Heat Exchanger Foundation

CALCULATION SHEET

Sheet No :-

Calc. by :-

Reliance Engineering Associates Pvt. ltd. Chekd. by:-

Jamnagar – 361140, India. Unit No :- -

Title :- FCO / VMP-UTL Date :- 27/06/05Subject :- FOUNDATION DESIGN FOR ME-EE952-S082

Supplier : TEMA India Ltd.length of saddle baseplate : 1150 mmWidth of saddle base plate : 420 mmConsider pedestal Size : 1400 mm x 600 mm

HPP : 41.100FGL : 40.800

SBC at foundation Level : 225U/S of Base Plate : 42.300

U/s BP 42.300

1.2

0

m

HPP 41.100

1.5

0

m

FGL 40.800

39.600

0.8

0 m

BOF 38.800

0.30 m 4.27 m 0.30 m

4.87 m

Width of Foundation Base : 2.30 m

Load Calculations :

Foundation Mat = 4.87 x 2.3 x 0.81 x 25 = 224.020 KN

Pedestal = 1.4x0.6x2.7 x 2 x 25 = 113.400 KN

Soil above = ( 4.87x2.3 - 2 x 1.4x0.6 ) x 1.2x21 = 239.929 KN

Total 577.349 KN

Empty Wt. 97.300 KN

KN/m2

CALCULATION SHEET

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Title :- FCO / VMP-UTL Date :- 27/06/05Operating Wt. 166.600 KN Hydro Test Wt. 166.600 KN

CALCULATION SHEET

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Title :- FCO / VMP-UTL Date :- 27/06/05

To calculate Fundamental Period (t)Length of Pier : 1400 mm

14

00

mm

Widht of Pier : 600 mm

Height of Pier 2700 mm

I trans = 1/12x1400x600x600x600 = 25.200 600 mm(x dir)

I long = 1/12x1400x1400x1400x600 = 137.200(y dir)

Mass empty : 9730 kgMass operating : 16660 kgMass column : 5670 kg

Concrete Modulus of Elasticity :

Ec = 5000 Fck = 5000 25

fck = 25

= 25000

= 2500Empty Case :

To Calculate fundamental frequency and time period in X dir.

100x

3 x Ec x I trans

(x dir)

100x

3 x2500 x 25.2

(x dir) 6.28 2700 9730 + 33 / 150 x 5670 )

= 14.885 Time Period = 0.067 sec (x dir)

To Calculate fundamental frequency and time period in Y dir.

100x

3 x Ec x I long

(y dir)

100x

3 x2500 x 137.2

(y dir) 6.28 2700 9730 + 33 / 150 x 5670 )

x 10 9 mm4

x 10 9 mm4

mm2

N/mm2

Kg/mm2

f empty =

2 p Ph3 x ( M empty + 33/150 Mc)

f empty = x 10 9

3 (

sec -1

f empty =

2 p Ph3 x ( M empty + 33/150 Mc)

f empty = x 10 9

3 (

CALCULATION SHEET

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= 34.732 Time Period = 0.029 sec (y dir)sec -1

CALCULATION SHEET

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Oprating Case :

To Calculate fundamental frequency and time period in X dir.

100x

3 x Ec x I trans

(x dir)

100x

3 x2500 x 25.2

(x dir) 6.28 2700 16660 + 33 / 150 x 5670 )

= 11.654 Time Period = 0.086 sec (x dir)

To Calculate fundamental frequency and time period in Y dir.

100x

3 x Ec x I long

(y dir)

100x

3 x2500 x 137.2

(y dir) 6.28 2700 16660 + 33 / 150 x 5670 )

= 27.194 Time Period = 0.037 sec (y dir)

Tabulating Time Period :

Empty OpratingCase CaseSec Sec

In X Dir 0.067 0.086

In Y Dir 0.029 0.037

Foundation should be act as Flexible Foundation in X DirectionFoundation should be act as Rigid Foundation in Y Direction

f oprating =

2 p Ph3 x ( M opr + 33/150 Mc)

f oprating = x 10 9

3 (

sec -1

f oprating =

2 p Ph3 x ( M opr + 33/150 Mc)

f oprating = x 10 9

3 (

sec -1

CALCULATION SHEET

Sheet No :-Calc. by :-

Reliance Engineering Associates Pvt. ltd. Chekd. by:-Jamnagar – 361140, India. Unit No :- -Title :- FCO / VMP-UTLSubject :- FOUNDATION DESIGN FOR ME-EE952-S082 Date :- 27/06/05

