STANDARDS PUBLICATION
KOC RECOMMENDED PRACTICE FOR ENGINEERING DESIGN BASIS OF CIVIL AND STRUCTURAL WORK DOC. NO. KOC-C-002
STANDARDS TEAM
DOC. NO. KOC-C-002 OC-C-00 2
Page age 1 of 7 4
STANDARDS PUBLICATION
KOC RECOMMENDED PRACTICE FOR ENGINEERING DESIGN BASIS OF CIVIL AND STRUCTURAL WORK DOC. NO. KOC-C-002
STANDARDS TEAM
REV. 2
DOC. NO. KOC-C-002 OC-C-00 2
Page age 1 of 7 4
STANDARDS PUBLICATION
KOC RECOMMENDED PRACTICE FOR ENGINEERING DESIGN BASIS OF CIVIL AND STRUCTURAL WORK DOC. NO. KOC-C-002
STANDARDS TEAM
REV. 2
DOC. NO. KOC-C-002
Page 3 of 74
REV. 2
TABLE OF CONTENTS Page No. FOREWORD
7
1.0
SCOPE
9
2.0
APPLICATION
9
3.0
TERMINOLOGY
9
3.1 3.2
9 10
4.0
Definitions Abbreviations
REFERENCE STANDARDS AND CODES
10
4.1 4.2 4.3 4.4
10 10 16
Conflicts List of Standards and Codes KOC Standard Drawings KOC Health, Safety & Environment Management System (HSEMS)
16
5.0
ENVIRONMENTAL CONDITIONS
16
6.0
HEALTH, SAFETY AND ENVIRONMENT
17
7.0
BASIC ENGINEERING INFORMATION
17
7.1 7.2 7.3 7.4 7.5
17 17 18 18 19
8.0
9.0
General Site and Subsurface Information Site Preparation and Earthwork Site Drainage Basic Design Plinth Levels
GENERAL DESIGN BASIS
20
8.1 8.2 8.3 8.4 8.5
20 20 20 21 22
Design Loads Design Load Combinations Allowable Functional Limits Bearing Pressures and Settlements Designated Materials
FOUNDATIONS
22
9.1 9.2 9.3 9.4 9.5 9.6 9.7
22 24 24 25 26 27 28
General Foundation Types Shallow Foundations Deep Foundations Buoyancy Foundations Plant, Pipework and Steelwork Supports Foundation Protection
DOC. NO. KOC-C-002 10.0
11.0
12.0
13.0
14.0
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PLANT STRUCTURES
28
10.1 10.2 10.3 10.4 10.5
28 29 31 31 32
Dynamic Equipment Structures and Overhead Pipe Racks Fired Heaters Process Tankage Steel Stacks
PLANT AND NON-PLANT BUILDINGS
33
11.1 11.2 11.3 11.4
33 35 38 38
Substation Buildings and Transformers Control Buildings Other Plant Buildings Non-Plant Buildings
PAVING AND ACCESSWAYS
38
12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8
38 40 40 41 41 41 42 42
General Paving Arrangement Edging and Kerbing Widths of Access-ways Live (Imposed) Loads Soil Supported Concrete Paving Joints Unpaved Areas
ROADWAYS
43
13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 13.9 13.10 13.11 13.12 13.13 13.14
43 43 43 43 43 44 44 44 46 46 46 46 47 47
General Roadway Construction Duty Vehicular Loads Design Life Existing Roads Road Bridges Road Geometry Road Shoulders Road Drainage Road Blockers & Vehicle Barriers Kerbing Road / Traffic Markings Traffic Signs
MISCELLANEOUS CIVIL WORKS FOR SERVICES AND PIPELINES
47
14.1 14.2 14.3 14.4 14.5 14.6 14.7
47 48 48 49 49 50 50
Electrical and Instrument Cable Trenches Telephone Cable Trenches Pipe Trenches Cable Ducts Ducts for Instrument Cables Ducts and Cable Trenches at Buildings Pipe Sleeves
DOC. NO. KOC-C-002 14.8 14.9 14.10 14.11 14.12 14.13 15.0
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Valve Pits Floodlight Masts Fire Hydrant Pits Earthing Lightning Protection Warning Lights
REV. 2 51 51 52 52 52 52
STEEL STORAGE TANKS
52
15.1 15.2 15.3 15.4 15.5
52 53 54 55 56
General Foundation Design Criteria Foundation Design Dikes Drainage Within Dikes
16.0
CONCRETE STORAGE TANKS
56
17.0
FENCING
57
17.1 17.2 17.3 17.4
57 57 57 58
18.0
19.0
20.0
21.0
General Type of Fencing Chain Link Fencing Corrugated Sheet Fencing
STRUCTURAL WORK
58
18.1 18.2 18.3 18.4 18.5 18.6 18.7
58 59 59 61 62 62 62
General Structural Form Design Conditions Design Stress Levels Passive Fire Protection Painting / Galvanizing Connections
MISCELLANEOUS METAL WORK
63
19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8
63 64 64 65 65 66 66 66
Platforms Steel Flooring Stairways Spiral Stairways Ladders Handrails and Toe Plates Ramps Claddings
CONCRETE WORK
66
20.1 20.2 20.3 20.4
66 68 69 69
Design Consideration for Concrete Work Maximum and Minimum Reinforcement Spacing Minimum Reinforcement Joints
PRECAST CONCRETE
69
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22.0
ANCHOR BOLT
69
23.0
CONCRETE MASONRY STRUCTURES
70
24.0
GROUTING
70
25.0
OVERHEAD CLEARANCES
70
26.0
DESIGN SOFTWARES
71
27.0
QUALITY ASSURANCE
71
28.0
DOCUMENTATION
71
28.1 28.2
71 72
General Deliverables
ACKNOWLEDGEMENT
73
Major Changes in this Revision (Rev.2) Sl. No
Clause No.
1
Foreword
2
3.0
3
4.0 & 6.0
4
7.0 & 8.0
5
9.0
6
10.0 & 11.0
7
12.0
Changes Foreword updated. Clauses 3.1.1, 3.1.2 & 3.2 are updated Clauses 4.1 to 4.3 & 6.0 are updated. New clause 4.4 is added. Sub-clause 7.5.2, Table-1 & 8.4.5 are updated. New sub-clause 7.3.5 is added. Original clause 8.5.3 is deleted. Accordingly, subclauses 8.5.4 and 8.5.5 are renumbered. New sub-clause 9.1.5 is added. Sub-clauses 9.3.1, 9.3.2, 9.4.5, 9.5.4, 9.6.1 & 9.6.5, 9.7.1 & 9.7.2 are updated. Sub-Clause 9.7.3 is deleted Original sub-clause 10.2.8 is deleted. Accordingly, sub-clauses 10.2.9 to 10.2.11 are renumbered and updated. Sub-clauses 10.5.2, 11.1.3, 11.1.6, 11.1.11 to 11.1.14, 11.2.2, 11.2.4, 11.2.6, are updated. Original sub-clause 11.1.15 is deleted. Original clause 12.5 is deleted and incorporated in clause no 25.0. Also original Table IV is deleted. Accordingly, Clauses 12.6 to 12.9 are renumbered. Sub-clauses 13.4, 13.8.2, 13.8.3, 13.8.4, 13.10.3, 13.11.1, 14.2, 14.3.2, 14.3.3, 14.4.1, 14.7.1(iv), 14.8.1, 14.8.4, 14.12.1, 15.1.2, 15.1.3, 15.4.3 & 16.4 are updated. Original sub-clauses 13.7.3 & 14.12.2 are deleted. Original Sub-clause 13.15 is deleted and incorporated in clause no 25.0. New sub-clause 14.8.5 is added. Sub-clauses 17.4.2, 18.3.2, 18.7.1 to 18.7.4 are updated. New subclauses 18.3.3 to 18.3.21 are added. Clauses 19.2.1 & 19.3.7 are updated. New sub-clause 19.5.7 is added.
8
13.0, 14.0, 15.0 & 16.0
9
17 & 18.0
10
19.0
11
20.0 to 26.0
New clauses 20.0 to 26.0 are added.
12
27.0 & 28.0
Original clauses 20.0 & 21.0 are renumbered as 27.0 & 28.0
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FOREWORD I 2 I This document “KOC Recommended Practice for Engineering Design Basis of Civil and Structural Work” (KOC-C-002) is intended to 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. The earlier document KOC-C-002 Rev.1, issued in June 2003 has been revised for conformance with the latest revisions of relevant International / National Standards. This KOC Recommended Practice (RP) has been approved by the Standards Team in consultation with the Standards Technical Committee (STC) for use throughout the Engineering and Operational functions of Kuwait Oil Company (K.S.C). This RP sets out to achieve the f ollowing objectives: a)
To recommend the general practices to be adopted in the design of plant / nonplant buildings and plant structures including foundation for equipment / storage tanks, paving and access-ways, roadways and other miscellaneous civil and structural works within KOC onshore plants & Facilities.
b)
To establish the practical guidelines on the engineering design basis describing various design aspects with a view to achieving reasonably safe and economical construction as well as reliable service life.
c)
To assist the designers by giving an access to the necessary level of documented technical information with a view to optimizing their design efforts and productivity.
d)
To provide general technical guidance for developing project specifications and design / construction drawings in order to ensure a consistent approach for sound engineering basis, material selection and workmanship in civil and structural work.
e)
To set out minimum requirements to monitor compliance with a contract.
Feedback as well as any comments or suggestions derived from the application of this Recommended Practice (RP) at any stage of design, engineering, construction, fabrication, erection, maintenance and field experiences are invited and should be directed to: Team Leader Standards (Chairman, Standards Technical Committee) Projects Support Services Group, K.O.C. P.O.Box-9758, Ahmadi - 61008 State of Kuwait
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Task Force Responsible for the Revision of this Recommended Practice I 2 I The Revision of this Recommended Practice was entrusted by the Standards Technical Committee to the Task Force (TF-C/21) comprising of the following members:Mr. Narayan Roy
Standards Team
TF Leader
Tel. 61469
Mr. M. Javaid Masood
Project Mgmt.(NK) Team
Member
Tel. 23931
Mr. Javed Ahmad
General Projects Team
Member
Tel. 71430
Mr. Nataraj Ramaswami
Technical Expertise Team
Member
Tel. 61381
Mr. Shamshad Alam
Project Mgmt.(WK) Team
Member
Tel. 20625
Dr. Waleed Hindi
PMC - Flour
Member
Tel. 61852
Mr. Farahbakhsh Behnam
PMC - AMEC
Member
Tel. 63574
Mr. Omar Warrich
PMC - Worley Parsons
Member
Tel. 63158
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1.0
SCOPE
1.1
This Recommended Practice (RP) specifies the basic technical requirements and defines the sound engineering design basis for general civil and structural works including plant / non-plant buildings, plant structures, foundation for equipment / storage tanks, paving and access-ways, roadways and other miscellaneous civil and structural works for installations at the KOC onshore plants and Facilities within Kuwait.
1.2
This RP 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 with tanker berths.
1.3
This RP shall not be applicable to 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.
1.4
The contents of this RP are intended to be adopted as a design guide to meet the minimum KOC requirements. However, the detailed specifications / design shall be provided by the Designer / Contractor for KOC approval.
2.0
APPLICATION
2.1
The design, materials and workmanship of any civil and structural work shall conform to the requirements of this RP and the reference standards and codes mentioned herein.
2.2
Any exceptions or deviations from this RP, along with their merits and justifications, shall be brought to the attention of KOC Controlling Team(s) for their review, consideration and amendment by Standards Team (if required).
2.3
Compliance with this RP does not of itself confer immunity from legal or statutory obligations.
3.0
TERMINOLOGY
3.1
Definitions For the purposes of this RP, the following definitions shall apply.
3.1.1
Contractor I 2 I The person, persons, firm or company contracted by KOC to undertake the execution of the Work defined by the Contract.
3.1.2
Designer I 2 I Person or persons from KOC or from Consultant / Contractor approved by KOC, who undertakes the responsibility of the actual design and detailed specifications of civil and structural work. NB : For other applicable terminology, refer to the relevant definitions in the family of KOC Standards mentioned in clause 4.2.2 of this RP.
DOC. NO. KOC-C-002 3.2
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REV. 2
Abbreviations I 2 I AASHTO BS CIRIA EPA EPDM FFL FGL GC HPP HSE HVAC IBC KOC LRFD NGL OSHA OMC TOC UL
American Association of State Highways and Transportation Officials Booster Station Construction Industry Research and Information Association Environmental Public Authority Epoxy Damp-proof Membrane Finished Floor Level Finished Grade Level Gathering Center Highest Paving Point Health, Safety and Environment Heating, Ventilating, and Air Conditioning International Building Code Kuwait Oil Company (K.S.C.) Load and Resistance Factor Design Natural Ground Level Occupational Safety & Health Administration Optimum Moisture Content Top of Concrete Underwriters Laboratories
4.0
REFERENCE STANDARDS AND CODES I 2 I
4.1
Conflicts I 2 I In the event of conflicts between this RP and the latest edition of 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 to the attention of KOC Controlling Team.
