1.1 TP-1ZZZA-CV-BOD-0001_D3

Total pages: 131
NUMALIGARH REFINERY LIMITED
NRL EXPANSION PROJECT
ENGINEERING DESIGN BASIS

FOR
CIVIL, STRUCTURAL,
ARCHITECTURAL AND U/G NETWORK
Revision Note: Modified / Added / Deleted lines are indicated by a line on the left border.
D3 01/12/2021 Approved for Design TMB PKB KC

A1 16/06/2020 Issued for Review TMB PKB KC
Rev. Date Reason for Issue Prepared Checked Approved Prepared Review Review
Discipline Discipline Contractor Discipline Project Department
Engineer Lead Representative Engineer Engineer Head
TPIL NRL
Category Code Description
TECHNIP INDIA LIMITED Facility Area Code 1Z Common Document
NRL’s PO NO: 4300062833-AMA/16.06.2020 Document Type BOD Basis Of Design

TP DOC REF: 082176C-ZZZ-JSD-1700-0001_D3 System Number 00 General
Life Cycle 02 Disk Ref.:
Originator/ Asset Discipline Document Sequence Revision
This document is copyright and shall not be Contractor Code Type Number
reproduced without permission of NRL
TP 1ZZZA CV BOD 0001 D3
Numaligarh Refinery Limited NRL Expansion Project
Engineering Design Basis For Civil, Structural, Architectural and U/G network TP-1ZZZA-CV-BOD-0001_D3
TABLE OF CONTENTS
1 INTRODUCTION: .................................................................................................................................. 4
2 DEFINITIONS & ABBREVIATIONS ....................................................................................................... 4
3 PURPOSE: ............................................................................................................................................ 4
4 CONFLICTS & DEVIATIONS ................................................................................................................. 5
5 BASIC GUIDELINES ............................................................................................................................. 5
6 UNIT ...................................................................................................................................................... 5
PART-A ......................................................................................................................................................... 7
CIVIL AND STRUCTURAL ............................................................................................................................ 7
1. GENERAL........................................................................................................................................... 8
2. REFERENCE STANDARDS AND PUBLICATIONS ............................................................................ 8
3. MATERIAL OF CONSTRUCTION .................................................................................................... 13
4. LOADS AND FORCES ..................................................................................................................... 19
5. LOAD COMBINATIONS.................................................................................................................... 33
6. DESIGN OF FOUNDATIONS / FOOTINGS ...................................................................................... 41
7. PLINTH PROTECTION: .................................................................................................................... 50
8. RAMPS: ............................................................................................................................................ 50
9. COVERING OF PITS / BASINS: ....................................................................................................... 50
10. FLOORING DETAILS FOR BUILDINGS & SHEDS: ...................................................................... 50
11. SPECIAL CONSIDERATIONS FOR RCC STRUCTURES: ........................................................... 51
12. SPECIAL CONSIDERATIONS FOR STEEL STRUCTURES: ........................................................ 56
13. SPECIAL CONSIDERATIONS FOR MASONRY WORKS: ............................................................ 63
14. PLATFORM BELOW AIR COOLERS: ........................................................................................... 63
15. RCC AND STEEL CHIMNEYS: ..................................................................................................... 64
16. TANK FOUNDATIONS: ................................................................................................................. 64
PART-B ....................................................................................................................................................... 65
SEISMIC DESIGN ....................................................................................................................................... 65
1. GENERAL......................................................................................................................................... 66
2. DESIGN CONSIDERATION:............................................................................................................. 68
3. PERMISSIBLE STRESSES: ............................................................................................................. 69
4. METHOD OF SEISMIC DESIGN: ..................................................................................................... 70
5. DUCTILE DETAILING ....................................................................................................................... 73
6. SPECIAL PROVISION FOR STORAGE TANKS............................................................................... 73
PART-C ....................................................................................................................................................... 74
ARCHITECTURAL WORKS ........................................................................................................................ 74
1 SCOPE ............................................................................................................................................. 75
2 DESIGN PHILOSOPHY / CRITERIA - GENERAL............................................................................. 75
3 ARCHITECTURAL FINISHES........................................................................................................... 89
4 GENERAL REQUIREMENTS ......................................................................................................... 104
Page 2 of 131 TP DOC REF: 082176C-ZZZ-JSD-1700-0001_D3
PART-D ..................................................................................................................................................... 106

GENERAL CIVIL ....................................................................................................................................... 106
1. SCOPE: .......................................................................................................................................... 107
2. UNITS OF MEASUREMENTS: ....................................................................................................... 107
3. DEFINITIONS: ................................................................................................................................ 107
4. CODES & STANDARDS: ................................................................................................................ 107
5. OVERALL PLOT PLAN: .................................................................................................................. 110
6. SITE GRADING: ............................................................................................................................. 110
7. ROADS: .......................................................................................................................................... 111
8. CONCRETE PAVEMENT: .............................................................................................................. 114
9. SITE FINISH: .................................................................................................................................. 117
10. STORM WATER DRAINAGE: ..................................................................................................... 118
11. WATER SYSTEM: ....................................................................................................................... 122
12. SEWERS:.................................................................................................................................... 123
13. STORAGE TANK FOUNDATION AND DYKE WALL: ................................................................. 129
14. FENCING AND BOUNDARY WALL: ........................................................................................... 130
15. ENTRANCE GATE: ..................................................................................................................... 130
16. PIPE SLEEPERS: ....................................................................................................................... 130
17. ELECTRICAL / INSTRUMENTATION CABLE ROAD CROSSING (ERC / IRC): ......................... 130
18. BARRICADE: .............................................................................................................................. 131
19. SPECIFIC REQUIREMENT: ........................................................................................................ 131
20. REMOVAL / REROUTING OF OBSTRUCTIONS ........................................................................ 131

1 INTRODUCTION:
NUMALIGARH REFINERY LIMITED (NRL) has awarded Project Management Consultancy

services (Managing PMC) M/s. Technip India Limited (TPIL) to provide PMC/EPCM services for
Numaligarh Refinery Expansion Project (NREP) from 3 to 9 MMTPA of its Refinery in Numaligarh,
Golaghat District, Assam, India.
2 DEFINITIONS & ABBREVIATIONS
Wherever used in this procedure, the following words shall have the meaning as given hereunder:
Abbreviation Definition /Expanded form

NRL / OWNER / shall mean Numaligarh Refinery Limited
CLIENT
MPMC Managing PMC (shall mean Technip India Limited)
CONSULTANT Shall mean EPCM/ EPCM 1/ EPCM 2/ BOO
LICENSOR Party responsible for process technology ownership for any UNIT
CONTRACTOR Party whose services are obtained for performing the works
specified as part of LSTK / EPC packages.
LSTK Lump Sum Turn Key execution of EPC package by the
CONTRACTOR
EPC Engineering Procurement & Construction execution on Lumpsum
basis by the CONTRACTOR
SUB- Party whose services are obtained by CONTRACTOR for performing
CONTRACTOR the works specified as part of LSTK / EPC packages
VENDOR Any third party supplying the equipment/materials for setting up the
Plant
EPCM-1 A portion of NREP for which NRL is engaging another Consultant to
perform Engineering, Procurement, Construction management
services as required within the battery limits of UNITs assigned to it
EPCM-2 A portion of NREP for which NRL is engaging another Consultant to
perform Engineering, Procurement, Construction management
services as required within the battery limits of UNITs assigned to it
BOO Build Own Operate – A portion of NREP for which NRL is engaging
a CONTRACTOR on “Build Own Operate “mode to supply the output
to be consumed in rest of the UNITs
UNIT Indicates any particular portion of the NREP to be built which can be
Process related or Utilities/Offsites related
BIS Bureau of Indian Standards
OISD Oil Industry Safety Directorate
E-I-C Engineer In Charge
3 PURPOSE:
The purpose of this document is to lay down the basic requirements for design and development
of Civil & Structural, Building and Under Ground (U/G) Activities, including the philosophy,
schematic, functional requirement to be taken in design, manufacture, testing, supply, construction
and installation. This shall be applicable for all CONSULTANTS/ CONTRACTOR / Sub-
CONTRACTOR working in Numaligarh Refinery Expansion Project to meet the overall
requirements of the CLIENT.

4 CONFLICTS & DEVIATIONS

If conflicting statements exist within this document or between this document and other applicable
specifications, Standard Drawings, Industry standards, codes, etc., it shall be brought to CLIENT /
MPMC notice for clarification and proper approval shall be obtained before implementation.
Decision of CLIENT / MPMC shall be final.
In case of contradiction between licensor specification, design basis and Job Supply Specifications
/ data Sheets, it has to be brought to the notice of CLIENT / MPMC and Decision of CLIENT /
MPMC shall be binding on CONTRACTOR / VENDOR.
In general, order of priority of the documents shall be as follows,
• Local regulatory and statutory requirement.

• Licensor Requirements (as applicable)
• Project specification and datasheets, wherever applicable.
• This specification and relevant equipment/system specification.
• Codes and standard
5 BASIC GUIDELINES
1) All Civil / Structural designs shall be carried out in accordance with latest IS Codes (with all
amendments issued there to) on the notified date of tender
2) Internal / External materials of construction for buildings shall conform to Specifications.
3) Construction material such as sand, cement, aggregate, water, reinforcement, weld-mesh
and structural steel & structural steel sections, etc., shall conform to relevant BIS Codes &
specifications. All other material shall be in accordance with specifications.
4) IS Codes shall be followed for workmanship and testing of materials.
5) Apart from the IS codes particularly mentioned in various clauses of this document, all
other relevant codes related to specific job under consideration and/or referred to in the
above-mentioned codes, shall be followed wherever applicable. Reference to some of the
codes in various clauses of this document does not limit or restrict the scope of applicability
of other relevant Codes.
6 UNIT
The International System of Units (SI) shall be used.

INDEX
Part Sections No. of sheets Pages
A CIVIL AND STRUCTURAL 57 07 to 64

B SEISMIC 8 65 to 72
C ARCHITECTURAL 32 74 to 105
D GENERAL CIVIL 26 106 to 131

PART-A
CIVIL AND STRUCTURAL

1. GENERAL
This specification defines the design criteria and loads that should be taken in to account for the
design of all industrial plant and non-plant structures and buildings.
2. REFERENCE STANDARDS AND PUBLICATIONS

(All codes & Standards including all parts shall be latest revision with all amendments issued
thereto)
Sl No. Description Code
1. Paving Bitumen – Specification IS:73
2. Mild Steel wire for general engineering purposes IS: 280

Specification for Coarse and Fine aggregates for natural sources for
3. IS:383
Concrete
4. Classification of Commercial Timbers & their zonal distribution IS:399
5. Specification for expanded metal steel sheets for general purposes IS:412
Specification for mild steel and medium tensile steel bars and hard-
6. IS:432
drawn steel wire for concrete reinforcement.
7. Specification for Portland slag cement IS:455
8. Code of practice for plain & reinforced concrete IS:456
9. Specification for test sieves: Part-1 Wire cloth test sieves IS:460
10. Methods of test for strength of concrete IS:516
11. Code of practice for general construction in steel IS:800

Code of practice for use of cold formed light gauge steel structural
12. IS:801
members in general building construction
Code of practice for use of structural steel in overhead transmission
13. IS:802
line towers
Code of practice for design, fabrication and erection of vertical mild
14. IS:803
steel cylindrical welded storage tanks
15. Code of practice for use of steel tubes in general building construction IS:806
16. Cold formed light gauge structural steel section IS:811

Covered electrodes for manual metal arc welding of carbon and
17. IS:814
carbon manganese steel
18. Code of practice for use of metal arc welding for general construction IS:816
Code of practice for design loads (other than Earth quake for building
19. IS:875
and structures)
Code of practice for Design of structural timber in building
20. IS:883
21. Common burnt clay building bricks specifications IS:1077

Code of practice for design and construction of shoulder foundations
22. IS:1080
in soils (other than raft, ring and shell)

23. Method of identification of natural building stone IS:1123

Method of test for Determination of water absorption, apparent specific
24. IS:1124
gravity and porosity of natural building stone.
Recommendations for dimensions and workmanship of natural
25. IS:1127
building stone for masonry work
26. Recommendations for dressing of natural building stones IS:1129
27. Steel tubes for structural purposes- specification IS:1161
28. Code of Basic requirements for water supply, drainage and Sanitation IS:1172
29. Bitumen-Mastic for flooring- specification IS:1195
30. Methods of sampling and analysis of concrete IS:1199
31. Steel tubes, tubulars & other wrought steel fittings IS:1239
32. Methods of sampling and test for anaerobic adhesives and sealants. IS:1305
33. Specification for bitumen felts for water proofing and damp proofing IS:1322
34. Code of Practice for Pre-stressed Concrete IS:1343

Hexagon Head bolts, screws and nuts of product grade 'C' - Part-1:
35. IS:1363
Hexagon Head Bolts
36. Technical supply conditions for threaded steel fasteners IS:1367
37. Specification for portland pozzolana cement IS:1489

Specification for hard-drawn Steel Wire Fabric for Concrete
38. IS:1566
reinforcement
39. Code of practice for construction of stone masonry IS:1597
Dimensions for steel plates, sheets strips and flats for general
40. IS:1730
engineering purposes
41. Code of Practice for Building Drainage IS:1742
Specification for high strength deformed steel bars and wires for
42. IS:1786
concrete reinforcement
43. Specification for hot applied Sealing Compounds for Joints in concrete IS:1834
44. Fillers for expansion joints IS:1838
45. Criteria for earthquake resistant design of structures (Part 1 to 4) IS:1893
46. Design & Construction of Foundations in solids IS:1904
47. Code of practice for structural use of unreinforced masonry IS:1905
48. Specification for plain washers IS:2016
49. Hot rolled low, Medium and high tensile structural steel IS:2062

50. Code of Practice for Water Supply in Buildings IS:2065
51. Specification for sand for masonry mortars IS:2116
52. Specification for concrete masonry units IS:2185
53. Code of practice for brick works IS:2212
54. Code of practice for preparation and use of masonry mortars IS:2250
55. Steel wire ropes for General Engineering purposes- Specification IS:2266
56. Specifications for thimbles for wire ropes IS:2315
57. Bulldog grips- specification IS:2361
58. Methods of test for aggregates for concrete (Part-II) IS:2386
59. Methods for sampling of aggregates for concrete IS:2430
60. Drop forged sockets for wire ropes for General Engineering purposes IS:2485
Code of Practice for Bending and Fixing of Bars for Concrete
61. IS:2502
Reinforcement
62. Recommended practice for hot dipped galvanizing on iron and steel IS:2629
63. Methods for testing uniformity of coating of zinc coated articles IS:2633
Integral waterproofing compounds for cement mortar and concrete-
64. IS:2645
specification
65. Code of practice for design and construction of pile foundation IS:2911
66. Code of practice for design & construction of raft foundations IS:2950
67. Code of practice for design & construction of machine foundations IS:2974
Methods of sampling & test (physical & chemical) for water and
68. IS:3025
wastewater
69. Specification for bitumen mastic for use in water proofing of roofs IS:3037
70. Specification for ballies for general purposes IS:3337
71. Code of practice for concrete structures for storage of Liquids IS:3370
Specification for bitumen primer for use in water proofing and damp
72. IS:3384
proofing
73. Design & Installation of Joints in Buildings IS:3414
74. Crane Rail Sections IS:3443
75. Specification for masonry cement IS:3466
76. Methods of test of burnt clay building bricks IS:3495

77. Steel chequered plates: specifications IS:3502
78. Specification for structural timber in building IS:3629
79. Specification for high strength structural bolts IS:3757
80. Roof Extractor Units IS:3963
81. High strength bolts in steel structures- code of practice IS:4000
82. Methods of physical tests for hydraulic cement IS:4031

Recommendations on stacking and storage of construction materials
83. IS:4082
and components at site
Code of practice for design and construction of foundation for
84. IS:4091
transmission line towers and poles
85. ISO general purpose Metric Screw thread IS:4218
Code of practice for earthquake resistant design and construction of
86. IS:4326
buildings
87. Hollow steel sections for structural use IS:4923
88. Ready-Mixed Concrete - Code of Practice IS:4926

Recommendations for Buildings and facilities for the Physically
89. IS:4963
Handicapped
90. Unplasticized PVC pipes for potable water supplies specifications IS:4985
91. Plywood for concrete shuttering works - specifications IS:4990

Criteria for Blast resistant design of structures for explosions above
92. IS:4991
ground
93. Criteria for design of reinforced concrete bins. IS:4995
94. Criteria for design of RCC chimneys IS:4998
95. Determination of dynamic properties of soil IS:5249
96. Cement paint IS:5410
97. Methods of sampling of clay building bricks IS:5454
98. Specification of bitumen mastic for tanking and damp proofing IS:5871
99. Code of practice for anti-termite measures in buildings IS:6313

Code of practice for determination of bearing capacity of shallow
100. IS:6403
foundation
101. Specification for High Alumina Cement for structural use IS:6452
Code of practice for water-proofing of underground water reservoirs
102. IS:6494
and swimming pools
103. Code of practice for installation of joints in concrete Pavements IS:6509

104. Code of practice for design & construction of steel chimney IS:6533
105. Method for determination of mass of zinc coating IS:6745
106. Specification for glass fibre base bitumen felts IS:7193
107. Code of practice for damp-proofing using bitumen mastic IS:7198
108. Tolerances for Fabrication of Steel Structures IS:7215
109. Code of practice for calculation of settlements of foundation IS:8009
110. Specification for 43 grade ordinary portland cement IS:8112

Specification for bitumen mastic, Anti-static and electrically conducting
111. IS:8374
grade
112. Chlorpyrifos emulsifiable concentrates IS:8944
113. Concrete admixtures- Specifications IS:9103
114. Criteria for design of steel bins for storage of bulk Materials IS:9178
Recommendations for metal arc welding of carbon and carbon
115. IS:9595
manganese steel
116. Recommended guidelines for concrete mix design IS:10262
117. Code of practice for design and construction of ring Foundation IS:11089
118. Specification for one part polysulphide base joints sealant IS:11433
Code of practice for design & construction of shallow foundations on
119. IS:12070
rock
120. Two parts polysulphide based sealants IS:12118
Pro vision of water-stops at Transverse contraction joints in masonry
121. IS:12200
& concrete dam- code of practice
122. Specification of 53 grade Ordinary Portland Cement IS:12269
123. Specification for sulphate resisting Portland cement IS:12330

Hot -dip Zinc Coating on Structural Steel Bars for Concrete
124. IS:12594
Reinforcement – Specification
Hot rolled parallel flanged steel sections for beams, columns and
125. IS:12778
bearing piles- Dimensions and section properties
126. Tolerances for Erection of Steel Structures IS:12843
127. Pulverised fuel ash Lime bricks- specifications IS:12894

Guidelines for selection of ground improvement technique for
128. IS:13094
foundation in weak soils
129. Guidelines for vibration isolation for machine foundations IS:13301
130. Fusion bonded epoxy coated Reinforcing bars IS:13620


Code of practice for ductile detailing of reinforced concrete structures
131. IS:13920
subjected to seismic forces
132. Control Room Safety (a publication of Oil Industry Safety Directorate)
OISD-STD-163
133. Fire Proofing in Oil and Gas Industry (a publication of Oil Industry
OISD-STD-164
Safety Directorate)
134. Inspection, Maintenance, Repairs & Rehabilitation of foundations &
OISD-STD-170
Structures
135. Fire Protection System for Electrical Installations (a publication of Oil
OISD-STD-173
Industry Safety Directorate)
136. National Building Code
137. Building Bye Laws
138. Factory Rules
139. Indian Roads Congress (IRC) codes
140. CPWD specifications
141. IBR specifications
142. Airport Authority Rules
143. LPG Rules
144. Method for evaluation of results of accelerated corrosion test. IS 6009
Note:
The above list is suggestive not exhaustive. Apart from these basic codes any other codes should
also be followed wherever required.
3. MATERIAL OF CONSTRUCTION
3.1 General
Unless otherwise specified in the drawings, material specifications should conform to the following.
3.1.1 Cement:
Generally, for all concrete works both above and below ground, the use of one of the following
type of cements shall be considered, with due regard given to suitable for type of structure and/or
chemical resistance:
♦ 43 Grade or 53 Grade Ordinary Portland Cement (OPC) conforming to IS: 8112/IS: 12269.
OPC shall be used for all the important structures.
♦ Portland Slag Cement (PSC) confirming to IS: 455.
♦ Portland Pozzolana Cement (PPC, fly ash based) confirming to IS: 1489 Part 1.
♦ Portland Pozzolana Cement (PPC, calcined based) confirming to IS: 1489 Part 2.
♦ Sulphate Resistant Portland Cement (SRC) confirming to IS: 12330 shall be used for
foundations and below ground structures (if required as per soil recommendation for
respective site).

Use of specific type of cement for U/G works and foundations, piling shall depend on the soil
condition.
3.1.2 Aggregate:
Aggregates used in concrete works shall be conforming to IS: 383 sourced from approved quarries
or source. For most works, graded 20 mm down aggregate shall be used. Where there is no
restriction to the flow of concrete into sections, 40 mm down aggregate shall be used in special
cases. Before using, the aggregates shall be tested as per IS 2386. The grading of fine
aggregates, when determined as described in IS: 2386 (Part-I) shall be within the limits as given in
IS: 383. If required, the aggregates shall be thoroughly washed as directed by EIC.
Blast furnace slag and manufactured sand shall not be used as aggregates.
3.1.3 Reinforcement:
Reinforcement shall be High Strength deformed TMT bars of grade Fe 500D (Alternatively Fe
550D acceptable) conforming to IS: 1786.
Reinforcement steel of minimum grade Fe500D to be used. Unless specifically stated otherwise
use of mild steel is not permitted in R.C.C. works. If used shall be of Grade I conforming to IS: 432
Part I. Reinforcement steel shall be procured from suppliers listed in the Master Supplier list -
Document No. -TP-1ZZZA-PQ-VNL-0002
Corrosion resistant steel (CRS-rebars) to be used for liquid retaining structures like sump,
reservoir, Cooling tower cell etc.,
3.1.4 Binding Wire:
18 gauge black soft annealed SWG wire confirm to IS 280 shall be used for binding of
reinforcement bars.
3.1.5 Admixtures:
Admixtures shall conform to IS: 9103 and are to be mixed with concrete strictly as per
manufacturer’s recommendations.
3.1.6 Grouting:
Refer Document No.NR-0ZZZZ-CV-SPE-0004 – Specification for Grouting and Clause 6.14 of this
document for additional grouting information.
3.1.7 Anchor Bolts
Anchor bolts shall be of mild steel conforming to Grade A of IS: 2062 and fabricated as per
Document “Construction Standards for Concrete Works”. Minimum two nuts shall be used for all
anchor bolts except for ladder, stair and handrail. High strength bolts of grade ASTM A193 B7 on
specific cases (required by vendor or specified in equipment data sheet) may be used in lieu of
E650A grade bolts and approved by OWNER/MPMC.
3.1.8 Structural Steel
Structural Steel shall conform to IS: 2062 with minimum yield Strength of 250 N/mm2 & shapes
shall be as per SP 6 of IS: 800 / IS: 12778 (wide flange/narrow flange sections) or Universal
beams and Columns as per BS.
Structural Steel shall comply with requirements as follows:
a) For ISMB, ISMC, ISA (Angles), NPB, WPB : IS 2062 Grade E250BR
b) For Flats : IS 2062 Grade E250BR
c) For Plates : IS 2062 Grade E250BR / E350BR
d) For Universal Columns/Beams : BSEN 10025 S275JR / S275J0 / S355J0

Tubular / Hollow steel should conform to Yst 310 of IS:1161.
Properties of steel section shall be as follows:
a) Rolled section as per IS: 808
b) Parallel flanged sections as per IS: 12778.
c) Circular Hollow sections (CHS) as per IS: 1161.
d) Square Hollow sections (SHS) / Rectangular Hollow Sections (RHS) as per IS: 4923.
Steel sheets shall conform to IS: 1079.
Crane rails shall conform to IS: 3443.
3.1.9 Structural Bolts
Unless otherwise specified in the item, Bolts shall be Snug Tight High Strength Bolts of Grade 8.8
or 10.9 conforming to IS: 3757 & IS: 4000. Bolts shall be half/partial threaded and avoid threaded
length do not encroach within thickness of connected members/plates. Ordinary Black bolts of
grade 4.6 allowed for Handrails.
Nuts shall conform to IS 6623 (or IS 1367 part 3 for bolts >M36) applicable for bolt type & strength
and as shown in the drawing. Unless otherwise specified nuts and bolts heads shall be hexagonal.
Class of nuts and bolts shall be compatible. Wherever shown in the drawing, high strength
function grip bolts and nuts conforming to IS: 3757 and IS: 6623 respectively shall be used.
Washers: Plain washers shall be made of MS conforming to IS:5369 unless otherwise specified.
Two number of washers and one nut shall be used for bolt set, Washer should be under nut and
head of bolt (i.e., 1 bolt = 2 washers + 1 nut). Helical spring washers conforming to IS: 6755 shall
be provided for bolts carrying dynamic or foundation loads and direct loads. Tapered washers
conforming to IS: 5372 and IS: 5374 shall be used for channels and beams respectively. Washers
for high strength friction bolts shall conform to IS: 6649.
All Bolts, Nuts and Washers shall be Hot Dip Galvanized as per IS1367 part 13.
All connection bolts for structural steel shall be high strength structural steel bolts of property class
8.8 (min) conforming to IS 3757 & IS 4000. Hexagonal nuts shall conform to IS 6623. Washers
shall conform to IS 6649. for handrails and ladders grade 4.6 bolts as per IS 1367 may be used.
3.1.10 Insert Plates
Insert plates should be of structural steel grade E250 (FE 410W) Quality BR/ Quality B0
conforming to IS: 2062 and should be provided with mild steel lugs and /or TMT bar lugs as per
drawings/ standards. Stainless Steel inserts shall be used when inserts expose to Acid/Alkali
materials.
Mild steel bars should conform to IS: 432. Minimum thickness of Insert plate shall be 10mm.
3.1.11 Gratings
Electro-forged hot dip galvanized MS Gratings shall be minimum 25mm deep. The maximum size
of voids in the grating shall be limited to 30mm x 100mm. Bearing bars shall be 5mm thick.
Maximum span of grating shall be as per supplier recommendation (data sheet to be provided for
OWNER/PMC approval). galvanizing shall be as per IS 2629. Maximum deflection of grating shall
be limited to Span/200 or 6mm whichever is greater, Span shall be limited to 1.4m.

