SOK0902485 0506087 AB04 D02 CV CL 0099 - 0 - BHComments

FOUNDATION & STRUCTURAL DESIGN CALCULATION REPORT FOR
PIPE RACK-D05-PR01
SOK0902485
NASRIYA & GHARRAF FLARE GAS RECOVERY

FOUNDATION & STRUCTURAL DESIGN
CALCULATION REPORT FOR PIPE RACK-D05-PR01
TITLE DOCUMENT CODE REVISION

FOUNDATION & STRUCTURAL DESIGN CALCULATION REPORT FOR
PIPE RACK-D05-PR01 SOK0902485
REVISION DESCRIPTION: APPROVED Electronically Stored
DATE SECURITY CODE
CHECKED Electronically Stored N
VENDOR SUPPLIED DRAWING
SCALE REPLACES/DERIVED FROM 1st ISSUE ORIGINAL JOB SIZE LANGUAGE
N/A N/A 0506087 4 A
This document is filed under Nuovo Pignone Tecnologie S.r.l. Supplier drawing number. This document will be revised in its entirety only by originator. SHEET
Nuovo Pignone Tecnologie S.r.l. Supplier revision number may differ from original title block. 1 of 17
NASRIYA & GHARRAF FLARE GAS TREATMENT PLANT Rev : 0 No
FOUNDATION & STRUCTURAL DESIGN CALCULATION REPORT FOR Date : 11-Aug-23
PIPE RACK-D05-PR01 Sheet : 2 of 17
Contract Number: 0506087

Project Title: EPC For Nasriya & Gharraf Flare Gas Treatment Plant
Contractor: Baker Hughes
Subcontractor’s Name: ALBILAL GROUP For General Contracts Co. Ltd.
Subcontractor’s Reference Number and 0506087-AB04-D02-CV-CL-0099 Rev. 0
Revision:
Document Description: FOUNDATION & STRUCTURAL DESIGN CALCULATION REPORT

FOR PIPE RACK-D05-PR01
Equipment / Tag Number(s): M-0001
Review Code and Status

☐ Code 1 Approved
☐ Code 2 Accepted For Information Only
☐ Code 3 Accepted With Comments (Work May Proceed)
☐ Code 4 Return With Comments (Work Not Proceeding)
☐ Code C Rejected (Revise & Resubmit, Work May Not Proceed)
☐ Code S Superseded
Date: 4/12/2023 Sign: GDP
BH Approval does not relieve ABG’s responsibility in complying fully with the project specification,
contract, and Iraqi law.
Any deviation must be highlighted via formal deviation request; subject to BH approval.
0 I Issued For Design 11-Aug-23 RK SP MH

Rev. Doc. Class. Reason For Issue Date Author Checker Approver
HOLD LIST
HOLD NO. PARA. DESCRIPTION OF HOLD
Revision History
REV NO. PARA. DESCRIPTION OF REVISION
Note:
1. Changes shall be marked in Blue <#>.

