civil design basis

7/30/2019 Civil Design Basis

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VISAKH MARKETING INSTALLATION REISTEMENT

PROJECT LPG TERMINAL

Doc No:256324-500-DB-CIV-001 Rev: B Page 1 of 41

P:\Andheri\IndiaProject\256324 HPCL- LPG\10 Procurement\TENDER\07 PEB\Final Tender to be uploaded-24-Aug-

09\Editable\Annexure - X- Attachments\Civil design basis.doc

DESIGN BASIS

FOR

(Civil, Structural & Architectural)

Mott MacDonald Consultants (India) Pvt. Ltd.

Kothari House, CTS No. 185

Off Andheri - Kurla Road

Andheri (East)

Mumbai 400 059

Hindustan Petroleum Corporation Ltd

Krishna Shree, 2nd

Floor, Gandhi Nagar

1st

Main Road - Adyar

Chennai 600 020


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DESIGN BASIS

FOR

(Civil, Structural & Architectural)

Client HINDUSTAN PETROLEUM CORPORATION LTD.

MMCI Project No. 256324

Issue and Revision Record:

Rev Date Originator Checked Approved Description

A 24/03/09 GBP PKB KGN Issued for Approval

B 26/06/09 DIN PKB SMA Issued for Design

C

Group Disclaimer

"This document has been prepared for the titled project or named part thereof and should not be relied upon or

used for any other project without an independent check being carried out as to its suitability and prior written

authority of Mott MacDonald being obtained. Mott MacDonald accepts no responsibility or liability for the

consequences of this document being used for a purpose other than the purposes for which it was commissioned.

Any person using or relying on the document for such other purpose agrees, and will by such use or reliance be

taken to confirm his agreement, to indemnify Mott MacDonald for all loss or damage resulting therefrom. Mott

MacDonald accepts no responsibility or liability for this document to any party other than the person by whom it

was commissioned..


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List of Contents Page No

1 Scope 7

2 Codes, Regulations, Specifications and Standards 72.1 Specifications: 7

2.2 Analysis & Design: 72.2.1 Loads: 72.2.2 Concrete Design: 82.2.3 Structural Steel Design: 82.2.4 Roads, Culverts, Drainage & Pavement Design: 82.2.5 Foundation Design: 92.2.6 Masonry Design: 92.2.7 Misc. Specifications: 9

3 General Topography & Climatic Conditions 9

4 Materials of Construction 9

5 Design Loads 10

5.1 General 10

5.2 Dead Loads (D) 10

5.3 Static & Dynamic Equipment Empty Loads (E) 10

5.4 Equipment Operating Loads (EO) 11

5.5 Equipment Hydro-Test Load (EH) 11

5.6 Piping Loads (P) for Pipe Supports/Trestles 11

6 DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS 12

6.1 Vertical Loading 12

6.2 Friction Force (Longitudinal and Transverse) 12

6.3 Anchor and Guide Force (Thermal load) 13

6.4 Loading on Intermediate Beam at Tier Level 13

6.5 Loading on Longitudinal Beams 13

7 Live Loads (L) 13

7.1 General 13

7.2 Live Loads on different structures/buildings 147.2.1 DG house 147.2.2 Service Platform 147.2.3 Substation/Control Room 147.2.4 Office building 147.2.5 Laboratory 147.2.6 Staircase 14

8 Contingency Loads 158.1 RCC Structures 15


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8.2 Structural Steel 15

9 Earth pressure (H) & Buoyancy: 15

10 Wind Loads (W) 15

11 Seismic Loads (S) 16

12 Thermal Loads (TL) 17

13 Impact Loads (I) 18

14 Vibration Loads (V) 18

15 Surcharge/Overburden Loads (B) 18

16 Load Combinations 1816.1 General 18

16.2 Load Factors and Combinations 18

17 Concrete Structures Design 20

17.1 General 20

17.2 Foundations 20

17.3 Minimum Foundation Sizes 21

17.4 Piles and pile caps 21

17.5 Anchor Bolts 22

17.6 Minimum Cover Requirements to Main Reinforcement 22

17.7 Staircase 22

17.8 Concrete Grade 23

17.9 Reinforcement Bars 23

17.10 Minimum Thickness of concrete members 23

17.11 Allowable Deflections for concrete buildings 23

18 Masonry Structures 24

18.1 General 24

19 Steel Structures design 24

19.1 General 24

19.2 Miscellaneous 25

20 Allowable Deflections for structural steel buildings 25

20.1 General 25

20.2 Crane Beams or Girders 25

21 Surface Drainage, Paving & Sewerage: - 26

21.1 Table showing paving type selection 26


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21.2 Joints 27

22 Drainage General 27

22.1 Drain details 27

22.2 Storm Water Drainage 28

23 Site grading & roads: - 29

23.1 Site Grading: - 29

23.2 Roads:- 29

24 Substations buildings and blast resistant design: 29

24.1 General 29

24.2 General principles of steel tank foundation design: 30

24.3 Analysis & design procedure for ring walls & RCC pile caps for Steel Tanks: 30

24.4 Analysis & design procedure for RCC underground tanks: 30

25 Design Philosophy/Criteria 31

25.1 Architectural Design 3125.1.1 Spatial Requirements 3125.1.2 Functional Spaces 3125.1.3 Circulation Spaces 3225.1.4 Amenity Spaces 3225.1.5 Utility Spaces 3325.1.6 Sizes of Spaces 3325.1.7 Day Light and Natural Ventilation 3325.1.8 Natural Ventilation 3325.1.9 Acoustics and Sound Insulation 3325.1.10Safety Requirements 34

25.2 Site Planning 34

25.3 Building Services 3525.3.1 Water supply, Distribution and Drainage Sanitary Services 3525.3.2 Electrical Services 3525.3.3 Air conditioning and Heating 35

25.4 Aesthetics 35

25.5 Structural and Architectural Construction Elements 3625.5.1 Plinth protection 3625.5.2 Finished Floor Level (FFL) 3625.5.3 Steps/ ramps/ Staircases 3625.5.4 Walls 3725.5.5 Doors 3825.5.6 Windows/ ventilators 3825.5.7 Canopy/Overhang 3925.5.8 Shading Devices 3925.5.9 Parapet 3925.5.10Roof Gutter 39

25.5.11Rain Water Pipes Spouts 3925.5.12Entrance Lobby 3925.5.13Passages/Corridors 40


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25.5.14Service Entry 4025.5.15Air-Lock Lobby 4025.5.16Emergency Exits 4025.5.17Railings 40

25.5.18Toilets 4025.5.19False Ceiling 4025.5.20False/Cavity flooring 4125.5.21Transformer Gate 4125.5.22Under deck Insulation 4125.5.23Architectural Finishes 41

26 Mounded Bullets 41


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1 Scope

The engineering design basis defines the minimum design criteria that shall form the basis for carrying

out detailed civil, architectural and structural design of all structures like Fire water tank foundations,

TW Gantry , Tank Truck Gantry, connecting platforms, Pipe tracks, plant buildings (like DG

Sheds/Pump Sheds/MCC-Air Compressor Room etc.), non-plant buildings (like

Administration/Security/Amenity/Planning buildings etc.) included in bid document.

This document also includes the design criteria that shall form the basis for carrying out design and

engineering of items under general civil (viz. roads, paving drainage etc.).

This document shall be read in conjunction with technical specifications and scope of works.

This specification describes the materials, loads, design requirements and methods to be used for design

of structures / buildings as described below:

(Reference drawing: Overall Plot Plan Drg. No 256324-500-PIP-3000)

The various structures, buildings and equipment included in the scope are:

SCHDULE OF LPG FACILITIES

As per Plot Plan

LPG PUMP DETAILS

As per Plot Plan

2 Codes, Regulations, Specifications and Standards

Following technical specifications shall be referred along with this design basis.

2.1 Specifications:

Sr.

NoTitle

STD. Specification

No.

1.Technical Specification for Earthwork (Excavation

& Filling )256324-500-SP-CIV-001

2. Specification for Plain & Reinforced concrete works 256324-500-SP-CIV-002

3. Technical Specification for Structural Steel Works 256324-500-SP-CIV-003

4. Specification for Masonry works 256324-500-SP-CIV-004

5. Specification for Roads & Storm Drain works 256324-500-SP-CIV-005

2.2 Analysis & Design:(For general notes, legend and abbreviations refer Drg. No. (256324-500-CIV-2801)


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2.2.1 Loads:

IS 875 : Part 1: 1987 Code of practice for design loads ( other than earthquakes)

for buildings & structures ,Part 1 Dead loads

IS 875 : Part 2 : 1987 Code of practice for design loads ( other than earthquakes)

for buildings & structures ,Part II Imposed loads

IS 875 : Part 3 : 1987 Code of practice for design loads ( other than earthquakes)

for buildings & structures ,Part III Wind loads

IS 1893: -1984

- Pt I , 2002

- Pt II , 2005

1984- Criteria for earthquake resistant design of structures

Part 1, 2002 Code of practice for earthquake resistant

design of structures General Provisions & buildings

Part IV, 2005- Code of practice for earthquake resistant

design of structures Industrial structures including stack

like structures.