Steel chequered plates shall conform to IS: 3502. U-type galvanized grating clamps may be used
for grating fixing, shall rigidly hold the gratings. Clamps shall be inspected and approved by
Engineer-In-Charge.
All gratings shall be Hot dip galvanized with minimum thickness of galvanization shall be 120
micron.
3.1.12 Handrails
Hand rails, 1000mm high (from top of grating / top of chequered plate / FFL), should be provided
to all walkways, platforms, staircases. Toe plate (100mmx5mm) should be provided for all
horizontal hand railing (except for hand railing in inclined portion of staircases). Spacing of
uprights should be 1500mm (maximum). Removable hand rails upright spacing shall be restricted
to 1250mm and maximum length of one piece of removable handrail shall be 3750mm.
Two types of hand railing should be provided:
I. For Tech. structures, walkways, platforms (except platform around/on circular/horizontal
vessels), staircases: Top rail, mid-rail and upright should be 32mm dia (NB) galvanized
medium grade MS tubes.
II. For platforms around circular vessels: Top rail should be 32mm dia (NB) galvanized
medium grade MS tubes but mid rail shall be 50X6 MS flat and vertical post shall be of
angle section L50X50X6.
Handrails shall be galvanized and further painted for safety reasons. Galvanization thickness shall
be 610 gsm minimum. Epoxy Painting for Galvanized Hand rails shall be provided with color code
as per safety requirements. Refer to Painting Specification TP-1ZZZA-PI-SPE-0003.
3.1.13 Design Strength of Concrete
Unless otherwise specified, the minimum concrete grade should be as follows,
Related Work Grade Designation
Piles M30
Liquid Retaining Structures M30
Structural Concrete M30
Trench/ Drainage M25 / M30
Grade Slab / paving* M30 / M25
Leveling Concrete M20
Filling / Mass / Plum Concrete M7.5 /M10
Dense Fire proofing M20
Precast concrete super structure M35
* Refer to clause 6 in Part-D General Civil.
Minimum cement content, maximum water cement ratio and minimum grade of concrete for
different exposures shall be as per IS: 456 (Latest edition). Special type of Cement shall be used,
if required as per Soil report.
Unless otherwise stated, the mix design is to be carried out by the Contractor for approval of PMC/
NRL.
3.1.14 Plain Cement Concrete (PCC):
1) 75 mm thick lean concrete of grade 1:4:8 (M7.5) should be provided under all RCC
foundations except under base slab of liquid retaining structures where 100mm thick
concrete of grade 1:3:6 shall be used.

2) The lean concrete shall extend 50mm beyond the foundation for normal foundations and
75mm under liquid retaining structures.
3) Plain Cement Concrete PCC of grade M20 of minimum 150mm thickness shall be provided
under all masonry wall foundations.
4) Plain Cement Concrete (PCC) mud mat of grade M20 (nominal mix) of minimum 150 mm
thickness shall be provided under all masonry wall foundations.
5) Acrylic based waterproofing compound (2% by weight of cement) shall be mixed in concrete
used as damp proof course of minimum 40mm thickness at plinth level of all masonry walls.
6) Plain cement concrete of grade M20 (nominal mix) of minimum 40 mm thickness shall be
provided as damp proof course at plinth level of all masonry walls. Integral waterproofing
compound conforming to IS:2645 shall be mixed with concrete (as per manufacturer’s
specifications) and coated with bitumen emulsion.
7) Minimum grade of concrete for General Civil work should be as specified in Detail
specification for General Civil works.
3.2 Material Of Construction Also refer Sr. No. F2 in Annexure 1 to Material Requisition
Unless otherwise specified in the drawings, material of construction for various Type of Structures
should conform to the following:
S. Type of Material of Level Up Fire Proofing Remarks

No Structure Construction to Upto
1.0 Technological
Structures
1.1 Supporting Steel Above RCC Air Cooler For MOC,

Process Portion Supporting Level Refer Note- a.
Equipments with upto Top
Air Coolers
1.2 Supporting Steel Above RCC As per

Process Portion OISDSTD-164 or
Equipments upto Top 9.1 m above
without Air HPP, whichever
Coolers is higher.
2.0 Pipe Rack
2.1 Inside Process RCC Up to 1st NA

Unit Tier Level
above HPP
(without Air
Cooler)
Steel Above RCC As per OISDSTD-
Portion 164 or 9.1 m above
upto Top HPP, whichever is
higher.
2.2 Inside Process RCC Up to 1st NA
Unit Tier Level
above HPP

(with Air Cooler)
Steel Above RCC Air Cooler For MOC,

Portion upto Supporting Level
Refer Note-a.
Top
2.3 Offsite & Utilities Steel Top NA
Area
3.0 All Shed type Steel Top NA For MOC,

structures e.g.
Refer Note-b.
compressor
house, pump
house etc.
4.0 All plant & non RCC Top NA Refer Note-c.

plant buildings,
including blast
resistant
buildings
5.0 All enabling RCC / Steel/ Top NA Refer Note-d.

buildings e.g. PEB
Warehouse,
cement godown
etc.
6.0 Cable Trenches RCC (Precast NA NA

/ Cast in-situ)
♦ Technological structures (supporting process equipment) shall be in Concrete / Structural

Steel with fire-proofing as per Section 12 and Specification NR-0ZZZZ-CV-SPE-0006. All
operating floors should be in GRATINGS unless RCC floor is required from operations
considerations. In order to decide the steel/ concrete floor, nature of operating environment
such as corrosive/acidic/other chemical aggressiveness etc., should be taken into
consideration.
♦ Encasing of steel structures for reciprocating compressors pipe supports etc. if required
should be as per analog study. (For pulsating flow lines detailed thermal and vibration
analysis by analog study shall be done to decide on location of anchor supports and guides
etc. Pulsating flow lines shall be as identified by licensor/owner).
♦ All Pipe racks shall be in Structural Steel/ Concrete. Fire proofing for steel structure shall be
provided as per OISD requirements.
♦ Unless otherwise specifically stated, all shed type structures such as Pump House,
Compressor house, ware house etc. shall be in structural steel. Roofing and side cladding
shall be as per Architectural Design basis/specification. Preferably these buildings shall be
designed & constructed as PEB (Pre-Engineered Buildings)
♦ All buildings should be of RCC Frame type construction with brick masonry / AAC Block
walls.

♦ In acid and caustic handling units / dosing areas and sulfur handing units, steel structure to
be avoided. If unavoidable, suitable protective coatings shall be provided as per site specific
exposure conditions / panting specifications.
♦ Masonry shall be plastered with CM 1:6, 12mm thick on inside surfaces and 20mm thick on
external surfaces.
♦ Bipolar concrete penetrating corrosion inhibitors shall be used for all underground concrete
activities like foundation, piling works, basins, etc.,
Notes:
a) Blind floor below air cooler shall be in RCC over metal decking (left-in/ sacrificial shuttering).
b) Roofing & side cladding shall be as per Architecture Design Basis.
c) Buildings shall have RCC floors & masonry infill walls, however blast resistant buildings shall
have RCC walls. Material of construction of masonry shall be as per Architecture Design
Basis.
d) Material of construction for buildings shall be as per Architecture Design Basis.
e) Electro-forged galvanized grating shall be used for flooring at all operating floors, unless
RCC floor is required from operations considerations (e.g. blind floor below air coolers
supported on technological structure & pipe rack, plant & non-plant buildings), However
chequered plate can be used only at unavoidable locations based on approval from
OWNER/PMC.
f) Fire-proofing material for steel structures wherever required provided as per Clause 12.2 of
this part of document
4. LOADS AND FORCES

4.1 General
This specification covers the Definitions and Combinations of Design Loads which shall be
considered in the Design and Engineering for Concrete, Structural Steel and General Civil
facilities. Design shall be done with due considerations of functional requirements, the conditions
at site so that the requirements of this specification are met and economical, effective methods
and materials be used.
4.2 Design Loads
All foundations and structures, irrespective of the material employed for their construction, shall be
designed for the worst possible load combination in accordance with the corresponding tables
given in this document. However, in case of special loadings for which load combination is
unavailable in this Design Basis, relevant provisions in IS/International Codes & Publications may
be referred to.
The various types of loads for design are:
DL : Dead Load
IL : Imposed / Live Load
E(E) : Equipment Loads for Erection / Empty
E(O) : Equipment Loads for Operation

E(T) : Equipment Loads for Testing

BP : Bundle Pull
VL : Impact / Vibratory Load
WL : Wind Load
SL : Seismic / Earthquake Load
SNL : Snow Load (Not Applicable)
P(E) : Piping Loads for Erection / Empty
P(O) : Piping Loads for Operation
P(T) : Piping Loads for Testing
TL : Thermal Load and Friction Load
TA : Thermal Anchor Load
CRL : Crane Load
H : Earth Pressure Load, Hydrostatic Loads
Hd : Handling Device Load, Loads from Lifting appliances
BL : Blast Force / Load
P(A) : Accidental Loads (pressure relief valves)
4.3 Dead Load (DL)

Dead load shall be the weights of all permanent construction, including foundations, walls, floors,
roofs, and partitions, stairways, equipment excluding their contents. During the estimation of loads
for the weight of process equipment, only empty weight including all the associated piping, fixtures
and excluding the contents will be considered.
The weight of all permanent construction including self-weight of structural members, walls, fire
proofing, refractory, burner, duct, floors, roofs, partitions, stair ways & fixed services & other
(Electrical /Instrument cable trays including cables) shall be considered.
If piping weight is not indicated separately or included in the weight of the equipment, the same
shall be taken as 10% of the operating weight of the equipment. Component of soil backfill weight
over foundation slab shall be considered as foundation dead load. The unit weight of
materials in general, shall be in accordance with IS: 875 part-1 (Latest edition).
Also, the following unit weights or actual weight whichever is higher shall be considered for the
purpose of Design.
Material of construction Density
Reinforced Concrete 25 kN/m3
Plain Concrete 24 kN /m3
Brickwork 19 kN/m3
Blockwork 20 kN/m3
Structural Steel 78.5 kN /m3
Backfill Soil 18 kN /m3
Water 10 kN /m3
Finishes As per Actual loads

Roofing As per Actual loads

Operating floor with grating 1.0 kN/m2
Steel Staircase 1.4 kN /m2
6 mm thk. Chequered plate 0.55 kN /m2
25 mm thk Grating 0.50 kN /m2
Handrail 0.16 kN /m
Ladder 0.40 kN /m
Heavy duty tar felting 0.30 kN /m2
Electrical Panel Load As per Actual panel loads
Electrical Trays Load As per Actual panel loads
Electrical Ducts Load As per Actual duct loads
Instrumentation Panel Load As per Actual panel loads
Battery backup Load As per Actual panel loads
4.4 Imposed Load (IL)
Imposed loads shall mean the total weight of moving or movable external loads on structures,
buildings and / or foundations, produced by people, tools, furnishings of buildings etc., which are
not permanently fixed there to.
However, weight for small equipments and miscellaneous facilities like following, which may be
permanently fixed there to, shall be included in imposed loads.
♦ Local lighting facilities
♦ Local instrumentation & electrical facilities & cables except for substation and control room.
4.4.1 Imposed Loads on locations other than roofs

Imposed loads should, in general, be as per IS:875 Part-II. However, the following minimum live
loads should be considered in the design of structures to account for maintenance and erection as
well:
Location Design Imposed Loads

1. Process Building or Technological
Structure (Open / Enclosed Type)
Operating Area 5.0 kN /m2 or as per actual Working
condition whichever is more
Maintenance Area 7.5 kN /m2 or as per actual working condition
whichever is more
Ground Floor Slab/ Grade slab 10 kN/m2
2. Compressor House/TG house
Operating Area 7.5 kN /m2 or as per actual working condition
whichever is more
Maintenance Area 7.5 kN /m2 or as specified by Machine
vendor whichever is more
Ground Floor Slab/ Grade slab 10 kN/m2
3. Substation/Control Room
Panel floor 10.0 kN /m2 (Minimum) or subjected to
actual panel load whichever is more.
Other areas 5.0 kN /m2


Partitions 1.0 kN /m2
4. Office Building
Office area 3.0 kN /m2
Lobby 5.0 kN /m2
Document Storage Area 10 kN/m2
Exit way 5.0 kN /m2
Partitions / Misc. Portions 1.0 kN /m2
5. Laboratory
Upper Floors 4.0 kN /m2
Ground Floor Slab/ Grade slab 5.0 kN /m2
6. Cooling Tower
Operating platform/
3.0 kN /m2
Hot water basin & Sump cover slab
7. Staircase
Process Building / Technological
5.0 kN /m2
Structures
Office 5.0 kN /m2
5.0 kN /m2 or as per actual working condition
Substation / Control Room whichever is more
Laboratory 4.0 kN /m2
Service Platform 2.5 kN /m2
8. Platforms & Walkway
Walkway of Gantry Girder 3.0 kN /m2
Access-way 3.0 kN /m2
Service platform around Vessel
3.0 kN /m2
/Tower
Isolated Platform
3.0 kN /m2
(For valve operation)
Pipe Rack (Walkway) 2.5 kN /m2
Cross over 2.5 kN /m2
Pipe Rack
(Blind Floor below Air Fin Cooler /
Valve Operation)
5.0 kN /m2
* Wherever a lower floor load is
expected, suitable reduction over
specified load shall be adopted.
Operating platform in GT
3.0 kN /m2
Buildings/ DM Plant/ ETP
9. Ware House & Work Shop (type of load : light, medium, heavy as per
actual loads / as per building specification)
Light 5.0 kN/m2
Medium 7.5 kN/m2
Heavy 10.0 kN/m2
10. Storage Areas (type of Areas : light, medium, heavy as per
actual loads / as per building specification)


Light Storage Areas 5.0 kN/m2
Medium Storage Areas 7.5 kN/m2
Heavy Storage Areas 12.0 kN/m2
11. Miscellaneous
False Ceiling 0.75 kN /m2
Archive Area / Documentation 6.0 kN/m2
Loads on account of equipment and incidental loads shall be taken over and above the loads
indicated in the table.
1 kN/m² allowance or actual loads which ever is greater shall be made for services supported from
bottom of the floor such as small pipes, secondary cables trays, ducts, etc. This loads shall be
considered in addition to Piping Loads supported on the top of floor (Refer Section 4.17.2), if there
are any supports hanging below the floor.
Apart from specified live loads, any other equipment load or possible overloading during
construction/hydrotest/ maintenance/erection shall also be considered in design.
4.4.2 Imposed Loads on roofs
Flat Roof, Sloping Roof with slope <= 100
With Access 1.5 kN /m2
Without Access except for maintenance 0.75 kN /m2
Sloping Roof with slope > 100
0.75 kN /m2 less 0.02 kN /m2 for every degree
For roof membrane sheet or purlins increase in slope over 10 degrees subject to
minimum of 0.4 kN /m2
For all other buildings not covered in the above table the live loads /imposed loads shall be taken
as per IS:875 (Part-II).
4.5 Equipment Loads
The empty / operating / test weight of process equipment including all fixtures, platforms, ladders
and attached piping but excluding contents, shall be considered.
Equipment Loads shall be defined as per the following 3 cases, according to the governing
conditions of erection, operation and testing.
4.5.1 Equipment Loads for Erection / Empty (E(E)):
This shall mean the weight of equipment during erection/empty and exclude the weight of
internals, fluids and solids within the equipment, platforms, insulation and piping attached to the
equipment.
4.5.2 Equipment Loads for Operation (E(O)):
This shall mean, the load of equipment during normal operating conditions, loads due to thermal
expansion subjected to design temperature, including the weight of internals, fluids and solids
within the equipment and all materials permanently attached to the equipment, such as platforms,
insulation and piping. For silos, the contents shall be considered as operating load.
Vibration caused by operation of equipment shall be considered separately as vibration loads.
Weight application on Channel side and shell side applied according to equipment drawings,
distributed based on CG location with reference to supports.

4.5.3 Equipment Loads for Testing (E(T)):

This shall mean, the load of equipment during hydrostatic testing after erection / installation,
including the weight of water completely fill within the equipment, piping and all materials
permanently attached to the equipment, such as platforms, insulation and piping. Hydrotest shall
be considered for one equipment system at a given time in-place erected conditions on the
structure/foundation. Further, under hydro-test condition the wind force shall be taken as 25% of
normal wind loading. Seismic forces need not be considered while hydro-testing.
4.6 Wind Load (WL)
Wind loads will be calculated in accordance with IS 875 Part 3 and the following:
Basic wind speed, Vb = 50 m/sec.
Risk Coefficient (k1) = 1.0
However, Temporary sheds, structures such as those used during construction operations (e.g.
formwork and false work), structures during construction stages and boundary walls shall be
designed for mean probable design life span of 5 years. For Important structures and equipment
refer IS 875 part 3.
Terrain and height - Factor (k2) = As per IS 875 (Part-3) and Terrain Category-2
Topography Factor (k3) = As per IS 875 (Part-3)
Terrain slope to consider as per Annexure C of IS 875 part 3 – as per site terrain condition
Importance factor for cyclonic region, (k4) = As per IS 875 (Part-3)
Design Wind Speed (Vz) = Vb*k1*k2*k3*k4 m/s
Wind Pressure (pz) = 0.6*VZ2 N/m2
Design wind pressure, pd = Kd Ka Kc pz
Value of pd shall not be less than 0.7 pz
Wind directionality factor, Kd - As per IS 875 (Part-3)
Area averaging factor, Ka - As per IS 875 (Part-3)
Combination factor, Kc - As per IS 875 (Part-3)
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 sheets of the equipment.
In calculation of wind force frictional drag shall be considered wherever applicable.
Flexible slender structures and structural elements shall be investigated to ascertain the
importance of wind induced oscillations or excitations along and across the direction of wind.
Guidelines given in IS:875 (Part-3) shall be used to examine the problems of wind induced
oscillations.
For switch yard structures & transmission towers, IS:802 shall be applicable.
4.7 Seismic Loads (SL)
Refer to PART-B of This document and Document TP-1ZZZA-CV-BOD-0002.
4.8 Impact Load / Vibratory Load (VL)
Structures subjected to impact or vibratory loads should be designed as per the provisions of
IS:875 (Part 2) & IS:2974 part 1, 3 & 4 and recommendations of Equipment Vendor.
Requirement of monorails and overhead cranes shall be as per IS: 800, IS:875 or manufacturer’s
data, whichever is more stringent.
Vibration loads should mean the vibration forces caused by heavy vibrating equipment or
machinery and dynamic forces caused by fluids in the normal operation. Frames, structures and
foundations for machinery or equipment causing vibration should be designed to limit vibrations to
an acceptable level.
It should be designed such that whether they are independent or part of the building, it should not
only safely carry the loads for such items but also prevent resonance.
Dynamic analysis shall be carried out for foundations of critical equipment like compressors &
pumps. While carrying out dynamic analysis of foundation/structures supporting dynamically
loaded equipment’s, the loads indicated by vendor in his documents shall be used.
However, in the absence of such vendor data, the following load shall be assumed as the
equivalent static loads when the dynamic analysis is not carried out for pumps upto 50kN weight.
S. N Equipment Type & Direction Equivalent Static Load (additional

load over equipment weight)
1. Rotating (Centrifugal) Type
Vertical 0.5 times the weight of equipment /

machinery.
Along direction of rotation 0.25 times the weight of equipment /
(perpendicular to centerline machinery.
Horizontal of shaft)
Along direction of shaft axis 0.10 times the weight of equipment /
machinery.
2. Reciprocating Type
Vertical 0.5 times the weight of equipment /

machinery.
Along direction of 0.25 times the weight of equipment /
reciprocating motion machinery.
Horizontal
Along direction 0.10 times the weight of equipment /
perpendicular to machinery.
reciprocating motion
4.9 Blast Forces
Structures subjected to blast forces generated due to accidental blasts from hydrocarbon ignitions
shall be designed to withstand maximum of the following:
♦ Actual Blast Pressure.
♦ Minimum equivalent pressure of 21 kPa as per OISD-STD-163.
♦ Suction Blast pressure equivalent to static pressure 7kPa acting on all extreme surfaces
♦ Blast over pressure protection as recommended in IS 4991
♦ Blast over pressure protection as recommended in Blast overpressure modelling report /
Rapid Risk Analysis (RRA) report.

4.9.1 Design of blast resistant control building

The design of blast resistant control building shall be according to the following minimum blast-
loading conditions:
Condition 1:
Any of the following combinations:
1A, 1B, 1C whichever is the most critical
21 KPa on walls and roof (minimum) or as per cl. 4.9.
1B 1C
1A
Condition 2:
7 KPa on Interior wall and
Roof Surfaces (minimum) or as per cl. 4.9.
2
4.9.2 Structural Design Criteria

♦ Design of Blast resistant building shall be as per Specification NR-0ZZZZ-CV-SPE-0007:
Specification for Blast Resistant Design of Buildings.
♦ Design the structure as a shear wall structure with the roof acting as a horizontal diaphragm
that transfers the transverse loads to the side shear walls. External shear walls shall be
continued up to 1.5 m below GL or up to founding level whichever is less.
♦ Design of walls and roof shall be based on the “Yield Line Theory”.
♦ Provide cast-in-situ reinforced concrete walls and roof of load-bearing type, designed to
resist bending and transmit horizontal shear. Precast concrete panels may be used but shall
be either mechanically bonded to cast-in-situ reinforced concrete columns or provided with
built-in load transmitting steel plates or angles so that the panels can be welded in place.
♦ Anchor walls to foundations and concrete roof slabs with steel reinforcing bars to provide full
moment connections.
♦ Provide roof framing with adequate bearing and good anchorage to the supporting walls.
Weld roof form decking if used to the top member of the roof frame.
♦ Distribute loads on roofs and walls in two directions where possible.
♦ Consider stress reversals at each member and provide a minimum 20% stress reversal.
♦ Design reinforced concrete members with good ductile properties. Limit tension steel to 1%
of the concrete area and 2% of the concrete area for tension plus compression steel. To
allow for stress reversal provides reinforcing steel in both concrete faces and set shear bars
perpendicular, not inclined.
♦ Provide local strengthening of concrete at opening by additional reinforcing without local

thickening where possible.
4.9.3 Load combinations with blast loads
- For Flexure: 1.0 (Dead load + Blast load)
- For Shear: 1.2 (Dead load + Blast load)
Note: Live load shall not be considered on the roof during blast.
4.9.4 Soil Bearing Capacity /Pile Capacity

Design bearing pressure shall be taken as equal to twice the allowable static bearing pressure for
load combinations with blast load. Pile capacity (vertical/shear) increase by 50% check
4.9.5 Stability Ratio

Factor of Safety in case of load combinations with blast load shall be as follows:
Overturning - 1.2
Sliding - 1.3
4.9.6 Openings
♦ Minimize openings in the building enclosure and locate openings to avoid or be shielded
from direct blast pressures.
♦ Windows, if unavoidable shall be limited in size and provided with special glazing.
♦ Select external doors, louvers and similar items, together with their frames, capable of
withstanding the pressures. Do not use glass panels in these doors. Provide for personnel at
least for two access doors, located remote from each other and where possible not in
opposite walls. The size of equipment doors for manoeuvring factory-fabricated control
boards into or out of the control room.
4.10 Bundle Pull
♦ Structures and foundations supporting heat exchangers with removable tube bundle shall be
designed to withstand a longitudinal horizontal force applied at the center of it due to the
removal operation.
♦ The fixed saddle only shall support such force, that shall be equal to 100% of the tube
bundle weight or 10 kN, whichever is greater ( Including kettle type exchangers). Above
figure can be reduced if special extraction devices are provided as per Vendor’s
recommendations and adjusted accordingly. Bundle pulling force is not applicable when
bundles are pulled by means of a mechanical device which acts on the principle of
equilibrium of forces (no forces on the support structure).
♦ In case of stacked equipments, it shall be assumed that the bundle pulling of equipment is
not simultaneous.
4.11 Thermal Expansion
Horizontal force due to thermal expansion of horizontal vessels / exchangers shall be relieved by
using slotted holes, guide clamps and slide plates and remaining force derived from the product of
the sliding saddle gravity load and the coefficient of friction taking shall be applied to each support.

