TEL-SRPD-EGD-CIV-001 Design Basis For Civil and Structural Rev B PDF
TEL-SRPD-EGD-CIV-001 Design Basis For Civil and Structural Rev B PDF
TEL-SRPD-EGD-CIV-001 Design Basis For Civil and Structural Rev B PDF
TABLE OF CONTENTS
1.0 INTRODUCTION
PT. Tanjung Enim Lestari (TeL), is long last known established since 1990 as a Foreign
Investment Company (PMA)-Marubeni Corporation, Japan and became the National Vital
Objects Industrial sector (OVNI) declared by the Minister of Industry in 2014. TeL is also
well known as a world class manufacturer of high product quality and environmental friendly
market pulp mill. Currently TeL was expanding its pulp production base from Acacia
Mangium Wood. Regarding to its expansion of production plant, TeL required more supply
of gas fuel for Kiln Process and concerned to build its own new gas facility. The plant is
located in Muara Enim, South Sumatra and has marketed pulp both domestic and
international market with total design production capacity of 490,000 Adt/year. The new gas
facility will be provided to support and maintain the supply of dry gas as a fuel Kiln burner
at the existing Mill Plant of Tanjung Enim Lestari Pulp Pre-Production. The gas will flow by
rate 6 MMSCFD where 3 MMSCFD will take as a future flowrate. The gas also will be taken
from the existing gas pipeline facility. As planned, the tapping will be derived from Pertagas
Existing pipeline. Gas will be transported by +10 km pipeline before entering the next station
(Metering/Regulating Station) which is located close to the Existing Mill Plant at TEL.
Block Diagram for the new pipeline and facility can be seen as below.
The overall facility includes One Metering Station, Pipeline and One Metering/Regulating
Station. Also, the facility scope of work includes of civil works, supply of main and supporting
material.
Company/user name: Consultant name: Contractor name:
2.0 OBJECTIVE
The objective of this document is to provide basis data, assumption, and operating
parameter to be used for engineering design of minimum requirement for civil and structural
B engineering applicable for Pipeline Development of Tanjung Enim Lestari.
ASTM A53 Standard Specification for Pipe, Steel, Black and Dipped Zinc Coated,
Welded and Seamless
ASTM A185 Standard Specification for Steel Welded Wire Reinforcement Plain for
Concrete
ASTM A307 Standard Specification for Carbon Steel Bolts and Studs 60.000 psi
Tensile Strength
ASTM A325 Standard Specification for Structural Bolts, Steel, Heat Treated,
120/105 ksi Minimum Tensile Strength
ASTM A563-07a Standard Specification for Carbon and Alloy Steel Nuts
ASTM A615 Standard Specification for Deformed and Plain Carbon Steel Bars for
Concrete Reinforcement
ASTM C33 Standard Specification for Concrete aggregate
ASTM C39 Standard Test Method for Compressive Strength of Cylindrical
Concrete Specimens
ASTM C150 Standard Specification for Portland Cement
ASTM 494 Standard Specification for Chemical Admixture for Concrete
ASTM C1218 Standard Test Method for Water-Soluble Chloride in Mortar and
Concrete
Japan Industrial Standards
JIS B 1185 High Strength Bolt
JIS G 3101 Structural Steel
B
JIS G 3112.87 Reinforce Steel Bar
American Society of Civil Engineers
ASCE 7-10 Minimum Design Load for Building and Other Structure
International Building Code
IBC 2009 International Building Code
3.2. Conflicting Requirements
In the event of any conflict between this specification and any requirements of statutory and
safety regulation, codes, standards, and other documents, the most stringent shall prevail.
B The order of priority of document shall be as follows:
1. Indonesian Codes and Regulations.
2. Technical Requisition and its attachments.
3. This specification
4. Other project specifications.
5. International Codes and Standards.
All apparent conflicts shall be reported to the COMPANY in writing for resolution.
Company/user name: Consultant name: Contractor name:
7.0 MATERIAL
7.1. General
Material to meet the requirements of the codes and standard as listed in this chapter or
equivalent shall be used. As for the materials other then specified below, locally available
materials may be used upon condition that they are suitable for their specific use to quality
and quantity.