IS 4326 :1993 Code of practice for earthquake resistant design andconstruction of buildings.

2.2.2 Concrete Design:

IS 456 2000 Plain & Reinforced Concrete - Code of practice

Special Publication,

SP 16:

Design Aids to IS 456

IS 13920 :1993 Ductile detailing of Reinforced Concrete Structures

subjected to Seismic Forces Code of Practice

IS 3370 Parts I 1965

IS 3370 Parts II 1965

IS 3370 Parts III 1967

IS 3370 Parts IV 1967

All 4 parts reaffirmed in 1999.

Code of Practice for concrete structures for storage of liquids

:

Part I - General Requirements

Part II Reinforced Concrete Structures

Part III Pre stressed concrete structures

Part IV Design Tables

2.2.3 Structural Steel Design:

IS 800 :2007 for allowable

(Working)stress design **

General construction in steel Code of practice

IS 806 :1968 Code of practice for use of structural steel tubes in General

Building ConstructionIS 1161 :1998 Code of practice for steel tubes in general building

construction

IS 1905 :1986 Code of practice for structural use of un-reinforced

masonry

IS 4991 - 1968 Criteria for blast resistant design of structures for

explosions above ground

2.2.4 Roads, Culverts, Drainage & Pavement Design:

IRC 5 -1998 Code of practice for roads & bridges

IRC 6 -2000 Code of practice for roads & bridges, Section II Loads &

Stresses


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IRC 37 -2001 Guidelines for the design of flexible pavements

IRC 58 -2001 Guidelines for the design of rigid pavements

IS 1172-1993 Code of basic requirements for water supply, drainage &sanitation

IS 1742-1983 Code of practice for building drainage

IS 2065-1983 Code of practice for water supply in buildings

IS 8835-1978 Guidelines for design of surface drains

2.2.5 Foundation Design:

IS 1080 :1985 Code of practice for design & construction of shallow

foundations in soil

IS 1904 :1986 Code of practice for design & construction of foundations

in soil general requirements

IS 2950, Part 1 1981 Code of practice for design & construction of raftFoundations, Part I - Design

IS 2911 Pt. 1 Section- I

1979

Code of Practice for Design and Construction of Pile

Foundation.- Driven Cast in situ concrete pile

IS 2911 Pt. 1 Section- II

1979


Foundation. Bored cast in situ piles

IS 2911 Pt. IV

1985


Foundation Load test on piles

IS 6403 1981 Code of Practice for determination of bearing capacity of

shallow foundations

2.2.6 Masonry Design:

IS 1905 :1987 Code of practice for structural use of un-reinforced

masonry

2.2.7 Misc. Specifications:

OISD-STD-109-Aug1999 Process Design & operating philosophy on blow down &

sewer systems

OISD-STD-118-July2008 Layouts for oil and gas installations

OISD-STD-163-Sept 2004 Safety of Control Room for Hydrocarbon Industry

OISD-STD-164-July 1998 Fireproofing in Oil & Gas Industry Safety Factory Rules3 General Topography & Climatic Conditions

Refer Project Design Basis.

4 Materials of Construction

The materials used for construction shall be strictly as per the relevant technical specifications

and as per the relevant I. S. Codes & specifications.

All non plant buildings shall be R.C.C. frame type buildings with foundations as per soil

report. For e.g. the non plant buildings include following;

Administration Building, Security Office, Drivers Block, Weighbridge & Weighbridge Cabin

etc,


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All plant buildings shall be R.C.C. frame type buildings with foundations as per soil report.

For e.g. the plant buildings include following;

DG Sheds, MCC & Air Compressor Room etc.

All Pipe/Cable Tracks shall be Slippers with Either Open/Pile foundations as per soil report.All Tanks shall be supported on pile foundations with ring beam as per final soil report.

The shed type buildings shall be following

Tank truck Gantry sheds, Cylinder Storage Shed, DG Shed, Cylinder Loading Platform,

Cylinder unloading Platform etc.

5 Design Loads

5.1 General

5.1.1 Structures shall be designed to have sufficient structural capacity and integrity to resist safely

and effectively all loads and effects of load combinations that may reasonably be expected.

5.1.2 The design loads used for the structures, buildings and foundations shall conform to the

requirements of the governing codes and specifications. As a minimum the design loads shall

include dead load, operating loads, live load, rain load, wind load and seismic load. Where

applicable, the design loads shall also include thermal load, anchor loads, hydro test load,

impact load, vibration load, surcharge load and bundle pull loads.

5.1.3 The units to be used for design and drawings are SI units.

5.2 Dead Loads (D)

5.2.1 Dead load comprises of the weight of all permanent construction including walls, fire-

proofing, floors, roofs, partitions, stairways, fixed services and other equipments excludingtheir content.

Dead loads (D) shall consist of total loads due to the structure (framing, walls, roofing etc.),

equipment, piping, insulation, refractory, overburden soil, and other load permanently

supported by the structure. If in-situ hydro test is planned, the dead load shall include water

filled vessels and piping. Foundation dead loads shall contain the weight of the soil

immediately above the foundation.

Weight of the structure: The self-weight of the structure shall be calculated based on the

following unit weights of the structure:

Items Unit Weight (kN/m3)

Steel 78.5

Reinforced Concrete 25

Plain Concrete 24

Water 10

Soil (dry earth ) 18

Soil in Ground Water 8

Bricks Masonry 20

Dry Sand 18

5.3 Static & Dynamic Equipment Empty Loads (E)

Equipment loads shall be supplied by Vendor drawings and/or data sheets and shall includeempty weight.


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The empty weight of the static process equipment including all fixtures, platforms, ladders,

attached piping, pipe supports & insulation (if applicable) shall be considered. If piping

weight is not indicated separately or included in the weight of the equipment, the same shall

be considered as 10% of the weight of the equipment. The empty (dead) weight shall be

considered as per inputs received from vendors. Static equipments viz. Vessels, tanks etc.

Dead/Empty Weight of equipment Weight of dynamic/rotary equipment like pumps/motors,

D.G. Sets, and skid-mounted equipment shall be derived as far as possible from

manufacturers data and includes piping data. Insulation installed on piping and equipment

shall be also considered.

Empty/dead weight Fabricated/Erected equipment weight from manufacturers data.

5.4 Equipment Operating Loads (EO)

Operating Weight of equipment Weight of equipment like pumps, tanks and vessels shall be

derived as far as possible from manufacturers data and includes mechanical/piping data.

Insulation installed on piping and equipment shall be also considered.

The operating loads (OP) for the process and utility equipment, including piping (P), shall be

the dead loads plus weight of the liquid / contents under normal conditions at maximum

operating level. Permanent stored materials for operation shall be included as operating loads.

Vessels, Tanks etc. The weight to be included in the calculations depend on the extent to

which it is filled with liquid.

Operating weight = Weight of the maximum contents of the equipment during operating

condition of plant plus the empty weight.

5.5 Equipment Hydro-Test Load (EH)

Hydrostatic test load = The weight of Full volume of the water filled in Equipment plus the

empty weight.

Equipment hydro test loads (EH) shall consist of the equipment empty weight plus the weight

of the test content (usually water) contained in the system to be considered.

Foundation design to take account of:

- fully dressed load with hydro test.

- undressed condition with worst wind load effects.

For hydro testing of vessels, piping and the like allow for test case full of water.

Under hydro-test condition the wind force shall be considered as 25% of normal loading.

5.6 Piping Loads (P) for Pipe Supports/Trestles

5.6.1 Pipe loads (P) in Operating Condition shall be considered as follows:

Up to 300 mm diameter 0.8 KN/ Sq. m Dead Load (Self weight)

1.2 KN/ Sq. m Live Load (Contents weight)

300 mm dia. and over Consider individual/actual point loads as per piping inputs

Friction Force (Longitudinal & Transverse)


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Longitudinal & transverse friction force in (both directions) 10 % of design vertical load of

pipes for four or more pipes supported on a tier. (This is done due to reversible flow directions

and forces)

Longitudinal & transverse friction force in (both directions) 10 % of design vertical load of

pipes for four or more pipes supported on a tier. (This is done due to reversible flow directions

and forces)

Longitudinal friction force (30 % of design vertical load of pipes) & transverse force (10 % of

design vertical load of pipes) for single to three pipes supported on a tier for global design

where as for local beam member design for single pipe frictional force of 30% to be

considered in longitudinal and transverse direction or as per piping/stress load inputs. The

local beam member design shall not be combined with seismic/wind loads.

