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MARYNEAL DSI Hydrated Lime System –

Civil & Structural Engineering Scope of Work


STM project #SE180201
12Apr2018

Civil and Structural Engineering scope is as defined below.


Plant location Buzzi Unicem Maryneal TX plant.

Description of silo and piping and “alleviator / De-aerator” have been


included for your information.
Also included are some sketches of the proposed layout.

Civil & Structural Engineering:


Structural Engineer to provide TX state PE stamp on all structural and foundation designs.
Foundations:
Design foundation for lime silo and provide drawing suitable for foundation contractor to
install foundation.
Exact location of pad to be determined.
Pad to also accommodate other equipment. See GA.
Provide drawing of foundation for future sodium bicarbonate silo.
Exact location to be determined, adjacent to lime silo.
Silo to be identified as “Future Sodium Bicarbonate silo 1,500 cu ft silo x 12ft
diam x 75 lb/cu ft material density.”
Foundation to be identical to lime silo requiring no additional design work.
Design and draw foundations for pipe bridge,
possibly design and draw foundations for “alleviator” (to separate material from
transport air) at bucket elevator.
Structural design:
Show pipe routing on plant GA and detail drawings,
Pipe supports,
Design and draw Pipe bridge,
Design and draw Support for “alleviator” (to separate material from transport air)
at bucket elevator.

Information to be provided:
Silo supplier is to provide lime silo drawing and foundation loads with state of TX PE stamp.
STM will provide “alleviator” dimensions and weight.

On site civil work:


Design foundations for lime silo, and for future sodium bicarbonate silo.
Advise client of area required, and required density of any backfill.
Client to remove any existing foundations and backfill with required density of fill.
Excavate and install foundations, c/w embedded silo anchor bolts.

CIVIL WORKS
Solid foundation earthen material is assumed to be found at an average depth of 2’-0”
from grade.
Scope of work to be in accordance with foundation design drawings, and to include:
Silo Foundation Pad:
• Excavation of existing earthen material up to 36" deep. Additional removal of
another 12" of material around perimeter max for 30’-0" x 30’-0" wide footing.
• Installation of 12”-24" of compacted rock under pad inside perimeter footing.
• Installation of qty 4 x #6 bar in footings, and two mats of #4 bar on 24" centers
for pad. (To be confirmed with foundation design drawings)
• Concrete to be 30' x 30’ x 24" deep pad and 30” wide x 30” deep footing at the
outside of the pad. (To be confirmed with foundation design drawings)
• Silo Pad. Installation of 4,000 (psi) mix cement with a broom finish at a finish
height of 4" above grade. (To be confirmed with foundation design drawings)
• Installation of two 10' x 3/4" grounding rods, at opposite corners of the pad.
• Ground cable (4/0 BARE copper cable) to be buried in concrete,
To be thermo welded to: existing ground grid (location to be determined
at site), each grounding rod, and with a single pig tail for silo connection.
50’ max length allowed.
Grounding for pipe bridge will need to be determined.

Pipe bridge foundation:


• Foundation requirements to be evaluated
Alleviator Support foundation:
• Foundation requirements to be evaluated

• Note: All concrete to be supplied, mixed and delivered to the site by Buzzi at no cost to
STM or foundation installation subcontractor. (Any testing required, if it is required by
contract or governing law, is to be carried out by foundation installation subcontractor.

Schedule:
Submit drawings for approval 4 weeks after award.
Foundation work to start approx. 12 weeks after drawing approval.

Silo:
Silo to be designed for lime or sodium bicarbonate (including support skirt
and foundation loads) See if silo can be designed for 75 lbs/cu ft.
3
Capacity: 7000 ft . May want to revise. TO BE DETERMINED.
Silo Diameter: 12 or 14 ft??
Hopper Outlet Diameter: 6 or 7 ft.
Hopper outlet elevation: to be determined.
Actual Bulk Density: 32 lb/ft3
Structural Design Bulk Density: 60 lb/ft3 (determine whether any additional cost to design for
75lbs/cu ft)

Skirt Supported
Hopper Slope: 60 Degree
Carbon steel
Shop painted
External Spiral Staircase to roof
Interior And Exterior hand Rails on stairs (as per customer spec and manufacturer standard).
Door at grade: 6'-0" X 6'-8" Double Door
Hopper Platform at bottom of hopper level, elevation to be determined.
Hopper platform access via regular single door and external spiral stairs.
Hopper platform steel to support Rotary plow and screw feeders. Dimensions and weights and
support points to be provided.
Bin Activator flange to be welded to hopper in shop, to STM specification.

