KOC-C-002

KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOC RECOMMENDED PRACTICE

FOR

ENGINEERING DESIGN BASIS OF

CIVIL AND STRUCTURAL WORK

DOC. NO. KOC-C-002

9

kh;

(

+&)

KUWAIT OIL COMPANY (K.S.C.)

DOC. NO. KOC-C-002

STANDARDS PUBLICATION

REV. 1

KOC RECOMMENDED PRACTICE

FOR

ENGINEERING DESIGN BASIS OF

CIVIL AND STRUCTURAL WORK

DOC. NO. KOC-C-002

DOC. NO. KOC-C-002

KOC RECOMMENDED PRACTICE

FOR

ENGINEERING DESIGN BASIS OF

CIVIL AND STRUCTURAL WORK

DOC. NO. KOC-C-002

ISSUING AUTHORITY:

STANDARDS TEAM

1 Rev 10/06/03 Date Issued as KOC Recommended Practice Description Task Force I TF-c/o4 I Prepared by Snr. E&< Te161407 A g Team Leader Sfds. Tel 6 7 8 9 6

DOC. NO. KOC-C-002 TABLE OF CONTENTS FOREWORD SCOPE APPLICATION TERMINOLOGY 3.1 Definitions 3.2 Abbreviations

REFERENCE STANDARDS AND CODES

4.1 Conflicts

4.2 List of Standards and Codes 4 . 3 KOC Standard Drawings ENVIRONMENTAL CONDITIONS

HEALTH, SAFETY AND ENVIRONMENT BASIC ENGINEERING INFORMATION

7.1 General

7.2 Site and Subsurface Information

7.3 Site Preparation and Earthwork

7.4 Site Drainage

7.5 Basic Design Plinth Levels GENERAL DESIGN BASIS

8.1 Design Loads

8.2 Design Loads Combinations

8.3 Allowable Functional Limits

8.4 Bearing Pressures and Settlements

8.5 Designated Materials FOUNDATIONS 9.1 General 9.2 Foundation Types 9.3 Shallow Foundations 9.4 Deep Foundations 9.5 Buoyancy Foundations

9.6 Plant, Pipework and Steelwork Supports

9.7 Foundation Protection

PLANT STRUCTURES 1 0 . 1 Dynamic Equipment

10.2 Structures and Overhead Piperacks

10.3 Fired Heaters

10.4 Process Tankage

10.5 Steel Stacks

DOC. NO. KOC-C-002

PLANT AND NON-PLANT BUILDINGS

1 1 .I Substation Buildings and Transformers 1 1.2 Control Buildings

1 1 . 3 Other Plant Buildings 1 1.4 Non-Plant Buildings

Page 4 of 6 9

11

REV.l

PAVING AND ACCESSWAYS

12.1 General

12.2 Paving Arrangement

1 2 . 3 Edging and Kerbing

12.4 Widths of Access-ways

12.5 Overhead Clearances

12.6 Live (Imposed) Loads

12.7 Soil Supported Concrete Paving

12.8 Joints 12.9 Unpaved Areas ROADWAYS 13.1 General 13.2 Roadway Construction 13.3 Duty 13.4 Vehicular Loads 13.5 Design Life 13.6 Existing Roads 13.7 Road Bridges 13.8 Road Geometry 13.9 Road Shoulders 13.1 0 Road Drainage

13.1 1 Crash Barriers & Protection Barriers 13.1 2 Kerbing

13.1

3

Road 1 Traffic Markings 13.14 Traffic Signs

13.1 5 Overhead Clearances

MICELLANEOUS CIVIL WORKS FOR SERVICES AND PIPELINES

14.1 Electrical and lnstrument Cable Trenches

14.2 Telephone Cable Trenches

14.3 Pipe Trenches

14.4 Cable Ducts

14.5 Ducts for lnstrument Cables

14.6 Ducts and Cable Trenches at Buildings

14.7 Pipe Sleeves

14.9

Floodlight Masts

14.10

Fire Hydrant Pits

14.1

1

Earthing

14.1

2

Lightning Protection

14.1

3

Warning Lights STEEL STORAGE TANKS

15.1

General

15.2

Foundation Design Criteria

15.3

Foundation Design

15.4

Dikes

15.5

Drainage Within Dikes CONCRETE STORAGE TANKS FENCING

17.1

General

17.2

Type of Fencing

17.3

Chain Link Fencing

17.4

Corrugated Sheet Fencing STRUCTURAL WORK

18.1

General

18.2

Structural Form

18.3

Design Conditions

18.4

Design Stress Levels

18.5

Passive Fire Protection

18.6

Painting 1 Galvanizing

18.7

Connections

MISCELLANEOUS METAL WORK

19.1

Platforms

19.2

Steel Flooring

19.3

Stairways

19.4

Spiral Stairways

19.5

Ladders

19.6

Handrails and Toe Plates

19.7

Ramps

19.8

Claddings QUALITY ASSURANCE DOCUMENTATION

21

.I

General

21.2

Deliverables ACKNOWLEDGEMENT

FOREWORD

-

-DOC. NO. KOC-(2-002

This document " KOC Recommended Practice for Engineering Design Basis of Civil

and Structural Work " (KOC-C-002) is intended t o provide consistent and practical

guidelines for the design of general civil engineering works including foundations, buildings, and structures made of concrete and structural steel as well as other associated works.

This Recommended Practice (RP) complements the families of listed KOC Standards; but refers t o specifically KOC-C-001 "KOC Standard for Basic Civil Engineering Design Data", as a part of general design basis of various civil and structural works.

Page 6 of 69

This KOC Recommended Practice (RP) has been approved b y Standards Division in consultation w i t h the Standards Technical Committee for use throughout the corporate engineering and operational functions of Kuwait Oil Company (K.S.C)

REV. 1

This RP sets out t o achieve the following objectives:

To recommend the general practices t o be adopted in the design specifications

of plantlnon-plant buildings and plant structures including equipment

foundations, storage tanks, paving and access-ways within KOC plants &

facilities, roadways, and other miscellaneous civil and structural works.

To establish the practical guidelines on the engineering design basis describing various design aspects w i t h a view t o achieving reasonably safe and economical construction as well as reliable service life.

To assist the designers b y giving an access t o the necessary level of documented technical information w i t h a view t o optimizing their design efforts and productivity.

To provide general technical guidance for developing project specifications and

design

I

construction drawings in order t o ensure a consistent approach for

sound engineering basis, material selection and workmanship in civil and structural work.

