Attachment 1 - 1 TAKREER LPG - Cross Section - Flat Foundation

Tank design description
Tank Design Description

Ruwais Refinery Expansion Project Takreer Propylene Storage Tank
(47.000m)
Alternative: Flat Foundation
revision
date
prepared
checked
approved
changes
09.09.2009
signature
Schiebel
Salvatore
Dr. Roetzer
First internal revision
el.
el.
el.
Takreer Propylene Storage Tank design description_00_flat.doc
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0 Contents
0 1 2 2.1 2.2 2.3 CONTENTS ................................................................................................................. 2 APPLICABLE DOCUMENTS....................................................................................... 4 DESCRIPTION OF THE TANK SYSTEM..................................................................... 5
TANK SYSTEM ........................................................................................................ 5 TANK DATA.............................................................................................................. 6 DESCRIPTION OF THE CONCRETE TANK STRUCTURE ..................................... 8 2.3.1 GENERAL........................................................................................................ 8 2.3.2 TANK BASE SLAB........................................................................................... 8 2.3.3 WALL ............................................................................................................... 8 2.3.4 RINGBEAM...................................................................................................... 8 2.3.5 ROOF .............................................................................................................. 9 2.3.6 MISCELLANEOUS........................................................................................... 9 2.3.7 TANK TEMPORARY ACCESS OPENINGS....................................................10 2.4 BOTTOM HEATING.................................................................................................10 2.5 TANK SETTLEMENT MONITORING.......................................................................10 2.5.1 REFERENCE POINTS....................................................................................10 2.5.2 INCLINOMETER SYSTEM..............................................................................10 2.6 PRE-STRESSING SYSTEM ....................................................................................11 2.6.1 TENDON LAYOUT..........................................................................................11 2.6.2 PRE-STRESSING OPERATION .....................................................................12 3 3.1 BASIS FOR ANALYSIS..............................................................................................14
DESIGN CRITERIA .................................................................................................14 3.1.1 ULTIMATE LIMIT STATE (ULS)......................................................................15 3.1.2 SERVICEABILITY LIMIT STATE (SLS)...........................................................15 3.2 DESIGN OF PRE-STRESSING ...............................................................................17 3.3 DESIGN CODES .....................................................................................................18 3.3.1 MATERIAL AND LOAD PARTIAL SAFETY FACTORS...................................18 3.3.2 SERVICEABILITY LIMIT STATE (SLS)...........................................................18 3.3.3 ULTIMATE LIMIT STATE (ULS)......................................................................18 3.4 MATERIALS ............................................................................................................19 3.4.1 CONCRETE....................................................................................................19 3.4.2 REINFORCEMENT .........................................................................................19 3.4.2.1 LOW TEMPERATURE (CRYOGENIC) REINFORCEMENT ....................19 3.4.2.2 NON CRYOGENIC REINFORCEMENT ..................................................19 3.4.2.3 PRE-STRESSING REINFORCEMENT ...................................................20 3.4.2.4 USE FOR CRYOGENIC REBAR.............................................................20
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3.5 DESIGN PROCEDURE ...........................................................................................21 3.5.1 CALCULATIONS.............................................................................................21 3.5.2 ANALYSIS METHODS....................................................................................24 3.5.2.1 SOFTWARE ............................................................................................24 3.5.2.2 LINEAR ELASTIC ANALYSIS .................................................................24 3.5.2.3 NON-LINEAR ANALYSES.......................................................................25 3.5.2.4 SEISMIC ANALYSIS ...............................................................................26 3.5.2.5 THERMAL MODELS ...............................................................................29 3.5.2.6 CRACK WIDTH CALCULATION .............................................................30 3.5.3 NORMAL SITUATIONS: .................................................................................31 3.5.4 EMERGENCY SITUATIONS:..........................................................................31 3.5.5 LOAD COMBINATIONS..................................................................................33 FOUNDATION ............................................................................................................36
4 4.1 4.2 4.3
APPLICABLE DOCUMENTS ...................................................................................36 GENERAL INFORMATION......................................................................................36 FLAT FOUNDATION CONCEPT .............................................................................37 4.3.1 SETTLEMENTS ..............................................................................................38 4.4 SETTLEMENT REQUIREMENTS............................................................................40
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1 Applicable Documents
Following documents are applicable or will be referred to: /1.1/ Geotechnical Investigation for Ruwais Refinery Expansion Project, NO.5578 Agreement NO.07-5578-F-1 Ruwais, Abu Dhabi, UAE S08000288 Factual Report Revision 2 /1.2/ Geotechnical Investigation for Ruwais Refinery Expansion Project, NO.5578 Agreement NO.07-5578-F-1 Ruwais, Abu Dhabi, UAE S08000288 Recommendation Report Revision 3 /1.3/ Ruwais Refinery Expansion Project Project Specification Addendum Design General Specification - Rotating Equipment-Minimum General Requirements Bechtel Document Number 25418-1000-3PS-M000-M0004 Rev. 1 /1.4/ Ruwais Refinery Expansion Project Project Specification Earthworks and Reclamation Bechtel Document Number 5418-1000-3PS-CG00-C0002 Rev. 3
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2 Description of the Tank System