4.2
List of Standards and Codes I 2 I The latest edition of the following standards, codes and specifications (including amendment if any) shall apply:
4.2.1
International / National Standards and Codes American Association of State Highways and Transportation Officials (AASTHO) AASHTO GDPS
Guide for Design of Pavement Structures
AASHTO LRFDUS AASHTO LRFD Bridge Design Specifications American Concrete Institute (ACI) ACI 224.3R
Joints in Concrete Construction
ACI 301
Specifications for Structural Concrete
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ACI 302.1R
Guide for Concrete Floor and Slab Construction
ACI 305R
Guide to Hot Weather Concreting
ACI 318M
Building Code Requirements for Reinforced Concrete
ACI 336.2R
Suggested Analysis and Design Procedures for Combined Footings and Mats
ACI 343R
Analysis and Design of Reinforced Concrete Bridge Structures
ACI 350
Code Requirements for Environmental Concrete Structures and Commentary
ACI 530/530.1
Building Code Requirements and Specification for Masonry Structures
ACI SP-66
ACI Detailing Manual
Engineering
American Institute of Steel Construction (AISC) AISC 325
Steel Construction Manual
AISC 326
Detailing for Steel Construction
AISC 327
Seismic Design Manual
AISC 341
Seismic Provisions for Structural Steel Buildings
AISC 360
Specification for Structural Steel Buildings
American Ladder Institute (ALI) ALI A14.3
American National Standard for Ladders - Fixed Safety Requirements
American Petroleum Institute (API) API STD 650
Welded Tanks for Oil Storage
API RP 752
Management of Hazards Associated with Location of Process Plant Permanent Buildings
American Society of Civil Engineers (ASCE) ASCE 5 & 6
Building Code Requirements for Masonry Structures and Specifications for Masonry Structures
ASCE 7
Minimum Design Loads for Buildings and Other Structures
ASCE 10
Design of Latticed Steel Transmission Structures
ASCE 41258
Anchorage Design for Petrochemical Facilities
ASTM International (ASTM) ASTM A6/6M
Standard Specification for General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling
ASTM A36/A36M
Specification for Carbon Structural Steel
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ASTM A121
Standard Specification for Metallic-Coated Carbon Steel Barbed Wire
ASTM A307
Standard Specification for Carbon Steel Bolts, Studs, and Threaded Rod 60000 psi Tensile Strength
ASTM A325M
Standard Specification for Structural Bolts, Steel, Heat Treated 830 MPa Minimum Tensile Strength (Metric)
ASTM A392
Standard Specification for Zinc-Coated Steel Chain-Link Fence Fabric
ASTM A449
Standard Specification for Hex Cap Screws, Bolts and Studs, Steel, Heat Treated, 120/105/90 ksi Minimum Tensile Strength, General Use
ASTM A475
Standard Specification for Zinc-Coated Steel Wire Str and
ASTM A490M
Standard Specification for High-Strength Steel Bolts, Classes 10.9 and 10.9.3, for Structural Steel Joints (Metric)
ASTM A586
Standard Specification for Zinc-Coated Parallel and Helical Steel Wire Structural Strand
ASTM A603
Standard Specification for Zinc-Coated Steel Structural Wire Rope
ASTM A615/A615M
Standard Specification for Deformed and Plain CarbonSteel Bars for Concrete Reinforcement
ASTM A653/A653M
Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process
ASTM D1751
Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)
ASTM E814
Standard Test Method for Fire Tests of Penetration Firestop Systems
ASTM F1083
Standard Specification for Pipe, Steel, Hot-Dipped Zinc Coated (Galvanized) Welded, for Fence Structures
ASTM F1554
Standard Specification for Anchor Bolts, Steel, 36, 55, and 105-ksi Yield Strength
ASTM F1637
Standard Practice for Safe Walking Surfaces
American Society of Safety Engineers (ASSE) ASSE 1264.1
Safety Requirements for Workplace Walking / Working Surfaces & Their Access; Workplace Floor, Wall & Roof Openings; Stairs & Guardrails Systems
American Welding Society (AWS) AWS D1.1/D1.1M
Structural Welding Code - Steel
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British Standards Institution (BSI) BS 4-1
Structural Steel Sections - Part 1: Specification for HotRolled Sections
BS 476 Pt 20 & 21 Fire Tests on Building Materials and Structures Part 20: Method for Determination of the Fire Resistance of Elements of Construction (General Principles) Part 21: Methods for Determination of the Fire Resistance of Loadbearing Elements of Construction BS 3083
Specification for Hot-Dip Zinc Coated and Hot-Dip Aluminum / Zinc Coated Corrugated Steel Sheets for General Purposes
BS 3692
ISO Metric Precision Hexagon Bolts, Screws and Nuts Specification
BS 4190
ISO Metric Black Hexagon Bolts, Screws and Nuts Specification
BS 4449
Steel for the Reinforcement of Concrete - Weldable Reinforcing Steel - Bar, Coil and Decoiled Product – Specification
BS 4483
Steel Fabric Specification
BS 4592 Part 1
Industrial Type Flooring and Stair Treads - Part 1: Metal Open Bar Gratings - Specification
BS 5427 Part 1
Code of Practice for the Use of Profiled Sheet for Roof and Wall Cladding on Buildings Part 1: Design
BS 8666
Scheduling, Dimensioning, Bending and Cutting of Steel Reinforcement for Concrete – Specification
BS CP 143
Sheet Roof and Wall Coverings - Part 10: Galvanized Corrugated Steel - Metric units
BS CP 2012
Code of Practice for Foundations for Machinery - Part 1: Foundations for Reciprocating Machines
BS EN 1992
Eurocode 2: Design of Concrete Structures
BS EN 1993
Eurocode 3: Design of Steel Structures
BS EN 1993-3-1
Eurocode 3 - Design of Steel Structures - Part 3-1: Towers, Masts and Chimneys - Towers and Masts
BS EN 1996
Eurocode 6 - Design of Masonry Structures
BS EN 1997-1
Eurocode 7: Geotechnical Design - Part 1: General Rules
BS EN 10025
Hot Rolled Products of Structural Steels
for
the
Reinforcement
of
Concrete
-
DOC. NO. KOC-C-002 BS EN 10056
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Structural Steel Equal and Unequal Leg Angles Part 1: Dimensions Part 2: Tolerances on Shape and Dimensions
BS EN 10210
Hot Finished Structural Hollow Sections of Non-Alloy and Fine Grain Steels Part 1: Technical Delivery Requirements Part 2: Tolerances, Dimensions and Sectional properties
BS EN 14399
High-Strength Structural Bolting Assemblies for Preloading (Part 1 to 10)
BS EN ISO1461
Hot Dip Galvanized Coatings on Fabricated Iron and Steel Articles - Specifications and Test Methods
International Electrotechnical Commission (IEC) IEC 62305
Protection Against Lightning
IEC 62561
Lightning Protection Components (LPSC) - Part Requirements for Earthing Enhancing Compounds
7:
International Organization for Standardization (ISO) ISO 12944 Part-1
Paints and Varnishes - Corrosion Protection of Steel Structures by Protective Paint Systems - Part 1: General Introduction
ISO 14713
Zinc coatings - Guidelines and Recommendations for the Protection Against Corrosion of Iron and Steel in Structures
National Association of Corrosion Engineers (NACE) NACE SP0187
Design Considerations for Corrosion Control of Reinforcing Steel in Concrete
National Fire Protection Association (NFPA)
4.2.2
NFPA 251
Standard Methods of Tests of Fire Resistance of Building Construction and Materials
NFPA 780
Standard for the Installation of Systems
SSPC SP6
Commercial Blast Cleaning
Lightning Protection
KOC Standards KOC-C-001
KOC Standard for Basic Civil Engineering Design Data
KOC-C-003
KOC Standard for Geotechnical Investigation (Onshore)
KOC-C-005
KOC Standard for Materials and Workmanship - Site Preparation and Earthworks
KOC-C-006
KOC Standard for Concrete Work Construction
- Materials and
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KOC-C-007
KOC Standard for Structural Steel Work - Materials, Fabrication and Erection
KOC-C-008
KOC Standard for Masonry Works and Plastering Materials and Workmanship
KOC-C-024
KOC Standard for Materials and Workmanship - Roadways, Paving and Hard Standing: Part 1: Flexible Pavement
KOC-C-024
KOC Standard for Materials and Workmanship - Roadways, Paving and Hard Standing: Part 2: Miscellaneous Works & Rigid Pavement
KOC-C-025
KOC Recommended Practice for Drainage Systems Design, Materials and Construction
KOC-C-026
KOC Standard for Storage Tank Foundation
KOC-C-027
KOC Standard for Fireproofing of Structural Steelwork
KOC-C-030
KOC Recommended Practice for Blast Resistant Design of Buildings
KOC-C-033
KOC Standard for Bund Walls for Storage Tanks Materials and Workmanship
KOC-E-003 Pt.1
KOC Recommended Practice Selection of Electrical systems
KOC-E-008
KOC Recommended Practice for the Design, Selection and Installation of Electric Cables, Cable Systems and Wiring
KOC-E-024
KOC Recommended Practice for Earthing and Bonding
KOC-G-007
KOC Standard for Basic Design Data
KOC-G-019 Pt. 2
KOC Standard for Security Systems: Part 2 - Security Fences, Gates, Road Blockers, Vehicle Barriers, New Buildings and Guard Houses
KOC-I-002
KOC Standard for Instrument Installation.
KOC-L-002
KOC Recommended Practice for the Protection of KOC Services: Clearance Requirements for Buried Pipelines, Cables, Underground Structures, Buildings and Housing Projects
KOC-L-006
KOC Standard for Fire & Gas Detection Equipment
KOC-L-009
KOC Standard for Fire Protection Systems and Safety Equipment
KOC-L-025
KOC Recommended Practice for Scaffolding
KOC-L-026
KOC Recommended Practice for External Protection of On-Grade Steel Tank Bottom
KOC-L-027
KOC Standard for Layout, Spacing and Aboveground Petroleum Storage Tanks
KOC-L-028
KOC Recommended Practice for Plant Layout (including Spacing Charts)
for
Design
Basis and
Cathodic Diking of
DOC. NO. KOC-C-002 KOC-P-001 KOC-S-001 KOC-T-008 4.3
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KOC Standard for Painting and Coating of External Metal Surfaces Standard Guideline for Safe Roads, Road Closure and Installation of Display Boards / Signs on KOC Roads KOC Recommended Practice for Installation of Optical Fibre Cable
KOC Standard Drawings I 2 I 55-02-17
Standard Security Fence - Chain Link Fencing & General Details
55-02-18
Security Fence - Shallow Foundation Fencing and Details
55-02-20
Security Fence - Gate Details
55-02-25
Chain Link Fence and Gate Details (1.8 m High)
55-02-26
Galvanized Corrugated Iron Sheet Fence (1.9 m High) General Arrangement and Details
55-02-28
Security Chain Link Fence Details (2.4 m High)
55-02-30
Galvanized Corrugated Iron Sheet Fence (2.4 m High) General Arrangement and Details
55-02-31
Galvanized Corrugated Iron Sheet Gate (2.4 m High) General Arrangement and Details
55-04-77
Standard Pipe Sleeves for Metallic & (RTRP/GRE/HDPE/PVC/Etc.) Carrier Pipes
55-02-54
Platforms and Crossovers Details
55-02-62
Steel Anchor Bolts
55-02-39
Valve Pit for Pipelines
55-02-40
Pipe Crash Barrier Details
55-02-57
Standard Ladder Details
55-02-58
Standard Handrail Details
55-02-59
Circular and Rectangular Platforms-Typical Details
55-02-61
Steel Stair Details
55-02-64
Standard Stiles and Walkways
Non-Metallic
KOC Health, Safety & Environment Management System (HSEMS) I 2 I KOC.PS.001
Process Safety Management Manual
KOC HSE Policy KOC HSEMS Guide Relevant KOC HSEMS Procedures (Latest), as applicable 5.0
ENVIRONMENTAL CONDITIONS
5.1
The environmental conditions in Kuwait are severe. Due regard should be given
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to the consistently high levels of solar radiation experienced in Kuwait, which may develop surface temperatures of over 80 C (176F) in exposed metals. 5.2
Refer to 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.
6.0
HEALTH, SAFETY AND ENVIRONMENT I 2 I
6.1
The engineering design should meet all the applicable Kuwait EPA Regulations and should conform to the applicable HSEMS procedures to protect personnel and surrounding environment within KOC Facilities.
6.2
All relevant HSE requirements of KOC HSE Policy, HSEMS Guide and relevant applicable HSEMS Procedures shall be adhered to during the design of plant / non-plant buildings, structures and foundations in KOC Facilities.
7.0
BASIC ENGINEERING INFORMATION
7.1
General
7.1.1
Prior to commencement of any preliminary design activities of civil and structural work, the Site should be established by KOC; and the layout of plant and facility including equipment, utilities and necessary infrastructure should be finalized to meet the basic requirements of the project(s) in accordance with the State regulations and all relevant International / National and KOC Standards as appropriate.
7.1.2
As all the technical information about the major equipment 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.
7.2
Site and Subsurface Information
7.2.1
Where available, a summary of the ground conditions, site topography and subsurface data shall be provided by KOC through the latest topographical survey and geo-technical investigation reports.
7.2.2
Where the information is insufficient, the necessary detailed topographical survey shall be further carried out to establish the Site co-ordinates (Northing & Easting) and Site formation levels as per KOC-C-001 “KOC Standard for Basic Civil Engineering Design Data”.
7.2.3
If necessary, detailed soil exploration program shall be conducted to determine the general subsurface characteristics of the ground at different locations in accordance with KOC-C-003 “KOC Standard for Geotechnical 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 to establish the reliable and sound engineering design basis for any civil and structural work.
7.2.4
For climatic conditions, refer to KOC-G-007 “KOC Standard for Basic Design Data”.
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7.2.5
Permanent monuments or survey points shall be established at all sites and their locations shall be indicated on a record drawing, together with their grid references and elevations.
7.2.6
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.
7.3
Site Preparation and Earthwork I 2 I
7.3.1
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 Earthworks" in accordance with the grid lines, grades and levels decided by the designer / contractor in line with the recommended basic design plinth levels in Table-1 of this RP. Grading shall be carried out as per the KOC approved grading plans. Site preparation and earthwork shall also comply all applicable KOC HSEMS Procedures.
7.3.2
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 down in the relevant clauses of KOC-C-005.
7.3.3
Placement of these materials in successive layers of 150 mm to 200 mm maximum and compaction to at least 95% of the maximum dry density at OMC by equipment suitable for that purpose, shall comply with the requirements of KOC-C-005.
7.3.4
Spread foundations including storage tanks and plant paving, road sub-grades and any other settlement sensitive equipment supported on fill material shall be designed to ensure that any settlement that may occur should be within tolerable limits, as given in the relevant clause of this RP and / or as specified by the equipment Manufacturer.
7.3.5
Earthwork slopes against storm water / wind erosion for road embankments and general earthwork slopes shall be protected by asphalt lining, bitumen sand mix lining, or concrete lining.
7.4
Site Drainage
7.4.1
Natural topography of Site and surrounding areas should be considered as practicable as possible in the planning of overall drainage of the plant / Facilities by gravity flow; and shall be graded accordingly to collect all surface flows and effluents generated in the plant.
7.4.2
Drainage systems for the plant and Facilities should be planned adequately with provisions for future extension; and shall be provided to collect and direct all the surface flows and effluents to the segregated systems as detailed in KOC-C-025 “KOC Recommended Practice for Drainage Systems - Design, Materials and Construction”.
7.4.3
Adequate slopes as required shall be provided across the grids of the plant or Facilities site in order to prevent accumulation of any liquids such as rainwater and or leaked / spilled products and ensure quick disposal without ponding.
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7.5
Basic Design Plinth Levels I 2 I
7.5.1
The Site Grade Level shall be established for the entire works, where such works should be constructed on a site of graded level ground by 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 recommendation in the Table-1 of this RP. Table-1: Recommended Basic Design Plinth Levels Sl. No.
Description
Basic Design Plinth Level (Minimum)
1
High Points of Plant Paving (HPP)
FGL + Paving Thickness
2
Unpaved Areas within Plant Plot Limits, (Maximum)
FGL - 75 mm
3
General Buildings (FFL)
FGL + 300 mm
4
Elevated Substation and Switchgear Buildings (FFL / TOC)
Preferably FGL + Clear Headroom 2100 mm + Beam Depth
5
Normal Substation and General Control Buildings
FGL + 450 mm
(FFL / TOC) 6
7
8
Control Buildings with Mezzanine type floors / spaces As decided, but preferably FGL for Cables (FFL / TOC)
+ 2100 mm + Floor Thickness
Top of concrete Foundation for Columns, Towers, Major Vessels, Static / Dynamic Equipment, Storage
HPP + 150 mm (Paved area)
Tanks, Structural Base Plates of Plant Structures, Pipe Racks, Steelworks etc. (TOC)
FGL + 450 mm (Unpaved area)
Top of concrete Foundation for Minor Equipment like small Pumps, Tanks, Miscellaneous Electrical /
HPP + 150mm
Instrument Items supported on Paving Slab (TOC) 9
Low Points
of
Floors
to
Open-sided
Pump
/
FGL + 200 mm
Compressor Shelters adjacent to surrounding Paving (TOC) 10
Top of concrete foundations for Stairway and Ladder in Plant Paving (TOC)
Paving Level + 100 mm
11
Top of Concrete foundations for Stairway and Ladder in Unpaved Areas (TOC)
FGL + 150 mm
12
Top of Cable Trenches with Covers in Paved Areas (TOC)
Flush with Paving
13
Top of Cable Trenches with Covers in Unpaved Areas (TOC)
FGL + 150 mm
14
Top of Covers over Pipe Trenches and Drainage Manholes, Hydrant Pits & Sumps etc. as follows: a) Within Paved Areas (TOC) b) In Unpaved Areas (TOC)
Flush with Paving FGL + 150 mm
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8.0
GENERAL DESIGN BASIS
8.1
Design Loads
8.1.1
Engineering design basis of any civil and structural work shall be established to consider all possible types of appropriate loads and combinations thereof that will act on the structure(s) within its service life.
8.1.2
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, earth pressures, load due to differential settlements, 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”.
8.2
Design Load Combinations
8.2.1
The designer / contractor shall comply with all the relevant load combinations as specified in KOC-C-001, applicable to the design of specific buildings and structures supporting equipment / cranes / monorails / hoists etc.; and shall also be responsible to determine any other load combination which may cause the worst condition to the structure for a particular application or situation.
8.2.2
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 with KOC-C-001.
8.2.3
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.
8.2.4
In addition to the above, the governing load combination for each structure should be established to give the most critical criteria in the design.
8.3
Allowable Functional Limits
8.3.1
Structures shall be designed to perform 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 to achieve reliability of good performance and reasonable safety.
8.3.2
Any foundation designed for dynamic loads resulting from reciprocating and rotary machines shall comply with the allowable frequency and amplitude limits as specified in KOC-C-001 or as recommended by the Manufacturer in order to avoid resonance conditions. In case of difference, the most stringent shall apply.
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8.4
Bearing Pressures and Settlements I 2 I
8.4.1
Bearing pressure and settlement are the two most critical factors in the design considerations for foundations, and a professionally conducted soil investigation to assess them should be the essential part of the engineering design basis.
8.4.2
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:
8.4.3
a)
From 2.0 to 3.0 based on the type of structure and the reliability of the soil condition for normal operating loads.
b)
From 1.5 to 2.25 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 to 25 mm maximum and differential settlement to 18 mm maximum so that the 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 with KOC-C-026 “KOC Standard for Storage Tank Foundation”.
8.4.4
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 to 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.
8.4.5
The net maximum pressure under eccentric loading on foundations shall not exceed the net allowable bearing pressure. Net allowable bearing pressure may be increased by 25% due to wind and seismic loads or as dictated by the Design Code / Standard used.
8.4.6
In case of tall structures (stacks / columns) and towers, due to the effects of possible sway, the maximum applied bearing pressure under eccentric loading due to wind shall not exceed the allowable bearing pressure.
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8.5
Designated Materials I 2 I
8.5.1
All superstructures shall be normally made of either structural concrete or structural steel as specified by the designer in accordance with the clause 10.0 of KOC-C-001 ”KOC Standard for Basic for Basic Civil Engineering Design Data” and Data” and as described elsewhere in this RP; while all foundations including other substructures shall be generally constructed in concrete in accordance with KOC-C-006 “KOC Standard for Concrete Work - Materials and Construction”. Construction”.
8.5.2
All concrete structures and foundations should be designed and constructed with the applicable National / International codes given in clause 4.2 of this RP.
8.5.3
All materials, workmanship and construction of reinforced, plain and mass concrete shall be in accordance with KOC-C-006. For concreting in hot weather like Kuwait, the provisions of ACI 305R and KOC-C-006 shall be followed particularly during construction.
8.5.4
All Welding should should comply with the procedures as laid down in AWS D1.1/D1.1M and KOC-C-007 “KOC Standard for Structural Steel Work Materials, Fabrication and Erection”. Erection”.
9.0
FOUNDATIONS
9.1
General I 2 I
9.1.1
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 to accommodate movement of their foundations, and the design of both the structure and the foundation shall be considered interrelated.
