Pipe Rack Design Loads for Zubair Project
Pipe Rack Design Loads for Zubair Project
ISSUE FOR
EX-DE 00 18/07/14 [Link] [Link] [Link] [Link] [Link]
DESIGN
Validity Rev.
Status number Prepared Checked Approved Contractor Company
Date Description
by by by Approval Approval
Revision Index
Company logo and business name Project name Company Identification
ZUBAIR OIL FIELD 00251210DAST3Z028
DEVELOPMENT
eni iraq b.v. PROJECT Job N.
Contractor logo and business name Contractor Identification
00251210DAST3Z028
SAMSUNG ENGINEERING Contract N. 252/2011/DK/ZU
Vendor logo and business name Vendor Identification
Order N.
Facility Name Location Scale Sheet of Sheets
ZUBAIR-NORTH ONSHORE n.a. 1 of 19
NEW DEGASSING STATION
Document Title Supersedes N.
REVISION HISTORY
INDEX
1 General ...................................................................................................................................... 4
1.1 Introduction ............................................................................................................................ 4
1.2 Scope ..................................................................................................................................... 5
2 Codes and Standards .............................................................................................................. 5
2.1 Local Codes and Regulation .................................................................................................. 5
2.2 National and International Standards .................................................................................... 5
3 Reference Documents ............................................................................................................. 6
3.1 Project Specifications ............................................................................................................. 6
3.2 Project Standards and Design Practices ............................................................................... 6
4 Design Loads ............................................................................................................................ 6
4.1 Self Weight and Permanent load (G) ..................................................................................... 6
4.2 Fireproofing load .................................................................................................................... 6
4.3 Live Load (L, Lr) ..................................................................................................................... 6
4.4 Equipment and Piping Loads (E, P) ....................................................................................... 8
4.5 Thermal Loads from Piping and Equipment (Tr, Th) ............................................................. 9
4.6 Cable Trays (Ct) ................................................................................................................... 10
4.7 Erection Load (Er) ................................................................................................................ 10
4.8 Cranes and Lifting Appliances (C) ....................................................................................... 10
4.9 Bundle Pull (F) ..................................................................................................................... 10
4.10 Sand Load (S) ...................................................................................................................... 11
4.11 Differential Settlement (D) .................................................................................................... 11
4.12 Load acting on vibrating machine foundations (V)............................................................... 11
4.13 Thermal Load from Environmental Conditions (Te) ............................................................. 11
4.14 Wind Load (W) ..................................................................................................................... 11
4.15 Seismic Load (Se) ................................................................................................................ 13
4.16 Blast Load (B) ...................................................................................................................... 14
4.17 Paving and Trench Cover Loads ......................................................................................... 14
5 Load Combinations ................................................................................................................ 15
5.1 Ordinary R.C buildings ......................................................................................................... 15
5.2 R.C Structures and Foundations supporting Steel/Concrete Structures or Equipment ...... 16
5.3 Steel Structures Supporting Equipment or Service Steel Structure .................................... 17
1 General
1.1 Introduction
ENI has been awarded the Zubair project for the development of an oil field
(ZUBAIR FIELD) in joint venture with Occidental, Korea Gas and Missan Oil
COMPANY (as state partner), with Eni as operator.
The Zubair Field is located in the southern area of Iraq, 20 km from Basra city.
The structure of the Zubair Field is a relatively gentle anticline oriented NNW -
SSE, approximately 60 km long and 10-15 km wide.
The Zubair project is a “brown field project”, with existing facilities and
infrastructure. The field is currently in production.
The oil is produced from reservoir with natural flowing and artificial lift systems
requiring also water injection to support reservoir pressure and maintain it above
saturation pressure.
The Zubair Field Development Plan foresees the rehabilitation of the existing
facilities in order to maintain them operable and reliable whilst the new facilities
required for the ramp-up of the field are installed.
The oil production increase targets require the installation of new production
facilities to achieve the plateau rate 850 kBOPD of oil.
The total plateau rate capacity will be achieved and managed through new
facilities, subdivided in IPF (Initial Production Facilities) with total capacity of 300
kBOPD and New DGS’s of which sum up 550 kBOPD of treating capacity.
Altogether, IPF plus New DGS’s will match the overall plateau rate capacity
requirements (850 kBOPD). New facilities include also water injection capacity to
meet the reservoir injection water requirements.
On existing DGS's wells are currently connected only through dedicated single
flowlines (no remote manifolds) directly to 5 existing DGS's and Safwan flow
station.