Roof:
Top Deck Slope: 10 Degree
Deck Perimeter Guardrail – OSHA – Hot dipped carbon steel or Aluminum, clarify with
Jared the type of handrail that is acceptable.
Fill Line 4” Diameter Sch. 40 CS (with 4” male camlock fitting like Festus)
Anchor Bolts (set in concrete)
Silo hold down to use inner flange and hold down clips (like Pryor) so template for hold down
bolts not necessary.
Unistrut Assy Brackets For Conduit up side of silo (or 100% specify and ask shop to install
conduit), (or ask shop can they install conduit inside silo)
Qty 4 x 8” Diameter reinforced openings in skirt wall for Feeders. Close to grade level. Location
to be advised.
One opening required in skirt wall large enough to allow smaller of two electrical panels to pass
through.

Design Criteria
• Seismic Zone 0, Location Maryneal, TX.
• Basic wind speed: Ninety miles per hour (90 mph)
• Design Pressure & Vacuum: 14 Oz/in2 Positive, 1 Oz/in2 Negative
• 20 PSF Roof Deck Live Load
• Minimum snow load: 20 PSF
• Platform live loads: 50 PSF
• Ambient Operating Temperature: 14° to 113° F (-10° to 45 °C)

Surface Protection: (shop applied)


• Surface Preparation: SP6 surface profile.
• Interior skirt coating: Polyamide epoxy 2.0 mils min. DFT
• Exterior coating: Polyamide epoxy 2.0 mils min. DFT (Prime coat?)YES
• Exterior finish coat: Polyurethane 2.0 mils min. DFT
• Top Deck Finish Coat: Ferrox Non-Skid Coating
Welding Requirements
• Plates and nozzles: Full Penetration Double Welds where possible or manufacturer
standard.
• Hopper To Cylinder: PJP Single Bevel Weld (Partial joint penetration)

Foundation loads stamped by TX PE


Hopper mounted devices:
Hopper level Sensor (at lowest possible in hopper, still accessible from hopper platform.)
Bin Activator
Silo Roof mounted devices:
Bin Vent minimum 120 ft2 filtration area, ventilated with fan.
Compressed air pulse cleaning.
Mechanical Pressure Vent (+ve & -ve pressure relief valve) standard use WAM safety
valve, or some other company that Joe is considering.
Mechanical Pressure Switch
Continuous Level Sensor (radar based like Festus)
Top Point Level Sensor (on extra long standoff like Festus)

Transport Piping
4” S40 Galvanized Carbon Steel piping with
Plate flange connections (not standard 150# flanges)
Cost of 4” flanges:
std flange SS $40.
Plate flanges CS $11.90 pipe fittings direct.com. $48 for ss304.
Slip on flange CS 150# $15.70.
Socket weld CS 150# $18.67.
Weld neck flange CS 150# $18.69.
Do we do threaded to avoid having to paint threaded = $18.73 CS 150#.
Work out details later.
All pipe runs are to be horizontal and vertical.
Supported on existing support steel (where required)
. 1 and 400 ft to Point 2.
Transportation pipe to be supported over the road to north of silo by a pipe bridge.
As simple as possible.
Support for pipe bridge to be simple foundations.
Is it possible to use existing pipe rack? A little longer route, but less work?

Pigging system by STM


Transport pipe access opening,
attachments for pigging operation,
3 pipe cleaning pigs. Same scope as at Festus.

Injection points in two locations:


Point 1) in ducting at cone valve outlet / Kiln baghouse inlet, approx. 200’ from silo.
Injection method = injection lance. Injection points quantity = ONE.
Point 2) into the bucket elevator, approx. 400’ away from silo. One point only, need
alleviator (to separate material from transport air) & RV and/or screw conveyor.
Note: Previously used ID Fan inlet injection point is no longer going to be used.

Injection Lance support box


Located at injection Point 1.
Quantity: ONE
Carbon steel, without insulation or refractory. Maybe we can use the existing support
box.

Alleviator / Filter Receiver System / De-aerator / Bucket Elevator Transfer Point (to
separate material from transport air at bucket elevator feed)
Qty = 1. Approx dimensions 4 ft diameter x 8 foot tall x 7500 lbs.
Complete with filter and integral receiver hopper to receive material,
Filter receiver, (similar to bin vent on silo at Alpena, larger bin vent than Festus. We
need to work out what to use here.)
Compressed air pulse cleaning
Includes filters and fan. We are not sure if a fan is needed.
Model: STM Model FRIS-100 (just a made up model number)
Material: Carbon Steel
Feeder Screw Motor: 1 kW

Possible Arrangements considered:


 Mount filter receiver at grade on support steel, use screw conveyor to lift material to
approx. 8 – 10 ft? to bucket elevator. Requirement for foundations to be evaluated
 Or mount filter receiver at a higher elevation, possibly hanging from available? Support
steel above, and use rotary valve to drop through chute to bucket elevator.
 NEEDS FURTHER CONSIDERATION.

For Reference, please see attached:


P&ID - from client enquiry
This is a guide only. Scope of supply should be determined from this document.
GA – from STM proposal for reference.
Buzzi’s Maryneal DSI System – Location Plan
For an indication of the approximate layout of the plant.

END OF SCOPE DEFINITION