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VISAKH MARKETING INSTALLATION REISTEMENT

PROJECT WHITE OIL TERMINAL

Doc No:254624-400-DB-CIV-001 Rev: B Page 1 of 45

P:\Andheri\IndiaProject\254624 HPCL- White Oil Terminal\02 Civil\1-DELIVERABLE LIST (ISSUED

FOLDER)\DOCUMENT\DESIGN BASIS\Design Basis_B.doc

CIVIL DESIGN BASIS

FOR

OFFSITES & UTILITIES

(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







List of Contents Page No

1 Scope 7

2 Codes, Regulations, Specifications and Standards 9

2.1 Specifications: 9

2.2 Analysis & Design: 10 2.2.1 Loads: 10 2.2.2 Concrete Design: 10 2.2.3 Structural Steel Design: 10 2.2.4 Roads, Culverts, Drainage & Pavement Design: 11 2.2.5 Foundation Design: 11 2.2.6 Masonry Design: 11 2.2.7 Misc. Specifications: 11

3 General Topography & Climatic Conditions 12

4 Materials of Construction 12

5 Design Loads 12

5.1 General 12

5.2 Dead Loads (D) 12

5.3 Static & Dynamic Equipment Empty Loads (E) 13

5.4 Equipment Operating Loads (EO) 13

5.5 Equipment Hydro-Test Load (EH) 13

5.6 Piping Loads (P) for Pipe Supports/Trestles 14

6 DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS 15

6.1 Vertical Loading 15

6.2 Friction Force (Longitudinal and Transverse) 15

6.3 Anchor and Guide Force (Thermal load) 15

6.4 Loading on Intermediate Beam at Tier Level 15

6.5 Loading on Longitudinal Beams 16

6.6 Cable Tray/Ducts and Walkway Loads 16

6.7 Wind Force 16

7 Live Loads (L) 16

7.1 General 16

7.2 Live Loads on different structures/buildings 17 7.2.1 Service Platform 17 7.2.2 Substation/Control Room 17 7.2.3 Office building 17 7.2.4 Staircase 17

8 Contingency Loads 18

8.1 RCC Structures 18






8.2 Structural Steel 18

9 Earth pressure (H) & Buoyancy: 18

10 Wind Loads (W) 18

11 Seismic Loads (S) 19

12 Thermal Loads (TL) 20

13 Impact Loads (I) 21

14 Vibration Loads (V) 21

15 Surcharge/Overburden Loads (B) 21

16 Load Combinations 21

16.1 General 21

16.2 Load Factors and Combinations 21

17 Concrete Structures – Design 23

17.1 General 23

17.2 Foundations 24

17.3 Minimum Foundation Sizes 24

17.4 Piles and Pile Caps 24

17.5 Anchor Bolts 25

17.6 Minimum Cover Requirements to Main Reinforcement 25

17.7 Staircase 25

17.8 Concrete Grade 26

17.9 Reinforcement Bars 26

17.10 Minimum Thickness of concrete members 26

17.11 Allowable Deflections for concrete buildings 26

18 Masonry Structures 27

18.1 General 27

19 Steel Structures design 27

19.1 General 27

19.2 Miscellaneous 28

20 Allowable Deflections for structural steel buildings 28

20.1 General 28

20.2 Crane Beams or Girders 28

21 Surface Drainage, Paving & Sewerage: - 29

21.1 Table showing paving type selection 29






21.2 Joints 30

22 Drainage General 31

22.1 Drain details 31

22.2 Storm Water Drainage 31

22.3 Oily Water Sump system (OWS): 32

23 Site grading & roads: - 32

23.1 Site Grading: - 32

23.2 Roads:- 32

24 RCC bund walls & bunded area discharge: 33

24.1 Bunded area discharge: 33

25 Substations buildings and blast resistant design: 33

25.1 General 33

25.2 General principles of steel tank foundation design: 34

25.3 Analysis & design procedure for RCC underground tanks: 34

26 Design Philosophy/Criteria 34

26.1 Architectural Design 34 26.1.1 Spatial Requirements 35 26.1.2 Functional Spaces 35 26.1.3 Circulation Spaces 35 26.1.4 Amenity Spaces 35 26.1.5 Utility Spaces 36 26.1.6 Sizes of Spaces 36 26.1.7 Day Light and Natural Ventilation 36 26.1.8 Natural Ventilation 37 26.1.9 Acoustics and Sound Insulation 37 26.1.10 Safety Requirements 37

26.2 Site Planning 38

26.3 Building Services 38 26.3.1 Water supply, Distribution and Drainage Sanitary Services 38 26.3.2 Electrical Services 38 26.3.3 Air conditioning and Heating 39

26.4 Aesthetics 39

26.5 Structural and Architectural Construction Elements 39 26.5.1 Plinth protection 39 26.5.2 Finished Floor Level (FFL) 39 26.5.3 Steps/ ramps/ Staircases 40 26.5.4 Walls 41 26.5.5 Doors 41 26.5.6 Windows/ ventilators 42 26.5.7 Canopy/Overhang 42 26.5.8 Shading Devices 42 26.5.9 Parapet 42 26.5.10 Roof Gutter 43