Table of Contents
1.0 INTRODUCTION ........................................................................................................................5
1.1. Purpose Of This Document ........................................................................................................5
1.2. Project Background...................................................................................................................5
2.0 ACRONYMS AND ABBREVIATIONS .............................................................................................6
3.0 REFERENCE DOCUMENTS ..........................................................................................................6
3.1. Order Of Precedence of Documents ..........................................................................................6
3.2. International Codes & Standards ...............................................................................................6
3.2.1. American Standard .................................................................................................................................. 6
3.2.2. Project Reference Documents ................................................................................................................. 7
4.0 DESIGN DATA ...........................................................................................................................7
4.1. Concrete...................................................................................................................................7
4.2. Reinforcement ..........................................................................................................................7
4.3. Soil Report................................................................................................................................7
4.4. Factor Of Safety ........................................................................................................................8
4.5. Concrete Cover .........................................................................................................................8
4.6. Grout .......................................................................................................................................8
4.7. Steel .........................................................................................................................................8
4.8. Anchor Bolts .............................................................................................................................8
4.9. Piping Input (IDIT) .....................................................................................................................9
4.10. Module Input ...........................................................................................................................9
5.0 DRAWINGS ...............................................................................................................................9
6.0 DESCRIPTION ............................................................................................................................9
7.0 LOAD CASES & LOAD COMBINATIONS .......................................................................................9
7.1 Primary load cases and combinations ........................................................................................9
8.0 DESIGN RESULT....................................................................................................................... 10
8.1 Foundation Design .................................................................................................................. 10
8.2 Foundation Summary ............................................................................................................. 10
8.3 Pile Reactions ......................................................................................................................... 11
8.4 Foundation reinforcement summary, ...................................................................................... 11
8.5 Structural Steel Geometry & Design ........................................................................................ 14
8.6 List of Attachments ................................................................................................................. 17
1.0 INTRODUCTION
1.1. Purpose Of This Document
This Document presents the Foundation and Superstructure Design Calculation for Pipe Rack D05-PR01.
This document includes brief description of equipment, basic design data, design loads, load
combinations and details of Foundation Design & Serviceability checks. Pile foundation is designed to
support the pipe Rack.
Foundation is designed for the piping input received vide IDIT (Inter-Disciplinary Information Transfer)
and module M-0001. The objective is to achieve an effective and acceptable design of foundation that
meets the intended purpose during its life cycle.
The dimension of the pipe Rack D05-PR01 is 25.0m (L) x 6.00m (W) x 8.00m (H).
1.2. Project Background

The Flare Recovery Plant will be used to process the gases currently flared in Nassirya and Gharraf
degassing stations recovering LPG and condensates and injecting the natural gas into an existing gas
pipeline. The Plant will treat 200 MMSFCD (80 MMSCFD from Nasriya and 120 MMSCFD from Gharraf)
of de-flared gas. The gas is collected from Gharraf and Nasriya Degassing Stations and supplied via two
independent pipelines to the site. Pig receivers are installed on both natural gas pipelines. The liquid is
removed from the two gas streams by means of dedicated slug catchers and then the gases are merged.
The merged gas is boosted to approximately 43 barg in an electric motor driven centrifugal compressor
to feed the dehydration system. The natural gas will be processed by gas liquefaction system, with
propane based refrigeration system, designed to separate the LPG and Condensate from the gas. The
condensate and LPG are injected into separate pipelines. Pig launchers are installed for the product gas,
LPG and condensate pipelines. Two LPG truck loading bays are provided together with a daily Condensate
and LPG storage tanks bands. The remaining gas is compressed to 71 barg for injection into an existing
the pipeline. The recovered dry gas, LPG, and condensate will meet the specifications required by the
Customer.
2.0 ACRONYMS AND ABBREVIATIONS
Term Definition
AISC American Institute of Steel Construction
AWS American Welding Society
ASCE American Society of Civil Engineers
ASTM American Society for Testing and Materials
AASHTO American Association of State Highway & Transportation Officials
ANSI American National Standard Institute
API American Petroleum Institute
ASME American Society for Mechanical Engineers
IBC International Building Code
BS British Standards
NDE Non-destructive examinations
ITP Inspection and Test Plan
WPS Welding Procedure Specifications
PQR Procedure Qualification Records
3.0 REFERENCE DOCUMENTS

3.1. Order Of Precedence of Documents
The design of civil work shall be in accordance with the following Specifications, Codes of Practice and
Publications.
In case of any conflict among the provisions in various codes, standards and specifications, following
order of precedence shall be followed.
• Local Regulation
• Epc Subcontract Technical Spec Package Sok9954113 Rev-3
• Basis Of Design (Bod) Sok 7357663 Rev-0
• Project References
• International Standards
In the event of non-compliance with the above requirements ENGINEERING SUBCONTRACTOR shall seek
guidance from CONTRACTOR to give direction against its own standards set.
3.2. International Codes & Standards
3.2.1. American Standard
CODE DESCRIPTION
ASCE7-10 Minimum Design Loads for Buildings and Other Structures
ACI318-14 Building Code Requirements for Structural Concrete
ACI315 Details and Detailing of Concrete Reinforcement
ACI351.3R-04 Foundations for Dynamic Equipment
Standard Specification for Anchor Bolts, Steel, 36, 55, and 105 ksi Yield
ASTM F1554
Strength
CODE DESCRIPTION
ASTM A36M Specification for Structural steel
Specification for high strength, low alloy columbium vanadium steel of
ASTM A572M
structural quality
PIP STC01015 Process Industry Practices Structural Design Criteria
UBC97 Uniform Building Code
IBC2015 International Building Code (IBC)
3.2.2. Project Reference Documents
DOC. No.: DESCRIPTION

