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PURPOSE This practice establishes guidelines and recommended procedures for the design of Exchanger, Heat Exchanger and Horizontal Drum foundations using AFES(=Automatic Foundation Engineering System). AFES can design Exchanger foundations as either soil- or pile-supported footings. CONTENTS This practice comprises the following:
Create or Open New Project Setting Soil and Pile Parameters. Creating New Structure. Exporting Load Combination. Assign Foundation Grouping. Editing footing sizes and other parameters. Pier and Footing Reinforcement Set Pile Layout for Pile Foundations. Import Load Combination for various foundation groups. Performing Design and Analysis functions. Quantity BOM(Bill of Material) function Construction Drawing Export 3D Modeling Data (PDMS, PDS Frame Work Plus)
There is a need to gather all necessary data from responsible disciplines such as load data of machine or equipment from Mechanical group, etc. before proceeding to modeling. You can input loads directly to AFES through the Load Case/Combination feature or import superstructure analysis result files for foundation analysis and design.
Below figures are foundation types commonly used for Horizontal Vessel and Exchanger equipment supports.
Use : Hex Foundation Modules
Design data sample for equipment is shown below based from actual projects. This equipment is a Exchanger and Horizontal Drum supported by rectangular shape foundation. DESIGN DATA Equipment Design Data
Sample spreadsheet calculation for wind and seismic load is presented below which was applied for actual project. This kind of calculation can be done by manual, excel, visual basic or in any form provided to satisfy code and standard requirements.
b) Select New Project option then click OK button. A window dialogue will display as shown.
1.2 Open Existing Project a) From File menu, select New/Open Project. A window will display as shown.
2. Setting Soil and Pile Parameters. Setting of constants options include design information that AFES needs in order to design a foundation. This includes a number of parameters such as design code, safety factor, bearing capacity of soil, capacity of pile, material and unit weight, clear cover, allowable increase of soil, allowable increase of pile, strength reduction factors, supports and anchor bolt options. In case of New project, set all design parameters from the Setting of Constant form. 2.1 Set Bearing Capacity of Soil from the Setting of Constant command. a) Click Setting of Constant button. b) Select Bearing Capacity of Soil tab.
c) Enter name in the Soil Bearing Capacity Name text box. d) Enter Soil Bearing Capacity (Qa) value. e) Click Save button.
2.2 Set Capacity of Pile from the Setting of Constant button. a) Select Capacity of Pile tab.
b) Enter name in the Pile Name text box. c) Select Pile Type. d) Select Pile Shape. e) Enter values for Pile dimensions f) Enter values for Allowable Capacities. g) Enter values for Elastic Modulus (Ep) and Pile Area. h) Click Save button.
3. Creating New Structure. Every input and output data can be saved in AFES Data Base according to projects, which provide work efficiency in control over project information. An engineer is able to create a file for a new project, reuse data from projects conducted previously, or eliminate old and useless data for the users own sake. 3.1 Choose Create New Structure button. Add : New Structure Name dialog window will appear. Input structure name, and then click on the New button.
d) Click Export button. e) Choose directory to save file, assign file name then click Save button.
The foundation modules in red box shown in above figure are normally used for Horizontal Vessel and Exchanger equipment. At the end of this step, we will create the structure as shown below.
5.1 Click Geometric Data button. 5.2 Create 8 nodes by clicking Add button 8 times.
5.5 Assign group for nodes 1 and 5. a) Click New button. b) Assign name from the Group name text box. c) Select Heat_Excng from the Group type. d) Select Non Pile fdn. option. e) Select Same size. f) Select nodes 1 and 5 from the Using node list form. g) Click arrow pointing to the right. h) Click Save button.
5.6 Assign group for nodes 2 and 6. a) Click New button. b) Assign name from the Group name text box. c) Select Heat_Excng from the Group type. d) Select Non Pile fdn. option. e) Select Same size. f) Select nodes 2 and 6 from the Using node list form. g) Click arrow pointing to the right. h) Click Save button.