26.5.11 Rain Water Pipes Spouts 43 26.5.12 Entrance Lobby 43 26.5.13 Passages/Corridors 43 26.5.14 Service Entry 43 26.5.15 Air-Lock Lobby 43 26.5.16 Emergency Exits 43 26.5.17 Railings 44 26.5.18 Toilets 44 26.5.19 False Ceiling 44 26.5.20 False/Cavity flooring 44 26.5.21 Transformer Gate 44 26.5.22 Under deck Insulation 44 26.5.23 Architectural Finishes 44

27 Railway Siding Work 45






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 tank

foundations, T/T & Wagon Loading/Unloading Gantry sheds, checking platforms, Pipe racks,

Pipe tracks, plant buildings (like DG Sheds/Pump Sheds/MCC-Control 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 254624-400-PIP-3000)

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

STORAGE TANK DETAILS

Sr. No. DYKE No. TANK TAG No. Fluid Content DIA HEIGHT

1 1 400T-001A HSD 40 18

2 1 400T-001B HSD 40 18

3 1 400T-004A HSD 40 18

4 1 400T-004B HSD 40 18

5 2 400T-010A MS 25 18

6 2 400T-010B MS 25 18

7 2 400T-012A MS 25 18

8 2 400T-012B MS 25 18

9 2 400T-040A NAPHTHA 20 18

10 2 400T-040B NAPHTHA 20 18

11 3 400T-002 HSD/SOFT SKO 28 18

12 3 400T-020A SKO 25 18

13 3 400T-020B SKO 25 18

14 3 400T-020C SOFT SKO 25 18

15 4 400T-030A ATF 17 18

16 4 400T-030B ATF 17 18

17 4 400T-030C ATF 17 18

18 4 400T-030D ATF 17 18

19 5 400T-050A MTO 10.5 7.5

20 5 400T-050B MTO 10.5 7.5

21 5 400T-061A ETHANOL 9 10

22 5 400T-061B ETHANOL 9 10

23 6 400T-070 MS 5 5.6

HORIZONTAL VESSELS

Sr.no. TANK TAG No. Fluid Content DIA LENGTH

1 400T-003 HSD-I 3 11.5

2 400T-011 MS-I 3 11.5






B

Sr.no. TANK TAG No. Fluid Content DIA LENGTH

3 400T-022 SKO 3 11.5

4 400T-041 NAPHTHA 3 11.5

5 400T-062A/B HEXANE 3 11.5

6 400T-005 HSD-I 3 11.5

7 400T-013 MS-II 3 11.5

8 400T-023 ATF 3 11.5

OTHER STRUCTURES/AREAS

Sr.No. Description Nos

1 Security Cabin & Lock room 1

2 Workers Amenity , Contractor’s Amenity & Canteen 1

3 Automation room and Administration Building

4 8 Bay T/T Gantry 3

5 D.G. Yard 1

6 MCC Room 1

7 HT Room 1

8 Calibration Shed 1

9 Lube Godown 1

10 Engineering Store + Site office 1

11 Lube Yard 1

12 Planning Room 1

13 Garage & Fire Station 1

14 Transformer Yard 1

15 Rail Staff Room & Two Gantry Office + Railway staff Amenity

room 1

16 OWS For Pol ETP 1

17 TW Gantry 1

18 Lorry Drivers Amenity Room 1

19 Sealing Platform 1

20 Weigh Bridge 1

21 Truck Parking 1

22 9 KL Underground Diesel Tank 1

23 Area For Additive Dozing 1

24 Area For Additive Dozing Drums 1

25 HT Yard 1

26 Pump House 1

27 Septic Tank 1

28 Scrap Yard 1

29 Area For U/G Tank And Pumps 1

30 Vapour Recovery System 2

31 Watch Tower 1

32 Fire Water Tank (400T-091A/B) 1

33 Fire Water Pump House 1

34 Fire Water Make Up Tank 1

35 High mast pole -

36 Laboratory 1

37 Air compressor 1

38 Sewage treatment plant 1

39 Foam skid package 1






B

PUMP DETAILS

Sr.No. PUMP NO DESCRIPTION QTY.

1 400P-001A/B HSD Pump For Tank Truck Filling 2

2 400P-002 HSD I Pump For Tank Truck Filling 1

3 400P-003 HSD II Pump For Tank Truck Filling 1

4 400P-005A/B/C/S HSD II Pump For Tank Wagon Filling 4

5 400P-006A/S HSD Pump For OMC 2

6 400P-010 MS I Pump For Tank Truck Filling 1

7 400P-011 MS II Pump For Tank Truck Filling 1

8 400P-013 MS Pump For OMC 1

9 400P-020 SKO Pump For Tank Truck Filling 1

10 400P-021A/B/C SKO/ATF Pump For Tank Wagon 3

11 400P-022 SKO Pump For OMC 1

12 400P-030A/S ATF Pump For Tank Truck Filling 2

13 400P-040A/S NAPHTHA Pump For Tank Truck Filling 2

14 400P-041A/B/C NAPHTHA/MS II Pump For Tank Wagon 3

15 400P-050A/S MTO Pump For Tank Truck 2

16 400P-061A/B/S ETHANOL Pump For Tank Truck Unloading 3

17 400P-031A/S ATF Pump For OMC 2

18 400P-043 NAPHTHA Pump For OMC 1

19 400P-062A/S

HEXANE Pump For Tank Truck loading &

Unloading 2

20 400P-080A/S Pump 2

21 400P-007 Sick Wagon Unloading Pump 1







28 400P-070 Diesel Pump 1

2 Codes, Regulations, Specifications and Standards

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

2.1 Specifications:

Sr.