DESIGN PHILOSOPHY:

a) The following loads are taken from the Technical Data Sheet:* Operating weight* Fabrication weight Empty weight* Bundle weightOperating weight have been increased by 10% to cater to additional loads due to ladders platforms , external piping attached to the vessel, insulation if any and any other incidental loads to calculate seismic shear only. The empty weight has not been factored.

b) Wind Load: Wind load has been calculated based on IS 875(Part 3). To take care of the wind resistance generated by external attachment to the vessels like ladder P/F, piping etc., the effective area of the vessel has been taken as the vessel I/D multiplied by the area increase factor as given in Bechtel Design Guide EDG-C0101, Engineering Design Guide For wind and earthquake design.

c) Seismic Load: In calculating the seismic load for the vessel spec. 22960-3PS-SC-002 Design of rigid and flexible foundations for horizontal vessels subject to seismic forces) has been followed. As seismic force may generate in any direction, the worst effect may be encountered while considering 100% seismic load in one direction and 30% seismic in the perpendicular direction as per UBC 94 SECTION 1631. This assumption has been adopted in designing the foundation for Horizontal Vessels.

d) Thermal Load:* Along longitudinal direction - Horizontal thermal load has been considered as per the guidelines given in 22960-3PS- SC-002. Friction load induced to thermal force will be considered in the design.* Along transverse direction - Horizontal thermal load in transverse direction due to connected piping is obtained from data supplied by Piping or as per the guideleines given in 22960-3PS-SC-002.

1.0 LOADING

1.1 BASIC DESIGN / VESSEL DATA

238 kN

238 kN

139 kN

82 kN

5) Bolt Dia and Nos. = 4 Nos 36 Dia Bolts

50.00 m/s

0.30 Refer Spec No. 22960-3PS-SC-002-R3

8) Seismic Coefficient for Supports, Cs = 0.276Refer Spec No. 22960-3PS-SC-002-R3

0.675

10) Grade of Concrete to be used = M 25

25000

12) Overall Length of the exchanger = 7.648 m13) Diameter of each Vessel , D = 1.503 m ( Assuming on higher side )14) Vertical Dist from TOC to lower vessel , L1 = 1.15 m15) Distance between Centre line of vessles, L2 = 0 m16) Distance between Center line of Supports , L3 = 4.27 mAdopt , Width of Support , Pw = 600 mm 600Length of Support , Pl = 1400 mmHeight of Support , Ph = 2650 mm ( height above Raft ) 1400

1) Operating Weight per exchanger ( Wo) =

2) Test Weight per exchanger (Wtp) =

3) Empty Weight per exchanger (Wep) =

4) Bundle Weight per exchanger (Wb) =

6) Basic Wind Speed, Vb =

7) Coefficient of Sliding friction , Cslf =

9) Seismic Coefficient for Bolts, Csb =

11) Modulus of Elasticity of concrete , Ec = N/mm2

CALCULATION SHEET



1.2 Design Vertical Load Calculation

70 % of Total Vertical Load will be taken on Fixed Support and 60 % of Total Vertical Loadshall be taken on Sliding Support.( to account for offset between CG of vessel and midpoint between Supports and apply 10 % extra for empty weight for piping attachments and nozzles)

261.8 kN

261.8 kN

152.9 kN

82 kN

1.3 Bundle Pull Reactions at supportsBundle Weight of top exchanger = 82 kNConsider 100% Bundle weight as Bundle PullBundle Pull acting during Bundle pull out = 82 kN ( At Fixed Support only )Overturning Moemnt due to Bundle Pull = 94.3 kN-mAxial force due to Bundle Pull = Overturning Moment due to Bundle pull

c/c distance between Supports= 23 kN

1.4 Design Seismic Load Calculation( Assume fixed end to take 100% of seismic loading in Longitudinal direction for all cases )

Assuming behaviour of overall supporting system as flexible in longitudinal directionSeismic Coefficient for Supports, Cs = 0.276

0.675

1.4.1 Longitudinal Seismic Force at top of fixed Support ( Support/Fdn design )

72.26 kN

42.20 kN

1.4.2 Longitudinal Seismic Force at top of fixed Support ( Bolt / Shear key design )

176.72 kN

1.4.3 Transverse Shear at C/L of Vessel on Fixed / Sliding Support ( Support/Fdn design )Assuming behaviour of overall supporting system as Rigid in transverse directionSeismic Coefficient for Supports, Cs = 0.15