SOK7300452 Civil Works and Structures Design Criteria
SOS5014175 Painting Specification
YOK00003033 Specification for Concrete Work
SOS7300405 Concrete Work Execution Specification
SOK0856578 General Notes for Civil Works
SOK2313061 Geotechnical Survey Report
4.0 DESIGN DATA

4.1. Concrete
Min Cylindrical compressive
Type of Concrete
strength (N/mm2)
Lean Concrete 18
Below Ground Concrete 30
Above Ground Concrete 25
Precast concrete structures & piles 35
Water Retaining basins/Pits 25
Concrete Paving, Grade Slabs 25
4.2. Reinforcement
Reinforcement Class ASTM A615 (Grade 60)

Yield Strength fy = 420 Mpa
Elastic Modulus Es = 200000 Mpa
Unit weight for Reinforcement Steel Bar γs = 78.5 kN/m³
4.3. Soil Report

The report and related recommendation are included in the document GEOTECHNICAL SURVEY REPORT
SOK2313061 REV-1 .
Dry density 15.5-16.5 kN/m3

Internal friction angle 30 degree
Allowable Gross Soil Pressure 115 kN/m2 For Strip foundation up to 2m depth
Allowable Net Soil Pressure 82 kN/m2 For Strip foundation up to 2.0m depth
0.3 (Between Concrete & 500mm Structural fill, Lower
Co-efficient of friction
value assumed conservatively)
Allowable Capacities of Precast
Compression : 750 kN
Pile (285mm x 315mm)
Tension : 250 kN
Shear : 33 kN
4.4. Factor Of Safety

Serviceability Condition Min FOS
FOS against Overturning 1.5
FOS against Sliding 1.5
FOS against Sliding considering Passive pressure 2.0
4.5. Concrete Cover

Cover Value (mm)
Above Ground Concrete Cover
Internal Faces of Suspended Slab 30
Exposed Faces of Suspended slab/Beams/Column & Wall 50
Internal Face of Column & Wall 50
Below Ground Concrete Cover
Faces in contact with Soil including Lean Concrete 75
All other Faces (E.g. Internal Facesc of Cable Trench etc.) 50
4.6. Grout
Type Material Thickness
Non-Shrink BASF Masterflow 928 ( Ex. EMACO S55 ) or equivalent grout

25-50 mm
Cementitious grout BASF Masterflow 980 ( Ex. EMACO S33 ) or equivalent grout
As per Vendor recommendation As per Vendor
Epoxy grout
recommendation
4.7. Steel
Structural Material BS EN 10025 Grade S275

Yield Strength fy = 265 Mpa
Elastic Modulus Es = 200000 Mpa
Unit weight for Structural Steel γs = 78.5 kN/m³
Connection Bolts ASTM A325 or equivalent
4.8. Anchor Bolts
Anchor Bolt grade ASTM F1554 GR.36

Allowable tensile stress 400 N/mm2

Allowable yield strength 248 N/mm2
4.9. Piping Input (IDIT)

The loads on the pipe Rack are considered as per piping input received vide IDIT (Inter-Disciplinary
Information Transfer) form – 0506087-PIP-CIV-0006_Rev 0 attached in Appendix-B.
4.10. Module Input

The loads on the pipe Rack are considered as per module input document number SOK2313127_Rev1C
attached in Appendix-B.
5.0 DRAWINGS
Sr. No. Drawing Title Drawing Number
1 GENERAL ARRANGEMENT & FOUNDATION
0506087-AB04-D02-CV-GA-0157
DETAIL FOR PIPE RACK-D05-PR01
2 STRUCTURAL GENERAL ARRANGEMENT
0506087-AB04-D02-CS-GA-0033
DRAWING FOR PIPE RACK-D05-PR01
6.0 DESCRIPTION
This document covers Mainly Foundation, Pedestal and structural design of Pipe Rack D05-PR01.
Mat 3D software is used for Design of foundation & its corresponding Pedestal, in accordance with ACI
318M. Kindly refer Appendix-D for Detailed foundation calculation.
Foundation & Pedestal Design calculations are carried out as follows;