No Title

STD. Specification

No.

1. Technical Specification for Earthwork (Excavation

& Filling ) 254624-400-SP-CIV-001

2. Specification for Plain & Reinforced concrete works 254624-400-SP-CIV-002

3. Technical Specification for Structural Steel Works 254624-400-SP-CIV-003

4. Specification for Masonry works 254624-400-SP-CIV-004

5. Specification for Roads & Storm Drain works 254624-400-SP-CIV-005

6. Specification for Piling 254624-400-SP-CIV-006






2.2 Analysis & Design:

(For general notes, legend and abbreviations refer Drg. No. 254625-300-CIV-2801)

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 and

construction of buildings.

2.2.2 Concrete Design:

IS 456 – 2000 Plain & Reinforced Concrete - Code of practice

Special Publication,

SP 16:1980

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

IS 432 :Part I - 1982 Part I – Mild Steel And Medium Tensile Steel Bars

IS 1786 :1985 Specification For High strength deformed steel bars and wires

for concrete reinforcement

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 Construction

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

construction

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

IRC 37 -2001

Guidelines for the design of flexible pavements

IRC 58 -2002

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 raft

Foundations, 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 -Aug. 1999 Process Design & operating philosophy on blow down &

sewer systems

OISD-STD-118 -July 2008 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 Rules

OISD-STD/GDN-115- July 2000 Guidelines on Fire Fighting Equipment and Appliances

OISD-STD-116-July 2008 Fire Protection Facilities For Petroleum Refineries

OISD-STD-117-July 2008 Fire Protection Facilities For Petroleum

Depots,Terminals,Pipeline Installations and Lube Oil

Installations






OISD-STD-173-Sept.2003 Fire Prevention and Protection System For Electrical

Installations.

3 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 Building, Drivers Amenity Room, Weighbridge &

Weighbridge Cabin, Planning Room., Lock room

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;

MCC Room, Transformer yard, HT Room, Rail Staff room & TWD Gantry office, MCC

room etc.

All Pipe/Cable racks shall be Structural Steel with Pile foundations as per soil report. All

Pipe/Cable Tracks shall be Slippers with Either Open/Pile foundations as per soil report.

All Tanks shall be supported on pile foundations.

The shed type buildings shall be following

Engineering Store & Lube Godown, T/T Loading Gantry sheds, Product Pump House TT

Loading, Pump House TW Gantry, Calibration Shed, Lube Yard, Garrage and Fire Stations.

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 excluding

their 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 include

empty weight.

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

manufacturer’s data and includes piping data. Insulation installed on piping and equipment

shall be also considered.

Empty/dead weight – Fabricated/Erected equipment weight from manufacturer’s 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 manufacturer’s 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 1.0 KN/ Sq. m Dead Load (Self weight)

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

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

For pipe racks, where actual loads from pipes are used, they shall not be less than 2.0 KN/ Sq.

m on each level.

Friction Force (Longitudinal & Transverse)

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 vertical

loading & transverse 10% of the vertical loading. Both longitudinal and transverse friction

forces shall be considered to act simultaneously.

5.6.2 Electrical and Instrumentation 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 If no Stress analysis piping loads is available at the time of design, the following minimum

anchor loads shall be used:

(a) for pipe rack span less than 3600mm, apply 5 KN at the middle of the span;

(b) for pipe rack span more than 3600mm, apply 5 KN at 1/4 and 3/4 of the span;

5.6.6 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

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 50% of the

load on the transverse beams. This total load shall be assumed as two equal concentrated loads

acting 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.

6.6 Cable Tray/Ducts and Walkway Loads

The estimated actual load from electrical trays and instrumentation ducts shall be considered at

the specified locations, together with walkways, if provided.

6.7 Wind Force

Transverse wind loading shall be calculated depending on the width of the Pipe Rack as follows:

a) Basic wind pressure shall be considered as per IS: 875.

b) To calculate wind load in transverse direction of pipe-rack, a projected height of 1.25m/1.5m/2.0m shall be considered on all tiers irrespective of height between two tiers of rack widths of 4m/6m/8m and 10m respectively. For pipe-racks of widths greater than 10m, the above projected height shall be taken as 0.8[diameter of largest pipe including insulation (m)] + tan 10° [width of rack (m)]. However, this shall not exceed the height between consecutive tiers.