2.1 Tank system
The tank system will be designed and constructed as a full containment type LPG storage tank with a concrete roof and a flat foundation on tank pad of selected fill material. The typical cross section of the concrete outer tank is shown in figure 2.1.
The tank consists of the following main components: a flat foundation a monolithic concrete outer tank, comprising a reinforced concrete base slab and a pre-stressed circular wall and a spherical concrete roof. The wall has a constant thickness. a ring beam on top of the wall a steel frame roof platform a self supporting, open top steel inner tank a suspended ceiling fastened to the roof insulation system mainly comprising of foamglas blocks on top of the base slab, perlite within the annular space between inner and outer tank together with a resilient blanket at the outer surface of the inner steel tank and fiberglass blankets on top of the suspended ceiling steel liner (vapor barrier) at the inner surface of the concrete tank a corner and bottom protection system (TPS) connected to the outer tank wall and extended between the foamglas layers of the tank bottom a settlement monitoring system a bottom heating system
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2.2 Tank Data

gross capacity net capacity inner tank diameter inner tank wall height minimum width of annular space inner diameter of outer tank wall height of outer tank height of ring beam outer diameter of base slab thickness of base slab DB hB Da Ha Vbr Vnet Di Hi 56,411 47,000 65,00 17,00 1,00 67,00 18,00 2,50 71,60 1,20/0,50 m m m m m m m m m m
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Fig. 2.1 Cross section of tank system
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2.3 Description of the Concrete Tank Structure
2.3.1 General
The outer tank consists of a concrete structure with concrete roof resting on a flat foundation. Base slab, wall and roof are connected monolithically. The connection wall-to-slab will be protected against low temperatures in extreme situations leakage of inner tank by a thermal protection system (TPS) min. 5,00 m above the secondary bottom. The water vapour ingress will be prevented by a carbon steel liner on the inner surfaces of the concrete tank. For the wall liner vertical anchor rails are provided in a distance of approx. 2 m, on which the liner plates are welded. The liner on top of the base slab is unanchored.
2.3.2 Tank Base Slab

The circular base slab made of reinforced concrete has a diameter of 71,60 m with a thickness of 1,2 m in the rim area and of 0,5 m in the centre area. Temporary drainpipes will be installed in the concrete base slab in order to drain e.g. rainwater during construction. These pipes will be closed with concrete after installation of the roof. In the rim area of the base slab horizontal pre-stressing tendons with 19 strands - will be placed in hoop direction in order to create a smooth transition between the pre-stressed wall and the reinforced base slab.
2.3.3 Wall
The outer cylindrical tank wall is made of pre-stressed concrete. The wall has a constant thickness of 0,80 m. The ring beam above the wall has a constant thickness of 1,20 m and a height of 2,50 m. The inner diameter of the cylindrical concrete tank is 67,00 m. The wall and ring beam are pre-stressed in vertical- and horizontal direction, see section 2.6.
2.3.4 Ringbeam
A roof ring beam of 2,50 m height and a thickness of 1.20 m completes the wall. The ring beam is made of pre-stressed concrete and of the same concrete quality as the wall. The function of the roof ring beam is to pick up the membrane forces of the domed roof structure. Therefore, the roof ring beam is horizontally pre-stressed. A walkway is located on top of the ring beam.
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2.3.5 Roof
The spherical roof is a concrete dome with an inner sphere radius of 67,00 m. Due to the given diameter of the cylindrical wall of 67,00 m the inner height of the sphere segment will be approx. 9,0m. All loads hanging above the inner steel tank - resulting e.g. from the suspended deck and its insulation - have to be supported by the roof structure. In addition, the pump wells will be suspended from the roof. The piping and pump platform consists of a steel frame structure with a steel grating floor on top. The platform is arranged on the outer part of the roof and supported by the roof shell and roof ring beam.
2.3.6 Miscellaneous
An inner pressure of maximum 105 mbarg will be applied during service of the tank (= design pressure). Between the concrete wall and the inner steel tank there is an annular space of 1,00 m. The reinforcement at the inner surface of the wall above the corner protection system, which is affected by cryogenic design temperatures of -48 C, shall be suitable for the applied temperature. The reinforcement at the outer surface of the wall, as well as for the base slab and ringbeam will be normal hot rolled high yield steel. The reinforced and pre-stressed concrete elements of the outer tank will be made of concrete with a minimum required 28 day characteristic strength acc. to section 3.4
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2.3.7 Tank Temporary Access Openings

Based on our experience, two access openings in the wall of the outer concrete tank during construction are foreseen: - a large opening for transport of material into the tank - a smaller opening as an access and escape route for personnel and for ventilation The location of the openings in the circumferential direction depends on the site installation and will be fixed at a later stage. It is intended to arrange the openings as far as possible opposite to each other. It is also possible to arrange two large openings. In vertical direction, both openings are in alignment with each other with a bottom level of about 0,70 m above the top of the concrete base slab and a top level at least 1,0 m below TCP elevation (height of opening: approx. 3,00 m).
2.4 Bottom Heating

A bottom heating system will be installed to prevent freezing of the subsoil.
2.5 Tank Settlement Monitoring

2.5.1 Reference Points
Along the perimeter of the base slab of the outer concrete tank, 18 survey/reference points will be installed for monitoring the settlements of the outer tank. The levels of these points will be measured using precise leveling instruments, e.g. theodolites.
2.5.2 Inclinometer system

A horizontal inclinometer system is applied in the base slab. A zero leveling will be carried out after completion of the base slab. Further measurements will be conducted during construction of the wall, after completion of the dome, during the hydro test and the pre-commissioning phase.
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2.6 Pre-stressing System

