Industrial TrainingReport2014-2015

Petrofac Engineering Services India (Pvt.) Ltd.ON

“DESIGN AND ANALYSIS OF PRECAST CONCRETE PIPE RACK”

FORMina Abdulla Refinery

Kuwait National Petroleum Corporation (KNPC)Kuwait

Guided By- P. Govinda Reddy

Designation - Senior Engineer (Civil & Structural)

Ankit Verma (A7615811061)

22

B.Tech. (Civil); 3 rd Year

33

DECLARATION

I hereby declare that the project work entitled “DESIGN AND ANALYSIS OF PRECAST CONCRETE PIPE RACK” is an authentic record of my own work carried

out at Petrofac, Gurgaon as requirements of eight weeks project for the award of degree of Bachelor of Technology in Civil Engineering, Amity

University Uttar Pradesh, Lucknow Campus, under the guidance of my project

mentor Mr. P. Govinda Reddy during May to July 2014.

Ankit VermaDated: 03-07-2014 B.Tech (Civil) (2011-15)

A7615811061

Certified that the above statement made by the student is correct to the

best of our knowledge and belief.

P. Govinda Reddy

44

Senior Engineer (Civil & Structural)

Petrofac Engineering Services India (Pvt) Ltd.

Gurgaon

ACKNOWLEDGEMENT

“A novice cannot do great tasks. Many great people contribute to completion

of his work directly or indirectly.”

Words fail me to express my sincerest gratitude to this esteemed

organization, which has conferred on us the privilege to pragmatically

convert our theoretical knowledge into practical viable experience. During

the course of my training at Petrofac, Gurgaon so many people have guided

me and I will remain indebted to them throughout my life for making my

training at Petrofac, Gurgaon a wonderful learning experience.

I would like to thank Mr. Ajay Malhotra, my project head, who gave me

opportunity to work in his department and guided me through my project time

to time. The exposure to the working of the industry that I have got here

would not have been possible without his kind support.

In the end I would like to thank Mr. P. Govinda Reddy, Mr. Manish Jain,

Mr. Sandeep and others for providing me the opportunity to add a new

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dimension in my knowledge and helping me throughout my training period by

getting trained in this esteemed organization.

Ankit Verma

B.TECH (Civil) 2011-15

AMITY UNIVERSITY

TABLE OF CONTENTS

PAGE

1. INTRODUCTION ABOUT PETROFAC…………………………………………………………...... 06

2. INTRODUCTION ABOUT KNPC –MAB …………………………………………………………… 06

3. DEFINITION OF PIPE RACK……………………………………………………………………...... 06

4. PURPOSE……………………………………………………………………………………………… 06

66

5. REFERENCES…………………………………………………………………………………………. 06

6. INPUT DATA…………………………………………………………………………………………... 06

7. ASSUMPTIONS / CONSIDERATIONS………………………………………………………………. 06

8. MATERIAL……………………………………………………………………………….……………. 07..

9. DESIGN METHODOLODGY…………………………………………………………………………. 08

10. DIFFERENT PIPE RACK VIEWS…………………………………………………………..………….........12

a. As Modeled in STAAD Prob. Top viewc. Longitudinal view of pipe racksd. Transverse view of pipe rackse. Dimensions

11. LOAD APPLICATIONS…………………………………………………………………………….… 15

a. Dead loadb. Live loadc. Equipment loadd. Piping loade. Frictional loadf. Temperature loadg. Wind loadh. Seismic loadi. Crane (monorail) load

12. CONNECTIONS………………………………………………………………………………………….. 29

a. Bolted Moment Connectionb. Base Plate Design for pinned conditionc. RC Corbel designd. Precast Concrete column to Precast column connectione. Cast in situ concrete column to precast concrete column connection

13. DEFLECTION CHECK……………………………………………………………………………….…... 30

14. UTILITY RATIO CHECK………………………………………………………..…………………..…… 30

15. CONCLUSION………………………………………………………………..…………..………..……... 32

APPENDICES and ATTACHMENTS

77

ATTACHMENT-A Pipe rack plot plan and exchanger details (05 Sheets)

ATTACHMENT-B Wind Load Calculations(05 Sheets)

ATTACHMENT-C Seismic Load Calculations(09 Sheets)

ATTACHMENT-D Load Combination Calculations(02 Sheets)

ATTACHMENT-E Abbreviations(01 Sheets)

ATTACHMENT-F Base Plate Design for pinned condition(03 Sheets)

ATTACHMENT-G RC Corbel design(04 Sheets)

ATTACHMENT-H Precast Concrete column to Precast columnconnection (04 Sheets)

ATTACHMENT-I Cast in situ concrete column to precastconcrete column (04 Sheets)

Connection

ATTACHMENT–J GA Drawings(03 Sheets)

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DESIGN AND ANALYSIS OF PRECAST CONCRETE PIPE RACK

1. INTRODUCTION ABOUT PETROFAC:

Petrofac is a leading international service provider to the oil & gas production and processing industry. Petrofac designs and builds oil & gas facilities; operates, maintains and manages facilities and trains personnel; With more than 18,000 employees, Petrofac operates out of seven strategically located operational centers, in Aberdeen, Sharjah, Abu Dhabi,Woking(UK), Chennai, Mumbai, Delhi and Kuala Lumpur and has a further 24 offices worldwide.

2. MINA ABDULLA REFINERY : Kuwait National Petroleum Company, which aimed at upgrading and expanding the existing KNPC refinery at Mina Abdulla, Mina Abdulla Refinery Established in 1958, Located in southern Kuwait about ≈ 60 KM fromKuwait City, Occupies an Area of 7.9 sq. KM, Total refining capacity of this refinery will go up to 800,000 barrels per day.