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 Uniform Loads

(KN/m2)*

Specified Point Loads

(KN)**

Ladder Rungs - 2.2

Office floor, labs, walkways 5.0 9.0

Minimum roof load 1.5 3.75

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 act

concurrently. ** Distribute concentrated loads over 300mm x 300mm area. For evaluation of local effects

of 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 be

used.

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 loads

shall be considered in the design of structures to account for maintenance and erection as

well:\

7.2.1 Service Platform

Vessel/Tower 3.0 KN/m2

Isolated platform (for valve operation) 3.0 KN/m2

Access way 2.5 KN/m2

Cross over 2.0 KN/m2

7.2.2 Substation/Control Room

Panel floor 10.0 KN/m2

Partitions 1.0 KN/m2

7.2.3 Office building

Office area 3.0 KN/m2

Lobby 5.0 KN/m2

Exit way 5.0 KN/m2

Partitions 1.0 KN/m2

7.2.4 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 acting

simultaneously 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 ground water level is around 0.7 m 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 and

recommended practices listed in IS 875, Part III.

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 / sec

k 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

k 3 = Topography factor = 1.0

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






Design wind pressure, p z_gen = 0.6*Vz 2 = 1441 N/m

2 = 1.44 Kn /m

2 for general buildings at

structures of height up to 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

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 be calculated 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 as per Geotechnical Investigation and in accordance with the requirements of the IS standard as mentioned 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 shall be 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 codes and specification.

12.2 Thermal Loads caused by expansion and contraction due to a change in temperature from the erection condition shall be carefully considered. Included are forces due to anchorage of piping and equipment, sliding and rolling of equipment, and expansion and contraction of structures.

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

(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 the structure and provisions shall be made to relieve the forces too large for the equipment or the supporting 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 per information given on civil assignment drawing of equipment supplier. Impact loads shall be considered 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 manufacturer’s recommendations & Indian standards.

A three-dimensional vibration analysis for rotating equipment foundations shall be done to satisfy manufacturer’s recommendation if any, and provisions of Indian standards.

The natural frequency of the supporting structures and foundations shall be below 80 % or above 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 adjacent ground.

16 Load Combinations

16.1 General

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

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

16.2 Load Factors and Combinations

16.2.1 Load notations shall be as follows :

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 forces

1.2*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 for design 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

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 +E

D + 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






B

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 for

garage 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, each applicable load shall be added to the above load combinations with a factor of 1.0 for service load combinations and 1.5 or 1.2 for strength load combinations. For permanent loads for strength design factor 1.5 shall be used & for transient loads .factor 1.2 shall be used.

17 Concrete Structures – Design

17.1 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 designed to meet the deflection criteria as given in clause 17.11.12






B

17.2 Foundations

17.2.1 All major foundations shall be piled Foundations for minor structures shallow spread foundations 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 pedestal

shall 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 utilize more than 50 percent of

the gross plan area, it is common to use a mat type of spread footing that supports several

items.

17.4 Piles and Pile Caps

(a) All major foundations are considered to be supported on 500, 600 & 750 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 rectangular

square, trapezoidal or triangular pile cap system or along concentric rings for pile cap

supporting tank.

(c) Piles shall be cast in situ approximately 27 m long. For piling specification refer

document no 254624-400-CIV-006.

(d) Pile cap shall be designed in flexure and shear. Minimum thickness shall be 750 mm

for individual piles and group piles Except for Vertical storage tanks and lube godown

and are to be designed per IS 2911.

(e) The capacity of the piles shall be per final soil investigation report.

TABLE FOR PILE CAPACITIES

Pile Description Pile load capacities Sr.

No. Dia in

MM

Length

in

Metres

Compression

KN

Tension

KN

Shear

KN

Remarks

1 500 27 1000 75 50

2 600 27 1200 100 60

3 750 27 1600 150 60

As per soil

report






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. 254624-400-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, IS

456)

50 top & sides

Exposed to earth, weather or water for less

important structures

50 for foundations, walls, beams, columns in

contact 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

or in contact with the ground

Slabs, walls, joints

Beams, girders, columns

30

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/cage ladder shall be

provided for access to the roofs for maintenance.






B

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 and foundations except for grade slabs / paving for which M20 may be used. Severe condition of exposure as per IS: 456 shall be considered for concrete mix designing for all RCC structures except for RCC in pavements which shall be designed for moderate exposure condition.

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

75 mm thick lean concrete of grade M10 (nominal mix) shall be provided under all RCC foundations except under base slab of liquid retaining structures where 100 thick concrete of mix M-10 (nominal mix) shall be used. The lean concrete shall extend 75 mm beyond the foundation 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 thickness shall be provided under all masonry wall foundations.

17.9 Reinforcement Bars

High strength deformed steel bars of grade Fe 500 conforming to IS: 1786 shall 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)

Slab thickness in raft foundations with beam 300 mm

& slab construction.

Floor / Roof slab, Walkway canopy, slab 125 mm

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.

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

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

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

19.1.1 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.