1. Pile Capacity Check
2. One Way Shear & Punching Shear Check
3. Design of Reinforcement
7.0 LOAD CASES & LOAD COMBINATIONS
Following Primary load cases are used for Design of Pipe Rack foundation as per Basis of design.
7.1 Primary load cases and combinations
For loads cases and combinations refer appendix A
BASIC LOAD SYMB Description Reference
OL / Remarks
Dead load (Self
Ds Weight of the foundation/pedestal and weight of the soil
Weight)
Erection Weight Df Fabricated weight of equipment
Empty weight of the equipment, including all attachments,
Empty Weight De trays, internals, insulation, fireproofing, agitators, piping,
ladders, platforms, etc
Empty dead load of the equipment plus the maximum
Operating Weight Do
content (fluid) weight
Empty dead load of the equipment plus the maximum test
Test Weight Dt
medium (fluid) weight
Live load L Live load on platforms
Wind load on equipment Longitudinal (From Vendor
Wind load WL
drawing)
BASIC LOAD SYMB Description Reference

OL / Remarks
Wind load on equipment Transverse (From Vendor
Wind load WT
drawing)
Temperature TS-R Temperature Rise (Sustained Thermal Expansion)
Temperature TS.F Temperature Fall (Sustained Thermal Contraction)
Friction load Tt.L Friction loads longitudinal (Temporary Thermal: Friction)
Friction load Tt.T Friction load Transverse (Temporary Thermal: Friction)
Seismic load Eo.L Seismic OPER-Longitudinal
Seismic load Eo.T Seismic OPER-Transverse
Seismic load Ee.L Seismic Empty-Longitudinal
Seismic load Ee.T Seismic Empty- Transverse
Bundle pull load Bp Bundle pull load of equipment (from Vendor drawing)
8.0 DESIGN RESULT

8.1 Foundation Design
For Detailed stability analysis and Strength design of foundation, Refer Appendix-D.
8.2 Foundation Summary
D05-PR01
The Critical valuses of Pile capacity for all foundation, under permanent & transient loading are tabulated
below,
The pile foundation summary is tabulated below,
Item Allowable
Pile Compression Capacity (kN) 750
Pile Tension Capacity (kN) 250
Pile Shear Capacity (kN) 33
Pile Punching Shear (N/mm2) 1.3556
8.3 Pile Reactions

FDN Actual Actual Actual Shear Result
MARK Compression (kN) Tension (kN) (kN)
F1 323 0 6.3 OK
F2 274 0 5.3 OK
F3 361 4 13.9 OK
F4 305 0 12.4 OK
F5 468 0 23.4 OK
F6 315 0 27.7 OK
F7 135 0 1 OK
8.4 Foundation reinforcement summary,
Area Required Area Provided

Reinforcement Details
(mm2 / m) (mm2 / m)
Foundatio Base slab
n Mark size Direction Direction Direction
X Z X Z X Z
7.767 x 119 185 1329 1320 T-16 @ 150 (T) T-16 @ 150 (T)
3.327 x
Fdn F1
0.7(Rectan
gular) 1260 1260 1329 1320 T-16 @ 150 (B) T-16 @ 150 (B)
4.6 x 3.8 x
33 551 1314 1311 T-16 @ 150 (T) T-16 @ 150 (T)
0.7(Rectan
Fdn F2
gular)
1260 1260 1314 1311 T-16 @ 150 (B) T-16 @ 150 (B)
1.5 x 3.3 x
81 647 1291 1340.4 T-16 @ 150 (T) T-16 @ 150 (T)
0.7(Rectan
Fdn F3
gular)
1260 1260 1291 1340.4 T-16 @ 150 (B) T-16 @ 150 (B)
6.0 x 2.8 x
824 0 2020 2042 T-20 @ 150 (T) T-20 @ 150 (T)
0.7(Rectan
Fdn F4
gular)
1260 1260 2020 2042 T-20 @ 150 (B) T-20 @ 150 (B)
8.0 x 6.4 x
1077 1446 2020 2042 T-20 @ 150 (T) T-20 @ 150 (T)
0.7(Rectan
Fdn F5
gular)
1260 1260 2020 2042 T-20 @ 150 (B) T-20 @ 150 (B)
6.4 x 5.0 x
1498 559 2020 2042 T-20 @ 150 (T) T-20 @ 150 (T)
0.7(Rectan
Fdn F6
gular)
1260 1260 2020 2042 T-20 @ 150 (B) T-20 @ 150 (B)
1.5X3.327X
7 14 1273 1340 T-16 @ 150 (T) T-16 @ 150 (T)
0.7(Rectan
Fdn F7
gular)
1260 1260 1273 1340 T-16 @ 150 (B) T-16 @ 150 (B)
Shear Check for Foundation,
One Way Shear Two Way Shear