3. PIPE RACK:

Pipe rack in a refinery plant supports mainly pipelines which include Process pipe lines, flare lines and utility lines.

Pipe rack is the main artery of any plant. This carries the pipes and cable trays (raceways) from one equipment to equipment within a process unit (called ISBL pipe rack) or carries the pipe and cable trays from one

99

unit to another unit (called OSBL pipe rack). Sometimes AIR COOLED HEAT EXCHANGERS also the part of pipe rack.

Continuous Pipe rack is essentially a system where multiple 2-dimensional (2D) frame assemblies (commonly called bents), comprised of twoor more columns with transverse beams, are tied together in the longitudinal direction utilizing beam struts (for support of transverse pipe and raceway elements and for longitudinal stability of the system) andvertical bracing to form a 3D space frame arrangement. Pipe racks supporting equipment such as air-cooled heat exchangers must utilize the continuous system approach.

4. PURPOSE

The purpose of this calculation is to analyze and design the Precast Concrete Pipe rack for Mina Abdulla Refinery (MAB-2) at Kuwait for Kuwait National Petroleum Corporations (KNPC).

5. REFERENCES

a. Steel Construction Manual 14th Edition - AISC 360-10b. Minimum Design Loads for Buildings and Other Structures - ASCE 7-10c. AISC Steel Design Guide 1 for Base Plate & Anchor Rod Designd. Building Code Requirements for Structural Concrete and Commentary -

ACI 318-11e. Engineering Design Guide - Wind & Earthquake – Attachment B & Cf. International Building Code - IBC 2012

6. INPUT DATA

Due to the “fast track” nature associated with most of the projects, often the final piping, raceway, and equipment information is not availableat initiation of the pipe rack design. Therefore, a Civil/Structural Engineer should coordinate with the Piping group, Electrical, Control Systems, and Mechanical groups to obtain as much preliminary information aspossible. When received, all design information should be documented for future reference and verification. In the initial design, the Engineer should use judgement when applying or allowing for loads that are not known, justifying them in the design basis under "Design Philosophy"

The following should be reviewed for design information: Plot plans and equipment location plans

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3D model showing piping layout, cable tray layout, and Pipe rack bent spacing and elevation of support levels in the transverse direction, Elevation of longitudinal beam struts and locations of vertical bracing. And location of pipe bridge, if any.

Piping orthographic drawings.

Vendor prints of equipment located on the rack, e.g., air coolers and exchangers. The vendor prints should include the equipment layout, mounting locations and details, access and maintenance requirements, and the magnitude and direction of loads being transmitted to the pipe rack.

Electrical and control systems drawings showing the routing and location of electrical and instrumentation raceways and/or supports.

Underground drawings that show the locations of buried pipes, concrete structures and foundations, duct banks, etc. in the area ofthe pipe rack.

Pipe rack construction material (Steel, Cast-in-situ concrete, Pre-cast concrete) shall be as per project design criteria.

Allowance and provision for future pipes is made for future addition of pipe and raceway as per inputs from respected departures.

The general input for this calculation is obtained from the FEED done by Flour Corporation and Updated by PIL Piping Discipline. All Load calculations and Load combinations done based on AISC-7-10 Petrofac Standard Practice and Design Guide.

7. ASSUMPTIONS/ CONSIDERATIONS

a. In the absence of any pipe load information, a uniform pipe load of 1.7 KN/m2 has been considered for operating condition in Pipe rack as per pipe rack design guide & standard practice.

b. The Live Load for the platforms and walkways has been considered as 5 KN/m2 & for Staircase as 5 KN/m2 as per KNPC MAB-1 Design Basis.

c. Wind load has been calculated based on provisions of ASCE 7-10. Basic Wind Speed is 45 m/s with Exposure Category “C” as per ProjectDesign basis. Wind Load on piping has been estimated by considering

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the piping as per KNPC Design Basis and applied on STAAD as a point load on transverse beam and as nodal load at effected Column beam junctions.

d. Snow load has is not applicable at this site.

e. Seismic loads are calculated based on provisions of ASCE 7-10. Seismic Design Category “B” with

Spectral response accelerations for short period and one second periods are Ss = 0.32g, S1 = 0.13g respectively and Importance Factor 1.25 as per Project Design Basis. For detail Seismic calculation, Refer Attachment C_Seismic Load.

f. Load Factors and Load Combinations for Serviceability and LRFD Design are considered in accordance with IBC 2012 section 1605 and ASCE 7-10, Chapter 2, Refer Attachment D_ Load Combination

g. Dead load of serrated grating has been considered @ 0.5 KN/m2.

h. Piping load has been applied as per loads provided by Piping Discipline.

i. Piping friction load has been considered @30% of Vertical load for framed supports only.

j. All the supports of pipe rack structure are considered to be fixed Base.

k. Slenderness factor for Major axis i.e. "Kz" for all the steel columns has been assumed as 1.2. Values of Lz and 1.0 for Ly in STAAD has been considered as applicable.

l. The "R" values for Pipe rack Steel structure are considered as 3.0.

m. Monorail capacity 10 KN is given by Mechanical as discussed and designed accordingly.

n. Based on Monorail Beam W18x45, Mechanical will purchase lifting hoist so that it will fit in to Monorail Beam flange as per requirement.