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 mm

Grout for structural columns As required but minimum 25 mm

Grout for equipments As required but minimum 40 mm

19.2 Miscellaneous

19.2.1 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.

19.2.2 Materials for sheeting: (hold)

Roof sheeting for structural buildings shall be pre-coated/ corrugated GI sheeting 20 CGI

sheet & 22 CGI sheet (corrugated) for side cladding. Translucent sheet shall be used covering

5 %of the area of side sheet & roof sheet with polycarbonate.

19.2.3 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.

19.2.5 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.

19.2.6 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 shall

be so designed that the span/depth ratio is 20.

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/200

of 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/Brick Tiles

Gravels Or

Stones

Compacted Dressed

Earth Surface

Acid/ Alkali Proof

Coating

Roads √

Approaches to units

√

Tank Farm √

T/T Loading

Gantry Sheds

√

Pump Sheds √

Area Around

Non plant

Bldgs.

√

Transformer

Yard

√

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 to indicated levels including provision of required slopes and finishes.

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

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

Type 1 (200 mm thick RCC M20)






21.1.2 Non vehicular movement areas

i. Units & Tank Farm area - Type 2 (150 mm thick RCC M20)

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

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

21.1.3 Pipe rack where crane movement for maintenance is envisaged paving shall be designed for the

loads arising from the same as per equipment layout requirements

21.1.4 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.

21.1.5 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.

21.1.6 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.

21.1.8 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.

21.1.9 Hard stands should be designed and provided based on required crane capacity, demolished and

surface 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.

21.1.10 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.

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 General

22.1 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 to

minimise 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 = 1.0

b) Bituminous Paved area = 0.9

c) Compacted but Unpaved areas = 0.7

d) Unusable/Green Belt area = 0.4

Design of drains shall be based on Manning’s formula:-

V= [(R2/3

) * (S1/2

)] / n

V= Flow velocity in m/s

R= Hydraulic radius

S= Slope

n= Roughness Coefficient






B

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 and 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.

22.3 Oily Water Sump system (OWS):

Oily water sewers carry water contaminated with oil, e.g. from tank dykes, pump, floor and

paving drains in oily areas etc. These are conveyed to oil separators by means of pipes

through trenches/pipes.

RCC oily water sumps shall be provided as per requirement. All of these shall be connected

through pipes to convey the contaminated water to OWS.

Trenches

The electrical cables are buried in trenches and these cables enter in cellar below the

substation floor.

23 Site grading & roads: -

23.1 Site Grading: -

The site is to be rough graded to RL 4.2 m level .

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 cross

section.

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






B

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 around tank farms/Dyked Areas 7.5 m 6 m

ii. Access to building 4 m 2.5 m

Camber: 2.5% on bitumen surfacing.

3% on shoulder.

2% on Cement concrete surfacing

Radius Of horizontal Curve: 12 to 15 m for 7.5 m wide road.

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

Headroom Clearance: Minimum 7 meter to underside of pipe-racks at overhead road

crossing.

24 RCC bund walls & bunded area discharge:

24.1 Bunded area discharge:

Dyke walls shall be provided as per piping equipment layout requirements shown in plot plan.

All oil tank fluids shall be surrounded by RCC bund walls of height as shown in equipment

layouts. The maximum height of dyke wall shall be as per equipment layout measured from

top of inside paving, to take care of any incidence of leakage from oil tanks.

Analysis & design procedure of RCC bund wall: Concrete grade M30 shall be used for Dyke

walls. Dyke walls shall be designed for retaining liquid in case of rupture of the largest tank in

the farm.

RCC bund walls shall be designed against water pressure from inside for full height as

cantilever as per provisions of IS 3370, Pts I –IV as cracked section. Adequate number of

structural steel/masonry crossovers & stair shall be provided for access.

25 Substations buildings and blast resistant design:

25.1 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 the

panels. 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.

25.2 General principles of steel tank foundation design:

Tanks are utilised for storage of liquids – water, oil and hazardous chemicals. Tanks are often

with piled foundation.

25.3 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 tank

empty 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. For

tanks 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) Outside water pressure up to FGL 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 (Ka=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) &

Reynolds’s /Moody’s 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) Depending on criticality of underground tank analysis & design may be checked by

STAAD-PRO software using finite element method also after routine calculation in

excel.

26 Design Philosophy/Criteria

26.1 Architectural Design

Architectural 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.






26.1.1 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.

26.1.2 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-à-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.

26.1.3 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

26.1.4 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

26.1.5 Utility Spaces

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

conditioning, pressurisation, fire fighting, electrical, telephone etc. Following are examples.

These spaces shall be provided as per required building services.

Air-conditioning plant room

Air handling rooms

Pressurisation blower plant room

Electrical distribution panels rooms

Service ducts

Fire fighting equipment room

UPS room (UPS Room for C&A will be located in Control Room)

Battery room

26.1.6 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

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.

26.1.7 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 artificial

illumination particularly at fire exit.

26.1.8 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.

26.1.9 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)

26.1.10 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

State Factories Act

OISD-STD/GDN-115

OISD-STD-116

OISD-STD-117

OISD-STD-173






26.2 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 network

and 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.