9.1.2
The design shall take into account of the following: a)
All possible relative movements between different parts of a foundation if supported on compressible and weak soil;
b)
Movement of the supporting ground or soils due to seasonal effects, erosion, natural consolidation or compaction due to vibration; and
c)
Relative movements between adjacent structures particularly when there are interconnecting pipes or utilities or equipment.
9.1.3
At sites where the immediate subsoil is found to be highly compressible, foundations shall be taken down to deeper depth at a soil stratum of lower compressibility in order to minimize the long-term settlement problems.
9.1.4
As an alternative to the deeper construction, special measure of ground improvement techniques should be considered. Specialist companies in this field should be consulted to select a simple, cost effective and appropriate ground improvement technique.
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Foundation design, in addition to the above applicable criteria, shall include the following requirements: a)
Foundations shall be designed in accordance with the project geo-technical report. Foundations for structures shall be sized and stability determinations shall be made using service loads only. Load factors shall not be used for service loads. For the foundations subject to horizontal forces / moments, related design shall include the two load cases namely (i) with soil overburden and (ii) without soil overburden; and the most adverse case shall be considered in the design.
b)
Individual foundations are normally used for major equipment. If combined foundations are required, the centroid of the bearing area should coincide with the resultant of the applied operating load (excluding live load).
c)
All foundations shall be placed on blinding concrete. The blindiing concrete shall be placed on firm & well compacted ground. However, blinding concrete may be placed on well-compacted earth fill, if approved by the KOC. In such cases, cases, the engineering drawings shall shall specify the kind of fill material and the degree of compaction required for the fill material.
d)
Spread footings and combined footings should be designed assuming linear soil pressure distribution. Where the rigidity of the foundation is questionable, foundation analysis to be carried out by considering the interaction between flexibility of the foundation and the subgrade soil reaction. In this condition, mat foundation can be considered. ACI 336.2R contains suggested design procedures for mat foundation.
e)
Foundations shall be proportioned so as to minimize general and differential settlements.Where seasonal changes in soil moisture content are extreme at a site, special details may be required to minimize foundation movements. Control of foundation movement is especially critical for masonry structures. The Designer shall determine design parameters to control movement.
f)
Foundation bottom level shall be defined taking into consideration geo-technical report. Maintain same bottom of footing elevations wherever possible. Consideration shall be given to interferences with underground services.
g)
Overlapping of foundations (one over another at different levels) is not allowed unless alternative arrangement is not feasible. In such cases suitable additional loading shall be considered in the design of lower level foundations and additional protection measures to be agreed with KOC.
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Foundation Types
9.2.1
General Considerations
9.2.2
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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 pressure and permissible settlement at the founding f ounding level.
b)
Except those for minor structures, building foundations shall not be laid generally in areas of soft and or compressible subsoil to avoid possible cracks on their load bearing frames and infill masonry walls due to 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 to blast loading shall be designed to 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.
c)
Problems associated with construction (high water table, unstable soil).
9.3
Shallow Foundations I 2 I
9.3.1
Generally Shallow foundations shall be provided for Single / Multistoried structures such as buildings (control building, substation, residential, public, office, administrative, amenity, storage, laboratory, utility etc.), industrial structures like Pipe-Racks, equipment supported structure, workshop, and warehouse etc. Depth of foundation (i.e formation level) shall be such that the top of footing is minimum 1.0 m below paved level to facilitate passage of underground services.
9.3.2
Foundations shall be laid on firm strata of soil. Depth of foundation (i.e. formation level) shall be as per the recommended soil investigation report approved by KOC. If loose / contaminated or weak soil is encountered, the foundation formation level shall be suitably lowered to reach firm strata and if the same is not practical, a well compacted structural fill or blinding grade mass concrete may be provided below the foundation. Alternatively, if provision of
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shallow foundation is not feasible, then deep foundations (i.e. piled foundation) may be considered. 9.3.3
Plant structures having heavy equipment should be decided for the appropriate foundation types, which shall be laid at the subsoil levels in compliance with the recommendations, allowable bearing capacity and sound judgment of the designer.
9.3.4
Shallow foundations are generally preferred to 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 75% of the structure or building plan area due to a low permissible soil bearing pressure, raft or mat foundation should be generally recommended for economy and faster construction.
9.3.5
Raft foundations shall be used also in areas where high and non-uniform settlements are expected due to subsoil conditions and / or due to non-uniform distribution of heavy loads on the structures. In that case, the foundation level shall be carefully set to 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.
9.3.6
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 by oil or chemicals, which may have percolated down through loose or porous surface soils to the bearing stratum. In that case, foundations should be of such depth as to ensure safe bearing below any oil softened subsurface or chemically contaminated subsoil.
9.3.7
If a new 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 two adjacent footings should be maintained at least equal to 45 (1:1), but shall not be less than 30 with the horizontal.
9.3.8
Where foundations are expected to settle due to 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 by such settlements, nor cause surface water to flow into or pond around the foundation slabs or floors.
9.4
Deep Foundations I 2 I
9.4.1
Deep foundations should be provided where shallow foundations are neither feasible due to weak subsoil conditions, resulting low bearing capacity and / or unacceptable high settlements, nor due to high loadings giving rise to various design problems such as stability of structures or overlapping of several foundations at shallow depths.
9.4.2
Deep foundations should be selected after carefully considering the economy, type of foundation required and method of construction to be adopted. These may be in the form of raft foundations at deeper depths, pile foundations, piers, caissons or retaining walls.
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9.4.3
The designer / contractor shall comply with the general principles of design for the type of deep foundation as mentioned above to 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 to the most reliable foundation depths, in accordance with ACI codes and standards mentioned in clause 4.2 of this RP.
9.4.4
Retaining walls if required, shall be provided for the underground structures and basements to 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 with “AASHTO LRFD Bridge Design Specifications”. Retaining walls should also be provided as necessary to protect any filled-up elevated areas inside the plants like elevated roads that are subject to heavy loads or frequent erosion.
9.4.5
Pile foundations should only be considered as an exceptional case, where they are essential to transfer either the heavy vertical loads to a very deep strata or large amount of lateral forces to the surrounding soils in order to avoid very deep open cut excavations and massive foundations or where soil structural behavior can be affected by liquefaction from excessive vibrations such as those generating from high frequency vibrating equipment in high water table zones or where the soil condition is very poor.
9.4.6
Pile foundations should be selected for the appropriate pile type (friction / gravity), based on the recommended length & diameter to achieve the required pile load bearing capacity as per the soil report; and should also consider the cost effective modes of pile installations (short / long, bored / driven, cast-in-situ / 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 to the proprietary contractor's expertise.
9.5
Buoyancy Foundations I 2 I
9.5.1
In some cases, underground structures like basements, tanks, sumps, manholes and pits may become unstable and buoyant due to high ground water table. The total weight of structure shall be provided under this condition to neutralize the uplift pressure from the ground water, especially during empty condition.
9.5.2
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.
9.5.3
The design shall also consider to avoid the possibility of flammable gases and / or liquids to be collected inside the foundation.
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9.5.4
All underground concrete structures for retaining aqueous liquids such as basements, tanks, manholes, sumps and pits etc. shall be designed and constructed as per the provisions made in ACI 350 with low water cement ratio to make dense concrete to minimize cracks and ensure water tightness in order to prevent any entry of ground and / or rain water through the bottom slabs and side walls. The design of such structures shall include the effects of ground water pressures and buoyancy. All joints shall be fully detailed by Designer. For limitation of crack width refer relevant clause of KOC-C-001 “KOC Standard for Basic Civil Engineering Design Data”. Also for concrete protection detail refer clause no. 9.7 of this RP.
9.6
Plant, Pipework and Steelwork Supports I 2 I
9.6.1
Concrete columns, pedestals and sub-grade or grade tie beams shall be adequately anchored into the supporting foundations or to the underlying foundation slabs, especially where they may be subject to horizontal loads, overturning or vibrating forces. Reinforcements sufficiently embedded in the substructures, or sufficiently long holding down bolts, shall be provided to ensure their integral action. Reinforcements of concrete pedestals shall be adequately anchored into the slab to ensure that the full transfer of the applied forces where pedestals are supported on the paving.
9.6.2
Concrete foundation, plinths and pedestals should extend not less than 50 mm beyond the edges of equipment skids, base plates or slide plates. Sufficient clearance shall be kept between the edge of concrete and anchor bolts pockets / sleeves or anchor plates to avoid any conflict with t he reinforcements.
9.6.3
High or slender concrete pedestals / piers shall be designed as load bearing concrete columns or walls (where applicable) with due allowance for horizontal loads due to thermal forces, and for tube bundle removal or replacement.
9.6.4
Major structural bases, all plant and equipment base plates and rings shall be grouted with a flowable non-shrink non-metallic grout.
9.6.5
Top of Concrete sleepers for grade pipe-ways shall be minimum 600 mm above the adjacent / surrounding ground level. However, the final levels shall be decided to satisfy all the piping requirements (available clear height for drain valves, flange connections with 90 bend from the bottom, operability of valves etc.) and shall be made as specified in the approved piping drawings. Sleepers shall be provided with plain round steel bars of 20 mm / 25 mm diameter, welded to a minimum 12 mm thick steel plate flushed with concrete top. The top surface of the sleeper should slope away from the steel flat plate.
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9.7
Foundation Protection I 2 I
9.7.1
All underground and aboveground concrete surfaces shall be protected in accordance with KOC-C-006 “KOC Standard for Concrete Work - Materials and Construction”.
9.7.2
Unless otherwise specified in other KOC Standards / Project documents, protection to internal exposed surfaces of buried RCC structures such as sumps, pits etc. shall be assessed during project execution and shall be subject to type of internal content, level of ground water table, water tightness requirements etc.
10.0
PLANT STRUCTURES
10.1
Dynamic Equipment
10.1.1
Dynamic equipment (reciprocating / rotating) such as pumps, compressors, turbines and similar machines shall be designed for their bases and foundations taking into consideration of all appropriate static and dynamic loads as recommended by the Manufacturer(s) and in accordance with BS CP 2012 Part 1.
10.1.2
The base and foundation sizes of these equipment(s) shall be proportioned to distribute their masses in such a way that the vibration and amplitude limits shall be achieved in compliance with KOC-C-001 ”KOC Standard for Basic Civil Engineering Design Data” and / or as recommended by the Manufacturer(s).
10.1.3
Large machines or any machine which may have large out of-balance forces should be supported on structures and foundations in order to minimize: a)
Vibration of the machine;
b)
Transmission of vibration to adjacent foundations, equipment and buildings.
10.1.4
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 to process layout considerations or due to underlying soft soil areas. In that case, each machine on the combined foundation shall be separated by an upstand kerbing with a drain to prevent drifting of spilled liquid onto the other part of foundation.
10.1.5
Drivers and driven units should be supported on a common base block adequately stiff to limit distortion within the tolerance permitted by the Manufacturers.
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10.1.6
With independent pump blocks or bases, anchor supports to the pump suction and discharge lines should, whenever possible, be integral and monolithic with the pump base.
10.1.7
Foundations should extend not less than 50 mm beyond the edges of fixed bedplates or sliding plates. Adequate clearance should be provided between any projecting bolt lugs, holding down pockets, sleeves or anchor plates and the concrete edge or the reinforcement.
10.1.8
Holding down bolts shall be designed to adequately resist all horizontal forces and dynamic forces, in addition to the vertical forces, originating from the machine. The distance from a pocket or bolt to the edge of the concrete block should be at least 100 mm in order to allow for reinforcement.
10.1.9
Pump and compressor foundations shall be adequately reinforced (vertically and horizontally) in all surfaces. Where foundations of small pumps are integral with floors or paving slabs, the designer should ensure that slabs are sufficiently thick at those locations and adequate reinforcements are provided to prevent the propagation of cracks from the surface due to vibration.
10.1.10 Holding down bolt pockets and the space under the bedplates shall be completely filled with grout and all air expelled. Grout thickness should be within the range of 25 mm to 50 mm. 10.1.11 However, large machines or any other machines with large out-of-balance forces should be grouted in accordance with Manufacturer's requirements, using a flowable non-metallic non-shrink grout. Special grouts shall be placed in compliance with the Manufacturer’s instructions. If necessary, placing should be supervised by a qualified representative of the Manufacturer. 10.1.12 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 by the Manufacturer. 10.1.13 Separation joints of minimum 20 mm width shall be provided between the equipment foundations and surrounding floor or paving slabs. The joints shall be filled with preformed compressible mineral fibre board and non-shrink grout. 10.2
Structures and Overhead Pipe Racks I 2 I
10.2.1
Generally structures supporting equipment, process pipes, heat exchangers, vessels, air coolers and electrical / instrument cable racks & cable trays, should preferably be designed in structural steel to transfer the loads by means of either moment resisting frames or braced frames in compliance with AISC as specified in clause 18.0 of this RP. However if necessary, the designer may choose to support the above on the structures made of concrete, which shall comply with the requirements as per ACI 318M.
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10.2.2
Structures shall be designed to resist all the appropriate loads, considering various load combinations thereof and design limits as specified in KOC-C-001 ”KOC Standard for Basic Civil Engineering Design Data”.
10.2.3
Overhead pipe racks shall be wide enough to include all the proposed pipes at one or two levels; and should also consider additional 25% space for future extension. For multilevel pipe rack generally, the top tier should be catered for utility lines and cable trays to run the electrical and telecom cables separately.
10.2.4
Pipe racks shall be provided with pipe shoes or plain steel round bars below the pipes to reduce the friction forces at the various levels.
10.2.5
Pipe racks shall be designed as the moment resisting frames in the transverse direction perpendicular to the run of pipes and as the braced frames in the longitudinal direction of pipes.
10.2.6
The horizontal spacing of moment resisting frames, composed of steel columns (stanchions) and main beams, and restrained by longitudinal struts or tie beams, shall be determined by the sizes of pipelines to be supported and plant layout in the adjoining areas. For acceptable piping spans with full loads, the column spacing is recommended in the ranges of 6.0 m to 7.5 m to achieve reasonably economical pipe racks; but in no case shall exceed 12.0 m for any special design condition, as it leads to heavier pipe racks. However, minimum column spacing shall be limited to 4.5 m for smaller pipelines of diameters including and up to 76 mm (3”). Spacing less than 6.0 m is not generally preferred to accommodate the lesser allowable spans of smaller pipelines and conduits, which then should be supported by intermediate crossbeams.
10.2.7
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 to be installed. Adequate clearance should be provided for lines to lay the pipe-way and for reasonable accessibility for completing field welds, insulation and painting, as well as for fittings and elbows. Generally, a clear distance of 1.2 m to 1.8 m should be considered from top of the first tier beam to the underside of the second tier beam for the average lines.
10.2.8
Where steel structures support plant and equipment handling flammable materials and overhead pipe rack having pipes conveying flammable materials like gas, fire proofing shall be provided for the specified fire rating in accordance with KOC-C-027 “KOC Standard for Fireproofing of Structural Steel Work” to satisfy the passive fire protection requirements.
10.2.9
All the supporting columns for heavy structures shall be suitably tied together at the foundation levels by means of grade or sub grade tie beams. However, tie beams connecting supports for light structures may be omitted, if they are
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adequately embedded in the concrete paving where sufficient lateral restraint is provided by the concrete slab. 10.2.10 The area should have proper draining facility connected to the plant drainage system to prevent accumulation of flammable liquid in case of spillage. 10.3
Fired Heaters
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 to drying and shrinkage due to heat, without adequate air gap and sufficient depth of footings.
10.3.2
The design shall consider the horizontal movements and thrusts to the columns or piers supporting heaters due to thermal expansion of the heater.
10.3.3
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.
10.4
Process Tankage
10.4.1
Process tanks shall generally comprise of vertical or horizontal cylindrical steel tanks or vessels, including items like blow down tanks and coolers, which primarily form part of process units located within plant plot limits.
10.4.2
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 with concrete ring walls under the tank perimeter.
c)
Steel or concrete cradles for horizontal cylindrical tanks.
d)
Concrete sleeper walls to support a vertical steel tank bottom clear of the ground.
10.4.3
The top surface of tank foundations as per item (a) or (b) above should be finished with 50 mm clean sand cushion as a bearing surface and sand layer shall be protected by an upstand curbing around the periphery from overflowing.
10.4.4
Cradles for horizontal cylindrical tanks should normally be of steel saddles, welded to the tank shell and saddle supports bearing on 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 to excessive rigidity of the foundations should be avoided. The saddle base plates may have fixed connection with oversized holes at one end and sliding connection with slotted holes at the other end to minimize this rigidity.
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Cradles of concrete should be designed to 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 to prevent moisture absorption. 10.4.5
For tanks containing flammable materials, the passive fireproofing shall be provided in accordance with KOC-C-027 “KOC Standard for Fireproofing of Structural Steelwork”; and the cradle frames shall have provision of drain holes to avoid accumulation of any liquids.
10.4.6
Only two supports should be provided for horizontal 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.
10.5
Steel Stacks I 2 I
10.5.1
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 to provide structural stability.
10.5.2
Stacks shall be welded, and shall be embedded into the ground with rigid foundations on the hard bearing stratum at founding levels, that may be selected deeper than the normal founding depths, for stability due to wind / seismic loads.
10.5.3
Steel stacks and tall cylindrical structures are susceptible to large amplitude oscillations during steady winds of moderate velocity giving rise to resonance conditions and ovalling vibrations, if not properly taken care in t he design.