For New Facilities, well fluids will be collected by individual flow lines which are
routed to local manifolds or remote manifold which conveys well fluid to each
New DGS's through trunklines.
New train shall be configured with two 3-phase separators, a dehydrator and a
desalter. Treated oil from desalter will be degassed in a gas boot and than stored
in a flow tanks.
1.2 Scope
This specification contains the loads and loads combination to perform the
Civil/Structural Design of steel and concrete structures for the Zubair Oil Field
Development Project.
The works shall comply in all aspects with Local Regulations, Planning Law and
other Statutory Regulations.
3 Reference Documents
4 Design Loads
Foundations and structures shall be designed for all loads and combination listed
below.
The permanent load shall be the self weight of all the structural and non-
structural components of a building or structure, including fireproofing, if present,
insulation and casing, forming permanent part of the structure and foundation.
(Note: insulation and casing shall not be considered in erection case).
The specific gravity of materials shall be assumed as follows:
Material adopted for passive fire protection and structures or pipe racks to be
fireproofed shall be defined according to hazard assessment and
00250600BASG10014 “General Specification for Cementitious Concrete
Fireproofing”.
4.3 Live Load (L, Lr)
"Live Loads" (L) shall be the imposed and moving loads on the structure, floor,
Platforms, floors walkways, stairs and ladders for all structures shall be designed
for the applied live load specified below:
Loadings for floors, stairs, and roof (Lr, live load on roof) in buildings shall
conform to the requirements of ASCE-7 and IBC 2006.
In case exceptional live loads are present, the same shall be carefully evaluated
and taken into consideration during detailed design.
The equipments (such as vessels, heat exchangers, stacks, pumps, pipe etc.)
load shall be the empty weight of equipment only, inclusive of internal and
external parts, thermal insulation, platforms and pipes directly supported by the
equipment.
Electrical feeders, internal partition, false ceiling etc. supported by the structure
shall be also considered as an equipment load.
The following requirements apply to elevated and grade level pipes up to 12"
diameter. For larger pipes individual conditions must be investigated. Process
piping dead load shall be the empty weight of pipe which, in absence of indication
from piping design, can be estimated as 60% of the weight of the pipe full of
water, or operation condition.
Vertical test load on structure supporting up to four pipes (in addition to pipes
dead load) shall be taken as the weight of water in full pipes.
Vertical test load on structure supporting more than four pipes (in addition to
pipes dead load) shall be taken as half the weight of water in full pipes applied to
produce maximum stresses.
Generally the plant layout will avoid the need for elevated piperacks but if
required, shall as a minimum, be designed for the following:
Pipe anchors (Tr) shall be designed for the forces developed from the line
stressing.
When more than one anchor is supported on one support actual directions of
thrusts shall be considered, but in any case members shall be designed to resist
at least each single anchor thrust as a minimum. Anchor support members in
structures shall be suitably braced to reduce deflection to a minimum.
Horizontal load on the anchor bays (Tr) shall be taken as the greatest of:
The mentioned loads, applicable only for anchor bay (i.e. vertical bracing bay),
shall be considered for the design of columns, longitudinal beams, bracing and
relevant foundation.
"Thermal Pipe Loading" (Th) shall be the load acting upon a structure due to
change in temperature of pipes, machinery or process equipment.
Pipe anchors (Tr) and Thermal piping loading (Th) shall act simultaneously.
When thermal expansion results in friction between equipment and supports, the
friction force shall be taken as the operating load on the support factored with
friction coefficients given in the table below.
Note: Use 'Lubrite' only if bearing stress or temperature range prohibits the use of
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It shall neither be shown to Third Parties nor used for purposes other than those for which it has been sent.
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'Teflon'.
The friction force at the 'free' end of vessel is applied at both 'fixed' and
'free' end.
Any external thermal force is applied directly to the 'fixed' end.
The loads during erection shall be established by taking account of the erection
sequence for each structure.
Electric Hand
Operation Operation
Vertical loads - increase static
wheel loads by
25% 10%
Horizontal force transverse to
rails taken as percentage of 10% 5%
(load + crab weight)
Horizontal force along rails
taken as percentage of (load +
crab weight)
5% 5%
The supports of heat exchangers shall be designed to withstand the tube bundle
pushing and pulling forces along the longitudinal axis of the heat exchanger. The
forces shall be based on the type of fluid on the shell side of the exchanger. For
crude residue, cracked tar, and similar services, 150 percent of the weight of the
tube bundle shall be used. For distilled oil, vapour, clean water, and steam, 100
percent shall be used. The foundation at the fixed end shall be designed for 100
percent of the calculated pushing and pulling force, and the foundation at the
sliding end shall be designed for at least 50 percent of the calculated pushing
This document is property of eni Iraq B.V.
