COVER25-02-2004KOCA4PWB.XLS.......CONTRACTORAREA.......FACILITY UPGRADE & RELOCATION OF U/G PROCESS PIPINGBFor Review and CommentsDPGKVK/PKMS.FOR GC 3, 4, 6, 7, 8, 21, 23, BS 140 & BS 150 (GROUP A)AFor Review and CommentsDPGKVK/PKMSBUNDWALLS CONTAINMENT CAPACITYREV.AMENDMENTSPRPDCKDAPPDAPPDDATEPREPARED.CHECKED.APPROVED.CALCULATIONSKOC APPROVALSAPPROVED.DATE.SCALEN ACONTRACTOR DOC. No.REV.K.O.C. DOC. No.REV.DEPARTMENTSIGNATUREDESIGNATIONDATEPROJECT -FACILITY UPGRADE & RELOCATION OF U/G PROCESS PIPINGJI-180-021-ECV-CAL-050BXXX-XX-XXXXFOR GC 3, 4, 6, 7, 8, 21, 23, BS 140 & BS 150 (GROUP A)PROJECT No.-EF/1500CONTRACT No.-26155

BUNDWALLS CONTAINMENT CAPACITYCALCULATIONS( FOR GC -21 )

IndexClient : Kuwait Oil CompanyProject : Facility Upgrade and Relocation of Under Ground Process PipingJob No :JI-180Doc No :JI-180-021-ECV-CAL-050Subject :BUND WALLS CONTAINMENT CAPACITYRev No :BCALCULATIONS ( FOR GC-21 )Prep. By :DipakCheckd. By :K. GirishINDEXSR NODESCRIPTIONPAGE NO1Introduction12Containment Capacity Calculations2.1 For Main Crude Oil Tank TK - 1526.32.2 For Test Tank TK-1527.52.3 For Wet Crude Tank 021-TK-001.72.4 For Dry Tank 021-TN-001B.93Design of Cantilever Walkway at Top of Dyke Wall114Design of Concrete Bund Wall4.1 Introduction134.2 Scope of Work134.3 Design of Concrete Bund Wall for Main Crude Oil Tank TK - 1526.154.4 Design of Concrete Bund Wall for Test Tank TK-1527.334.5 Design of Concrete Bund Wall for Wet Crude Tank 21-TK-001.514.6 Design of Concrete Bund Wall for Dry Tank 21-TN-001B.69ANNEXURE - I Piping & Instrumentation Diagrams for TanksANNEXURE - II Letter from KOC Ref: 26155/KP/L/0549 Dated 10th December, 2005.

1.0Client : Kuwait Oil CompanyProject : Facility Upgrade and Relocation of Under Ground Process PipingJob No :JI-180Doc No :JI-180-021-ECV-CAL-050Subject :BUND WALLS CONTAINMENT CAPACITYRev No :BCALCULATIONS ( FOR GC-21 )Prep. By :DipakCheckd. By :K. Girish1.0 IntroductionSR NOTABLE OF CONTENTSPAGE NO1.1Introduction11.2Design Basis11.3Reference Documents1