10.5.4
Mass and geometry of stacks with respect to heights shall be chosen in such a way that the critical wind velocity should normally be more than the design wind velocity at the top of the stacks in order to avoid susceptibility of oscillation. Otherwise, the structure shall be critically damped not to exceed the acceptable limits of amplitudes due to wind-induced vibrations.
10.5.5
Thin-wall stacks are also susceptible to ovalling vibrations i.e., oscillations where the stack cross-section vibrates as a ring. Whenever applicable, additional circumferential stiffeners shall be provided to the stack in the helical forms (spoilers / strakes) at the top one-third height to prevent ovalling.
10.5.6
If guys are to be used to support the steel stacks, they shall be made of galvanized steel structural strands or steel wire ropes as required. Structural strands shall conform to the requirements as specified in ASTM A475 for sizes up to 5/8 inches and ASTM A586 for sizes over 5/8 inches; whereas structural wire ropes shall be as per ASTM A603.
10.5.7
Guys when placed should be fixed at an angle of inclination of 45 for most efficient use, but when not possible due to any constraints, they should be connected at multi-levels to the stack. However, guys shall not be fixed to the stack at slopes lesser than 30 with the horizontal.
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10.5.8
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.
10.5.9
Guys shall be orientated to avoid crossing of any roads and access-ways.
11.0
PLANT AND NON-PLANT BUILDINGS
11.1
Substation Buildings and Transformers I 2 I
11.1.1
Substation buildings comprising of switchgear rooms, control rooms, battery rooms, capacitor rooms etc. and transformer bays should be sized adequately to accommodate all the electrical equipment with the necessary safety clearances from the walls and the adjacent equipment in compliance with KOC-E-003, Part-1 “KOC Recommended Practice for Design Basis and Selection of Electrical systems (Part-1)”.
11.1.2
Substation buildings shall be located in the unclassified (safe) areas. These buildings shall normally be single storied on the ground for small substations; or elevated type to suit the project requirements for bigger substations with the basic plinth levels as per Table-1 of this RP. The sizing of substation building shall also include additional space requirement for any future addition. For general guidance on future space requirement KOC-E-003 Part-1 shall be referred.
11.1.3
The floor level of elevated substations shall be designed in accordance with the KOC-E-003, Part 1. Adequate openings / cutouts shall be provided in the equipment floor slab for cable entry with future openings. Floor openings for future cables shall be filled flush with the floor level using a lean concrete of Grade E1 as per KOC-C-006 or provided with checker plate or removable slab panels as specified in the project documents. For non-elevated Substations, access ramps of non-slip type shall be provided from the surrounding area with a slope not exceeding 1 in 8 to all equipment rooms if required, as per project documents.
11.1.4
Reinforced Concrete (RCC) cable trenches, wherever provided, should not be left open, and shall be covered with hot-dipped galvanized steel checker plates or sand filled and covered with removable concrete slabs.
11.1.5
The entry and exit points of cables in the RCC trenches shall be through the sleeves embedded into the walls, which shall be sealed properly with nonsetting, non-flammable and non-toxic liquid-tight sealant approved by KOC to prevent ingress of any water or flammable liquids. Empty sleeves if provided in walls for future requirements, shall be flanged type and shall be blanked off with blind flanges.
11.1.6
Room height of substations shall be determined in accordance with the KOC-E-003, Part 1.
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11.1.7
Substation buildings shall be adequately protected against ingress of dust, sand, vermin and rain with double air sealed doors. Concrete protection walkway of at least 1000 mm wide shall be provided all around the building.
11.1.8
Floors shall be made of reinforced concrete to support heavy electrical equipment and shall be smooth trowel finished self-leveling screed with floor hardener. The finished floor shall be painted with light grey colour epoxy paint. If required, steel rolled sections (joists or channels) should be embedded flush with the floor to roll out the equipment.
11.1.9
Roofs shall be made water leak proof with the necessary treatments and watertight membranes such as EPDM or equal as specified by the designer and approved by KOC. Roofs shall be protected with steel hand railings with the toe plate or concrete parapet walls of similar height with access facility for maintenance of electromechanical equipment to be installed thereon.
11.1.10 Electrical control panel room in the substation building shall have raised access flooring consisting of 600 mm x 600 mm removable type non-slip anti-static vinyl finished noncombustible panels, unless otherwise specified in the project documents. These floor panels shall be mounted on removable telescopic type electro-zinc plated steel pipe supports with threaded studs to allow for level adjustments. When finally assembled, the floor shall be rigid and free from vibration rocking, rattling and squeaking. 11.1.11 If rooms like office / storage / filing etc. are to be constructed attached to the substation building, they shall be provided with independent entrance door from outside; and shall be completely isolated from the substation building by fire rated walls, doors and windows. Minimum fire rating of external walls, internal walls, doors and windows shall be in accordance with KOC-C-001 “KOC Standard for Basic Civil Engineering Design Data”; and the openings for cables (power, lighting, telephone etc.) and for HVAC ducts shall be provided with UL approved through-penetration fire stops to achieve minimum fire rating of two (2) hours as per ASTM E 814. 11.1.12 For elevated type substation buildings, the open space between the ground beams and equipment floor beams shall be closed with chain link fence panels and minimum two (2) Nos. of 1000 mm wide personnel entry gates with pad lock provisions shall be provided on the opposite sides of the fence. Cable trays shall not block escape routes to these gates and a minimum of 2100mm unobstructed head room shall be maintained along the escape routes . Chain link fabric shall be of 25 mm x 25 mm mesh, hot dip galvanized with PVC coating.
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11.1.13 Battery rooms shall be independently ventilated. The battery room walls shall be finished with KOC approved acid / alkali resistant wall cladding tiles. The floor shall be provided with KOC approved acid / alkali resistant tiles of anti-slip type, drain for 'flushing & neutralising' spilled electrolyte etc. Tiles should be bedded and jointed in chemical resistant mortar. Drain(s) shall be provided in the battery room(s) with floor sloping from all directions towards the drain points, which should be connected to chemical drain network. Height of wall tiles above FFL shall be as per project design requirements. However it shall not be less than 2100 mm or top of highest battery rack +1000 mm, whichever is higher. 11.1.14 Transformers should be located in separate covered bays adjoining but outside the substation buildings, and shall be supported on independent concrete foundations. In case more than one transformer (oil filled type) are to be installed adjacent to each other, fire walls of minimum two (2) hours fire rating made of brickwork / concrete blockwork or reinforced concrete work should be provided to minimize the degree of fire risk. Roof covering may be of either preengineered steel structure or reinforced concrete canopy slab extended from the building. 11.1.15 All transformers shall be protected by enclosures and roof including fences with gates for access in compliance with clause 17.0 of this RP. 11.2
Control Buildings I 2 I
11.2.1
Control buildings shall be planned independently, depending on available plot size, as the single storied or double storied building, catering to all the requirements for operations of the plants (GC / BS etc.). Adequate spaces shall be provided to the operators and other essential personnel with Facilities for 24 hours operation every day and for the necessary equipment to be located within the building.
11.2.2
Control buildings should include as a minimum, but shall not be limited to the following Facilities only: a)
Control room
b)
Auxiliary / Marshalling rooms
c)
Telecom / LAN room
d)
Conference & Training rooms
e)
Rest rooms
f)
Toilets (Gents & Ladies), shower and locker rooms
g)
Prayer room
h)
Pantry
i)
Offices
j)
Instrument room
k)
Electrical room
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l)
Mechanical room (HVAC)
m)
Engineering room
n)
Store room(s)
o)
Other if any.
REV. 2
11.2.3
The design of control buildings should consider the under-floor space / basement to serve as air return and passage for routing electrical / instrument cables. Suitable vapour barriers and seals shall be used; and absolute minimum openings shall be allowed to assure dryness. Conduit bank entrance shall have the provision to eliminate the possibility of any liquid (water or oil) entry.
11.2.4
If control building is required to be blast resistant based on the Quantitative Risk Assessment (QRA) Report in accordance with KOC-C-030 “KOC Recommended Practice for Blast Resistant Design of Buildings”, it should be designed safe, considering the dynamic forces generated out of overpressures due to any blast loads, its anticipated direction and distance of the source. Dynamic analysis should be used to derive the forces acting on the building with minimum openings. Alternately, independent blast resistant walls should be considered outside exterior doors to reduce blast pressures acting on the doors. These walls shall be constructed with concrete of suitable thickness, and shall be fully reinforced on both sides vertically and horizontally as per the actual design. The design of blast resistant Control room shall comply with KOC-C-030.
11.2.5
Control building(s) should be located in the unclassified (safe) area; but if happens to be within hazardous area, it shall be designed to maintain a positive internal pressure to prevent ingress of hazardous vapour / fumes inside the building. In such case, air lock shall be provided at the main entrance of control building. The control buildings in safe areas are also preferred to be pressurized to ensure that the wind blown dust and harmful gases should not enter into them.
11.2.6
Control buildings should preferably be comprised of concrete load bearing structural frames with infill materials for cavity walls. For more details on cavity walls refer to KOC-C-008 “KOC Standard for Masonry Works and Plastering Materials and Workmanship”.
11.2.7
Room heights shall be made adequate by taking proper allowances for light fittings, HVAC ducts etc. and a lightweight suspended acoustic ceiling of approved quality and make shall be provided at not less than minimum 3000 mm above the finished floor level.
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Control buildings should have floors with smooth finishes as specified by the designer as per the facility requirements. However, raised access flooring shall be provided in the control room, auxiliary room, marshalling room and telecom / LAN room for running large number of cables. The flooring system shall be of approved type and make, to satisfy the following:
11.2.9
a)
The floor shall be made of 600 mm x 600 mm removable type non-slip anti-static vinyl finished noncombustible panels. These panels shall be mounted on removable telescopic type electro-zinc plated steel pipe supports with threaded studs to allow for level adjustments, and shall be installed over the reinforced concrete sunken slab as per the installation requirements.
b)
The floor shall be rigid when finally assembled; and shall be free from any rocking and squeaking.
c)
The under floor area shall be sealed with a suitable paint to suppress dust.
d)
Proper ventilation shall be provided to the under floor space.
Roofs shall be made water leak proof with the necessary treatments and with watertight membranes such as EPDM or equal as specified by the designer and approved by KOC. Roofs shall be protected with steel hand railings with the toe plate or concrete parapet walls of similar height with access facility for maintenance of equipment(s) to be installed thereon.
11.2.10 Control buildings except blast resistant type shall have normal size windows as necessary, with splinter proof, non-spalling type glasses. However, control room windows should be kept to the optimum area for adequate daylight illumination without excessive glare or heat loss. 11.2.11 Where control building is more than single storied, emergency / fire escape stairways shall be provided. 11.2.12 Control buildings shall be furnished with the fire and gas alarms in accordance with KOC-L-006 “KOC Standard for Fire & Gas Detection Equipment” and shall be equipped with fire fighting facility as per KOC-L-009 “KOC Standard for Fire Protection Systems and Safety Equipment”. 11.2.13 Control buildings shall be provided with 1500 mm wide concrete protection walkway around the buildings.
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11.3
Other Plant Buildings
11.3.1
Other plant buildings such as compressor house, pump house, chemical storage building should be made either of structural steel in framed structures with sheet claddings or of reinforced concrete in load bearing frames with block walls, as decided by the designer with prior approval from KOC.
11.3.2
Building layout, sizes and equipment clearances shall be subject to KOC review prior to detail design that should meet all the functional and safety requirements as envisaged or specified by KOC.
11.3.3
The design shall be carried out with the appropriate loads in accordance with the relevant provisions specified in KOC-C-001 “KOC Standard for Basic Civil Engineering Design Data”, and shall comply with applicable codes and standards of AISC or ACI given in clause 4.2 of this RP.
11.3.4
All other requirements of roof / wall coverings, ceilings, doors / windows and finishes etc. shall be assessed and developed in the detailed specifications by the designer / contractor as appropriate subject to KOC approval.
11.4
Non-Plant Buildings
11.4.1
Non-plant buildings such as administrative offices, workshops, warehouses, stores, laboratory, amenity and residential buildings should be planned as per the KOC requirements; and should be designed in accordance with the relevant clauses of KOC-C-001 “KOC Standard for Basic Civil Engineering Design Data” for the appropriate loads as well as with applicable design codes and standards of AISC or ACI given in clause 4.2 of this RP.
11.4.2
The buildings should be constructed with the materials, either concrete or steel or combination of both, as specified by either KOC or the designer; and should be finished good to suit the general aesthetic and construction requirements with KOC approval.
12.0
PAVING AND ACCESSWAYS
12.1
General The designer should determine the need for paving areas and their extent within each site. All intended uses and loading requirements for paving including culverts, suspended and removable paving slabs, should be considered in the design. In general, paved surface areas should be kept to a minimum consistent with following general requirements listed below.
12.1.1
Process Plot Areas a)
Concrete paving should be provided within plot limits only where necessary for vehicular and pedestrian access to process plant, equipment buildings and maintenance areas, and as a drainage surface in areas, which may be subject to oil or chemical spillage during operations or maintenance.
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Paved areas, other than meeting the requirements for collection of surface water, oil or chemical spillage, should also consider in the design the following conditions and additional requirements: i)
Flammable liquid spills do not collect under process equipment.
ii)
Firewater should not spread to process or plant areas unaffected by fire incident.
iii)
Specific catchment areas for drainage within a process or plant unit should be defined in relation to the layout of the individual parts of the unit and applicable fire fighting methods.
c)
Catchments should be generally defined by high points of the paving or in particular cases by upstand kerbs. However, trip hazards or obstruction of access-ways shall be avoided.
d)
If a specific potential fire risk has been identified within a plant, additional paving may also be needed to allow efficient drainage of the high volume of firewater flows.
e)
Additional paving may be required in some areas of the plant as a protective layer against erosion of certain soil types.
f)
Concrete paving should generally be provided for:i)
Vehicular access-ways from process plot limits to the paved areas.
ii)
Walkways.
iii)
Maintenance access comprising of 1200 mm wide paving around any individual equipment isolated from main paved areas.
iv)
Tube pulling areas for heat exchangers, where oil may be spilt during extraction and removal of tube bundles, even where such areas are outside plot limits.
v)
All groups of pumps and compressors, continuously around and piping manifolds, associated with pump stations as well as generally under all structures supporting process plant overhead.
vi)
Access ramps for maintenance vehicles, trolleys etc.
g)
Concrete access-ways should be provided from two opposite direction to all critical equipment such as Fire Water Pump, Instrument Air Compressor etc. to cater for operation and maintenance in case of emergency situation.
h)
Concrete paving should not normally be provided for walkway access to isolated floodlight towers and manholes.
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Offsite Areas There are no general requirements for paving in offsite areas. However, paving may be required at particular locations such as pump areas, metering areas and manifold areas where hydrocarbon and chemical leakage or spillage could occur.
12.1.3
Tankage Areas For paving details in tankage areas, refer to clause 15.0 of this RP.
12.2
Paving Arrangement
12.2.1
Concrete paving should be laid to falls sloping with a gradient 1 in 100 to drainage points. Bituminous paving wherever provided, should have minimum slopes not less than 1 in 60 to ensure adequate drainage without ponding.
12.2.2
Drain points and valley lines should be located to ensure an unhindered flow past all bases, plinths, columns and other obstructions. High points should be located along cable trenches, expansion joints and over sub-grade beams, and the valleys along any pipe trenches.
12.2.3
Paving layout drawings should show all bases, plinths, columns and other obstructions, with paving valley lines and ridges indicated and all falls shown with arrows in order to eliminate any dead areas that could cause ponding.
12.2.4
Surface drainage collection points should be provided with their top level set 25 mm below the paving surface, pipe trench bottom or other underground surface to be drained.
12.2.5
Paving should be kept as free as possible from all obstructions liable to cause a trip hazard. Covers for cable and pipe trenches, manholes, sockets and the like should be graded flush with the paving with handgrips sunk below. Open pits and sumps should be protected by railings.
12.2.6
Pipe trenches within the paved areas should be avoided wherever possible. Pipe trenches below paving level where unavoidable, should comply with the clause 14.3 of this RP.
12.2.7
Where permanent access-ways from the plant to the surrounding roads are ramped, the slope should not exceed 1 in 15.
12.3
Edging and Kerbing
12.3.1
Protection should generally be provided to the paving formation at the perimeter or edge of all paving. The pavement edging may be formed either by inverted kerbs or downstand edge beams of minimum dimensions 150 mm width x 300 mm depth where:a)
offsite fill or natural ground beyond the plot limit is more than 100 mm below the edge of the plot paving.
b)
offsite pipe tracks, cable trenches or draw pits, manholes or valve pits are at lower levels immediately adjacent to the plot paving limit.
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12.3.2
Inverted kerbs or downstand edge beams are not required for the edges of concrete paving and access-ways where they terminate at unpaved areas within the plot limits or directly adjoin offsite roads or paving.
12.3.3
Where concrete paved access-ways from the plot meet bituminous paving of offsite roads, a flush edge kerb should be provided. Where such access-ways adjoin surrounding roads, a minimum internal radius of 9.0 m should be provided at the junction of paved access-ways. Fully supported upstand kerbing to a height of 150 mm should be provided around the bend and for 1000 mm beyond the tangent points. The top surface of the 1000 mm beyond the tangent point should slope down to road and access-way level.