8. MATERIAL

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CONCRETE

Grade of Concrete shall be M30

Reinforcing steel shall be ASTM A615

STRUCTURAL STEEL

W Shape shall be of ASTM A992

Structural Bolts Shall be of ASTM A325N / A490N

Anchor Bolts shall be of ASTM F1554 (grade as reqd.)

Bracings shall be ASTM A992

Base Plate & Angle shall be ASTM A36

9. DESIGN METHODOLOGY

Kuwait is having three Refineries; Mina Abdulla Refinery is one of largest refinery in Kuwait. KNPC wants to expand their refinery capacity to1.2 million barrels per day, Total project is spitted into two parts, PIL, Samsung and CB&I won the MAB-1 consortium, Floor & Daewoo won MAB-2 projects, MAB-1 is holding units like CDU, HCR, VRU, DHT, NHT, HOC…etc.

All unit are having Pipe racks and needs fire proofing, so that precast concrete pipe rack is more economical by 30% than steel pipe rack and speedof construction is fast as compared to Cast in situ concrete Pipe rack.

This calculations dealt for HCR (Hydrocracker ) Unit only, The width of pipe rack 12m having three columns, i.e.; 2x6m=12m, and overall length of HCR (unit-114) pipe rack is 333.0m (North south rack=237.0m, East-west Rack=60m and fire heater connecting Rack= 3 x 12m=36m) .Pipe racks are carrying only process pipe lines, utility pipe lines & pipe lines for fired pre heater. All cables are passing through underground Trenches, So no need to consider any cable tray loads in pipe rack calculations.

For construction flexibility, foundation and column up to +2.7m from groundlevel considered as Cast–in situ concrete pipe rack, Level from +2.7m to

1313

+14.0m considered as Precast Concrete Pipe Rack and from +14.0m to +21.0m considered as steel pipe rack where fire proofing is not mandatory.

The pipe rack is Five tier rack with main Elevation levels (TOS) of Steel Pipe rack at +121.0m , Top of steel for PSV platform at +115m, Top of concrete beam elevations of fired preheated at+112.5m, Top of concrete beamElevation for utility piping at +110m, and Top of concrete beam elevation for Process Pipelines at +107.5m, & +105m.

Total Precast frame is divided into four modules as Module-1(Bottom Module), Module-2, Module-3 and Module-4(Top Module). Here Module-1and Module-2 has Frame Rack-1 and Frame Rack-2 respectively. At elevation +115.0m there is a PSV platform. As Module-2 and Module-3 is Intermediate Module.

The plan size of the Bottom Module is 3.3m x 12.0m (height from TOCi.e. EL+102.70m).

The plan size of the Intermediate Module is 2.5m x 12.0m and

The plan size of the Top Module is 3.0m x 12.0m (height).

The pipe rack shall be Concentrically Braced steel framed structure, supported on Isolated foundation. TheColumns have been considered as fixed but released moment along longitudinal direction at base.

The platform shall be designed for worst load combinations out from Primaryload cases mentioned below.

FRAMING OF CONTINUOUS/CONVENTIONAL PIPE RACK:

Frames:Main pipe racks are usually designed as moment-resisting frames in the

transverse direction. In the longitudinal direction, there should be at least one continuous level of beam struts on each side. For pipe racks withmore than one tier, the beam struts should be located at a level that is usually equal to one-half tier spacing above or below the bottom tier. Vertical bracing in the longitudinal direction should be provided to carry the longitudinal forces, transmitted through the beam struts, to the base plate / foundation level.

Transverse Beam:

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Transverse beams must be capable of resisting all forces, moments, andshears produced by the load combinations. Transverse beams are generally a moment-resisting frame, modelled and analysed as part of the frame system. The analysis model must reflect the appropriate beam end conditions. In thedesign of beams, consideration should be given to

• Large pipes that are to be hydro-tested.• Anchor and friction load with large magnitude

Central Spine:For steel pipe racks with spans of equal to or more than 6 m, a centre

spine consisting of a system of horizontal braces and struts located at midspan of each level of piping should be considered . This additional light horizontal framing greatly increases the capacity of the transverse pipe support beams to resist friction and anchor forces, and also serves toreduce the unbraced length of the beam compression flange in flexure and toreduce the unbraced length of the beam about the weak-axis in axial compression. This concept reduces the required beam sizes and provides a mechanism for eliminating or minimizing design, fabrication, or field modifications that could otherwise be required due to late receipt of unanticipated large pipe anchor forces.

For Precast Concrete Pipe racks with span more than 6m, Intermediate beam may be required for supporting small pipes (Less than 100mm) & Cable trays.

Longitudinal Beam Strut:For typical continuous pipe rack systems, the longitudinal beam struts should be designed as axially loaded members that are provided for longitudinal loads and stability. Additionally, the longitudinal beam struts that support piping or raceway should be designed for 50% of the gravity loading assumed for the transverse pipe or raceway support beams, unless unusual loading is encountered. This 50% gravity loading will account for the usual piping and raceway take-offs. Normally, the gravity loading carried by the beam struts should not be added to the design loads for the columns or footings since pipes or raceway contributing to the loadon the beam struts would be relieving an equivalent load on the transverse beams. For any continuous pipe rack system where the anticipated piping andraceway take-offs are minimal or none, the 50% loading criteria does not apply. In such cases, the beam struts should be designed primarily as axially loaded members. Do not provide beam struts if they are not needed for piping or raceway support, or for system stability. Conversely, the 3D model should be checked to verify that beam struts subjected to unusually large loads (such as at expansion loops) have been given special

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consideration. All longitudinal beam struts, including connections, should be designed to resist the axial loads produced by the longitudinal forces.When designing the longitudinal beam struts for flexural loads, the full length of the beam should be considered as the unbraced length for the compression flange.