For Pipe-racks; longitudinal friction force shall be considered as uniformly distributed over

the entire span of the beam at each tier and transverse friction force shall be considered as a

concentrated load at each tier level.

Friction forces on T-supports & trestles shall be considered as longitudinal 30% of the verticalloading & transverse 10% of the vertical loading. Both longitudinal and transverse friction

forces shall be considered to act simultaneously.

5.6.2 Electrical information shall be investigated to determine the approximate weight, location of

the electrical trays and/or conduits. A minimum weight of 1.2 KN/ Sq. m shall be used for

single level trays and 3.0 KN/ Sq. m for double trays, regardless of the tray width.

5.6.3 Special consideration shall be given to unusual loads such as large valves, unusual piping or

electrical configurations, etc.

5.6.4 Anchor loads (TA) shall be as per the Stress analysis piping loads provided by Stress Group.

5.6.5 Anchor loads shall be only applied on piping level.

6 DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS

PIPE RACK

For designing the pipe rack superstructure and foundation the following loads shall be

considered.

6.1 Vertical Loading

Actual weights of pipes coming at each tier shall be calculated. In calculating the actual weight of

pipe, the class of pipe, material content and insulation, if any, shall be taken into consideration.Minimum Insulation density shall be taken as 2600 N/m3. In case of gas/steam carrying pipes,

the material content shall be taken as 1/3rd volume of pipe filled with water. The total actual

weight thus calculated shall then be divided by the actual extent of the span covered by the pipes

to get the uniform distributed load per unit length of the span. To obtain the design uniformly

distributed load over the entire span, the udl (uniformly distributed load) obtained as above shall

be assumed to be spread over the entire span. However, minimum loading for any pipe rack shall

not be less than 2.0 KN/m2. In case, the calculated loading is higher than 2.0 kN/m2, this shall be

rounded off to the nearest multiple of 0.25 (i.e. 2.25, 2.50, 2.75 kN/m2).

6.2 Friction Force (Longitudinal and Transverse)

Where the pipes are of similar diameter and service condition, the friction force at each tier on

every portal, both in longitudinal and transverse directions shall be 10% of the design vertical


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loading of the pipes for four or more pipes supported on a tier for global design, and 30% of the

design vertical loading of the pipes in longitudinal direction & 10% of the design vertical loading

of the pipes in transverse direction for single to three pipes supported on a tier. Longitudinal

friction force shall be considered as uniformly distributed over the entire span of the beam at each

tier and transverse friction force shall be considered as a concentrated load at each tier level.Friction force on T-supports and trestles shall be taken as 30% and 10% in longitudinal and

transverse directions respectively of the vertical loading. Both longitudinal and transverse friction

forces shall be considered to be acting simultaneously.

For local beam/member design shall be checked for frictional forces 30% of the vertical loads in

both longitudinal and transverse directions acting simultaneously. The local beam design shall not

be checked for seismic/wind loads acting simultaneously along with the frictional forces.

6.3 Anchor and Guide Force (Thermal load)

The Anchor or Guide Forces in longitudinal and transverse directions shall be as per piping

inputs.

6.4 Loading on Intermediate Beam at Tier Level

Intermediate beam at tier level shall be designed for 25% of load on main portal beams in

transverse direction. A reduction of 10% in vertical loading shall be considered for main portal

beams if intermediate beams are provided.

6.5 Loading on Longitudinal Beams

Longitudinal beams connecting portal columns shall be sufficiently strong to sustain 25% of the

load on the transverse beams. This total load shall be assumed as two equal concentrated loadsacting at 1/3rd span. Other longitudinal axial forces coming on it from the design of the

supporting system shall also be simultaneously taken into account in the design of the

longitudinal beam. Friction and Anchor Forces, if specifically given by the piping stress engineer

shall also be catered for in the design. Loads from monorails, when supported from these beams,

shall also be considered to be acting simultaneously along with all other loads mentioned above.

These beams shall be designed locally for monorail loads. The monorail loads shall not be

combined with wind & seismic. It shall be considered for local monorail member design.

7 Live Loads (L)

7.1 General

7.1.1 Live loads (L) shall consist of loads due to the intended use and occupancy of the structure.

Minimum live loads due to use and occupancy shall be as follows, unless otherwise specified

on process / assignment drawings. Reduction in Live load shall be per Cl 3.2 of IS: 875 - Part

II.

Area Specified UniformLoads

(KN/m2)*

Specified PointLoads

(KN)**

Ladder Rungs - 2.2

Office floor, labs, walkways 5.0 9.0

Minimum roof load 1.5 3.75


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Operating, maintenance, platform 5.0 6.7

Suspended piping on main roof 1.0 None

Vessel platform 5.0 None

Access platform 3.0 None

Electrical, computer and control room 10.0 9.0

Toilet bathroom 2.0 9.0

Stair / Corridors / Passages 5.0 4.5

* Minimum specified uniform loads and minimum specified concentrated loads do not actconcurrently.

** Distribute concentrated loads over 300mm x 300mm area. For evaluation of local effectsof crushing (Ref. Cl 3.1.1 IS 875 Part II).

7.1.2 For railings, a horizontal force of 1.0kN at any one point or uniform load of 0.75kN/m shall beused.

7.1.3 For structural calculations, the actual loading situation shall be adhered to if these are more

stringent. If heavy equipment has to be supported, the weight of this equipment in excess of

the live load specified above shall be taken into account.

7.1.4 For garages and fire stations, the live loads shall also include the maximum weight of the

trucks and/or fire fighting equipment.

7.2 Live Loads on different structures/buildings

Live loads shall, in general, be as per IS: 875. However, the following minimum live loadsshall be considered in the design of structures to account for maintenance and erection as well:

7.2.1 DG house

Operating area 7.5 KN/m2

Maintenance area 7.5 KN/m2

(or as specified by machine vendor)

7.2.2 Service Platform

Vessel/Tower 3.0 KN/m2

Isolated platform (for valve operation) 3.0 KN/m2Access way 2.5 KN/m

2

Cross over 2.0 KN/m2

7.2.3 Substation/Control Room

Panel floor 10.0 KN/m2

Partitions 1.0 KN/m2

7.2.4 Office building

Office area 3.0 KN/m2

Lobby 5.0 KN/m2Exit way 5.0 KN/m

2

Partitions 1.0 KN/m2


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7.2.5 Laboratory

Upper floors 4.0 KN/m2

7.2.6 Staircase

Office 5.0 KN/m2

Substation/Control Room 5.0 KN/m2

Laboratory 3.0 KN/m2

Service platform 2.5 KN/m2

8 Contingency Loads

8.1 RCC Structures

All floor slabs and beams shall be designed for a concentrated load of 10 KN actingsimultaneously with the uniform live load, but not with actual concentrated loads from

equipment, piping etc. This load shall be placed to result in maximum moment and / or

maximum shear, it shall not be considered for the design of columns, foundations and in

overall frame analysis. For floor slabs, the load shall be considered to be distributed over an

area of 0.75 m x 0.75 m.

8.2 Structural Steel

For process plants, the following contingency additional loading shall be applied to individual

beam elements. These shall be applied as point loads to produce worst shear and bending

stresses:Platform Walkways 3 KN

Secondary Floor Trimmers 5 KN

Primary beams 10 KN

9 Earth pressure (H) & Buoyancy:

For evaluating earth pressure on walls of trenches and pits co-efficient of earth pressure at rest

shall be considered, its minimum value being taken as 0.5. If a higher value is obtained from

soil characteristics, the same shall be adopted.Temporary rise of ground water level shall be duly considered and hydrostatic pressure arising

there from shall be considered for design of trenches, pits and basements more than 1.25 m in

depth.

Maximum permanent ground water level is around 1 m ( Hold) below Finished Ground Level.

Factor of safety for underground tanks etc against floatation shall be greater than 1.2. During

construction, factor of safety shall be at least greater than 1.05.

10 Wind Loads (W)

Wind loads (W) shall be in accordance with the applicable codes, specifications andrecommended practices listed in IS 875, Part III.