To set out minimum requirements t o monitor compliance w i t h a contract. Feedback as well as any comments or suggestions from the application of this Standard derived at any stage of conceptual design, engineering, construction, fabrication, erection or maintenance are encouraged and should be directed t o :

The Team Leader Standards

(Chairman, Standards Technical Committee) Industrial Services Group, KOC

P.O. Box - 9 7 5 8 , Ahmadi 6 1 0 0 8 State of Kuwait

I(

DOC. NO. KOC-C-002 REV. 1

Task Force Responsible for this Recommended Practice - -

The preparation of this RP has been entrusted b y the Standards Technical Committee (STCI t o the Task Force No. (TF-C/O41 comprising of the following members:

Mr. S. Kumar Standards Team Task Force Leader Tel. No. 6 1 4 0 7

Mr. Adel Al-Zaid Design Team Member Tel. No. 6 1 8 3 5

Mr. Khaled Al-Sayed Gen. Proj. Team Member Tel. No. 6 1 6 1 3

Mr. Hisham A.Gharieb Proj. Design Team Member Tel. No. 6 6 5 7 5

SCOPE

p~ -

DOC. NO. KOC-C-002

This Recommended Practice (RP) specifies the basic technical requirements and defines the sound engineering design basis of the general civil and structural works including plantinon-plant buildings, plant structures, equipment foundations, paving and access-ways, roadways, storage tanks and other miscellaneous civil and structural works for installations at the KOC onshore plants and facilities within Kuwait.

Page 8 of 69 REV.l

This R P does not cover the design of high rise buildings, pile foundations, foundations for storage tanks containing corrosive, hot or cryogenic fluids, rig foundations, radio structures, and offshore structures including jetties and marine terminals w i t h tanker berths.

This RP shall not be applicable t o any structures that use, as a form of

construction, pre-stressed concrete and structural sections such as

aluminum and stainless steel. Any structural work made of cold formed and light gauge steel sections are also excluded from this RP, which shall be covered separately under KOC-C-031.

The contents of this RP are intended t o be adopted as a design guide t o meet the minimum KOC requirements. However, the specifications and detailed design shall be provided by the DesigneriContractor for KOC approval.

The design, materials and workmanship of any civil and structural work shall conform t o the requirements of this RP and the reference standards and codes mentioned herein.

Any exceptions or deviations from this RP, along w i t h their merits and justifications, shall be brought t o the attention of KOC Controlling Team(s) for their review, consideration and amendment b y Standards Team (if required).

Compliance w i t h this RP does not of itself confer immunity from legal or statutory obligations.

TERMINOLOGY

For the purposes of this RP, the following definitions shall apply.

Any approved firm or company contracted by KOC, w h o are undertaking the execution of civil and structural work.

Designer

DOC. NO. KOC-C-002

Person or persons from KOC or from Contractor or any consulting firm approved b y KOC, w h o are undertaking the responsibilities of the actual design and detailed specifications of civil and structural work.

NB : For other applicable terminology, refer t o the relevant definitions in the

family of KOC Standards mentioned in clause 4.2.2 of this RP.

Page 9 of 69 Abbreviations REV.l AASHTO E PA EPDM FFL FGL HSE KOC NGL OMC

American Association of State Highways and Transportation Officials

Environmental Public Authority Epoxy Damp-proof Membrane Finished Floor Level

Finished Ground Level

Health, Safety and Environment Kuwait Oil Company (K.S.C) Natural Ground Level

Optimum Moisture Content REFERENCE STANDARDS AND CODES

-.

Conflicts

- -

In the event of conflicts between this RP and the standards

!

codes

referenced herein, or other contractual requirements, the most stringent requirement shall apply. In case further clarifications are required, the subject shall be brought t o the attention of KOC Controlling Team.

List of Standards and Codes

-

The latest edition o f the following standards, codes and specifications shall apply:

National

1

International Standards

AASHTO Guide for Design of Pavement Structures

ACI 224R Control of Cracking in Concrete Structures

ACI 3 0 5 Hot Weather Concreting

AC1 3 1 8 M / Building Code Requirements for Structural Concrete

ACI 3 1 8RM

ACI 343R Analysis and Design of Reinforced Concrete Bridge

ACI SP-66 ACI Detailing Manual

AlSC Specification for Structural Steel Buildings - Allowable

Stress Design and Plastic Design

AlSC Manual of Steel Construction - Working Stress Design

AlSC Manual of Steel Construction - Load and Resistance

Factor Design (Vol. I)

AlSC Manual of Steel Construction (Vol. II) - Connections

API RP 7 5 2 Management of Hazards Associated w i t h Location of

Process Plant Buildings C M A Manager's Guide

ASCE 7 Minimum Design Loads for Buildings and Other Structures

ASTM A616M Specification for General Requirements for Rolled

Structural Steel Bars, Plates, Shapes and Sheet Piling ASTM A36136M Specification for Carbon Structural Steel

ASTM A 5 3 Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-

Coated, Welded and Seamless

ASTM A 1 2 1 Specification for Metallic-Coated Carbon Steel Barbed

Wire

ASTM A 3 0 7 Carbon Steel Bolts and Studs, 6 0 0 0 0 PSI Tensile Strength

ASTM A 3 2 5 Specification for Structural Bolts, Steel, Heat Treated, 1 2 0

11 0 5 ksi Minimum Tensile Strength

ASTM A 3 2 5 M Specification for Structural Bolts, Steel, Heat Treated,

830MPa Minimum Tensile Strength (Metric)

ASTM A 3 9 2 Specification for Zinc-Coated Steel Chain-Link Fence

Fabric

ASTM A 4 4 9 Specification for Quenched and Tempered Steel Bolts and

Studs

ASTM A 4 7 5 Specification for Zinc-Coated Steel Wire Strand

ASTM A 4 9 0 Specification for Heat-Treated Steel Structural Bolts, 1 5 0

ksi Minimum Tensile Strength

ASTM A 4 9 0 M Specification for High-Strength Steel Bolts, Classes 1 0 . 9

and 10.9.3. for Structural Steel Joints (Metric)

ASTM A 5 8 6

DOC. NO. KOC-C-002

ASTM A 6 0 3 ASTM A 6 1 5 ASTM A 6 5 3 Page 1 1 of 69 ASTM D l 7 5 1 REV. 1 ASTM E 8 1 4 ASTM F 1 5 5 4 ASTM F 1 6 3 7 A W S D l . I BS 4 Part1 BS 4 4 9 Part 2 BS 4 7 6 Parts 2 0 & 21

Specification for Zinc-Coated Parallel and Helical Steel Wire Structural Strand

Specification for Zinc-Coated Steel Structural Wire Rope Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcements

Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

Specification for Preformed Expansion Joint Filler for

Concrete Paving and Structural Construction (Non-

extruding and Resilient Bituminous Types)

Standard Test Method for Fire Tests of Through Penetration Fire Stops

Specification for Anchor Bolts, Steel, 36, 55, and 1 0 5 ksi Yield Strength

Standard Practice for Safe Walking Surfaces

Structural Welding Society - Steel

Structural Steel Sections: Part 1 : Specification for Hot-Rolled Sections

Specification for The Use of Structural Steel in Building: Part 2: Metric Units

Fire Tests on Building Materials and Structures

Part 2 0 : Method for Determination of the Fire Resistance of Elements of Construction

Part 2 1 : Methods for Determination of the Fire Resistance of Load Bearing Elements of Construction