Foundation % of Reinf. Capacity
Dir. Actual Capacity Actual
Mark Provided Result (N/mm2 Result
(N/mm2) (N/mm2) (kN)
)
X 0.38 0.28 0.6983 OK

Fdn F1 0.26 1.36 OK
Z 0.38 0.07 0.6983 OK
X 0.38 0.12 0.6983 OK

Fdn F2 0.15 1.36 OK
Z 0.38 0.14 0.6983 OK
X 0.38 0.01 0.6983 OK

Fdn F3 0.28 1.36 OK
Z 0.38 0.131 0.6983 OK
X 0.56 0.05 0.6983 OK

Fdn F4 0.48 1.36 OK
Z 0.56 0.14 0.6983 OK
Fdn F5 X 0.56 0.145 0.6983 OK 1.0517 1.36 OK

Z 0.56 0.13 0.6983 OK
X 0.56 0.16 0.6983 OK

Fdn F6 0.89 1.36 OK
Z 0.56 0.08 0.6983 OK
X 0.38 0.01 0.6983 OK

Fdn F7 0.095 1.36 OK
Z 0.38 0.02 0.6983 OK
Pedestal Details,
Pedestal Pedestal (Ties)

Pedestal Pedestal Main
Capacity Shear Additional information
Size reinforcement
Raito reinforcement
Additional confinement
12 Nos -T20 4.26
P1&P5 0.6 x 0.6 T-10 @ 150 reinforcement is provided
(2413 mm2)
at top @ 75 mm spacing
20 Nos -T20 5.5
P2&P4 0.8 x 0.8 T-10 @ 150 reinforcement is provided
(6283 mm2)
22 Nos -T20 1.5
P3 0.9 x 1.2 T-10 @ 150 reinforcement is provided
(6930 mm2)
24 Nos -T20 140
P6 1.1 x 0.8 T-10 @ 150 reinforcement is provided
(7540 mm2)
For Detailed design of Foundation, Refer Appendix-D

8.5 Structural Steel Geometry & Design
Column Design:
Member Design Member Mark Section Size Utility Allowable Remark

Type Check Ratio Ratio
Column Strength 5 39 40 53 54 294 304 UB 610X229X125 0.794 1
330 340 366 367 424 425
532 533 542 548 To 554
557 559 560 562 566 To
568 570 574 To 576 578
582 To 584 627 630 632
636 To 638 640 642 645
683 To 695 758 759 768
843 950
Column Strength 786 788 792 To 794 796 UB 457X152X74 0.522 1
797 801 807 816 817 819
844 845 847 848 853 854
856 857 862 863 865 866
868 869 871 872 881 919
953 960 974 976 978 979
996 997 1000 1013 1014
1017 1021 1022 1025
1037 1038 1040 1049
1050 1065 To 1067 1083
1092 To 1095
Beam & Bracing Design:
Member Design Member Mark Section Size Utility Allowable Remark