0.225

Shear at top of Supports, Vost = 23.56 kN

Shear at top of Supports, Vest = 13.76 kN

Moment at Top of Supports, Most = 27.10 kN-m

Moment at Top of Supports, Mest = 15.83 kN-m

1.4.5 Transverse Seismic Force at top of each Support ( Bolt / Shear key design )

35.34 kN

1) Total Operating Weight ( Wo) =

2) Total Test Weight (Wtp) =

3) Total Empty Weight (Wep) =

4) Bundle Weight (Wb) per exchanger =

Seismic Coefficient for Bolts, Csb =

Shear, Vosl = In Operating Condition ( Vosl = WoxCs )

Shear, Vesl = In Empty Condition ( Vesl = WexCs )

Shear, Vosl = In Operating Condition ( Vosl = WoxCsb )

Seismic Coefficient for Bolts, Csb =

( Vost = 0.6xWoxCs )

( Vost = 0.6xWexCs )

( Vost x Ht. Of Vessel C/Ls from POS )

( Vest x Ht. Of Vessel C/Ls from POS )

Shear, Vosl = In Operating Condition ( Vosl = WoxCsb )

CALCULATION SHEET



1.5 Design Wind Load Calculation on ExchangerBasic Wind Speed , Vb = 50 m/sProbability factor , Risk Coefficient , k1 = 1.08Terrain, Height and Structure size factor ,k2 = 1 ( Category 2 terrain, Class A structure )Topography factor , k3 = 1Design Wind velocity, Vz = Vb*k1*k2*k3 = 54 m/sReferring Tb-23 on sh 40 of IS:875 - Part 3 For plan shape on 1 Cf for Longitudinal direction = 0.7 (As per H/B Ratio equal1901.5 / 1503 = 1.27 )For plan shape on 1 Cf for Transverse direction = 0.8 (As per H/B Ratio equal7648 / 1503 = 5.09 )

1.5.1 Transverse Wind Forces Calculation :-1.20 ( Assuming )

###

###

###

###

1.5.2 Longitudinal Wind Forces Calculation :-

Longitudinal force on Each Exchanger = 4.20 kN

Long. Moment @ TOC of fixed Support = Tl x L1 = ###Axial Thrust on Supports due to the moment , Awl = 1.13 kN ( +/- )

1.6 Thermal and Friction Load Calculation

1.6.1 Thermal Load along Longitudinal direction on Top of Supports ( Support/Fdn Design )( To be combined with Seismic force only )

Total Shear on Supports, VTOL = 18.326 kN

1.6.2 Thermal Loads along Longitudinal directions on Top of Supports ( Support/Fdn Design )

Total Shear on Supports, VFOL = 54.978 kN

1.6.3 Thermal Load along Longitudinal direction on Top of Supports ( Bolt/Shear key Design )( To be combined with Seismic force only )

Total Shear on Supports, VTOL = 16.66 kN

1.6.4 Thermal Loads along Longitudinal directions on Top of Supports ( Bolt/Shear key Design )

Total Shear on Supports, VFOL = 49.98 kN

1.6.5 Thermal Load along Transverse direction on Top of Supports ( Support/Fdn Design )( To be combined with Seismic force only )

Total Shear on Supports, = 26.18 kN

Total Shear on each Support , VTOL = 13.09 kN

###

Area Increase factor Af =

Thus Effective Area in Transverse dir., Ae = Af x h x D =

Design Wind Pressure Pd = 0.6x(Vz)2 =

Transverse wind force on Vessel , Tf = Cft x Ae x Pd x 0.001 =

Transverse Moment @ TOC of each support = 0.6 x Tf x L1 =

Force Coefficient Cfl for Longitudinal direction shall be Cf2

Af x Cfl x (D/2+L1)x D x Pd =

( VTOL = 10% of WO x 0.7 )

( VTOL = CSLF X 0.7 X of WO )

( VTOL = 10% of WO x 0.7 )

( VTOL = CSLF X 0.7 X of WO )

( VTOL = 10% of WO )