IntroductionClient : Kuwait Oil CompanyProject : Facility Upgrade and Relocation of Under Ground Process PipingJob No :JI-180Doc No :JI-180-021-ECV-CAL-050Subject :BUND WALLS CONTAINMENT CAPACITYRev No :BCALCULATIONS ( FOR GC-21 )Prep. By :DipakCheckd. By :K. Girish1.1 Introduction:This document describes the methodology adopted for Design of Tank Bund Wall for KOCFacility Upgrade & Relocation of U/G Process Piping project in Kuwait.1.2 Design Basis:a) Earthen bund wall :New bund wall is located clearing proposed pipeways and existing features. As the existing earthen bund wallheight can not be increased due to presence of many existing features on both sides of bund, top elevationof new bund wall is kept same as existing earthen bund wall for that tank.Proposed bund is sized to contain 115% of tank's nominal capacity. The free board available for the proposedbund is calculated. If the free board available is more than 600mm, the same free board is provided. If thefree board available for the proposed bund is less than 600mm, the free board available for the existing bund(I.e. before modifying the layout ) is calculated with a containment capacity of 115% of tank's nominalcapacity and a minimum free board of lesser of the following is provided.a) 300mm as per standard engneering practiceb) Free board available for the existing bund wall.Bund wall shall have side slopes of one (1) Vertical to one and one half ( 1 1/2) Horizontal. The top width shallbe kept minimum as 900 mm.b) RCC dyke wall design :Here, Dyke wall has been designed as a cantilever retaining wall and following critical cases has beenconsideredCase-1 Soil pressure and wind on one side of wall and empty on tank side.In this case cantilever wall has been analyzed for the active earth pressure from one side only,while checking for the stability, weight of earth from both the side has been considered.Case-2 Liquid pressure due to spilled liquid on tank side and soil pressure on the other side.In this case liquid presure & submerged soil pressure from tank side and dry soilpressure under passive condition from outside has been considered. While checking for thestability, liquid weight from tank side and weight of earth from both the sides have been considered.Soil parameters are used as per JI-180-000-ECV-SPE-001. The RC wall is designed as per BS 8110. Thecrack width for the thermal shrikange and flexure are calculated as per BS 8110. The crack width is limited to0.3mm as per BS-8110.1.3 Reference Documents:1. JI-180-000-ECV-SPE-001- Civil & Structural Design Philosophy2. KOC-G-007- Basic Design Data3. KOC-C-001- Basic Civil Engineering Design Data4. KOC-C-033- KOC Standard for Bund Wall for Storage Tanks5. KOC-L-027- KOC Standard for Layout, Spacing and Dyking of Storage Tanks

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2.0Client : Kuwait Oil CompanyProject : Facility Upgrade and Relocation of Under Ground Process PipingJob No :JI-180Doc No :JI-180-021-ECV-CAL-050Subject :BUND WALLS CONTAINMENT CAPACITYRev No :BCALCULATIONS ( FOR GC-21 )Prep. By :DipakCheckd. By :K. Girish2.0 Containment Capacity CalculationsSR NOTABLE OF CONTENTSPAGE NO2.1For Main Crude Oil Tank TK - 1526.32.2For Test Tank TK-1527.52.3For Wet Crude Tank 021-TK-001.72.4For Dry Tank 021-TN-001B.9

TK-1526Client : Kuwait Oil CompanyProject : Facility Upgrade and Relocation of Under Ground Process PipingJob No :JI-180Doc No :JI-180-021-ECV-CAL-050Subject :BUND WALLS CONTAINMENT CAPACITYRev No :BCALCULATIONS ( FOR GC-21 )Prep. By :DipakCheckd. By :K. Girish2.1 DESIGN CALCULATION FOR TANK BUND WALLTK - 1526 ( Main Crude Oil Tank )Bund Wall on 2 sides and Retaining Wall on 2 adjacent sides ( East & South Sides ) :Dia of tank=26.213mHeight of tank=12.192mCapacity of Tank=6037m3Capacity of Tank adding 15% extra, Q=6942m3from Doc.# KOC-L-027For calculation of capacity of tank the liquid height in the tank shall be considered as 1m lessthan the height of the tank.Bunded Area Sizing :Length of area enclosed at bottom, lb=56.28m( Conforms to safe distance criteria as per KOC-C-033 )55.85Width of the area enclosed at bottom,wb=49.40m49.40Effective height of Bund/Retaining Wall , d=2.50m2.55Side slope for Bund Wall, s1V :1.5Hfrom Doc.Length of enclosed area at ht. d, ld=lb+sd=60.03m# KOC-C-033Width of the enclosed area at ht d, wd=wb+sd=53.15mCapacity of enclosed area upto Ht. d, Vb=7438m3Height of Tank Fdn. above grade level, hf=0.38mDiameter of Tank Foundation, df=26.8mVolume occupied by Tank Fdn. above grade=214.4m3Adding 10% to take care of volume occupied by miscelleneous Pipe Support Fdn., Pipes and Access stairs etc. Vf=235.8m3Volume occupied by fill for Access Road inside enclosed area, Vr=256.9m3Net Capacity of Bunded Area V = Vb-Vf -Vr=6945.7m3Hence sizing of Bund wall is OKWidth of Bund Wall at Top=0.9mfrom Doc.Side slopes are protected by asphalt prime coat.# KOC-C-033Average top elevation of existing bund wall (north)=E+L 101.00Average top elevation of existing bund wall (south) =E+L 100.71Average top elevation of existing bund wall (west) =E+L 101.53Average top elevation of existing bund wall (east) =E+L 100.49Average ground level inside the bunded area=E+L 97.50Min top elevation of existing earthen bundwall=E+L 101.00Average height of bundwall within the bunded area=EL 101.00 - EL 97.50=3.50mCalculated height of liquid to be=2.50mcontained within the bunded areaThe liquid level to be contained within=EL 97.50 + 2.50the bunded area=E+L 100.00Free Board=0.30mThe top elevation required for R.C.C retaining wall=EL 100.00 + 0.30=E+L 100.30SayE+L 100.30However,keep the top elevation of retaining wall at EL 100.5 so as to match with that of existing earthen bundwall atthe junction.Top elevation of retaining wall=E+L 100.50mThe actual minimum freeboard available=EL 100.50 - EL 100.00=0.500mThe actual free board of 500mm for the bund wall is less than the 600mm required as per KOC-L-027.However, the free board provided meets the requirements of standard engineering practice which is 300mm.The height of R.C.C retaining wall=EL 100.50 - EL 97.50=3.00mTK - 1526 ( Main Crude Oil Tank )Tanklb = 56.2805wb =49.3974.52.2Access RampRetaining WallsPlan0.9 mBund wallSlope 1 :1.53.50 mFGLSection Details of Bund Wall3.00 mFGLSection Details of Retaining WallCALCULATION OF VOLUME OF RAMP.Top elevation of Access Ramp=E+L 101.25Bottom elevation of Access Ramp=E+L 98.40Height of ramp=2.85mSlope=1 V : 7.00 HLength of ramp=19.95mTaking 3% extra for curvature of ramp=20.55mArea of ramp=180.31m2Volume of ramp=256.95m3