Hot-Dip Zinc Coated and Hot-Dip Aluminum / Zinc Coated

Corrugated Steel Sheets for General Purposes

I S 0 Metric Precision Hexagon Bolts, Screws and Nuts -

Specification

Specification for Sulfate-Resisting Portland Cement

I S 0 Metric Black Hexagon Bolts, Screws and Nuts -

DOC. NO. KOC-C-002 BS 4 3 9 5 Parts 1 & 2 BS 4 5 9 2 Part BS 4 6 0 4 Part BS 5 4 2 7 Part BS 5 6 2 8 BS 5 9 5 0 Parts 2 & 8 BS 6 3 9 9 Part BS 8 1 0 0 Parts 1 & 4

High Strength Friction Grip Bolts and Associated Nuts and Washers for Structural Engineering. Metric Series

Part 1 : General Grade

Part 2: Higher Grade Bolts and Nuts and General Grade

Washers

Specification for Carbon Steel Bars for the Reinforcement of Concrete

Specification for Steel Fabric for the Reinforcement of Concrete

Industrial Type Metal Flooring, Walkways and Stair Treads Part 1: Specification for Open Bar Gratings

Use of High Strength Friction Grip Bolts in Structural Steel Work. Metric Series: Part 1: General Grade

Code of Practice for the Use of Profiled Sheeting for Roof

and Wall Cladding on Buildings Part

I

: design

Code of Practice for Use of Masonry Structural Use of Steel Work in Building:

Part 2: Specification for Materials, Fabrication and Erection: Hot Rolled Sections

Part 8 : Code of Practice for Fire Resistant Design

Loading for Buildings - Code of Practice for Dead and

Imposed Loads

Code of Practice for Protection of Structures against Lightning

Code of Practice for Earthing

Code of Practice for Fatigue Design and Assessment of Steel Structures

Code of Practice for Earth Retaining Structures Code of Practice for Foundations

Code of Practice for Design of Concrete Structures for Retaining Aqueous Liquids

Lattice Towers and Masts

Part 1 : Code of Practice for Loading

DOC. NO. KOC-C-002 REV. 1

BS 8 1 0 2 Code of Practice for Protection of Structures against

Water from the Ground

BS 8 1 1 0 Part 1 Structural Use of Concrete - Part I :Code of Practice for

Design and Construction

BS CP 3 Part 2 BS CP 1 4 3 Part 1 0 BS CP 2 0 1 2 Part 1 BS EN 1 0 0 2 5 BS EN 1 0 0 5 6 Parts 1 & 2 BS EN 1 0 2 1 0 Parts 1 & 2

Specification for Scheduling, Dimensioning, Bending and Cutting of Reinforcements for Concrete

Code of Basic Data for the Design of Buildings Chapter V : Loading Part 2: Wind Loads

Code of Practice for Sheet Roof and Wall Coverings Part 1 0 : Galvanized Corrugated Steel. Metric Units Code of Practice for Foundations for Machinery Part 1 Foundations for Reciprocating Machines

Hot Rolled Products of Non-Alloy Structural Steels Technical Delivery Conditions

Specification for Structural Steel Equal and Unequal Leg Angles

Part 1 : Dimensions

Part 2: Tolerances on Shape and Dimensions

Hot Finished Structural Hollow Sections of Non-Alloy and Fine Grain Structural Steels

Part 1 : Technical Delivery Requirements

Part 2: Tolerances, Dimensions and Sectional Properties

BS EN I S 0 1 4 6 1 Hot Dip Galvanized Coatings on Fabricated lron and Steel

Articles

DIN 4 0 2 4 Part 2 Machine Foundations: Part 2: Rigid Foundations for Machinery w i t h Periodic Excitation

Part 1

IEC 6 1 0 2 4 - 1 Protection of Structures against Lightning Part 1 : General

Principles I S 0 1 2 9 4 4

Part 1

NACE RPO

Paints and Varnishes - Corrosion Protection of Steel

Structures by Protective Paint Systems -

Part 1: General Introduction

Protection Against Corrosion of lron and Steel in

Structures - Zinc and Aluminum Coating

1 8 7 Design Considerations for Corrosion Control of Reinforcing

DOC. NO. KOC-C-002 NFPA 2 5 1 NFPA 7 8 0 SSPC SP 6 UBC (Vol. 1 - 3 ) UFC 4 . 2 . 2 KOC Standards KOC-C-00 I K O C - ( - 0 0 3 KOC-(-005 K O C - ( - 0 2 4 Part 1 KOC-C-024 Part 2

Standard Methods of Tests of Fire Endurance of Building Construction and Materials

Standard for the lnstallation of Lightning Protection Systems

The Society for Protective Coating - Commercial Blast

Cleaning NACE No.

3

- 2 0 0 0 (Steel Structures Painting

Manual, Ch. 2 - Surface Preparation Specifications)

Uniform Building Code

Vol. 1 - Administrative Fire and Life Safety, and Field

Inspection Provisions

Vol. 2 - Structural Engineering Design Provisions

Vol.

3

- Material, Testing and lnstallation standards Uniform Fire Code

KOC Standard for Basic Civil Engineering Design Data KOC Standard for Geotechnical Investigation (Onshore)

KOC Standard for Materials and Workmanship - Site

Preparation and Earthwork

KOC Standard for Concrete Work - Materials and

Construction

KOC Standard for Structural Steel Work - Materials,

Fabrication and Erection

KOC Standard for Materials and Workmanship -

Roadways, Paving and Hard Standing : Flexible Pavement

KOC Standard for Materials and Workmanship -

Roadways, Paving and Hard Standing : Miscellaneous

Works & Rigid Pavement

KOC Recommended Practice for Drainage Systems KOC Standard for Storage Tank Foundations

KOC Standard for Materials and Workmanship - Fire

Proofing of Structural Steel Work

DOC. NO. KOC-C-002 Page 15 of 69 R E V . l K O C - ( - 0 3 3 KOC-E-024 KOC-G-002 KOC-G-007 KOC-L-002 KOC-L-006 KOC-L-009 KOC-L-026 KOC-L-027 KOC-P-001 3 8 1 11 3 Part 1 3 8 11020 3 8 1 / 0 2 2

KOC Standard for Materials and Workmanship - Bund Wall

for Storage Tanks

KOC Recommended Practice for Earthing and Bonding KOC Standard for Hazardous Area Classification

KOC Standard for Basic Design Data

KOC Recommended Practice for the Protection of KOC Services: Spacing Between Pipelines, Piping, Cables and Buildings 1 Housing Projects

KOC Standard for Fire and Gas Detection Equipment KOC Standard for Fire Protection and Safety Equipment

KOC Recommended Practice for External Cathodic

Protection of New Steel Tank Bottoms

KOC Standard for Layout, Spacing and Diking of Aboveground Petroleum Storage Tanks

KOC Standard for Painting and Coating of Metal Surfaces - N e w Construction

Standard Requirements and Regulations for the Protection of KOC Services Part 1: Crossing of Roads and

Motorways under Construction

General Specification of Electrical Engineering (March, 1 9 8 3 )

General Specification for Civil Engineering and Building Works (Feb. 1 9 8 3 )

KOC Fire & Safety Regulations

4.3 KOC Standard D r a w i n s

1 5 - 2 - 6 Standard Security Fence - Chain Link Fencing & General Details

1 5-2-7 Standard Security Fence - Shallow Foundation for Fencing and

Details

1 5 - 5 - 7 5 Chain Link Fence and Gate Details ( 1 . 8 m High)