26.3 Building Services

Following services shall be provided for all building/sheds as essential services.

26.3.1 Water supply, Distribution and Drainage Sanitary Services

This service is essential for all habitable buildings/sheds. All buildings with human occupancy

shall have toilet and drinking water facility as per following references.

National Building Code of India Part IX, Section 1 & 2

State Factories Act

Drinking water provisions, including sufficient number of water cooler, minimum one per

area shall be provided within an enclosure separated from the toilets. Space for janitor shall be

provided in the toilets. All service pipes on the external wall shall be suitably concealed or

shall be provided within a shaft.

26.3.2 Electrical Services

This service shall be provided as essential service for all buildings/sheds. Electrical services

for buildings shall consist of electrical supply and distributions. Electrical lighting

installations, telephone network, fans, exhaust fans, lighting protection system etc. including

all accessories, cabling etc. All electrical switches / sockets shall be of modular type (Anchor-

Roma or equivalent as per Electrical design basis or drawings).






26.3.3 Air conditioning and Heating

Areas of control room, administration building, medical centre, substations etc spaces housing

equipment/machinery/panels etc. which require conditioned environment and certain specified

areas like offices, specific office accommodation shall be air-conditioned if specified by

means of Room air-conditioner/split unit or A.C. plant (AHU) depending on the load.

26.4 Aesthetics

Apart from the fulfilment of functional & safety requirement, aesthetic requirement of the

building/sheds shall be taken care of in the design. As specific guidelines for achieving

required aesthetics are difficult to establish, following guidelines shall be followed:

Preliminary Drawings including schematic plans, elevations/views indicating architectural

treatment proposals shall be submitted for Owner's approval.

Following elements shall be considered as contributory elements to aesthetics and their design

etc. shall be subjected to the Owner's approval. Any change/modifications sought for

aesthetics improvements with regards to these elements shall be carried out. Any incidental

elements like brickwork, RCC work etc. required for such changes/modifications shall also be

added.

Building/shed shape and features

Canopies, overhangs & shading devices

Gutters

Entrance/exit steps, door

Window/Ventilator composition

External wall location with respect to columns

Colour scheme, grooves in plaster

Spatial arrangement

26.5 Structural and Architectural Construction Elements

Type of structure & construction shall be as per structural design. Control Room building

shall be either blast resistant (fully R.C.C.) structure or otherwise as per equipment layout to

withstand the specified blast pressure. Other buildings (Sub Stations etc.) shall be R.C.C.

framed structure (columns, beams and R.C.C. roof slab) as per relevant equipment layouts.

Type of Structure & Construction shall be as required as per structural design. The structural

system shall be as specified in Design Basis/Design Philosophy.

26.5.1 Plinth protection

All the buildings & sheds shall be provided with minimum 1000 mm wide plinth protection

around the building/shed.

26.5.2 Finished Floor Level (FFL)

In general, FFL of the Building shall be determined with respect to top of approach road or

pavement. Following schedule shall be adhered to for FFL of the building:

Control Room Building: Top of Approach road level + 150 mm + Height of false flooring






Electrical Sub Station Buildings:

Top of approach Road level + height of false floor minimum 300 mm (Assumed Cable Cellar

floor height as 300 minimum)

Top of approach Road level +150 mm (Transformer bays) with pebbles/gravels

FGL (Finished Ground Level) + approx. 1000 mm high from top of road (in case of single

storey Substation Building with trenches as per electrical equipment layout requirement.

Plant Buildings (Unit area) floors (HPP) shall be maintained as per site grading with respect to

Design Basis & relevant area equipment layouts.

Other Non Plant Buildings: Top of approach Road level +150 mm to 450 mm and or as per

functional requirement.

Vehicle scooter, cycle shed including fire tender bays, repair shop: Top of approach Road level

+150 mm

Loading, Unloading bays Platforms: Top of approach Road level +1100 mm

Notes:

In case of approaches with different top levels, the highest top level of approach road/pavement

shall be considered.

FFL shall be same throughout in a building.

FFL of external loading/unloading bays/ platforms, toilet, pantry, and kitchen shall be 6-12 mm

lower than that of the building’s/shed’s FFL to check ingress/spillage of water.

26.5.3 Steps/ ramps/ Staircases

Staircases shall be provided for vertical circulation & emergency exits. Number of staircases

shall be based on building sizes more than 500 Sq.M ground covered area shall have two stairs

(NBC-Part IV). Emergency exit requirements shall be as per safety distance requirement. At

least one no. staircase / ladder shall be provided for access to the flat roof top for maintenance.

Total number of staircase shall depend on a travel distance to exit points as determined by

statutory rules.

Steps/ ramps shall be provided for access to the Building for pedestrian/ vehicular, equipment

entry as per relevant code. Minimum 1000 mm wide platform shall be provided in between

entrance door and steps/ramps. Following dimensions of the steps/ ramps shall be adhered to.