When the thermal expansion or contraction results in friction between the equipment & its support
at the sliding end, the friction force shall be calculated in accordance with the following coefficient
of static friction & sliding ends in opposite directions:
Concrete to soil………...0.40
Steel on Steel…………. 0.30
Steel on concrete……... 0.45
PTFE to PTFE………… 0.10*
* Comp stress on PTFE (Poly-tetra-fluoro-ethylene / Teflon) shall be minimum 3.5 N/mm2.
4.12 Non-Static Loading
Foundations and structures supporting vessels subject to surge loading, such as Deaerators
shall be designed with sufficient stiffness and rigidity to resist a notional horizontal force of 10% of
those derived from the Vessel’s operating weight or the given surge load whichever is the greater.
The surge forces shall be applied at the vessel’s center of gravity and act longitudinally or
transversely, if the surge loads not provided by vendor. Consideration shall be given to bracing
these structures.
The design of foundations and structures supporting agitated vessels, centrifuges, reactors and
other variable load equipment shall take full account of all the loading data provided by the
equipment vendors. Where no loads are available, consideration shall be given to applying
additional force at 10% of operating weight acting in longitudinal and transverse direction.
In addition, for dynamic effect loads will be increased by 50% of steam agitated equipment and
25% for mechanical agitated vessels in vertical direction.
Where two or more similar items of such equipment are supported on a common foundation or
structure, the design must be based on assumption that these items will resonate in phase.
Rotating Equipment
Comprehensive loading data of mechanical equipment, such as, fans, blowers, pumps,
compressors, D.G. Sets, turbines, motors engines etc., as furnished by the equipment vendor
shall be considered.
4.13 Earth Pressure/Liquid Pressure/Buoyancy

Earth pressure shall mean pressure of the soil acting on the underground structure and/or
foundation of retaining walls /dykes. Earth pressure at rest, acting on basement, trenches and pit
shall be calculated from the following equations:
q
a) Above ground water level
PV = H ± q q H
Ph = K0 PV GWT 1
H h0
b) Below ground water level
PV = H +q+ ’(ho-H) + w (ho - H)
Ph =K0 (H +q+’ (ho-H) +w (ho-H) ( ’ + w) X (h0 – H)

Where,
PV = Vertical soil pressure
Ph = Horizontal soil pressure
= Unit weight of soil
h0 = Soil depth from grade surface (m)
q = Distributed load on ground surface
H = Underground water level from grade surface (m)
’ = Submerged weight of soil in water
w = Unit weight of water

K0 = Ratio of horizontal to vertical pressure = tan2 (45° - ɸ/2)
ɸ = Internal friction angle of soil (As per geotechnical report)
Active and passive earth pressure acting on retaining wall shall be calculated from Coulomb’s or Rankine’s
earth pressure equation.
Liquid Pressure
Liquid Pressure shall mean the pressure of liquid acting on in-side of the Pit/Basin structures.
Liquid pressure shall be calculated by using the following equation:
P1 =  x h1
Where,
P1 = Liquid pressure
h1 = Depth of liquid content (m)
 = Unit weight of liquid
4.14 Traffic Loads

Minimum wheel load of 5 MT for 10 MT hydras on precast covers and minimum surcharge load of
1.0 T/m2 on cable trench wall shall be applied for design. Similar loads are also being considered
for U/G drainage pipes wherever applicable.
Culverts shall be designed for a minimum class-A loading and Crane movement shall be designed
for appropriate loading as per IRC 6.
4.15 Handling Facilities
Permanent handling facilities shall be designed for the following loads:
♦ Trolley beams and their supports shall be designed to IS 800/ IS 807/ IS 3177 with an
allowance of 25 % of the total load for vertical impact. Where the hoist is to be operated
with a grade mounted winch, a line pull of not less than 25 % of the lifted load shall be
included.
i.e. Design Load = 1.25 (W + 0.25 W + weight of trolley).
This line pull allowance assumes the pulley system has a mechanical advantage of 4.
♦ Crane beams and supports for travelling cranes shall be designed in accordance with IS
800/ IS 807/ IS 3177.

♦ Davits shall be designed for the heaviest item to be lifted plus 25 % for impact but not less
than a total of 450 kg. Lateral forces shall be assumed as 20 % of the lifted load. A line pull
of 100 % of the lifted load shall be included to provide for the possibility of the load being
handled by a line over a single pulley.
4.16 Process Vibration
Structures supporting process equipment subject to vibration due to normal process surging, e.g.
fluid crackers, fluid hydroformers and fluid cokers, shall be designed for the following dynamic
loads which will be periodic in the range of 60 to 100 cycles per minute (1 to 1.67 Hz):
Fluid coker as per Vendor data/Licensor requirement
Fluid cracker and Hydroformer as per Vendor data/Licensor requirement
4.17 Piping Load & Pipe Rack design requirements:
Piping Loads shall be defined as per the following 3 cases, according to the governing conditions
of erection/empty, operation and testing.
4.17.1 Piping Loads for Erection / Empty (P(E)):
This shall mean the weight of piping during erection or non-operating conditions (empty), exclude
the weight of internals fluid and insulation.
Insulation density shall be taken as 2600 N/m3 minimum. 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 obtained as above shall be increased by 20% to account for
fittings and accessories and shall be assumed to be spread over the entire span. Structures
supporting piping shall be designed for the rigidity assumed in pipe stress analysis.
Vertical loads of flare pipe shall be taken as one third full of water for piping within units & one
sixth full for outside unit battery line. All flare line independent support shall be of four legged
braced open tower type construction.
In addition to piping loads, gravity loads due to encasement, if any, shall be considered.
4.17.2 Piping Loads for Operation (P(O)):
This shall mean, the load of piping during normal operating conditions, including the weight of
internals fluids & insulation.
Piping Loads shall be calculated considering the pipe diameters and piping arrangement subject to
minimum of 1.5 kN/m2 over entire span.
However, minimum loading for any pipe rack shall not be less than 1.5 kN/m2. In case, the
calculated loading is higher than 1.5 kN/m2, this shall be rounded off to the nearest multiple of
0.25 (i.e. 1.50, 1.75, 2.0 kN/m2).
4.17.3 Piping Loads for Testing (P(T)):
This shall mean, the load of piping during hydrostatic testing after erection / installation, including
the weight of water within the piping & insulation.
Only one biggest pipe of diameter ≥ 12” on tier shall be considered at a time, along with all other
pipes in empty condition. Otherwise, simultaneous hydro testing of pipes of diameter ≤ 6” shall be
considered.
For lines of diameter between 6” & 12”, two lines can be tested simultaneously.

4.17.4 Frictional Force:

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, and 30% of the design vertical
loading of the pipes 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% of the vertical loading. Both longitudinal and
transverse friction forces shall be considered to be acting simultaneously.
4.17.5 Anchor and Guide Force (Thermal load) (TA):

Piping Anchor and guide forces shall be considered as per piping input resulting from Piping stress
analysis. These anchor forces shall be transferred to the appropriate resisting frames /Concrete or
Steel beams / bracings and foundations. Support beams (Concrete/Steel) shall be designed to
withstand any eccentricity due to application of Lateral loads w.r.to axis of beam.
4.17.6 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.
4.17.7 Loading on Longitudinal & Transverse 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 loads
acting at 1/3 span. Other longitudinal axial forces coming on it from the design of the supporting
system shall also be simultaneously take into account in the design of the longitudinal beam.
Friction & Anchor forces, if specifically given by the Piping Specialist shall also be catered for in
the design. Loads from monorails, when supported from these beams shall also be considered
acting simultaneously along with all other loads mentioned above.
Intermediate beam at tier level shall be designed for 25% of load on main portal beams in
transverse direction or actual loads whichever is more. A reduction of 10% in vertical loading shall
be considered for main portal beams if intermediate beams are provided.
4.17.8 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) This force shall be considered irrespective of height between two tiers as per following table.
Width of Pipe Rack Wind force at each tier level

Up to 4.0 m 1.25 x p x s
Above 4.0m but up to 6.0m 1.50 x p x s
Above 6.0m but up to 10.0m 2.00 x p x s
Above 10.0 m Hxpxs
p = design wind pressure as per IS: 875 (Part 3) in N/m².

s = spacing of portals (in m).

H = Projected height (m)
Pipe racks should be adequately braced in all possible directions, consistent with functional
requirements.
Limiting permissible horizontal deflection for pipe rack shall be as per IS 800 (Latest code).
4.18 Buoyancy
If the structure or footing extends below the design water level, the effect due to uplift and subsoil
water table shall be considered.
4.19 Elevator Loads:

All Elevator loads shall be increased by 100% for impact and the Structural Supports shall be
designed within the limits of deflection prescribed by the elevators' vendor.
Dynamic analysis (required if any) shall be carried out due to adjacent vibrating
machine/equipment (if any).
4.20 Contingency Load
4.20.1 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 distributed over an area of 0.75 m x 0.75 m
4.20.2 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
4.21 Temperature Loads:
Temperature loads are forces caused by temperature variations on the structure (i.e., caused by
variations of ambient temperature). The design shall be done in accordance with IS 456 cl 19.5 for
concrete structure and IS 800 cl 3.4 for steel structures.
4.22 Construction Loads:
Construction Loads are temporary forces that may be present during erection phases of structure
or equipment. In static calculations they may be considered as live loads with appropriate safety
factor.
4.23 Other Loads:
Apart from the specified live loads, any other equipment load or possible overloading during
construction/hydro-test maintenance/erection shall also be considered in the design. All handrails,
parapets, parapet walls, balustrades shall be designed for horizontal load mentioned in Table 3 of
IS:875 (Part 2).
Operational load shall be defined as the dead load of Piping plus weight of any liquids or solids,
normally present within piping during operation. Design of all structures should also consider any
other relevant and consequential load/stress imparted to the structure.
All liquid retaining/storage structures should be designed assuming liquid upto the full height of
wall irrespective of provision of any over flow arrangement. Pressure relief valves or similar
pressure relieving devices should not be made in underground water retaining/storage RCC
structures. Hot water basin in Cooling tower should be designed for the weight of water up to top
of parapet wall.
All buildings/ structures shall be designed to resist the worst combination of the above loads (in
accordance with IS:875 Part-5, other than seismic loads). However, wind/ seismic loads shall not
be considered in combination together or with loads during maintenance.
Consideration shall be given to loads of a special nature such as piping counterweights, spring
hangers, thrusts from expansion joints, expansion loads from horizontal vessels and exchangers,
purpose made handling equipment such as counterbalanced crane hooks, and thermal expansion
of the structure.
5. LOAD COMBINATIONS
It should be recognized in load combinations that the simultaneous occurrence of maximum
values of wind, earthquake, imposed and snow load is not likely. Selection of Load combinations
to be considered in analysis and design shall be decided based on the type of structure under
consideration. Design shall be done to resist the worst combination of the above loads.
The overall stability of the structure and foundations may need to be reviewed against a more
critical load combination than combinations defined below depending upon configuration of
structure.
Load Combinations shall generally follow codal requirements. Below listed load combinations are
not exhaustive, additional combinations shall be added, if needed by the design and erection /
operation / test requirement.
Earthquake Load shall be considered in all the three directions SLX+SLY+SLZ and combined as
per IS 1893. Various load combination shall be taken as follow:
5.1 Load Combination for Foundations for Stacks, Towers and Vertical vessels
5.1.1 Load Combinations for check of soil bearing pressure / pile capacity and stability of foundation.
Load condition Load combination
DL + E(E)
Erection
DL + E(E)  WL
DL + E(O)
Operating DL + E(O)  WL
DL + E(O)  SL
DL + E(T)
Test
DL + E(T)  0.25 WL

5.1.2 Load combinations for RC Member Design viz. for footing, pedestal etc.

1.5 [DL + E(E)]
Erection 1.5 [DL + E(E)  WL]
0.9 [DL + E(E)]  1.5 WL
1.5 [DL + E(O)]
1.5 [DL + E(O)  WL]
Operating 1.5 [DL + E(O)  SL]
0.9 [DL + E(O)]  1.5 WL
0.9 [DL + E(O)]  1.5 SL
1.5 [DL + E(T)]
Test 1.5 [DL + E(T)]  1.5 [0.25 WL]
0.9 [DL + E(T)]  1.5 [0.25 WL]
5.2 Load Combination for Foundations for Horizontal Vessels / Exchangers

5.2.1 Load Combinations for check of soil bearing pressure / pile capacity and stability of foundation.
DL + E(E)
Erection
DL + E(E)  WL
DL + E(O)  TL
Operating DL + E(O)  TL  WL
DL + E(O)  TL  SL
DL + E(T)
Test
DL + E(T)  0.25 WL
Maintenance (For
DL + E(E) + BP
Exchanger only)
5.2.2 Load combinations for RC Member Design viz. for footing, pedestal etc.
1.5 [DL + E(E)]
Erection 1.5 [DL + E(E)  WL]
0.9 [DL + E(E)]  1.5 WL
1.5 [DL + E(O)  TL]
1.5 [DL + E(O)  TL WL]
Operating 1.5 [DL + E(O)  TL  SL]
0.9 [DL + E(O)  TL]  1.5 WL
0.9 [DL + E(O)  TL]  1.5 SL
1.5 [DL + E(T)]

Test 1.5 [DL + E(T)]  1.5 [0.25 WL]
0.9 [DL + E(T)]  1.5 [0.25 WL]
Maintenance (For
1.5 [DL + E(E)] + 1.5 [BP]
Exchanger only)
5.3 Load Combinations for Pipe Rack / Structures

5.3.1 Load Combinations for check for stability of foundation and soil bearing pressure for foundations /
Pile Capacity
Load Condition Load Combination

DL + E(E) + P(E)
DL + E(E) + P(E) + IL
ERECTION
DL + E(E) + P(E) ± WL
DL + IL + E(E) + P(E) ± WL
DL + E(T) + P(T)
DL + E(T) + P(T) + IL
TEST DL + E(T) + P(T)) ± 0.25WL
DL + E(T) + P(T)) + 0.5IL ± 0.25WL
DL + E(O) + P(O) + TA ± TL
DL + IL + E(O) + P(O) + TA ± TL
DL + E(O) + BP + VL + P(O) + TA ± TL
DL + IL + E(O) + VL + P(O) + TA ± TL
DL + IL + E(O) + P(O) + Hd ± TL
DL + E(O) + P(O) + TA ± TL ± WL
OPERATING DL + IL + E(O) + P(O) + TA ± TL ± WL
DL + 0.5IL + E(O) + BP + P(O) + TA ± WL
DL + 0.5IL + E(O) + P(O) + Hd ± TL ± WL
DL + EO + PO + TA ± TL ± SL
DL + 0.5IL + EO + PO + TA ± TL ± SL
DL + 0.5IL + EO + BP + PO + TA ± SL
DL + 0.5IL + EO + P(O) + Hd ± TL ± SL
DL + 0.5IL + E(E) + P(E) + BP
MAINTENANCE DL + IL + E(E) + BP + Hd
(with Exchanger) DL + IL + E(E) + BP + P(E) + 0.5WL
5.3.2 Load Combinations for Foundation Reinforcement design for Pipe rack / Structures

1.5 [ DL + E(E) + P(E) + IL ]
ERECTION 1.2 [ DL + IL + E(E) + P(E) ] ± 1.2 WL
1.5 [ DL + E(E) + P(E) ] ± 1.5 WL
TEST 1.5 [ DL + IL + E(T) + P(T) ]

1.2 [ DL+ 0.5IL + E(T) + P(T) ] ±1.2 [0.25WL]
1.5 [ DL + E(T) + P(T) ] ± 1.5[0.25 WL]
1.5 [ DL + IL + E(O) + P(O) + TA ± TL ]
1.5[DL + P(O)] + 1.2[E(O) + BP + VL + TA]  1.2TL
1.5IL + 1.2 [DL + E(O) + VL + P(O) + TA]  1.2TL
1.2 (DL + E(O) + BP + Hd) + 1.5IL
1.5 [ DL + E(O) + P(O) + TA ± TL ] ± 1.5 WL
1.2 [ DL + IL + E(O) + P(O) + TA] ± 1.2TL ± 1.2 WL
OPERATING
0.9 [ DL + E(O) + P(O) + TA  TL ]  1.5WL
0.5IL + 1.2 [DL + E(O) + BP + P(O) + TA]  1.5WL
1.5 [ DL + E(O) + P(O) + TA ± TL ] ± 1.5 SL
1.2 [ DL + 0.5 IL + E(O) + P(O) + TA] ± 1.2 TL ± 1.2 SL
0.9 [ DL + E(O) + P(O) + TA  TL ]  1.5 SL
0.5IL + 1.2 [DL + EO + BP + PO + TA]  1.5SL
1.2DL + 1.2x(0.5IL) + 1.2E(E) + 1.2P(E) + 1.2BP
MAINTENANCE 1.2DL + 1.2IL + 1.2E(E) + 1.2BP + 1.2Hd
(with Exchangers) 1.2DL + 1.2(0.5IL) + 1.2E(E) + 1.2BP + 1.2P(E) + 1.2(0.5WL)
5.3.3 Load Combinations for Serviceability check for Pipe rack / Open Technological Structures

DL + E(E) + P(E)
DL + E(E) + P(E) + IL
ERECTION
DL + E(E) + P(E) ± WL
DL + IL + E(E) + P(E) ± WL
DL + E(T) + P(T)
DL + E(T) + P(T) + IL
TEST DL + E(T) + P(T)) ± 0.25WL
DL + E(T) + P(T)) + 0.5IL ± 0.25WL
DL + E(O) + P(O) + TA ± TL
DL + IL + E(O) + P(O) + TA ± TL
DL + E(O) + BP + VL + P(O) + TA ± TL
OPERATING DL + IL + E(O) + VL + P(O) + TA ± TL
DL + IL + E(O) + P(O) + Hd ± TL
DL + E(O) + P(O) + TA ± TL ± WL
DL + IL + E(O) + P(O) + TA ± TL ± WL

DL + 0.5IL + E(O) + BP + P(O) + TA ± WL

DL + 0.5IL + E(O) + P(O) + Hd ± TL ± WL
DL + EO + PO + TA ± TL ± SL
DL + 0.5IL + EO + PO + TA ± TL ± SL
DL + 0.5IL + EO + BP + PO + TA ± SL
DL + 0.5IL + EO + P(O) + Hd ± TL ± SL
DL + 0.5IL + E(E) + P(E) + BP
MAINTENANCE
DL + 0.5IL + E(E) + BP + P(E) + 0.5WL
(with exchangers )
DL + IL + E(E) + BP + Hd
5.3.4 Load Combinations for RC / Steel Member Design.

1.5 [ DL + IL + E(E) + P(E) ]
ERECTION 1.2 ( DL + IL + E(E) + P(E) ]  1.2 WL
1.5 ( DL + E(E) + P(E) ]  1.5 WL
1.5 [ DL + IL + E(T) + P(T) ]
1.2 [ DL+ 0.5IL + E(T) + P(T) ]  1.2 [0.25WL]

TEST
1.5 [ DL + E(T) + P(T) ]  1.5 [0.25 WL]
1.5 [ DL + IL + E(O) + P(O) + TA  TL ]
1.5 [DL + P(O)] + 1.2[E(O) + BP + VL + TA]  1.2 TL
1.5IL + 1.2 [DL + EO + VL + PO + TA]  1.2 TL
1.5 [ DL + IL + E(O) + P(O) + Hd ]  1.5 TL
1.5 [ DL + E(O) + P(O) + TA  TL ]  1.5 WL
OPERATING
0.9 [ DL + E(O) + P(O) + TA]  0.9TL  1.5WL
1.2 [ DL + IL + E(O) + P(O) + TA]  1.2 TL  1.2 WL
1.5 [ DL + E(O) + P(O) + TA  TL ]  1.5 SL
1.2 [ DL + 0.5 IL + E(O) + P(O) + TA]  1.2 TL  1.2 SL
0.9 [ DL + E(O) + P(O) + TA  TL]  1.5 SL
1.2 [ DL + 0.5IL + E(O) + P(O) + Hd +TA  TL]  1.2 SL


1.2DL + 1.2x(0.5IL) + 1.2E(E) + 1.2P(E) + 1.2BP
MAINTENANCE
1.2DL + 1.2(0.5IL) + 1.2E(E) + 1.2BP + 1.2P(E) + 1.2x(0.5WL)
(with exchangers )
1.2DL + 1.2IL + 1.2E(E) + 1.2BP + 1.2Hd
Also load combinations specified in all relevant codes to be considered for RC / steel structure
member design.
5.4 Shed Type building with Crane loads

5.4.1 Load Combinations for check for stability of foundation and soil bearing pressure for foundations /
Pile Capacity and deflection Check.

NORMAL DL + IL + CRL
DL + IL + 0.5 WL + CRL
WIND**
DL + 0.5 IL + WL + 0.5 CRL
DL + 0.5IL + CRL + 0.5 SL
SEISMIC
DL + 0.5 IL + 0.5 CRL + SL
5.4.2 Load Combinations for RC Structure Member Design.

NORMAL 1.5 DL + 1.5 IL + 1.5 CRL
1.2 DL + 1.2 IL + 0.6 WL + 1.2 CRL
WIND**
1.5 DL + 0.75 IL + 1.5WL + 0.75 CRL
1.2 DL + 1.2 (0.5IL) + 0.5 SL + 1.2 CRL
SEISMIC
1.5 DL + 0.75 IL + 1.5 SL + 0.75 CRL
(**) Wind Load check with Parallel and Perpendicular to Ridge.
5.5 For General Buildings & Buildings (with or without Equipment) and their Foundations
5.5.1 Load Combinations for Foundation sizing.
DL + IL (optional)
DL + IL + Hd
NORMAL DL + IL + EE (optional)
DL + ET
DL + IL + EO

DL + BL
DL ± WL
DL + IL ± WL + EE+ Hd
DL + EE ± 0.8WL (optional)
WIND DL + EO ± 0.8WL
DL + IL + EE ± 0.8WL
DL + 0.8IL + ET ± 0.8(0.25WL)
DL + 0.8IL + EO ± 0.8WL
DL ± SL
DL + 0.5IL ± SL + Hd
DL + EE ± 0.8SL
SEISMIC DL + EO ± 0.8SL
DL + IL + EE ± 0.8SL (optional)
DL + 0.8(0.5IL) + EO ± 0.8SL
5.5.2 Load Combinations for Deflection Check.

NORMAL DL + IL
DL ± WL
WIND
DL + 0.8 IL ± 0.8 WL
DL ± SL
SEISMIC
DL + 0.4 IL ± 0.8 SL
5.5.3 Load Combinations for Reinforcement design for Buildings.

1.5 DL (optional)
1.5 [ DL + IL ] (optional)
1.5 [ DL + IL + Hd ] + 1.5 EE
NORMAL 1.5 [ DL + IL + EE ] (optional)
1.5 [ DL + ET ]
1.5 [ DL + IL + EO ]
1.2 [ DL + BL] (shear)
0.9 DL ± 1.5 WL
1.2 [ DL + IL] ± 1.2WL
1.2 [ DL + IL + Hd ] ± 1.2 WL
1.5 DL ± 1.5 WL
1.5 [ DL + EE ] ± 1.5 WL (optional)
WIND
0.9 [ DL + EE ] ± 1.5 WL (optional)
1.5 [ DL + EO ] ± 1.5 WL
1.2 [ DL + 0.5IL + EE ] ± 1.2 WL (optional)
1.2 [ DL + 0.5IL + EO ] ± 1.2 WL

0.9 DL ± 1.5 SL
1.2 DL + 0.6 IL ± 1.2 SL
1.2 [ DL + IL + Hd ] ± 1.2 SL
1.5 DL ± 1.5 SL
SEISMIC
1.5 [ DL + EE ] ± 1.5 SL
0.9 [ DL + EE ] ± 1.5 SL
1.5 [ DL + EO ] ± 1.5 SL
1.2 [ DL + 0.5IL + EE ] ± 1.2 SL (optional)
1.2 [ DL + 0.5IL + ET ] ± 1.2 SL (optional)
1.2 [ DL + 0.5IL + EO ] ± 1.2 SL
5.6 For Composite Building and Structures (with or without Equipment) and their Foundations
Load Combinations for Composite Structure and Buildings such as Process Shelters with
operating floors, Buildings with Pipe loads, etc., shall consider Load combinations from both type
of structures given above for analysis and design.

6. DESIGN OF FOUNDATIONS / FOOTINGS

6.1 General Requirements:
1) Foundation design should be as per Geo-Technical Data. Minimum depth of foundation for
all structures should be as per Geo-Technical Data.
2) The design ground water level should be as per the Geo-Technical Data and the hydrostatic
pressure should be adequately accounted for in design.
3) Pile capacities (compression, shear and uplift/tension) and pile stiffness shall be per
Geotechnical Recommendations and verified by test pile data.
4) For transient loadings, e.g. wind/seismic, SBC (safe bearing capacity) shall be considered
based on shear criteria instead of settlement criteria.
5) Permissible increase in SBC/ Pile capacities (for compression, shear and uplift/tension) shall
be as per the Geotechnical Recommendations.
6) Under blast (due to hydrocarbon explosion) load combinations the SBC of soil shall not
exceed 2.0 times allowable static bearing pressure of soil.
7) Under blast (due to hydrocarbon explosion) load combinations Pile capacity shall not exceed
1.5 times the permissible capacity under compression, tension and shear modes.
8) Foundation for vibrating equipment shall be kept independent of building floors/ foundations
and other adjacent foundations.
9) Foundation for tanks upto 10m diameter shall be of RCC ring wall type, unless required from
anchorage or counterweight considerations.
10) For load combinations including earthquake, the Safe Bearing Pressure of Soil and the Safe
Bearing Load of piles shall be increased as permitted in IS:1893.
11) Pile Stiffness used in calculations shall be derived from soil report and confirmed by pile test.
6.2 Stability against Overturning & Sliding
Foundations should be checked for stability against overturning & sliding, while checking against
sliding/overturning, the following should be considered.
Minimum Stability Ratio i.e. Factor of safety required against overturning (MR/MO) both being
calculated at the leading edge of the foundation considering all forces and moments.
MR = Resistant moment and
MO = Over turning moment should be restricted to the followings for the worst load
case combination.
The resistance to sliding should be calculated from the following, where applicable: -
♦ Foundation / soil friction
♦ Passive soil resistance to the side of the foundation
♦ Passive soil resistance of soil bearing against keys

FOUNDATION DESIGN - FACTORS OF SAFETY
Minimum Factor of Safety Against Overturning Minimum Factor Of

Erection Condition Operating Condition Safety Against Sliding
Type Of
Structure With Wind Without With Wind Without With Without
Or Wind Or Or Wind Or Wind or Wind or
Seismic Seismic Seismic Seismic Seismic Seismic
All Buildings/
Structures
/ Pipe racks/
Equipments in 1.5 1.75
1.5 1.5 1.5 2.0
Units, Heater/
Boiler Chimneys.
Including offsite
and utilities
Over Head Water 1.5 (empty) 1.5 (empty) 1.5 -
- -
Tank 2.0 (full) 2.0 (full)
Flood Light Mast 1.5 - 1.5 - 1.5 -
Retaining Wall - - 1.5 2.0 1.5 1.75
Flare Supporting 1.5 -
1.5 - 1.5 -
Structure
Blast Resistant 2.0 1.5 1.5
- - 1.5
Structures Or 1.2#
Transmission
Tower / Switch 1.5 2.0 1.5 2.0 1.5 1.75
Yard Structure
# With blast pressure.
Percentage weight of overburden shall be taken as 100% & to be considered on projected plan
area of footing. In case area is paved, overburden should be based on NGL (for area under filling)
or 600mm below HPP whichever is lower. In case of unpaved area, it should be w.r.t. FGL.
6.3 Stability against Uplift
In case area is paved, overburden shall be based on NGL (for area under filling) or 600mm below
HPP whichever is lower. In case of unpaved area, it shall be w.r.t FGL.
Minimum factor of safety against Uplift shall be 1.2 for all structures. (Note: In case of sumps,
lining weight should not be included).
In the design of foundations, the upward pressure of water (buoyancy effect), where applicable,
should be taken as the full hydrostatic pressure applied over the whole area. The hydrostatic head
shall be measured from the underside of construction. The beneficial load of backfill can be
included only in circumstances where it will never be removed.
Uplift in Pile foundations shall be limited as per geotechnical recommendation.