12.3.4
Where paved and unpaved plot limits adjoin offsite fill or natural ground more than 100 mm below the edge of the plot paving, provision should be made for fill to be graded down from plot limits to the lower offsite levels.
12.4
Widths of Access-ways Widths of access-ways should be such that they serve the intended purpose without any inconvenience, and should be neither too narrow nor too wide. As a guidance, the minimum widths should conform to the following as given in Table-2: Table-2: Recommended Widths of Access-ways Sl. No.
12.5
Description
Minimum Width
1
Access-ways for vehicles within Plant Plot limits
6.0 m
2
Access-ways for Pedestrian
1.0 m
3
Elevated walkways within Plant Plot Limits
1.0 m
4
Clear Access for Maintenance around individual equipment and its appurtenances isolated from the main paved areas
1.0 m
5
Stairways in Tankage areas
1.0 m
Live (Imposed) Loads I 2 I Culverts, bridges, pipe crossings, suspended concrete paving slabs and removable cover slabs for service trenches should be designed in accordance with the live / imposed (vehicular) loads mentioned in KOC-C-001 ”KOC Standard for Basic Civil Engineering Design Data”.
12.6
Soil Supported Concrete Paving I 2 I
12.6.1
Concrete paving should be designed for the appropriate thickness with adequate reinforcements for the loads, arising out of the above intended usage of the paving within the plant plot limits, offsite and remote places; and shall be laid on compacted soil to have uniform support.
12.6.2
Sometimes, minor static equipment, low level manifolds, small diameter pipes, platforms and stairs are supported on the concrete paving in place of separate
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footings. In that case, the supporting areas of the paving should be thickened over the normal thickness and should be strengthened with additional reinforcements. 12.6.3
Access-ways and paving accessible to vehicles / mobile equipment, and drop out areas where heavy loads may be placed or handled during maintenance, should have a minimum thickness of 150 mm, adequately reinforced in top and bottom to suit loading and ground conditions.
12.6.4
Paving not accessible to vehicles should be reinforced and should have a minimum thickness of 125 mm.
12.6.5
Permanent ladders from paved / ground level should be connected, wherever possible, directly to its supporting structure and should be kept clear of the paving to avoid effects of any settlement and corrosion at ground level.
12.6.6
Paving to cable trenches not subject to vehicular loading and supported on compacted sand fill should be 75 mm thick concrete screed of characteristic strength 10 N/mm2, generally without reinforcement. Where cable trenches are subject to vehicular loads, removable type cover slabs should be installed in place of in-situ paving.
12.6.7
Paved walkways of the main paved areas should be of 50 mm thick precast concrete paving tiles of KOC approved quality, pattern, size and colour.
12.7
Joints
12.7.1
Paving slabs shall be provided with movement joints (contraction / expansion) to minimize the potential cracks in concrete due to the high temperature variation in Kuwait. Hydrocarbon resistant mastic sealing compounds should be used for joint sealants. Steel reinforcements should be either made continuous through contraction joints or curtailed at joints as specified by the designer to suit the requirements. For more details refer to KOC-C-001 “KOC Standard for Basic Civil Engineering Design Data”.
12.7.2
Paving shall be discontinued around equipment bases, pedestals, columns, grade beams and manholes unless otherwise specified. A clear gap of suitable width ranging from 12 mm to 25 mm shall be provided all around. The joint should be filled with preformed compressible mineral fibre board and should be sealed with approved sealing materials to prevent ingress of water, soil, chemicals and other foreign materials.
12.7.3
However screeds should be poured in-situ against the adjacent paving edges without jointing or sealing, and for a maximum length of 5 m at one time.
12.8
Unpaved Areas
12.8.1
Unpaved areas adjacent to building structures shall be sloped (1 in 100) to direct rainwater (from roof and walkways) away from the structure to the nearest drainage system.
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12.8.2
Unpaved areas not occupied by equipment, buildings or any structures should be graded to have adequate continuous slopes to drain towards drainage swales, storm water inlets, roadways or natural water courses. The surface runoff shall be carried under walkways and roadways in pipes of sufficient sizes to avoid clogging by debris and other materials.
13.0
ROADWAYS
13.1
General Roadways, which provide smooth vehicular movement and access to the KOC plants and Facilities within KOC areas, within plot perimeter of KOC plants and Facilities, offsite areas and Ahmadi residential areas, should be designed in accordance with the appropriate national or local regulations and practices and shall comply with the following requirements as listed below.
13.2
Roadway Construction
13.2.1
All main facility access and primary roads, offsite (secondary / service) and plot perimeter roads of KOC Facilities should of bituminous construction and shall be made in compliance with KOC-C-024 Part 1 “KOC Standard for Materials and Workmanship - Roadways, Paving and Hard Standing: Part 1: Flexible Pavement”.
13.2.2
Paved areas adjoining roadways within KOC Facilities should be of bituminous construction, if not subject to contamination by spillage or leakage of hydrocarbons, or alternatively of concrete.
13.2.3
However, access-ways and paving inside the plants shall be of concrete construction as described in clause 12.0 of this RP.
13.3
Duty Permanent roads should be sealed and surfaced smooth with the class of wearing coat as per KOC-C-024 Part 1, unless required solely for fire access or infrequent maintenance access. Temporary roads should be made of “Gatch” as per KOC-C-005 “KOC Standard for Materials and Workmanship - Site Preparation and Earthworks” and may remain unsurfaced depending on the degree of maintenance.
13.4
Vehicular Loads I 2 I The roadways should be designed in accordance with AASHTO GDPS “Guide for Design of Pavement Structures” for the maximum vehicle loads expected during the design life of roads. For vehicular load detail, refer relevant clauses of KOC-C-001 “KOC Standard for Basic Civil Engineering Design Data”.
13.5
Design Life The design life of roads should be compatible with that used for plant or works, but shall not be less than 20 years as minimum. However, by means of regular maintenance and resurfacing, this life can be further extended, until and unless
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the growth of vehicular traffic and heavy vehicles exceeds far the anticipated numbers of vehicles within its design life. 13.6
Existing Roads The performance and requirements of maintenance for existing roads should be evaluated based on their conditions, frequency of heavy vehicles, daily traffic volumes and number of traffic lanes required. Existing roads should be periodically resurfaced with new asphalt and repaired for the cracks, depressions and potholes. When necessary, existing roads should be widened, dug out and reconstructed with new bituminous materials and traffic markings as per KOC-C-024 Part 2 “KOC Standard for Materials and Workmanship- Roadways, Paving and Hard Standing: Part 2: Miscellaneous Works & Rigid Pavement” to give a new lease of life and meet the present / future requirements.
13.7
Road Bridges
13.7.1
Where road bridges / culverts are required to cross over pipe tracks and water channels or streams, the width between parapets, alignment of centre line and profile of the flexible surface layer should be fully compatible with the adjoining roads.
13.7.2
Gentle ramps with maximum slope 1 in 15 may be provided from top of road to top of bridge level, but not at road junctions. Crash barriers are recommended, where any accidental loss of vehicular control may damage the adjacent Facilities.
13.7.3
Guard railing should be installed on the bridge parapet.
13.8
Road Geometry I 2 I
13.8.1
Proper care should be taken from the initial planning stage, particularly where large plant items or pre-assembled units require special considerations for safe movement. Attention should be paid to the proper geometry of road with the location of plants and Facilities to have the maximum clear visibility with the natural surrounds during driving, and should avoid abruptly sharp turns and blinds. For more detail on road speed limit, super elevations, gradient, sight distance, Roundabouts, Intersections etc. refer to KOC-S-001 “Standard Guideline for Safe Roads, Road Closure and Installation of Display Boards / Signs on KOC Roads”.
13.8.2
Road junctions or bends shall provide for the safe movement of traffic without undue restrictions. The design should allow for the type of vehicles to be used and the limitations of space at such locations, generally the internal radius to the edge of road (i.e. kerbing or shoulder as applicable) should not be less than 10 m. Barriers such as guardrail, bollards etc. are required for all junctions
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where there exists the potential risks for damage to the adjoining Facilities or the potential risk of vehicle overturning. 13.8.3
Permanently surfaced roads, as classified in KOC-C-024 Part 1 according to traffic density, should conform to the minimum widths with the types of shoulders on each side, as recommended in Table-3. Table-3: Recommended Widths of Roadways I 2 I Sl. No.
Road Classification
Recommended Width (Minimum)
Width of Shoulder
1
Main Facility Access (with hard shoulders)
8.0 m (Unless noted otherwise on the Project Drawings)
2.5 m
2
Primary Roads shoulders)
hard
7.0 m
2.5 m
3
Secondary Roads (with hard shoulders)
6.0m
2.0m
4
Secondary Roads (without hard
6.0m
May have 1.5m soft
shoulders) (Note-1)
(Unless noted otherwise on the Project Drawings)
shoulders, if shown on the Project drawings
Plant Access Roads (Without shoulders but with sunken or
6.0m (Unless noted otherwise
-
raised kerbs, as appropriate)
on the Project Drawings)
Temporary Roads with Gatch
6.0 m to 7.0 m
5
6
(with
-
Note-1: May also be called Service Roads
13.8.4
General gradients of roads should be chosen taking into account the natural slopes of the surrounding areas for drainage and ease of driving. The sustained gradients should be neither too steep nor too flat and should be limited to the following values recommended in Table-4 below. Table-4: Recommended Gradients I 2 I Sl. No.
Designated Areas
Gradients (Maximum)
Gradients (Minimum)
1
Main Facility Access and Primary Roads (Longitudinal)
1 in 30 (3%) for Residential areas and 1 in 16.67 (6%) for Industrial areas
1 in 200 (0.5%)
2
Secondary Roads
1 in 30 (3%) for Residential areas and
1 in 200 (0.5%)
(Longitudinal) 3
Service Roads
1 in 16.67 (6%) for Industrial areas 1 in 20
(5%)
1 in 200 (0.5%)
(Longitudinal) 4
Ramps (Longitudinal)
5
Parking Areas
6
Cross-fall on each way for all roads
7
Cross-fall on shoulders
1 in 15
(6.5%)
1 in 20
(5%)
1 in 30
(3%)
1 in 25
(4%)
1 in 100 (1%) 1 in 50
(2%)
1 in 50
(2%)
DOC. NO. KOC-C-002
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13.9
Road Shoulders
13.9.1
Shoulders (hard / soft) should be laid and finished as specified in clause 12.0 of KOC-C-024 Part 1.
13.9.2
Shoulders at roads without kerbing should be generally free from anything protruding above its grade; otherwise a minimum 1000 mm clearance shall be maintained between the shoulder edge and any structure thereon. However, lighting poles, guardrails and traffic signs may be located at a distance not less than minimum 600 mm from the edge.
13.10
Road Drainage I 2 I
13.10.1 The maximum level of the ground water table should be established to determine whether subsoil drainage is required to maintain a stable condition during the rainy period. 13.10.2 The road surface should be crowned to drain surface water away from both sides on to the adjoining grade, and then by percolation into adjacent ground where natural ground is below the grade level. However, if the natural ground is above the crown of road, surface water should be drained to run off to drainage channels, which are generally open ditches and / or lined swales. Where this is not feasible due to ground impermeability or where such practice would contravene the local regulations, drainage should be provided via an underground piped system. 13.10.3 Refer to KOC-C-024 Part 2 for more details related to road drainage. 13.11
Road Blockers & Vehicle Barriers I 2 I
13.11.1 Road blockers and vehicle barriers where required shall be provided in accordance with KOC-G-019 Part 2 “KOC Standard for Security Systems: Part 2, Security Fences, Gates, Road Blockers, Vehicle Barriers, New Buildings and Guard Houses”. However, where the horizontal alignment of any type of road changes abruptly, and potentially any out-of-control vehicle could cause damage to pipework, cabling or items of installation, a safety barrier shall be provided. If for any reason, pipework or an item of the installation is located immediately adjacent to a road, a protective barrier shall be erected for safety. 13.11.2 Where required, protective barriers should generally be located at the outer edge of the hard shoulder and not less than 1000 mm from the road edge. 13.12
Kerbing
13.12.1 Kerbing shall be provided generally at the plot perimeter roads inside the plants and Facilities as well as at the road network inside Ahmadi residential areas to protect the surrounding areas from any flooding of water and hydrocarbon spillage and shall be provided in accordance with KOC-C-024 Part 1.
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13.12.2 Kerbing shall also be provided at road / vehicle access-way junctions, where there is a specific requirement to contain contaminated runoff or spillages. 13.13
Road / Traffic Markings Traffic markings for all roads in the offsite areas shall be provided in accordance with KOC-C-024 Part 1 “KOC Standard for Materials and Workmanship - Roadways, Paving and Hard Standing: Part 1: Flexible Pavement”.
13.14
Traffic Signs Traffic signs for all major roads outside the plant areas within KOC jurisdiction shall be provided in accordance with KOC-C-024 Part 2 “KOC Standard for Materials and Workmanship - Roadways, Paving and Hard Standing: Part 2: Miscellaneous Works & Rigid Pavement”.
14.0
MISCELLANEOUS CIVIL WORKS FOR SERVICES AND PIPELINES
14.1
Electrical and Instrument Cable Trenches
14.1.1
Paved Areas a)
Cable trenches for electrical and instrument cables, where required to be provided through the plant paved areas, should generally be constructed with a reinforced concrete base with walls made of either reinforced concrete or precast concrete block work.
b)
Trench filling should be carried out after cable being installed and then filled with sand as specified in KOC-E-003, Part-1 “KOC Recommended Practice for Design Basis and Selection of Electrical systems (Part-1)”.
c)
Paving should be provided over cable trenches as per clauses 12.5 and 12.6 of this RP.
d)
Partition walls should be provided in a multipurpose cable trench extending the full depth of the trench. Instrument and telecommunication cables should be separated from power cables.
e)
Weep holes of nominal sizes 100 mm x 100 mm at 5.0 m centre to centre should be provided at the junction of the base slab and walls for the passage of moisture.
f)
Cable entry through the trench walls should be via built in ducts.
g)
Such trenches should be designed taking into consideration the effects of the following: i) ii) iii)
Soil conditions and loads. Vehicular loads. Wall heights.
DOC. NO. KOC-C-002 iv) v) 14.1.2
14.1.3
14.2
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Cover slab spans or trench surfacing. Other requirements like cable laying etc.
Unpaved Areas a)
Electrical and instrument cables in unpaved areas, which may be located within, adjacent to, or remote from plant plot limits, should be direct buried.
b)
Where cables are buried direct, they should be laid over a 100 mm thick compacted bed of uncontaminated clean sand at a minimum depth of 750 mm for low voltage cables and 1000 mm for 3.3 kV / 11 kV cables below the unpaved surface in compliance with KOC-E-008 “KOC Recommended Practice for The Design, Selection and Installation of Electric Cables, Cable Systems and Wiring”. They shall be protected by cable tiles and identified with non-corrodible tags as appropriate.
Concrete Cable Trenches a)
At road crossings cable ducts should be provided; but where large numbers of ducts are required, reinforced concrete in-situ trenches may be used as an alternative with removable cover slabs, which should be designed to carry the vehicular loads as per KOC-C-001.
b)
The top level of covers to trenches abutting or within paved areas should be flush with the plot paving level. In unpaved areas adjacent to plot paving, covers should generally be 150 mm above adjacent graded level, but suitable transition levels shall be provided, where they connect with trenches within paved areas.
c)
Lifting slots should be provided in every fifth removable type cover for ease of maintenance.
d)
Trenches shall be supported directly on the subsoil, which shall be levelled and compacted.
Telephone Cable Trenches I 2 I Outdoor telephone cables shall be laid underground inside buried ducts with minimum separation distances from power cables as recommended in KOC-L-002 “KOC Recommended Practice for the Protection of KOC Services: Clearance Requirements for Buried Pipelines, Cables, Underground Structures, Buildings and Housing Projects”. For installation details of Optical Fibre Cables refer to KOC-T-008 “KOC Recommended Practice for Installation of Optical Fibre Cable”.
14.3
Pipe Trenches I 2 I
14.3.1
Trenches for plant piping should generally be avoided, unless otherwise necessary. However, if provided, they should conform to the minimum requirements of clearance to pipe work, gradients for drainage, spacing of firebreaks, trench flooring, trench covers and provision of gully traps.
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14.3.2
Trenches in plot-paved areas should be made of reinforced concrete with covers.
14.3.3
Trench covers shall be made of either precast concrete or hot dipped galvanized steel checker plates / gratings as per project documents.
14.3.4
Trench firebreaks should be provided as required. Large pipes and all pipes subject to thermal movement should be sleeved, and the annulus plugged and then sealed with a hydrocarbon resistant mastic seal. All pipes or sleeves in contact with the fill material contained within firebreak should be protected against corrosion.
14.3.5
The filling to firebreaks between concrete work should be of sandy soil, compacted around the pipes in as dry a state as practicable. In paved areas, trench firebreaks should be topped with a 50 mm concrete screed.