TABLE

1 Stairs width = 1200 mm minimum

= 1000 mm minimum (Emergency exit)

2 Tread = 260 mm minimum

3 Riser = 175 mm maximum & 150 mm minimum

4 Slope of Ramp = Not steeper than 1:6 but preferred 1:10 or as

Per layout requirement

5 Ratio of Tread & Riser = 2 Riser + Tread= 600 to 650 mm

6 No. of risers per flight = 12 Nos. In general

= 16 Nos. Emergency Exits

7 Landing width = 1000 mm minimum






26.5.4 Walls

Following schedule shall be adhered to for wall material and thickness:

External Walls = 230 mm thick brick wall (including plaster)

Internal partition wall= 230/115 mm thick brick wall depending on the overall length and

height of the wall (Refer note below)

Transformer Perfect Party/Fire resistant Walls= 350 mm (including plaster) thick brick wall or

200 mm thick RCC wall

Concrete wall (Blast resistant) = Minimum 230 thick RCC wall as per structural design

Notes:

115 mm Thick brick partition walls (with nominal steel requirement as per structure design)

shall be provided with 230 mm thick brick pillars or RCC transoms/mullions for stability.

Wherever conduits or pipes are required to be concealed within partition wall, the wall

thickness shall be increased suitably.

Wherever, bricks are not commonly available, suitable alternative material shall be used after

obtaining owner’s approval.

26.5.5 Doors

Doors shall be provided for access, security and safety at all entry & exits of rooms, functional

areas & the buildings. Air tight door shall be provided in pressurized area and in gaseous

protection area. Fire door shall be with two hours rating as per statuary requirement.

Emergency door shall be opened outwards. Sizes of the doors shall be determined on the basis

of the following schedule:

Equipment, Panel area: Size of maximum equipment including packing.

Other areas: Volume of movement through door, W.C., Bath etc.

Cubicle Door: 800 mm x 2100mm (masonry wall opening size)

Minimum Size of other doors: 1000mm x 2100mm (masonry wall opening)

Notes:

Entrance doors shall be provided covering full width of the entrance lobby. In that case the

door shall be of composite type consisting of operable shutters & fixed panels. Entrance lobby

shall be provided with elaborate canopy.

Rolling shutters shall be provided wherever size of opening exceeds 2500 mm x 2500 mm.

Rolling shutters shall be provided for equipment entry for Switchgear Room/ Electrical Room,

A.C. Plant Room etc.

Mechanically operated rolling shutters shall be provided for opening sizes exceeding 8 m2.

Blast resistant Control room entry door shall be provided with blast resistant baffle wall in

front of entry door and shall have 45 degree/ 90 degree overlap on both sides. Refer OISD-STD

163.

Fireproof door shall be provided as per TAC, electrical, process statutory requirements etc.

All doors except toilet door will be glazed, anodized Aluminium door with 5.5 mm thick.

toughened glass. For internal area plain glass shall be used.






26.5.6 Windows/ ventilators

Windows/ ventilators shall be provided in all areas for natural lighting, ventilation and

visibility at working level. For the purposes of ventilation, total operable area of the

windows/ventilators shall be as per Factory Act subjected to a minimum of 15% of the floor

area to be ventilated. However, for control room and in office areas, etc. where visibility from

inside is also important, increased window area shall be provided as per OISD guide line.

Areas accommodating panels/equipments shall be normally provided with ventilators at high

level for unobstructed distributed lighting. Wherever due to limitation of external wall area or

any other reasons, stipulated area of window/ ventilation cannot be provided, suitable

mechanical devices shall be provided. For Workshop/Warehouse sheds etc. with pre-

coated/corrugated GI roof sheeting etc. suitable monitor may added in provide additional

ventilation.

Blast resistant Control room windows openings through wall may be provided as per OISD-

STD 163.

Notes:

Requirements of window/ventilations area as stipulated above is for maximum room height of

4000 mm. For heights more than 4000 mm, additional window/ventilator shall be provided in

the same manner at every work area/platforms at all levels.

Fly mesh shutters shall be provided for windows/ventilators in Kitchen, Pantry, Dining hall etc.

Ventilator shall be able to serve as smoke vents in the event of fire.

Fireproof windows shall be provided as per TAC, electrical, process etc. statutory

requirements.

All windows/ventilators will be glazed, anodized Aluminium window/ventilator.

All glazing on external faces of building shall be toughened glass (5 mm thick).

26.5.7 Canopy/Overhang

RCC/steel Canopy/Overhangs shall be provided at all entrances for rain and sun protection,

accentuation of the entrance and pedestrian movement as per the following schedule:

For all offices, control rooms, composite buildings/sheds accommodating offices, canopy shall

be provided at all entrances. Size of the canopy shall be decided based on vehicle parking and

pedestrian movement in addition to aesthetics of the building/shed.

Overhangs shall be provided over all exits. Size of the overhang shall be decided on the

aesthetics of the building/shed subjected to minimum of 1000 mm.

Blast proof Control Rooms shall not have any projections with outer face of its walls except

with false treatment for aesthetics of the building.