Vertical Bracing:When moment-resisting frame design is not used in the longitudinal

direction, vertical bracing should be used to transmit the longitudinal forces from the beam struts to the foundations. Knee-bracing or K-bracing is most often used for this purpose. Unless precluded by equipment arrangement or interferences, bracing should be placed equidistant between two expansion joints. Design calculations and drawings must reflect a breakin the beam strut continuity between adjacent braced sections through the use of slotted connections or by eliminating the beam struts in the bays designated as free bays. The maximum length of a braced section should be limited to 48m to 50m. If the braced bay is not located equidistant from the free bays, the maximum distance from the braced bay to a free bay should be limited such that the maximum total longitudinal growth or shrinkage of the unrestrained segment does not exceed 40 mm.

Considered expansion joint at every 30m interval, consider long slotted holes for free expansion and contraction of structures for steel pipe racks & over sized holes at corbel beam connection joint for allowing free expansion and contraction due to pipe stresses & environmental stresses for precast concrete pipe rack.

Column:The columns must be capable of resisting all loads, moments, and

shears produced by the load combinations. A moment-resisting frame analysis should normally be used to determine the axial load, moment, and shear at points along the columns.

Primary Load cases considered for Precast Concrete Pipe rack:Load 1: DSW (Self weight)Load 2: DS (Dead surface) Not usedLoad 3: DFP (Cable Tray Load) Not usedLoad 4: DPE (Piping Empty)Load 5: DPO (Piping Operating-Content)Load 6: DPT (Piping Test-Content)Load 7: PAL (Pipe Anchor-Long)Load 8: PAT (Pipe Anchor-Trans)Load 9: LF (Floor Live Load)Load 10: LB (Live Bundle Pull)

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Load 11: DE (Equipment Empty)Load 12: DO (Equipment Operating)Load 13: DT (Equipment Test (Content)Load 14: PF (Thermal / Friction)Load 15: TR (Temperature Rise)Load 16: TF (Temperature Fall)Load 17: WX (Wind Long)Load 18: WZ (Wind-Transverse)Load 19: LB1 (Left Blank for Future) Not usedLoad 20: LB2 (Left Blank for Future) Not usedLoad 21: EX (EQ-Long)Load 22: EL (EQ-Trans)Load 23: PSVV (PSV Pop Up- Vertical) Not UsedLoad 24: PSVL (PSV Pop Up- Long) Not UsedLoad 25: PSVT (PSV Pop Up- Trans) Not UsedLoad 26: Crane (Left side)Load 27: Crane (Right side)Load 28: Crane (Parked) Not Used

Please Refer Attachment D_ Load Combination for load combination details.

The load combinations for serviceability and LRFD shall be as per Section 1605 of IBC 2012.

Analysis and Design of Steel frame shall be carried out in accordance with AISC LRFD using STAAD pro V8iSoftware. MathCAD, Version-15 and MS Excel 2010 are used to prepare calculations.

The entire design calculation as described above is presented in the subsequent pages.

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10. DIFFERENT PIPE RACK VIEWS

As modeled in STAAD pro

Load 14X

Y

Z

TOP VIEW

237.00m

12.00m

60.00m 12.00m

24.00m

249.00m

Load 21XY

Z

Longitudinal View

1818

28.00m

12.00m 237.00m

24.00m

Load 21X

YZ

Longitudinal View of North South Pipe Rack

237.00m

24.00m

Load 21X

YZ

Longitudinal View of East West Pipe Rack

60.00m

28.00m

6.00m 6.00m

Load 21XY

Z

Transverse View

Transverse View of East South Pipe Rack

1919

Load 28X

YZ

Transverse View of North South Pipe Rack

Load 28XY

Z

Dimensions

2020

6.00m

6.00m

6.00m

6.00m

6.00m

6.50m

2.50m

2.50m

2.50m

2.50m

1.50m

6.00m

5.70m

2.30m

2.50m

2.50m

2.50m

1.50m

7.00m

Load 21X

Y

Z

11. LOAD APPLICATIONS

DEAD LOAD

Self Weight of structure (Except weight of Grating and handrail) is automatically generated by STAAD pro based on member sizes and density provided. However factor of 1.1 has been provided to take care of loading due to connection’s weight. The weight of all structural members, includingfireproofing, should be considered in the design of the pipe rack.

Self weight of serrated grating has been applied @ 0.5KN/m2 (Considering Grating Bar of size 1-1/2" X3/16)

2121

-3.000 kN /m-3.000 kN /m

Load 1XY

Z

Dead Self Weight (DSW)

LIVE LOAD

Live load (L) on access platforms and walkways and on equipment platforms should be considered, as applicable.

Uniform live load on steel grating floor @ 5KN/m2 (As per Project Design Criteria)

Live Load on each beam = 5 KN/m2 x 6.0 m (Beam Span) = 30KN/m

Live Load

2222

-30.000 kN /m -30.000 kN /m

Load 9XY

Z

EQUIPMENT LOAD

Equipment weights, including erection, empty, operating, and test (if the equipment is to be hydro-tested on the pipe rack), should be obtained from the vendor drawings. The equipment weight should include the dead weight ofall associated platforms, ladders, and walkways, as applicable.

Special Loads: Special consideration should be given to unusual loads, suchas large valves, expansion loops, and unusual piping or electrical configurations.