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The effects of wind induced vibration shall be taken into effect as required by the applicable

codes, specifications and recommended practices listed in Section 2.1.

Basic wind loading parameters at HPCL site: -

Basic wind speed at Visakhapatanam, Vb = 50 metres / seck 1 = Probability factor (Risk coefficient for different class of structure in different wind speed

zone) = 1.0 for general buildings & structures.

k 2 = Terrain, height & structure size factor , for terrain category 2 , Structure class B,

(structure Size between 20m & 50m) at height 10 m = 0.98

k3 = Topography factor = 1.0

Design wind speed, Vz = k1*k2*k3*Vb = 49 metres /sec

Design wind pressure, p z_gen = 0.6*Vz2

= 1441 N/m2

= 1.44 Kn /m2

for general buildings at

structures at height 10 m above FGL

The sheds with louvers as cladding shall be considered as fully clad.

The design life span of all structures (units & offsite) shall be taken as 50 years. Temporary

structures shall be designed for a design life span of 25 years. Design life span for boundary wall

shall be as provided in IS: 875.

To account for surface area of piping, platforms and other attachments fixed to the equipment

the surface area of the equipment (vessel/column) exposed to wind shall be increased by 20% or

as specified in the mechanical data sheet of the equipment.

11 Seismic Loads (S)

11.1 Categorisation of Structures / Equipment

Structures / equipment shall be classified into the following four categories.

Category -I

The Structures/equipments whose failure can lead to extensive loss of life /property to

population at large in the surrounding of the plant complex

Category - II

Structures/equipments whose failure can lead to serious fire hazard / extensive damage within

the plant complex

Structures/equipments which are required to handle emergencies immediately after an

earthquake

Category - III

Structures/equipments whose failure, although expensive does not lead to serious hazard within

the plant complex

Category - IV

All non-plant and non-hazardous structures / equipment fall within this category.

Above philosophy of categorisation is meant to ensure, on one hand safety and on other

hand economy in total capital outlay.

Generally structures / equipment have large capacities of energy absorption in its inelastic

region. Structures which are detailed as per IS: 4326/IS: 13920 or IS: 800 and equipment which


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are made of ductile materials can withstand earthquakes with spectra four times higher than the

design spectra without collapse; and damage in such cases is restricted to cracking only.

In view of above it may be noted and the term "failure" used in the definition of categories

implies cracking and not complete collapse. Pressurised equipment where cracking can lead

to rupture may be categorised by the consequences of rupture.

Such equipment / structures where cracking will not lead to hazards are to be placed in

category-III and where it may lead to hazards within the complex are to be placed in category

- II. Category -I earthquake is an extreme event with little possibility of its occurrence.

Nevertheless in the remote case when it occurs, structures / equipment whose failure can lead

to loss of life at large are to be designed so as to avoid failure.

Following is the grouping of the areas/structures.

Category I: Blast Resistant Control Building

Category II: All equipments and their supporting structures, Bullets, Tanks & their

foundations etc.

Category III: Pipe-racks, Control Room-Substations Buildings, DG Sheds, F.W. Tank etc.

Category IV: Non-plant Buildings viz. Pump houses, Admin Building, Security Room,

Planning Room etc.

11.2 Seismic load (S) induced on structures, buildings, equipments, and foundations shall becalculated in accordance of the requirements the IS standard as mentioned in Section 2.

11.3 Factors for the calculation of the seismic loading, i.e. seismic zone, soil profile, etc. shall be asper Geotechnical Investigation and in accordance with the requirements of the IS standard asmentioned in Section 2.

11.4 Basic Seismic Loading parameters:

Ref. Annex E, IS 1893 Part 1, 2002, Seismic Zone for HPCL site II,

Seismic Zone factor, Z = 0.10,

Design horizontal seismic coefficient, Ref. Cl 6.4.2, IS 1893: 2002

The Fundamental natural period shall be as per, Ref. Cl 7.6, IS 1893: 2002

For percentage of live load to be considered during seismic action for load evaluation, Ref

Table 8, IS 1893, Pt 1, 2002.

The seismic base shear VB = Ah* W

12 Thermal Loads (TL)

Generally the thermal loads shall be issued by piping stress analysis group. These loads shallbe used for design of pipe supports/structures.

The design of structure and foundation shall satisfy following minimum requirements.

12.1 The calculation of thermal loads (TL) shall be as per the requirements of the governing codesand specification.

12.2 Thermal Loads caused by expansion and contraction due to a change in temperature from theerection condition shall be carefully considered. Included are forces due to anchorage of


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piping and equipment, sliding and rolling of equipment, and expansion and contraction ofstructures.

12.3 Thermal loads due to the constraints and frictional forces of piping shall be considered asfollows:

(a) A minimum of 10% (in both longitudinal & transverse directions) of the gravity load for the

pipe supports / sleepers carrying 4 or more lines.

(b) A minimum of 30% of the gravity load in longitudinal direction & 10% in transverse

direction on pipe supports / sleepers carrying less than 4 lines.

Equipment on structural supports shall be analyzed for thermal loads to be resisted by thestructure and provisions shall be made to relieve the forces too large for the equipment or thesupporting structure. The friction factors to be used are the ones defined hereunder.

Steel To Steel = 0.3

Steel to PTFE Pad = 0.08

Steel to Concrete = 0.4

13 Impact Loads (I)

Impact loads (I) shall be calculated in accordance with the requirements of IS: 875 (Part 5)and IS: 2974 codes. For loads being given by equipment supplier, impact loads shall be as perinformation given on civil assignment drawing of equipment supplier. Impact loads shall beconsidered for local member design & it shall not be used with wind/seismic load cases.

14 Vibration Loads (V)

Vibration loads (V) shall be as per manufacturers recommendations & Indian standards.A three-dimensional vibration analysis for rotating equipment foundations shall be done tosatisfy manufacturers recommendation if any, and provisions of Indian standards.

The natural frequency of the supporting structures and foundations shall be below 80 % orabove 120 % of the natural frequency of the machine in the first mode.

15 Surcharge/Overburden Loads (B)

Surcharge loads (B) shall be considered for structures (tanks, pits etc.) and walls retaining soil,if any, in addition to usual soil pressure.

Surcharge pressure shall be generally considered as 15kN/m2 on top slab and also on adjacentground.

16 Load Combinations

16.1 General

16.1.1 Structures, buildings and foundations shall be designed for all individual load cases and thevarious load combinations that may act together.

16.1.2 Load combinations using Working Stress Design or Limit State Design shall be as per therequirements of the IS standard as mentioned in Section 2.

16.2 Load Factors and Combinations

16.2.1 Load notations shall be as follows :


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D Dead Load

L Live / Imposed Load

E Equipment Load (Empty Equipment)

EH Equipment Hydro test Load (Equipment with water load)

EO Equipment Operating Load (Equipment with operating fluid)W Wind Load

S Seismic / Earthquake Load

OP Operating Load of piping and fluids

TL Thermal Load

TA Thermal Anchor Load

BP Bundle Pull Load

V Vibration Loads

H Earth Pressure Load

B Surcharge Load

f1 factor for Load

16.2.2 Strength load combinations for buildings with or without equipment shall be as per IS: 456-2000.

1.5*D

1.5*D + 1.5*L

1.5*D + 1.5*L + 1.5*E

1.5*D + 1.5*EH

1.5*D + 1.5*L + 1.5*EO

1.5*D + 1.5*(W or S)

0.9*D + 1.5*(W or S) reversible wind/seismic forces

1.5*D + 1.5*E + 1.5*(W or S) reversible wind/seismic forces


1.5*D + 1.5*EO + 1.5*(W or S) reversible wind/seismic forces1.2*D + 1.2*L + 1.2*(W or S) reversible wind/seismic forces

1.2*D + 1.2*L +1.2*E + 1.2*(W or S) reversible wind/seismic forces

1.2*D + 1.2*L +1.2*EH + 1.2*(W or S) reversible wind/seismic forces

1.2*D + 1.2*L +1.2*EO + 1.2*(W or S) reversible wind/seismic forces

16.2.3 Service load combinations for general buildings shall be as per IS: 456-2000.

1.0*D

1.0*D + 1.0*L

1.0*D + 1.0*L + 1.0*E

1.0*D + 1.0*EH

1.0*D + 1.0*L + 1.0*EO

1.0*D + 1.0*(W or S) reversible wind/seismic forces


1.0*D + 1.0*EO + 0.8*(W or S) reversible wind/seismic forces

1.0*D + 1.0*L + 0.8*(W or S) reversible wind/seismic forces

1.0*D + 0.8*L +1.0*E + 0.8*(W or S) reversible wind/seismic forces

1.0*D + 0.8*L +1.0*EH + 0.8*(W or S) reversible wind/seismic forces

1.0*D + 0.8*L +1.0*EO + 0.8*(W or S) reversible wind/seismic forces

16.2.4 IS: 800 Allowable stress design method shall be used with following load combinations fordesign of structural steel open structures/sheds/pipe-racks. This is done in view of use of

STAAD PRO software for the analysis & design.