6.4 Allowable loss of contact area

Allowable loss of contact area between underside of foundation and soil (due to resultant
overturning moment) under different loading conditions should be as given below.
Load Combination Allowable % Loss of

Sr.No.
Contact Area
1 For Foundations on soils
a Operating with or without LL, for worst cases 0 to 10%
b Operating with Wind or Earthquake (with or without LL, Up to 25%

for worst cases)
2 For Foundations on Rocks
a Operating with or without LL, for worst cases 0 to 20%
b Operating with Wind or Earthquake (with or without LL, Up to 30%

for worst cases)
6.5 Allowable Net SBC based on the settlement criteria:

Allowable Net Safe Bearing Capacity (SBC) of soil for isolated/ raft/pile/ tank foundations shall be
based on the settlement criteria for dead plus imposed load conditions, as follows:
a) For foundations in Unit areas, Utility areas and foundations of Plant buildings, settlement
shall be considered as 25mm.
b) Allowable total settlement of foundation for Machine foundations and critical equipment with
interconnected piping shall be considered as per manufacturer recommendations.
c) For foundations of Non-plant buildings, settlement shall be considered as 40mm.
d) For Raft foundations, settlement shall be considered as 40mm.
e) For foundation of Cone roof/ Dome roof Storage Tanks, settlement shall be considered as
300mm at edge and differential settlement shall be considered as 1 in 300 along periphery.
f) For foundations of Floating Roof Storage Tanks, settlement to be considered as 150mm at
edge and differential settlement shall be considered as 1 in 500 along periphery.
g) For Mounded Bullets, differential Settlement of 25 mm & overall settlement of 60mm shall be
considered for design.
Beneficial load of backfill can be included only in circumstances where it will never be removed.
6.6 Soil and hydrostatic pressure on walls below grade:
In the design of walls below grade, provision should be made for the lateral pressure of adjacent
soil. Due allowance should be made for possible surcharge from fixed or moving loads. When a
portion or whole of the adjacent soil is below a free water surface, computations should be based
on the weight of the soil diminished by buoyancy, plus full hydrostatic lateral pressure.
The lateral pressure from surcharge loads should be taken in addition to the lateral earth pressure
loads.

6.7 Foundations for Rotating and Reciprocating Equipment

a) General:
1) Foundation for rotating and reciprocating equipments such as turbines, engines,
compressors and generators should be designed to secure the dynamic stability of the
foundation system, as well as the static stability.
2) Dynamic stability for foundation supporting heavy vibrating equipments like the following
should be secured by dynamic analysis in general:
♦ Heavy vibrating equipment,
♦ Equipment sensitive to vibration,
♦ Equipment causing large dynamic force
b) General Requirements for Design:
Following minimum requirements should be take into account for foundation design in
principle.
1) Foundation for heavy vibrating equipment should be kept independent of building
floors/foundations and other adjacent foundations.
2) The weight of foundation slab should not be less than the combined weight of the structure
and the machine.
3) Foundation should be of uniform rectangular/ square shape. Beams and columns of
foundations should be of uniform rectangular/ square shape.
4) The horizontal eccentricity, in any direction, between the center of gravity of the machine -
foundation system and the center of base contact area or centroid of the pile group, should
be within 5% for block foundations and 3% for frame foundations. However, in highly
compressible soils no eccentricity should be permitted.
5) The geometric layout of the foundation and structure should be basically symmetric with
respect to the vertical plane passing through the rotational axis of the equipment.
6) Mechanical equipment foundations should satisfy the requirements of IS: 2974 and any
other parameters as per machine vendors.
7) Foundation block extensions supporting auxiliary equipments requiring rigid positioning
with respect to the main equipment should be detailed to act integrally with the block.
8) Generally, foundations and structures supporting rotating machinery should be so
proportioned that their natural frequency should not fall within the range of 0.8 to 1.2 of
normal operating speed of the equipment.
9) Design should be carried out such that amplitude of vibration during normal operation or
other critical conditions should not exceed the allowable amplitude specified by the
equipment manufacturer or IS: 2974, whichever is more stringent.
10) The above design criterion may be omitted for centrifugal pumps and fans and other minor
rotating equipment weighing less than 1 ton or if the mass of the rotating parts are less
than1/100th of the mass of foundation installed directly on concrete foundation, provided
that the weight of foundation is not less than 3 times of the equipment weight. In such
cases, dynamic analysis is not necessary.
11) Where deviations (resulting from inaccuracies in soil parameter measurements,
approximations in design method, etc.) from calculated natural frequencies, leading to
amplitudes in excess of specified limits, are foreseen, provisions for increasing foundation
mass without removal of the machine and without affecting surrounding space availability
or connected piping should be made, if possible.
12) Machine foundations should satisfy the following requirements:
• Minimum reinforcement as per requirements of IS: 2974 should be provided unless
required otherwise by design. All units of the foundation system, except foundation raft
should be provided with symmetric reinforcement on opposite faces, even if not
required by design considerations.
• No common raft should be designed for set of machines.
13) The soil stress below foundations under dead loads should not exceed 80% of the
allowable soil bearing capacity, or safe load on pile, for static loading.
14) It should be ensured that there is no transfer of vibrations from machine foundations to any
part of the adjoining structures. Such foundations should be isolated from other
foundations and floor /paving slab by providing adequate gap between the foundation
faces and surrounding soil mass; the gap should be filled with bitumen impregnated fiber
board unless otherwise stated in the item.
15) Special note should be given on the drawing regarding isolation joints, and suitable details
should be shown as required.
16) Block foundations for machine should be cast in a single concreting operation.
17) Foundations consisting of various blocks of the same machine seated on a common
foundation raft may be provided with a single, properly designed construction joint at the
top of base raft. However, a special note should always be given on the drawing regarding
the recommended procedure of construction.
18) All faces of the foundation block should be provided with surface reinforcement. Minimum
reinforcement diameter in horizontal and vertical directions should be 12Ø, and maximum
spacing of bars should not exceed 200 mm.
19) For frame foundations, base raft should be cast in a single concreting operation. A properly
designed construction joint should be provided between the base slab and columns. The
entire superstructure of columns and upper deck should be cast in a continuous concreting
operation. If height of the frame columns above raft level exceeds 8.0m, an additional
construction joint at the junction of columns / top-deck may be provided.
20) The location of beams and columns, and their reinforcement should be arranged, as far as
possible, symmetrically with respect to the vertical plane passing through the longitudinal
axis of the machine.
21) The minimum beam depth should be one-fifth of the span and the beam width is normally
equal to the width of the column, consistent with anchor bolt requirements, embedded
depth, and edge distances etc.
22) Weight of base raft of the frame foundation should not be less than the combined weight of
the machine and foundation superstructure above the base raft, i.e. columns, top-deck
slab/beams etc.
23) For frame type of foundations, all the elements of foundations should be provided with top
and bottom, two way reinforcements. Reinforcement should be provided on all the faces of
beams and columns even if not required by design calculations. The diameter of main bars
in column / beam should be so selected to limit the maximum spacing of bars to 150 mm.
24) For tie beams below ground, consideration shall be given for designing, additionally, for
superimposed load and/or traffic loading, where applicable.
c) Dynamic Analysis:
1) General
Dynamic analysis should be performed by suitable and approved method so that dynamic
feature can be evaluated correctly.
Following effects should be taken into account:
♦ Dynamic features of subsoil
♦ Dynamic features of supporting foundation system
♦ Dynamic effect of the foundation system
♦ Dynamic forces of equipment
All machine foundations shall satisfy two fundamental criteria that resonance does not
occur between the frequencies of the pulsating loads and natural frequency of
foundation/soil system and also the amplitude of vibration does not exceed safe limits.
Data of dynamic load to be used for the dynamic analysis should be supplied by
Equipment Supplier and should state unbalanced force due to:
♦ Eccentricity of dynamic mass of rotating equipment.
♦ Different crank arrangement of reciprocating equipment.
2) Evaluation of Dynamic Analysis:
Foundations should be so designed that natural frequency of the foundation system should
not resonate with the following:
♦ Operating speed of the motor.
♦ Operating speed of the machine.
♦ 2 times operating speed of the machine
♦ (This condition should be complied only when the manufacturer has furnished
the unbalanced forces related to 2 times the operating speed of the machine)
♦ Critical speed of the machine (for centrifugal machines)
Natural frequency of the foundation should be as per Clause 6.7b (8). However,
amplitudes of vibration of the foundation block should always be checked to be
within permissible limits.
3) Allowable amplitude due to dynamic load:

Amplitude of the foundation systems for vibrating equipment should be calculated through
dynamic analysis by using dynamic load supplied by supplier and the allowable amplitude
should conform to supplier’s requirement.
If supplier’s requirement on amplitude is not specified, Permissible Amplitudes mentioned
in IS: 2974, Part-1 shall be adopted.
Unless otherwise specified foundation design shall follow general criteria indicated below.

CRITERIA APPLICATION
Dynamic * Allowable amplitude, Natural Rotating : P ≥ 400 KW

Analysis frequency of foundation Reciprocating : P ≥ 100 KW
Natural frequency of Rotating : P ≥ 100 KW

foundation Reciprocating : P ≥ 40 KW
Foundation More than 3 x equip. weight Rotating : P < 100 KW

weight
control More than 5 x equip. weight Reciprocating : P < 40 KW
P = Rated Power output of equipment (unit KW).

*If the supplier’s requirement is available, it shall be considered.
6.8 Pile Foundations:
1) Piles should be designed as per IS: 2911(part 1 to 4) such that the Safe Working Load on
the piles should not be exceeded based on pile capacity value arrived from soil parameter
available in referred soil report.
2) Safe working load on piles should be confirmed by the Piling CONTRACTOR as per
specification or by conducting confirmatory pile test /soil test. Pile stiffness used in FEM
model shall be as per Geotechnical recommendations and confirmed by pile testing.
3) The increase in Safe Working Load permitted due to wind /earthquake should apply equally
to uplift and shear conditions, subject to confirmations by the piling contractor in respect to
the particular piling system.
4) Design capacity should be established by conducting sufficient number of initial load tests.
Routine pile load tests should be carried out as per relevant IS code. When any major
machinery is to be supported on piles, behavior of the piles under dynamic loading
conditions as established by necessary field tests should be considered.
5) The capacity of pile groups should be obtained by applying appropriate group efficiency
factors.
6) Where piles pass through filled ground the available pile safe working load should be
suitably reduced to account for negative skin friction caused by settlement of fill. Where
suitable consideration should be given to reducing draw down effects by slip coating the
piles.
7) While computing horizontal capacity, piles should be treated as fixed head or free head
depending on the degree of fixity at the top.
8) Driven cast in-situ piles should have safe distance (as per IS Code requirement) from the
existing structure to avoid any damage due to vibration.
9) Minimum embedment of piles in pile caps should be 100 mm.
10) Pile reinforcement dowels shall be anchored in to the pile cap with required Ld (development
length/anchorage length), preferably L-shape

6.9 Anti Termite Treatment:

All buildings coming in units, offsite and utility areas shall be provided with Post Constructional
anti-termite treatment shall be done as per IS: 6313 and IS: 8944.
6.10 Foundation Bolts:
Minimum Cover to Foundation Bolts: Minimum distance from the centerline of foundation/anchor
bolt to edge of pedestal should be the maximum of the following:
1) Clear distance from the edge of the base plate/base frame to the outer edge of the pedestal
should be minimum 50mm.
2) Clear distance from the face of pocket to the outer edge of the pedestal should be 100mm.
3) Clear distance from the edge of the sleeve or anchor plate to the edge of pedestal should be
100mm.
4) Minimum distance between a standard holding down bolt or anchor sleeve and the face of
foundation/pedestal shall not be less than 6 times dia of bolt in mm.
The tension capacities of anchor bolts shall be worked out based on the bolt to bolt spacing and
the distance between anchor bolt to the edge of concrete. If required, additional reinforcement
around anchor bolts shall be provided in the concrete pedestal.
In case of no tension loads in the anchor bolts of equipment such as small towers, tanks, heat
exchangers, pumps, blowers, compressors, etc. anchor bolts shall generally be set in anchor
boxes unless embedment is required.
Anchor bolts for heavy towers, which are subject to pull out force, shall be embedded into the
foundation at the time of placing concrete using templates.
Minimum size of bolts shall be 16mm (10mm & 12mm can be used for miscellaneous structures).
Minimum center-to-center distance of bolts shall be 2.5 times nominal diameter.
All anchor bolts shall also be provided with a nut and lock nut.
Sleeve type anchor bolts shall be used preferably.
6.11 Height of Pedestals:

Minimum height of pedestals from finished paving / floor/ ground:
Sr.
Description Pedestal Height
No.
1 Building plinth 600 mm above finished ground level.
300 mm (min.) above the finished floor level (FFL)

/Highest point of paving (HPP) /Finished grade for
Pedestals for structural outdoor and
2
columns
150mm (min) above FFL/HPP for indoor located
pedestals.
3 Covered area (building etc.) 150 mm (min.) OR as indicated in drawing
4 Storage tank foundation As per equipment layout

All equipment supporting

5
foundations /pedestals
a Open area As required but not less than 300 mm above FGL
b Covered area As required but not less than 150 mm
200 mm (min.) OR as indicated in equipment

6 Stair Pedestals
layout drawing
7 Ladder pedestals 200 mm
8 Offsite pipe rack / pipe As required but not less than 500 mm above FGL
bridges/ pipe support
pedestals
6.12 Grouting & Minimum Grout Thickness:

1) Unless otherwise specified by equipment manufacturers, top of foundations except for local
foundations should be provided with an allowance for grouting as specified below:
Process Columns (heavy equipment), unless otherwise Min. 50 mm

required in equipment datasheet
Foundation for large heavy duty compressors, generator, etc 50 mm
Foundation for large towers (>20 m) 50 mm
Other foundation bases for other equipments, columns, 30mm

trusses, etc
2) All anchor bolt sleeves/ pockets and spaces under column bases, shoe plates etc. shall be
grouted with free flow, non shrink (premix type) grout with 28 day minimum cube crushing
strength of 40 N/sq mm.
3) Nominal thickness of grouting between the top of concrete foundation levels and the
underside of base plates should be 30 mm, for up to a plate dimension of 500 mm and 50
mm for plate sizes in excess of 500 mm - grout edges & sides shall be splayed at 45
degrees.
4) The thickness of grout should not be less than 30 mm and should not be more than 50mm
(Unless otherwise required in equipment datasheet).
5) Neat cement should not be used for grouting under any condition.
6) Grouting requirement for machines and equipment are not covered here. The same should
be governed by vendor’s requirement. For rotating equipment bases, (above 300 kW rating)
grout shall be as per requirements of equipment vendor; or in absence of any stated
requirements, grout type shall be Non-Shrink Epoxy Grout.
7) Grout shall be finished at a slope of 1:1 from the Bottom of Base Plates to the finished
concrete level.

8) Non-Shrink Cement Base Grout, as per specifications shall be applied for major Steel
Structures and Stationary Equipment’s unless Epoxy Grout is used.
9) Ordinary cement sand (1:2) grout should only be used under the base plates of cross-overs,
short pipe supports (not exceeding 1.5 m height) and small operating platforms (not
exceeding 2 m height) not supporting any equipment.
7. PLINTH PROTECTION:
Each building shall be provided with 1.0 m wide and 100mm thick plinth protection (100mm high
from top of Approach Road Level) in concrete M20, laid over 75 mm thick PCC M7.5 concrete with
brick bats all round as plinth protection, with building drain around the building. Paving shall be
sloped for a rapid run-off of rain water away from the building. Plinth Protection Edge to Road
Edge shall be covered with Interlocking Paver Blocks.
8. RAMPS:
Ramps for building entrance shall be cast in situ R.C.C designed as a grade slab and the slope of
ramps shall not be steeper than 1 in 10. Minimum thickness of the slab shall be 150mm.
Ramps for physically challenged persons shall be designed in accordance with IS: 4963 and
National Building Code.
9. COVERING OF PITS / BASINS:
1) Open pits and basins without roofing or covering should have safety railings. Stepladders
should also be provided for the pits and basins having a depth of more than 1 m.
2) The minimum 600 mm diameter cover for access should be provided for pits and basins with
roofing.
10. FLOORING DETAILS FOR BUILDINGS & SHEDS:
The specifications given hereunder should be adopted for the non- suspended ground floor slabs
for buildings & sheds as categorized in following table:
Sr. Flooring Type

Description
No. I II III
Earth fill base

To be To be To be
1.1 compacted to
provided provided provided
95% dry density
Compacted layer
Sub Grade of sand/ boulder
packing over 150mm
1.2 200mm thick 200mm thick
thoroughly thick
compacted Earth
fill (in mm)
2 Structural Lean concrete 50mm thick 50mm thick 50mm

Grade 1:5:10 over sand thick
Slab layer (in mm)

Structural Non
100 mm
suspended slab in
150 mm thick thick slab
M20 Grade 150 mm thick
slab with (single
concrete slab with
reinforcement layer T8
(Reinforced with reinforcement
placed in 2 @300 both
8mm dia bars @ placed
layers (at top ways
200mm c/c both centrally
& bottom) /welded
ways) over lean
mesh)
concrete
3 Finish Floor Finish As per Architectural Details
Notes:
a) Flooring details as given above shall be adopted for the non-suspended ground floor slabs for
buildings & sheds only as categorized for various flooring types.
b) Flooring Type I shall be considered for Control Rooms, Satellite Rack Rooms, Sub-Stations,
Pump houses, Utility Compressor Houses, Parking Areas, Stores, Porches.
c) Flooring Type II shall be considered for Ware Houses, Workshops, Cement Godowns, Fire
Stations, Process Compressor Houses.
d) Flooring Type III shall be considered for Administration, Laboratory, Canteen, Time Office,
Gate House, Training Centre, Guest House, Residential buildings.
e) Reinforcement steel grade shall be as per other relevant clause of this document.
f) Expansion gap if provided in the building shall be provided in flooring also.
g) Outdoor pavements shall be as per Engineering Design Basis – General Civil. However, 20
mm gap to be provided between floor slab and equipment foundation/ column and shall be
sealed using joint sealing compound.
11. SPECIAL CONSIDERATIONS FOR RCC STRUCTURES:

11.1 General/design methods:
a) All buildings, structures, foundations, machine/equipment foundations, liquid
retaining/storage structures, trenches, pits etc. should be of RCC and designed based on
the following IS Codes (latest revision with all amendments issued there to) in general and
other relevant IS Codes applicable: IS:456, 875, 1893, 1904, 2911, 2950, 2974, 3370, 4091,
4326, 4991, 4995, 4998, 5249, 6403, 8009, 13920.
b) Only limit state method as per IS:456 should be followed in the design unless otherwise
specified elsewhere in this document for special structures.
c) All structures shall be of frame type construction, with ductile detailing as per IS: 13920.
d) Bi-polar concrete penetrating corrosion inhibiting admixture shall be used in concrete works
exposed to moderate to Extreme environment based on the environmental exposure
condition given in IS: 456.
e) Where the specified design depth of groundwater table so warrants, all underground pits,
tunnels, basements etc. (excluding appurtenances of storm water/effluent collection system,
cable trench, pipe trench) should be of leak-proof RCC construction using approved make of
waterproofing compounds.

f) All liquid retaining/storage RCC structures should be leak-proof and designed as un-cracked
section (or with limited crack width in limit state design) as per IS:3370. However, the parts
of such structures not coming in direct contact with the liquid should be designed according
to IS:456 except ribs of beams of suspended floor slabs, counter forts of walls (located on
the side remote from the liquid) and roof which should be designed as un-cracked section.
No increase in permissible stresses in concrete and reinforcement should be made under
wind or seismic conditions for such structures.
g) All liquid retaining/storage RCC structures/Sludge pits etc. shall be lined with HDPE/LDPE
lining or any other suitable impermeable media such that no leaching takes place at any
point of time. Adequate safety measures shall also be implemented to protect the
structures/pits from getting breached.
h) The walls and base slabs of liquid retaining/storage structures should be provided with
reinforcement on both faces for thickness greater than or equal to 150mm. In all liquid
retaining structures, PVC water bars (minimum size 230mm wide x 5mm thick) should be
provided at each construction joint (horizontal and vertical).
i) The coating requirement for underground RCC structures which are in contact with soil, shall
be in line with that required by Codes of practices and other recommendation of confirmatory
soil investigation.
j) Coating requirement of Liquid retaining structures like CT cell, reservoir etc shall be as per
IS:6494.
k) Hot/cold water basin and other primary framing members of Cooling towers or similar liquid
retaining structures which remain constantly in contact with water (stored/sprayed) should be
designed as un-cracked sections.
l) Following conditions shall be also considered for design of liquid retaining structures,
basement, trenches and other underground structure:
i. Only water pressure from inside and no earth pressure, groundwater pressure or
surcharge from outside wherever such a condition is likely to exist either in operation
or during installation / testing.
ii. Earth pressure, surcharge pressure or ground water pressure from outside and no
water pressure from inside.
iii. Base slab shall also be designed for the empty condition during construction and
maintenance stages with maximum ground water table.
iv. Intermediate dividing walls of pump sumps shall be designed considering water in
one pump sump only and the other sump being empty for maintenance.
m) Structures analysis and design shall be done using STAAD Pro Software.
n) Minimum Head Room Clearance of 2.2m shall be provided for under side of beams, slabs,
lintels, etc. For specific requirements, head room clearances shall be followed as per
Project/Layout requirements.-
11.2 Concrete:
a) The minimum grade of reinforced cement concrete to be used for superstructure &
substructure (in case otherwise specified in Geotechnical Recommendations, higher grade
shall be followed for substructure) shall be M30 (design mix) as per IS:456 based on Severe
exposure condition.

b) Minimum cement content for concrete in foundation shall be as per Geotechnical

Recommendations document.
c) Crystalline water-proofing compound of approved make shall be mixed with concrete for all
liquid retaining/ leak-proof structures.
d) Minimum grade of concrete for General Civil work shall be as specified in Engineering
Design Basis – General Civil.
e) From durability considerations, the minimum cement content and maximum free water-
cement ratio shall be as per table given under relevant other clause of this document.
f) However, the maximum cement content shall not exceed 450 kg/cum.
g) Concrete beams shall be designed to resist additional stresses due to pipe
clamps/guide/stoppers.
11.3 Minimum Cover to Main Reinforcement:

Unless specified otherwise, actual concrete cover should not deviate from required nominal cover
by +10 mm.
Nominal cover to meet durability requirement and specified period of fire resistance shall be as per
IS: 456.
Nominal cover should be as per IS: 456, however the following minimum clear cover should be
provided for RCC works. Concrete cover including ties or links shall not be less than following
Sr.No. Description Minimum clear cover
Slab (roof & floors, canopy,

1 25 mm
cantilever, waist slab)
2 Beam (roof, floor, tie & lintel) 45 mm or dia. of bar whichever is

greater
50 mm above FGL
3 Column
75 mm below FGL
4 Retaining wall, Basement and Pit
Wall
a) Face in contact with earth 50 mm
45 mm or dia. of bar whichever is

b) Free face
greater
5 Liquid retaining structure
a) Face in contact with liquid 50 mm or dia. of bar whichever is

greater
b) Face away from liquid but in 50 mm
contact with earth
c) Free face 45 mm or dia. of bar whichever is

greater

6 Foundation slab, base slab, 75 mm

pedestal, plinth beam
7 Pile Cap
a) Bottom face 125 mm
b) Top & Sides 75 mm
The above requirements shall not be applied to concrete construction of trench, local foundation,
minor platform foundation, sump pit/ manhole, paving and other miscellaneous concrete
construction, for which minimum clear cover shall be 40 mm.
Designer shall ensure that the reinforcement cover, mentioned above shall in no case be lower
than that required by Codes of practices as per exposure condition of site and other
recommendation of confirmatory soil investigation report.
11.4 Minimum Thickness of Structural Concrete Elements:
The following minimum thickness should be followed:
Minimum
Sr.No. Description
Thickness
Footings (all types with or without beams)
1 (Note: Tapered footings should not have thickness 300 mm

less than 150mm at the edges. Minimum average
thickness should not be less than 300mm)
2 Pile Cap 500mm
Liquid Retaining / Leak-proof structure / Basement /

3
Underground Pit:
a Walls 150 mm
b Base slab with beams 200 mm
c Base slab without beams 300 mm
Slab thickness in Raft foundations with beam & slab

4 225 mm
construction
5 Floor/Roof Slab, Walkway, Canopy Slab 150 mm
6 Cable/Pipe Trench/Launder Walls & Base Slab 125 mm
7 Parapet 125 mm
8 Louvre / Fin 125 mm
9 Precast Trench Cover/Precast Floor Slab 125 mm
10 Louvre (in contact with liquid) 125 mm

11.5 Minimum Bar Diameter:

Minimum bar diameter shall be as follows:
Piles – Main Bars 12 mm
Piles – Ties 8 mm
Major Foundation 12 mm
Block Foundation - Main Bars & Tie Bars 12 mm
Minor Foundation (Local foundation etc.) 12 mm
Column, Pedestal - Main Bars 12 mm
Column, Pedestal – Ties 8 mm
Beam - Main Bars 12 mm
Beam - Anchor Bars 10 mm
Beam – Stirrups 8 mm
Slab & Wall - Main Bars 10 mm
Slab & Wall - Distribution Bars 8 mm
Minor Elements such as Chajjas, Lintel, Parapet etc. 8 mm
Slab and Wall for Blast Resistant building 12 mm
11.6 Deflections:
Deflections in concrete structures shall in generally be limited by adherence to the limits on span
by depth ratio for beams and slabs and length to lateral dimension ratios for columns as
prescribed in IS: 456. Where special functional / serviceability requirements or large spans
demand actual deflections and / or crack widths shall be calculated and the following limits
adhered to:
Total vertical deflection due to all loads including Span/250
the effects of temperature creep and shrinkage
Crack width (for non-liquid retaining structural) 0.3 mm
Total horizontal deflection between two floors Storey height / 200 (for wind)
Storey height / 250 (for earthquake)
11.7 Bar Spacing:
Minimum and maximum bar spacing for Foundations, Slabs, Stirrups for Beams, Ties for Columns,
Pedestals, Walls etc. should be 100 mm and 300 mm respectively. Bar spacing should be
provided in multiples of 5 mm.
11.8 Cathodic Protection of Reinforcement:
Where reinforcement is to be cathodically protected, reference should be made to IS 8062/ BS
7361 for guidance on design and detailing requirements.