Sr. No Equipment’sName

VendorDrawingNumber

Vendor Name Weight ofEquipment

Equipmentat

Elevation(m)

1 Air CooledHeat

Exchanger

307044(P-031)

S&TCORPORATION(SEOUL,

KOREA)

See belowTable-1 &

2

+121.00

Table-1(Exchanger Details)No. Item No. Uni

tBay Bun W(m) L(m) C(m) TW(m) TL(m)

Bay Bun1 114-E- 1 1 2 4.30 2.08 12.40 11.50 4.30 14.73

2323

01082 114-E-

01101 8 16 6.02 2.94 12.40 11.50 50.96 14.73

3 114-E-0111

1 1 1 3.65 3.65 12.40 11.50 3.65 14.73

4 114-E-0120

1 4 8 5.61 2.74 12.40 11.50 23.64 14.73

5 114-E-0121

1 4 8 6.24 3.06 12.40 11.50 26.16 14.73

6 114-E-0125

1 7 14 8.48 2.98 12.40 11.50 61.76 14.73

7 114-E-0126

1 1 1 3.04 3.04 12.40 11.50 3.04 14.73

8 114-E-0131

1 2 4 5.07 2.79 12.40 11.50 11.80 14.73

9 114-E-0134

1 6 12 6.24 3.06 12.40 11.50 39.44 14.73

10 114-E-0136

1 1 2 6.27 3.07 12.40 11.50 6.27 14.73

11 114-E-0140

1 3 6 5.00 2.43 12.40 11.50 15.80 14.73

12 114-E-0143

1 1 2 5.32 2.80 12.40 11.50 5.32 14.73

13 114-E-0145

1 3 6 6.17 3.02 12.40 11.50 19.31 14.73

14 114-E-0147

1 1 2 6.81 3.34 12.40 11.50 6.81 14.73

15 114-E-0151

1 1 1 1.97 1.97 3.90 3.00 1.97 6.23

Table-2(ExchangerDescription)No. Item No. Description Weight(Ton) Volume(CBM)

1 114-E-0108

Hot flash vapor condenser 28 111

2 114-E-0110

First stage hot separator vapor condenser

278 1098

3 114-E-0111

Ip condensate cooler 20 85

4 114-E-0120

Second stage hot separator vapor condenser

156 561

2424

5 114-E-0121

Stripper condenser 137 575

6 114-E-0125

Product fractionators bottoms cooler

528 1689

7 114-E-0126

Diesel pump around cooler 18 76

8 114-E-0131

Kerosene pump around cooler 70 270

9 114-E-0134

Product fractionators condenser

218 861

10 114-E-0136

Debutanizer condenser 34 146

11 114-E-0140

Naphtha splitter condenser 92 352

12 114-E-0143

Heavy naphtha product cooler

29 114

13 114-E-0145

Kerosene product cooler 111 432

14 114-E-0147

Diesel product cooler 49 180

15 114-E-0151

Flash Steam condenser 7 25

For exchanger plot plan please Refer Attachment A_Pipe rack plot plan and exchanger details.

It comprises of various loads:

Equipment Empty- It is in-situ weight of equipment along with internal piping, insulation and platforms, but excluding weight of fluids or products.

Load Calculation Example: -

Weight of 114-E-143 = 29 MT for 1 bays Each bay = 29/1 = 29 MT =290 KN Reaction on each column = 290/4 = 72.5KN

Weight of 114-E-125 = 528 MT for 1 bays

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Each bay = 528/7= 75.43 MT =754.3 KN Reaction on each column = 754.3/4 = 188.6KN

Equipment Empty -72.500 kN

-72.500 kN

-17.500 kN-17.500 kN

-50.000 kN

-72.500 kN

-50.000 kN-45.000 kN

-45.000 kN

-85.000 kN

-72.500 kN

-17.500 kN-17.500 kN

-50.000 kN-50.000 kN-45.000 kN

-45.000 kN

-85.000 kN

Load 11X

YZ

Equipment Operating- It is the weight of equipment including liquid weight in operating conditions.

2626

Load Calculation Example: - Equipment operating (content) is calculated by multiplying 1.5 with dead equipment empty as per discussion with mechanical discipline.

Weight of 114-E-143 = 29 MT for 1 bays Each bay = 29/1 = 29 MT =290 KN Reaction on each column = 290/4 = 72.5KN Equipment Operating Load = 72.5X1.5 =108.8KN

Equipment Operating

2727

-108.800 kN

-108.800 kN

-26.300 kN-26.300 kN

-75.000 kN

-108.800 kN

-75.000 kN-67.500 kN

-67.500 kN

-127.500 kN

-108.800 kN

-26.300 kN-26.300 kN

-75.000 kN-75.000 kN-67.500 kN

-67.500 kN

-127.500 kN

Load 12X

YZ

Equipment Test (Content) - It is the weight of equipment including hydrotest liquid, usually water, required hydro testing.

Load calculation Example: - Equipment Test (content) is calculated by multiplying 1.5 with dead equipment empty as per discussion with Mechanical Discipline.