Moment due to shear , MTOL = VTOL x C/L Ht of Vessel POS =

CALCULATION SHEET



Summary of Loads for Foundation and Support design

Load Description

Load Distribution OnFixed Support Sliding Support

Axial Shear Moment Axial Shear MomentkN kN kN-m kN kN kN-m

A) DEAD LOADOperating Weight 183.26 - - 157.08 - -Test Weight 183.26 - - 157.08 - -Empty / Erection Weight 107.03 - - 91.74 - -

B) LONGITUDINALSEISMIC LOAD

Operating Weight 19.46 72.26 - - - -Empty / Erection Weight 11.37 42.20 - - - -

C) TRANSVERSE SEISMIC LOAD

Operating Weight - 23.56 27.10 - 23.56 27.10Empty / Erection Weight - 13.76 15.83 - 13.76 15.83

D) BUNDLE PULL 23 kN 82.00 -23 kN

E) LONGITUDINAL WIND LOAD 1.13 4.20 - -1.13 - -

F) TRANSVERSE WIND LOAD - 19.31 13.32 - 19.31 13.32

G) THERMAL LOAD ( LONG. ) - 54.978 - - - -

H) THERMAL LOAD ( TRANS. ) - 13.09 15.05 - 13.09 15.05

I) THERMAL LOAD ( LONG. ) - 18.326 - - 18.326 -

( Due to operating load to be combined with Seismic load )

CALCULATION SHEET



SUMMARY OF LOAD ON FIXED PIER

TYPE OF LOAD AXIAL SHEAR_L SHEAR_TMOMENT_LMOMENT_T AXIAL DUE TO BPL

(KN) (KN) (KN) (KN-M) (KN-M) (KN)----- EMPTY WT (EL) 107.03----- OPERATING WT (OL) 183.26----- BUNDLE PULL (BPL) 82.00 23.00----- WIND_L (WL_L) 4.20 1.13----- WIND_T (WL_T) 19.31 13.32----- SEISMIC_L (SL_L) 72.26 19.46----- SEISMIC_T (SL_T) 23.56 27.10

LOAD COMBINATIONS1 OL+WL_L 183.26 4.20 1.132 OL+WL_T 183.26 19.31 13.323* OL+100%SL_L+30%SL_T 183.26 72.26 7.07 8.13 19.464* OL+100%SL_T+30%SL_L 183.26 21.68 23.56 27.10 5.845 EL+WL_L 107.03 4.20 1.136 EL+WL_T 107.03 19.31 13.327 EL+BPL 107.03 82.00 23.00

SUMMARY OF LOAD ON SLIDING PIER

TYPE OF LOAD AXIAL SHAR_L SHEAR_TMOMENT_LMOMENT_T AXIAL DUE TO BPL

(KN) (KN) (KN) (KN-M) (KN-M) (KN)----- EMPTY WT (EL) 91.74----- OPERATING WT (OL) 157.08----- BUNDLE PULL (BPL) -23.00----- WIND_L (WL_L) -1.13----- WIND_T (WL_T) 19.31 13.32----- SEISMIC_L (SL_L) -19.46----- SEISMIC_T (SL_T) 23.56 27.10

LOAD COMBINATIONS1 OL+WL_L 157.08 -1.132 OL+WL_T 157.08 19.31 13.323* OL+100%SL_L+30%SL_T 157.08 7.07 8.13 -19.464* OL+100%SL_T+30%SL_L 157.08 23.56 27.10 -5.845 EL+WL_L 91.74 -1.136 EL+WL_T 91.74 19.31 13.327 EL+BPL 91.74 -23.00

SUMMARY OF LOADS FOR ANCHOR BOLT DESIGN

LCB-1 OL+100%SL_L 183.26 72.26 19.46LCB-2 OL+100%SL_T 183.26 23.56 27.10LCB-3 EL+BPL 107.03 82.00 23.00

Longitudinal Load = 27.17 kN 30 % ( LONGITUDINAL SEISMIC LOAD + LONGITUDINAL FRICTION LOAD )

Transverse Load = 36.65 kN (TRANSVERSE SEISMIC LOAD + TRANSVERSE THERMAL LOAD )

Transverse Moments = 42.15 kN-m (TRANSVERSE SEISMIC LOAD + TRANSVERSE THERMAL LOAD )

( Load Combination 3 = OP + Thermal / Friction )Vertical Load = 183.26 kN ( OPERATING LOAD ON Support )