11.9 Blast Resistant Construction:

1) Minimum thickness of Reinforced Concrete Blast walls should be 250mm to meet the criteria
of T.A.C. (Tariff Advisory Committee).
2) R.C.C. blast walls should be taken up to 1.5m below FGL or up to top of footing whichever is
lower, maintaining the wall thickness and reinforcement same as in superstructure.
3) Members should be designed for reversal of stresses.
4) Minimum reinforcement in wall in each face should be 1% (as total in both directions) of
gross cross sectional area or as calculated from structural design considerations. Maximum
reinforcement in each face should not exceed 2%.
5) Roof slab shall be doubly reinforced. Minimum reinforcement in roof slab in each face should
be 1% (as total in both directions) of gross cross sectional area or as calculated from
structural design considerations.
6) Minimum bar diameter in walls and slab should be 12mm.
7) Maximum spacing of bars in walls and roof slab should not exceed 150mm c/c.
8) The structure shall be designed on shear wall concept with roof acting as a diaphragm that
transfers the transverse loads to the side shear wall & columns in proportion to their
stiffness. Internal partitions & division walls shall not be designed as shear wall.
9) Design bearing pressure of soil shall not exceed twice the allowable static bearing pressure
of soil for blast load combination only.
10) Allowable Pile capacity in Compression, Uplift & Shear may be increased by 50% under
blast load combination.
11) Layout of the Blast resistant building shall meet the requirements of All disciplines (ex:
Electrical and Instrumentation)
11.10 Expansion Joint:
Expansion joints in concrete structures shall be provided at 30-35 m intervals. The expansion joint
shall be provided preferably by way of twin columns on a common foundation. Sliding joints shall
be avoided as far as possible. Design and installation of Joints shall be as per IS: 3414. For
sumps and basins expansion joints shall be provided as per IS 3370. When expansion joints are
omitted, the structure shall be designed for stresses developed by temperature variation.
12. SPECIAL CONSIDERATIONS FOR STEEL STRUCTURES:

12.1 General/design methods:
a) Design, fabrication and erection of the Steel Structures should be carried out in accordance
with the following IS Codes as applicable to the specific structures, viz. IS:800, 801, 802,
806, 814, 816, 875, 1893, 6533, 7215, 9178, 9595 etc. Basic consideration of structural
frame work should primarily be stability, ease of fabrication/erection and overall economy
satisfying relevant Indian Standard Codes of Practice. Simple and fully rigid design as per
IS:800 should be used. Where fully rigid joints are adopted they should generally be
confined to the major axis of the column member.
b) Structural elements continuously exposed to temperatures above 215°C should be designed
for reduced stress as per Table 4 of IS:6533 (Part 2) / clause 16.4 (Fig. 24) of IS: 800. The
expected temperature of steel components should not be allowed to exceed 400°C.

c) Fireproofing shall be carried out on all exposed structural steel members in process and
Tankage areas as per OISD-164 norms.
d) Crane gantry girders should generally be of welded construction and of single span length.
Chequered plate should be used for gantry girder walkway flooring.
e) Steel staircases for main approaches to operating platforms should have channels provided
as stringers with minimum clear width of 900mm and slope of app. 41 degree. The vertical
height between successive landings should not exceed 4.0 meters. Treads should be
minimum 250mm wide made of electro-forged galvanized grating (with suitable nosing)
spaced equally so as to restrict the rise to maximum 200mm. However, for non-important
structures like crossovers etc. the minimum width of stair shall be 750 mm).
f) It is preferred to have welded connections and shall be adopted as far as practicable except
for the removable members where bolted connections are required viz. removable members,
Galvanized electrical switchyard structures and transmission towers. Field / Site connections
shall be bolted. Structural connections should have minimum two bolts of 16mm dia. unless
otherwise limited by the size of members.
g) Dedicated monorail for every pump with driver rating of 75 kw and above shall be provided.
The monorail shall be placed longitudinally along the centerline of the pump and its drive
Monorail and trolley shall also be arranged for pumps with driver rating of 30 to 75 kw. But in
such cases, different clusters can be formed with the like pumps and a monorail can be
placed across every cluster of pumps over the line joining the CGs of the motors in that
cluster.
h) Minimum design capacity of monorail shall be 3 MT or 1.5 times weight of concerned
equipment, whichever is higher.
i) Minimum two nuts should be used for all anchor bolts except for ladder, stair and handrail.
j) Lock nuts shall be provided for anchor bolts of tall structures, tall process columns, vibrating
equipments etc.
k) Framing and bracing shall be planned so that the stiffness of the structure can be well
balanced with the loads and the structural stability can be secured.
l) Vertical & Horizontal bracings shall be arranged properly, considering the following
requirements:
• Plant Layout
• Equipment / Piping arrangement
• Structural layout
• Construction, operation & maintenance requirement.
• Seismic design requirement
m) The Vertical bracings provided for lateral stability of structure may be diagonal or V type and
shall satisfy clearance and rigidity requirements. Requirements of IS 800 2007 clause
12.8.1.2 shall also be followed for bracings for design.
n) Expansion joints for the structure shall be as per IS: 800.
o) Removable stoppers, fixed with bolts shall be provided on both sides of Hoist Beams.
p) Structures analysis and design using STAAD pro Software.

q) Torsion on Open web steel profiles shall be avoided as far as possible. Where ever Steel
members subject to torsion, effect of additional shear stresses shall be considered.
r) All members of supporting system on which pipes are laid shall be erected & painted prior to
installing pipes. No contact surface of the supports/ structure with pipe shall be without paint/
coating
s) Minimum Head Room Clearance of 2.2m shall be provided for under side (or passage way)
of beams, braces, gussets, cleats, etc. For specific requirements, head room clearances
shall be followed as per Project/Layout requirements
12.2 Fireproofing of steel structures:
Fire proofing for steel structures and equipment supports that could collapse under fire condition
and contribute to intensity of the fire shall be provided to meet the requirements of OISD 164 (Fire
Proofing in Oil and Gas Industry).
Fire-proofing of steel structures should be with vermiculite, wherever required as per OISD-STD-
164, and should be done for 2 hours fire rating as per Specifications or as required as per TAC
rules and Fire Risk Assessment of Plant Structures/Equipment.
Fire resistance of a material is defined by fire rating, evaluated through a fire test based on applied
thickness and time taken to reach the defined critical steel temperature. Fire rating adopted is
based on UL-1709 rapid rise fire tests of protection materials for structural steel, conducted by
Underwriters Laboratory, USA. In this test, fire resistance of a material is evaluated on a W10x49
steel column as per UL-1709 fire curve and fire rating is published in a UL design number under
XR category for thickness and time. In addition to the fire rating, under this test, material for
exterior use is also evaluated for accelerated ageing, high humidity, salt spray, wet-freeze-dry
cycling, acid spray, solvent spray etc.
For the structures / equipment with fireproofing, considering the risk of corrosion under fireproofing
(Refer note under Table 11 of TP-1ZZZA-PI-SPE-0003) as per table 2 of NACE SP0198, suitable
compatible protective coating system should be applied prior to the fireproofing application.
12.2.1 Thickness of fireproof coating to be applied shall be based on the following:
1) Type-I : In-situ cement concrete for application up to 1.8m from grade level for steel
structures shall be applied with minimum 50mm thickness. For Equipments, entire skirt of
equipment/saddle support steel/support frame shall be provided with fireproofing.
2) Type-II : Structural steel members such as column, beam etc. which shall be protected for 2
hours from reaching critical temperature 538°C, shall be applied with vermiculite based
lightweight cementitious fireproof of thickness corresponding to 2 hours fire rating as per
respective UL design number under UL-1709 (XR category) subject to a minimum of 40mm.
3) Type-III : For equipment skirts/ saddles/ supports (which shall be protected for 2 hours from
reaching critical temperature 427°C), 2 hours fire rating as per UL design is not adequate as
the UL-1709 test is based on 538°C critical temperature. Therefore, for the required fire
protection from reaching 427°C, higher thickness shall be necessary. For this, fireproof
thickness corresponding to 3 hours fire rating as per respective UL design number under
UL-1709 (XR category) shall be adopted subject to a minimum of 40mm.
4) Type-IV : Epoxy Intumescent Coating, shall be provided with prior approval from OWNER
For Technical requirements and other details refer to document NR-0ZZZZ-CV-SPE-0006:

Specification for Fire proofing of Steel Structures.
12.2.2 Weather Barrier Finish Coat (for both Vermiculite based cementitious and In-situ concrete)
1) Sealer Coat
A sealer coat of epoxy polyamide shall be applied over the fireproofing surface as a base for the finish
coat. The sealing compound shall be compatible and approved by fireproofing material supplier.
(Paint FP-3B with DFT 100 micron. thickness as per TP-1ZZZA-PI-SPE-0003)
2) Finish Coat
The finish coat shall be pre-qualified for coating system No. 1 of NORSOK Standard M-501. Two
coats of acrylic elastomeric or polyurethane coating shall be used as finish coat. The sealing
compound shall be compatible and approved by fireproofing material supplier.
(Paint two coats of FP-1 with DFT 40 micron thickness as per TP-1ZZZA-PI-SPE-0003)
Paint data sheet and selected product shall be compatible with PFP material.
12.3 Limiting permissible Stresses:
1) Permissible stresses in structural members should be as specified in:
IS:800 Hot rolled sections (excluding transmission towers and
switchyard structures).
IS:801 Cold formed light gauge sections
IS:806 Tubular structures
IS: 802 Transmission Towers & Switchyard structures.
2) Permissible stresses in bolts should be as specified in:
IS:800 Hot rolled sections (excluding transmission towers and switchyard

structures).
IS: 802 Transmission Towers & Switchyard structures.
3) Permissible stresses in welds should be as specified in:
IS:816 Metal Arc Welding
12.4 Limiting Deflection:
The limiting permissible vertical/horizontal deflection for structural steel members such as gantry
girder for electric overhead crane, manually operated crane, purlin supporting any type of roofing
material under dead + live load or dead + wind load conditions shall be as specified in IS: 800.

1) Pipe Rack and Equipment Supporting Structure

Allowable deflection of beams and columns, to support Pipe and / or Equipment directly
during normal operation, shall be as stated below for unfactored load.
Pipe Rack Beams Span / 325

Equipment Supporting Structure:
Static Equipment supporting Span / 325, but not more than 30mm
Beams
Vibrating Equipment / Hoist Span / 450, but not more than 30mm
Supporting Beams
Other Beams Span / 325, but not more than 30mm
Testing condition Span / 240
Stack Height / 200

Cantilevers Span / 250, but not more than 20mm at free
end
Duct (Refractory lined) Span / 360

Duct (Others) Span / 240
Horizontal Sway at top of Column

of each Story for:
Open framed Structures Height / 200
Cladded Structures Height / 325
Pipe Rack Height / 325
2) Crane Girders
Allowable Vertical deflection of girders for traveling cranes during normal operation,
depending on types, shall be as stated below:
Manually Operated Crane Span / 500

Electrical Overhead travelling Crane up to 50T Span / 750
Electrical Overhead travelling Crane over 50T Span / 1000
Other Moving Loads E.g. Charging Cars, etc. Span / 600
3) Miscellaneous
Allowable vertical deflection of miscellaneous members shall be as stated below:
Monorails and Hoist Beams Span / 500
Joists Span / 325

Purlins, Cladding Runners Span / 200
Span / 200 or 6mm

Grating / Chequered plates
whichever is minimum
The limiting permissible horizontal deflection for structural steel members shall be as
specified below, where 'H' represents the height:
S.No. Type of Structure Deflection Unit

Value
Multi storeyed steel
1 As per IS: 800 Same as 'H'
structure/ building
2 Flare stack supporting H / 200 Same as 'H'

structures
12.5 Minimum Thickness:

The minimum thickness of various structural components (Hot rolled sections) should be as given:
1.0 Trusses, purlins, side girts & bracings 6 mm
2.0 Columns, beams 7 mm

3.0 Gussets in trusses & girders
3.1 Up to and including 12m span 8 mm
3.2 above 12m span 10 mm
4.0 Stiffeners 8 mm
5.0 Base Plates 12 mm
6.0 Chequered plate 6mm (on plain)
7.0 Grating 3 mm
8.0 Tubes 4 mm
Notes:
a) The ends of all tubes shall be sealed by using 6 mm thick plates welded all round.
b) Structural members exposed to marked corrosive action should be increased in thickness or
otherwise suitably protected against corrosion.
c) The minimum thickness of structural components (except gratings & chequered plates)
which are directly exposed to weather and inaccessible for repainting should be 8mm.
Chequered plates shall be avoided on structures exposed to atmosphere.
d) For Transmission Towers & Switchyard Structures, the minimum thickness of various
structural components should be as per IS:802.
e) The minimum thickness for rolled beams and channels should be mean flange thickness
regardless of the web thickness.
f) The minimum thickness of tubes should be as specified in IS: 806.

12.6 Connections:
Unless otherwise specified, the following shall be followed:
1) Shop connections shall be welded and all welds shall be continuous fillet / butt structural
welds. Where galvanizing is specified, seal welding is required at all shop connections prior
to hot-dip galvanizing. Welding subsequent to galvanizing shall not be permitted generally.
But from construction point of view, if openings in gratings are provided after erection,
galvanizing spray shall be used on cut & welded surfaces.
2) Field connection for Ladder, Handrails, post, stair stringers, removable members, platform
framing members shall be made with Black Bolts.
3) Bolted connection for structural members shall be made, with at least two bolts except for
lacing bolt, where it may be with single bolt.
4) High Tensile Friction Grip bolts shall be used for connections subjected to repetitive cycles
of loadings and moments.
5) Ordinary black bolts & nuts (property class 4.6) shall conform to IS: 1367, part 3 shall be
used for purlins, side runners, grade platforms, ladders. Etc. High strength bolts (property
class 8.8 or 10.9) shall conform to IS: 3757 shall be used for main structure members, such
as beams, columns, bracings, floor beams, etc.
6) Minimum two nuts shall be used for all Anchor Bolts.
7) Crane gantry girders shall generally be of welded construction and of single span length.
8) Permissible stresses in bolts shall be as specified in IS: 800.
9) Connections shall be designed as per provisions of IS 800 Sec 12 : Design Detailing for
Earth Quake Loads
12.7 Platforms and Walkways:
1) Platform and walkways shall be as per piping design basis and shall be made of grating
flooring unless otherwise specified. Platforms below the air fin coolers shall be provided with
RCC platform.
2) The minimum clear headroom over platforms and walkways shall be 2250 mm to the lowest
point of overhead structural framing or equipment.
12.8 Ladders:
1) Ladders shall be 450 mm wide and shall be made of stringers with 20 mm diameter M.S.
rungs at 300 mm (max.) intervals.
2) The flight of Ladder without the intermediate platform shall not exceed 6000 mm. However,
wherever feasible, staircase shall be provided .
3) Ladders over 3500 mm in height or originated from a point which is 3500 mm or more above
grade, shall be provided with safety cages, originating 2400mm from the bottom.
4) Ladder access openings shall be provided with the safety chain/safety bars.
5) Ladders shall preferably be vertical. In no case, will the angle with the vertical exceed 5
degrees.
12.9 Electrical switchyard structure and Transmission Tower:
All electrical switchyard structure and Transmission Tower should be bolted connection structural
steel and designed on the basis of IS:802.

Structural Steel members including bolts, Nuts and washers should be hot dip galvanized in
accordance with relevant IS Codes. The zinc coating on tower members shall not be less than 900
gm/ sqm of the surface area.
12.10 Slenderness Ratio:
Maximum slenderness ratio of a member shall be in accordance with IS: 800.
12.11 Painting:
Painting including shop primer to Structural Steel should be as per the painting specification to be
adopted for the concerned project. For structural steel painting details Refer to Painting
Specification TP-1ZZZA-PI-SPE-0003.
13. SPECIAL CONSIDERATIONS FOR MASONRY WORKS:

1) All masonry works should be designed in accordance with IS:1905, IS:1597, IS:2185,
IS:4326, IS:12894, IS: 1077, IS: 4860 and other relevant IS Codes as applicable. All
external brick masonry walls should be of minimum 230mm thickness except for fire walls.
For General Civil work, refer General Civil Design Basis.
2) In case of Concrete Solid/Hollow block work the minimum thickness of all external wall
shall be 200mm.
3) All masonry walls from ground floor shall be placed on R.C.C grade beams. However, light
internal partitions may be placed on ground floor slab.
4) All masonry work should be constructed in cement sand mortar 1:4 for load bearing walls
and 1:6 cement sand mortar for non-load bearing walls except half brick partition walls
which should be constructed in 1:4 cement sand mortar with two numbers of 6mm
diameter MS bars provided at every fourth course properly anchored with cross walls or
pillars.
5) Thickness of masonry firewalls around transformers shall be 355mm (including plaster) or
as per OISD-STD-173, whichever is more. In case of concrete solid block work, the wall
thickness shall be 300mm
6) Masonry shall be plastered with CM 1:6, 12mm thick plastering for inside surfaces and
20mm thick plastering for external surfaces shall be provided
7) All buildings walls upto plinth shall be with locally available class 1 bricks of class 7.5
conforming to IS 1077 shall be used. For walls above plinth locally available class 1 bricks
of class 7.5 or AAC blocks of minimum density 651 to 750 with minimum compressive
strength of 5.0 N/mm2 confirm to IS 2185.
14. PLATFORM BELOW AIR COOLERS:

Blind floors should be provided below air coolers located on Pipe Rack/Technological Structure, if
pump handling hydrocarbon or other equipment is located below air cooler the entire are will be
designated as blind floor/platform. If there is no pump/ otherwise, as minimum requirement 2m
center platform with 3m wide local extension should be provided below motors.

15. RCC AND STEEL CHIMNEYS:

RCC and Steel chimneys should be designed as per the requirements of IS:4998 and IS:6533
Criteria for selection of RCC or Steel Chimneys.
16. TANK FOUNDATIONS:

Type of Tanks foundations is recommended as following,
Diameter of Tank Foundation type
Dia ≤3m Solid Octagonal/square
3m<Dia≤6m Slab foundation
6m<Dia≤20m Ring wall foundation (Reinforced Concrete)
>20m Ring wall (Crushed Stone) or in case of space constraint use Ring Wall
Foundations (RCC)
However, based on soil condition, soil improvement and economical design point of view the
foundation type shall be decided during detail engineering.
Anticorrosive layer of 50mm thick bitumen sand mix shall be provided below storage tanks directly
resting on grade.

PART-B
SEISMIC DESIGN

1. GENERAL
1.1 Scope:
This establishes the basic inputs required for seismic design of the plant and provides certain
guidelines for the methods used for seismic analysis of structures/equipment. However, detailed
mathematical formulations of seismic analysis are outside its scope.
Calculations of Seismic forces shall be made as per the provisions of latest revision of IS: 1893 as
well as this document and design shall be done based on greater of the two forces obtained.
The Analysis and Design of structures and foundations shall be based on IS1893(Part 4) - (Latest
edition) and for general guidance IS:1893 (Part 1) - (Latest Edition) shall be referred and Project
specific recommendations & Site Specific Response Spectra (Refer Document TP-1ZZZA-CV-
BOD-0002), whichever is stringent. Earthquake Zone–V shall be considered in design of all
Structures & Foundations.
For Process columns, vessels, tanks, exchangers, compressors etc., seismic loads shall be taken
from Mechanical Group / Equipment design data.
Natural frequency calculation, modal analysis, missing mass corrections. method of modal
combinations, DBE/MCE equipment.
1.2 Codes and Standards:

Latest editions of codes and standard Latest revision including all parts and amendments as
referred below shall be followed:
Sr. No. IS Code Description
1 IS 456 Code of practice for plain and reinforced concrete.

2 IS 800 Code of Practice for General Construction in Steel
2 IS 1786 High strength deformed steel bars and wires for concrete
reinforcement.
3 IS 1893 Criteria for earthquake resistant design of structures.
4 IS 1893 Part-1 Criteria for Earthquake Resistant Design of Structures - Part 1 :

General Provisions and Buildings
5 IS 1893 Part-2 Criteria for Earthquake Resistant Design of Structures Part 2

Liquid retaining structures

Bridges and Retaining walls

Industrial Structures Including Stack-Like Structures
6 IS 2062 Steel for general structural purposes
6 IS 2911 Design and Construction of pile foundations - Code of practice

Part 1 Concrete Piles.

7 IS: 875 Part-1 Code of practice for design loads (other than earthquake) for
buildings and structures Part 1 Dead loads - Unit weights of
building material and stored materials
buildings and structures: Part 2 Imposed loads
9 IS: 875 Part-3 Code of Practice for Design Loads (Other than Earthquake) for
Buildings and Structures - Part 3: Wind Loads
buildings and structures Part 4 Snow loads
buildings and structures Part 5 special loads and load
combinations
12 IS 3370 Part-1 Code of practice for concrete structures for storage of liquids;
Part 1 General requirements.
Part 2 Reinforced concrete structures.
Part 4 Design tables.
15 IS 4326 Earthquake resistant design and construction of buildings -
code practice.
16 IS 4994 Criteria for blast resistant design of structures for explosions
above ground
17 IS 13920 Ductile detailing of reinforced concrete structures subjected to
seismic forces - Code of Practice.
Licensor’s standard/ standard specification shall be followed wherever applicable /available.
Note: The above list is suggestive and not exhaustive. Apart from these basic codes any other
related codes shall be also followed wherever required.
1.3 Categorization of Structures/ Equipments:

Structures/equipments shall be classified into the following four categories.
1.3.1 Category-I:
Structures / Equipment whose failure can cause conditions that can lead directly or indirectly
to extensive loss of life/ property to population at large in the areas adjacent to the plant complex.
List of Equipment Tags coming under category-1 shall be confirmed by Process Safety.
1.3.2 Category-II :
Structures / Equipment whose failure can cause conditions that can lead directly or indirectly to
serious fire hazard / extensive damage within the plant complex.
Structures / Equipment which are required to handle emergencies immediately after an
earthquake, also are included.
1.3.3 Category-III :
Structures / Equipment whose failure, although expensive, does not lead to serious hazard within
the plant complex.
1.3.4 Category-IV :
All other structures / Equipment.
Typical categorization of Industrial structures shall be as per Table-6 given in the IS: 1893 Part-4.
Category of structures not covered in Table-6 of IS: 1893 Part-4, shall be determined based on the
above definition of different categories and confirmed by Process Safety,
The term failure used in the definition of categories implies loss of function and not complete
collapse.
Pressurized equipment where cracking can lead to rupture may be categorized by the
consequences of rupture.
Structures which are ductile detailed as per IS 13920 or IS 800 and equipment which are made of
ductile materials can withstand earthquakes many fold higher than the design spectra without
collapse; and damage in such cases is restricted to cracking only.
Generally, 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.
2. DESIGN CONSIDERATION:
2.1 Design Site data consideration:
Sr.No. Parameter Reference and Details

1. Plant Location Numaligarh, Assam
2. Seismic Zone V (Annex D of IS 1893 part IV; Town: Jorhat)
3. Zone Factor, (Z) 0.36 (table 14 of IS 1893 part IV)
4. Important Factor - I For non-plant buildings, as per IS-1893 Part-I;
For Industrial Structures including Stack-like Structures
as per IS:1893 Part-IV
5. Soil Type As per Geotechnical data and soil profile
6. Structure category As per Table 6 of IS 1893 (Part – IV) and process

safety requirement
7. Response Reduction As per IS 1893 (Part – I & Part – IV)

Factor (R)
For Steel structures refer to IS800 section 12.