14.4
Cable Ducts I 2 I
14.4.1
Cable crossings, under offsite roads and vehicular access-ways not part of the plot paving, should be formed of ducts encased in reinforced concrete. Ducting should extend a sufficient distance beyond the road or hard shoulder edge to ensure that there will be no damage or undermining of the road or hard shoulder during any subsequent excavation to duct invert level. For spare ducts requirements, refer to KOC-E-008 “KOC Recommended Practice for the Design, Selection and Installation of Electric Cables, Cable Systems and Wiring”.
14.4.2
The design of such ducts, their bedding, concrete surround and reinforcement shall withstand the appropriate traffic loading as mentioned in clause 13.4 of this RP. The top level of duct shall be maintained at a minimum depth of 1200 mm below the crown level of the road or the access-way. If cables enter at the end of the duct into a trench, a suitable transition pit should be provided with floor sloping at an angle not greater than 30 degrees and with removable concrete covers and clean sand filling above the cables.
14.5
Ducts for Instrument Cables
14.5.1
Ducts for instrument cables crossing under roads or access-ways from process units to adjoining or centralized control building should be constructed in accordance with clause 14.4 above.
14.5.2
Instrument cables after installation in the ducts should be sealed with KOC approved cable duct sealant. For more detail on installation of instrument cables in ducts, refer to KOC-I-002 “KOC Standard for Instrument Installation”.
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14.6
Ducts and Cable Trenches at Buildings
14.6.1
Provision should be made to prevent any accumulation of flammable liquids and gases in buildings, due to entry via service ducts, cable trenches or drains.
14.6.2
The bottom levels of cable trenches required within control room, substation and switchgear buildings and invert level of any entry holes or ducts thereto, should be specified to suit as necessary.
14.7
Pipe Sleeves I 2 I
14.7.1
Road Crossings a)
Load bearing sleeves should be provided to pipes crossing under KOC field roads and all vehicular access-ways, where provision of a culvert would be uneconomical due to few numbers of pipelines, and where: i)
The strength of the pipe is inadequate for the anticipated loading.
ii)
The pipe is subject to excessive thermal movement.
iii)
The pipe is to be more protected from any accidental damage due to transfer of any loads.
iv)
14.7.2
For operational convenience, safety and to avoid disruption to traffic, the pipe is to be replaced without excavation at main facility access road crossings.
b)
Flexible end seals, resistant to hydrocarbons where appropriate, should be fitted between pipes and sleeves at both sides of the crossing.
c)
Pipe sleeves shall be provided in accordance with KOC Standard Drawing No. “55-04-77”.
Pipes Through Structures a)
Large diameter pipes and all pipes subject to thermal movement should be sleeved, when passing through walls or other structural elements or firebreaks. Such sleeves should generally be of steel, except that in any exposed condition above grade, they should be of non-corroding material in order to obviate rusting and spalling of the surrounding concrete or mortar.
b)
Where necessary, flexible end seals resistant to hydrocarbon and of non-flammable, non-setting and non-toxic type should be fitted between the pipe and its sleeve.
DOC. NO. KOC-C-002 14.7.3
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REV. 2
Pipes Through Earthen Dikes a)
Piping or conduits should not generally pass through earthen dike walls in compliance with KOC-L-027 “KOC Standard for Layout, Spacing and Diking of Aboveground Petroleum Storage Tanks”. However, if necessary to penetrate through the dike walls, they shall be adequately protected from external corrosion by use of coatings and pipe sleeves. Where pipe sleeves penetrates through the dike walls, the surrounding area shall be filled with concrete to prevent dike erosion and collapse.
b)
The annular space between the pipe and its sleeve should be fitted with the appropriate liquid tight end seals. Such seals should be hydrocarbon resistant, non-flammable, non-setting and non-toxic type, and should be capable to withstand the hydrostatic pressure appropriate for the height of the dike.
14.8
Valve Pits I 2 I
14.8.1
All Valve pits for underground pipelines shall be constructed with Reinforced Concrete. Construction details and sizes shall be in accordance with KOC Standard Drawing No. “55-02-39”.
14.8.2
For pipelines where restraint is needed against thermal movement, and for large size deeper valve pits where earth and hydrostatic pressures from the ground water become the governing design criteria, construction shall be in accordance with the requirements of liquid retaining structures as specified in ACI 350; and shall also comply with the requirements as given in KOC-L-002. The pits shall be made watertight to prevent any ingress of ground or rainwater through the sidewalls and bottom slabs.
14.8.3
Where pipes penetrate walls at a level below the highest expected water table, the pipes should be fitted with puddle flanges located in the centre of the wall and the walls near to the pipe should be at least 250 mm thick.
14.8.4
The top of Valve pits should be finished 150 mm above in concrete paved areas and 450 mm above ground level in unpaved areas. Valve pits may be either left open but protected with handrails or covered with 6mm thick removable chequered plate as per project specification. Pit floors should be sloped to a shallow sump, to allow for pumping out of liquids, and where necessary the pit walls should be provided with step irons.
14.8.5
Corrosion Monitoring Pit shall be provided with intermediate access / working platform wherever specified for maintenance and operation requirements.
14.9
Floodlight Masts
14.9.1
Floodlights, when they are not mounted on plant structures, should be mounted on masts with foundations either spread or integral with the plot paving, thickened and reinforced as required. Masts shall be guyed for stability against winds and wind-excited vibrations; and shall be designed in accordance with ASCE 10.
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14.9.2
Floodlights, when required to be installed at great heights above the ground, are generally mounted on top of the tall freestanding towers in either triangular or quadrilateral shapes. Towers should be of lattice type structures, which shall be designed in compliance with ASCE 10.
14.10
Fire Hydrant Pits The use of fire hydrants pits should be discouraged.
14.11
Earthing Earthing for buildings and steel structures shall be provided in accordance with KOC-E-024 “KOC Recommended Practice for Earthing and Bonding”.
14.12
Lightning Protection I 2 I
14.12.1 Appropriate lightning protection systems for buildings and tall structures shall be provided in accordance with the requirements of IEC 62305 and KOC-E-024. 14.13
Warning Lights Aviation warning lights shall be installed on tall structures for obstruction as per the Federal Aviation Regulations for safety.
15.0
STEEL STORAGE TANKS
15.1
General I 2 I
15.1.1
The layout and spacing of several numbers of aboveground vertical steel storage tanks, which are basically meant for storing crude petroleum and flammable liquids within KOC Facilities (plants / tank farms), shall be decided in accordance with KOC-L-027 “KOC Standard for Layout, Spacing and Diking of Aboveground Petroleum Storage Tanks”.
15.1.2
The various factors mentioned in KOC-C-026 & KOC-L-027 shall be taken into considerations while the layout / design of the above tanks are finalized.
15.1.3
The layout and spacing of other aboveground vertical steel storage tanks for storing non-petroleum liquids (brackish / fire water / potable water) within KOC Facilities (plants / tank farms etc.), shall be established in accordance with KOC-L-028 “KOC Recommended Practice for Plant Layout (including spacing Charts)” and taking into consideration of the following: a)
Topography with good and flat surface.
b)
Subsurface having not too deep load bearing hard soil strata.
c)
Safe distances from the nearest road(s) and adjoining public / private properties.
DOC. NO. KOC-C-002 d)
15.1.4
Page 53 of 74
REV. 2
Good accessibility in the tankage area and smooth movement of the fire fighting equipment, in case of any fire incident.
The design grade levels of tanks other than pumping requirements and tie-in points, should take account of subsoil conditions, drainage, ground water table and earthwork requirements on the site. Normally grade level on which a tank bottom rests, should be kept 300 mm above the finished grade level (FGL) or as specified by the designer. If anode grid type cathodic protection to be installed under the tank foundation, the design level should be checked for the adequate space required for embedding the system below the tank bottom and may be increased to minimum 750 mm, if necessary to accommodate it.
15.1.5
Grade levels, wherever possible, should be determined to balance the cut and fill earthwork requirements in the storage area with the associated levels of tank pads and roads.
15.2
Foundation Design Criteria
15.2.1
A geotechnical investigation shall be conducted to establish the ground conditions at any tank site and its suitability for the proposed tank sizes in relation to the allowable bearing capacity and settlement criteria.
15.2.2
The sub-grade shall be capable enough to support the load of tank with its content; and should be assessed for the immediate (short) and long term conditions whether tank foundations will encounter any appreciably high settlements that may strain the connecting piping or produce gauging inaccuracies and may cause the deformations of the tank shell and bottom within its acceptable limits.
15.2.3
The ultimate bearing capacity of the tank foundation should be determined by a comprehensive stability analysis, and an adequate factor of safety against failure under the worst loading conditions shall be applied as specified in the relevant clause of KOC-C-026 “KOC Standard for Storage Tank Foundation”.
15.2.4
Settlement criteria for the immediate and long-term conditions should be established at an early stage in the design in relation to:
15.2.5
a)
Total settlement.
b)
Edge to center differential settlement and localized rotation of the floor plates.
c)
Peripheral differential settlement.
Settlement criteria should be defined to ensure that excessive settlements will not result in the tank and its fittings being overstressed, and in the case of floating roof tanks, to limit deformation of the shell so that the roof remains free to move and the seals retain their integrity.
DOC. NO. KOC-C-002
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REV. 2
As the settlement calculations are of limited accuracy even with detailed investigation and analysis, tanks shall not be designed to depend for their integrity on precise settlement predictions. 15.2.6
However as a guidance, the permissible ranges of predicted settlements for tank foundations should be considered in accordance with the relevant clauses of KOC-C-026 for floating and fixed roof tanks. The maximum recommended uniform (total) settlement should not exceed 150 mm for long-term condition.
15.2.7
At tank sites where subsoil conditions indicate the presence of weak and poor sub-grade with high compressibility and fail to satisfy the above criteria, ground improvement may be necessary and should be considered as outlined in KOC-C-026.
15.3
Foundation Design
15.3.1
Types of Foundation Depending on the tank sizes (diameter & height), types of foundations for aboveground vertical steel storage tanks should be considered as given below unless otherwise specified in project geo-technical report:a)
Tank Diameter 35 m & Height
15 m - Earth foundation with Concrete Ring wall
b)
Tank Diameter 35 m & Height
15 m - Earth foundation without Concrete Ring wall
15.3.2
The earth foundations for any aboveground steel storage tanks shall be constructed with or without concrete ring walls in compliance with all the design, materials and construction requirements as specified in KOC-C-026 “KOC Standard for Storage Tank Foundation”.
15.3.3
In the first type, a reinforced concrete (RC) ring wall is provided to support directly the tank shell, whereas in the other type it is being supported by a compacted crushed stone ring wall composed of 25 mm well-graded crushed stone or gravel with screenings and clean sand. In both types, the tank bottom is rested on a compacted earth pad as inner core finished with several layers of stable permeable materials as described below and shown in the appendices of KOC-C-026.
15.3.4
The core of the earth pad shall be constructed from highly compactable, chemically inert, locally available material like “Gatch”, which is generally noncorrosive and having low compressibility but sufficient strength. It should satisfy the specific soil properties in accordance with KOC-C-005 “KOC Standard for Materials and Workmanship - Site Preparation and Earthworks” and shall be compacted to at least 95% dry density up to the tank grade level. On top of the core, layers of free draining permeable material shall be provided to prevent tank base corrosion by capillary action of soil; and they shall be made of graded sand-gravel mix of minimum 100 mm thick with a final layer of minimum 100 mm to 150 mm thick graded clean washed sand cushion as the bearing surface of tank bottom.
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The area of earth pad outside the tank shell shall be sloped for drainage, and shall be finished with a 75 mm thick protective layer of asphalt concrete including the side slopes to form a firm shoulder around the tank. The shoulder around the tank shell should be minimum 900 mm wide for ease of maintenance. 15.3.5
Environmental Protection For tanks storing crude and petroleum products, potential environmental damages to subsoil and ground water etc. in the event of any leakages should be studied in detail. API STD 650 recommends a non-mandatory provision of laying secondary containment barrier such as flexible impermeable membrane liner or other suitable system below the earth pad. The effectiveness of these membrane liners should be judged in relation to the presence of ground water (generally deep except coastal areas in Kuwait) and other maintenance problems; and decision should be taken in consultation with the specialists whether liners below the tank base should be provided or not in the design. However, in view of increasing global consciousness regarding environment, the final design should satisfy the regulations of Kuwait EPA and KOC HSEMS requirements in this regard.
15.4
Dikes I 2 I
15.4.1
Dikes shall be provided around tanks storing crude and flammable petroleum products to safeguard important Facilities, nearby surroundings, waterways and properties from any accidental discharge.
15.4.2
Dikes shall be liquid-tight, impervious to the liquid and shall be designed to withstand a full hydrostatic height.
15.4.3
The volumetric capacity of the diked area shall be sized to contain the volume of liquid equal to 115% of tank rated capacity for Single tank. In case of two or more tanks within the same diked area, the volume of the diked area shall also contain the volume of liquid equal to 115% of rated capacity of the largest tank. Accordingly, dike height shall be decided in the tank layout. Generally, the dike height should be limited to not more than 1800 mm above the interior grade level for the convenience of approach, proper ventilation within diked areas and ease of fire fighting, but more height may be permitted if special provisions are provided as described in KOC-L-027 “KOC Standard for Layout, Spacing and Diking of Aboveground Petroleum Storage Tanks”.
15.4.4
Dikes shall normally be of earth construction with KOC approved locally available suitable fill materials in accordance with KOC-C-033 “KOC Standard for Bund Walls for Storage Tanks - Materials and Workmanship”.
DOC. NO. KOC-C-002 15.4.5
Page 56 of 74
REV. 2
Dikes should have stable side slopes consistent with the angle of repose of soil; and the crest and sloping sides should be stabilized and protected from erosion by one of the following protective lining(s) as per KOC-C-033 :a)
Asphalt lining (short life but inexpensive).
b)
Bitumen sand lining (medium life and medium cost).
c)
Concrete lining (long life but high cost).
Depending on the dike areas, life cycles and costs involved for protective linings, the appropriate material should be decided case-by-case basis. 15.4.6
Earthen dikes should have minimum flat top width of 900 mm for heights above 1200 mm to provide a walkway on top, and should be accessed inside the dike area by stairways from at least one convenient location of each side from the surrounding roads.
15.4.7
Stairways should be at least 1000 mm wide with steps not less than 300 mm, and should be provided with handrails for safety.
15.4.8
Proper access ramps should be provided for entry of vacuum trucks and maintenance vehicles inside the dikes.
15.5
Drainage Within Dikes
15.5.1
Areas inside the dikes shall be graded for surface drainage with a minimum slope not less than 1 in 100 (1%) from the edges of the tank foundations towards drain pit(s) or sump(s) or any impounding basin as appropriate.
15.5.2
The drainage from the dikes should meet the requirements as given in KOC-L-027 and shall be connected to the disposal system as provided.
16.0
CONCRETE STORAGE TANKS I 2 I
16.1
Concrete tanks, storing mainly potable water, are generally overhead tanks of various shapes to serve the functional and aesthetic purposes. Based on the tank sizes required, the shapes should be decided as follows: a)
Rectangular / Trapezoidal for smaller capacity;
b)
Cylindrical with domed roof & bottom for medium and large capacity;
c)
Hyperbolic or Spheroids for large capacity.
16.2
The height of tank(s) above ground should be decided according to the specific requirements of plants / Facilities, residential localities to be served and their distances from the tank location in order to maintain the necessary supply pressures.
16.3
The storage capacity should be estimated in excess to those required to meet the daily consumption criteria and future projected demands in compliance with the local practices and regulations.
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16.4
Concrete tanks shall be designed as liquid retaining structures to make them watertight and leak proof by controlling the crack widths in the concrete with the appropriate construction details for joints in compliance with ACI 318M and ACI 350 as applicable.
16.5
Concrete columns should be adequately tied for lateral restraint and shall be capable to transfer all the design loads to the foundations. Foundations shall be checked for stability and soil weight not more than 50% on the foundations shall be accounted in the stability calculation.
17.0
FENCING
17.1
General
17.1.1
Fencing should be provided in accordance with KOC-G-019, Part-2 “KOC Standard for Security Systems: Part 2 Security Fences, Gates, Road Blockers, Vehicle Barriers, New Buildings and Guard Houses” for security around plant and Facilities to restrict unauthorized access, and to protect equipment at isolated places as well as in remote and desert locations for safety.
17.1.2
Fencing including all accessories with openable gates and locks should be erected at KOC approved locations to the specified height for its purpose as given below.
17.2
Type of Fencing
17.2.1
Fencing should be of permanent or temporary type depending on its purpose, duty and durability.
17.2.2
The permanent fencing should be made from the following chain-link types: a)
General purpose fencing
: 1800 mm high
b)
Transformer compound fencing
: 1800 mm high
c)
Industrial security fencing
: 2400 mm high
17.2.3
In transformer compounds, adequate provision of frame mounted and bolted type removable sections of fencing should be provided to ensure maximum access for, and removal of, transformers. In addition, an outward opening lockable access gate should be provided to each separate transformer compound.
17.2.4
Temporary fencing should provide the safety and security conforming to its duty, although it need not have the same durability of permanent fencing. If this duty is met, some departures may be acceptable for the materials and workmanship requirements of permanent fencing.