The DYWIDAG Pre-stressing System will be used in order to pre-stress the rim area of the base slab, the wall and the ring beam of the concrete tank in horizontal and vertical direction. The design of the pre-stressing will be based on bundled strand tendons consisting of seven-wire strands of 0,60'' (15,2 mm) diameter. The strands have a very low relaxation. The post-tensioning system shall be qualified by testing at cryogenic temperatures. Impermeable PP/PE sheathing for tendon installation will be used, providing a secondary corrosion protection whilst the primary corrosion protection is provided by the alkalinity of grout and concrete.
2.6.1 Tendon Layout

In the DYWIDAG pre-stressing system the strand tendons are post-tensioned and injected with cement grout to achieve bond with concrete structure. The sheating is installed in the formwork prior to concreting the structural member. After concreting, the strands are pulled or pushed one by one into the ducts. The horizontal tendons are equipped with stressable live-end anchors on both ends. The horizontal tendons extend over 180 of the tank perimeter so that two tendons are necessary to form a complete ring. They are anchored at buttresses. Neighbouring rings are rotated progressively by 90 against each other in order to get an uniform stresses in the wall, see Fig. 2.2 In the wall/ringbeam and in the base slab 4 buttresses are arranged. The vertical tendons are straight and run from top of the ring-beam to the base slab. They are equipped with live-end anchors at top of the ring-beam and with loops in the base slab. They will be stressed from top of the ring-beam see Fig. 2.3
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2.6.2 Pre-stressing operation

After the concrete is sufficiently hardened, the individual horizontal tendons are tensioned with hydraulic jacks from both sides. The pre-stressing instructions, which are part of the structural analysis, provide the basis of the pre-stressing operations. The instructions provide the specified forces and the sequence of pre-stressing. The jacking stations are numbered in accordance with the pre-stressing drawings.
Fig. 2.2 Layout of horizontal pre-stressing tendons (schematically)
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Fig. 2.3 Layout of vertical tendons with loop anchors (schematically)
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3 Basis for Analysis

The concrete containment shall be designed for all possible combinations of normal and emergency loads, which may occur during construction, testing, commissioning, operating, decommissioning and maintenance of the tank. Design load combinations include the most severe combinations of loads. Emergency load situations are considered separately, i.e. only one emergency load is considered to prevail at any one time.
3.1 Design Criteria

The LPG storage tank will be designed on Ultimate Limit State (ULS) and Serviceability Limit State (SLS) for construction, all normal operation situations and for the emergency situations defined in this section. For all other emergency situations the concrete structure will be designed on ULS. The design will be performed according to the partial safetyfactored design method following. For reinforcing steel bars exposed to LPG temperatures at the inner face of the wall, rebars suitable to cryogenic temperatures (Krybar 50) will be used. Therefore a limitation of steel stresses other than yield stress does not apply in this case. Such limitations refer only to normal carbon steel reinforcement in case of use at cryogenic temperatures.
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3.1.1 Ultimate Limit State (ULS)

Ultimate Limit State Stage - Construction phases - Hydro test and pneumatic test pressure - Operation - Earthquake OBE Performance Criteria Design Criteria - Ultimate steel strain: 1 % (prestressing and reinforcement steel) - Ultimate concrete strain: 0.35 % - consideration of the reduced stiffness due to crack formation - Ultimate steel strain: 1 % (prestressing and reinforcement steel) - Ultimate concrete strain: 0.35 % - consideration of the reduced stiffness due to crack formation - Ultimate steel strain: 1 % (prestressing and reinforcement steel) - Ultimate concrete strain: 0.35 % - consideration of the reduced stiffness due to crack formation - Ultimate steel strain: 1 % (prestressing and reinforcement steel) - Ultimate concrete strain: 0.35 % - consideration of the reduced stiffness due to crack formation - steel strain < yield strain (prestressing and reinforcement steel) - Ultimate concrete strain: 0.35 % - consideration of the reduced stiffness due to crack formation only local effect
Stability
- Earthquake SSE
Stability
- Liquid spill inner tank
Stability
- Liquid spill inner tank + OBE
Stability
- Pressure relief fire - Adjacent fire - Impact of projectiles on tank shell
Stability
No perforation
Fig. 3.1 Ultimate Limit State Scenarios (ULS)
3.1.2 Serviceability Limit State (SLS)

For durability reasons, during construction and normal conditions, the maximum crack width will be limited to wlim = 0.30 mm for base slab and roof, to wlim = 0.20 mm for wall and ringbeam. This will apply for load conditions as described in the table below. The corner protection system at the inner surface of the lower concrete tank wall, as well as the steel liner as an extension of the corner protection system and located within the cellular glass blocks of the bottom insulation, ensures liquid-tightness during the emergency situations of liquid spill in order to protect the outer tank from direct contact with LPG in these areas.
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Serviceability Limit State Performance Criteria - Construction phases Durability Stage Design Criteria maximum crack width: - overall structure: wlim = 0.30 mm - consideration of the reduced stiffness due to crack formation maximum crack width: - prestressed concrete wall sections: wlim = 0.20 mm - reinforced concrete sections of base slab and roof: wlim = 0.30 mm - consideration of the reduced stiffness due to crack formation pre-stressed concrete wall: remaining compression zone: - 10% of wall thickness, 100 mm - average compressive stress of 1 MPa within the residual compression zone - consideration of the reduced stiffness due to crack formation
- Hydrotest and pneu- Durability matic test pressure - Operation - Earthquake OBE
- Liquid spill
Liquid tightness (liquid tightness of the base slab and lower part of the wall by means of a corner protection system)
Fig. 3.2 Serviceability Limit State Scenarios (SLS)
In case of a liquid spill it can be demonstrated that a residual compression zone in the wall of at least 100 mm and an average concrete compressive stress of about 1 N/mm2 within the compression zone can generally be maintained in the principle direction of pre-stress above the corner protection system. The crack width limitation and the residual compressive zone requirements are considered not to be applied to the worst-case consideration of inner tank spill in addition to OBE.
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3.2 Design of Pre-stressing

