20075 the Design of Onshore Civil Works

PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

TECHNICAL SPECIFICATION

THE DESIGN OF ONSHORE CIVIL

WORKS

PTS 20.075

DECEMBER 1988

PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,of PETRONAS OPUs/Divisions.

They are based on the experience acquired during the involvement with the design, construction,operation and maintenance of processing units and facilities. Where appropriate they are basedon, or reference is made to, national and international standards and codes of practice.

The objective is to set the recommended standard for good technical practice to be applied byPETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemicalplants, marketing facilities or any other such facility, and thereby to achieve maximum technicaland economic benefit from standardisation.

The information set forth in these publications is provided to users for their consideration anddecision to implement. This is of particular importance where PTS may not cover everyrequirement or diversity of condition at each locality. The system of PTS is expected to besufficiently flexible to allow individual operating units to adapt the information set forth in PTS totheir own environment and requirements.

When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for thequality of work and the attainment of the required design and engineering standards. Inparticular, for those requirements not specifically covered, the Principal will expect them to followthose design and engineering practices which will achieve the same level of integrity as reflectedin the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from hisown responsibility, consult the Principal or its technical advisor.

The right to use PTS rests with three categories of users :

1) PETRONAS and its affiliates.2) Other parties who are authorised to use PTS subject to appropriate contractual

arrangements.3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with

users referred to under 1) and 2) which requires that tenders for projects,materials supplied or - generally - work performed on behalf of the said userscomply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements withusers, PETRONAS disclaims any liability of whatsoever nature for any damage (including injuryor death) suffered by any company or person whomsoever as a result of or in connection with theuse, application or implementation of any PTS, combination of PTS or any part thereof. Thebenefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliatedto PETRONAS that may issue PTS or require the use of PTS.

Without prejudice to any specific terms in respect of confidentiality under relevant contractualarrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed byusers to any company or person whomsoever and the PTS shall be used exclusively for thepurpose they have been provided to the user. They shall be returned after use, including anycopies which shall only be made by users with the express prior written consent of PETRONAS.The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safecustody and PETRONAS may at any time require information satisfactory to PETRONAS in orderto ascertain how users implement this requirement.

PTS No 20.075

THE DESIGN OF ONSHORE CIVIL WORKS

The specification contained herein sets out the standard requirements and procedures to be compliedwith by CONTRACTORS carrying out work directly or indirectly for PETRONAS.

For a given project, the Contract Documents related thereto may specify requirements and procedureswhich deviate from or qualify those sat out in, this standard specification. The CONTRACTOR shall beresponsible for identifying any and all such deviations and qualifications and ensuring that the work iscompleted in strict accordance therewith.

CONTENTS

1. Scope

2. References, Codes and Standards

3. Bundwalls, Catchment Basin and Tank Pads

4. Drainage System

5. Road and Carpark

6. Storage Tanks

7. Stacks

REVISION REGISTER

REVISION NO DATE . DETAILS OF REVISION

1 11/83 FIRST ISSUE

2 12/88 SECOND REVISION

1. Scope

This specification describes the requirements for the design of onshore civil works for refineryand oilfield storage areas.

2. References, Codes and Standards

The following Codes and Standards are referred to in this specification.

A. PETRONAS Technical Standards (PTS)

1) PTS 34.14.20.31 Refinery Drainage 1979 System

2) PTS 34.13.20.31 Road, Paving Surfacing,1983 Slope Protection andFencing

3) PTS 30.10.01.10 Requisition for Storage Tanks (Form No. PTS34.51.01.93).

4) PTS 34.28.00.31 Steel Structures

5) PTS 00.00.10.05. Approval Drawings Specification (Form No. PTS05.00.54.81).

6) PTS 00.00.10.05. Final Drawings Specification (Form No. PTS05.00.54.82)

7) PTS 34.24.26.31. Steel Stacks May, 1983.

8) PTS 34.24.27.31. Reinforced Concrete Stacks March, 1987.

9) PTS 34.00.01.30. Minimum Requirements for Structural Design andEngineering June, 1983.

10) PTS 34.19.20.31. Reinforced Concrete Foundations and Structures

11) PTS 40.48.00.30 Paints and Paint Materials, November, 1981.