5.7 Assign group for nodes 3 and 4. a) Click New button. b) Assign name from the Group name text box. c) Select Heat_Excng from the Group type. d) Select Non Pile fdn. option. e) Select Same size. f) Select nodes 3 and 4 from the Using node list form. g) Click arrow pointing to the right. h) Click Save button.
5.5 Assign group for nodes 7 and 8. a) Click New button. b) Assign name from the Group name text box. c) Select Heat_Excng from the Group type. d) Select Non Pile fdn. option. e) Select Same size. f) Select nodes 7 and 8 from the Using node list form. g) Click arrow pointing to the right. h) Click Save button.
b) Click Feature Data/Dimension button. c) Choose SUPT-01 in the Soil Name selection.
<Footing tab>
<Pier tab> d) Enter values as shown in the Feature form for Footing. e) Click Save button. 6.2 Edit footing size of group G2. a) Select G2 from the Group selection in top menu.
b) Click Feature Data/Dimension button. c) Choose SUPT-01 in the Soil Name selection.
<Footing tab>
<Pier tab>
d) Enter values as shown in the Feature form for Footing and Pier. e) Click Save button. 6.3 Edit footing size of group G3. a) Select G3 from the Group selection in top menu.
b) Click Feature Data/Dimension button. c) Choose SUPT-01 in the Soil Name selection.
<Footing tab>
<Pier tab> d) Enter values as shown in the Feature form for Footing. e) Select T SUPPORT (RECTANGLE) for pier shape. f) Enter values as shown in the Feature form for Pier. g) Click Save button. 6.4 Edit footing size of group G4. a) Select G4 from the Group selection in top menu.
b) Click Feature Data/Dimension button. c) Choose SUPT-01 in the Soil Name selection.
<Footing tab>
<Pier tab>
d) Enter values as shown in the Feature form for Footing. e) Select T SUPPORT (RECTANGLE) for pier shape. f) Enter values as shown in the Feature form for Pier. g) Click Save button.
7. Adding Tie-Girder
The Tie-Girder Data command is used to add beams between two supports. It can be located to any point above the footing. The tie-girder dimension and reinforcement bar arrangements can also set in the dialogue window. 7.1 Add tie-girder between piers 2 and 6. a) Click Tie-Girder Data command button. b) From your mouse, select node 2 and node 6 then click Add tie girder message when it appears.
c) Set values in the form as shown in figure below then click Save button.
7.2 Add tie-girder between piers 4 and 8. a) Click Tie-Girder Data command button. b) From your mouse, select node 4 and node 8 then click Add tie girder message when it appears.
c) Set values in the form as shown in figure below then click Save button.
8. Pier and Footing Reinforcement The Reinforcement Data command is used to assign bar sizes and spacing for piers and footings. Reinforcement bar sizes depend on the design code designated in the Setting of Constant command. Set of bar array options are available in the Footing option. The arrangement of footing bars are parallel to the X and Y axis except for Tank1 and Tank2 Ring type modules which are in radial and longitudinal directions. Below are based from our company standards. Minimum Pier Reinforcement Piers should be designed as cantilever beams with two layers of reinforcement. When the required reinforcing approaches max, investigate the pier as a column. Size and reinforcement for each pier should normally be the same. Dowel splices are not required if the vertical pier reinforcing projection is less than 6 feet in height, or the rebar size in feet above the top of the footing. For cases that exceed this limit, use dowels with minimum projections required for tension splices in accordance with Building Code. Minimum reinforcing for piers is #5 at 12 inches on each face with #4 ties at 12 inches. Place double ties at top of piers to protect anchor bolts. All ties should encircle the vertical reinforcement. Pier ties are not normally detailed as column ties. If longitudinal reinforcing is not required to resist vertical loads, as is normally the case, through ties are not required. Size and reinforcement for both columns should normally be the same. Use dowels to transfer the column loads to the footings. Minimum dowel projection should be that required for a tension splice in accordance with Building Code. Minimum Footing Reinforcement The minimum amount of bottom reinforcing is #5 at 12 inches c/c. If top reinforcing is required, minimum reinforcing is #4 at 12 inches c/c.