7.2. Concrete
Compressive strengths of concrete at 28 days monitored by cylinder specimen test, shall be as
follow unless otherwise specified :
Table 7.1 Classification of Concrete Grade
Min Compressive Strength
Application
28 Days of Cylinder Specimen
Major foundation such as : Equipment Foundation,
F’c : 34,48 Mpa ( 350 kg/cm2) building structure and foundation, culvert, and
anchor block.
B Structural concrete, pavement, pipe support
foundation, pipe sleeper, manhole, catch basin,
pit, cable trench, ditch, lighting, pole foundation, ell
F’c : 27.60 Mpa ( 300 kg/cm2) junction box/ panels box and stanchion support, ell
duct bank and encasement, fence and gate
foundation, foot step, walkway, concrete
pavement.
F’c : 13,39 Mpa ( 136 kg/cm2) Lean concrete
b. Plain bar type shall be used for stirrups and non structural bars, conform to ASTM A615
grade 40, or equal to SNI-07-2052-2002 BJTP 24 with min yield strength 240 Mpa.
Table 7.3 Dimension of plain bars (SNI : 07-2052, BJTP 24)
Bar Diameter Weight Cross Sectional
Symbol 2 Remarks
( mm ) ( kg/m ) ( cm2 )
Ø6 6 0.220 ± 7 % 0.283 Length : 12 m
c. Steel wire
Table 7.4 Dimension of wire fabric reinforcement ( ASTM A185 )
Main Wire Cross Wire Unit
No Diameter Spacing Area Diameter Spacing Area Weight
(mm) (mm) (cm2/m) (mm) (mm) (cm2/m) (kg/m)
7.4. Cement
Cement shall conform to SNI 15-2049- 2004, ASTM C150, or equivalent:
a. Type I (ordinary Portland cement) for upperstructure (above ground) or substructure
B
Company/user name: Consultant name: Contractor name:
7.10. Welds
Base material shall conform to ASTM A36. Pipe material that used to structural shall conform to
ASTM A53 Grade B. Material of Welding electrode shall conform to AWS A5.1 Table 2. E70xx
or equivalent, which tensile strength is 70 ksi or equal to 4920 kg/cm2. Allowable stress of
welding material refers to AWS D1.1 table 2.3, as follow s :
a. Complete-penetration groove welds
Allowable stress for shear on effective area is 1476 kg/cm2
Other than above is same as base metal
b. Fillet welds
Allowable stress for shear on effective area is 1476 kg/cm2
Other than above is same as base metal
7.11. Anchor Bolt
Material of Anchor bolts shall be in accordance with ASTM F1554 Grade 36, with a minimum
tensile strength is 4000 kg/cm2.
Description:
L = length t = plate thickness
D1= diameter B = embedment
S1 = top thread A = bottom of bolt
S2 = bottom thread
Note:
1) No corrosion allowance is considered in the allowable tensile force based on AISC.
2) Projection of Anchor Bolt = A + thickness of base plate.
Company/user name: Consultant name: Contractor name:
7.14. Grouting
Grout shall be used for supporting structures and equipment on foundations. Grout to be used
for equipment shall be used non shrinking grout.
B Non Shrinking Grout shall be cement based in pre-packaged containers. Metallic fillers or
calcium chloride additives shall not be used. Minimum compressive strength of grout at 7 days
shall be 60 MPa. Expansion characteristic at 3 days is less than 0.2% maximum initial set 5
hours and final set 6 hours and thickness is 25 mm.
7.15. Water Stop
Water stop shall be made from plastic base consisting of resin polyvinyl chloride ( PVC ) with
additional resin, plasticizers and stabilizer as necessary to produce a durable material with a
high fatigue point, resistant to acid, chloride and sulphate compounds.
7.16. Water Proofing
Water proofing material may use PVC water proofing membrane of geotextile materials with felt
bearing surface or any equivalent such system. The material used shall be impermeable to water
and impervious to degradation of environmental condition for design life or concrete Structure.
7.17. Formwork
Formwork shall be constructed from suitable rigid materials that leave a surface finish of a
geometry and appearance that complies with the requirements of the design. Permanent form
ties shall be non-corrodible.
Formwork shutter release agents applied to formwork shall not degrade the appearance or
integrity of the concrete finish.