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TK-1527Client : Kuwait Oil CompanyProject : Facility Upgrade and Relocation of Under Ground Process PipingJob No :JI-180Doc No :JI-180-021-ECV-CAL-050Subject :BUND WALLS CONTAINMENT CAPACITYRev No :BCALCULATIONS ( FOR GC-21 )Prep. By :DipakCheckd. By :K. Girish2.2 DESIGN CALCULATION FOR TANK BUND WALLTK-1527 (TEST TANK)Bund Wall on 2 sides and Retaining Wall on 2 adjacent sides ( East & North Sides ) :Dia of tank=13.106mHeight of tank=12.192mCapacity of Tank=1509m3Capacity of Tank adding 15% extra, Q=1735m3from Doc.# KOC-L-027For calculation of capacity of tank the liquid height in the tank shall be considered as 1m lessthan the height of the tank.Bunded Area Sizing :Length of area enclosed at bottom, lb=24.1mWidth of the area enclosed at bottom,wb=26.2mEffective height of Bund/Retaining Wall , d=2.51mSide slope for Bund Wall, s1V :1.5Hfrom Doc.Length of enclosed area at ht. d, ld=lb+sd=27.87m# KOC-C-033Width of the enclosed area at ht d, wd=wb+sd=30.01mCapacity of enclosed area upto Ht. d, Vb=1818.78m3Height of Tank Fdn. above grade level, hf=0.3mDiameter of Tank Foundation, df=13.7mVolume occupied by Tank Fdn. above grade=44.22m3Adding 10% to take care of volume occupied by miscelleneous Pipe Support Fdn., Pipes and Access stairs etc. Vf=48.65m3Volume occupied by fill for Access Road inside enclosed area, Vr=0.00m3Net Capacity of Bunded Area V = Vb-Vf -Vr=1770.1m3Hence sizing of Bund wall is OKWidth of Bund Wall at Top=0.9mfrom Doc.Side slopes are protected by asphalt prime coat.# KOC-C-033Average top elevation of existing bund wall (north)=E+L 100.55Average top elevation of existing bund wall (south)=E+L 100.31Average top elevation of existing bund wall (west)=E+L 100.99Average top elevation of existing bund wall (east)=E+L 100.39Average ground level inside the bunded area=E+L 97.50Min top elevation of existing earthen bundwall=E+L 100.31Average height of bundwall within the bunded area=EL 100.31 - EL 97.50=2.81mCalculated height of liquid to be=2.51mcontained within the bunded areaThe liquid level to be contained within=EL 97.50 + 2.51the bunded area=E+L 100.01The actual minimum freeboard available=EL 100.31 - EL 100.01m=0.300mThe actual free board of 300mm for the bund wall is less than the 600mm required as per KOC-L-027.However, the free board provided is as per the standard engineering practice.However,keep the top elevation of retaining wall at EL 100.5 so as to match with that of existing earthen bundwall atthe junction.Top elevation of retaining wall=E+L 100.50mActual Free Board available for retaining wall=EL 100.50 - 100.01=0.49mThe height of R.C.C retaining wall=EL 100.50 - EL 97.50=3.00mTK-1527 (TEST TANK)RETAINING WALL2.20wb =26.254.50lb =24.10TankPlan0.9 mBund wallSlope 1 :1.52.81 mFGLSection Details of Bund Wall3.00 mFGLSection Details of Retaining Wall