1 5 - 5 - 7 9 Fence Details

DOC. NO. KOC-C-002

1 5 - 5 - 8 0 Security Chain Link Fence Details ( 2 . 4 m High)

Page 16 of 69

1 5 - 5 - 8 2 Galvanized Corrugated lron Sheet Fence (2.4 m High)

1 5 - 5 - 8 3 Galvanized Corrugated lron Sheet Gate ( 2 . 4 m High) 1 5-1 4-1 3 Standard P i ~ e Sleeves

15-30-1 1 1 Standard Platforms and Crossovers Details 1 5 - 3 0 1 2 0 Standard Steel Anchor Bolts

15-34-1 9 Pipe Crash Barrier Detail

1 5 - 3 9 - 5 3 Standard Steel Ladder Detail 1 5 - 3 9 - 5 4 Standard Handrail Details

1 5 - 3 9 - 5 5 Standard Circular and Rectangular Platforms

1 5 - 3 9 - 5 6 Standard Steel Stair Details

1 5 - 3 9 - 5 7 Standard Stiles and Walkways

ENVIRONMENTAL CONDITIONS

The environmental conditions in Kuwait are severe. Due regard should be given t o the consistently high levels of solar radiation experienced in Kuwait, which may develop surface temperatures of over 80°C (176°F) in exposed metals.

Refer t o KOC-G-007 "KOC Standard for Basic Design Data" which provides the detailed design information regarding the environmental, site and utility supply conditions prevailing throughout the KOC facilities.

HEALTH, SAFETY AND ENVIRONMENT

The engineering design should meet all the applicable Kuwaiti EPA Regulations and should conform t o the relevant KOC Health and Environment (H&E) Guidelines w i t h a view t o protecting personnel and surrounding environment.

All relevant safety requirements of KOC Fire & Safety Regulations and KOC

Health, Safety & Environment Management System (HSEMS) shall be

adhered to, b y the designer

1

contractor, while designing the plant building, structures and foundations t o be installed within KOC areas.

6 3ENGINEERING INFORMATION DOC. NO. KOC-C-002

Prior t o commencement of any preliminary design activities of civil and structural work, the Site should be established b y KOC; and the layout of plant and facility including equipment, utilities and necessary infrastructure should be finalized t o meet the basic requirements of the project(s) in

accordance w i t h the State regulations and all relevant International I

National and KOC Standards as appropriate.

Page 17 of 69

As all the technical information about the major equipment(s) may not be available at the initial design stage, some adjustments should be envisaged in the layout, which shall not affect the planned progress of design.

_Site and Subsurface Information

Where available, a summary of the ground conditions, site topography and subsurface data shall be provided b y KOC through the latest topographical survey and geo-technical investigation reports.

Where the information is insufficient, the necessary detailed topographical survey shall be further carried out t o establish the Site co-ordinates

(Northing & Easting) and Site formation levels as per KOC-C-001"KOC

Standard for Basic Civil Engineering Design Data".

If necessary, detailed soil exploration program shall be conducted t o determine the general subsurface characteristics of the ground at different locations in accordance w i t h K O C - ( - 0 0 3 "KOC Standard for Geo-technical Investigation (Onshore)".

The final report shall, as minimum, provide the soil parameters, ground water table, recommended bearing capacity and settlement criteria at the locations/sites of major structures in order t o establish the reliable and sound engineering design basis for any civil and structural work.

For climatic conditions, refer t o KOC-G-007 "KOC Standard for Basic Design Data".

Permanent monuments or survey points shall be established at all sites and their locations shall be indicated on a record drawing, together w i t h their grid references and elevations.

The Site "Grade Datum Level" shall be decided considering groundwater level and drainage requirements, and shall generally be derived from the high point of plant paving or roadways. The relationship between this level and the Mina Ahmadi Construction Datum (MACD) shall be shown on all major drawings.

DOC. NO. KOC-C-002 Page 18 of 69 REV. 1 Site Preparation and Earthwork

The site preparation and earthwork shall be carried out at the proposed Site(s) as described in KOC-C-005 "KOC Standard for Materials and

Workmanship - Site Preparation and Earthwork" in accordance w i t h the grid

lines, grades and levels decided by the designer

I

contractor in line w i t h the recommended basic design plinth levels in Table I of this RP or as per actual site conditions. Grading shall be carried out as per the approved grading plans.

In case of filling either "Gatch" or locally available materials, suitable as site fill, shall be used on the basis of soil properties as laid d o w n in the relevant clauses of KOC-C-005.

Placement of these materials in successive layers of 1 5 0 m m t o 2 0 0 m m maximum and compaction t o at least 9 5 % of the maximum dry density at O M C by equipment suitable for that purpose, shall comply w i t h the requirements of KOC-C-005.

Spread foundations including storage tanks and plant paving, road sub- grades and any other settlement sensitive equipment supported on fill material shall be designed t o ensure that any settlement that may occur should be within tolerable limits, as given in the relevant clause of this RP

and I or as specified by the equipment manufacturer.

Site Drainaqe

Natural topography of Site and surrounding areas should be considered as

practicable as possible in the planning of overall drainage of the plant 1

facilities b y gravity flow; and shall be graded accordingly t o collect all surface f l o w s and effluents generated in the plant.

Drainage systems for the plant and facilities should be planned adequately w i t h provisions for future extension; and shall be provided t o collect and direct all the surface f l o w s and effluents t o the segregated systems as

detailed in KOC-C-025 "KOC Recommended Practice for Drainage

Systems".

Adequate slopes as required shall be provided across the grids of the plant or facilities site in order t o prevent accumulation of any liquids such as

rainwater and or leaked I spilled products and ensure quick disposal without

ponding.

Basic Desiqn Plinth Levels

The Site Grade Level shall be established for the entire works, where such works should be constructed on a site of graded level ground b y cutting and or filling.

7 . 5 . 2 Basic design plinth levels relative to the appropriate Finished Grade Level

(FGL) of the various work(s) should be followed as a minimum as per the

DOC. NO. KOC-C-002

recommendation in the Table I of this RP.

Table I: k c o m m e n d e d Basic Desiqn Plinth Levels

REV. 1

-

-

SI. No.