12) PTS 64.24.32.30. Insulating Refractory Concrete Linings, January, 1982.

13) PTS 34.51.01.31. Standard Vertical Tanks, Design and FabricationDecember, 1983.

14) PTS 64.51.01.31. Standard Vertical Tanks, Erection and TestingJune,1983.

15) PTS 34.18.51.10. Minimum Requirements For Construction andMaintenance of Tank Foundations, Bundwall, drainagesystems for Small Storage Installations.

B. PETRONAS Technical Specifications

1) PTS 30.48.00.31-P Protective Coatings and Lining

C. British Standards

1) BS. 5950 The use of Structural steel in Building

2) BS. 8004 Foundations, 1986.

3) BS. 8007 The structural use of Concrete for Retaining AqueousLiquids, 1987.

4) BS 12 Specification for Ordinary and Rapid Hardening PortlandCement, 1978.

5) BS. 146 Specification for Portland - Blast Furnace Cement.

6) BS. 1881 Methods of Testing Concrete

7) BS. 4027 Sulphate Resisting Portland Cement

8) BS. 8110 The Structural Use of Concrete, 1985.

9) IP Code Part 1 Electrical Safety CodePart 2 Refinery Safety Code

D. American Standards

1) API-650 Welded Steel tank for oil storage. (latest Edition)

2) ASME Code IX Welding Qualifications - Latest Edition

3) IIW /IIS-6-58 Radiography

4) ANSI/ACI 307 Design and Construction of Reinforced ConcreteChimneys

3. Bundwalls, Catchment Basin and Tank Pads

3.1 General

Bundwalls are the embankments or dwarf walls surrounding a storage tank or a group of storagetanks to confine oil spillage in case of tank rupture. Bundwalls may be built of compactedearth/sand, concrete or reinforced earth. For earth/sand type of bundwalls, slope protection isrequired. Rainwater drainage system within the bunded area shall also be incorporated in thedesign.

When natural sits topography permits and depending on the design philosophy, catchment basinmay be constructed to serve as a temporary holding basin for a group of tanks in the event oftank rupture. A catchment basin is a low lying area, normally adjacent to the tank group, walledup by embankments to form a basin. Oil spillage from any of the tanks shall be channelled intothe basin via drains and/or spillways.

A tank pad is a banked-up base supporting a storage tank.

3.2 Bundwalls

The capacity and sizes of bundwalls shall be designed to conform with Institute of Petroleum(I.P) Code Part 3 on Refinery Safety.

For compacted earth/sand type of bundwall; it requires a minimum top width of 2'-6" or one meterwith camber ridge + 50 mm and bank slopes as follow

(a) For sand fill - 1:2.

(b) For sandy clay fill - 1 :1 to 1:2.

(c) For clay fill - 1:1 to 1:1 .

(d) For cut slope - 1:1 max.

3.3 Catchment Area

The capacities of the basin and drains and/or spillways between the tanks and the catchmentbasin be designed to hydraulic analyses. Hydraulic model test may be required to verify theactual functioning of the design, if the scale of the project can justify such test.

3.4 Tank Pad

Tank pads for tanks greater than 6 meter in diameter shall normally consists of consolidated filland sand bed sealed with a layer of wet-sand-mix or sand and "cut back" mixture on top of the filland around the slope of the base.

The slope shall be protected with a layer of concrete, wet-sand mix, sand "cut back" mixture orasphaltic concrete with PTS 34.14.20.31. 1986 - Drainage and Primary Treatment System.,

4. Drainage System

4.1 General

Drainage system in the refinery and tank farm area shall be designed to handle all accidentallyoil- contaminated water, continuously oil-contaminated water and oil free water. The oil-contaminated water shall go through the required effluent treatment facilities to reduce oil contentin water to a level within an acceptable tolerance before it can be discharged into public water.

4.2 Drains

Oil free water may be discharged into public water by gravity flow via lined or unlined openchannels culverts etc.

Continuously oil-contaminated water from tank bottoms, emulsion treatment and dehydrationprocess water shall normally be piped to effluent treatment facilities via a closed drainagesystem. Design of refinery and tank farm drainage system shall conform to PTS 34.14.20.311986 - Drainage and Primary Treatment System.