Longitudinal Load = 54.98 kN 100% ( LONGITUDINAL THERMAL LOAD )

Transverse Load = 3.93 kN 30% OF (TRANSVERSE THERMAL LOAD )

Transverse Moments = 4.52 kN-m DUE TO 30 % (TRANSVERSE THERMAL LOAD )

( Load Combination 4 = OP + Thermal / Friction )Vertical Load = 183.26 kN ( OPERATING LOAD )

Longitudinal Load = 16.49 kN 30 % ( LONGITUDINAL THERMAL LOAD )

Transverse Load = 13.09 kN (TRANSVERSE THERMAL LOAD )

Transverse Moments = 15.05 kN-m (TRANSVERSETHERMAL LOAD )

LOAD CASE

LOAD CASE

CALCULATION SHEET



1 OL+WL_L2 OL+WL_T3 OL+100%SL_L+30%SL_T4 OL+100%SL_T+30%SL_L5 EL+WL_L6 EL+WL_T7 EL+BPL8 OL+100%SL_L+30%SL_T + 100% Therm_L + 30% Therm_T9 OL+100%SL_T+30%SL_L+ 100% Therm_T + 30% Therm_L

10 OL + Thermal / Friction11 OL + Thermal / Friction

Bolt / Shearkey Design ( Fixed Support )Provide 4 Nos M 36 Anchor bolts - Type IV on both Supports

Allowable Shear force per Bolt = 30.59 kN ( For 8.8 grade bolts )

Maximum Shear force on Bolts = ### > 122.36 kNVTOL + VOSL =

CALCULATION SHEET

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Load Case :

5.840 KN 5.840 KNWt. Of Foundation = 224.020 KNWt. Of Pedestal = 57.000 KN

183.260 KN 157.080 KN Wt. Of Soil = 239.929 KN

27.17

3.5

00

m

4.270 m4.870 m

Horz. Force in Y direction (on Fied Pier) = 36.650 KN @ ht. above foundn base 4.650 mHorz. Force in Y direction (on Fied Pier) = 36.650 KN @ ht. above foundn base 4.650 mHorz. Force in X direction (on Fied Pier) = 27.170 KN @ ht. above foundn base 3.500 m

Total Pull Push Due to longitudinal Force : 5.840 KN

Total Resultant Forces on foundation 4.270 m

P = 918.289 KN

2.3

00

mMx = 95.095 KN-M

My = 340.845 KN-M

Zx = 1/6 x 2.3 x 4.87 x 4.87 = 9.092

Zy = 1/6 x 2.3 x 2.3 x 4.87 = 4.2944.870 m

Pressure at base of foundation :

Pmax / Pmin =P

+ / -Mx

+ / -My

A Zx Zy

Pmax / Pmin =918.289

+ / -95.095

+ / -340.845

11.201 9.091 4.294

Pmax / Pmin = 81.983 + / - 10.460 + / - 79.382

Pmax = 171.825 Within the allowable bearing pressure

Pmin = -7.859 Tension Develop in Base

m3

m3

KN/m2

KN/m2

CALCULATION SHEET

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Check Stability in X direction :

Sliding Check :

Sliding Forcee = 27.170 KN Resisting Force ( 0.4 x 918.29 ) = 367.316 KN

F.O.S. (Sliding) = 27.17 / 367.316 = 13.519 Ok

Overturning Check :

Ovrn. Mom. = 95.095 KN-MRest. Mom. = 224.02 x 2.435 + 239.93 x 2.435 + ( 157.08+5.84+57 ) x 0.3 + ( 183.26-5.84+57 ) x 4.57

= 2266.992 KN-M

F.O.S. (Sliding) = 95.095 / 2266.992 = 23.839 Ok

Check Stability in Y direction :

Sliding check :

Sliding Forcee = 73.300 KN Resisting Force ( 0.4 x -7.86 ) = 367.316 KN

F.O.S. (Sliding) = 73.3 / 367.316 = 5.011 Ok

Overturning Check :

Ovrn. Mom. = 340.845 KN-MRest. Mom. = 224.02 x 1.15 + 239.93 x 1.15 + ( 157.08+5.84+57 ) x 1.15 + ( 183.26-5.84+57 ) x 1.15

= 1056.033 KN-M

F.O.S. (Sliding) = 340.845 / 1056.033 = 3.098 Ok

Heat Exchanger Foundation

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