same load factor as
live load.
4. Load Combinations
4.1 General
Buildings, structures, equipment, and foundations shall be designed for the
appropriate load combinations from ASCE 7, local building codes, any other
applicable design codes and standards, and any other probable and realistic
combination of loads.
5. Structural Design
5.1 Steel
5.1.1 Steel design shall be in accordance with AISC ASD or AISC LRFD
specifications. For cold-formed shapes, design shall be in accordance with
AISI specifications. Steel joists shall be designed in accordance with SJI
standards.
5.1.2 Steel design, including steel joists and metal decking, shall be designed in
accordance with OSHA 29 CFR 1926, Subpart R, to provide structural
stability during erection and to protect employees from the hazards
associated with steel erection activities. A brief summary of some the more
common requirements that effect steel design follows. (This is not an all
inclusive list):
a. All column base plates must be designed with a minimum of four
anchor bolts. Posts (which weigh less than 300 pounds [136 kg]) are
distinguished from columns and are excluded from the four-anchor bolt
requirement.
b. Columns, column base plates, and their foundations must be designed
to resist a minimum eccentric gravity load of 300 pounds (136 kg)
located 18 inches (450 mm) from the extreme outer face of the column
in each direction at the top of the column shaft. Column splices must be
designed to meet the same load-resisting characteristics as those of the
columns.
c. Double connections through column webs or at beams that frame over
the tops of columns must be designed so that at least one installed bolt
remains in place to support the first beam while the second beam is
being erected. Alternatively, the fabricator must supply a seat or
equivalent device with a means of positive attachment to support the
first beam while the second beam is being erected.
d. Perimeter columns must extend 48 inches (1200 mm) above the
finished floor (unless constructability does not allow) to allow the
installation of perimeter safety cables. Provision shall be made for the
attachment of safety cables.
e. Structural members of framed metal deck openings must be turned
down to allow continuous decking, except where not allowed by design
constraints or constructability. The openings in the metal deck shall not
be cut until the hole is needed.
f. Shear stud connectors that will project vertically from or horizontally
across the top flange of the member are not to be attached to the top
flanges of beams, joists, or beam attachments until after the metal
decking or other walking/working surface has been installed.
5.1.3 Unless otherwise required, all bolted structural connections shall be type-N
(bearing-type with threads included in a shear plane) with bolts in
conformance with ASTM A325.
5.1.4 All welded structural connections shall use weld filler material conforming
to AWS D 1.1 Section 3.3 (including Table 3.1) and have an electrode
strength of 58 ksi (400 MPa) minimum yield strength and 70 ksi (480 MPa)
tensile strength, unless otherwise required.
5.1.5 Structural steel wide-flange shapes, including WT shapes, shall be in
accordance with ASTM A992, unless otherwise specified. All other structural
shapes, plates, and bars shall be in accordance with ASTM A36/A36M, unless
otherwise specified.
5.2 Concrete
5.2.1 Concrete design shall be in accordance with ACI 318/318R. Concrete design
for liquid-containing structures shall also be designed in accordance with
ACI 350R.
5.2.2 Unless otherwise specified, all reinforcing steel shall be in accordance with
ASTM A615/A615M Grade 60 deformed. ASTM A615 Grade 60 plain wire
conforming to ASTM A82 may be used for spiral reinforcement. Welded wire
fabric shall conform to ASTM A185.
5.2.3 Reinforcement designed to resist earthquake-induced flexural and axial
forces in frame members and in wall boundary elements shall comply with
ASTM A706. ASTM A615 Grade 60 reinforcement is acceptable for these
members if (a) the actual yield strength based on mill tests does not exceed
the specified yield strength by more than 18,000 psi (retests shall not exceed
this value by more than an additional 3,000 psi), and (b) the ratio of the
actual ultimate tensile strength to the actual tensile yield strength is not less
than 1.25.
5.2.4 Precast and prestressed concrete shall be in accordance with the PCI Design
Handbook.
5.3 Masonry
Masonry design shall be in accordance with ACI 530/ASCE 5.
5.5.2 Vertical deflection of jib crane support beams shall not exceed L/225 (where
L = the maximum distance from the support column to load location along
the length of the jib beam when loaded with the maximum lifted plus hoist
load(s), without impact.
5.5.3 Lateral deflection of support runway girders for cranes with lateral moving
trolleys shall not exceed L/400 (where L = the span length) when loaded
with a total crane lateral force not less than 20 percent of the sum of the
weights of the lifted load (without impact) and the crane trolley. The lateral
force shall be distributed to each runway girder with due regard for the
lateral stiffness of the runway girders and the structure supporting the
runway girders.
5.5.4 Crane stops shall be designed according to manufacturers requirements or,
if not specified, for the following load:
2
F = W V /(2gTn)
where:
F = Design force on crane stop, kips (kN)
W = 50% of bridge weight + 90% of trolley weight, excluding
the lifted load, kips (kN)
V = Rated crane speed, ft/sec (m/sec)
2 2
g = Acceleration of gravity, 32.2 ft/sec (9.8 m/sec )
T = Length of travel (ft) of spring or plunger required to stop
crane, from crane Manufacturer, usually 0.15 ft (50 mm)
n = Bumper efficiency factor (0.5 for helical springs; see
manufacturer for hydraulic plunger)
5.6.2 Except as indicated in the following subsections, the allowable wind story
drift limits for occupied buildings shall not exceed H/200 (where H = story
height).
5.6.3 Allowable wind drift limits for pre-engineered metal buildings shall not
exceed H/80 (where H = building height).
5.6.4 Allowable wind drift limits for buildings with a bridge crane, which is
required to be in service even during hurricanes, shall not exceed H/400 or 2
inches (50 mm), whichever is less (where H = the height from the base of the
crane support structure to the top of the runway girder).
5.6.5 Allowable wind drift limits for buildings with bridge cranes that will not be
in service during hurricanes shall not exceed H/140 or 2 inches (50 mm)
whichever is less (see paragraph 5.6.4 for definition of H).
5.6.6 Allowable wind drift limits for process structures, and personnel access
platforms shall not exceed H/200 (where H = structure height at elevation of
drift consideration).
5.6.7 Allowable seismic drift limits shall be in accordance with ASCE 7.
5.7 Foundations
5.7.1 Foundation design shall be based on the results of a geotechnical engineering
investigation.
5.7.2 The minimum factor of safety for overturning caused by loads other than
seismic shall be 1.5.
5.7.3 The minimum factor of safety against sliding caused by loads other than
seismic shall be 1.5. Both friction and passive soil resistance, in accordance
with the geotechnical report, may be considered as resisting sliding.
5.7.4 The minimum factor of safety against overturning and sliding caused by
seismic loads shall be 1.0. For additional guidance, see Chapter 5 of ASCE
Guidelines for Seismic Evaluation and Design of Petrochemical Facilities.
5.7.5 The minimum factor of safety against buoyancy shall be 1.2.
5.7.6 Long-term and differential settlement shall be considered when designing
foundations supporting interconnected, settlement-sensitive equipment or
piping systems.