Live Load other than the above mentioned shall refer to ASCE 7-10.
b. Live load for handrail shall be 30 kg/m’ (or point load of 90 kg at any point) along the top
applied in any direction.
c. Reduction of Live Load (L*)
Reduction of Live Load may be made in accordance with ANSI/ASCE 7- 10 Section 4.7.
8.4. Process Load
The design of underground structures, foundations and such like elements shall be designed
taking into full account the process loads involved, including fluid loads during operation and
hydro testing, vibration loads, surge vibration loads (lateral inertia caused by the surging action)
B
and other loads generated by the Plant and fluids handled.
There are two condition where the load design is taken for this analysis, as describe below:
1. The operating load, is the load imposed during the normal operating condition. It is the
selfweight of equipment/ piping plus the weight of fluids and solids within the equipment.
2. The testing loads, is the load imposed during hydrostatic testing. It is the the selfweight of
equipment/ piping plus the weight of water inside. The testing loads need be considered
for future maintenance even if equipment is hydrostatically tested only at vendor shop.
But consideration need not be taken that all of the equipment on the same structure is
tested at the same test.
8.5. Dynamic Load (J)
Foundations supporting large rotating equipment such as compressors and blowers, etc., shall
be designed to safely withstand static loads plus dynamic loads. Large rotating equipment is
B defined as reciprocating equipment or machinery, centrifugal compressors, turbines, fans,
pumps, etc. and their drivers over 500 HP. Dynamic loads shall be in accordance with the data
issued from manufacturer.
8.6. Vehicle Load (Vh)
Vehicle load standards for the design of road pavement design conform to AASHTO 1983
Chapter 6.3 , as follows:
a. MST (Toughest axis load) for single-axis = 8 tons
b. MST ( Toughest axis load) for the dual axis = 15 tons
c. MST (Toughest axis load) for the triple-axis = 20 tons
Note that these provisions apply to the operation of vehicles (on highway vehicle).
8.7. Ground Load
The design shall accommodate the loads imposed on underground support structures and
foundations by earth, rock and water pressure and the degree to which these vary with location.
Structures and foundations subject to the jurisdiction of local authorities shall also be evaluated
using geotechnical parameters specified by local building codes and the safest result adopted.
Company/user name: Consultant name: Contractor name:
The minimum and maximum characteristic values for existing soil materials and for backfill shall
be identified and the most unfavourable values for the structural element under consideration
shall be used. Erosion shall be taken into account. On land, appropriate surcharge loads from
overburden shall be taken into account.
8.8. Equipment Load
Equipment load means the weight of equipment and its appurtenances and contents, and shall
be classified into the following three cases depending on their conditions. Loads by machinery
shall be included in this equipment loads.
8.9. Piping Load
Piping load means the weight of pipe considering thickness deviation, fittings, valves, coating,
insulation and the fluid contents of piping and shall be classified into the following three cases
depending on their conditions.
8.10. Wind Load
Wind load shall be calculated in accordance with the formula as given in ASCE 7-10 and UBC -
97. For wind load design calculation shall refers to ASCE 7-10 as basic calculation, Other
condition that ASCE 7-10 does not cover can be conformed to UBC -97.
a. Determine risk category of structure
Using table 1.5
b. Determine the basic wind speed for the applicable risk category
Using Figure 26.5
For this analysis, wind speed is taken 25 m/s or 90 km/h..
.
c. Determine wind load parameters :
- Wind directional ( Kd )
Using table 26.6
- Exposure category ( C )
Using Section 26.7
- Topographic factor ( Kzt )
Using Figure 26.8
- Gust effect factor ( G )
Using Section 26.9
- Enclosure classification
Using Section 26.10
- Internal pressure coefficient ( GCpi )
Using Section 26.11 and Table 26.11
d. Determine Velocity Pressure ( qz )
qz = 0.613 Kz Kzt Kd (V)2 (N/m2) … (Eq. 27.3-1) ASCE 7-10
Where:
Kz : Velocity Pressure Exposure Coefficient
Company/user name: Consultant name: Contractor name:
Table 8.3 Value of Cpa taken from “Pressure Vessel Design Manual”
by Moss. Dennis R. with value of Cpa
Diameter of Vessels ( inch) Cpa
< 34 1.50
36 to 52 1.37
54 to 76 1.28
78 to 100 1.20
> 102 1.18
Where,
Cs : Seismic response coefficient
W : Effective seismic weight
Seismic response coefficient, Cs calculated by equations below :
𝑆𝐷𝑆
𝐶𝑠 =
𝑅
( )
𝐼𝑒
𝑆𝐷1
𝐶𝑠1 =
𝑅
𝑇( )
𝐼𝑒
CS2 = 0,044 SDS Ie ≥ 0,01
Cs shall be greater than Cs2 and not less than Cs 1
Spectral acceleration parameter, SDS and SD 1 calculated by equation bellow :
2
𝑆𝐷𝑆 = 3𝑆𝑀𝑆
2
𝑆𝐷1 = 3𝑆𝑀𝑆1
SMS = Fa x Ss
SM1 = Fv x S1
Company/user name: Consultant name: Contractor name:
B
Company/user name: Consultant name: Contractor name:
Continued
0,8.Z .Nv.I
V .W
R
Where :
Cv , Ca : Seismic coefficient base on zone and type of soil.