26.5.8 Shading Devices

RCC Shading devices shall be provided over all windows, operable ventilators for rain and sun

protection. These devices shall be in form of horizontal projections, vertical projected fins in

addition as per building facade treatment. Minimum projection shall be 600 mm.

26.5.9 Parapet

Parapets shall be of RCC for all buildings with minimum 300 mm high for non-approachable

roof and 1000 mm high for approachable roof.






26.5.10 Roof Gutter

Gutter with rain water pipes or R.C.C. shafts shall be provided for all the buildings/sheds with

pitched roof for roof water drainage. Sizing of the gutter shall be based on area to be drained

and number of outlets. Gutters shall be of RCC or sheet metal. For Workshop/ Warehouse shed

with Corrugated pre-coated GI roof sheeting, pre-coated GI sheets gutters may be provided and

for big size of workshops/warehouse. RCC shaft may be provided at the end of gutter.

26.5.11 Rain Water Pipes Spouts

Rain water pipes shall be provided for roof water drainage. Number of rain water pipes shall be

decided on the basis of roof area, slope and rainfall intensity as per NBC-IX Section 2. Rain

water pipes shall be embedded in concrete. RCC/PVC/CI/ GI spouts may be used for drainage

of chajja /small canopies of ground floor. The minimum diameter of rain water pipe shall be

150 mm.

26.5.12 Entrance Lobby

Entrance lobby shall be provided as a common entrance for all buildings/sheds accommodating

separate functional spaces integrated together. Individual entries to such functional spaces shall

be from this lobby by means of passages/corridors. Apart from common entry lobby, separate

independent entries to these functional spaces shall also be provided if functionally required.

Size of the entrance lobby shall be decided on the basis of volume of movement.

26.5.13 Passages/Corridors

Passages/corridors shall be provided to integrate various spaces. Width of the

passages/corridors shall be as per statutory requirements.

26.5.14 Service Entry

Separate service entry shall be provided for service areas such as kitchen, air-conditioning

/pressurisation plant room, and electrical rooms. A common service entry may be provided

depending on spatial arrangement.

26.5.15 Air-Lock Lobby

Air-lock lobby shall be provided to all entry and exits of pressurised/centrally air conditioned

areas.

26.5.16 Emergency Exits

Emergency exits shall be provided for the building as per State Factory Rules & OISD Norms,

NBC-Part IV and for individual functional spaces such as Control Room/Instrument Equipment

Room, Console area, Electrical room etc. Emergency exits shall be located in such a manner

that escape route is direct, unobstructed & without passing through any other functional areas

to safe area.






26.5.17 Railings

Railings shall be provided in roofs, stairs, and in all unprotected openings in slabs as a safety

device. Steel railings in high level loading/ unloading bay of substations shall be of removable

type. Parapets shall be given precedence over railings on roofs. All railings shall be as per

standard drawings issued.

26.5.18 Toilets

Toilets shall be provided for all habitable buildings/sheds. Gents & ladies toilet, drinking water

enclosure and janitor space, all shall be provided as required. The fittings/fixtures provided for

bath / toilet shall be of luxury/coloured type.

26.5.19 False Ceiling

False ceilings shall be provided in the all air-conditioned areas for the purpose of reducing

room volume and to hide air conditioned ducting etc. and also to maintain acoustic level inside

any space. Also it reduces habitable room, corridor, lobby, toilet heights located in high ceiling

building/shed to a reasonable & satisfactory height of 3 metre.

In fire rated areas where walls & doors are required to be fire rated, false ceiling shall also have

complementing fire rating. It is to be noted that false ceiling have limitations in their fire

performance due to openings in them for lighting & air-conditioning. Therefore, alternative

systems to prevent puncturing of ceiling must be used.

26.5.20 False/Cavity flooring

False/ cavity flooring shall be provided to accommodate under floor cabling in Instrumentation

areas like Console Room, Rack Room, Computer Room etc. Extent of false/ cavity flooring

shall be as per Electrical/Instrumentation requirements.

26.5.21 Transformer Gate

Steel gate of suitable size in front of transformer bays in substations building may be provided

as per electrical requirement.

26.5.22 Under deck Insulation

Under deck insulation below RCC roof and over false ceiling (both locations) shall be provided

for air-conditioned office / space.

26.5.23 Architectural Finishes

All the buildings shall be provided with Architectural finishes such as floor finishes, plastering

& painting on walls & ceilings, doors/ windows/ ventilators, roof treatment, plinth protection

etc. as below:

For the purposes of schedule of Architectural finishes, buildings are categorized into following

types.

Type A Important buildings like, Main Control Room, Main Gate House, Administration

Building.






Type B Non plant buildings like, Fire Station, Security/ Gate Houses, Secondary Gate Houses,

and buildings like Sub station/ Switchgear room, MCC, etc. which are not included in other

categories.

Type C Sheds like DG Shed, Pump Shed, T/T Loading Gantry Shed and buildings like Watch

Tower, and Parking Shed etc.

Details Hold

27 Railway Siding Work

Design basis for railway siding work will be included in document no. 254624-400-DB-CIV-

002.

Date post:	11-Mar-2018
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