It shall neither be shown to Third Parties nor used for purposes other than those for which it has been sent.
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Sand load shall be derived from local experience of sandstorms that can continue
for 7 days, as per 00250600BGSG09005 “Site and Climatic Conditions”.
Sand load shall be additive to live loads only when the area under construction is
used as a work area.
The effect of sand accumulating behind walls and upstands shall be considered
in the design of walls and roofs.
The variability of the soil strata may result in differential settlement. The resulting
bending moments, shear and axial forces shall be considered.
The thermal effects due to temperature variation need to be taken into account in
calculations, especially for structures expose to external air, considering a ∆t of
±30°.
The thermal load shall be applied in any case in the design of the structure.
Buildings and structures shall be calculated with regard to the wind action
according to the requirement of ASCE-7/05 and to 00250600BGSG09005 “Site
and Climatic Conditions”.
The following parameters shall be adopted:
The wind velocity pressure shall be evaluated as per section 6.5.10 as follow:
qz=0.613KzKztKdV2I
Kzt : topographic factor =1.0
Kd : directionality factor=0.85
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It shall neither be shown to Third Parties nor used for purposes other than those for which it has been sent.
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Design wind load for buildings and other structures shall be determined as per
sections from 6.5.12 to 6.5.15 of ASCE-7/05.
Wind loads on piping or equipment supported on, or in, steel or concrete frames
shall be added to the wind loads on the frames.
Design wind load on an open type structure shall be the sum of the design wind
loads on its parts, taking into account effects of both shielding and group action
of the parts.
Where:
The windstrip height in accordance with ASCE - “Wind loads and anchor bolt
design for petrochemical facilities”, shall be taken as:
hw = Dm + 0.1 Wr
The area of all columns and the area of the outter beams should be used in the
wind load calculations. Refer to the figure below
Buildings and structures shall be designed with regard to the seismic action
according to the requirement of UBC 1997, ASCE 7 and to
00250600BGSG09005 “Site and Climatic Conditions”. (UBC only for seismic
zone definition)
For the calculation of seismic action the following parameters shall be adopted:
All other parameters shall be defined according to UBC 1997 and Soil Report.
Seismic design for storage tanks at grade shall be in accordance with API 650
“Welded Steel Tanks or Oil Storage”, considering the following parameters:
All other parameters shall be defined according to API 650 and Soil Report.
The seismic design parameters shall be defined according to the soil type, site
location and condition described in the geotechnical report.
The seismic base shear,V, in a given direction shall be determined in accordance with the
following equation:
• V = Cs W
Where:
The effective seismic weight, W, of a structure include the total dead load and other loads
lists below:
- In areas used for storage, a minimum of 25 percent of the floor live load (floor live
load in public garages and open parking structures need not be included).
- Where provision for partitions is required by Section 4.2.2 of ASCE 7-05 in the
floor load design, the actual partition weight or a minimum weight of 0.48 kn/m2 of
floor area, whichever is greater,
- Total operation weight of permanent equipment.
• Cs = Sds / (R/I)
Where:
The blast, fragment impact and thermal radiation load information shall be
obtained from a hazard assessment.
Concrete paving and cover slab in heavy traffic zone shall be designed with a
vertical load of 145 kN, considering an HS-20 truck load.
Concrete paving and cover slab in light traffic zone shall be designed with a
vertical load of 13.6 kN.
5 Load Combinations
All ordinary R.C. buildings and their foundations shall be designed according to
ACI 318-08.
The live load for building shall be evaluated according to ASCE-7/05.