Horizontal: The load cases governing the design of the horizontal pre-stressing (principle direction) force are as follows: - hydrostatic pressure due to liquid spill - internal overpressure - creep, shrinkage and relaxation Vertical: The vertical pre-stressing force will be designed in such a way, that there are no axial tensile stresses in vertical direction due to operation situation. However, tensile stresses at the edge of a cross section will not be limited. Cracking of concrete sections will be controlled, too, by vertical pre-stressing, by the amount and distribution of bonded reinforcement bars and by measurements; the crack width will be limited as stated in table Fig. 3.2 Early age cracking is considered by means of concrete technology reducing the required crack reinforcement (i.e. acc. to CIRIA - Construction Industry Research and Information Association, Report C660).
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3.3 Design Codes

Governing design code for concrete structure is BS8110.
3.3.1 Material and Load Partial Safety Factors

The following Limit States shall be investigated: (i) Serviceability Limit State (SLS) (ii) Ultimate Limit State (ULS)
3.3.2 Serviceability Limit State (SLS)

Serviceability Limit State (SLS) includes different scenarios as described in Fig. 3.2 This design state shall be utilized to determine crack width, strains, stresses and liquid tightness in different conditions. All material factors are taken as 1.0. The load safety factors are taken acc. to chapter 3.5.5
3.3.3 Ultimate Limit State (ULS)

Ultimate Limit State (ULS) includes all loading conditions. This design state shall be utilized to determine concrete section adequacy per the strength requirements of governing design code using material partial safety factors according to Fig. 3.3 and load partial safety factors according to chapter 3.5.5 Operating, Test, and OBE conditions 1,15 1,50 Emergency condition 1,00 1,30
Strength Parameter Reinforcement Concrete in flexure or axial load
Fig. 3.3 Material partial safety factors for the ULS
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3.4 Materials
3.4.1 Concrete
The following concrete qualities are proposed in accordance with project specifications. The characteristic strength is defined as 28-day concrete strength acc. to BS 8110
member Blinding Base slab Wall / Ringbeam Roof
cube strength (BS 8110) 20,0 40,0 40,0 40,0 N/mm2 N/mm2 N/mm2 N/mm2
3.4.2 Reinforcement
3.4.2.1 Low temperature (cryogenic) reinforcement Reinforcement at the inner face of the wall, which is subject to cryogenic temperatures, shall be suitable for use at design temperature according to BS 7777-3:1993 6.3.4 at -50.0 C (Krybar -50 C). Characteristic strength (yield strength): 500 MN/m - Krybar -50 C (500 B acc. to BS 4449) 3.4.2.2 Non cryogenic reinforcement All other reinforcement is made of hot rolled high yield steel bars according to BS 4449 Characteristic strength (yield strength): Grade 500 (acc. to BS 4449 - 2005)
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3.4.2.3 Pre-stressing reinforcement Bundled strand tendons made of 7-wire super strands (0.6) according to DYWIDAG Prestressing System and ETAG 013 (European Technical Approval Guideline) with low relaxation shall be used. The system incl. strands and anchorages shall be suitable for cryogenic applications acc. to FIP reports 904/128:1982 and SR 88/2, June 1988. The steel for posttensioning tendons shall comply with ASTM A 416. Characteristic strength (yield strength): Nominal size: 3.4.2.4 Use for Cryogenic Rebar The tank is equipped with a corner protection system. The corner protection system made of steel is located at the inner face of the lower part of the concrete tank wall min. 5,0 m above the secondary base slab and further within the foam glass blocks of the bottom insulation. It ensures the liquid-tightness during the emergency situations of liquid spill and thus protects the outer tank concrete wall from direct contact with LPG in these areas. However, the inner face of the concrete wall above the corner protection is unprotected, thus in the case of liquid spill in direct contact with LPG. In order to ensure the structural integrity of the tank in this case, special precautions are required. 1860 MN/m 140 mm
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3.5 Design Procedure

