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Application of Controlled Modulus Columns For Refinery and Petrochemical Tank Farm
Application of Controlled Modulus Columns For Refinery and Petrochemical Tank Farm
1- Menard Geosystems Sdn Bhd, Kuala Lumpur, Malaysia Received: 1 November 2016
2- Menard Geosystems Singapore Pte Ltd., Singapore. Revised: 11 July 2017
3- Menard SNC, Paris, France Accepted: 14 August 2017
Printed: 20 October 2017
1. Introduction
Nghi Son Refinery Petrochemical Complex Project (NSRP) is located in the Mai
Lam Area, Tinh Gia District, Thanh Hoa Province, Vietnam. The project is situated
about 200 km south of the Vietnamese capital, Hanoi, and approximately 80 km north of
Vinh City. The site, situated near the East Vietnam Sea coast, is surrounded by a few
hills in the north-western and southern parts. The ground improvement scope of work
awarded to Menard relates to 32 tanks (as depicted on Figure 1) being part of a
petrochemical complex as well as energy facilities, pipelines and storage systems.
Nghi Son refinery is the second refinery built in Vietnam, after Dung Quat refinery
that is operational since 2009 and for which Menard was also in charge of the
reinforcement of the tanks with diameter up to 69 m. The ground improvement adopted
was a combination of Dynamic Compaction and Dynamic Replacement (DC/DR).
2. Ground conditions
A significant number of field exploration works were carried out between July to
November 2013 to determine the general ground conditions on site and more particularly
below each tank’s footprint. This ground investigation campaign consisted in deep
boreholes with standard penetration test (SPT) as well as cone penetration test (CPT),
some with pore-water pressure measurement (CPTu). Table 1 gives the frequency at
which those tests have been performed as a function of the diameter of the tank.
It has to be noted that the distribution and the frequency at which the CPTu has been
done around the circumference of the tanks corresponds to those advised by API 653
(2003) when positioning the settlement markers prior to the surveying of the settlement
during an hydrostatic testing. Consequently, as CPTu below the tank shell were equally
distributed, they have been used to assess the deformed shape of the bottom plate below
Journal of Earth Engineering (JEE), Vol. 2, No.1, (2017), 13-26.
Application of Controlled Modulus Columns for Refinery … 15
the tank shell during the design stage. Overall, there are more than 80 boreholes with
SPT and 460 cone penetration tests that were performed below the 32 studied tanks.
Also, typical laboratory tests were performed on samples taken from boreholes such as
grain size analyses, Atterberg limits, triaxial tests and consolidation tests.
The geology of the site is made up of Quaternary deposits over Triassic bedrock. The
Quaternary Vinh Phuc Formation is shown covering most of the site and corresponds to
silty clay, clay, sandy silt and sand of 5 m to 25 m thick. The upper part of the stratum
comprises continental deposits of alluvial origin while the lower part appears to be
originated from fluvio-marine deposits, including a very soft marine clay layer (C3),
with traces of organic matters. The complex layering of soils encountered on site could
be explained by the deltaic nature of the fluvio-marine deposits.
The underlying Triassic, Dong Do Formation, has been identified as sandstone,
gritstone, siltstone and coaly shale. No faulting on the site has been shown on the
geological map. The general stratigraphy is summarized in Table 2.
The first four layers encountered on site are highly heterogeneous in terms of
strength, deformation and thickness as revealed by the soil investigation campaign. They
are defined as follow:
Layer AB (i.e. Layer A and Layer B): comprises the recent fill for the upper part and
man-made ground, top soil and subsoil for the lower part. It is mainly made up of
sandy silt and it is characterized by high heterogeneities in terms of strength and
deformation characteristics. Its thickness scatters from 4 m to 5 m in the studied area.
Layer C1: mainly composed by a layer of medium dense sand to dense sand. This
layer is encountered in all the studied area and its thickness varies from 0.5 m to 5 m.
Also, its compactness, although heterogeneous with qc values scattering from 5 MPa
to 50 MPa with an average of 15 MPa, presents good geo-mechanical properties.
Layer C2: corresponds to soft to firm clayey soils. Silt can also be encountered. It is
located below AB or C1 and can also be found between C3 and D1 layers.
Layer C3: corresponds to a soft to very soft clay layer with traces of organic matter
and fine grained sand that is explained as a result of marine deposits. This layer is
characterized by a very soft nature that has been analyzed with careful attention. It is
characterized by SPT blow count not more than 4 and q c not more than 0.7 MPa.
Layer D1: corresponds to firm to very stiff clayey soils. It is encountered around 15
m below the natural ground level. The very stiff part of this layer presents enough
strength, typically with SPT blow count greater or equal to 18, and will be used as
anchorage for the CMC.