Sr.No. Parameter Reference and Details

8. Spectral Acceleration IS 1893 (Part – I & Part – IV)
/ Site Specific Response Spectra Refer Document TP-
1ZZZA-CV-BOD-0002 (TP document ref 082176C-
ZZZ-JSD-1700-0002)
9. Damping Factor Table - 5, IS- 1893- Part-IV
10. Multiplication factor Table-15, IS- 1893- Part-IV
2.2 Design Acceleration Due to Earthquake:

The Horizontal seismic coefficient Ah and Vertical acceleration shall be obtained as per the IS:
1893 Part- 1 & 4/ as per Site Specific Response Spectra Refer DocumentTP-1ZZZA-CV-BOD-
0002.
2.3 Ductile Detailing

Appropriate ductility details, for reinforced concrete members, should be provided as per the
provisions of IS: 13920 to avoid premature failure during earthquake.
In steel structures, members and their connections should be so proportioned that high ductility is
obtained to ensure that premature failure due to elastic or inelastic buckling does not occur.
Ductile detailing of steel structures shall be carried out as per the provisions of IS: 4326 and IS:
1893 and chapter 12 of IS 800.
3. PERMISSIBLE STRESSES:
3.1 Material Stresses:

Whenever seismic forces are considered along with other normal design forces, the
permissible stresses in material shall be governed by the respective codes as per which the
structure/equipment is being designed. In the absence of such code/standard, provision of IS:1893
shall be used.
3.2 Increase in stresses

For permissible Increase in allowable bearing pressure of Soil and Pile Capacity Provisions of IS:
1893 (Part-1) shall be used.
Earthquake shall not be considered to act simultaneously with wind.

4. METHOD OF SEISMIC DESIGN:
4.1 General:
This document provides certain guidelines for the methods to be used for seismic analysis of
structures/equipment. However, detailed mathematical formulations of seismic analysis are
outside its scope. IS:1893 essentially defines the acceleration spectra to be used in different
zones and gives the method of design of various kinds of structures. If available, acceleration
spectra for the project site are not to be taken from IS:1893, but is to be taken from site-dependent
spectra. Apart from the modifications of acceleration values, other provisions given in IS:1893 in
respect of the applicability of the methods remain unaltered.
If Site-Specific Spectrum gives design MCE acceleration spectrum Ah value less than that by
the MCE (Maximum Considered Earthquake) Spectrum value specified (as per IS 1893 Part-IV),
the latter shall govern.
If Site-Specific Spectrum gives design DBE (Design Basis Earthquake) acceleration
spectrum Ah value less than that by the DBE Spectrum value specified (as per IS 1893 Part-IV),
the latter shall govern.
All category-I Industrial structures shall be analyzed using site specific spectra. However, if site
specific studies are not carried out, the code specified spectra may be used with modifications as
per the provisions given in IS: 1893 (Part-IV). For all other structures the spectra and seismic zone
shall be as per IS: 1893 (Part-I & IV).
Site specific earthquake hazard assessment may not be required for Category-2, 3 & 4 Industrial
structures.
4.2 Fundamental Natural Period of Structure/Equipment:

This shall be determined by any of the standard methods described in IS: 1893 Part-4.
4.3 Mathematical modelling:

The mathematical model used for analysis of structure shall represent the structure appropriately
and shall include;
All elements of lateral force-resistant system.
Stiffness and strength of elements, which are significantly influence of lateral forces distribution.
Proper representation of special distribution of mass of equipment, cable trays and piping system
along with associated accessories. Mass model of equipment shall be applied with appropriate CG
of the equipment or any other method.
Interaction effects between structure and equipment as indicated in IS 1893 (Part 4)
4.4 Method of Analysis:

Detailed analysis shall be carried out for structures of Category 1, in aIl seismic zones.
Detailed analysis shall be carried out for all structures of Category 2 and 3 in seismic zones III, IV
and V.
Simplified analysis may be used for structures of Category 2 and 3 in seismic zone II.
Simplified analysis may be used for structures of Category 4 in all seismic zones. However, those
structures of Category 4, which could be identified as buildings, may be analysed as per
provisions of IS 1893 (Part 1).

This shall be determined by any of the standard methods described in IS: 1893 Part-4.
In seismic analysis mass participation of minimum 90% shall be ensured and correction for
missing mass shall be taken.
Analysis and design shall be performed using STAAD Pro software with appropriate design
parameters.
4.5 Effect of Masonry Infill Walls:

In RC buildings with moment resisting frames and unreinforced masonry (URM) infill walls,
variation of storey stiffness and storey strength shall be examined along the height of the building
considering in-plane
stiffness and strength of URM infill walls. If storey stiffness and strength variations along the height
of the building render it to be irregular as per IS: 1893 (Part 1), the irregularity shall be corrected
especially in Seismic Zones III, IV and V.
The estimation of in-plane stiffness and strength of URM infill walls shall be based on provisions
given in IS: 1893 (Part 1).
4.6 Lateral Force:

Buildings shall be designed for the design lateral force VB given by:
VB = Ah x W
where,
Ah is Design horizontal seismic coefficient,
W is Seismic Weight of floors.
Buildings and portions thereof shall be designed and constructed to resist at least the effects of
lateral force specified above. But, regardless of design earthquake forces arrived at, buildings
shall have lateral load resisting systems capable of resisting a horizontal force not less than as
specified below:
Sl. No. Seismic Zone Percent

1 II 0.7
2 III 1.1
3 IV 1.6
4 V 2.4
4.7 Structures / Equipment not covered in IS: 1893

If fundamental time period is less than or equal to 0.04 sec. equipment / structure may be treated
as a rigid body and Ah corresponding to zero period may be used in conjunction with the use of
pseudo static method (a method of design whereby seismic force on any structures / equipment is
assumed to be static and acting at C.G and its magnitude is given by the weight of body multiplied
by Ah). It has been observed that generally horizontal heat exchangers and horizontal storage
vessels mounted directly on the foundations having nominal support height fall in this category.
If fundamental time period is greater than 0.04 second, one may use pseudo static method or
response spectrum method depending on the height of structure / equipment. The height above
which one should use response spectrum method shall be as per the discretion of the designer.

In the pseudo static method, value of Ah corresponding to the fundamental period of structure is
taken from the site dependent spectra. Small vessels supported on lugs and storage vessels
which can be approximated as single degree of freedom system are examples where pseudo
static method may be used.
Steps involved in response spectra method are given briefly:
a) Calculate all natural periods above 0.04 second and their mode shapes.
b) Pick up Ah corresponding to each period from the site dependent spectra curve.
c) Calculate response of structure for each mode. (i.e. Displacement, bending moment, shear
force etc.).
d) Combine response of each mode by SRSS (square root of sum of squares) CQC Method.
For seismic analysis of piping, seismic coefficient method is not valid and one has to resort to the
use of response spectrum method. Thermal loading calls for a flexible system while seismic
loading calls for a rigid system and the designer has to make an optimum choice. Generally, it is
seen that pipes are provided with supports in the vertical direction with little or no support in the
horizontal plane. Such supporting arrangement gives large seismic forces and moments on the
equipment / vessel nozzles. As far as possible supports which restrain the motion of pipe in
horizontal plane, should be provided without exceeding the seismic forces and moments on the
equipment/vessel nozzles.
4.8 Combination of Responses Due to Multi-Component Seismic Accelerations

All types of structures/equipments shall be designed for multicomponent earthquakes as per the
provisions given in IS: 1893 Part-4.
4.9 Damping
The variety of damping displayed in different types of structures has made the choice of a suitable
damping co-efficient for a given structure largely a matter of judgement. In general, damping
increases with increase in stress amplitude or displacement amplitude or both. Moreover, damping
exhibited in lower-frequency modes of vibration is generally lower than that exhibited in higher-
frequency modes. For detail design, Bidder shall follow values in IS: 1893 Part-1.
4.10 Base isolation and energy absorbing devices

Base isolation and energy absorbing devices may be used for earthquake resistant design. Only
standard devices having detailed experimental data on the performance should be used. The
designer must demonstrate by detailed analyses that these devices provide sufficient protection to
the buildings and equipment as envisaged in IS:1893. Performance of all assembled isolation and
energy absorbing devices should be evaluated experimentally, and duly approved by the
competent authority identified by the client / owner of the structure, before such devices are used
in practice. Design of buildings and equipment using such device should be reviewed by a
competent authority. In general, base isolation systems are found useful for short period
structures, say those with fundamental periods, including soil-structure interaction less than 0.7s.
To control the serious loss of life and economic loss, the technique of base isolation can be an
alternate damage control strategy, which should be promoted or encouraged in Seismic Zones III,
IV and V. The commonly used seismic isolators are:
i. laminated natural rubber bearings,
ii. high damping rubber bearings,

iii. laminated lead rubber bearings, and

iv. sliding bearings.
A combination of different types of isolators can be adopted to achieve satisfactory stiffness of the
isolation system. Supplementary dampers (viscous or metallic yielding dampers) can be used
along with base isolation systems, to reduce relative displacement demand on the isolated
superstructure.
5. DUCTILE DETAILING
Appropriate ductility details of reinforced concrete members should be provided as per the
provisions of IS:13920 to avoid premature failure during earthquake. In steel structures, members
and their connections should be so proportioned that high ductility is obtained to ensure that
premature failure due to elastic or inelastic buckling does not occur. Ductile detailing of steel
structures should be carried out as per the provisions of IS 800 chapter 12, IS: 4326 and IS: 1893.
Deformations Lateral and joint rotation shall be checked as per provisions of IS 1893.
6. SPECIAL PROVISION FOR STORAGE TANKS

Seismic design of storage tanks shall be carried out as per the provisions of API 650 Appendix-E /
API 620 Appendix-L (as applicable). For double-walled tanks inner and outer tanks have to be
checked separately and the outer tank has also to be checked for possible inner tank failure.
The value of Z and I (refer API 650 Appendix-E/ API 620 Appendix-L) shall be taken as unity
unless otherwise specified. The spectral acceleration values for periods greater than 3.0 seconds
may be considered same as that for 3.0 seconds.

PART-C
ARCHITECTURAL WORKS

1 SCOPE
This Part of specification defines the design criteria and loads that should be taken in to account
for the design of all architectural works.
1.1 Referenced Standards & Publications
1) National Building Code of India
2) State Govt. Factory Acts
3) Local Municipality or any other Authority’s Bye- Laws as applicable.
4) TAC (Tariff Advisory Committee) Rules.
5) OISD Standards.
6) BPE (Bureau of Public Enterprise) Norms.
7) Bye-laws of Town & Country Planning Organization.
8) BIS (Bureau of Indian Standards) Codes.
9) (IER) Indian Electricity Rules.
10) CEA (Central Electricity Authority).
11) Guidelines of IGBC/ GRIHA/ LEED for Green Building concept.
12) Pollution Control Board norms.
13) Any other applicable Law, Rules, Standard as referred in respective clause.
14) Code of Practice for Building Bye Laws IS 1256
15) Process Control Room Safety
Note: The above list is suggestive and not exhaustive. Apart from the basic codes, any other
related codes shall also be followed whenever required.
1.2 Standard Specifications Codes & Practices
Engineering design incorporates Codes and Standards as referred in the design philosophy of
respective engineering disciplines as well as applicable standards and specifications. All codes &
Standards shall be latest revision with all amendments issued thereto. However, effort shall be
made for effective utilization of space and facilities for cost effective design.
2 DESIGN PHILOSOPHY / CRITERIA - GENERAL
2.1 Architectural Design
Architectural Design of Buildings / Sheds shall be in accordance with this Design Basis and
References as stated above to meet the functional requirements. In plant area, no underground /
basement shall be provided in the building.
2.2 Building Requirements
2.2.1 Spatial Requirements
Spatial requirements inside a Building / Shed shall be decided based on equipment / panel layout,
activities to be performed in the building and consequent occupancy pattern, Equipment Layout,
etc. Sizes of various type of spaces shall be decided based on occupancy/ equipment/Panel
layout, clearances, maintenance & safety requirements. The objective of spatial arrangement shall
be to satisfy functional requirements, physical comfort and safety regulations as well as aesthetics.

Requirement of services/utilities such as air conditioning, LAN etc. shall be finalized as per
Owner’s specific requirement. Special care shall be taken to design buildings (Except Plant
buildings such as Satellite Rack Room, Substation, Control Room etc.) to meet the criteria of
Green Buildings as per the standards of IGBC/ GRIHA or any other Green Building rating system
decided by Owner, for desired rating.
Spaces can be generally classified as follows, which shall be provided in all the Buildings / Sheds.
1) Functional Spaces
Functional areas of any building / shed are constituted by main activity areas for which
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.
a) Activities, group of activities and consequent work-flow pattern.
b) Site conditions i.e., dimensions, contours, etc.
c) Climatic conditions vis-à-vis orientation.
d) Site Planning (solar geometry, approaches, adjoining facilities, safety standards
etc.)
e) General arrangement of equipments
f) Health, Safety & environmental standards & regulations.
g) Lighting and Ventilation
h) Acoustics
i) Building utilities, amenities & Services
j) Security
k) Economy
l) Aesthetics
m) Statutory requirements (viz. local building authority bye-laws, fire authority
approval, airport authority approval, environmental clearance, forest authority
approval, power utility & requirement approval, consent to establish / operate etc.)
n) Any Specific requirements pertaining to particular buildings
o) 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 working and living conditions.
2) Circulation Spaces
Following spaces are classified as circulation spaces. These spaces shall be provided for
integrating various types of spaces and as means of access / exit / escape.
a) Corridors & passages
b) Staircases
c) Elevators
d) Entrance lobby / Foyer including reception & waiting

e) Gangways / Walkways
f) Equipment loading / unloading platforms
g) Emergency exits
h) Ramps for physically challenged and equipment entry/exit as applicable.
3) Amenity Spaces
Following spaces are classified as amenity spaces.
a) Toilet
b) Drinking Water Facility
c) Locker & Change room
d) Rest room / Lunch room
e) Wash rooms & space for drying clothes
f) Canteen / Pantry room
Out of the above-mentioned areas, a) Toilet, b) Drinking Water enclosure shall be
mandatory requirement for human occupied buildings / sheds. Other requirements shall be
provided as required.
4) Utility Spaces
Utility spaces are space requirements which materialize due to provision of services like
air- conditioning, pressurization, firefighting, electrical, telephone etc. These spaces shall
be provided as per required building services. Following are examples.
a) Air-conditioning plant room.
b) Air handling rooms.
c) Pressurization blower plant room
d) Electrical distribution panels rooms
e) Service ducts
f) Firefighting equipment room
g) Telephone exchange equipment room
h) UPS room
i) Battery room
NBC shall be followed for Minimum width/ dimension of the spaces of the building.
However, following are the minimum sizes/ dimensions for various purposes, which are
to be adhered to.
Minimum size of any habitable 9.5 sq.m. with minimum dimension not less than
room 2.75 m.
For Residential Buildings, 3.0m which may be
reduced to 2.75 m for air-conditioned areas.
Minimum height of any habitable Headroom below beams: min. 2.4m.
room For Educational & Industrial Buildings, the
minimum height shall be 3.6 m & 3 m for air
conditioned spaces.

Maximum height of habitable room

3.6 m or as stipulated by local byelaws.
@ 14cu.m.per occupant.
Scale of accommodation for Minimum clear height of such workspaces shall
Industrial be 3.6m.
workspaces Heights above 4.25m shall not be taken into
account.
Minimum height of Fire Station
5.0 m
Building / Control Room
All height dimensions are to underside of ceiling or beams, whichever is lower.

The height shall be determined considering the clearance from equipment, bus duct
and lighting fixtures etc.
5) Multi-Storey Concepts
Due to Layout constraints, All the building shall be studied for multi-storied in discussion
with Owner/MPMC. Feasible solutions shall be proposed on approval shall be
implemented.
2.2.2 Day Lighting
Established level of illumination shall be maintained for all parts of the buildings by means of
windows, skylights, ventilators etc. Following references shall be adhered to in this regard.
a) National Building Codes of India
b) BIS (Bureau of Indian Standards) Codes
c) State Factory 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.
2.2.3 Ventilation
1) 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:
a) National Building Code of India
b) BIS (Bureau of Indian Standards) Codes
c) State Factory Act
d) Any other relevant rules / Codes etc.
Natural Ventilation shall also be supplemented by mechanical or electrical means of
ventilation in all human occupied areas. Sufficient no. of Glazed/Louvered
windows/Ventilators shall be provided and supplemented by exhaust fans.

2) Mechanical Ventilation
In addition to natural ventilation, if required Mechanical or electrical ventilation is provided
depending on the type of building and its use. Refer Design Basis of Packaged Equipment
for its requirement and applications.
2.2.4 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:
2) State Factory Act
3) Limitations on decibel level stated elsewhere, if any, in the bid document
Required noise level in any space shall be maintained by means of
1) Segregating noise sources by buffer zones
2) Dampening of noise levels by damping devices
3) Providing Acoustic treatment with acoustic material (on walls, ceilings, floors, as required).
2.2.5 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 emergency. The exits shall be in terms of doorway, corridors,
passage ways to internal / external staircase or to areas having access to the outside. Control
room building shall be provided with emergency exit on the other side of the entrance.
Following references shall be adhered to in this regard.
3) OISD
2.2.6 Site planning & landscaping
Site planning of building shall take into account aspects like interrelationship of the buildings with
the whole system, movement pattern, traffic and road net-work, safety regulations, service
network, fire safety, climatic and environmental aspects, site conditions like site dimension,
contour, drainage, noise level, view, future expansion, visual aspects, Natural Light and Ventilation
etc.
Main and service/ maintenance entrances of buildings shall be provided with vehicular access. All
exit points shall also be provided with footpath/ vehicular access. Truck movement space in
accordance with traffic pattern shall be provided for the building as per the location of hoisting
bay/loading, unloading platform. Road network and open space around the buildings shall be
designed considering movement and functioning of Fire tenders and cranes etc. Parking space in
accordance with traffic load shall be provided to all buildings.
Climatic factors like wind direction, solar geometry shall be taken into account in orienting the
buildings depending on type of climate. 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 buildings. Sufficient open space
shall also be provided around the buildings for lighting and ventilation in accordance with Factory
Acts & National Building Code. Open spaces in a plot and around buildings proportional to the
height of the structure shall satisfy the requirements of the local byelaws.
Suitable Landscaping treatment shall also be done around the important buildings. Such treatment
shall generally consist of lawns, road side plantation and beautification of building entrance areas.
Standard landscape elements such as earth contours, paving, flower beds, hedges, shrubs,
ground cover and ornamental trees shall be incorporated in landscape treatment. Necessary water
supply/sprinklers shall also be provided.
2.3 Building Services
Following services shall be provided for all buildings / sheds as essential services.
2.3.1 Water Supply, Distribution and Drainage, Sanitary Services
This service is essential for all human occupied buildings / sheds. All buildings with human
occupancy shall have toilet and drinking water facility and accordingly water supply, distribution
and drainage, sanitary services as per the following references:
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 to be provided in
each toilet block.
All service pipes showing on the external wall shall be suitably concealed or shall be provided
within a shaft.
Each building shall be equipped with approved PVC overhead water tanks of capacity based on
occupancy and as recommended by code.
2.3.2 Electrical services
This service shall be provided as essential service for all the buildings. Electrical services for
building shall consist of electrical supply, and distributions, electrical lighting installations,
telephone network, fans, exhaust fans, lighting protection system etc., including all accessories,
cabling etc. including Emergency power supply, all as defined under Engineering Design Basis of
Electrical.
2.3.3 Air Conditioning and Heating
Control Room Building, Satellite Rack Rooms, Administration Building, Amenity Building, Training
Center etc. shall be centrally air-conditioned. Accordingly, A.C. Plant/ AHU etc. of the require
capacity (depending on the requirement) shall be provided and suitably housed. Some designated
rooms (as per Electrical requirement) in the Sub Station Buildings or in other buildings like
canteen; scale room etc. may be required to be air-conditioned. For this suitable window/ split/
package type units may be provided as per requirement w.r.t. the Design Basis of Packaged
Equipment.
2.4 Aesthetics
Apart from the fulfillment of functional & safety requirement, aesthetic requirement of the building
shall be taken care of in the design. As specific guidelines for achieving required aesthetics are
difficult to establish, preliminary drawings indicating Architectural treatment (with minimum three
different alternative proposals) shall be submitted for Owner’s approval.

Architectural scheme shall be based on general principles of Aesthetics. Building facades shall
reflect such principles like symmetry, balance, proportion, rhythm, light and shade etc.
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, roof projections
♦ Entrance/exit steps, door
♦ Window/Ventilator composition
♦ External wall location with respect to columns
♦ Colour scheme, grooves in plaster
♦ Spatial arrangement
Local Climatic conditions shall be considered while designing the buildings.
Architectural scheme including design of above mentioned elements shall be subjected to Owner/
PMC approval.
2.5 Structural and Construction Elements
Blast resistance control room buildings, if provided, shall be fully R.C.C. structure to withstand the
specified blast pressure. Other buildings (Non-blast proof Control Room Buildings, Sub Stations
etc.) shall be R.C.C. framed structure (columns, beams and R.C.C. roof slab) with brick masonry /
Burnt clay fly ash building bricks / AAC block infill walls. Structural & Construction elements shall
be designed as per the details given in Engineering Design Basis-Structural.
2.6 Building Elements
1) Plinth protection
All the buildings & sheds shall be provided with minimum 1000 mm wide (top of plinth
protection shall be 100mm high from top of Approach Road Level) plinth Protection with
building drain around the building /shed.
2) Finished Floor Level (FFL)
In general, FFL of the buildings, sheds shall be determined with respect to top of Approach
road or pavement. Following schedule shall be adhered to for FFL of various buildings &
sheds.
Control Room
Building/Satellite Rack Top Road level of Approach road + 450 mm + Height of false
Room Building (Building flooring
having false flooring)
Top of approach Road level + 300 mm (Cable Cellar floor)
Sub Station Buildings Top of approach Road level + 150 mm (Transformer bays)
with pebbles

F.G.L. (+) approx. 1000 mm (or) decided as per actual

requirement high from top of road (in case of single storey
Substation Building with trenches as per electrical
requirement)
Plant Buildings (Unit (HPP) shall be maintained as per site grading w.r.t. Design
area) Basis of General Civil
Other Top of approach Road level + 450 mm(min.) and or as per

Buildings/Sheds functional requirement
Vehicle Scooter, Cycle
Shed including Fire Top of approach Road level + 150 mm
Tender Bays, Repair
Shop
Loading, Unloading Top of approach Road level + 1100 mm
platforms
False Floor area As specified in the Instrumentation design document
(Control Room)
Electrical Rooms As specified in the Electrical design document
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/shed. Split levels may be considered in
exceptional cases due to ground terrain etc.
♦ FFL of external loading/unloading bays/platforms, toilet, pantry, kitchen shall be 10-15
mm lower than that of the building/shed’s FFL to check ingress of rainwater.
♦ In case of discrepancy, philosophy of levels shall be followed.
♦ FFL of Loading/ Unloading bays of Warehouses, Godowns, stores shall be
maintained as Loading platform level of trucks with outward slope to avoid ingress of
rain water splash.
3) Steps / Ramps / Stairs
Steps/ramps shall be provided for access to the buildings/sheds 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:
1500 mm minimum (Refer NBC cl 12.18)

Stairs width 1250 mm minimum for one side open staircase (Emergency
Exit)
Tread 300 mm minimum
Riser 150 mm maximum
Slope of ramp Not steeper than 1:12 or as per requirement
Ratio of Tread & Riser 2Riser+Tread = 600 mm

No. of Risers per flight 15 nos. maximum
Landing width 1500 mm minimum
Width of step / ramp 1500 mm minimum
Handrail shall be provided as per the provisions of National Building Code and IS: 4963.
(Recommendations for Buildings and facilities for the physically challenged).
Edge of treads shall be provided with friction grip strips or similar anti-skid arrangement.
Ramps for physically challenged persons shall be designed in accordance with IS: 4963.
4) Wall
Following schedule shall be adhered to for wall material and thickness.
External walls 230 mm thk. Brick / fly-ash building brick wall
230mm / 115 mm thk. Brick / fly ash building brick / AAC

Internal partition wall block wall depending on the overall length and height of
the wall (refer note below)
250 thk. RCC or 355 thick (including plastering) fire brick

Transformer walls / Fire Walls walls as per Electrical requirements (OISD /IER).
Transformer wall shall extend upto bottom side of roof.
Concrete wall (Blast resistant) As per structural design basis
Notes:
♦ 115 mm thick. Brick partition walls (with nominal steel requirement as per structure
design) shall be provided with 230 mm thick. brick pillars for stability depending upon
the length and height of wall.
♦ 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 for obtaining OWNER’s/PMC approval
5) Doors
Doors shall be provided for access, security and safety to all entry & exits of rooms,
functional areas in a building. Air tight door shall be provided in pressurized area and in
gaseous protection area. Fire check doors shall be with minimum two hours rating as per
statutory requirement. Emergency door shall be opened outwards. Sizes of the doors shall
be determined on the basis of the following schedule:
a) Equipment, Panel area: Maximum size of equipment including packing.
b) Other areas: Volume of movement through door.
c) Minimum door size at entrance: 1500 mm x 2100 mm (wall opening size)
d) W.C. bath Cubicle door: 800 mm x 2100 mm (wall opening size)
e) Minimum size of other doors: 1000 mm x 2100 mm (wall opening size)
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 openable shutters & fixed
panels. Entrance lobby shall be provided with elaborate canopy.
♦ Rolling shutters shall be provided wherever size of opening exceeds 2500 mm width x
2700 mm height.
♦ Mechanically operated rolling shutters shall be provided for opening sizes exceeding
8 Sq.m
♦ 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.
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 openable area of the windows/ventilators shall be as
required for necessary air changes as per Factory Act subjected to a minimum of 15% of
the floor area to be ventilated. However, the % shall finally depend on the Climate Zones
(complying with NBC) and shall count only the openable area of the windows.
Windows/ ventilators are also elements of building aesthetics and shall be provided in
accordance with approved Architectural control scheme. Windows shall be provided at
working levels. For the purpose of natural lighting total glass area shall be minimum 15% of
the floor area. However, in case of offices, work places etc. windows shall be provided for
the full length of walls as per approved Architectural scheme.
Areas accommodating panels/ equipments shall be normally provided with ventilators at
high level for unobstructed distributed lighting. Ventilators shall be provided below roof
beam. Ventilators shall be with Aluminium louvers in case of buildings. In case of Sheds,
Aluminium louvers or cladding sheet louvers as approved shall be provided.
Rooms, spaces, sheds having height more than 4 metre shall have windows and
ventilators at multiple levels to ensure required natural lighting and ventilation at all levels.
Such windows & ventilators must be provided at all intermediate working levels of such
high rooms, spaces, sheds.
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.
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/GI roof sheeting etc. suitable monitor
may added in provide additional ventilation.
Transparent roof light sheeting / Light Pipe / Light Tube shall be provided in roofing of shed
type structures for day lighting.
Blast resistant Control room windows openings through wall may be provided as per OISD-
STD 163.