D + OP + TA + TL + V


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D + OP + TA + TL + V +E

D + OP + TA + TL + V +EH

D + OP + TA + TL + V +EO

D + OP + L + TA + TL + V

D + OP + L + TA + TL + V +ED + OP + L + TA + TL + V +EH

D + OP + L + TA + TL + V +EO

D + OP + TA + TL + EO

D + OP + TA + TL + EO + W reversible wind forces

D + OP + TA + TL + EO + S reversible seismic forces

D + OP +H + L

D + OP + H + B

0.9*D +0.9*OP +W reversible wind/seismic forces

0.9*D + 0.9*OP +S reversible wind/seismic forces

16.2.5 Strength load combinations for design of foundations shall be as per IS: 456-2000.1.5*D + 1.5*OP + 1.5*L

1.5*D + 1.5*OP + 1.2*EO + 1.2*TA + 1.2*TL + 1.2*V + 1.2*B

1.2*D + 1.2*OP + 1.2*EO + 1.5*L + 1.2*TA + 1.2*TL + 1.2*V

1.2*D +1.2*OP + 1.2*EO + 1.2*TA + 1.5*W + f1*L + 1.2*B

1.2*D +1.2*OP + 1.2*EO + 1.2*TA + 1.5*S + f1*L + 1.2*B

1.2*D + 1.2*H + 1.5*L + 1.5*W reversible wind forces

1.2*D + 1.2*H + 1.5*L + 1.5*S reversible seismic forces

1.2*D + 1.2*EO + 1.5*L + 1.2*B + 1.2*H

0.9*D + 0.9*E + 1.5*W reversible wind forces

0.9*D + 0.9*E+ 1.5*S reversible seismic forces

16.2.6 Service load combinations for foundations shall be as per IS: 456-2000.1.0*D + 1.0*OP + 1.0*L

1.0*D + 1.0*OP + 1.0*EO + 1.0*TA + 1.0*TL + 1.0*V + 1.0*B

1.0*D + 1.0*OP + 1.0*EO + 1.0*L + 1.0*TA + 1.0*TL + 1.0*V

1.0*D +1.0*OP + 1.0*EO + 1.0*TA + 1.0*W + f1*L + 1.0*B

1.0*D +1.0*OP + 1.0*EO + 1.0*TA + 1.0*S + f1*L + 1.0*B

1.0*D + 1.0*H + 1.0*L + 1.0*W reversible wind forces

1.0*D + 1.0*H + 1.0*L + 1.0*S reversible seismic forces

1.0*D + 1.0*EO + 1.0*L + 1.0*B + 1.0*H

1.0*D + 0.8*E + 0.8*W reversible wind forces

1.0*D + 0.8*E+ 0.8*S reversible seismic forces

16.2.7 The factor f1 for load L (Live loads) shall be as following:

1.0 for floors in places of public assembly, for live loads in excess 5 kN/m2, and forgarage live loads;

0.5 for other loads.16.2.8 The load combinations for deflection calculations shall be:

1.0*(D or/& OP) + y* (L + E + W or S + TL or TA)

y = 1.0 when one of the loads L/E, W/S, or T act.

y = 0.7 when two of the loads L/E, W/S, or T act.

Y = 0.6 when all of the loads L/E, W/S, and T act.

16.2.9 Where loads other than those mentioned in Section 16.2.5 are to be considered in design, eachapplicable load shall be added to the above load combinations with a factor of 1.0 for service


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load combinations and 1.5 or 1.2 for strength load combinations. For permanent loads forstrength design factor 1.5 shall be used & for transient loads .factor 1.2 shall be used.

17 Concrete Structures Design17.1 General

17.1.1 All structures shall be analysed/designed in STAAD PRO and mainly in limit state as per IS:

456-2000, by allowable stress design as per IS 3370. Generally the concrete beam members

shall be so designed that the span/depth ratio is 10.

17.2 Foundations

17.2.1 All major foundations shall be on piles for LPG. For minor structures shallow spreadfoundations or mat/raft foundations shall be designed if specified in soil report.

17.3 Minimum Foundation Sizes

17.3.1 The minimum width for a strip footing is 1000 mm. The minimum width for a spread footing

is 1200 mm. The minimum thickness of footing shall be 300mm.

17.3.2 Minimum cover to the Foundation/Anchor bolts:

Minimum distance from the centre line of the foundation anchor bolts to the edge of the

pedestal shall be the maximum of the following:-

(a) Clear distance from the edge of the base-plate/base frame to the outer edge of the pedestalshall be minimum 50 mm

(b) Clear distance from the face of the pocket/ edge of pipe sleeve to the outer edge of the

pedestal shall be minimum 100 mm

Generally the distance of the bolt centre from the pedestal face shall be 125-150 mm. The

centre to centre distance between the anchor bolts shall be 8 times bolt diameter and the edge

distance from the bolt centre to the face of pocket 4 times bolt diameter.

17.3.3 The top of concrete elevation shall be a minimum of 300 mm above grade for pedestals, piers

and pads and 150 mm above finished floors (concrete grade slabs).

17.3.4 For the support of items at close spacing, such that the footings or pile caps utilize more than

50 percent of the gross plan area, it is common to use a mat type of spread footing, or pile cap,

that supports several items.

17.4 Piles and pile caps

a) All major foundations are considered to be supported on 500 & 600 mm diameter piles,the capacity shall be arrived per calculation based on soil strata or as per pile load test

whichever is less.

b) Pile shall be spaced at 3.0*d (d = diameter of piles) apart in regular grids in rectangularsquare, trapezoidal or triangular pile cap system or along concentric rings for pile cap

supporting tank.

c) Piles shall be cast in situ, driven type approximately 24 m long. For piling specificationrefer document no. 256324-500-SP-CIV-006

d) Pile cap shall be designed in flexure and shear. Minimum thickness shall be 750 mm andare to be designed per IS 2911.


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e) The capacity of the piles shall be as per final soil investigation report.TABLE FOR PILE CAPACITIES

Pile Description Pile load capacitiesSr.

No. Size in

MM.

Length

In

Metres

Type Compression

KN

Tension

KN

Shear

KN

Remarks

1 500

Dia.

24 Driven Cast In

Situ

1000 75 50

2 600

Dia.

24 Driven Pre-

cast

1200 100 60

17.5 Anchor Bolts

For reference of standard details of anchor bolts refer standard drawing.

17.5.1 Anchor bolts shall be designed to resist the applied tensile loads and shear.

17.5.2 Anchor bolts that resist tensile loads shall be designed with an anchor head or plate to transfer

the load through tension in the concrete.

17.5.3 Anchor bolts for all equipments viz. vertical vessels/tanks & structural steel structures like

columns of pipe-racks, sheds, trestles, portals shall have double nuts.

17.5.4 Anchor bolts on horizontal vessels shall have 1 nut per anchor bolt at the fixed end and 2 nuts

per anchor bolt at the sliding end, 1 loose nut and 1 locknut.

17.6 Minimum Cover Requirements to Main Reinforcement

17.6.1 All reinforcement shall have clear concrete cover requirements as per following table &

General Notes, Legend & Abbreviation Drg. No. 256324-500-CIV-2801 whichever is more.

Cast-in-place Concrete Minimum cover (mm)

Cast against and permanently exposed to

earth for major foundation

75 bottom for open footing, (Ref Table 16, IS456)

50 top & sides

100 at bottom for pile-caps

Exposed to earth, weather or water for lessimportant structures

50 for foundations, walls, beams, columns incontact with earth

70 pedestals/columns in contact with earth

Not exposed to weather or in contact with

the ground

40 for beams & 50 for columns/pedestals

above ground

25 for walls & slabs above ground

Precast Concrete Minimum cover

(mm)

Exposed to earth, weather or

water

Wall panels

Other members

40

50

Not exposed to earth, weather Slabs, walls, joints 30


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or in contact with the ground Beams, girders, columns 50

In contact with or above sea

water

Underside and sides of slab

Top side of slab

Beams

75

50

75

17.7 Staircase

17.7.1 Minimum width of stairs shall be 900 mm. Stairs shall have a maximum riser height of 175

mm and a minimum tread width of 250 mm for equipment support platform, maximum riser

height of 150 mm and a minimum tread width of 300 mm for buildings. No of risers shall be

restricted preferably to 12 depending on occupancy. At least one staircase shall be provided

for access to the roofs for maintenance.