Journal of Earth Engineering (JEE), Vol. 2, No. 1, (2017), 13-26.
16 F. Leclaire & Y. Bourgoin
In summary, the total area included in the scope of works for this project can be
divided into 3 zones:
Zone A where the sensitive part of the Layer C3 has a thickness greater than 2 m and
where the thickness of the Layer C1 is less than 3 m.
Zone B where the sensitive part of the Layer C3 has a thickness less than 1m and
where the thickness of Layer C1 is less than 4 m.
Zone C where the sensitive part of the Layer C3 has a thickness less than 1m and
where the thickness of the Layer C1 is greater than 4m. Figure 2 and Figure 3 present
respectively the typical cone resistance profile of each zone and their distribution
thorough the project area.
Ground water level was deducted from the pore-water pressure induced by the
penetration of the cone. It varies from 0 m to approximately 3 m below the natural
ground level.
The following three types of foundations below the footprint of the tank were
planned to be used:
Earth foundation with earth mound (EM, Figure 4).
Earth foundation with concrete ring wall (RW, Figure 5).
Slab foundation with concrete ring wall (SF, Figure 6).
Figure 4. EM Cross-section
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18 F. Leclaire & Y. Bourgoin
Figure 5. RW Cross-section
Figure 6. SF Cross-section
Loads to be considered for the CMC design were larger (up to nearly 350 kPa in some
cases) than the loads presented in Table 3 as a result of the installation of the foundation
system, which either involved solely the placement of fill (e.g., Figure 4) or the
placement of fill coupled with the installation of a concrete structure (e.g., Figure 5 and
Figure 6), below and above the natural soil level.
Table 4 presents the types of foundation below the tank shell as well as the stratigraphy
encountered beneath its footprint for all the tank types encountered.
4. Settlement criteria
Settlement criteria are presented in Table 5. The differential settlement below the
tank shell directly impacting the structural integrity of the tank and it has been chosen to
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Application of Controlled Modulus Columns for Refinery … 19
define the circumferential criterion as the most stringent one in order to minimize the
out-of-plane deflection. Therefore, a fixed value of 13mm/10m has been retained,
regardless the steel properties of the tank shell and the diameter of the tank.
mechanically linked to the structure but the transfer of the load is ensured by a well
compacted granular fill called the load transfer platform (LTP). Therefore, rather than
transferring the load directly to the bearing layer like piles do, the load is mainly
transferred to the inclusions thanks to an arching effect occurring in the LTP as depicted
on Figure 8a. However, as opposed to piles, the load is never transferred entirely to the
CMC heads but to the surrounding soil too, as the LTP cannot transfer the load with an
efficiency of 100%.
The ratio of load transferred to the inclusions and the surrounding soil is therefore
controlled by the spacing between the columns, the replacement ratio and the material
properties and thickness of the LTP. Therefore, negative skin friction always develops
along the inclusions and should be added in the force equilibrium equations when
designing CMC. This state of equilibrium involves the following acting forces as
depicted on Figure 8b (Combarieu, 1988):
1. The vertical load (QP(0)) at the top of the CMC.
2. The negative skin friction (FN) acting on the upper zone of the CMC.
3. The positive skin friction (FS) acting on the lower zone.
4. The vertical reaction at the tip (QP(L)).
The CMC grid below the tank footprint has been designed considering that, referring
to the different criteria presented on Table 5, the circumferential criterion was the most
stringent one. As such, two different configurations have been adopted on each tank. At
the edge, two rows of CMC have been positioned following the footprint of the tank
shell, to make sure that the foundation would homogeneously be settling around the
structure. On the other hand, a rectangular configuration has been retained at the centre,
allowing an optimization of the quantities rather than if the geometry of the mesh would
have been kept circular from the edge to the centre.
In addition, the spacing of the columns has been tightened in the edge part, to avoid
any unaffordable deflection of the tank bottom plate below the tank shell. Therefore, the
hydrotesting vertical load taken by a CMC, N max, has been reduced from 70 t to 60 t at
the edge compared to a CMC located in the central part. Finally, the CMC composing
the last row were installed in staggered rows with an offset depending on the type of
foundation to avoid any hard point below the tank shell, increase stability of the
foundation and prevent high bending moments at the head of the inclusions. As such, an
offset of 40 cm from the middle of the foundation was retained for the earth mound; for
which the footprint was larger compared to the footprint of the concrete foundations.
Below concrete ring walls, an offset of 20 cm was therefore retained. Figure 9 presents
the general configuration of the CMC below the footprint of a reinforced tank.