17.3
Chain Link Fencing
17.3.1
Generally, fence shall be comprised of galvanized chain link fabric and fittings to the specified height, with tension wires at top and bottom and several rows of barbed strands at top. If the fence height is more than 1800 mm, one row of concertina barbed wire should be installed on top supported by extension arms and a continuous top and bottom rail.
DOC. NO. KOC-C-002
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REV. 2
17.3.2
The fence fabric shall be fastened to the side of line posts (pipes or angles) at 3000 mm apart, which shall be embedded into concrete blocks of suitable sizes. The fence shall be adequately braced at panels adjacent to gates and removable panels.
17.3.3
The fence fabric shall be as per ASTM A392, and shall be made of uniform square or diamond wire mesh of 50 mm from helically interwoven steel wires. The wires should be not less than 4 mm diameter, having class 2 zinc coating of minimum 610 g/m 2. The top and bottom edges of mesh should be twisted and barbed.
17.3.4
Galvanized barbed wire (barbed strands) shall conform to ASTM A121. Strand wire should be not less than 2.5 mm diameter with minimum zinc coating weight of 245 g/m2; and barbed wires should be 2.0 mm diameter with 200 g/m 2 minimum zinc coating.
17.3.5
Concertina barbed wire, if provided, shall have 3.0 mm diameter high tensile line wire with 2.0 mm diameter low carbon mild steel barbs and shall be galvanized. Coil diameter shall be of approximately 1000 mm.
17.3.6
Tension wires shall be of not less than 4.0 mm external diameter and shall be galvanized with zinc coating of minimum 610 g/m2.
17.3.7
All line posts, braces, fittings and frames shall be hot dip galvanized and shall conform to ASTM F1083, schedule 40 for pipes or to ASTM A36/A36M for angle sections.
17.3.8
For more details, refer to KOC Standard Drawing Nos. “55-02-17 & 55-02-28” and KOC-G-019 Part 2 for chain link fencing.
17.4
Corrugated Sheet Fencing I 2 I
17.4.1
Corrugated iron sheets, as fencing up to 2.4 m high are to be provided in some places like houses in the residential areas to prevent ingress of sands and accumulation thereof.
17.4.2
Corrugated sheets shall be minimum 22 gauge steel, galvanized with coating Type Z 350 as per BS 3083; and shall be installed in accordance with KOC Standard Drawing Nos. “55-02-26” for 1.8 m high or “55-02-30” for 2.4 m high fences. Gates shall be made as per KOC Standard Drawing No. “55-02-31”.
18.0
STRUCTURAL WORK
18.1
General
18.1.1
Structural steelwork should be used for multilevel plant structures, overhead pipe racks, heavy girders, large span frames and for industrial buildings covering large areas by trusses or portal frames and miscellaneous metal works like platforms, stairs, ladders etc. as well as for equipment supports and supporting structures, if not located at grade level.
DOC. NO. KOC-C-002 18.1.2
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REV. 2
Normally, the structural work made of weldable non-alloy, hot rolled steel sections is preferred over the other materials of construction due to the several factors as follows: a)
Ease of construction.
b)
Speed of construction.
c)
Ease of modifications and strengthening in future.
d)
Ease of periodic maintenance.
e)
Reliability of good structural strength and long life.
f)
Highly cost effective and economical.
18.2
Structural Form
18.2.1
Structural steelwork shall be made in the simpler forms of construction for ease of fabrication and erection; as well as for ease of general maintenance and painting.
18.2.2
As far as practicable, complex structural forms should be avoided; and lattice type structures other than towers and roof trusses should preferably not to be used.
18.2.3
Structural steelwork shall be generally shop fabricated by welding, and field assembled and erected by bolting at Site. Or, they should be fabricated in pieces and / or pre-assembled in a fabrication yard remote from the Site.
18.3
Design Conditions I 2 I
18.3.1
The structure or a part of the structure shall be designed to resist all applicable loads and worst load combinations within the deflection limits as specified in KOC-C-001 “KOC Standard for Basic Civil Engineering Design Data”.
18.3.2
Structural Steel Design shall be in accordance with the ANSI/AISC 360 “Specification for Structural Steel Buildings”, AISC 341 “Seismic Provisions for Structural Steel Building” and AISC 325 “Steel Construction Manual”. The Load and Resistance Factor Design (LRFD) method in AISC shall not be used in steel design and shall be fabricated with all the materials in compliance with the relevant technical specifications as specified in KOC-C-007 “KOC Standard for Structural Steel Work - Materials, Fabrication and Erection”.
18.3.3
Normally, only pinned column bases shall be used in the design of steel structures. However, to control the deflections for pipe racks and industrial buildings etc., fixed base plates design shall be used with prior approval from KOC.
18.3.4
Where headroom / access for personnel or equipment entry / exit are required, generally wind and other lateral loads on a steel structure shall preferably be carried to the foundations through vertical X-bracing or K-bracing placed in the transverse and longitudinal column lines of the structure. As a second choice, wind and other lateral loads on a structure should be transmitted to the foundations through moment resistant frames in one direction and vertical X-braced or K-braced frames in the other direction. Structures that resist lateral load with rigid frame systems in two directions should be avoided.
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18.3.5
Compression bracing for steel structures shall normally be designed with wide flange and structural tee shapes. For tension bracing, single angle or structural tees should be used. Double angle bracing, because of maintenance difficulties, is not permitted for either compression or tension bracing. When using structural tees in compression, the design shall include bending induced by eccentrically loaded connections. Rods / Cables as bracing members shall not be permitted.
18.3.6
Braces for structures subject to vibration from equipment shall be designed as compression members.
18.3.7
Horizontal bracing shall be provided in the plane of a floor, platform, or walkway, when necessary to resist lateral loads or to increase the lateral stiffness of the floor, platform, or walkway. Floor grating shall not be assumed to resist lateral loads in diaphragm action. Floor plate should be investigated before it is considered to resist loads in diaphragm action.
18.3.8
In a floor system, beam compression flanges should be considered to be fully braced when a concrete slab is cast to match the bottom face of the compression flanges on both sides, or when checkered plate is welded to the compression flanges. Grating is normally clipped or bolted and therefore shall not be considered as adequate compression flange bracing. In such cases, additional horizontal bracing in the floor system shall be provided.
18.3.9
Bar joist floor and roof systems are generally considered to be too light for heavy industrial plant work. However, when approved by KOC, bar joist systems should be used on a project.
18.3.10 Steel Structures shall be designed so that the surfaces of all parts will be readily accessible for inspection, cleaning and painting. Pockets for depressions which would hold water shall have drain holes or be otherwise protected. 18.3.11 The forces in truss members and all main bracing shall be shown on the engineering drawings with plus signs indicating tension and minus signs indicating compression or as per the calculation note provided by Designer. 18.3.12 Gusset plates shall not be thinner than the members to be connected, and shall have a thickness of at least 10 mm. 18.3.13 Contractor shall note that the minimum thickness of any plate or rolled section for use as a structural element should not be less than 6mm. 18.3.14 All bracing shall be arranged to minimize torsion and where practicable, be arranged concentrically about the resultant line of force. The connections wherever possible, shall be arranged so that their centroid lies on the resultant of the forces they are intended to resist.When the condition cannot be achieved, the members and connections shall be designed to resist any local bending due to the eccentricity of the force. 18.3.15 Bracings located within the fireproofing zone shall also be fireproofed similar to other members as bracings are part of structural stability. Fireproofing loads shall be considered under dead loads in the structural design. For detail of Passive Fire Protection of Structural Steel refer clause no. 18.5 of this RP.
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18.3.16 Structural steelworks generally shall be fabricated by welding. Stitch welds and one side welding are not accepted. Welds shall not be less than 6mm continuous fillet welding. 18.3.17 All load bearing structural steel members shall be hot rolled. Built-up steel sections shall not be allowed unless approved by the KOC in writing. If built-up steel sections are allowed by the KOC, minimum thickness of web and flange shall be 6 mm and 8 mm respectively and the flange shall be proportioned to provide a compact section. 18.3.18 Purlins, girts, fly bracings and sheetings shall not be considered as part of the bracing system for reducing the unsupported length or the buckling length of steel sections. Only a well-braced system shall be considered as effective in providing restraint to the compression flange of the steel sections. The roof and the side structure shall be adequately braced in its plane. 18.3.19 The slenderness ratio for all the structural steel members in compression (including bracings) shall be less than 200. 18.3.20
Lifting / transportation calculations, drawings and Method statement shall be provided to KOC if the structural components / modules are planned to be installed by lifting.
18.3.21 Guardrail configuration shall confirm to the IBC and OSHA requirements as a minimum. 18.3.22 Workplace walking and working surfaces shall conform to the safety requirements of ASSE A1264.1. 18.4
Design Stress Levels Allowable design stresses for the selected structural steel sections (rolled / hollow) conforming to BS EN 10025 Grade S275JR / S275 JOH or ASTM A36/A36M or equivalent shall be used in accordance with the applicable National codes and standards given in clause 4.2 of this RP. However, reduction in the allowable design stresses should be considered necessary as safety measures for the following conditions.
18.4.1 Fatigue
18.4.2
a)
Special structures, such as gantry girders with heavy moving loads from the crane(s), tall free-standing towers and guyed masts which are prone to fatigue due to cyclic loading, should consider in design, the appropriate safety factors and reduced stress levels in order to limit the allowable material stresses.
b)
Structural details, which should give rise to high local stress in these fatigue prone structures, should be avoided.
Fire a)
Structural steel can withstand temperature up to 200C (392F) without any significant reduction in the allowable stresses and can retain its integrity without change in its strain levels. But its loss of strength starts then at an increasingly faster rate, up to a temperature of about 750 C
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(1382F) with increased strain levels deformations as per BS EN 1993-1-2.
REV. 2 causing
serious
inelastic
b)
If the critical temperature for structural steel is intended to describe the steel temperature at which its strength reduces to such an extent that collapse is impending, this temperature should be judged with reasonable approximation in the range of 538 C (1000F).
c)
Where the structure supports equipment containing or handling flammable materials and where high risk of potential fire exists, suitable reduction in the allowable stresses should be considered in design as an additional protective measure other than encasing the structure with selected fire proofing material.
18.5
Passive Fire Protection
18.5.1
The passive fire protection of steel structures as needed shall be established for the requisite fire rating, wherever fireproofing requirements are specified by KOC or by the designer / contractor; and shall be provided in accordance with KOC-C-027 “KOC Standard for Fireproofing of Structural Steelwork”.
18.5.2
The materials shall be fire rated to maintain the temperature of 538C (1000F) on the steel substrate to a specified period of fire resistance, which should in general vary from minimum one (1) hour to maximum four (4) hours to provide the breathing time for the required fire fighting response. Accordingly, the material properties and thickness should be selected and verified by the fire tests certificates for suitability as per BS 476 Parts 20 and 21.
18.5.3
However, materials with two (2) hours of fire rating should be good enough as passive fire resistance in the form of in-situ dense concrete, lightweight vermiculite concrete or epoxy intumescent coating as specified in KOC-C-027.
18.6
Painting / Galvanizing
18.6.1
All metal surfaces shall be prepared as per SSPC SP6 and shall be painted, unless galvanized or otherwise specified, in accordance with KOC-P-001 “KOC Standard for Painting and Coating of External Metal Surfaces”.
18.6.2
All steelwork for miscellaneous metal work such as platforms, walkways (open grid flooring / checker plates), handrails, stair treads, ladders, cages and safety guards including bolts, nuts and washers shall be hot dip galvanized in accordance with BS EN ISO 1461, ASTM A123/A123M & ASTM A153/A153M. For more detail, refer KOC-C-001.
18.7
Connections I 2 I
18.7.1
Welded connections shall be carried out using the manual metallic arc process as per AWS D1.1/D1.1M. Welding procedure specification (WPS) for each class of work and procedure qualification records (PQR) as per AWS D1.1/D1.1M requirements shall be submitted for KOC approval prior to commencement of work.
18.7.2
Bolted connections shall be made with high strength structural bolts, except in the following minor connections where ordinary bolts should be used: a)
Purlins, girts, stair framing, sheeting rails and light bracings.
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b)
Platforms and walkways attached to vessels.
c)
Removable floor plates, removable hand railings and ladder cage assemblies.
Connections for steel structures shall conform to the following requirements: a)
Shop connections should be bolted or welded. Field connections shall normally be bolted; however, when approved by the KOC, welded field connections should be used.
b)
Bolted connections for primary members shall utilize high-strength bolts conforming to ASTM A325M Type 1 or ASTM A490M Type 1 or BS EN 14399 Property Class 8. These connections shall be designed as bearing type connections. Those connections subject to vibration or stress reversal shall be friction type. Loads for bearing type connections shall be based on threads included in shear plane. Turn of the nut method or load-indicator washers shall be used for tightening all connections. All bolts shall be designed, installed and inspected in accordance with “RCSC Specification for Structural Joints Using High Strength Bolts” (ASTM A325M or A490M).
c)
Connections shall be normally be designed and checked by the Contractor in accordance with the project construction specifications and loads shown on the drawings. Moment connections and special connections, however, shall be designed by the Designer and shall be shown on the engineering drawings.
d)
Moment connections shall be bolted or welded type depending on the type of structure and situation. The Designer will determine the type of connection to be used for each structure.
e)
All shear connections shall be designed and detailed by the Supplier and checked by the Designer. Reactions shall be shown on the engineering drawings or as per the calculation note provided by Designer.
18.7.4
For more detail of bolted connections, refer to KOC-C-001 “KOC Standard for Basic Civil Engineering Design Data”.
18.7.5
As far as practicable, various forms of connections should be minimized and complicated details should be preferably avoided for fabrication as a good engineering practice.
19.0
MISCELLANEOUS METAL WORK
19.1
Platforms
19.1.1
Platform(s) shall be provided at locations for access to equipment and their appurtenances for regular attention to operations or servicing and maintenance, when they are in operation and are placed more than 2000 mm above the grade level. Minimum width shall be not less than 1000 mm for operating platforms and access around equipment.
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Platforms should therefore be provided especially for access to: a)
Elevated man-ways on process equipment,
b)
Manifold locations,
c)
Instrument locations,
d)
High level fixed fire monitors.
19.1.2
Platforms, if provided at various levels and around different items, shall be interconnected by walkways, stairways or ladders with specific attention to escape routes in the event of fires.
19.1.3
Headroom clearance at all platforms shall not be less than 2100 mm considering the presence of electrical fittings and all other obstructions thereon.
19.1.4
Platforms shall be installed in the form of either open grid or solid checker plate steel flooring with stairways and ladders for access and exit; and shall be protected with handrails and toe plates.
19.1.5
Walkways shall be of open grid type and shall be provided with handrails and toe plates. Walkways shall not be less than minimum 750 mm in width.
19.1.6
Self closing gates should be provided at platform exits to all vertical ladders, which should open inwards towards the platform. Self-closing safety bars should be used in lieu of gates.
19.2
Steel Flooring I 2 I
19.2.1
Normally, steel flooring should be of open grid type and should be hot dip galvanized. However, checker plate flooring should be considered for safety where any chance of spillage exists from upper level to lower platforms or equipment. Contractor shall submit the design calculation of welded steel grating for light and heavy duty traffic for KOC approval.
19.2.2
Open grid type metal flooring in rectangular pattern is normally preferred with load bearing bars having anti-slip serrated top surface. The load bearing main bars shall be 30 mm deep x 5 mm thick @ 30 mm centers with 10 mm twisted cross bars @ 100 mm centres in transverse direction.
19.2.3
Checker floor plates shall have raised pattern to provide a non-slip surface and shall be minimum 6 mm thick excluding the pattern.
19.2.4
Floor panel shall be limited to span (L) having deflections not more than L/250 or 10 mm, whichever is smaller.
19.3
Stairways I 2 I
19.3.1
Stairways shall be provided for access to platforms serving equipment, which requires regular and frequent operational attendance or rapid escape or access in the event of an emergency.
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19.3.2
Stairways shall be arranged with the angle of slope between 30 to 38 to the horizontal. In some special cases, up to 45 may be provided subject to KOC approval.
19.3.3
Generally, stairs shall be provided with at least 750 mm minimum clear width between stringers. Stairs shall have minimum 240 mm tread width and maximum 190 mm riser height.
19.3.4
However, main access and escape stairs shall have at least minimum clear widths of 1000 mm and 1200 mm respectively between stringers.
19.3.5
The maximum rise in a single flight of stairs shall be limited to 3040 mm or 16 risers without landing. The minimum clear width of landing shall be 1200 mm.
19.3.6
Headroom clearance over stairs shall be minimum 2150 mm measured at the nose of a tread.
19.3.7
Treads for all stairs and landings shall be galvanized open grid flooring with full width anti-skid checker plate nosing and shall be made in accordance with clause 19.2.2 of this RP.
19.4
Spiral Stairways
19.4.1
Spiral stairways shall be generally provided to the circular structures like vessels and tanks for access to platforms.
19.4.2
Stair widths shall be at least minimum 1000 mm between stringers and slope shall be decided on the basis of number of landings, depending on the diameter and height of the structures.
19.4.3
Stairs and landings of stairways shall be galvanized open grid flooring. Treads of stairs and landings shall have full width anti-skid checker plate nosing and shall be made in accordance with clause 19.2.2 of this RP.