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WET CRUDE TANKClient : Kuwait Oil CompanyProject : Facility Upgrade and Relocation of Under Ground Process PipingJob No :JI-180Doc No :JI-180-021-ECV-CAL-050Subject :BUND WALLS CONTAINMENT CAPACITYRev No :BCALCULATIONS ( FOR GC-21 )Prep. By :DipakCheckd. By :K. Girish2.3 DESIGN CALCULATION FOR TANK BUND WALL021-TK-001 (WET CRUDE TANK)Bund Wall on 3 sides and Retaining Wall on 1 side ( on East side ) :Dia of tank=33mHeight of tank=15mCapacity of Tank=11968m3Capacity of Tank adding 15% extra, Q=13763m3from Doc.# KOC-L-027For calculation of capacity of tank the liquid height in the tank shall be considered as 1m lessthan the height of the tank.Bunded Area Sizing :Length of area enclosed at bottom, lb=60.09m( Conforms to safe distance criteria as per KOC-C-033 )Width of the area enclosed at bottom,wb=62.96mEffective height of Bund/Retaining Wall required to have 100% tank rated capacity , d=3.05mEffective height of Bund/Retaining Wall required to have 115% tank rated capacity , d=3.45Side slope for Bund Wall, s1V :1.5Hfrom Doc.Length of enclosed area at ht.'d' corresponding to 100% tank rated capacity, ld=lb+2sd=69.24m# KOC-C-033Width of the enclosed area at ht 'd' corresponding to 100% capacity, wd=wb+sd=67.535mLength of enclosed area at ht.'d' corresponding to 115% tank rated capacity, ld=lb+2sd=70.44Width of the enclosed area at ht 'd' corresponding to 115% capacity, wd=wb+sd=68.135Capacity of enclosed area upto Ht. 'd' corresponding to 100% tank rated capacity, Vb(100%)=12899.6m3Capacity of enclosed area upto Ht. 'd' corresponding to 115% tank rated capacity, Vb(115%)=14804.0Height of Tank Fdn. above grade level, hf=0.4mDiameter of Tank Foundation, df=33.6mVolume occupied by Tank Fdn. above grade=336.9m3Adding 10% to take care of volume occupied by miscelleneous Pipe Support Fdn., Pipes and Access stairs etc. Vf=370.6m3Volume occupied by fill for Access Road inside enclosed area, Vr=370.99m3Net Capacity of Bunded Area available corresponding to 100% tank rated capacity, V(at 100%) = Vb(100%)-Vf -Vr=12157.9m3Net Capacity of Bunded Area available corresponding to 115% tank rated capacity, V(at 115%) = Vb(115%)-Vf -Vr=14062.4m3Hence sizing of Bund wall is OKWidth of Bund Wall at Top=0.9mfrom Doc.Side slopes are protected by asphalt prime coat.# KOC-C-033Average top elevation of existing bund wall (north)=E+L 103.65Average top elevation of existing bund wall (south)=E+L 103.62Average top elevation of existing bund wall (west)=E+L 103.66Average top elevation of existing bund wall (east)=E+L 103.62Average ground level inside the bunded area=E+L 100.50Average top elevation of existing earthen bundwall=E+L 103.65Average height of bundwall within the bunded area=EL 103.65 - EL 100.50=3.15mCalculated height of liquid to be contained within the bunded area corresponding to 100% tank rated capacity=3.05mCalculated height of liquid to be contained within the bunded area corresponding to 115% tank rated capacity3.45mThe liquid level to be contained within the bunded area corresponding to 100 % tank rated capacity=100.5+3.05=E+L 103.55mThe liquid level to be contained within the bunded area corresponding to 115 % tank rated capacity=100.5+3.45=EL 103.950mFree Board available under 100% tank rated capacity=103.65-103.55=0.100mNOTE : For this tank, the existing available bunded area is not adequate to store the liquid volume corresponding to115% tank rated capacity. At present, there is no access road available for the bund. Since the access road is required to be provided, the available limited storage area gets further reduced.Due to these reasons, it is not possible to provide the freeboard under 115% tank rated capacity. However, it is still possible to contain the liquid corresponding to 100% tank rated capacity. But the free board available will be about 100mm which is less than the freeboard of 300mm as per standard engneering practice.In view of above, the top elevation of the proposed RCC retaining wall is kept at EL 103.650m so as to match with that ofthe existing earthen bund wall. The design of the retaining wall will be carried out considering the liquid level upto the topof the wall I.e. at EL 103.650m.The height of R.C.C retaining wall=103.65 - 100.5=3.15m021-TK-001 (WET CRUDE TANK)AccessRampTanklb=60.09wb=62.96Retaining WallPlan0.9 mBund wallSlope 1 :1.53.15 mFGLSection Details of Bund Wall3.15mFGLSection Details of Retaining WallCALCULATION OF VOLUME OF RAMP.Top elevation of Access Ramp=E+L 103.80Bottom elevation of Access Ramp=E+L 100.50Height of ramp=3.3mSlope=1 V : 7.00 HLength of ramp=23.1mTaking 3% extra for curvature of ramp=23.793mArea of ramp=224.844m2Volume of ramp=370.992m3