-

1

9

1

Basic Design Plinth Level

I

(Minimum)

Hlgh Points o f Plant Paving (HPP) Grade

+

P a v ~ n g Thickness

Unpaved Areas w i t h i n Plant Plot Limits. ( M a x i m u m )

Buildings General Plinth Level IFFL)

Grade - 7 5 m m

Grade

+

4 5 0 m m

Elevated S u b s t a t ~ o n and Switchgear Buildings iFFLlTOCi

Normal Substation and General Control Buildings

Vessels, Static I Dynamic Equipment Supports,

Storage Tanks, Structural Base Plates o f Plant Grade

+

4 0 0 m m Preferably Grade

+

Clear

Headroom 2 1 0 0 mrn

+

Beam D e p t h Grade

+

4 5 0 m m Control Buildings w i t h Mezzanine t y p e floors i

spaces f o r Cables (FFLITOC)

Concrete Bases f o r Columns, Towers, Major

A s decided, b u t preferably Grade

+

21 0 0 m m

+

Floor Thickness Paving Level

+

1 5 0 m m

Structures, Pipe Racks, Steelworks etc. (TOC)

S t a i r w a y and Ladder Bases in Unpaved Areas

I

Grade

+

1 5 0 m m (Unpaved area)

Pumps, Tanks, Miscellaneous Electrical I

Instrument Items supported o n Paving Slab (TOC) L o w Points of Floors t o Open-sided Pump I Compressor Shelters adjacent t o surrounding Paving ITOC)

S t a i r w a y and Ladder Bases in Plant Paving ITOCI

Grade

+

2 0 0 rnm

Paving Level

+

5 0 m m

I

Cable Trenches w i t h Covers in Unpaved Areas

1

Grade

+

1 5 0 m m Concrete Bases for Minor Equipment like small

ITOCI

Cable Trenches w i t h Covers i n Paved Areas (TOC)

ITOC)

Covers over Pipe TrenchesIDrainage Manholes,

Paving Level

+

1 5 0 m m

Paving Level

+

5 0 m m

T o p o f Hydrant Pits & S u m p s and Screeds e t c , as

I

a. W i t h i n Paved Areas (TOCI Flush w i t h Paving

DOC. NO. KOC-C-002

GENERAL DESIGN B !

Desiqn Loads -

Engineering design basis of any civil and structural work shall be established t o consider all possible types of appropriate loads and combinations thereof that will act on the structure(s) within its service life.

All categories of applicable design loads, such as static loads (dead & live), wind loads, seismic loads, dynamic loads (impact & machine induced), pipe- way loads (on elevated pipe racks and or on grade pipe-ways sleepers), friction loads, temperature loads, vehicular loads and fire loads including any unusual loads, shall be accounted as specified in KOC-C-001 "KOC Standard for Basic Civil Engineering Design Data".

Desiqn Load C o m b i n a m

The designerlcontractor shall comply w i t h all the relevant load combinations as specified in KOC-C-001, applicable t o the design of specific buildings and

structures supporting cranes

1

monorails

I

hoists etc.; and shall also be

responsible t o determine any other load combination which may cause the worst condition t o the structure for a particular application or situation.

Design of structures supporting equipment as well as vertical vessels shall consider the worst effects on structures, generated out of several load combinations under different conditions such as erection, test and operating condition(s) in compliance w i t h KOC-C-001.

Design of elevated pipe racks and grade pipe-way supports as well as horizontal vessels including exchanger supports shall take into account the specified load combinations as per KOC-C-001.

In addition t o the above, the governing load combination for each structure should be established t o give the most critical criteria in the design.

Allowable Functional Limits

Structures shall be designed t o behave within the allowable functional limits (stability, contact pressure, deflection, noise, corrosion, fire rating etc.) as appropriate and as stipulated in the relevant clauses of KOC-C-001 in order t o achieve reliability of good performance and reasonable safety.

Any foundation designed for dynamic loads resulting from reciprocating and rotary machines shall comply w i t h the allowable frequency and amplitude limits as specified in KOC-C-001 or as recommended b y the manufacturer in order t o avoid resonance conditions. In case of difference, the most stringent shall apply.

The net maximum pressure under eccentric loading on foundations shall not exceed the allowable bearing pressure.

DOC. NO. KOC-C-002

However, where the soil pressure under foundations due t o dead and wind loads are more than 2 5 % of that due t o dead and live loads, the foundations shall be so proportioned that the maximum net bearing pressure due t o combined dead, live and w i n d loads shall not exceed the allowable bearing pressure b y more than 2 5 % .

Bearinq Pressures and Settlements

Page 21 of 69

Bearing pressure and settlement are the t w o most critical factors in the design considerations for foundations, and a professionally conducted soil investigation t o assess them should be the essential part of the engineering design basis.

REV. 1

The soil report should recommend the foundation types and allowable bearing pressures for design at suitable depths, considering appropriate factors of safety. Following are the recommended ranges of factors of safety against ultimate bearing capacity failure:

a. From 2.0 t o 3 . 0 based on the type of structure and the reliability of the soil condition for normal operating loads.

b. From 1.5 t o 2 . 2 5 for normal operating loads plus the maximum wind or seismic (if applicable) loads as well as for hydrostatic tests where applicable.

Settlements at different points and depths shall be derived from the field tests, and should then be predicted for the buildings and structures under normal load conditions.

Uniform settlements shall generally be limited t o 2 5 m m maximum and

differential settlement to 18 m m maximum so that t h e buildings and

structures can absorb the effects without cracks or undue deformations. However, for storage tank foundations the permissible range of settlements is considered more than the above, and should comply w i t h K O C - ( - 0 2 6 "KOC Standard for Storage Tank Foundation".

The maximum pressure under a foundation shall be computed from the sum of all possible loads such as dead load including the self weight of foundation, live (or imposed) load on the plant, equipment or structure, and wind loads or seismic loads (both not acting together) and the moments transferred from the structural frames t o the base of foundation.

The net maximum pressure after deducting the displaced weight of soil by the foundation shall not exceed the recommended allowable bearing pressure at the foundation level.

DOC. NO. KOC-C-002

In case of tall structures (stacks

I

columns) and towers, due t o the effects of possible sway, the maximum applied bearing pressure under eccentric loading due t o w i n d shall not exceed the allowable bearing pressure.

Desiqnated Materials

All superstructures shall be normally made of either structural concrete or structural steel as specified by the designer in accordance w i t h the clause 1 0 . 0 of K O C - C - 0 0 1 and as described elsewhere in this RP; while all foundations including other substructures shall be generally constructed in concrete in accordance w i t h K O C - C - 0 0 6 .

All concrete structures and foundations should be designed and constructed w i t h the applicable National

I

International codes given in clause 4.2 of this RP. However, the design of concrete structures shall comply in particular w i t h all the requirements as specified in BS 8 1 1 0 , BS CP 3 or ACI 3 1 8 . All concrete structures for retaining aqueous liquids shall be designed and constructed as per the provisions made in BS 8 0 0 7 , w i t h l o w water cement ratio t o make dense concrete in order t o minimize cracks and ensure water tightness.

All materials, workmanship and construction of reinforced, plain and mass concrete shall be in accordance w i t h K O C - C - 0 0 6 . For concreting in hot weather like Kuwait, the provisions of ACI 3 0 5 and K O C - C - 0 0 6 shall be followed particularly during construction.

All structural steelwork shall be designed in compliance w i t h BS 449, AlSC or equivalent and should be fabricated as per K O C - C - 0 0 7 . Welding should comply w i t h the procedures as laid d o w n in A W S D l

. I

and K O C - C - 0 0 7 .

The design of foundations shall include all specified functional and testing requirements for the structures supported thereon. The responses of structures vary widely in their capacity t o accommodate movement of their foundations, and the design of both the structure and the foundation shall be considered interrelated.