17.7.2 Stairway in a single run shall have the same slope. The vertical rise of the stairways shall not

exceed 2.5 m for a single flight.

17.8 Concrete Grade

The minimum M30 grade of reinforced cement concrete shall be used for all structures andfoundations except for grade slabs / paving for which M20 may be used. Severe condition ofexposure as per IS: 456 shall be considered for concrete mix designing for all RCC structuresexcept for RCC in pavements which shall be designed for moderate exposure condition.

If soil investigation report recommendations require a higher cement content and/or specifictype of cement the same shall have precedence.

75 mm thick lean concrete of grade M10 (nominal mix) shall be provided under all RCCfoundations except under base slab of liquid retaining structures where 100 thick concrete ofmix M-10 (nominal mix) shall be used. The lean concrete shall extend 75 mm beyond thefoundation for normal foundations and under liquid retaining structures.

Concrete for encasing shall be M20 with 10 mm down aggregate.

Plain cement concrete (PCC) of grade M10 (nominal mix) of minimum 150 mm thicknessshall be provided under all masonry wall foundations.

17.9 Reinforcement Bars

High strength deformed steel bars of grade Fe 500- corrosion resistant conforming to IS: 1786shall be used.

M.S. round bars (Grade-I) conforming to IS: 432 may be used for holdfasts of inserts.

17.10 Minimum Thickness of concrete members

For structural concrete elements, the following minimum thickness shall be followed:

Footings (all types including raft foundations 300 mm

with out beams)

Pile Cap 750 mm

Slab thickness in raft foundations with beam 300 mm

& slab construction.Floor / Roof slab, Walkway canopy, slab 125 mm


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resting on beams

Cable / Pipe Trench / Launder Walls & 100 mm

Base Slab.

Pre-cast Trench Cover / Floor Slab 100 mm

Blast resistant wall 230 mm

Parapets, Louvre, fins, cantilever canopy 75 mm

Liquid retaining structure wall/ base slab above ground 150 mm

17.11 Allowable Deflections for concrete buildings

17.11.1 The deflections of the structures and buildings based on the worst load combination shall be

limited to an acceptable level as defined below.

17.11.2 Deflections in concrete structures shall be limited by adherence to the limits on span/depth

ratio for beams, slabs & length/lateral dimensions for columns as specified in IS: 456.

Calculated vertical deflections for structural members shall not exceed the following:

For concrete structures (Ref. Cl 23.2.1 of IS 456: 2000):

(a ) For cantilever beams 7

(b) For simply supported beams 20

(c) For continuous beams 26

17.11.3 Total vertical deflection due to all loads including the effects of temperature, creep &

shrinkage= Span/250

17.11.4 The calculated lateral deflections due to load combinations for building shall not exceed the

following:

(a) Occupied buildings = h/250

(b) Wall stanchions = h/350 or 20 mm whichever is less

18 Masonry Structures

18.1 General

Where needed, masonry structure design shall be in accordance with the applicable codes,specifications and recommended practices listed in Section 2.2.6

19 Steel Structures design

19.1 General

18.1.1 All steel structures shall be modelled, analyzed in STAAD PRO and designed as per IS 800-

1984.

All structures shall be framed in transverse direction and braced in longitudinal direction.

Both induced stresses and deflection shall be kept within provisions of IS codes & good

engineering practices.


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Structural Components

The minimum thickness of structural sections shall as given below;

Trusses/bracings 6 mm

Purlins, side girts/runners 6 mm

Columns, beams 7 mm

Gussets in trusses & girders

Up to & inclusive of 12 m span 8 mm

Above 12 m span 10 mm

Stiffeners 8 mm

Base-plates 12 mm

Chequered plates 6 mm on plain

Grating 25 mmGrout for structural columns As required but minimum 25 mm

Grout for equipments As required but minimum 40 mm

19.2 Miscellaneous

18.2.1 Gutter shall be made of mild steel quality of minimum 6 mm thickness; the section shall be

trapezoidal with proper supporting arrangement from purlin at regular interval of 1m to 1.5 m

spacing.

18.2.2 Materials for sheeting:

Roof sheeting for structural buildings shall be pre-coated/ corrugated GI sheeting 20 CGIsheet & 22 CGI sheet (corrugated) for side cladding. Translucent sheet shall be used covering

10%-20% of the area of side sheet & roof sheet with polycarbonate.

18.2.3 Down comer pipes at suitable positions as per design shall be fixed below gutter made of mild

steel of 3.55 mm thickness and minimum 150 mm diameter.

18.2.4 Wind bracing/tie runners of minimum size L50X50X6 shall be provided at 4 points in a truss

(one at each corner) for structural roof system i.e. this shall be designed as structural members

for proper transfer of wind forces to the foundation.

18.2.5 Forms of construction shall be rigid as per Cl. 4.2.1.1 of IS: 800-2007.

Class of sections to be used shall be Class 3 semi compact per Cl 3.7.2 of IS: 800- 2007.

All steel sections shall be of minimum thickness 8 mm except rolled sections (e.g. web of

ISMB, ISMC etc)

For trusses , camber shall be provided in such a way that for truss span > 15 m , that maximum

deflection due to Dead Load + 50% of superimposed load = Maximum camber.

20 Allowable Deflections for structural steel buildings

20.1 General

20.1.1 The deflections of the structures and buildings based on the worst load combination shall be

limited to an acceptable level as defined below. Generally the structural steel members shallbe so designed that the span/depth ratio is 20.


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20.2 Crane Beams or Girders

20.2.1 Calculated deflection of crane beams or girders (without impact) shall not exceed the

following:

a) Vertical (Ref. Table 6, IS 800 - 2007) L/500, light manual operated cranes L/750, electric operation up to 50T L/1000, electric operation over 50T

a) Lateral (Ref. Table 6, IS 800 2007) L/400, but not to exceed 10 mm

20.2.2 for steel structures, (Ref. Table 6, IS 800 -2007):

a)

Pipe rack, Industrial Shed spans = L/240 ( Simple span, Elastic cladding for sheds )b) Spans supporting equipment = L/360 ( Buildings, elements susceptible to cracking )c) Simply supported beams = L/300 ( Workshops /sheds, Brittle cladding brick )d) Cantilever beams = L/120 (Workshops / sheds, Elastic cladding )e) Purlins & Girts = L/150 (Workshops, elastic claddings)f) Spans supporting plastered ceilings = L/300 ( Buildings , spans not susceptible to cracking )g) Gratings/Chequered plates= L/200 or 6 mm which ever is lesser

20.2.3 Lateral deflections shall be as per Table 6, IS 800 -2007.

The maximum total horizontal deflections of the portal frames for sheds shall not exceed L/200of the height.

21 Surface Drainage, Paving & Sewerage: -

21.1 Table showing paving type selection

The surface treatment for the various areas shall be provided as enumerated in the table below.

AREA Concrete Paving Asphalt(Bituminous)

Paving

Concrete/BrickTiles

Gravels Or

Stones

CompactedDressed

EarthSurface

Acid/AlkaliProof

Coating

RoadsApproaches tounits

Fire water

Tanks

T/T Loading

Gantry Sheds

Pump Sheds

Area Around

Non plant

Bldgs.


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Transformer

Yard

Notes:1) Existing services where interfering with the new construction should be located and rerouted

as instructed by HPCL.

2) Micro grading shall be carried out by the Contractor over graded areas to bring the FGL toindicated levels including provision of required slopes and finishes.

3) 75 thick PCC (1:3:6) over compacted earth shall be provided under pipe track areas toprevent vegetation growth in case the area is not concrete/asphalt paved.

20.1.1 Paving within areas for Maintenance / Dropout/ Loading / Unloading / Vehicular movement-

Type 1 (200 mm thick RCC M20)

20.1.2 Non vehicular movement areas

i. Pump Sheds - Type 2 (150 mm thick RCC M20)

ii. Utilities - Type 2 (150 mm thick RCC M20)

20.1.3 Hard surface of 75 thick PCC (1:3:6) over compacted earth shall be provided below all new pipe

rack. This shall extend as indicated in respective layouts and it shall have approach @ 500 m c/c

from nearest road.