From the main tool bar, click the Reinforcement data shown in below figure.
a) Set Array Type Select from the array types of footing reinforcement layout. Different forms for single and double l ayer arrangement are presented.
c) Select Save then Close button. c) Select Pier tab. Enter the values of footing re-bar as shown.
d) Select Save then Close button. 8.2 Heat Exchanger Footing with T-Shaped Pier
a) Set Array Type Select from the array types of footing reinforcement layout. Different forms for single and double
d) Select Save then Close button. Fore further discussions, refer to Help documents.
Repeat above steps in creating new circular pile array arrangement then click Add Draw to include to
defined pile arrangement. 9.2 Set Pile Arrangement for foundation group G4. (Rectangular by Coordinates) a) Select G4 from the Group selection in top menu.
b) Click Pile Data command. c) Select Coordinates. d) Select Origin Point. c) Select PHC-12 from the Pile Name selection. d) Click Add button 8 times to create 8 piles. e) Enter coordinate values from the corresponding text boxes as shown. f) Click OK button.
Test Weight (Dt) The test weight is defined as the empty weight of the exchanger/vessel (De2) plus the weight of test fluid (usually water) and any attached piping and equipment required for the hydrostatic test. This information is taken from the vessel/exchanger drawings/data sheets. Note that this load condition is considered only when the exchanger/vessel is to be field-hydrotested. Verify with the Mechanical Discipline for this condition. Wind Loads (W) Transverse and longitudinal wind loads shall be determined in accordance with Design Guide 3DG-C01-00001 unless project criteria dictates otherwise. No allowance shall be made for shielding of wind loads by nearby equipment. The calculated design moments and shears due to wind load should be compared to those shown on the exchanger/vessel drawings. In case of major discrepancies between calculated wind loads and the loads shown on the equipment drawings, coordinate with the Mechanical Discipline for resolution. Seismic Loads (E) Seismic loads shall be determined in accordance with procedures presented in Company Design Guide unless project criteria dictates otherwise. The longitudinal seismic force shall be resisted by the fixed end pier only unless the piers are tied together by tie beams below the base plates. Transverse seismic forces shall be resisted by both piers using saddle or base plate reactions as the basis for computing base shear. The horizontal seismic loads shall be applied 100% in one direction and 30% in the orthogonal direction, i.e., E = (1.0 EH1 0.3 EH2) and E = (0.3 EH1 1.0 EH2). Thermal Load (T) The thermal load is defined as the load which results from thermal expansion or contraction of the exchanger/vessel in the longitudinal direction. The maximum thermal force is equal to the maximum static friction force (frictional resistance) acting at the equipment sliding support before the saddle begins to move. The frictional resistance equals the coefficient of friction times the vertical support reaction. The thermal load considered in foundation design shall be the smaller of the following: (a) The maximum pier reaction at the sliding end times the coefficient of friction of the sliding surfaces. (b) The force required to deflect each pier one-half the amount of the total thermal expansion between supports (assuming thermal loads of equal magnitude, but opposite directions, act on each pier). Generally, for short piers, the frictional force discussed in item (a) above governs the design. If it is impractical to provide for the thermal load in the cantilever pier design, a tie beam located below the vessel base plates may be utilized to resist the thermal load.