Weight of 114-E-143 = 29 MT for 1bays

Each bay = 29/1 = 29 MT =290 KN Reaction on each column = 290/4 = 72.5KN

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Equipment Operating Load = 72.5X1.5 =108.8KN

Equipment Test (Content) -108.800 kN

-108.800 kN

-26.300 kN-26.300 kN

-75.000 kN

-108.800 kN

-75.000 kN-67.500 kN

-67.500 kN

-127.500 kN

-108.800 kN

-26.300 kN-26.300 kN

-75.000 kN-75.000 kN-67.500 kN

-67.500 kN

-127.500 kN

Load 13X

YZ

PIPING LOADIn the absence of defined piping loads and locations, an assumed minimum uniform pipe load of 2.0 kPa should be used for preliminary design of pipe racks.  This corresponds to an equivalent load of 6 in (150 mm) lines full of water covered with 2 in (50 mm) thick insulation, and spaced on 12 in (300 mm) centers.  This assumption should be verified based on coordinationwith the Piping Group, and concentrated loads should also be applied for any anticipated large pipes.  When the actual loads and locations become

2929

known, as the project develops, the structural design should be checked against these assumed initial load parameters and revised as required. A concentrated load should then be added for pipes that are 12 in (300 mm) and larger in diameter. The concentrated load P should be:

P = (W - s x p x d)    

Where: s = Spacing of pipe rack bent, p = pipe weight considered (KPa),  d = pipe diameter,  W = pipe concentrated load.

It comprises of various loads: Piping Empty- It is in-situ weight of piping along with internal piping,

and insulation, but excluding weight of fluids or products.

Uniform piping load @ 1.2KN/m2 (As per Petrofac Design Guide & Standard practice) Piping load on each beam = 1.2KN/m2 x 6m (Beam Span) = 7.2KN/m (Acting as UDL) Piping Empty

-7.200 kN /m

-7.200 kN /m

-7.200 kN /m

-7.200 kN /m

-7.200 kN /m

-7.200 kN /m

-7.200 kN /m

-7.200 kN /m

Load 4XY

Z

Piping Operating- It is the weight of piping including liquid weight in operating conditions.

Uniform piping load @ 1.7KN/m2 (As per Petrofac Design Guide & Standard practice)

3030

Piping load on each beam = 1.7KN/m2 x 6m (Beam Span) = 10.2KN/m (Acting as UDL)

Piping Operating

-10.200 kN /m

-10.200 kN /m

-10.200 kN /m

-10.200 kN /m

-10.200 kN /m

-10.200 kN /m

-10.200 kN /m

-10.200 kN /m

Load 5XY

Z

Piping Hydro test- Loading due to hydrostatic testing of lines should beconsidered in the design, Coordinate the testing plan(s) with Construction, Startup, and/or the Piping Group as necessary, in order tofully understand how such loads will be applied to the pipe rack structure. Under most normal conditions, multiple lines will not be simultaneously tested. The hydro-test loads do not normally need to be considered concurrently with the other non-permanent loads, such as liveload, wind, earthquake, and thermal. Typical practice is to permit an overstress of 15% for the hydro-test condition. Because of these considerations, the hydro-test condition will not normally govern exceptfor very large diameter pipes.

Considered Uniform piping load @ 1.7KN/m2 (As per Petrofac Design Guide & Standard practice) Piping load on each beam = 1.7KN/m2 x 6m (Beam Span) =10.2KN/m (Acting as UDL)

Piping Test Content

3131

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

Load 6XY

Z

FRICTIONAL (THERMAL) LOAD

Friction forces caused by hot lines sliding across the pipe support during startup and shutdown are assumed to be partially resisted through friction by nearby 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 7.5% of the total pipe weight or 30% of any one or more lines known to act simultaneously in the same direction,whichever is larger, is assumed for pipe rack design. Friction between piping and supporting steel should not be relied upon to resist wind or seismic loads.

It comprises of various loads:

Piping Frictional Longitudinal- a. If number of Pipes > 6 then:

Longitudinal Friction forces considered as 10%of (Operating Empty Weight of Piping)

b. If number of Pipes 3 to 6 then: Longitudinal Friction forces considered as 20%of (Operating Empty Weight of Piping)

c. If number of Pipes < 3 then: Longitudinal Friction forces considered as 30%of (Operating Empty Weight of Piping)

3232

-1.520 kN/m-0.530 kN/m

-1.520 kN/m

-1.520 kN/m-0.530 kN/m

-1.520 kN/m-0.530 kN/m

-1.520 kN/m

-1.520 kN/m

-1.520 kN/m-0.530 kN/m

-1.520 kN/m

Load 14X

YZ

Piping Frictional Transverse- Transverse Friction forces considered as 5% of(Operating Empty Weight of Piping)

-0.530 kN /m

-0.530 kN /m

-0.530 kN /m

-0.530 kN /m

Load 14X

Y

Z

3333

ANCHOR LOAD

Pipe racks should be checked for anchor and guide loads as determined by the Pipe Stress Group.  It may be necessary to use horizontal bracing if large anchor forces are encountered. For conventional pipe rack systems, itis normally preferred to either have the anchors staggered along the paperback so that each support has only one or two anchors, or to anchor most pipes on one braced support.  For initial design, when anchor and guide loads are not known, use a longitudinal anchor force of 5.0 KN actingat midspan of each bent transverse beam (refer project design criteria). Guide loads are defined by the transverse anchor forces.  For non-continuous pipe rack systems, piping may be transversely guided or anchoredat both cantilever frames and anchor bays.  Longitudinal anchors may be located only at anchor bays.