The main design procedure is shown in Fig. 3.4
3.5.1 Calculations
In Fig. 3.5 a brief overview is given of the software to be used and of the results that will be obtained. Most of this software has been developed to analyze large and sophisticated structures and has been used for the design of LNG/LPG tanks constructed by DYWIDAG, e.g. LNG Tanks Brunei, LNG Tanks Inchon South Korea, LPG Tanks Abu Dhabi, LNG Tanks Oman, LNG Tanks Tongyoung South Korea, ALNG Train 4 Trinidad, LNG Tanks Sagunto Spain, LNG Tanks Bal Haf Yemen, Tombak LNG Project and LNG Tank Nynshamn Sweden. The software SOFISTIK will be applied for the design calculations, which have been used for previous LNG projects. NAFEMS benchmark tests have been carried out for the SOFISTIK software and are available.
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Fig. 3.4 Principle Design Procedure
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SOFISTIK
dynamic analyses - earthquake
Results: - global forces - accelerations (periods) - displacements
Determination of quasi-statical loadings based on the accelerations and tank masses
SOFISTIK
linear structural analysis of single load cases
Results (due to single load cases): axis- and non-axis-symmetrical settlement, deflections and linear sectional forces (based on axis-symmetrical geometry
SOFISTIK
superposition of linear sectional forces
Results (due to load combinations): superposed axis- and non-axis-symmetrical, settlement, deflections and linear sectional forces (based on axis-symmetrical geometry)
SOFISTIK
design of concrete sections
Results: reinforcement, crack width strain, stress
Constructiondrawings
SOFISTIK
non linear analysis
Results: axis-symmetrical deflections and sectional forces due to reduced stiffness, crack width, check of reinforcement temperature progress, strain, stress
CALCULATION BY FORMULA
Local impact by a flying valve
Results: Check of reinforcement
Fig. 3.5 Calculation Methods
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3.5.2 Analysis Methods

3.5.2.1 Software The analysis of linear sectional forces, moments and displacements, the seismic analysis of the tank structure and the calculation of the required percentage of reinforcement will be performed using the NAFEMS benchmarked computer program SOFISTIK. SOFISTIK is a commercial 3D-finite element program developed for all types of structures and used in our company over a period of more than 15 years. The program is provided with preprocessing, processing, post-processing and graphical presentation of the input and output data and results of the static and dynamic analysis. In cases in which the concrete is exposed to extreme temperature, i.e. liquid spill or valve fire, non-linear effects of the concrete behaviour by reduced stiffness due to concrete cracking will be taken into account for the stress analysis of the wall. The temperature distribution in the wall due to the various spill pool levels will be also analyzed with this software and introduced in the model. SOFISTIK will be used for all other non-linear calculations, in which cracked concrete sections will be taken into account. 3.5.2.2 Linear Elastic Analysis For the elastic analysis of linear sectional forces of the various operation and emergency loads, the main concrete tank structure will be modeled using a 3D-Finite Element computer program. The model comprises the base slab, the wall, the roof ring beam and roof. Loading, sectional forces and bending moments are graphically presented in relation to the line through the center of gravity. Spring elements (elastic bedding values) will be used to model the sub-soil taking into account the interaction between the tank structure and the sub-soil. The various load component results are superimposed in order to develop load combinations for the SLS and ULS design of the concrete components. In cases where cracked concrete sections will be taken into account in the design, a nonlinear analysis will be performed, see next section.
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3.5.2.3 Non-Linear Analyses In operation and emergency cases in which the concrete is exposed to high tensile stresses e.g. due to extreme temperatures due to liquid spill or in emergency cases, non-linear effects of the concrete behavior caused by the reduced stiffness due to crack formation have to be taken into account. Contrarily to the linear elastic analysis, where the individual single load cases can be superposed, a non-linear analysis must be carried out for load combinations determined before. For non-linear calculations the reinforcement is an input and will be determined by the results of the linear calculation. If this quantity isnt sufficient to fulfill the requirements (stress, strain, crack width etc.), it has to be adjusted. The calculation of non-linear sectional forces is an iteration process, which will be performed by the selected computer program SOFISTIK. The FE-model corresponds to the one used for the linear elastic calculation.
Fig. 3.6 Tank shell model
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3.5.2.4 Seismic Analysis The model for the seismic analysis consists of an axis-symmetrical lumped mass system using acceleration response spectra as excitation input. The whole system is required to remain within the elastic range, no physical or geometrical non-linearity shall occur. The system considering the interaction of the outer concrete tank, the inner steel tank and the liquid will be modeled using a FE-model, called tuning-fork-system, consisting of beam elements and lumped masses. For this analysis also the software SOFISTK is used. The liquid will be assigned as lumped masses to the nodes of the inner tank. The distribution of the liquid masses will be done in a parabolic form. The impulsive and sloshing portions of the liquid mass are calculated according to API 620, Appendix L. The results of a response analysis are not depending on time, because overall results (i.e. maximum sectional forces) will be calculated using the SRSS (square root of the sum of the squares) combination method. Superposition with other (statical) loadings: The dynamic models provide global bending moments, shear and normal forces of twodimensional beams or one-dimensional springs. These sectional forces will be expanded to the three-dimensional shell model for superimposing with the statical loadings. The overall bending moments (due to horizontal excitation) are distributed acc. to a costype shape along the tank wall. From the overall shear forces (due to horizontal excitation) and normal forces (due to vertical excitation) individual accelerations for base slab, wall and dome are calculated corresponding to their ideal unit weights. The modal analyses are performed for the horizontal and vertical directions separately. The superposition of the maximum values shall be done by considering the more unfavourable of the following two combinations:
(1) 1.0 Fx + 0.3 Fz (2) 0.3 Fx + 1.0 Fz Fx (horizontal direction), Fz (vertical direction)
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Fig. 3.7 Tuning fork system (lumped mass model) for horizontal excitation
Fig. 3.8 Lumped mass model for vertical excitation
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Following site specific response spectrum is defined for SSE conditions acc. to project specification Development of Preliminary 20006 IBC Design Ground Motion Estimates for the Tekreer Refinery Project, Ruwais, Abu Dhabi. It is developed for site class D and a return period of 2475 years.
0,100 0,090 0,080 0,070 0,060 SSE (g) 0,050 0,040 0,030 0,020 0,010 0,000 0 5 6 7 8 9 Period [sec] Vertical Acceleration Spectra = 2/3 * Horizontal Acceleration Spectra 1 2 3 4 10
Period
SSE [g]
0,038 0,041 0,070 0,094 0,094 0,094 0,094 0,083 0,055 0,041 0,021 0,009 0,005 0,003
2006 IBC
[sec]
0,00 0,01 0,10 0,18 0,20 0,30 0,88 1,00 1,50 2,00 4,00 6,00 8,00 10,00
Fig. 3.9 Spectrum acc. to 2006 IBC for site class D and return period of 2475 years
The shown spectrum is assumed to correspond with SSE. The OBE spectrum is scaled down by a factor of 1,5. Consequently, the horizontal PGA values are considered with 0,038 g for SSE and 0,025 g for OBE. The vertical PGA values are defined by project specification as 2/3*0,038 = 0,025 g for SSE and 2/3*0,025 = 0,017 g for OBE. For the preliminary design the following percentages of the critical damping are considered. The values are based on previous design experience and literature. OBE sloshing mass outer tank soil
Fig. 3.10 Critical damping
SSE 0,5% 4,0% 5,0% 20,0%
0,5% 2,0% 15,0%
inner tank + impulsive mass 2,0%
Note: Uplift during OBE/SSE is permitted if further performance and acceptance requirements specified for the project are met and provided that the foundation can withstand the resultant actions.
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3.5.2.5 Thermal models In principle two situations will be taken into account for the temperature analysis of the concrete tank: operation respectively spill situations and fire scenarios. Maximum and minimum ambient temperature profiles are considered as basis for the design for both situations. Besides the area of the base slab to wall connection onedimensional heat transfer dominates in wall as well as in base slab sections. In other areas than the corner protection system, a conventional calculation will therefore be performed using formulas published in the literature. In the wall to base slab connection area and on top of the corner protection system the influence of the two-dimensional heat transfer will be analyzed under spill condition using thermal finite element analysis in order to study the transition of the one-dimensional temperature gradient from the base slab to the wall sections and from the corner protection system to the unprotected wall. The structure is axis-symmetric. It is therefore sufficient to study the temperature distribution of a segment of the structure. The resulting temperature profiles will afterwards be transformed to the design models used for the operation and spill design calculations. The concrete outer tank and all insulation material layers located between the outer tank and the inner tank are considered for the determination of the temperature profiles. The steel plates (inner tank, secondary bottom and liners at the inner face of the concrete tank), however, will be neglected due to their high thermal conductivity. A constant LPG design temperature is considered at the inner face of the steel tank wall and of the steel tank bottom for the operations situations. In case of an LPG spill the LPG penetrates the perlite in the annular space and the cellular glass and sand layers above the secondary bottom plates. A constant LPG temperature is therefore taken into account at the inner face of the concrete wall, at the inner face of the corner protection system and on top of the secondary bottom plates for various spill conditions. Convection film coefficients are used to model the convective heat transfer between the outer face of the concrete wall and the surrounding air. The film coefficient depends on the air movement at the concrete surface. A film coefficient will be therefore not applied between the base slab and the soil. It will be assumed that an air movement will not occur there.
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3.5.2.6 Crack width calculation Control of cracking in flexural/tension members will be carried out acc. to BS 8110, part 2, section 3.8. Early age cracking is considered also acc. to BS 8110, part 2, section 3.8.
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Design Loading Summary Table The design will be prepared for the following situations:
3.5.3 Normal situations:

- Construction phases - Hydro test and pneumatic test - Operation phases - Earthquake OBE
3.5.4 Emergency situations:

- Earthquake SSE - LPG spill - LPG spill + OBE - Pressure relief valve fire - Missile impact The actions listed below are considered for the tank design
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dc, de
Operation and Test Situation: dead weight of the tank structure concrete (density 2500 kg/m), inner steel tank, steel liners, suspended ceiling, steel roof and platform, insulation etc. horizontal pressure due to perlite fill temporary loads during construction phases and stress history where appropriate effects of predicted differential centre to edge soil settlements will be considered by the soil-structure interaction (spring elements in the static model) pre-stressing incl. losses due to creep, shrinkage and relaxation ambient temperature operation : max. ambient temperature min. ambient temperature Basic Wind Speed for use with ASCE 7 live load on roof: uniform distributed load live load on platform and access ways : hydro test of inner tank with water, test level: 16,0 m pneumatic test pressure: 1,25 x 105 mbarg according to API 620, app G LPG filling inner tank: H = 16,0 m design density minimum design temperature design max. internal pressure: +105 mbarg
lcons
ss
lpre
top
50,0 C 5,0 C 160 km/h 1,5 kN/m2 2,4 kN/m2 = 1000 kg/m3 13,125 kN/m2
A A D
lw lr
C C
lp ftest ptest
fLPG
6,074 kN/m -48,0 C +10,5 kN/m2
B A B
pmax
Page 32 of 40
Emergency Situations eOBE operating base earthquake, pending depending on detailed site survey safe shut down earthquake, pending depending on detailed site survey leakage of inner tank at intermediate levels fsp liquid spill of inner tank, density tsp temperature liquid spill psp internal pressure due to liquid spill 125% missile impact (local effect): mass velocity impact diameter PGA: 0,025 g (hor.) PGA: 0,017 g (vert.) PGA: 0,038 g (hor.) PGA: 0,025 g (vert.) E E E E B 6,074 kN/m -48 C 13,125 kN/m2 50 kg 45,0 m/sec 100 mm 32,0 kW/m2 1 hour*
eSSE
fsp
limp
lvf
PRV- fire (acting on roof) maximum incident heat flux (concrete part) duration Fig. 3.11 Main loading values A B C D E
According to Project Specification, Doc. No. 25418-1000-3PS-MT00-M0004 According to Datasheet No. 25418-1041-MTD-MTD0-B0065 REV1 According to EN 14620-1 According to STRUCTURAL ENGINEERING DESIGN CRITERIA, 25418-1000-3PS-S000-C0001 Development of Preliminary 2006 IBC Design Ground Motion Estimates for the Takreer Refinery Project, Ruwais, Abu Dhabi
3.5.5 Load combinations