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21-TN-001B ( Dry Tank )Client : Kuwait Oil CompanyProject : Facility Upgrade and Relocation of Under Ground Process PipingJob No :JI-180Doc No :JI-180-021-ECV-CAL-050Subject :BUND WALLS CONTAINMENT CAPACITYRev No :BCALCULATIONS ( FOR GC-21 )Prep. By :DipakCheckd. By :K. Girish2.4 DESIGN CALCULATION FOR TANK BUND WALL21-TN-001B ( Dry Tank )Bund Wall on 4 sides with a part length ( 21m ) of Retaining Wall on East Side :Dia of tank=32.9mHeight of tank=12.2mCapacity of Tank=9092m3Capacity of Tank adding 15% extra, Q=10455m3from Doc.# KOC-L-027For calculation of capacity of tank the liquid height in the tank shall be considered as 1m lessthan the height of the tank.Bunded Area Sizing :Length of area enclosed at bottom, lb=62.98m( Conforms to safe distance criteria as per KOC-C-033 )Width of the area enclosed at bottom,wb=66.15mEffective height of Bund/Retaining Wall , d=2.45mSide slope for Bund Wall, s1V :1.5Hfrom Doc.Length of enclosed area at ht. d, ld=lb+2sd=70.33m# KOC-C-033Width of the enclosed area at ht d, wd=wb+2sd=73.50mCapacity of enclosed area upto Ht. d, Vb=11222.7m3Height of Tank Fdn. above grade level, hf=0.3mDiameter of Tank Foundation, df=33.5mVolume occupied by Tank Fdn. above grade=264.4m3Adding 10% to take care of volume occupied by miscelleneous Pipe Support Fdn., Pipes and Access stairs etc. Vf=290.9m3Volume occupied by fill for Access Road inside enclosed area, Vr=371.0m3Net Capacity of Bunded Area V = Vb-Vf -Vr=10560.8m3Hence sizing of Bund wall is OKWidth of Bund Wall at Top=0.9mfrom Doc.Side slopes are protected by asphalt prime coat.# KOC-C-033Average top elevation of existing bund wall (north)=E+L 103.62Average top elevation of existing bund wall (south)=E+L 102.25Average top elevation of existing bund wall (west)=E+L 102.00Average top elevation of existing bund wall (east)=E+L 102.00Average ground level inside the bunded area=E+L 99.00Min top elevation of existing earthen bundwall=E+L 102.00Average height of bundwall within the bunded area=EL 102.00 - EL 99.00=3.00mCalculated height of liquid to be=2.45mcontained within the bunded areaThe liquid level to be contained within=EL 99.00 + 2.45the bunded area=E+L 101.45Free Board available=EL 102.00 - EL 101.45=0.550However,keep the top elevation of retaining wall at EL 102.00 so as to match with that of existing earthen bundwall atthe junction.The height of R.C.C retaining wall=EL 102.00 - EL 99.00=3.00mThe actual free board is slightly less than 600mm requirement as per KOC-L-027. However, the actual free boardmeets the requirements of standard engineering practice.21-TN-001B ( Dry Tank )Retaining Wall20.7 4.2AccessTankRampwb=66.15lb= 62.98Plan0.9 mBund wallSlope 1 :1.53.00 mFGLSection Details of Bund Wall3.00 mFGLSection Details of Retaining WallCALCULATION OF VOLUME OF RAMP.Top elevation of Access Ramp=E+L 102.30Bottom elevation of Access Ramp=E+L 99.00Height of ramp=3.30mSlope=1 V : 7.00 HLength of ramp=23.1mTaking 3% extra for curvature of ramp=23.79mArea of ramp=224.84m2Volume of ramp=370.99m3