The design should take account of the following:

a. all possible relative movements between different parts of a foundation if supported o n compressible and weak soil;

b. movement of the supporting ground or soils due t o seasonal effects, erosion, natural consolidation or compaction due t o vibration; and

c. relative movements between adjacent structures particularly when there are interconnecting pipes or utilities or equipment.

A t sites where the immediate subsoil is found t o be highly compressible, foundations shall be taken d o w n t o deeper depth at a soil stratum of lower compressibility in order t o minimize the long term settlement problems.

DOC. NO. KOC-C-002

As an alternative t o the deeper construction, special measure of ground improvement techniques should be considered. Specialist companies in this field should be consulted t o select a simple, cost effective and appropriate ground improvement technique.

Page 23 of 69

Foundation Types

General Considerations

a. Foundation types (shallow or deep) should be selected after analyzing all

the applicable loads on the structures and their worst combinations, on the basis of recommended allowable soil bearing capacity and permissible settlement at the founding level.

b. Except those for minor structures, building foundations shall not be laid generally in areas of soft and or compressible subsoil t o avoid possible cracks on their load bearing frames and infill masonry walls due t o excessive and non-uniform (differential) settlements.

c. Building, structure and equipment shall not be placed partly on rigid or deep foundations and partly on shallow foundations or partly on compacted fill.

d. Any adjacent building or heavy structure may be founded on different type of foundations and at different soil strata, provided differential settlements are not harmful and are within acceptable limits; and sufficient flexibility should be provided into the design for all interconnecting structures, plant piping, drainage and service trenches. e. The foundation of any building subject t o blast loading shall be designed

t o withstand the dynamic loads and moments resulting from the blast

overpressure, which should be computed as per the current

recommended design models. Other Considerations

Foundation types (shallow or deep) should also be selected from the following requirements as below:

a. Speed of construction b. Cost of construction.

Shallow Foundations DOC. NO. KOC-C-002

Normally, single storied buildings (residential, public, office, amenity and the like), store and laboratory buildings shall be founded on shallow foundations within a minimum depth of 1.0 m t o 1.5 m from the natural ground level or as recommended in the soil investigation report, if the reasonably hard strata of soil is encountered within that depth.

Multistoried buildings such as administrative and control buildings, industrial buildings (workshops & factories), warehouses and utility buildings shall be laid on firm and hard strata generally within a minimum depth of 1 . 5 m t o 2.5 m from the natural ground level (NGL) or as recommended in the soil investigation report.

Page 24 of 69

Plant structures having heavy equipment should be decided for the appropriate foundation types, which shall be laid at the subsoil levels in compliance w i t h the recommendations, allowable bearing capacity and sound judgment of the designer.

R E V . l

Shallow foundations are generally preferred t o transfer loads from one or more columns in the form of isolated footings such as spread, combined or strap footings. But wherever the individual footings overlap or their total area exceeds 7 5 % of the structure or building plan area due t o a l o w permissible soil bearing pressure, raft or m a t foundation should be generally recommended for economv and faster construction.

Raft foundations shall be used also in areas where high and non-uniform

settlements are expected due t o subsoil conditions and / or due t o non-

uniform distribution of heavy loads on the structures. In that case, the foundation level shall be carefully set t o leave sufficient room above for running cable trenches and service lines above the raft. The remaining space between raft and paving shall be sand filled.

The design of spread foundations in the vicinity of existing units or in the place of any dismantled units, should allow for the possible soil contamination b y oil or chemicals, which may have percolated d o w n through loose or porous surface soils t o the bearing stratum.

In that case, foundations should be of such depth as t o ensure safe bearing below any oil softened subsurface or chemically contaminated subsoil.

If a n e w foundation be constructed near an existing foundation, the bottom of both the foundations should be preferably at the same level. Otherwise, slope between the bottom edges of t w o adjacent footings should be maintained at least equal t o 4 5 " ( 1 : 1 ) , but shall not be less than 30" w i t h the horizontal.

Where foundations are expected t o settle due t o the presence of underlying layers of soft subsoil, the initial construction levels should be fixed above

their final required levels so that the drainage of roads or paving surrounding the foundations shall not be adversely affected b y such settlements, nor cause surface water t o f l o w into or pond around the foundation slabs or floors.

Deep Foundations DOC. NO. KOC-C-002

Deep foundations should be provided where shallow foundations are neither feasible due t o weak subsoil conditions, resulting l o w bearing capacity and /

or unacceptable high settlements, nor due t o high loadings giving rise t o various design problems such as stability of structures or overlapping of several foundations at shallow depths.

Deep foundations should be selected after carefully considering the economy, type of foundation required and method of construction t o be adopted. These may be in the form of raft foundations at deeper depths, pile foundations, piers, caissons or retaining walls.

Page 2 5 of 69

The designer I contractor shall comply w i t h the general principles of design for the type of deep foundation as mentioned above t o transfer all the vertical & lateral forces and moments from the superstructures as well as the subsoil forces from the underlying soils (dry, saturated or submerged) and ground water acting on the substructures t o the most reliable

foundation depths, in accordance w i t h relevant BS and I or ACI codes and

standards mentioned in clause 4 . 2 of this RP.

REV. 1

Retaining walls if required, shall be provided for the underground structures and basements t o withstand all the pressures from the surrounding soils including any surcharge as well as from the ground water for stability of the structures in accordance w i t h BS 8 0 0 2 .

Retaining walls should also be provided as necessary t o protect any filled-up elevated areas inside the plants like elevated roads that are subject t o heavy loads or frequent erosion.

Pile foundations should only be considered as an exceptional case, where they are essential t o transfer either the heavy vertical loads t o a very deep strata or large amount of lateral forces t o the surrounding soils in order t o avoid very deep open cut excavations and massive foundations.

Pile foundations should be selected for the appropriate pile type (friction

1

gravity), based on the recommended length & diameter t o achieve the

required pile load bearing capacity as per the soil report; and should also consider the cost effective modes of pile installations (short

I

long, bored

I

driven, insitu

I

precast) for economy and speed of construction.

Note: Details of design and installation method of pile foundations are excluded from this RP and are subject t o the proprietary contractor's exoertise.

Buoyancy Foundations

In some cases, underground structures like basements, tanks and pits may become unstable and buoyant due t o high ground water table. The total weight of structure shall be provided under this condition t o neutralize the uplift pressure from the ground water, especially during empty condition. The minimum factor of safety against uplift shall be not less than 1.5 at empty condition.

The design of foundations under buoyancy condition shall consider the possibility of ingress of surface and ground water, and provision shall be made for pumping out water, which may collect through the voids of concrete in the foundation.

The design shall also consider t o avoid the possibility of flammable gases and / or liquids t o be collected in the foundation.

However, all below ground concrete structures including tanks and pits etc. shall be designed and constructed in compliance w i t h BS 8 0 0 7 or equivalent ACI t o make t h e m watertight in order t o prevent any entry of ground and / or rain water through the bottom slabs and side walls.

Plant. Pipework and Steelwork Supports

Concrete columns, pedestals and sub-grade or grade tie beams shall be adequately anchored into the supporting foundations or t o the underlying foundation slabs, especially where they may be subject t o horizontal loads, overturning or vibrating forces. Reinforcements sufficiently embedded in the substructures, or sufficiently long holding d o w n bolts, shall be provided t o ensure their integral action.