Typical load combinations for the design of the concrete structure of the tank system are shown in Fig. 3.12 for ULS and in Fig. 3.13 for SLS. Emergency loading situations are considered separately (i.e. only one emergency load shall be considered to prevail at any one time) except the situation liquid spill in combination with OBE.
Page 33 of 40
ULS Load Combination kind of loading *)

Construction phases
LPG Spill lcons fLPG pma ftest ptes lp, l PE PR PE PE PE V V V V V d lpre lshr ss
3) 2)
lw V V
top eOBE eSSE fsp tsp psp V V E E E E
tvf E
taf E
lblast lim E E ULS Normal
1,4 0,9 1,4 Hydro test and pneumatic test 0,9 Operation phases + imposed load + wind Operation + OBE Operation + SSE Inner tank liquid spill Spill + OBE Blast wave Pressure relief fire Adjacent fire Impact of projectiles Only local effect 1) 2) 3) 1,4 0,9 1,4 0,9 1,05 1,0 1,05 1,0 1,0 1,0 1,05 1,0 1,05 1,0 1,05 1,0
1,2 1,0 1,2 1,0 1,2 1,0 1,2 1,0 1,05 1,0 1,05 1,0 1,0 1,0 1,05 1,0 1,05 1,0 1,05 1,0 1,2 0,0 1,2 0,0 1,05 0,0 1,05 0,0 1,0 0,0 1,05 0,0 1,05 0,0 1,05 0,0
1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0
1,6 0,0
1,2 0,0 1,2 0,0 1,2 1,2 0,0
1,2 0,0
1,6 0,0 1,6 0,0 1,6 0,0 1,6 0,0 1,05 0,0 1,05 0,0 1,0 0,0 1,05 0,0 1,05 0,0 1,05 0,0 1,6 0,0 1,2 0,0 1,2 1,3 0,0 1,05 0,0
1,2 0,0 1,05 1,05 0,0
1,05 1,05 1,05 1,05
1,0 1,05
1,0
1,0
1,0
1,05 1,05 1,05
PE = Permanent Load, V = Live Load, E = Emergency Load the soil settlements will be considered by the interaction of the structure and the soil (spring elements in the static model) Ptso and Pts will be applied
Cool down and maintenance is covered by the operation situation

Fig. 3.12 Typical load combinations with load partial safety factors
Page 34 of 40
ULS Abnormal
1,05 0,0 1,05 0,0 1,05 0,0
1,05 0,0 1,05 0,0 1,05 0,0
1,05
SLS Load Combination kind of loading *)

Construction phases
LPG Spill lcons fLPG pma ftest ptes lp, l PE PR PE PE PE V V V V V d lpre lshr ss
3) 2)
lw V V
1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0
top eOBE eSSE fsp tsp psp V V E E E E
tvf E
taf E
lblast lim E E ULS Normal
1,0
1,0 1,0 1,0 1,0 1,0 0,0 1,0 0,0 1,0 0,0
1,0 1,0 1,0 1,0
1,0 0,0 1,0 0,0 1,0 1,0 0,0 1,0 0,0
Hydro test and pneumatic test 1,0 Operation phases + imposed load + wind Operation + OBE 1,0 1,0
1,0 0,0
1,0 0,0
1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0 1,0 0,0
1,0 0,0 1,0 0,0
1,0
Inner tank liquid spill
1,0
1,0
1,0
1,0
1,0
1,0
1) 2) 3)
PE = Permanent Load, V = Live Load, E = Emergency Load the soil settlements will be considered by the interaction of the structure and the soil (spring elements in the static model) Ptso and Pts will be applied
Cool down and maintenance is covered by the operation situation

Fig. 3.13 Typical load combinations with load partial safety factors
Page 35 of 40
ULS Abnormal

4 Foundation
4.1 Applicable Documents
Following documents are applicable or will be referred to: Following geotechnical reports are available: /1.1/ Geotechnical investigation for Ruwais Refinery Expansion Project, No.5578 Agreement No.07-5578-F-1 Ruwais, Abu Dhabi, UAE S08000288 Factual Report Revision 2 /1.2/ Geotechnical investigation for Ruwais Refinery Expansion Project, NO.5578 Agreement No 07-5578-F-1 Ruwais, Abu Dhabi, UAE S08000288 Recommendations Report Revision 3 Ruwais Refinery Expansion Project Project Specification Addendum Design General Specification - Rotating Equipment-Minimum General Requirements Bechtel Document Number 25418-1000-3PS-M000-M0004 Rev. 1
/1.3/
A factual geotechnical report describing the project area is available. An engineering geotechnical report is not available at present stage. A final engineering report for the tank area is required to finalize the foundation concept, especially a soil data report and a recommendation for the foundation by the geotechnical expert.
4.2 General information