Type Check Ratio Ratio
Longitudinal Strength 218 229 230 232 439 UB 305X165X40 0.570 1
Beams 534 535 558 564 569
572 577 580 585 588
589 593 597 599 To 601
603 605 607 609 611
619 622 623 625 628
633 635 639 647 To 654
659 660 675 676 697
700 703 727 738 747
770 771 783 790 798
802 810 811 813 821
823 827 884 To 886 889
To 893 904 927 928 935
936 951 985 To 989
1008 1009 1048
Transverse Strength 531 563 571 573 581 UB 457X152X74 0.591 1
Beams 594 To 596 598 624 696
698 699 701 702 717
722 725 740 742 784
787 789 791 833 838
901 903 956 958 1019
1020 1024 1026 1045
To 1047 1062
Vertical Strength 699 To 704 768 769 824 UC 203X203X46 0.443 1
Bracing 828 847 849
Plan Bracing Strength 699 To 704 768 769 824 UBT 0.905 1
828 847 849 133X102X13
For Detailed design of Structural Beam, Bracing & Column, Refer Appendix-E
Displacement Check:
In X Direction :
Displacement at Note 12 : 25.36mm LC 224

Height of Column : 7.85m
Allowable Displacement : L/200 i.e 39mm > 25.36 mm Hence Ok
In Z Direction :
Displacement at Note 3 : 6.622mm LC 226

Height of Column : 7.850m
Allowable Displacement : L/200 i.e 39mm > 6.62 mm Hence Ok
Base Plate Design:
For detail design of Base Plate, Refer Appendix-F
8.6 List of Attachments

APPENDIX A : LOAD COMBINATIONS
APPENDIX B : PIPING IDIT
APPENDIX C : STAAD PRO V8I (INPUT)
APPENDIX D : DETAIL DESIGN OF FOUNDATIONS (MAT 3D OUTPUT)
APPENDIX E : DETAIL DESIGN OF BEAM, BRACING & COLUMN (STAAD OUTPUT)
APPENDIX F : DESIGN OF BASE PLATE

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FOUNDATION & STRUCTURAL DESIGN CALCULATION REPORT FOR

NASRIYA & GHARRAF FLARE GAS RECOVERY

TITLE DOCUMENT CODE REVISION

Contract Number: 0506087

Document Description: FOUNDATION & STRUCTURAL DESIGN CALCULATION REPORT

Review Code and Status

0 I Issued For Design 11-Aug-23 RK SP MH

1. Changes shall be marked in Blue <#>.

1.2. Project Background

2.0 ACRONYMS AND ABBREVIATIONS

3.0 REFERENCE DOCUMENTS

3.2. International Codes & Standards

3.2.1. American Standard

3.2.2. Project Reference Documents

DOC. No.: DESCRIPTION

4.0 DESIGN DATA

Reinforcement Class ASTM A615 (Grade 60)

4.3. Soil Report

Dry density 15.5-16.5 kN/m3

4.4. Factor Of Safety

4.5. Concrete Cover

Non-Shrink BASF Masterflow 928 ( Ex. EMACO S55 ) or equivalent grout

Structural Material BS EN 10025 Grade S275

4.8. Anchor Bolts

Anchor Bolt grade ASTM F1554 GR.36

Allowable tensile stress 400 N/mm2

4.9. Piping Input (IDIT)

4.10. Module Input

Foundation & Pedestal Design calculations are carried out as follows;

BASIC LOAD SYMB Description Reference

8.0 DESIGN RESULT

The pile foundation summary is tabulated below,

8.3 Pile Reactions

8.4 Foundation reinforcement summary,

Area Required Area Provided

Shear Check for Foundation,

One Way Shear Two Way Shear

X 0.38 0.28 0.6983 OK

Z 0.38 0.07 0.6983 OK

X 0.38 0.12 0.6983 OK

X 0.38 0.01 0.6983 OK

X 0.56 0.05 0.6983 OK

Fdn F5 X 0.56 0.145 0.6983 OK 1.0517 1.36 OK

Z 0.56 0.13 0.6983 OK

X 0.56 0.16 0.6983 OK

X 0.38 0.01 0.6983 OK

Pedestal Pedestal (Ties)

For Detailed design of Foundation, Refer Appendix-D

8.5 Structural Steel Geometry & Design

Member Design Member Mark Section Size Utility Allowable Remark

Beam & Bracing Design:

Member Design Member Mark Section Size Utility Allowable Remark

Displacement at Note 12 : 25.36mm LC 224

Displacement at Note 3 : 6.622mm LC 226

Base Plate Design:

For detail design of Base Plate, Refer Appendix-F

8.6 List of Attachments

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