Required strength of the structure shall be at least equal to the effect of the
factored loads hereafter indicated, combined according to ASCE-7/05
1) 1.4 (G + E + P + Ct)
2) 1.2 (G + E + P + Ct + D + Te) + 1.6 L + 0.5 Lr
3) 1.2 (G + E + P + Ct + D + Te) + 1.6 L + 0.5 S
4) 1.2 (G + E + P + Ct) + 1.6 Lr + L
5) 1.2 (G + E + P + Ct) + 1.6 S + L
6) 1.2 (G + E + P + Ct) + 1.6 Lr ± 0.8 W
7) 1.2 (G + E + P + Ct) + 1.6 S ± 0.8 W
8) 1.2 (G + E + P + Ct) ± 1.6 W + L + 0.5 Lr
9) 1.2 (G + E + P + Ct) ± 1.6 W + L + 0.5 S
10) 1.2 (G + E + P + Ct) ± 1.0 Se + L + 0.2 S
11) 0.9 (G + E + P + Ct) ± 1.6 W
12) 0.9 (G + E + P + Ct) ± 1.0 Se
13) 1.2 (G + E + P + Ct) + 1.0 B + 0.5 L
14) 1.2 (G + E + P + Ct) + 1.0 B + 0.2 S
The serviceability limit states for the structure shall be checked with regards to
the effects of the factored loads hereafter indicated, combined according to
ASCE-7/05
1) 1.0 (G + E + P + Ct)
2) 1.0 (G + E + P + Ct) + 1.0 (L + D + Te)
3) 1.0 (G + E + P + Ct) + 1.0 Lr
4) 1.0 (G + E + P + Ct) + 1.0 S
Required strength of the structure shall be at least equal to the effect of the
factored loads hereafter indicated, combined according to ASCE-7/05.
Test Condition:
7) 1.4 (G + Et + Pt + Ct + D)
8) 1.2 (G + Et + Pt + Ct + D) ± 0.80 W + (C + L + V)
Erection Condition:
9) 0.9 (G + Ew + Pw + Ct + Er) ± 1.6 W
10) 1.2 (G + Ew + Pw + Ct + Er) ± 0.8 W + 1.6 (L + C + S)
Seismic Condition:
11) 1.2 (G + Eo + Po + Ct + Tr) ± 1.0 Se + 1.0 (L + V + S)
12) 0.9 (G + Eo + Po + Ct + Tr) ± 1.0 Se
The serviceability limit states for the structure shall be checked with regards to
the effects of the factored loads hereafter indicated, combined according to
ASCE-7/05.
Test Condition:
5) 1.0 (G + Et + Pt + Ct + D) ± 0.50 W
6) 1.0 (G + Et + Pt + Ct + D) ± 0.38 W + 0.75 (C + L + V)
Erection Condition:
7) 1.0 (G + Ew + Pw + Ct + Er) ± 1.0 W
8) 1.0 (G + Ew + Pw + Ct + Er) ± 0.75 W + 0.75 (L + C + S)
9) 1.0 (G + Ew + Pw + Ct) + 1.0 F
10) 1.0 (G + Ew + Pw + Ct) + 0.75 F + 0.75 (L + C + S)
Seismic Condition:
11) 1.0 (G + Eo + Po + Ct + Tr) ± 0.7 Se
12) 1.0 (G + Eo + Po + Ct + Tr) ± 0.53 Se + 0.75 (L + V + S)
Required strength of the structure shall be at least equal to the effect of the
factored loads hereafter indicated, combined according to ASCE-7/05.
Test Condition:
5) 1.4 (G + Et + Pt + Ct + D)
6) 1.2 (G + Et + Pt + Ct + D) ± 0.80 W + (C + L + V)
Erection Condition:
7) 0.9 (G + Ew + Pw + Ct + Er) ± 1.6 W
8) 1.2 (G + Ew + Pw + Ct + Er) ± 0.8 W + 1.6 (L + C + S)
Seismic Condition:
9) 1.2 (G + Eo + Po + Ct + Tr) ± 1.0 Se + 1.0 (L + V + S)
10) 0.9 (G + Eo + Po + Ct + Tr) ± 1.0 Se
The serviceability limit states for the structure shall be checked with regards to
the effects of the factored loads hereafter indicated, combined according to
ASCE-7/05.
Test Condition:
5) 1.0 (G + Et + Pt + Ct + D) ± 0.50 W
6) 1.0 (G + Et + Pt + Ct + D) ± 0.38 W + 0.75 (C + L + V)
Erection Condition:
7) 1.0 (G + Ew + Pw + Ct + Er) ± 1.0 W
8) 1.0 (G + Ew + Pw + Ct + Er) ± 0.75 W + 0.75 (L + C + S)
Seismic Condition:
9) 1.0 (G + Eo + Po + Ct + Tr) ± 0.7 Se
10) 1.0 (G + Eo + Po + Ct + Tr) ± 0.53 Se + 0.75 (L + V + S)