Reinforcements from concrete pedestals where supported on the paving, shall be adequately anchored into the slab t o assure the full transfer of the applied forces.

Concrete bases, plinths and pedestals should extend not less than 5 0 m m beyond the edges of plant or equipment rings, fixed base plates, or slide plates. Sufficient clearance shall be kept between the side of concrete, or the reinforcements, and holding d o w n bolt pockets, sleeves or anchor plates.

High or slender concrete pedestals

I

piers shall be designed as load bearing

concrete columns or walls (where applicable) w i t h due allowance for horizontal loads due t o thermal forces, and for tube bundle removal or replacement.

Major structural bases and all plant and equipment base plates and rings shall be grouted w i t h a flowable non-shrink non-metallic grout.

DOC. NO. KOC-C-002 Page 27 of 69 REV.l

Concrete sleepers for grade pipe-ways shall be minimum 6 0 0 m m above the ground. However, the final levels shall be decided t o satisfy all the piping requirements (available clear height for drain valves, flange connections w i t h 90" bend from the bottom, operability of valves etc.) and shall be made as specified in the approved piping drawings.

Sleepers shall be provided w i t h plain round steel bars of 2 0 m m I 2 5 m m diameter, welded t o a minimum 1 2 m m thick steel plate flushed w i t h concrete top. The t o p surface of the sleeper should slope away from the steel flat plate.

FoundatiBn Protection

Concrete surfaces below ground level that will be in contact w i t h soil except blinding concrete for foundations shall be protected b y three ( 3 ) coats of cold applied modified bituminous paint of total thickness of 1 0 0 0 microns ( 1 . 0 m m ) . Each coat of paint shall be left t o dry before the next coat is applied and backfilling shall commence only after the paint is completely dry.

Foundations shall be placed over a layer of polyethylene sheet, 1 0 0 0 gauge thick, laid over blinding concrete. All sides of foundations and column necks shall be permanently covered w i t h impervious polyethylene sheet of 1 0 0 0 gauge w i t h minimum 1 5 0 m m overlap of the sheeting.

Exposed external surfaces of concrete columns up t o 1 5 0 m m below ground level and concrete pedestals

1

piers up t o 3 0 0 m m above ground level shall be protected w i t h one ( 1 ) coat of l o w viscosity primer and then coated w i t h t w o ( 2 ) coats of light grey-colour epoxy paint of approved quality w i t h a minimum 1 2 5 microns dry film thickness (DFT) per coat.

PLANT STRUCTURES

DynamicEquipment

Dynamic equipment (reciprocatinglrotating) such as pumps, compressors, turbines and similar machines shall be designed for t h e ~ r bases and foundations taking into consideration of all appropriate static and dynamic loads as recommended b y the Manufactureds) and in accordance w i t h BS CP 2 0 1 2 Part 1 and

I

or DIN 4 0 2 4 Part 2.

The base and foundation sizes of these equipment(s) shall be proportioned t o distribute their masses in such a w a y that the vibration and amplitude

limits shall be achieved in compliance w i t h KOC-C-001 and 1 or as

recommended b y the Manufacturer(s).

Large machines or any machine which may have large out of-balance forces should be supported on structures and foundations in order t o minimize:

DOC. NO. KOC-C-002 Page 28 of 69

a. Vibration of the machine;

b. Transmission of vibration t o adjacent foundations, equipment and buildings.

Large pumps or compressors shall have individual foundations. But in case of series of smaller machines in a group, combined foundation(s) should preferably be provided due t o process layout considerations or due t o underlying soft soil areas. In that case, each machine on the combined foundation shall be separated by an upstand kerbing w i t h a drain t o prevent drifting of spilled liquid onto the other part of foundation.

Drivers and driven units should be supported on a common base block adequately stiff t o limit distortion within the tolerance permitted by the Manufacturers.

With independent pump blocks or bases, anchor supports t o the pump suction and discharge lines should, whenever possible, be integral and monolithic w i t h the pump base.

Bases should extend not less than 5 0 m m beyond the edges of fixed

bedplates or sliding plates. Adequate clearance should be provided between any projecting bolt lugs, holding d o w n pockets, sleeves or anchor plates and the concrete edge or the reinforcement.

Holding d o w n bolts shall be designed t o adequately resist all horizontal forces, in addition t o the vertical forces, originating from the machine. The distance from a pocket or bolt t o the edge of the block should be at least

1 0 0 m m in order t o allow for reinforcement.

Pump and compressor bases shall be adequately reinforced in all surfaces, vertical and horizontal. Where bases of small pumps are integral w i t h floors or paving slabs, the designer should ensure that slabs are sufficiently thick at those locations and adequate reinforcements are provided t o prevent the propagation of cracks from the surface due t o vibration.

10.1 . 1 0 Holding d o w n bolt pockets and the space under the bedplates shall be completely filled w i t h grout and all air expelled. Grout thickness should be within the range of 25 m m t o 5 0 m m .

10.1.1 1 However, large machines or any machines w i t h large out-of-balance forces should be grouted in accordance w i t h Manufacturer's requirements, using a flowable non-metallic non-shrink grout. Special grouts shall be placed in compliance w i t h the Manufacturer's instructions. If necessary, placing should be supervised b y a qualified representative of the Manufacturer. 10.1

. I

2 Some large machines, particularly those having out-of balance forces, i.e.

reciprocating compressors, may require alternative means of mounting such as channels set in the foundation block or as recommended b y the manufacturer.

DOC. N O . KOC-C-002 Page 29 of 69 R E V . l

10.1 . I 3 Seoaration ioints of minimum 20 m m w i d t h shall be provided between the equipment foundations and surrounding floor or paving slabs. The joints shall be filled w i t h preformed compressible mineral fibre board and non- shrink grout.

Structures and Overhead Pipe Ra&

Generally structures supporting equipment, process pipes, heat exchangers, vessels, air coolers and electrical I instrument cable racks & cable trays, should preferably be designed in structural steel t o transfer the loads by means of either moment resisting frames or braced frames in compliance w i t h BS 449, AlSC or equivalent as specified in clause 18.0 of this RP. However if necessary, the designer may choose t o support the above on the structures made of concrete, which shall comply w i t h the requirements as

per BS 81 10, ACI 31 8M / 31 8RM or equivalent.

Structures shall be designed t o resist all the appropriate loads, considering various load combinations thereof and design limits as specified in K O C - C ~

001.

Overhead pipe racks shall be wide enough t o include all the proposed pipes

at one or t w o levels; and should also consider additional 25% space for

future extension. For multilevel pipe rack generally, the t o p tier should be catered for utility lines and cable trays t o run the electrical and telecom cables separately.

Pipe racks shall be provided w i t h pipe shoes or plain steel round bars below the pipes t o reduce the friction forces at the various levels.

Pipe racks shall be designed as the moment resisting frames in the transverse direction perpendicular t o the run of pipes and as the braced frames in the longitudinal direction of pipes.