It comprises of various loads:

Piping Anchor Longitudinal-

Longitudinal Friction forces considered as 12% of (Operating Empty Weight of Piping)

(AS per Petrofac Design Guide & Standard practice)

Piping Anchor Longitudinal

3434

-1.200 kN/m

-1.200 kN/m

-1.200 kN/m

-1.200 kN/m

-1.200 kN/m

-1.200 kN/m

-1.200 kN/m

-1.200 kN/m

Load 7X

Y

Z

Piping Anchor Transverse-

Transverse Friction forces considered as 15% of(Operating Empty Weight of Piping) (AS per Petrofac Design Guide & Standard practice)

Piping Anchor Transverse

3535

-1.520 kN /m

-1.520 kN /m

-1.520 kN/m

-1.520 kN/m

Load 8XY

Z

TEMPERATURE LOAD

Pipe Rack is subjected to a thermal load due to fluctuation of ambientdesign temperature with respect to its construction temperature (i.e.stress free temperature). Pipe rack shall be designed for both maximumtemperature rise (TR) and minimum temperature fall (TF) as follow:

In summer Temperature rise= TRIn winter Temperature fall= TFConstruction Temperature=Tc

Structure to be designed for-

a. Temperature Rise, T=TR-Tc

b. Temperature Fall, T= TF-Tc

In this pipe rack we have considered: Temperature rise = 30oC Temperature fall = -30oC

(AS per Petrofac Design Guide & Standard practice)

3636

Temperature Load

Load 15X

Y

Z

WIND LOAD

Transverse wind load on structural members, piping, electrical trays,equipment, platforms, and ladders should be determined in accordance withproject approved design code. Longitudinal wind should typically be appliedto structural framing, cable tray vertical drop (if any), large dia pipesvertical drop (if any) and equipment only.  The effects of longitudinalwind on piping and trays running parallel to the wind direction should beneglected.

It comprises of various loads:

Wind Longitudinal Direction(X Direction)

3737

Load 17X

Y

Z

Wind Transverse Direction(Z Direction)

Load 18X

Y

Z

For wind load calculation please Refer Attachment B_Wind Load.

SEISMIC LOAD

Earthquake loads in the vertical, transverse, and longitudinal directionsshould be determined in accordance with the project design criteria.

3838

Vertical, transverse, and longitudinal seismic forces generated by thepipes, raceways, supported equipment, and the paperback structure should beconsidered and should be based on their operating weights. Pipes must beevaluated for seismic loads under both full and empty conditions and thencombined with the corresponding gravity loads.

Seismic loads are calculated based on provisions of ASCE 7-10. Seismic Design Category “B” with Spectral response accelerations for short period and one second periods are Ss = 0.32g, S1 = 0.13g respectively and Importance Factor 1.25 as per Project Design Basis.

It comprises of various loads:

Seismic Longitudinal Direction Seismic Transverse Direction

For seismic load calculation please Refer Attachment C_Seismic Load.

CRANE (MONORAIL) LOAD:

Monorail will be used to lift the pump portion of the pump. Motor will not be lifted by the monorail, Monorail capacity to be indicated on the drawing. Weight of chain and pulley block to be considered while designing the monorail

Crane (Monorail) Capacity = 10 KN (Taken same for all three cases defined below) It comprises of various loads:

Crane Load (Left Side) Crane Load (Right Side) Crane Load (Parked)

Crane Load (Left Side)

3939

-10.000 kN-10.000 kN

-10.000 kN-10.000 kN

-10.000 kN-10.000 kN

Load 26X

YZ

Crane Load (Right Side)

-10.000 kN-10.000 kN

-10.000 kN-10.000 kN

-10.000 kN-10.000 kN

Load 27X

YZ

LOAD COMBINATIONS:

The following considering while Appling load combinations: Earthquake load is a factored load.

4040

For load combinations that include wind or earthquake loads, use onlythe non-friction portion (anchor and guide portion) of the thermalloads, i.e., friction loads are not combined with wind or seismicloads. Friction loads are considered to be self-relieving during windand earthquake and should only be combined with anchor and guide loadswhen wind or earth-quake loads are not considered.

Hydrostatic test loads need not be combined with wind and earthquakeloads unless there is a reasonable probability of the occurrence ofeither of these loads during hydrostatic testing.

12. CONNECTIONS

For longitudinal beams, simple shear connections at ends and pinnedconnections for bracings are generally provided. Longitudinal beamsconnections are designed to carry axial loads. To allow for movement in thelongitudinal direction due to thermal expansion, a break in continuity isprovided in between adjacent racks. Constructability requirements shall beconsidered while designing the connections.

There are three types of connections between structural elements:

Moment Connections - This type of connection is provided in thetransverse Direction of pipe rack.

Shear Connections- This type of connection is provided in thelongitudinal direction of pipe rack

Axial Connections- This type of connection is provided for the bracingin the structure which is provided at the anchor bay location.

a. Bolted Moment Connection

b. Base Plate Design for pinned condition

For base plate calculation please Refer Attachment F_Base Plate

c. RC Corbel design: Corbels are cantilevers having shear span-to depthratios not greater than unity, which tend to act as simple trusses ordeep beams, rather than flexural members designed for shear. The corbel mayfail by shearing along the interface between the column

4141

and the corbel, by yielding of the tension tie, by crushing or splitting ofthe compression strut, or by localized bearing or shearing failure underthe loading plate.

For RC Corbel calculation please Refer Attachment G_RC Corbel

Design

d. Precast Concrete column to Precast column connection: Tensile forces are transferred between concrete column elements by

means of sleeves which are anchored into each side of the precast elements at the joint with continuity achieved by dowel action.

The method used here is grouted pipe sleeves with in-situ lapped reinforcement; generally sleeves are 20 to 30mm larger diameter thandowel diameter.

The dowel bar is inserted into the sleeve and grout is injected through a hole at the base. Alternatively, the grout may be placed by gravity pouring. In either case, the sleeve must be vented to prevent formation of air pockets.

To ensure effective force transfer, stirrups are placed along the lapping length.

Shear forces are transferred through shear key only. Concrete is considered cracked while calculating reinforcement to

resist Dowel tension and shear. In case reinforcement is provided to resist tension, the concrete

breakout strength of the Sleeve / Dowel in tension has not been considered in checking the Sleeve / Dowel size.