Bundle Pull Load (Lb) The bundle pull load is applicable only to foundations supporting exchangers with a removable tube bundle. It is the longitudinal force which results from the tube bundle removal operation during maintenance. This force shall be applied at the center of bundle elevation. In case of stacked exchangers, the more (most) critical load due to bundle pull, applied at the center of the respective bundle, shall be used. The force due to bundle pull shall be resisted by the fixed end pier only. Bundle pull load may be omitted if a bundle-pulling extractor is used for removal of the bundle. The method of bundle removal should be listed in the project design criteria. Unless the project design criteria dictates otherwise, the bundle pull load is considered to be 100% of the bundle weight. Bundle pull load should be considered as live load for assigning load factors. Piping Loads (Dp) Nozzle loads imposed by piping under operating conditions (including thermal effects on piping) shall be considered in the foundation design. loads Coordinate with the Pipe Stress Group for determination of these
LOAD COMBINATIONS Concrete Foundation Design The following factored load combinations should be used for design of the foundations
(a) 1.4 (Do + T + Dp) (b) 0.75 [1.4 De2 (or 1.4 De1)] 1.6 W (c) 1.2 De2 1.0 E (d) 0.75 (1.4 Do + 1.4 T + 1.4 Dp) 1.6 W (e) 1.2 (Do + T + Dp) 1.0 E (f) 1.4 De2 + 1.7 Lb (for exchanger foundations only) (g) 1.2 Dt Both the longitudinal and transverse directional wind or earthquake loads should be included in the loading
combinations. The load factors shown above are based on ACI 318, except for load combinations (c) and (e), which are based on the slightly more conservative requirements of IBC 2000. Also, in load combination (g), the factor of 1.2 is used (instead of 1.4) due to the transient nature of hydrotesting conditions. The load combinations 0.9D (1.6W or 1.0E), as listed in ACI 318, do not need to be considered since they are covered by load combinations (b) and (c). Wind load is calculated in accordance with ASCE 7-98 (including the directionality factor) and seismic load is calculated in accordance with IBC 2000 (based on strength-level methods, rather than service-level). If wind load is calculated using another code which does not include the wind directionality factor, the load factors for wind in the various load combinations should be reduced appropriately. Similarly, for service-level seismic loads based on another code, the seismic load factors should be increased as appropriate. (See Section R9.2 of ACI 318 for guidance.) The weight of the foundation and of the soil on top of the foundation shall be included as dead load in all of these load combinations. You can actually create new load combinations through the Load Combination button but in this example, we will use Import command. a) Click Load Combination button. The Load Combination form will display as shown.
b) Click Import button. c) Access the load combination file then click Open button. A warning message will appear as shown.
d) Select appropriate button as explained in the warning message form. e) Click Save button. Repeat same procedure for the other foundation groups.
11.2 Select Foundation Design New Version. 11.3 Click OK button. For through discussion on setting other functions such as General, Temperature and Shrinkage/Stability, Tank Design, Detail Report Option and Contents, you may refer to help menu. 11.4 Using Conventional Rigid Method. a) Select Rigid Method Foundation Design option.
c) Click OK button.
12.2 For All Foundation structures. a) From Design menu, select Quantity (BOM) then Take off BOM 3D (All Structure).
c) Click OK button. d) Check structures to include BOM Take off calculation from the form below.
e) Click OK button.
14. Export 3D Modeling Data (PDMS, PDS Frame Work Plus) Today, plant design works involve many design parts, modeling objects from each part allows other parts to assess those object on their work process helping streamlining the work process through project completion. A 3D foundation model of the objects designed by various design parts effectively communicates the geometric design data. Therefore automating the work process from design to 3D modeling forms an integral component of reducing overall project cost. With our design to modeling interface from AFES to Frameworks Plus, you will experience significant productivity. 14.1 Export to PDS a) Click Export PDS Data button. A dialogue form will display as shown.
b) Set Output unit and coordinate mapping options. c) Check Send Model Data to PDS option then click OK button. 14.2 Export to PDMS a) Click Export PDMS Data button. A dialogue form will display as shown.
b) Set various parameters accordingly and click OK button. For further discussions, you may refer to Help PDF manuals.