The horizontal spacing of moment resisting frames, composed of steel columns (stanchions) and main beams, and restrained b y longitudinal struts or tie beams, shall be determined by the sizes of pipelines t o be supported and plant layout in the adjoining areas.

For acceptable piping spans w i t h full loads, the column spacing is

recommended in the ranges of 6.0 m t o 7.5 m t o achieve reasonably

economical pipe racks; but in no case shall exceed 12.0 m for any special

design condition, as i t leads t o heavier pipe racks.

However, minimum column spacing shall be limited t o 4.5 m for smaller

pipelines of diameters including and up t o 7 6 m m ( 3 " ) . Spacing less than

6.0 m is not generally preferred t o accommodate the lesser allowable spans

of smaller pipelines and conduits, which then should be supported by intermediate crossbeams.

For multilevel pipe racks, the clear vertical distance between the first and second tiers should be decided on the basis of average and maximum pipeline sizes t o be installed. Adequate clearance should be provided for lines t o lay the pipe-way and for reasonable accessibility for completing field welds, insulation and painting, as well as for fittings and elbows.

DOC. NO. KOC-C-002

Generally, a clear distance of 1.2 m t o 1.8 m should be considered from t o p

of the first tier beam t o the underside of the second tier beam for the average lines.

The first tier of multilevel pipe rack for overhead transfer pipelines shall be fixed at 6 . 5 m clear above the plant roads for heavy cranes movement or 5 . 0 m clear above the process paving level for the smooth passage of major mobile equipment and vehicles without any hindrance.

Page 30 of 69

The first level of load bearing structures and general pipe racks having equipment and process piping shall be above 4 . 0 m clear from the process paved floor in general plant areas, which are accessible t o mobile equipment for the ease of maintenance.

REV.l

Where steel structures support plant and equipment handling flammable materials, fire proofing shall be provided for the specified fire rating in accordance w i t h K O C - C - 0 2 7 "KOC Standard for Materials and Workmanship

- Fireproofing of Structural Steel Works" t o satisfy the passive fire

protection requirements.

Overhead pipe racks having pipes conveying flammable material like gas shall be fire proofed up t o t w o ( 2 ) levels.

1 0 . 2 . 1 0 All the supporting columns for heavy structures shall be suitably tied together at the foundation levels b y means of grade or sub grade tie beams. However, tie beams connecting supports for light structures may be omitted, if they are adequately embedded in the concrete paving where sufficient lateral restraint is provided by the concrete slab.

1 0 . 2 . 1 1 The area should have proper draining facility connected t o the plant drainage system t o prevent accumulation of flammable liquid in case of spillage.

1 0 . 3 Fired Heateys

10.3.1 Foundations for heaters should provide ample natural ventilation between the underside of the firing floor and the concrete foundations. Heater foundations and grade level flue gas ducts should not be placed on such subsoil, which is prone t o drying and shrinkage due t o heat, without adequate air gap and sufficient depth of footings.

1 0 . 3 . 2 The design shall consider the horizontal movements and thrusts t o the columns or piers supporting heaters due t o thermal expansion of the heater.

In soft soil areas, foundations for the flue gas trunking should be arranged to prevent harmful differential settlements between the trunking and the heater stack.

DOC. NO. KOC-C-002

Process Tankaqe

Page 31 of 69 REV. 1

Process tanks shall generally comprise of vertical or horizontal cylindrical steel tanks or vessels, including items like b l o w d o w n tanks and coolers, which primarily form part of process units located within plant plot limits.

Foundations for process tankage should be provided at or near grade levels; and shall be any of the following:

a. Concrete bases or rafts bearing on the surface of the ground

b. Earth foundations w i t h concrete ring walls under the tank perimeter. c . Steel or concrete cradles for horizontal cylindrical tanks

d. Concrete sleeper walls t o support a vertical steel tank b o t t o m clear of the ground.

The t o p surface of tank foundations as per item (a) or (b) above should be finished w i t h 5 0 m m clean sand cushion as a bearing surface and sand layer shall be protected b y an upstand curbing around the periphery from overflowing.

Cradles for horizontal cylindrical tanks should normally be of steel saddles, welded t o the tank shell and saddle supports bearing o n low, flat topped

concrete foundation plinths generally described as in clause 9.6 of this RP.

In cases where tank shells are thin and thermal forces are high, overstressing of tank shells due t o excessive rigidity of the foundations should be avoided. The saddle base plates may have fixed connection w i t h oversized holes at one end and sliding connection w i t h slotted holes a t the other end t o minimize this rigidity.

Cradles of concrete should be designed t o take the full thrusts at their horns (top) and the tank shells should be insulated from any anticipated corrosion on the saddle by means of pads of filler board t o prevent moisture absorption.

For tanks containing flammable materials, the passive fireproofing shall be provided in accordance w i t h KOC-C-027; and the cradle frames shall have provision of drain holes t o avoid accumulation of any liquids.

Only t w o supports should be provided for horizonral cylindrical tanks, when founded on weak soils. In the case of such tanks containing hazardous materials, a rigid slab and multiple supports may be used as an alternative foundation.

DOC. NO. KOC-C-002 Page 3 2 of 69

Steel Stacks

Steel stacks (flares, vent stacks etc.) and process columns are generally thin walled tall cylindrical structures; and should be designed as self supporting wherever possible; or supported by guys t o provide structural stability.

Stacks shall be welded, and shall be embedded into the ground w i t h rigid foundations on the hard bearing stratum at founding levels, that may be selected deeper than the normal founding depths, for stability due t o wind loads. The factor of safety against overturning shall be considered not less than 2.0 as minimum.

Steel stacks and tall cylindrical structures are susceptible t o large amplitude oscillations during steady winds of moderate velocity giving rise t o resonance conditions and ovalling vibrations, if not properly taken care in the design.

Mass and geometry o f stacks w i t h respect t o heights shall be chosen in such a w a y that the critical w i n d velocity should normally be more than the design w i n d velocity at the t o p of the stacks in order t o avoid susceptibility of oscillation. Otherwise, the structure shall be critically damped not t o exceed the acceptable limits of amplitudes due t o wind-induced vibrations. Thin-wall stacks are also susceptible t o ovalling vibrations i.e., oscillations

where the stack cross-section vibrates as a ring. Whenever applicable, additional circumferential stiffeners shall be provided t o the stack in the helical forms (spoilerslstrakes) at the t o p one-third height t o prevent ovalling.

If guys are t o be used t o support the steel stacks, they shall be made of galvanized steel structural strands or steel wire ropes as required. Structural strands shall conform t o the requirements as specified in A S T M A 4 7 5 for sizes up t o 518 inches and ASTM A 5 8 6 for sizes over 518 inches; whereas structural wire ropes shall be as per ASTM A 6 0 3 .

Guys when placed should be fixed at an angle of inclination of 4 5 " for most efficient use, but when not possible due t o any constraints, they should be connected at multi-levels t o the stack. However, guys shall not be fixed t o the stack at slopes lesser than 30" from the horizontal.

Guys shall be anchored in the concrete blocks that shall be designed for the tensile forces from the guys and shall be adequately embedded into the ground.