For Precast Concrete column to precast column connection calculation please Refer Attachment I_ Precast Concrete column toprecast column connection

e. Cast in situ concrete column to precast concrete column connection: Tensile forces are transferred between concrete column elements by

means of Anchor bolts in Cast in situ columns and sleeves which are anchored into each side of the precast elements at the joint with continuity achieved by dowel action.

4242

The method used here is grouted pipe sleeves with in-situ lapped reinforcement; generally sleeves are 20 to 30mm larger diameter thandowel diameter.

The dowel bar is inserted into the sleeve and grout is injected through a hole at the base. Alternatively, the grout may be placed by gravity pouring. In either case, the sleeve must be vented to prevent formation of air pockets.

To ensure effective force transfer, stirrups are placed along the lapping length.

Shear forces are transferred through shear key only. Concrete is considered cracked while calculating reinforcement to

resist Dowel tension and shear. In case reinforcement is provided to resist tension, the concrete

breakout strength of the Sleeve / Dowel in tension has not been considered in checking the Sleeve / Dowel size.

For Cast in situ concrete column to precast concrete column connectioncalculation please Refer Attachment H_Cast in situ concrete column to precast concrete column connection

13. ALLOWABLE HORIZONTAL AND VERTICAL DEFLECTION:

Allowable deflections of pipe rack structures shall be as per projectdesign criteria, consider the following as limit of deflection: Lateraldeflection produced by load combinations that include wind or seismicforces: Pipe racks supporting equipment: h/100, unless a more stringentrequirement is given by the manufacturer of the equipment.

Pipe racks supporting piping and raceway only: h/200 or as per projectdesign criteria. Lateral deflection produced by sustained static forcessuch as pipe and anchor loads: h/200 or as per project design criteria,Vertical deflection of beams due to gravity pipe loads: as per projectdesign criteria, where h is the total height of the pipe rack structure.

14. UTILITY RATIO CHECK

Max. Utility ratio in members is as follows: -

ColumnsBeam Analysis

PropertyDesignProperet

y

ActualRatio

Allowable Ratio

Normalized Ratio

Clause L/C

4343

5917 W18x86 W18x86 0.703 0.850 0.827 ClauseH1/2

253

BeamsBeam Analysis

PropertyDesignProperet

y

ActualRatio

Allowable Ratio

Normalized Ratio

Clause L/C

1154 W18x76 W18x76 0.832 0.850 0.979 ClauseH1/2

217

Horizontal BracingsBeam Analysis

PropertyDesignProperet

y

ActualRatio

Allowable Ratio

Normalized Ratio

Clause L/C

Vertical BracingsBeam Analysis

PropertyDesignProperet

y

ActualRatio

Allowable Ratio

Normalized Ratio

Clause L/C

7215 WT18x33.5

WT18x33.5

0.608 0.850 0.716 Clause E 256

Columns and Beams

4444

0.671

0.703

0.488

0.701

0.832

0.513

0.566

0.671

0.369

0.488

0.622

0.407

0.719

0.513

0.566

0.671

0.703

0.622

0.701

0.832

Load 21X

Y

Z

Vertical Bracings

Note: Normalized ratio = (Actual

ratio / Allowable ratio) There are no horizontal

bracings in this pipe rack.

15. CONCLUSION:

Design calculations have been performed as per American Standards,LRFD method & Project

0.609

0.671

0.56

0.0646

0.608

0.608

0.729

0.607

0.567

0.0646

0.425

218

3498

217

258

3499

3106

257

Load 21X

Y

Z

4545

specifications. Based on the design calculations, Structural drawings have been prepared.

From the member utility ratio, it is seen that all the members have utilityratio less than 1.0 but restricted utility ration to 0.85 only because final input loads not received yet from piping discipline. It is concluded that Members and its connections are adequate from strength as well as serviceability conditions as per American standards.

Please refer Attachment J_GA Drawings for final output of pipe rack.

4646

ATTACHMENT- A:

Pipe Rack Plot Plan and Exchanger Details

4747

ATTACHMENT- B:

WIND LOAD CALCULATIONS

4848

ATTACHMENT- C

SEISMIC LOAD CALCULATIONS

4949

ATTACHMENT- D

5050

LOAD COMBINATIONS CALCULATION

ATTACHMENT- F

ABBREVIATIONS: KNPC Kuwait National Petroleum Corporations

PIL Petrofac Engineering India Private Limited

FW Foster wheeler

5151

GA General Arrangement

AISC American Institute of Steel Construction

ASCE American Society of Civil Engineers

ACI American Concrete Institute

IBC International Building Code

ASTM American Society for Testing and Materials

CDU Crude Distillation Unit

HCR Hydrocracker Unit

VRU Vacuum Rerun Unit

TOS Top of Steel

TOC Top of Concrete

LRFD Load & Resistance Factor Design

ASD Allowable stress design

FEED Front End Engineering & Design

NHT Naphtha Hydro theater.

DHT Diesel Hydro Theater

CCR Continuous Catalytic reformer

HOC Heavy oil cooling

5252

ATTACHMENT -F

BASE PLATE DESIGN FOR PINNED CONDITION

5353

ATTACHMENT- G

RC CORBEL DESGIN CALCULATIONS

5454

ATTACHMENT- H

Precast Concrete column to precast columnconnection

5555

5656

ATTACHMENT- I

Cast in situ concrete column to precast concretecolumn connection

5757

ATTACHMENT- J

GA Drawings

5858