19.5
Ladders I 2 I
19.5.1
Fixed ladders shall be provided for: a)
Access to all platforms not served by a stairway.
b)
An emergency escape from a platform, which is already served by a stairway.
c)
Access to locations where no platforms are provided.
19.5.2
All ladders shall be generally vertical. If inclined ladders are to be provided, the slope shall be not more than 15 to the vertical.
19.5.3
Changes in inclination of ladders shall not be allowed. Intermediate platforms shall be provided to avoid change of inclination within a f light.
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19.5.4
Side access ladders shall be preferred to front access. Safety bars shall be provided where ladders start close to the edge of an elevated platform.
19.5.5
Ladder shall be provided with safety cage, when ladder height is 5.0 m or more above ground or platform level. Safety cage shall start in that case from a height of 2.1 m minimum but not exceeding 2.4 m maximum from the ground or platform level. Safety cage shall be circular shape in plan with a radius ranging from minimum 340 mm to maximum 380 mm as applicable.
19.5.6
Ladder rungs shall be fitted into holes in the stringers and secured by welding. Ladder width shall be not less than minimum 380 mm but not more than 460 mm for ease of climb. For more details, refer to KOC Standard Drawing No. “55-02-57” for steel ladder.
19.5.7
All fixed ladders shall be in accordance with ALI A14.3.
19.6
Handrails and Toe Plates
19.6.1
Handrails shall be provided for safety around edges of all platforms and walkways, which are 500 mm, or more above ground or any operating level. Handrails shall be provided for stairways and all landings.
19.6.2
Toe plates shall be provided along all edges protected by handrails, at openings in flooring around equipment, but not across the entrance to platforms by stairs and ladders. Toe plate upstand shall be not less than 100 mm.
19.6.3
Refer to KOC Standard Drawing No. “55-02-58” for all structural details.
19.7
Ramps
19.7.1
Ramps, if made of steel, shall be provided with adequate width at emergency escapes in hospitals and buildings; and shall be of solid checker plates with raised anti-skid patterns. Checker plate shall be minimum 8 mm thick excluding the raised patterns.
19.7.2
Ramps or inclines shall have slopes not more than 15 and should never exceed 20 from the horizontal; and shall be laid over a smooth surface of thoroughly compacted base.
19.8
Claddings Roof and side claddings should be selected from hot dip galvanized steel profiled sheets with lightly bonded plastic finish both sides as per relevant BS 3083, BS 5427-1 and BS CP 143 Part 10 or ASTM A653/A653M or equivalent.
20.0
CONCRETE WORK I 2 I
20.1
Design Consideration for Concrete Work I 2 I
20.1.1
Concrete structures shall be designed in accordance with ACI 318M. The strength design method shall be used for the structural design of concrete members unless otherwise mentioned in the project documents.
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20.1.2
Construction joints in a concrete structure shall be located so as to least impair the integrity and strength of the structure. Construction joints in beams at column or pedestal faces should be avoided. The Designer shall show the position of all construction joints in the design drawings and same to be approved by KOC.
20.1.3
Hollow core slabs are not preferred in RCC building slab construction, since in oil and gas industry almost all are single story buildings and it leads to more frequent seepage and maintenance problem.
20.1.4
Designer shall consider the relative merits of pre-casting structural concrete elements such as small foundations, manholes, culverts and small structures. Precast foundation design shall include calculations for lifting and handling stresses.
20.1.5
No piping / cables shall pass through a foundation, unless for the equipment to be fixed on the same foundation itself. If some existing piping / cables are found in the way of new foundations, these shall be re-routed to the satisfaction of KOC.
20.1.6
Anchor bolts shall be cast along with the foundation concrete without provision for pockets / anchor boxes. Pockets / anchor boxes shall be permitted by the KOC for certain specific cases only, on valid justification.
20.1.7
As required by the design and Machine / Equipment Manufactur er’s recommendation, vibration isolation pad around dynamic foundations shall be provided.
20.1.8
All concrete faces for miscellaneous concrete elements (non-structural) - e.g. duct banks, guard rail foundations, etc. shall be provided with minimum reinforcement against shrinkage and thermal cracking.
20.1.9
Static Equipment weighting less than 500kg may be supported on thickened paved slabs.
20.1.10 Adequate cover in essential for resistance to corrosion. Concrete cover shall be provided in accordance with KOC-C-006 “KOC Standard for Concrete Work Materials and Construction”. Required covers shall not be reduced by provision of protective coatings, membranes or by membrane protective screed. 20.1.11 For conventional structures, shear keys shall not be used on pedestals / plinths. However, shear keys can be used in circumstances that restrict the use of adequate number of anchor bolts or any other situation after obtaining KOC approval with proper back up design calculation and justification for the same. 20.1.12 The durability and quality of the concrete itself is of paramount importance. Measures to increase durability of concrete shall be considered such as thermal insulation coating as recommended in the “CIRIA Guide to the Construction of Reinforced Concrete in the Arabian Peninsula”. Quality of concrete is achieved by good engineering and detailing, proper materials and proportioning, good construction techniques and concrete curing. One of the main characteristics influencing the durability of concrete is its permeability to the ingress of chlorides, water, oxygen, carbon dioxide, wind blown chloride contaminated dust and other deleterious substances.
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20.1.13 Coatings shall be applied to all buried and exposed concrete surfaces as an added protection against attack from chlorides and other harmful elements and to assist the concrete to develop a refined pore structure and enhanced impermeability. Coatings shall have crack bridging properties on flexural members. 20.2
Maximum and Minimum Reinforcement Spacing I 2 I
20.2.1
Minimum distance between individual reinforcing bars shall be in accordance with ACI 318M. Maximum center to center spacing of individual reinforcing bars shall be as follows: a)
Not more than 150 mm for main bars in beams, walls and slabs etc.
b)
Not more than 200 mm for minimum shrinkage and temperature reinforcing bars perpendicular to main bars in slabs and walls etc.
c)
Not more than 250 mm for longitudinal bars in columns and stirrups in beams. Column main bar spaced not more than 150 mm on center shall be laterally supported at a tie corner.
d)
Not more than 400 mm for any other bars not mentioned above.
20.2.2
Minimum elevated floor slab thicknesses shall be multiples of 20 mm or multiples of 50 mm but not less than 165 mm. For grade slab minimum thickness refer clause no. 12.6 of this RP.
20.2.3
Minimum wall thickness shall be 150mm incremented by 50 mm multiples.
20.2.4
In footings and foundations with a thickness of 250 mm or more, reinforcing bars shall be placed on both the top and bottom, over the full section. Minimum foundation thickness shall be 200 mm incremented by 50mm multiples.
20.2.5
Minimum diameter of main reinforcing bars shall be 12 mm dia and that of the stirrups / links shall be 8 mm but for compression member stirrups / links shall be 10 mm.
20.2.6
Use fabric reinforcement where possible (‘nested’ where necessary) as this gives better crack control.
20.2.7
Reinforcement shall be adequately detailed to eliminate congested areas, i.e. laps to be staggered.
20.2.8
The following reinforcement arrangements for the wall or slab openings shall be followed: a)
For opening with a width at right angles to the span not greater than 500 mm, the main reinforcement which interferes with the opening should be cut and replaced by bars of the same size placed evenly on all sides of the opening. Additional reinforcing bars will be required if an uneven number of bars are cut. All replacement bars should extend an anchorage length beyond the edges of the opening.
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For opening with a width not greater than 1000 mm, the main reinforcement should be treated in the same manner as described before but with additional bars of the same size shall be placed on the each side of the opening in the top of slab. Diagonal reinforcement in the form of links of the same size should be placed at the corners of the opening. The effective length of diagonal bars should be at least two anchorage lengths.
20.3
Minimum Reinforcement I 2 I
20.3.1
The minimum main tension reinforcement for all flexural members including beams, slabs, walls and deep beams shall be in accordance with ACI 318M.
20.3.2
Secondary and shrinkage requirements of ACI 318M.
20.4
Joints I 2 I
20.4.1
Expansion joints, contraction joints, and construction joints, where required by design, shall be detailed and shown on the Engineering Drawings.
20.4.2
Expansion joints, contraction joints and construction joints shall be detailed in accordance with ACI 301, ACI 302.1R and ACI 224.3R. For more details, refer KOC-C-001 “KOC Standard for Basic Civil Engineering Design Data”.
21.0
PRECAST CONCRETE I 2 I
21.1
Precast concrete whether cast at the job site or at a designated facility shall be designed in accordance with ACI 318M. Concrete cover requirements shall be those applicable to cast-in-situ concrete.
21.2
Anchoring of facing precast units to cast-in-situ concrete in buildings shall be by pre-installed stainless steel A304SS proprietary systems such as Halfen Anchoring Systems, USA or equal approved.
21.3
Anchoring details and locations shall be engineered by the Contractor and be clearly shown on shop drawings. Arbitrary site drilling or chipping for anchoring installation is prohibited and may subject non-conformant items to rejection.
21.4
Dynamic or reversal response shall be considered in the design of precast element connections in buildings subjected to blast loading to prevent their sudden failure.
22.0
ANCHOR BOLT I 2 I
22.1
For the minimum edge distance, design and detailing of anchor bolts refer to KOC Standard Drawing No. 55-02-62, “Steel Anchor Bolt”. Minimum edge distance between the center of anchor bolts to edge of base plate shall be 1.75 times the diameter of anchor bolts.
22.2
Anchor bolts subjected to combined tension and shear shall be designed in a rational manner to determine bolt size and embedment length. The generally recognized cone failure pattern, effect of pedestal main rebar development
temperature
reinforcement
shall
satisfy
the
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through the failure surface and effect of pedestal top confinement by narrowly spaced ties in resisting shear shall be considered. 22.3
Contractor shall prepare a design procedure of anchor bolts to address the above aspects supported by latest literature and trends in the industry for KOC approval. Provisions of ACI 318M and ASCE 41258 “ Anchorage Design for Petrochemical Facilities” shall be considered as applicable. Anchor bolts shall be designed for combined tension and shear as per ACI 318M.
22.4
Post-fixing bolts (mechanical fasteners of expansion type or chemical fasteners installed with resin) could be used for miscellaneous supports such as handrails, ladders, minor pipe supports, electrical and instrumentation supports, HVAC duct supports, building fire water deluge system supports, building doors & windows, gates and fences. Post-fixing bolts for any other application shall be subject to KOC approval and will be allowed only for certain specific cases, on valid justification. Post-fixing bolts shall be installed strictly as per Manufacturer’s instruction.
23.0
CONCRETE MASONRY STRUCTURES I 2 I The design of concrete masonry structures shall conform to ACI 530/530.1, ASCE 5 & 6.
24.0
GROUTING I 2 I All grout materials and application procedures shall be used in accordance with KOC-C-023. All grout materials and application procedures shall be approved by the Designer and the Manufacturer. Ordinary sand-cement grout shall not be used. Grout material used below base plates for machinery, pipe racks, pumps, pipe supports, etc. shall not be placed higher than the bottom of plate level and shall be sloped outward at a 1:1 slope away from the bottom of the base plate to prevent water accumulation near the base plate and also to prevent cracking of the grout as a result of corrosion around base plate edge. Contractor shall develop a detail to ensure an effective seal from exterior moisture is achieved around the perimeter of the baseplates at the point of intersection between grout and baseplates.
25.0
OVERHEAD CLEARANCES I 2 I Minimum clear vertical distance for all overhead structures, platforms, piping supports, first tier of multilevel pipe rack and equipment should be maintained as recommended values given in Table-5.
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Table-5: Recommended Overhead Clearances Sl. No.
Description
Vertical Clearance
Over Plant roads / Main facility road / Primary 1
2
road / Secondary road for vehicular traffic movement (heavy cranes / major mobile equipment / trucks etc.) (See Note-1 & 2) Over pumps and turbines
6.5 m
2.5 m (Minimum) or Higher vertical clearance required as per maintenance requirement.
3
Over walkways, passageways and platforms (See Note-2)
Note-1:
2.1 m
Incase where the above vertical clearance cannot be met due to genuine reasons like existing obstructions etc., then the clearance shall be decreased with prior approval from KOC. A warning sign showing clear height shall be installed on bridges.
Note-2:
Vertical measurement shall be taken from crown levels of roads / highest pavement of paving as applicable.
26.0
DESIGN SOFTWARES I 2 I In general the design software used shall be internationally recognized and well proven. Typical examples are: STAAD Pro, RISA, Prokon, Mat3D, Foundation 3D, Inroads, Microdrain. Contractor shall furnish the list of proposed design software’s to be used during project execution for KOC approval.
27.0
QUALITY ASSURANCE I 2 I
27.1
The Consultant / Contractor / Manufacturer shall operate a quality system preferably based on ISO 9000 series of standards to satisfy the requirements of this Recommended Practice. The Consultant / Contractor / Manufacturer shall demonstrate compliance by providing a copy of the accredited certificate or the Consultant’s / Contractor’s / Manufacturer’s quality manual.
27.2
Verification of the Consultant’s / Contractor’s / Manufacturer’s quality system is normally part of the pre-qualification procedure, and therefore not detailed in the core text of this Recommended Practice.
28.0
DOCUMENTATION I 2 I
28.1
General
28.1.1
All correspondence, instructions, data sheets, drawings, design calculations or any other written information shall be in English language. In case of dual languages, one language shall be English.
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28.1.2
All dimensions, units of measurement, physical constants etc. shall be in SI units unless otherwise specified in the project document. (Nominal bore pipe sizes to be generally mentioned in inches).
28.1.3
In addition to the hard copies, all documents (text, data sheets, specifications, drawings, test reports, design calculations etc.) shall be provided with electronic files in the approved software’s (MS Word, Excel, Auto Cad etc.). All calculations shall be submitted in approved and widely used software(s) agreed upon by KOC. The submission of calculations and drawings by the Contractor to the KOC shall include the editable native electronic format of the calculation input / output, for the ease of review by the KOC.
28.2
Deliverables Consultant / Designer / Contractor shall submit the necessary documents as a minimum to KOC for review and acceptance as given below, but is not limited to the following only: a) b) c) d) e) f) g) h) i) j) k)
l) m) n) o) p) q) r) s) t) u) v) w)
Geo-technical Investigation Report with slit trench information Topographical Survey Contour Maps Plot Layout Block Diagrams Area Drawings Grading Plans Drainage Plans Location Plans Architectural Plans, Elevations and Sectional Drawings for Buildings Architectural Plans for roofs, reflected ceilings, doors, windows, toilets & WC with internal plumbing, finishes & colour schedules and furniture etc. including all details for Buildings Structural Plans, Elevations and Sectional Drawings for various Units Structural Plans, Elevations and Sectional Drawings for Pipe Rack, equipment supporting structures, sheds etc. Paving Layout Drawings Structural Analysis and Design Calculations Design Drawings showing plans, elevations and details with dimensions, sizes, materials, reinforcements and connections Bar Bending Schedules and / or Fabrication Drawings (by Contractor) Master List of all Submittals Master List of Schedules for Planned Progress Work Breakdown Schedules (WBS) Inspection Certificates & Reports As built Drawings Any other as required.
DOC. NO. KOC-C-002
Page 73 of 74
REV. 2
ACKNOWLEDGEMENT I 2 I This Recommended Practice (Rev.2) has been approved by the Standards Technical Committee (STC) consisting of the following Members:Mr. Hamzah Ahmad
Standards Team
Chairman
Mr. Mohd. Emam
Insp. & Corr. (S&EK) Team
Deputy Chairman
Mr. A. Unnikrishnan
Standards Team
Secretary / Member
Mr. Mohd. Aslam Imadi
Tech. Exp. Team
Member
Mr. G. Unnikrishnan
Tech. Exp. Team
Member
Mr. Amer Jaragh
Insp. & Corr. (N&WK) Team
Member
Mr. Gopal Murti
Opns. Tech. Svcs. (WK) Team
Member
Mr. Nandkumar Aravind
HSE Systems Team
Member
Mr. Mohammad Al-Ajmi
Tech. Systems Team
Member
Mr. Haitam Aboughaith
Gen. Projects Team
Member
Mr. Abdulla Al-Yousef
Project Mgmt. (NK) Team
Member
The Revision of this Recommended Practice has been circulated to the KOC User Teams for their review and responses were received from the following: CORPORATE INFO. TECH. GROUP
GAS OPERATIONS GROUP
Team Leader Communications & Networks
Team Leader Gas Maint. (N&WK)
PROJ. SUPP. SERVICES GROUP
HS&E GROUP
Team Leader Tech. Expertise Team Leader PMC Mgmt.- AMEC
Team Leader Safety Team Leader Health & Environment
OPERATIONS SUPPORT (GAS) GROUP
OPERATIONS SUPPORT GROUP
Team Leader HSE-Gas
Team Leader HSE-S&EK
EXPORT OPERATIONS GROUP
SUPPORT SERVICES GROUP (NK)
Team Leader HSE-Exp. Opns. & Mar. Opns.
Team Leader Proj. Mgmt.- NK
TECHNICAL SUPPORT GROUP
OPERATIONS GROUP (EK)
Team Leader Drill. & W/Over Tech. Svcs.-I Team Leader Drill. & W/Over Tech. Svcs.-II
Team Leader Maint. EK-II
SUPPORT SERVICES GROUP (WK) Team Leader Proj. Mgmt.- WK Team Leader HSE-WK