The site preparation rough grading plan (Bechtel drawing no. 25418-1000-CG0-0000-C0111) Revision 5 indicates the proposed future rough grade level at +7.60 m. Plant plan overall site plan (Bechtel drawing no. 25418-1000-P10-0000-P0001) shows the propylene tanks in the range of approx. E = 670,500 N = 2,669,000. At this position the drilling of borehole BH-A16 has been carried out. The borehole data sheet of BH-A16 defines the existing ground level at +3.10 m and the ground water level at +1.80m.
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4.3 Flat foundation Concept
Acc. to the mentioned geotechnical information a flat foundation is envisaged, which is schematically displayed in the following figure. The tank area is handed over at + 7,60 m, which shall also be the final grade of the tank area. Groundwater is encountered at + 1,8 m. A tank pad varying from 80 cm to 150 cm, below the rim area respectively the centre area, is foreseen to accommodate in-homogeneity of the subsoil.
Fig. 4.1 Foundation Layers
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4.3.1 Settlements
The subsoil described in the factual geotechnical report consists basically of an upper weaker part (medium dense to very dense silts SAND) and a lower stiffer part (alternating SILTSTONE and SANDSTONE). Overhead the natural soil is a 4,50m thick soil layer; this layer - called DRY FILL - should have a compressive strength higher than Es = 20 Mpa in the area of the tank. Following soil layers and related stiffness have been assumed for preliminary settlement calculations and related bedding definitions. The detailed subsoil layers used for preliminary settlement investigations and the related E-Moduli acc. to the geotechnical reports mentioned in section 4.1 are shown in the following table. The definition of the soil layers and their thickness is based on the soil report. The following tables show an average of the soil layers resulting from borehole BH A32 and BH A 33. The expected Maximum settlements on this basis amount to approx. 132 - 171 mm. The differential settlements are within the limits specified in BS 7777.
Page 38 of 40

layer definition absolut level [m]
6,90 0 1 2 3 4 5 6 7 8 9 10 11 12 13 Tank Pad (average thickness) 6,10 DRY FILL 3,10 silty SAND, medium dense 1,10 silty SAND, medium dense -0,90 silty SAND, medium dense -2,90 silty SAND, medium dense -4,90 silty SAND, very dense -6,40 silty SAND, very dense -7,90 Very weathered, SANDSTONE -11,00 Very weathered, SANDSTONE -16,00 slightly weathered, MUDSTONE -17,00 Moderatly weathered, GYPSUM -18,00 slightly weathered, MUDSTONE -19,00 Very weathered, SILTSTONE -80,00 Fig. 4.2 Soil layers 61,00 -86,9 1,00 -25,9 100000 1,00 -24,9 80000 1,00 -23,9 10000 5,00 -22,9 80000 3,10 -17,9 100000 1,50 -14,8 100000 1,50 -13,3 60000 2,00 -11,8 60000 2,00 -9,8 45000 2,00 -7,8 45000 2,00 -5,8 20000 3,00 -3,8 20000 0,80 -0,8 20000
thickness [m]
relative level [m]

0,0
Es [kN/m]
70000
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4.4 Settlement requirements
The tank foundation shall be designed in order to fulfil following limits: Type of Settlement Tilt of the tank Tank floor settlement along a radial line from the periphery to the tank center Settlement around the periphery of the tank
Fig. 4.3 Differential settlements limits
Differential Settlement Limits 1 : 500 1 : 300 1 : 500 but not exceeding the maximum settlement limit calculated for tilt of the tank
The final design will be adjusted to the final engineering geotechnical report, which may lead to changes. If the above mentioned is confirmed by the final, still outstanding engineering report for tank area, the subsoil for the Tank foundation will be suitable for a flat foundation supported on engineering fill (tank pad) and keep the settlement requirements.
Page 40 of 40

Attachment 1 - 1 TAKREER LPG - Cross Section - Flat Foundation

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Tank design description

Tank Design Description

Alternative: Flat Foundation

First internal revision

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

4 4.1 4.2 4.3

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

2 Description of the Tank System

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

2.2 Tank Data

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

Fig. 2.1 Cross section of tank system

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

2.3.2 Tank Base Slab

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

2.3.7 Tank Temporary Access Openings

2.4 Bottom Heating

2.5 Tank Settlement Monitoring

2.5.2 Inclinometer system

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

2.6 Pre-stressing System

2.6.1 Tendon Layout

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

2.6.2 Pre-stressing operation

Fig. 2.2 Layout of horizontal pre-stressing tendons (schematically)

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

Fig. 2.3 Layout of vertical tendons with loop anchors (schematically)

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

3 Basis for Analysis

3.1 Design Criteria

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

3.1.1 Ultimate Limit State (ULS)

- Liquid spill inner tank

- Liquid spill inner tank + OBE

- Pressure relief fire - Adjacent fire - Impact of projectiles on tank shell

Fig. 3.1 Ultimate Limit State Scenarios (ULS)

3.1.2 Serviceability Limit State (SLS)

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

Fig. 3.2 Serviceability Limit State Scenarios (SLS)

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

3.2 Design of Pre-stressing

Takreer Propylene Storage Tank design description_00_flat.doc

Tank design description

3.3 Design Codes