20.1.4 Hard surface in PCC 1:3:6 (100 mm thick) over suitable bedding (gravel soiling) of suitable size

(1 m x 1 m or as specified) shall be provided with proper approach near drain point of offsite

piping, near drinking water installations, at washing facilities and at other places as required /

instructed by Engineer in charge, with suitable curbing and drainage arrangements as required for

the fluid being handled.

20.1.5 Suitable drainage arrangements will be provided within curbed areas around pumps, for draining

leaks, floor washes, rainwater falling in the area etc. Finishes, slopes will be as per materials

handled in the area.

20.1.6 Concrete Paving (Within Plant Areas)

Concrete paving shall be laid in alternate cast-in-situ panels of suitable size laid edge to edge,

except at expansion joints spaced not more than 15.0 m c/c.

20.1.7 Hard stands should be designed and provided based on required crane capacity, demolished andsurface made good on completion.

Provision of trenches, drains, sealing of trench covers, inserts, thickening for pipe / equipment

supports etc. shall be made while constructing pavements, as detailed in drawings.

20.1.8 Acid / alkali / chemical resistant coating as specified in equipment layout shall be applied in

areas where they are likely to come in contract with concrete.

21.2 Joints

Expansion joint of 20 mm shall consist of 20 thick impregnated fibre board, filled at top with

joint sealing compound 20 x 25.

Equipment / column pedestals will be separated from paving with 20 thick sand fill and sealing

compound 20 x 25 as shown in standard / drawings.


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Contraction joints will be sealed by sealing compound 20 x 40 as shown in the drawings.

Moving Machinery foundation/column pedestals will be separated from paving with 25 thk.

Shalitex Board.

22 Drainage General22.1 Drain details

Surface drainage includes all surface water discharge from clean plant areas attributable to

rainwater, firewater (except from bunds) and overflow water from water tank to drain via open

surface water drains, trenches and natural water courses to ultimate discharge point avoiding

accidental oily contaminated water system.

Drain section shall be rectangular type in and around units and in other areas. Material of

construction shall be brick drains with 20thk. Cement mortar plaster (1:4) and neat cement

punning shall be provided.

Hot dipped Galvanised electro forged steel grating covers, or pre-cast RCC (M20) covers of

designed thickness, hand railing, chain link fencing wherever necessary shall be provided tominimise the risk of falls by personnel. Oil water separator shall be provided with trenches,

sumps, valves and pipes including connecting to nearest OWS network for disposing the

collected oil to OWS. The separated oil to be transferred to slop tank and the remaining water to

the nearest storm water drain outlet/nallah.

Design rainfall intensity of 75 mm /hr shall be considered for design of storm water drainage

system.

Generally, the slope of the paving shall be 1:100 but the maximum drop in paving shall be

limited to 150 mm. Two way slopes in paving shall be avoided as far as possible.

Slope of main drain along shall be 1:1000. Slope of secondary drain shall be 1:750. Slope of

tertiary drains along east-west shall be 1:500.

22.2 Storm Water Drainage

Storm water drains shall be sized for the higher discharge arising out of either rain water or

fire fighting water and shall be connected to existing drain of adequate capacity.

Rain water run-off shall be computed by the formula:-

Q= (KIA)/360 where,

K= Surface run off coefficient

A= Catchments Area in hectares contributing towards the drain

I= Design Rainfall intensity in mm per hour

Q= Discharge

Runoff Coefficient shall be considered as follows;

a) Concrete Paved area = 1.0b) Bituminous Paved area = 0.9c) Compacted but Unpaved areas = 0.7d) Unusable/Green Belt area = 0.4Design of drains shall be based on Mannings formula:-

V= [(R2/3

) * (S1/2

)] / n

V= Flow velocity in m/s


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R= Hydraulic radius

S= Slope

n= Roughness Coefficient

Roughness Coefficient shall be considered as follows;

a) Plastered surfaces = 0.013

b) Cast in situ concrete = 0.015

c) Concrete/Brick Lining = 0.017

The following points are to be followed while sizing the storm water drains

Minimum velocity in drains = 0.6 m/s

Maximum (Scouring) velocity in drains = 2.4 m/s

Preferred (Self cleansing) velocity in drains = 1.0 m/s

Minimum depth of drains = 300 mm

Minimum width of rectangular drains = 300 mm (for depths 500 mm)

Minimum width of rectangular drains = 500 mm (for depths 500 mm)

Contaminated rain water / Oily water drainage are routed underground to OWS tanks as

appropriate. Sewage to be passed to septic tank & then routed through soak pit & sewage

treatment plant

Concrete pavement run-off surfaces shall slope at 1:100 to perimeter channels. Systems shall

be sized to cope with worst of storm water run-off or fire water run-off.

23 Site grading & roads: -

23.1 Site Grading: -

The site is rough graded to RL 4.2 considering HFL RL 3.5

23.2 Roads:-

All roads shall be asphalt roads and shall be designed for heavy vehicular traffic movements

per IRC loadings.

Design of cross section of roads, including roads for crane access shall be as per IRC 37.

However, the minimum section to be adopted shall be as given below under minimum crosssection. Ruling gradient shall be 1 in 30.

Main plant road widths shall be 7.5 m inclusive of 0.75 m wide shoulders on either side. The

internal access roads to individual areas shall be minimum 4.0 m wide with 0.75 m wide

shoulders. Design life of the same shall be 15 years (Ref. Cl 3.3.3 IRC 37-2001- pavements for

Nationals and State highways shall be designed for a life of 15 years).

Category Width Carriageway Width

i. All Internal Roads 7.5 m 6 m

ii. Access to building 4 m 2.5 m


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Camber: 1 In 50

Radius Of Curve: 6 m for 6 m wide road

Extent: As per Plot Plan & Equipment (Unit Area) Layouts

24 Substations buildings and blast resistant design:

24.1 General

These buildings house electrical switchgear and motor control centres with associated HVAC,

telecoms and battery accommodation. The buildings shall provisionally be designed as indicated

in equipment layout.

The screeded concrete floor shall be finished with an epoxy based hardener and sealant with

corrosion resistant finishes used in battery rooms. Overhead monorail of nominal capacity if

indicated in equipment layouts shall be provided in the main switchgear rooms per detailed

design requirements. There shall be cut-outs provided in cellar floor slab for supporting thepanels. The c/c distance between the stub columns shall be 2.0 m on which the cable trays shall

be supported. There shall be channels/insert plates all around cut-outs to support panels. In cable

cellar, cable tray support shall be of structural steel fixed with mild steel base plate at

bottom or top, at regular interval as per electrical requirement.

Access to the raised floor level shall be via concrete stair and platforms with equipment access

and demountable steel handrails. All doors shall be insulated metal construction with the

addition of removable transformer panels for equipment access where required. A roller shutter

door shall be provided for equipment entry to the main switchgear room.

Fire rated concrete walls shall be provided between the transformers and cable basement and the

transformer compound where required, for the separation of the larger non-sealed type of

transformers.

All mesh infill panels; gates, doors, locks etc. shall be specified to meet the requirements of

relevant codes and standards.

24.2 General principles of steel tank foundation design:

Tanks are utilised for storage of liquids Fire water, Service water ,oil . Tanks are often

provided with ring wall support. Concrete ring wall takes weight of shell as also hoop stress

generated due to active earth pressures & lateral pressure due to surcharge from product weight

and tank base weight.

24.3 Analysis & design procedure for ring walls & RCC pile caps for Steel Tanks:

a) Ring walls shall be designed to transfer vertical loads due to tank shell wall, roof, andincident load due to water or product /oil stored and abutting on ring wall top inside the

shell to firm bearing strata. The vertical load due to product stored or water in tank

during hydro test is transferred directly through tank base plate to firm bearing strata.

b) Ring walls shall also be designed to resist all horizontal loads due to earth pressure,surcharge pressure due to product stored or water stored in tank. Simultaneously ring

walls shall also resist all horizontal loads due to wind & seismic forces and moments

thereof. Hoop tension due to surcharge pressure shall be the primary stress in ring walls.

c) Sand fills or compacted earth fills shall be provided on the inside of the ring wall fromconical tank bottom till founding level of ring wall.