7) Ridge ventilators, Roof air extractors

In case of Sheds, water tight & leak proof ventilators/ extractors shall be provided over roof
to ensure required air changes as well as for hot air outlet in accordance with following
philosophy:
Area Design Philosophy
Ridge Air driven/ operated ridge ventilators, ridge

monitors,
Roof Roof mounted air driven extractors/ turbo ventilators

shall be provided
8) Canopy/Overhang
RCC Canopy/Overhangs shall be provided at all entrances and exits for rain & sun
protection. Size of the canopy/ porch shall be decided w.r.t. utility of the building and
other aesthetic. Blast proof Control Rooms shall not have any projections with outer face
of its walls except with false treatment for aesthetics of the building.
a) For all offices, control rooms (Non-Blast type), composite buildings/sheds
accommodating offices, canopy shall be provided at all entrances. Size of the
canopy shall be decided based on vehicle parking & pedestrian movement in
addition to aesthetics of the building/shed.
b) Overhangs shall be provided over all exits. Size of the overhang shall be decided
based on the aesthetics of the building/shed subjected to minimum of 1000 mm.
Waterproofing & drainage provision shall be provided for the canopies &
overhangs.
9) Shading Devices
RCC Shading devices shall be provided over all windows, openable ventilators for rain &
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. The top surface of the shading devices shall be finished with cement plaster
mixed with waterproofing (laid to slope) compound and shall be provided with GI spouts
for drainage. Cinder filling to be avoided in projections of door, window, porch etc.
10) Parapet
Parapets shall be of RCC for all buildings with minimum 600 mm high for non-
approachable roof and 1100 mm high for approachable roof from finished floor level after
water proofing treatment.
11) Roof Gutter
Gutter with rainwater pipes or RCC 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 depending on type
of structure. For Workshop/Warehouse shed with pre-coated roof sheeting, pre-coated
sheets gutters may be provided and for big size of workshops/warehouse RCC shaft may
be provided at the end of gutter.

Constructional details of rainwater gutters and downpipes and their fittings for drainage
shall be as per the provisions given in IS: 2527.
All buildings shall be provided with rainwater harvesting system (as per Assam Ground
water Control and Regulation Act 2012), for rain water harvesting system, site specific
scheme shall be developed. Provision in the Storm water drainage scheme of non-
contaminated water for replenishment of ground water/rain water harvesting shall be
provided.
12) Rainwater pipes, Spouts

C.I. /PVC rainwater pipes (min. 110mm dia.) shall be provided for roof water drainage.
Number of rainwater pipes shall be decided on the basis of roof area, slope and rainfall
intensity. However, minimum 1 pipe of 110mm dia. shall be provided for every 200 sq.m of
roof area. Finished terrace surface shall be even and slope not less than 1%. Rainwater
pipes shall be embedded in concrete / concealed as far as possible. RCC / PVC / GI
spouts shall not be used for drainage of chajja/small canopies to avoid possibility of
chocking (may be used for drainage of chajja / small canopies of ground floor).
13) Drainage Pipe for Air-Conditioning Units
Suitable arrangement shall be made in buildings for drainage of condensed water from Air-
conditioning units.
14) Air Lock Lobby
This shall be provided for all entries with centrally air-conditioned spaces. Air-Lock Lobby
Air-lock lobby shall be provided to all entry & exits of pressurized areas.
15) Entrance Lobby
Entrance lobby shall be provided as a common entrance for all buildings/sheds
accommodating separate or similar 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 subjected to minimum requirement of 9.5 Sq.m.
16) Passages/corridors
Passages/corridors shall be provided to integrate various spaces. Width of the passages/
corridors shall be as per following schedule and / or as per the statutory requirement.
Singly loaded passage/corridor Minimum 1500 mm
Doubly loaded passage/corridor Minimum 1800 mm
But whenever passages/ corridors are to be used for equipment/ machinery/panels etc. the
width shall be determined on the basis of equipment/machinery /panel sizes.
17) Service Entry
Separate service entry shall be provided for service areas such as kitchen, air-condition/
pressurization plant room, electrical rooms, battery & UPS room etc. A common service
entry may be provided depending on spatial arrangement.

18) Emergency exits

Emergency exits shall be provided for all the building/sheds as per statutory requirements.
Emergency exits for individual function spaces such as console area, cable cellar,
electrical room, switchgear hall shall also be provided. Emergency exits shall be located in
such a manner that escape route is unobstructed & without passing through any other
function areas. corridors/ staircases shall be provided as escape route to the emergency
exits.
19) Staircases
Staircases shall be provided in multi floor buildings for vertical circulation & emergency
exits. Number of staircases shall be based on building/shed sizes and emergency exit
requirements. At least one staircase/cage ladder shall be provided for access to the roofs
for maintenance.
Total number of staircases shall depend on travel distances to exit points as
determined by the statutory regulations. However, at least one staircase shall be provided
for every building as "ALTERNATE ESCAPE ROUTE".
20) Railings
Railings (1100 mm high) shall be provided in 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 in roofs. All hand
railings in buildings shall be SS-304 grade material to be used.
21) Toilets
Toilet shall be provided for all buildings/sheds having human occupancy. Toilet shall
consist of Gents Toilet, Ladies Toilet (as per requirement) and separate drinking water
enclosure and janitor space. Requirement of fittings & fixtures shall be as per National
Building Code of India & Factory Act.). Toilet shall be provided in accordance with following
principle.
Parameter Guidelines
Gents/Ladies Toilet shall be provided in all buildings /sheds

Gents/Ladies Toilet
having human occupancy as per requirement.
At least one number toilet for physically challenged shall be

provided in each floor of Admin building, Canteen, Training
Toilet for physically Centre, Laboratory, Office buildings and in other human occupied
challenged buildings where physically challenged personnel can be deployed.
Provisions shall be made for construction of toilets for physically
challenged as per IS: 4963 & NBC.
Janitor Each Toilet block shall be provided with suitable janitor facility.
Toilet plumbing, piping, etc. visible on external facade of building shall be visually
concealed by means of shafts etc considering building aesthetics.

Drinking water enclosure (as required) shall be provided in all buildings /sheds having
human occupancy. Drinking water facility may be provided in Pantry also.
22) Electrical Room:
Electrical Room may be provided to accommodate electrical/telephone main distribution
box. However, depending on size, space requirement, the same may be mounted in wall
recess.
23) Partitions
If required, partitions shall be provided for flexible space arrangement in Office spaces,
Control room etc. The partitions shall be of removable type. Glazed panels shall be
provided for visibility in the partitions as per requirement.
24) False Ceiling
False ceilings shall be provided for following purposes: -
a) To reduce room volume and hide ducting etc. for air conditioned spaces.
b) To maintain acoustic level inside any space.
c) To reduce habitable room, corridor, lobby, toilet heights located in high ceiling
building/shed to a reasonable and satisfactory height of minimum 2800 mm.
d) In fire-rated areas where walls and doors are required to be fire rated, false ceiling
shall also have complementing fire rating. It is appreciated that false ceiling have
limitations in their fire performance due to openings in them for lighting and air-
conditioning. Therefore, alternative systems to prevent puncturing the ceiling must
be employed.
25) Underdeck Insulation
If required as per design, Underdeck insulation below RCC roof and over false ceiling (both
locations) shall be provided for air-conditioned office / space.
26) False/Cavity flooring
False/cavity flooring shall be provided to accommodate under floor cabling in
instrumentation areas like console rooms, rack room, computer room, UPS room etc.
Extent of false/cavity flooring shall be as per instrumentation requirements
Wherever applicable, False flooring shall be fire rated to the level of fire rating of the walls,
doors and suspended ceiling in the compartment.
27) Transformer Gate
Steel gate of suitable size in front of transformer bays in substations building shall be
provided as per electrical requirement.
28) Fire water / Fire extinguisher
All buildings shall be provided with fire water network / fire extinguishers in compliance to
statutory requirement.
29) Solar Panels on Top of Building
Buildings shall be designed and provided with provision of Installation of Solar Panels as
per NRL requirement.

3 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 Buildings
Type A • Office Building
• Training Centre
• Gate House
• Marketing Office Building
• Canteen/Dining Hall
• Guest House
• Control Rooms
• Satellite Rack Room
Type B • Substation
• Switchgear Building
• MCC Room etc.
Type C • Laboratory
• Occupational Health Centre
• Fire Station
• Gate Houses (other than Main Gate House)
• Other non-plant/ process building not listed in any other
category
Type D All process/ plant buildings not listed in other category.
Type E • Stores
• Ware house
• Workshop
• Cement Godown
• Site Office
• Weigh Bridge
• Watch Towers
• Other storage/ maintenance buildings
Type F • Utility storage Sheds like D.G.shed, Pump Houses,
Compressor House, Analyzer Room etc.
• Process sheds & other sheds
Note: Incase of conflict between licensor/process/safety/statutory requirement and this

schedule of Architectural finishes, the former shall override.
Color Scheme: The Contractor shall provide NRL with three options of color scheme for each
type of buildings, NRL shall finalize one choice out of the three options for the Contractor to
proceed with painting procurement and execution.
3.1 External Finishes

3.1.1 External wall, RCC Surfaces
The schedule of Architectural finishes shall be finalized w.r.t the Type of Buildings from among the
following respective finishing options or a combination of the options:

Combination of:
Type "A" Buildings
• Plain cement plaster and texture coating
• Granite stone/sand stone cladding
• Plain cement plaster and Acrylic paint
• Composite Aluminum Panel & structural glazing
• GFRC Jaali
• Plain Cement plaster and Acrylic paint
• Plain cement plaster and texture coating and

Type "B" Buildings
• Plain Cement plaster and Acrylic paint
Combination of :
Type "C" Buildings
• Plain cement plaster and texture coating
• Granite stone/sand stone cladding
• Plain cement plaster and Acrylic paint
• Composite Aluminum Panel & structural glazing

• GFRC Jaali
Type "D" Buildings
Type "E" Buildings • Plain Cement plaster and Acrylic paint
Type "F" Buildings
Note: Grooves in plaster shall be provided at junction of different materials and as per
external facade treatment.
3.2 Internal Finishes

3.2.1 Floor Finishes
• Entrance Lobby, Reception, Lounge, Waiting area, Viewing gallery etc:
Type "A"
• Granite Stone
Type "B"
Type "C"
Type "D" • Vitrified Tiles
Type "E"

Type "F"
• Office and associated office areas like records/ storage, meeting/ conference room etc.:
Type "A"
Type "B"
Type "C"
• Vitrified Tiles
Type "D"
Type "E"
Type "F"
• Circulation area (Corridor, passage, etc.):
Type "A"
• Combination of Granite stones and Vitrified Tiles.
Type "B"
Type "C"
Type "D"
• Vitrified Tiles
Type "E"
Type "F"
• Kitchen, pantry & Dining hall etc.:
Type "A" • Combination of Granite stones and Vitrified Tiles.
Type "B"
Type "C"
Type "E"
Type "F"

• Toilet, Drinking water area etc.:Toilet, Drinking water area etc.:
Type "A" • Granite stones.
Type "B"
Type "C"
Type "D" • Ceramic Tiles
Type "E"
Type "F"
• Staircase area.:
Type "A" • Granite stones.
Type "B"
Type "C"
Type "E"
Type "F"
• Battery Room & Chemical handling areas.:
Type "A"
Type "B"
Type "C"
• Acid/Alkali Resistant Tiles & flooring /bedding.

Type "D"
Type "E"
Type "F"

• Electrical Room, Pressurization Room, AC Plant, Loading / Unloading bays, Equipment

handling areas, Product storage areas, Switchgear, MCC, Ware House, Work Shop,
Process/ Utility Sheds etc.:
Type "A"
Type "B"
• Heavy Duty Cement concrete flooring.
Type "C"
• Vacuum de-watering flooring in large Rooms/ areas
Type "D"
• Switchgear hall - epoxy coating over heavy duty
cement concrete flooring
Type "E"
Type "F"
• Console, Rack room, UPS Room, areas housing instrumentation Equipment’s requiring
under-floor cabling etc.:
Type "A"
Type "B"
Type "C" • Combination of vitrified Tile, cavity/ false flooring
Type "D" • Combination of Granite and Vitrified Tiles
Type "E"
Type "F"
• Executive Block Including all office areas, lounge, lobby, dining room, meeting/ conference
room, etc. of admin building:
Type "A"
Type "B"
Type "C"
• Combination of Granite and Vitrified Tiles
Type "D"
Type "E"
Type "F"

Note:
1) Only the back of CRT and small channel in front for carrying the cables of CRT etc. shall
be provided with false flooring. The area in front of panels shall have Vitrified tiles or as
specified.
2) Skirting shall be provided in all areas which shall be of same material as that of flooring.
Panel dividers shall be provided in cement concrete flooring.
3.2.2 Internal Wall Finishes
• Entrance Lobby, Reception, Lounge, Waiting area, Viewing gallery etc:
• Combination of Granite stone cladding and Cement

Plaster, POP punning & Plastic emulsion paint
Type "A"
• Cement Plaster, POP punning & Plastic emulsion
paint
Type "B"
paint
Type "C"
Plaster, POP punning & Plastic emulsion paint
Type "D"
Type "E"
paint
Type "F"
Type "A"
Type "B" • Cement Plaster, POP punning & Plastic emulsion

paint
Type "C"
Type "D"
Type "E"
• Cement Plaster and Oil Bound Distemper
Type "F"

• Granite Stone Cladding up to 1500 mm height and

Cement plaster, POP punning & Plastic emulsion
Type "A" paint above

paint
Type "B"
Type "C"
paint
Type "D"
Type "E"
Type "F"
• Kitchen, pantry & Dining hall etc.:

plaster, POP punning & Plastic emulsion paint
Type "A"
paint
Type "B"
Type "C" • Cement Plaster, POP punning & Plastic emulsion

paint
Type "D"
Type "E"
Type "F"
• Toilet, Drinking water area etc.:
• Granite Tile Dado up to Ceiling/ False Ceiling

Type "A"
• Vitrified Tile Dado up to Ceiling/ False Ceiling
Type "B" • Ceramic Tile Dado up to 2100 mm.

• Ceramic Tile Dado up to Ceiling/ False Ceiling

Type "C"
Type "D"
Type "E" • Ceramic Tile Dado up to 2100 mm.
Type "F"
• Staircase area.:
• Cement Plaster & Textured Coating Cement

Type "A"
Plaster, POP punning & Plastic Emulsion paint

Type "B"
paint
Type "C"
Plaster, POP punning & Plastic Emulsion paint
Type "D"
paint
Type "E"
Type "F" Plaster, POP punning & Plastic Emulsion paint
• Battery Room & Chemical handling areas.:
Type "A"
Type "B"
Type "C"
Type "D" • Acid/Alkali resistant tiles upto 2500mm height.

• Oil Bound Distemper above 2500mm height.
Type "E"
Type "F"
• Electrical Room, AC Plant, Loading / Unloading bays, Equipment handling areas, Storage
areas, Switchgear, MCC, Ware House, Work Shop, Process/ utility Sheds etc.:

Type "A"
Type "B"
Type "C"
• Cement Plaster & Oil Bound Distemper
Type "D"
paint (Switchgear hall & MCC)

Type "E"
Type "F"
• Rack room , Engineering room, UPS Room.:
Type "A"
Type "B"
Type "C"
Type "D" • Cement Plaster, POP punning & Plastic emulsion
paint
Type "E"
Type "F"
• Console Room.:
Type "A"
Type "B"
• Granite stone dado up to 1500mm height Cement
Type "C" plaster, POP punning & Plastic emulsion paint
above
Type "D"
• Cement Plaster, POP punning with plastic emulsion
Type "E" paint
Type "F"

Note:
Grooves in plaster shall be provided at all junctions of different material cladding and as per
external façade treatment. POP molding shall be provided in “A” & “B” type buildings as per
Architectural scheme.
3.2.3 Internal Ceiling Finishes:

following the respective finishing options or a combination of the options:
• Entrance Lobby, Reception, Lounge, Waiting area etc:
• Aluminium panel / Strip false ceiling
Type "A" • Combination of Gypsum & Mineral fiber tiles false

ceiling
• Aluminium panel / Strip false ceiling

Type "B"
• Combination of Gypsum & Mineral fiber tiles false
Type "C"
ceiling
Type "D" • Mineral fiber tiles false ceiling
Type "E" • Cement Plaster & Oil Bound Distemper

• Combination of Gypsum & Mineral fibre tiles false
ceiling
Type "F" • Cement Plaster & Oil Bound Distemper
Type "A"
Type "B"
•Combination of Gypsum & Mineral fibre tiles false
Type "C" ceiling
Type "D" •Aluminium panel/ Strip false ceiling
•Cement Plaster, POP punning & Plastic emulsion

Type "E" paint in records/ storage rooms
Type "F"


Type "A" ceiling
• Aluminium panel/ Strip false ceiling

• Cement Plaster & Plastic emulsion paint
Type "B"
• Combination of Gypsum & Mineral fiber tiles false
Type "C"
ceiling
Type "D"
Type "E" • Cement Plaster & Oil Bound Distemper
Type "F"
• Other AC areas etc., where false ceiling required :
Type "A"
Type "B"
Type "C"
Type "D" ceiling
Type "E"
Type "F"
• Rack room , Engineering room, UPS Room:
Type "A"
Type "B"
Type "C"
Type "D" • Combination of Gypsum & Mineral fibre tiles false

ceiling
Type "E"
Type "F"

• Other areas not indicated above if any:
Type "A"
Type "B" • Cement Plaster, POP punning & Plastic emulsion
Type "C" paint

• Cement Plaster & Oil Bound Distemper
Type "D" • Aluminum panel/ Strip false ceiling for Switchgear
Type "E" hall
Type "F"
Note:
1) Office area, Corridors circulation areas to be provided with false ceiling.
2) For Other areas – Architectural scheme shall be followed.
3) False ceiling to be provided in Air conditioned areas of other types of buildings also
depending upon the requirement.
3.3 Doors, Windows & Ventilators:
The schedule of Doors, Windows & Ventilators shall be finalized w.r.t the Type of Buildings from
among the following the respective options or a combination of the options:
3.3.1 Doors
• Entrance/ exit Doors
• Powder coated Aluminum glazed doors
Type "A"
Type "B" Note:
Type "C" • Wooden doors along with wooden frames shall

be provided in all office building.
Type "D" • Steel door with panic bar shall be provided in
Type "E" switchgear hall entry/exit, airlock lobby area &
cable cellar area.
Type "F"
• Doors in Circulation Area:

• Powder coated Aluminum glazed doors
Type "A"
Type "B" Note:

Type "D"

Type "E"
Type "F"
• Office Area Doors

• Powder coated Aluminum glazed doors with
Type "A"
partly etched glass
Type "B"
Type "C" Note:

• Wooden doors along with wooden frames shall
Type "D"
Type "E"
Type "F"
• All Electrical Room, A.C. Plant Room, Battery Room doors

• Pressed steel frame with Pressed steel shutter,
Type "A"
Powder coated
Type "B" Note:
Type "D"
Type "E"
Type "F"
• Toilet Doors:
• Cubicle system (with compact laminated board)
Type "A"
• PVC Doors
• PVC Doors
Type "B"
• Cubicle system (with compact laminated board)
Type "C"
• PVC Doors
Type "D"
Type "E" • PVC Doors
Type "F"
Note: Wooden doors along with wooden frames shall be provided in all office building.

3.3.1.1 Fire check/ resistant doors

Irrespective of above schedule, Fire check doors (minimum 2 hours rated) shall be provided
wherever required as per OISD/ Statutory requirements,
• Fire check doors In Control Room / Satellite Rack Room Building
a) Main entrance/ entry to Console:
- Glazed steel Fire check door
- Solid type steel fire check door (with 300mm x 300mm vision panel).
b) Other Rooms:
• Fire check doors In Administration Building

a) Main entrance/ entry / Circulation area:
- Wooden TW veneered fire check door (with 300mm x 300mm vision panel).
b) Other Rooms:
- Wooden TW veneered fire check door (with 300mm x 300mm vision panel).
• Fire check doors in Other buildings:

a) Main entrance/ entry / Circulation area:
b) Other Rooms:
Rolling shutters shall be provided in equipment areas like Switchgear/ MCC Room, Workshop,
Ware House etc. where opening size for door exceeds 3000 x 3000mm, in non-Air-conditioned
areas. Doors/windows/ventilators shall be complete with all fittings & fixtures for easy smooth
operation & locking facility.
Doors/windows/ventilators shall be complete with all fittings & fixtures for easy smooth operation &
locking facility.
3.3.2 Windows & Ventilators:
Type "A"
Type "B" • Powder coated Aluminum glazed windows &
Type "C" ventilators
Type "D"

Type "E"
Type "F"
3.4 Roof Treatment:

♦ Over deck Insulation cum Water Proofing system
Selection of roof waterproofing treatment shall be decided based on site location, rainfall intensity
and other climatic factors.
3.5 Sanitary Fittings & Fixtures
All the plumbing fixtures including toilets, faucet aerators and showerheads shall be preferably
fixed with low-flow plumbing fixtures (in line with Green Building requirements) that save
substantial amounts of water compared to conventional fixtures while providing the same utility.
• Water Closet (European type):

• Water efficient (dual flush) Wall hung type,
Type "A"
coloured (premium luxury model)
• Pedestal type, coloured
Type "B"
Type "C" • Wall hung type, coloured (premium luxury model)
• Pedestal type, coloured
Type "D" • Pedestal type, coloured / white
Type "E" • Pedestal type, coloured / white ceiling
Type "F" • Pedestal type, white
• Wash basins:
• Round/oval, coloured, with electronic sensor over

Type "A" granite counter
• Round/oval, coloured, over granite counter
Type "B" • Round/oval, coloured, over granite counter
Type "C" • Round/oval, coloured, with electronic sensor over

granite counter
• Round/oval, coloured, over granite counter
Type "D" • White, wall hung type

Type "E"
Type "F"
• Urinals:
• With Electronic Sensor (premium luxury model)

Type "A"
• Standard Wall hung type
Type "B" • Standard Wall hung type
Type "C" • With Electronic Sensor (premium luxury model)
• Standard Wall hung type
Type "D"
Type "E" • Standard Wall hung type
Type "F"
Note:
All toilets shall be provided with “Geysers” and automatic “No touch Hand drier”.
3.6 Roofing (Sheds/Workshops)
Precoated, profiled colour coated alloy / Galvalume / Zincalume steel sheeting of 0.5mm minimum
thickness (TCT) shall be of clip-lock arrangement.
3.7 Cladding
Precoated, profiled colour coated alloy / Galvalume / Zincalume steel sheeting of 0.5mm minimum
thickness (TCT) shall be of clip-lock arrangement. S-Type Louvres with frame shall be used for
ventilation.
4 GENERAL REQUIREMENTS
1) All free edges of chajjas and slab projections shall have drip mould in plaster 50 mm wide
and 20 mm drop unless the need is resolved in some other manner.
2) Sunken Floor slab in WC areas, toilet, pantry, kitchen floor slabs shall be avoided. Pipes
shall be camouflaged by using false ceiling. However, where required, floor slabs in WC
areas shall be sunk by 500 mm and toilet, pantry, kitchen floor slabs shall be sunk by 200
mm at all levels (including terrace, where future extension is envisaged).
3) All supporting framework members of partition walls within false ceiling areas shall go up to
roof level, partitions shall go up to false ceiling level except where there are fire
compartment wall where it shall be from floor to ceiling.

4) Preferably all cut outs in slab shall be provided with 200 high curb. Gaps in floor cut outs
shall be sealed with fireproof material for fire safety.
5) Roofs of RCC buildings should have mild slope towards rainwater gutters.
6) All instrument / Electrical cable trenches at the junction of the building (outside) shall be
covered with precast RCC slab.
7) Plinth beams level shall clear trenches if any.
8) Water tanks, AC plant, Cooling tower, Chiller units etc., where required, shall be located on
building roof as far as possible and it shall be positioned and supported to transfer its load
on to beams and columns and not to the slab. Such facilities should not be visible from
outside. Suitable side cladding shall be provided for this purpose.
Note:
Various Architectural finishes/items, Sanitary fitting & fixtures, door/window schedule etc.
indicated here are as per prevailing system in various units of Refineries. Any other preference
of the owner not covered here shall also be considered.