As the CMC need to be anchored usually between 0.5 m to 1.0 m in the competent
layer, their length depends on the depth and thickness of the bearing layer. Layer D1 has
been retained as the anchoring layer. Also, as the layer C1 was exhibiting good in-situ
properties, a concept of short/long columns has been implemented on site depending on
the zone the studied tank was belonging to. Therefore, the following reinforcement
scheme was followed:
Zone A: only long columns as this zone is the most sensitive in terms of strength and
deformation
Zone B: short/long columns configuration has been adopted whenever possible i.e.
when the sand layer was thick enough to be used as anchoring layer and the Layer C3
thin enough to not undergo large settlements.
Zone C: short/long columns configuration has been systematically adopted.
The maximum and minimum lengths of CMC adopted in this project are presented in
Table 6. In any case, short columns have been anchored with a maximum frequency of 1
on 2 columns in the centre and 1 on 4 columns in the edge (corresponding to 1 on 2
columns on the edge of the second to last row) in the layer C1. It has to be noted that this
particular configuration was not adopted for the peripheral row where only long columns
i.e. anchored in the layer D1 were installed. Table 7 summarizes the philosophy adopted
for the reinforcement of the tanks.
Finally, a 3D model has been run to determine the influence of the concept of short
and long CMC (see Figure 11) in terms of settlement and stress but also to check if it
was possible to take into account this influence in a 2D model, which would be solely
used during the design stage.
In terms of deformation, analysis outputs showed that the average between the
settlements given by the short CMC and the long CMC 2D unit-cell models was almost
equal to the settlement given by the more rigorous 3D model (15.3 cm vs 14.2 cm).
Calculating this average made sense as the ratio of long CMC over total number of CMC
was equal to 1/2 in the 3D model. In case this ratio was different, subsequent
calculations showed that this average could indeed be weighted by this ratio to get a
conservative value but still close to the value output from the 3D model.
In terms of vertical stress in the inclusions, the maximum stress for a short CMC is
the same whether or not the short CMC is coupled with a long CMC (3.66 MPa vs 3.67
MPa). However, for the 3D model, the maximum load transferred into the long CMC is
greater, of about 30%, than the maximum load in the 2D model’s long CMC
configuration. This percentage corresponds to the differential of load that is not taken by
the short CMC (5.98 – 3.66 = 2.32 MPa). A particular care has therefore been taken to
choose a mortar with sufficient resistance (see Table 6) so that the maximum vertical
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Application of Controlled Modulus Columns for Refinery … 25
stress in the CMC would always be within the acceptable ranges according to the
Eurocode 2, whichever configuration was retained. Figure 11 shows the load distribution
between the CMC in case of a short/long system.
Figure 11. 3D Model and Load Distribution for the Short/Long CMC
8. Conclusions
CMC is a modern ground improvement technology with considerable benefits such
as independence of lateral confinement from in-situ soil, ability to reduce settlements
more than other ground improvement technique involving reinforcement of soil,
negligible amounts of spoil per CMC with a vibration-less and extraction-less boring
technique, high production rates and absence of mechanical link between the CMC and
the structure. CMC has quickly became a game changer in EU countries and in the USA
where this technology is nowadays widely spread. In fact, significant references and
experience using this technique, which has already been successfully implemented
worldwide on numerous of projects (such as industrial and commercial buildings,
housing development, road and railway embankments, windfarm, airport runways,
power and petro-chemical plants, etc.) for the past two decades are well documented
(Racinais et al., 2016).
References
American Petroleum Institute, 2003, API 653, "Tank Inspection, Repair, Alteration, and
Reconstruction", 3rd edition, Appendix B – Evaluation of Tank Bottom Settlement.
Building Research Establishment (BRE), 2000, "Specifying Vibro Stone Columns", pp:13-14.
Comité Français de Mécanique des Sols (CFMS), 2011, "Recommendations for the Design,
Calculation", Construction and Quality Control of Stone Columns under Buildings and
Sensitive Structure.
ASIRI Standard, 2013, "Recommendations for the Design, Construction and Control of Rigid
Inclusions Ground Improvement", Presse des Ponts, Paris.
Combarieu, O., 1988, "Amélioration des sols par inclusions rigides verticales", Application à
l'édification de remblais sur sols médiocres, Revue Française de Géotechnique, Vol. 44, pp: 57-
79.
Varaksin, S., Hamidi, B., and Racinais, J., 2014, "The Thin Line between Deep Foundations and
Soil Improvement", Proceedings of the International Conference on Integrated Use and
Protection of underground spaces, Kungur Ice Cave, Perm Region, Russia.
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206-1", Part 1: Method of specifying and guidance for the specifier, 2nd Edition.
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Conference & 2nd AGSSEA Conference (19SEAGC & 2AGSSEA), Kuala Lumpur, Malaysia.
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