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3.0Client : Kuwait Oil CompanyProject : Facility Upgrade and Relocation of Under Ground Process PipingJob No :JI-180Doc No :JI-180-021-ECV-CAL-050Subject :BUND WALLS CONTAINMENT CAPACITYRev No :BCALCULATIONS ( FOR GC-21 )Prep. By :DipakCheckd. By :K. Girish3.0 Design of Cantilever Walkway at Top of Dyke WallSR NOTABLE OF CONTENTSPAGE NO3.1Design Data113.2Loading Calculation113.3Bending Moment And Shear Force Calculation11

Walk Way DesignClient : Kuwait Oil CompanyProject : Facility Upgrade and Relocation of Under Ground Process PipingJob No :JI-180Doc No :JI-180-021-ECV-CAL-050Subject :BUND WALLS CONTAINMENT CAPACITYRev No :BCALCULATIONS ( FOR GC-21 )Prep. By :DipakCheckd. By :K. Girish3.0 Design of cantiliver walk way at top of dyke wall :3.1 DESIGN DATA :Length of cantilever platform ( L )=0.5mThickness of wall at top ( twall )=0.3mEffective Length of cantilever platform ( Leff )=L - twall/2=0.35mThickness of Cantilever Walkway ( t )=0.15mClear Cover to Reinforcement ( c )=75mmDia of Reinforcement in wall ( f )=10mmEffective Thickness of Cantilever Walkway ( teff )=t -c - f/2mm=70mmDensity of Concrete ( gc )=24kN/m3Grade of Concrete ( Fcu )=30N/mm2Yield Strength of reinforcement ( Fy )=414N/mm23.2 LOADING CALCULATION :Live Load on Cantilever Platform ( LL )=5kN/m2(Ref. 3.3.1 of JI-180-000Dead Load Due to self Weight ( DL )=t x gcECV-SPE-001 )=3.6kN/m2Total Load On Cantilever Platform ( W )=DL + LL=8.6kN/m23.3 BENDING MOMENT AND SHEAR FORCE CALCULATION :Support Moment ( Madd )=W Leff2 / 20.53kNm/mShear Force ( Wadd )=W L=4.3kN/mFactor for dead load=1.43.2.1.2.2 BS 8110-1Factor for live load=1.6Factored load=1.4 ( 3.6 ) + 1.6 ( 5 )=13.04kN/mFactored bending momentMu=13.04 ( 0.35 )^2 / 2=0.8kN/mCantilever PlatformNow as per clause 3.4.4.4 of BS 8110 ( Part - I )0.5k=Mu / fcu bd2=0.80x 1060.3530x 1000x 70x 70=0.005