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d) For tanks which are supported on piles they are provided with RCC pile caps with orwith out ring walls. Ring wall shall rest on the RCC pile cap at a minimum depth of

1.2m below Finished Ground Level (T/o pile cap at 1.2 m below FGL).

e) Pile cap shall take all vertical & horizontal loads from ring walls as described in i) & ii)above as also the weight of product liquid or water during hydro test transferred directly

through tank bottom plate & sand fill. Load from ring wall shall be applied as a

concentric uniform load along centreline of ring wall. Product load & water load shall

be applied as area load on top of pile cap. Bending moments due to wind or seismic

horizontal loads shall be calculated at bottom of pile cap level.

f) Pile group shall be designed to resist both vertical loads resulting from external loads,self weight & vertical surcharge pressure as also all unbalanced external horizontal

loads, earth pressure & horizontal surcharge pressure. Pile group shall be preferably

arranged concentrically with ring wall centreline as the guiding circle. Critical

horizontal & vertical loads to be calculated in corner piles and they shall be kept within

safe pile capacities obtained from pile test report.

g) Pile cap shall be designed as bending member & pile shall be considered as hingedsupport with provision for tension reinforcement at bottom of pile cap.

h) Tanks may be resting on different systems of foundation: -a) On RCC piles and pile caps.

b) On earthen tank pad with or without ring wall.

24.4 Analysis & design procedure for RCC underground tanks:

i) Underground RCC tank has to be stable against buoyant water pressure from below.Critical load case shall be for tank empty condition. Factor of safety for buoyancy

during operation of the tank shall be 1.2. Factor of safety against buoyancy for tankempty condition during construction shall be at least greater than 1.05.

ii) For tanks with top slab, wall shall be taken as propped at top & fixed at bottom. Fortanks without top slab or major portion of top slab is cut out due to system requirements

the wall shall be designed as pure cantilever.

iii) If soil water is present and Ground water table (GWT) is above top of tank foundationraft, outside water pressure shall be added on to earth pressure to find out wall

reinforcement for tank empty condition.

iv) Evaluate dead load of RCC tank wall, RCC tank top slab & RCC tank raft.v) Evaluate water load and product load inside tank.vi) Evaluate earth pressure & surcharge pressure from outside. These loads shall be critical

for wall reinforcement when tank is empty. Underground RCC tank shall be a rigid

structure and earth pressure coefficient shall be earth pressure at rest (K a=0.5) bearing

against tank wall.

vii) Evaluate water pressure from inside when tank is full.viii) The coefficient for wall moments & shear shall be taken from IS: 3370 (Pts I IV) &

Reynoldss /Moodys charts. The boundary conditions for the tank walls considered as

plate elements shall be fixed at bottom & hinged (tank slab at top) or free (no slab at

top).

ix) Tank raft & wall shall be designed as un-cracked section.x) For underground RCC tanks resting on piles, piling arrangement shall be provided in

parallel lines & in staggered fashion on either side of the walls. The middle raft shall be


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provided with additional piles at centre or the slab can be suspended as dictated by the

criticality of load.

xi) If the tank bottom slab is suspended the section shall be thinner at middle & thicker atedges below wall (i.e. for the pile cap portion).

xii) Depending on criticality of underground tank analysis & design may be checked bySTAAD-PRO software using finite element method also after routine calculation in

excel.

25 Design Philosophy/Criteria

25.1 Architectural DesignArchitectural design of buildings/sheds shall be in accordance with this design basis and

references as stated herein, in addition to the applicable statutory requirements, layout

planning requirements and so on.

25.1.1 Spatial Requirements

Spatial requirements inside a building/shed shall be decided based on activities to be

performed in the building and consequent occupancy pattern, equipment layout etc. Spaces

can be generally classified as follows, which shall be provided in all the buildings/sheds.

25.1.2 Functional Spaces

Functional area of any building/shed is constituted by the main activity for which the building

is required. Various spaces/rooms shall be judiciously sized and shall be integrated logically

to generate the total building plan taking into account the following parameters.

Activities, group of activities and consequent work-flow pattern

Site conditions i.e. dimensions, contours etc.

Climatic conditions vis--vis orientation

Safety regulations

Lighting and ventilation

Acoustics

Services

Security

Economy

Aesthetics

Any specific requirement pertaining to particular buildings

All other established architectural design parameters

The objective of spatial arrangement shall be to satisfy functional requirements and physical

comfort and safety regulations as well as aesthetics which has significant role in creating a

favourable working and living condition.


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25.1.3 Circulation Spaces

Following spaces are classified as circulation spaces. These spaces shall be provided as per

required building services for integrating various types of spaces and as means of

access/exit/escape.

Corridors & passages

Staircases

Entrance lobby/Foyer including Reception & waiting

Gangway/walkways

Equipment loading/unloading platforms

Emergency Exits

25.1.4 Amenity Spaces

Following spaces are classified as amenity spaces. Out of the following areas, Toilet, Drinking

water, First Aid enclosures shall be mandatory requirement for human occupied

buildings/sheds. Other facilities shall be provided as required.

Toilet (Gents & Ladies)

Drinking Water Facility

Locker & Change Room

Rest room/Lunch room

Canteen/Pantry room

Wash rooms & space for drying clothes

First-aid room

25.1.5 Utility Spaces

Utility spaces are space requirements, which materialise due to provision of services like air-

conditioning, pressurisation, fire fighting, electrical, telephone etc.

25.1.6 Sizes of Spaces

Sizes of various types of spaces shall be decided based on occupancy / equipment/

panel/furniture layout, clearance, maintenance & safety requirements & ventilation

requirements.

Following are the limiting sizes/dimensions for various purposes, which shall be adhered to:

Minimum area of any habitable room = 9.5 m2

with minimum dimension

restricted to 2.5 m

Minimum height of any habitable room = 3 m which may be reduced to 2.75 m

for air conditioned areas. Headroom

below beams to min. 2.4 m

Maximum ht. Of habitable room = as stipulated by the local bye-laws


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Scale of accommodation for industrial work spaces = @ 14m3 per occupants. Minimum clear

heights such workspaces shall be 3.6 m. Height above 4.25 m shall not be taken into account.

25.1.7 Day Light and Natural Ventilation

Established level of illumination shall be maintained for all parts of the buildings by means of

windows, skylights etc. Following references shall be adhered to in this regard.

National Building Code of India

State Factories Act

The objective of day lighting shall be as follows:

Direct solar illumination shall not be considered and only sky radiation shall be taken as

contributing to illumination of the building

Openings shall be provided with shading devices to avoid glare.

For the purpose of illumination, day lighting shall also be supplemented by artificialillumination particularly at fire exit.

25.1.8 Natural Ventilation

Established level of ventilation in terms of air changes per hour shall be maintained for all

spaces. Following references shall be adhered to for the purpose.


State Factories Act

Natural ventilation shall also be supplemented by mechanical or electrical means of

ventilation in all areas of habitation.

25.1.9 Acoustics and Sound Insulation

Specified acceptable noise level and reverberation time shall be maintained inside a

building/shed. Following references shall be referred to for the purpose.


State Factories Act

Required noise level in any space shall be maintained by means of Segregating noise sources

by buffer zones.

Dampening of noise levels by damping devices

Providing Acoustic treatment with acoustic material (on waifs, ceilings, floors, as required)

25.1.10 Safety Requirements

Safety from fire and like emergencies shall be taken into account in building/shed design.

Every building/shed meant for human occupancy shall be provided with exits sufficient to

permit safe escape of occupants in case of an emergency. The exits shall be in terms of

doorway, corridors, and passageways to internal/external staircase or to areas having access to

the outside. Following references shall be adhered to in this regard. Control room building

shall be provided with emergency exit on the other side of the entrance.National Building Code of India Part IV


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State Factories Act

OISD-STD/GDN-115

OISD-STD-116

OISD-STD-117

OISD-STD-173

OISD-STD-144

25.2 Site Planning

Site planning of buildings shall take into account aspects like inter-relationship of the building

with the whole system, movement pattern, traffic and road network, safety regulations, service

network, fire safety, climatic and environmental aspects, site conditions like site dimension,

contour, drainage, noise level, view, future expansion, visual aspects etc.

Main and service/maintenance entrances of buildings shall be provided with vehicular access.

Parking space in accordance with traffic load shall be provided to all buildings. Road networkand open space around the buildings shall be designed considering movement and functioning

of fire tenders.

Climatic factors like wind direction, solar geometry shall be taken into account in orienting

the building. Orientation of building shall also consider noise and smell propagation, views,

and visual effect from various directions.

Sufficient open space shall be provided for planned expansion of building. Sufficient open

space shall also be provided around the buildings for lighting and ventilation in accordance

with Factories Acts.

Site plan shall also take into account landscaping aspects. The inherent characteristics of site,

such as contours, land form, vegetation and terrain shall be fully utilised in the design.Open Space Requirement

Open spaces in a plot and around buildings proportional to the height of the structure shall

satisfy the requirements of the local byelaws.

25.3 Building Services

Following services shall be provided for all building/sheds as

civil design basis

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