W : Dead load of structure.
R : Seismic resistance factor for structure
I : Virtue factor = 1,25.
T : Elastic fundamental period of vibration
Where :
T Ct hn
3
4
Where :
Company/user name: Consultant name: Contractor name:
1, C1, Ka1 h1 Pa1
Pa2
Where :
Pa : Active soil pressure
: Unit weight of soil
’ : Effective unit weight of soil ( sat - w )
w : Unit weight of water
Pw : Water pressure
Ka : Active soil pressure coefficient
H : Total thickness of soil
h1 : Thickness of soil above ground water level
h2 : Thickness of soil below ground water level
c : Cohesion factor of soil
Friction angle of soil
q : Uniform load on soil surface
8.16. Load Combination
All structures shall be designed for the following loading combination whichever produces
greater stresses. It is not necessary to consider combination of load that is obvious to produce
less stress than other combinations of load.
Company/user name: Consultant name: Contractor name:
Table 8.12 Combination loads for the design of soil bearing pressure
(Standard taken from AISC 9th Edition ASD Series)
Allowable
Stress
Combination of Load
Increasing
Factor
D + E +.P 1.00
D + E + P + 0.75 W 1.00
D+E+P+L+I+T 1.00
D + E + P + 0.75 L* + T + 0.75 W (or 0.7 V) 1.00
D+E+P+L+I 1.00
D + E + P + 0.75 L + 0.75 W· (or 0.7 V) 1.00
D+E+P+I 1.00
B
D+E+P+J 1.00
D+E+P+W 1.33
D+E+P+L+I+T 1.00
D + E + P + L* + T + W (or V) 1.33
D + E + P + 0.75 W 1.33
B D+E+P+L+I 1.00
D+E+P+L+J 1.00
D + E + P + L + W or V 1.33
Company/user name: Consultant name: Contractor name:
Where:
D : Dead load
L : Live load
E : Equipment Load
- E(E) : Equipment load (Empty)
- E(O) : Equipment load (Operating)
- E(T) : Equipment load (Test Load)
P : Piping Load
B - P(E) : Piping load (Empty)
- P(O) : Piping load (Operating)
- P(T) : Piping load (Test Load)
I : Impact load
J : Dynamic Load
SP : Lateral soil with/without ground water pressure
W : Wind load
V : Earthquake load
T : Thermal load
WT : Uplift due to ground water pressure (buoyancy)
13.0 DRAINAGE
13.1. Design Basis
a. Rainfall intensity
Plant drainage systems shall be designed using rainfall data for the last 10 years.
b. Run-off coefficient
Run off coefficient shall be as follows :
Asphalt C : 0.7 – 0.95
Concrete area C : 0.8 – 0.95
Concrete roof of buildings C : 0.95
Gravel paved areas C : 0.70
Unpaved areas C : 0.30
c. Discharge (Q) formula
Calculation of discharge will be used by Rational Formula :
Q = ( CIA/ 360 )m3/sec
Where :
C : Run-off coefficient
I : Rainfall intensity ( mm/hr )
Company/user name: Consultant name: Contractor name:
A : Catchment area ( ha )
d. Velocity ( V ) formula
Calculation of average velocity will be used by Manning Formula. The maximum and
minimum of average velocity will be 2.5 m/sec and 0.6 m/sec respectively. The liquid flow
velocity on the pipe and open channel shall be calculated as follow :