4.3 Effluent Treatment Structures

Effluent treatment structures shall include oil interceptor, oil catcher, holding basin and WemcoFlotation units, etc. Functional aspects of these structures requires specialist's design. "Manualon Disposal of Refinery Wastes Volume on Liquid Wastes" by American Petroleum Institutionmay serve as a guide to the design of some of these structures. The structural aspects of thedesign shall conform to the following codes :

(i) BS. 8007 - The structural use of Concrete for Retaining Aqueous Liquids, 1987.

(ii) BS. 8110 - The structural use of Concrete.

(iii) BS. 5950 - The use of Structural Steel in Building.

5. Road and Carpark

Concrete, asphalt, wet-sand-mix and bitumen Macadam are the common types of road and carpark construction for refinery areas, tank farm areas, material yards and housing areas.

The roads shall be designed to conform with PTS 34.13.20.31. 1983 "Road, Paving Surfacing,Slope Protection and Fencing" and "Street, Drainage and Building, Uniform Buildings, By-laws,Malaysia" Latest Edition, adopting whichever criteria are more stringent of both.

For layout design of the car park, reference may be made to : (a) "Architectural GraphicStandard" by Charles G. Ramsey and Harold R. Sleeper, (b) "Time-Saver Standards for BuildingTypes" by Joseph De Chiara and John Hancock Callender.

Road Note 29, "A Guide to the Structural Design of Pavements for New Roads by RoadResearch Laboratory, Department of the Environment, United Kingdom and "Specification forRoad and Bridge Works" by Ministry of Transport, United Kingdom may also serve as referencesto the road and car park design.

6. Storage Tanks

For the storage of oil base liquid, steel tanks are generally used. The design of storage tanksshall conform to the following specifications and standards:-

PETRONAS Technical Standards

(1) PTS 30.48.00.31-P Protective Coatings and Lining


(1) PTS 34.51.01.31 - Standard Vertical Tanks, Design and Fabrication December, 1983.

(2) PTS 64.51.01.31 - Standard Vertical Tanks, Erection and Testing, June 1983.

(3) PTS 30.10.01.10 - Requisition for Storage Tank (Form No. PTS 34.51.01.93 ).

(4) PTS 34.28.00.31 - Steel Structure July,1984.

(5) PTS 00.00.10.05 - Approval Drawings Specifications (Form No. PTS 05.00.54.81).

(6) PTS 00.00.10.05 - Final Drawings Specifications (Form No. PTS 05.00.54.82).

AMERICAN STANDARDS

(7) API-650, Welded Steel Tank for Oil Storage latest edition.

(8) ASME Code, Section IX, "Welding Qualifications" latest edition.

(9) IIW/IIS-6-58 for Radiography.

7. Stacks

Stacks intended for use in oil refineries, chemical plants, gas plants and in exploration andproduction, shall be designed to conform with one or more of the following codes and standards:-


(1) PTS 34.24.26.31. Steel Stacks May, 1983.

(2) PTS 34.24.27.31 . Reinforced Concrete stacks March, 1987.

(3) PTS 34.00.01.30 . Minimum Requirements for Civil Design and Engineering June, 1983.

(4) PTS 34.19.20.31. Reinforced Concrete Foundations and Structures" July 1983.

(5) PTS 34.28.00.31. Steel Structures July, 1984.

(6) PTS 40.48.00.30. Paints and Paint Material November, 1981.

(7) PTS 64.24.32.30 Insulating Refractory Concrete Linings January 1982.

BRITISH STANDARDS

(8) BS 8004 - Foundations, 1986.

(9) BS 12 - Specification for Ordinary and Rapid hardening Portland Cement, 1978

(10) BS 146 - Specification for Portland - Blast furnace Cement.

(11) BS 1881 - Methods of Testing Concrete.

(12) BS 4027 - Sulphate-resisting Portland Cement.

(13) IP Model Code of Safe Practice in the Petroleum Industry, Part 1 - Electrical Safety Codeand Part 2- Refinery Safety Code.

AMERICAN STANDARD

(14) ANSI/ACI 307 - "Design and Construction of Reinforced Concrete Chimneys".

TITLEPREFACECONTENTSScopeReferences, Codes and StandardsBundwalls, Catchment Basin and Tank PadsDrainage SystemRoad and CarparkStorage TanksStacks