PART-D
GENERAL CIVIL

1. SCOPE:
This document covers engineering design basis for Civil works such as compound wall, fencing,
site grading, roads, pavements, storm water drainage, water supply, waste collection &
disposal system, tank farm dyke, tank foundations, etc.
2. UNITS OF MEASUREMENTS:
Units of measurement in design shall be metric system
3. DEFINITIONS:
CCE Chief Controller of Explosives
TAC Tariff Advisory Committee
NFA National Fire Protection Association
IS Indian Standards
4. CODES & STANDARDS:
4.1 Latest editions of codes and standard as referred below shall be followed:
Sr. No. Description Standards / Codes
1 Process Design & Operating Philosophies on Blow down and OISD-STD-109

Sewer system
2 Layout of Oil & Gas Installations OISD-STD-118
3 Process Control Room safety OISD-STD-163
4 Specification for mild steel and medium tensile steel bars and IS: 432
hard-drawn steel wire for concrete reinforcement
5 Code of practice for plain and reinforced concrete IS: 456
6 Precast Concrete Pipes (With and Without Reinforcement) - IS: 458

Specification
7 Code of practice for general construction in steel IS: 800
8 Code of practice for design loads (Other than earthquake for IS: 875
buildings & structures
9 Hot rolled mild steel, medium tensile steel and high yield strength IS: 1139
steel deformed bars for concrete reinforcements
10 Code of basic requirements for water supply, drainage & IS: 1172
sanitation
11 Specification for Hard-drawn Steel Wire Fabric for Concrete IS: 1566
Reinforcement
12 Code of practice for building drainage IS: 1742

Sr. No. Description Standards / Codes
13 High Strength Deformed Steel Bars and Wires for Concrete IS: 1786
Reinforcement - Specification
14 Code of practice for structural use of unreinforced masonry. IS: 1905
15 Code of practice for water supply in buildings IS: 2065
16 Code of practice for brick work IS: 2212
17 Code of practice for installation of septic tanks IS: 2470
18 Methods of Test for Soils IS: 2720
19 Code of practice for concrete structures for storage of liquid IS: 3370
20 Cast iron spigot and socket drain pipes -- (Withdrawn Standards) IS: 3486
21 Code of practice for ancillary structures in sewerage system IS: 4111
22 Chemical Resistant Mortar-Silicate type IS: 4441
23 Chemical Resistant Mortar-Sulphur type IS: 4442
24 Chemical Resistant Mortar-Resin type IS: 4443
25 Testing of Mortar IS: 4456
26 Chemical Resistant Mortar (Parts I to III) IS: 4832
27 Specification for high density polyethylene pipes for potable IS: 4984
water supplies
28 Unplasticized PVC Pipes for Potable Water Supplies - IS: 4985
Specification
29 Guidelines for design of surface drains IS: 8835
30 Specification for precast concrete septic tanks IS: 9872
31 Specification for UPVC pipes for soil and waste discharge IS: 13592
systems inside buildings including ventilation and rainwater
system
32 Unplasticized Non-Pressure Polyvinyl Chloride (PVC - U ) Pipes IS: 15328
for use in Underground Drainage and Sewerage Systems -
Specification
33 Codes for Roads, Indian Roads Congress IRC
34 Process Licensor’s requirement, if any

4.2 Statutory Provisions:

1) Environmental guidelines for sitting of Industry published by Ministry of Environment
and Forest.
2) The Environmental Protection Act, 1986
3) Petroleum rules (for Hydrocarbon storage under Chief Controller of Explosives of PESO).
4) The static and mobile Pressure Vessels (unfired) rules- (For pressure storage of Gases
under Chief Controller of Explosives).
5) Director General of Civil Aviation (DGCA) Rules.
6) Manual for Water Supply and Treatment (by Ministry of Urban Development)
7) Manual on Sewerage and Sewage Treatment (by Ministry of Urban Development)
8) Specification for Road & Bridge Works (Published by IRC on behalf of the Government of
India, Ministry of Road Transport & Highway)
9) Gas Cylinder rules
10) Director General of mines (DGMS) and safety rules
4.3 Abbreviations:
Code Description
CBR California Bearing Ratio
CRWS Contaminated Rain Water Sewer
FGL Finished Ground Level
HFL High Flood Level
HPP Highest Pavement Point
IRC Indian Road Congress
MSA Million Standard Axle
MSL Mean Sea Level
OWS Oily Waste Sewer
PCC Plain Cement Concrete
RCC Reinforced Cement Concrete
WMM Water Mix Macadam
WBM Water Bound Macadam
EWS Environment, Water & Safety

5. OVERALL PLOT PLAN:
a) Plot plan shall be prepared based on Mechanical / Piping Design Basis showing
proposed facilities and referring the existing overall plot plan, taking care of the
requirements of PESO (Petroleum & Explosive safety Organisation), DGCA and good
engineering practice.
b) Overall Plot Plan shall also meet as applicable t h e requirement of OISD-STD-118,
OISD-STD-144,OISD-STD-163 and OISD-STD-169 depending upon the nature of the
plant and process licensors’ recommendations for Refineries & Petrochemical plants.
c) Existing services where interfering with the new construction should be located and
rerouted as instructed by Owner / Consultant.
d) The Overall Plot Plan shall be reviewed, modified and got approved by the Owner
before implementing any project or facility. After receipt of the Owner's approval only,
the Overall Plot Plan shall be valid for further engineering and statutory approvals.
6. SITE GRADING:
a) The work area shall be cleared and stripped completely of all bushes, roots, trees, shrubs
and Other vegetations, organic matter and other objectionable materials. All these should
be completely Uprooted and removed and not merely scraped at the surface.
b) The grading of the area shall be done by cutting and filling with the following:
Cutting area Thoroughly rolled and compacted

Compacted in layers not exceeding 30 cm in loose
Filling area thickness to achieve min. 95% of max. Proctor dry
density as per IS: 2720 Part-VII
Finished Ground Level 100.000 refers to 90.400 MSL
c) Site grading philosophy shall be based on following:

Elevation above mean sea RL 90.4 m (with respect to Golaghat Rly station which
level: is at 92.636 MSL)
Min. 0.6 m above Design High Flood Level (HFL) of the
Plant FGL area or based on drainage outfall level.
Min. 0.4 m above FGL for operating areas like units /
Unit HPP utilities.
d) Slope in Graded Area:
1 General Site Grading 1 in 500 to 1 in 1000
2 Micro grading (after completion of major 1 in 200 to 1 in 500
construction for road corridors)
3 Tanks Farms 1 in 200 to 1 in 300
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.

7. ROADS:
Cross section of roads shall be designed, including roads for crane access, as per IRC 37.
However, the minimum section to be adopted shall be as given below under 'Road Width' (Point.
b). Ruling gradient shall be 1 in 30. In case contractor proposes to use existing roads for
erection purposes, the same should be strengthened to cater for erection loads. Contractor shall
ensure that use of existing roads does not hinder normal activities in existing plants. The
contractor shall repair any damage to existing roads or other facilities, at the earliest, at no extra
cost.
7.1 Roads and Paving classification:
Plant road and paving shall be classified as under:
♦ Asphalt Road
♦ Concrete Paving
♦ Gravel Paving
Concrete Paving is further classified under Pt. 4 - "Concrete Pavement".
Note:
a) Roads susceptible to spillage of petroleum products specifically roads in loading gantry
area shall be of RCC.
b) Plant roads / Access roads shall be of widths as per plot plan and 1.0m shoulders on
both sides.
c) The surface slope of roads shall be 2.5% from the center to both road edges.
d) The shoulders shall be sloped with 3%.
e) The Longitudinal gradient of roads shall not be more than 5% on Heavy Duty roads and
10% on Light Duty roads.
f) The road crown elevation shall be minimum 450 mm above Finished Ground level.
g) Minimum 8.0 m clearance to underside of pipe racks at overh ead road crossing, shall be
provided.
7.2 Road Width:
Location Roadway Carriageway
Main roads for

product movement 16.0m 14.0m
12.5m /10.5m /9.0m 10.5m /8.5m /7.0m

Road around unit
14.0m (considering 12m outer width of

Road for high lift crane 16.0m crawlers of standard 650MT crane capacity
OR As per the requirement)
Plant approach road 9.0 m 7.0 m (two lane)

Roads around tank-
farm 7.5 m 5.5 m.

Patrolling roads (along

boundary walls) 6.0 m 4.0m
Access to Building 6.0 m 3.75m

Footpath 1.5 m 1.5 m. walkway
♦ Width of the road to be finalized as per site condition in consultation with OWNER/PMC
7.3 Camber:
Camber shall be 1 in 40.
7.4 Radius of Curve:
Radius of Curve Road width
15 m. 16.0 m wide roads and high lift crane roads.
12 m. 7.5m, 9.0m & 12.5m wide road
8 m. 6 m. wide road.
7.5 CBR to be used for design:

CBR data shall be considered as per Geotechnical recommendation.
7.6 Design Standard:
IRC 37 (using 2 msa and design CBR)
7.7 Road finish:
Thk.
Road Carriage
Material (mm) Refer
Class Layer Way (m) Way (m)
notes below
9.0 / 7.0 / Dense
10.5 / 8.5 / Bituminous
Surface 50
12.5 / 10.5 /
concrete
16.0 14.0
75mm thick
Shoulder 2 x 1m WBM in Grade- 75
II aggregates
WBM in Grade-
Base II aggregates
- 225
course (3 layers of
75mm thk.)
WBM in Grade-I
aggregates
Primary / Plant Sub-base - (2 layers of 300
150mm thk.)
Approach Road
Minimum
Drainage
- 150mm thick 150
Layer
GSB

Thk.
Road Carriage
Material (mm) Refer
Class Layer Way (m) Way (m)
notes below
Compacted
Sub-grade
- sub-grade -
Dense
bituminous
Surface 7.5 5.5 50
Secondary concrete
Road (around
tank farm) 75mm thick
Shoulder 2x1 WBM in Grade- 75
II aggregates
WBM in Grade-
Base II aggregates
- 150
course ( 2 layers of
75mm thk.)
Secondary WBM in Grade-I

Road (around aggregates
Sub-base - 200
tank farm) ( 2 layers of
100mm thk.)
Drainage Minimum
- 150
Layer 150mm thick
GSB
Compacted
Sub-grade - -
Sub-grade
Dense
Surface 6.0 4.0 bituminous 50
concrete
75mm thick
2x1 WBM in Grade-
Shoulder II aggregates 75
Patrol Road WBM in Grade-II

(Along Base aggregates 2
- 150
boundary course layers of 75mm
wall) thick.)
WBM in Grade-
I aggregates (2
Sub-base - 200
layers of 100mm
thick.)
Compacted
Sub-grade - -
sub-grade
Note:
♦ Provided thickness of all layers for different class of roads to be used as guide line.
However, all thicknesses are to be verified by design based on actual/projected traffic load
and geo-technical report for important stretch of road.
♦ Over Compacted subgrade minimum 150mm think GSB should be provided as drainage
layer

♦ Width of all types of roads, shoulders / berm road elevation of all new roads shall be in line
with existing Refinery roads. Thickness of new roads sections should not be less than that
of existing as followed in refinery for different uses.
7.8 Crossings:
♦ Pipe Ways under road & rails : RCC Box Culverts
♦ Storm Water Culverts Under road / rail : RCC Box Culverts
♦ Electric/Instruments Cable : RCC duct bank with PVC
Pipe Class01 (IS 4985)
7.9 Over Head Clearance:
Refer to document 082176C-ZZ-JSD-1300-0001 (Client Ref TP-1ZZZA-PI-BOD-0001): ENGINEERING
DESIGN BASIS FOR PIPING DESIGN.
8. CONCRETE PAVEMENT:
8.1 Pavement Slope:
Concrete Paving shall be sloped (along length) steepest to 1:100 unless otherwise shown in detail
engineering drawing. Slope of the sub-grade shall be prepared to match with the slope of
pavement.
Pavements below the pipe racks, pipe way bridges should have proper slope towards storm water
drain to avoid accumulation of water. Suitable gap between wall of pipe-way bridges and sleepers
shall be left for smooth drainage.
8.2 Type:
Type of Pavements
Type-I: 200 mm thick, RCC M30
Type-II: 150 mm thick, RCC M25
Type-III: 100 mm thick, RCC M25
Pavement type shall be chosen as following
Area Type
Vehicular movement area
Type-I (200 mm thick) RCC M30 (Two
Process Unit layers of 75mm thick WMM as sub-base
course)

Utilities layers of 75mm thick WMM as sub-base
course)
Non- Vehicular movement area
Process Unit & Tank Farm Area Type-II (150 mm thick) RCC M25
Utilities Type-II (150 mm thick) RCC M25
LPG Sphere, Bullet area Type-II (150 mm thick) RCC M25

Off-site pump station Type-III (100 mm thick) RCC M25

Note: 75mm thick PCC 1:5:10 as sub-base shall be provided for Type- II & Type-III
pavement.
layers of 75mm thick WMM as sub-base
course).
Truck Movement area (Solid & Liquid
(This is the minimum requirement, the
Product)
design shall be done as per actual load
condition and the same shall be provided).
Heavy Duty Paver Block wherever suitable
can also be considered.

layers of 75mm thick WMM as sub-base)
Truck Movement area & Road (This is the minimum requirement. The
Loading/Unloading gantry
design shall be done as per actual load
condition and the same shall be provided).
Where crane movement for maintenance

is envisaged (within battery limits of the
facilities), paving shall be designed for the
Pipe Racks loads arising from the same.
Paving with PCC M20 (100 mm thick) in the
offsite shall be provided. PCC in Pipe
sleeper areas are excluded.
Interlocking Precast concrete blocks of

Footpath
minimum thickness 60mm
Notes:
1) Sub-grade below RCC pavement shall be compacted to 95% of Laboratory dry density as
per IS: 2720 Part-VIII and the slope of sub- grade shall be same as top of pavement slope.
Geogrid & Geosynthetics may be used in sub-grade layers as per geotechnical
recommendations, site suitability & design requirements.
2) In case of poor soil, black cotton soil, treatment below base shall be carried out as per soil
investigation report.
3) For crane movement area pavement shall be designed as per loading and soil data.
Hardstand to be designed and provided only at the identified area and designed for the
actual capacity.
4) Hard surface of PCC M20 (100 mm thick) shall be provided below all pipe rack in order to
avoid growth of bushes and grass and to provide free passage This shall extend 600 mm
on either side for rack width less than 6 m, 900 mm on either side for pipe track having
width 6 M or more and it shall have approach @ 500 m c/c from nearest road. Hard surface
of PCC M20 (100mm thick) of size 1Mx1M 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.

5) Removable type RCC precast slab with leak proof joints using bitumen fill in all concrete
pavement covering underground piping shall be provided for maintenance/ inspection of
pipes.
6) Pavement and trenches including covers in process unit shall be suitable for Hydra crane
movement. Section of Trench and Trench cover shall be demarcated for hydra crane
movement and only the trench cover which are demarcated for hydra movement to be
designed.
7) The surface of concrete paving exposed to corrosive chemicals shall be protected with the
suitable anti-corrosive / chemical resistant material / coating which shall be selected and
applied fully in accordance with the manufacturer’s recommendations.
8) All edges of concrete paving adjacent to manholes and catch basins shall be suitably
thickened.
9) Raised concrete kerbs shall be provided wherever necessary to contain the spillage before
conveying them to the appropriate drainage system. Kerbs shall be 150 mm thick & 100
mm in height.
10) Provision of trenches, drains, sealing of trench covers, inserts, thickening for pipe /
equipment supports etc. shall be made while construction pavements, as detailed in
drawings.
8.3 Reinforcement:
Reinforcement shall conform to the requirement of IS: 432, IS: 1139 and IS: 1786 as relevant. The
dowel bars shall conform to Grade S 240 (with yield strength 240MPa) and tie bars
(deformed/plain) to Grade Fe-500 D deformed steel bars as per IS 1786 / IS 432. If steel mesh is
used, it shall conform to IS: 1566.
Temperature reinforcement shall be provided as per the provisions of IRC: 15.
The area of steel required per meter length of joint shall be computed as per IRC -15.
8.4 Joint arrangement:
8.4.1 Expansion joint:
In concrete paving, expansion joints shall be arranged at maximum interval of 14m for Type-I
pavements, 13m for Type-II pavements and 15m for Type III pavements. The joints shall be 20
mm wide and filled with bitumen impregnated fibre boards, with the top 25 mm filled with flexible
bituminous joint sealing compound.
Heavy-duty paving shall be provided with dowel bars. The dowel bars shall be provided in the
direction of traffic (longitudinal). Design of Dowel bars shall be done as per provisions given in
IRC: 58. Following shall be design considerations:
1) Mild steel round bars.
2) Dowel bars shall be bonded into concrete on one side of the joint and its other half length
shall be prevented from bonding with concrete.
3) One half of the dowel bar is painted with a bond-breaking layer of bitumen. This bond-
breaking layer shall preferably be provided on opposite sides of the joint in adjacent dowel
bar. In case of transverse expansion joints, the unbonded portion of the dowel is provided
with expansion cap at the end. Cotton waste or other compressible material shall be
inserted but not tightly packed before fitting the cap over the painted end of the dowel bar
so that there is sufficient gap between the bar end and the inside of the cap.

For slabs of thickness less than 150mm, no dowel bars may be provided.
8.4.2 Isolation joint:

Isolation joints shall be provided around equipment foundations, pedestals and columns within the
paved area. The joints shall be 20 mm wide and filled with sand, with the top 25 mm filled with
flexible bituminous joint sealing compound.
Equipment / column pedestals shall be separated from paving with 20 thick sand fill and sealing
compound 20 x 25.
8.4.3 Construction joint:
Concrete for paving shall be laid in alternate panels. Construction joints shall be provided in
paving at 7.5m c/c. The top portion of joints shall be 10 mm wide and 40 mm deep and filled with
flexible bituminous joint sealing compound.
9. SITE FINISH:
Sr. No. Area Finish
1 Operating Area (Units) Concrete Pavement

2 Non Operating Area (Units) Concrete Pavement
3 Road Bitumen finish with WMM base.
4 Approaches: For Plant Units Concrete Pavement
5 Approaches: For balance Bitumen finish with WMM base
facilities
6 Footpath Interlocking Pre-cast concrete blocks
7 Tank Farm (Inside dyke) Type-III (100 mm thick) RCC paving with HDPE
film lining
8 Between Unit & Roads (Except 100mm Thick PCC Paving -Grade M20. 150mm
approach road to units & thick concrete pad shall be provided all around
approaches to fire hydrant) hydrant and foundation for Fire-hose box, BA sets
etc.
9 Fire Hydrant protection Hydrant shall be provided with Guard system /
bollards to avoid damage from Traffic
10 Parking including truck parking RCC Concrete Pavement min. 250 thick and
Pavement shall be designed for actual loads
vehicle design condition
11 Truck Loading / Unloading area Concrete Pavement
12 Pipeways PCC M 15
13 Open storage / Main areas Other compacted earth surface
14 Sphere area (with Kerb wall) min. 100 mm thick PCC, M20 (No sphere area
envisaged in NREP)
15 Coke storage RCC pavement
16 Coke truck loading RCC pavement

10. STORM WATER DRAINAGE:

10.1 General
Storm water drainage system in the plant shall be designed and constructed to completely collect,
convey and dispose off the storm water as well as the uncontaminated waste water from the plant.
Drainage system shall also be capable to collect firewater run-off based on firefighting demand.
These shall be hooked up to nearest storm water drain along existing roads. Contaminated and
uncontaminated areas of units in line with licensor’s recommendations to be identified and the
same will be approved. The Licensor’s requirements for drainage, for various facilities shall be
adhered to.
10.2 Road Crossings:
At the road crossing the storm water drain shall be in precast box culvert type with 25% provision
for future expansion. This shall be designed for class A or class AA IRC loading whichever is
stringent.
10.3 Materials for storm water drain/ ditches: are as follows:
Type
Units Rectangular type
Other Area Rectangular and/or Trapezoidal type
Construction
Rectangular ditches (Unit) RCC
Rectangular ditches (offsite) Brick work in cement plaster/ pointing
Trapezoidal ditches PCC Lining
Pipe Concrete pipe for road crossing
Note:
♦ Tank farm drainage shall be provided in such way that the storm water discharge shall be
either sent to storm water drain or to the contaminated rain water sewer (CRWS) by
providing valve pit outside the dyke wall depending on its contamination.
♦ An oil catcher with baffle wall type arrangement shall be on storm water ditch before it
leaves the battery limit of the complex.
♦ Where ever feasible, Precast RCC sections shall be used for Rectangular ditches.
10.4 Discharge Quantity of Storm water:
Rainfall data: (a) for 1-hour period 90 mm in 1 hour (max)
Rainfall data: (b) for 24-hour 160 mm in 24 hours (max) (rainy season is from April to
period September – Tropical Heavy Monsoon)
The following rational method equation shall be used to calculate design quantities of storm
water.
Qr = (1/360) X C X I X A.
Where,
Qr : Design quantities of storm water (m3/sec)

C : Run-off coefficient (As per the below table)

I : Design rainfall intensity (mm/hr), 1-hour period shall be refer
from above table (max.) (or) fire water deluge whichever is
greater
A : Catchment area (ha)
Design Velocity of Drains: Min.= 0.6m/s Max.= 2.4m/s.
Surface Condition Run off coefficient

Roof 1.00
Concrete Road Paving 1.00
Asphalt Road Paving 0.90
Gravel Road Paving 0.50
Soil / Green Belt 0.40
Compacted Area such as tank farm / offsite areas /
0.70
expansion area
10.5 Hydraulic Design:
The velocity and quantity of hydraulic flow in open drains or underground pipes shall be calculated
by using the Manning formula as:
V= ( I ) * R 2/3 * I ½
n
Q =AxV
Where,
V : Velocity (m/sec)
n : Coefficient of Roughness (As per below table)
R : Hydraulic Radius (m)
I : Slope of channel
Q : Discharge Quantity (m3/sec)
A : Hydraulic section (m2)

Typical Coefficient of roughness:
Nature of Surface Coefficient of roughness 'n' Range

Concrete Pipe 0.012
Corrugated Metal Pipe 0.022
Vitrified Clay Pipe 0.014
Steel Pipe 0.011
Monolithic Concrete 0.017
Cement Rubble 0.024
Brick 0.015
Laminated Treated Wood 0.017

Open Channels:
Lined with Concrete 0.015
Earth, Clean after weathering 0.020
Earth, with grass & some weeds 0.030
Excavated in rock, smooth 0.040
Excavated in rock, jagged & irregular 0.045
Natural Stream Channels:

No boulders or brush 0.033
Dense growth of weeds 0.050
♦ Storm water drainage shall be designed as flowing full flow.

♦ Minimum depth of drain shall be kept as 300mm.
♦ Minimum width of rectangular drains shall be as follows:
For depth < 500mm : 300mm
For depth > 500mm : 500mm
10.6 Design Details and Materials:

A. Surface drain:
For st o r m w a t e r d r a i ns , t h e following specification s h a l l be adopted:
♦ Shape: Drains in process (unit) area shall be rectangular RC drain. Secondary drains
of Rectangular shape to be provided. Main drains of Rectangular / Trapezoidal shape
shall be provided in other area except Process (Unit) Area.
♦ Material of Construction:
Earth ditch type with PCC (M20) lining for both horizontal
Trapezoidal drains
and sloped portion.
R.C.C. (M25) Concrete (within process area).
Rectangular drains
Brick masonry with cement plaster (other area).
♦ 75 mm thick leveling base layer M7.5 concrete to be provided.
♦ All drains are open type.
♦ Design minimum freeboard of 150 mm.
♦ Line definitions
i. Main
A main may run through or around plot areas to an off-plot ponding area, disposal
facility, or lift station and collects the effluents from all of the blanches (submains and
laterals )of sewer piping network.
ii. Submain/ Secondary
A submain collects the effluents from the lateral and sublateral blanches.
The Effluents of submain are discharged into the main.
iii. Lateral/ Teritiary
A lateral collects the effluents from sublaterals.

Effluents of lateral are discharged into the submain or main.

♦ Adequate slope to be provided to meet velocity & discharge requirements and such
that no silting / scouring occurs. In general, the following slope may be adopted:
i. Slope of main drain = ≤ 1:1000.
ii. Slope of secondary drain = ≤ 1:750.
iii. Slope of tertiary drains = ≤ 1:500.
B. Culverts:
♦ Storm water drains shall cross the road by suitable precast / cast-in-situ box culverts as
the case may be. Material of construction of culverts shall be as below:
♦ Box culverts: R.C.C. construction (M25 concrete grade for in-situ concrete and
minimum M30 grade for Precast concrete).
♦ The top of bottom raft of the box culvert shall be sloped and connected to the nearest
storm water drain in a manner so that any water coming into the box culvert shall be
drained off. Alternate suitable arrangement (e.g. filling up of the box culvert till FGL
etc.) may be adopted so as to ensure that no water gets accumulated inside the box
culvert.
♦ Pipe culverts, if instructed to use by Owner/CONSULTANT, as per following
Pipe Culvert- Under road RCC p i p e s ( Class N P -3 a s p e r IS:458)
Pipe Culvert- Under Rail lines RCC p i p e s ( Class N P -4 a s p e r IS:458)
Storm Water Box culverts RCC Precast / Cast-in-situ Construction
C. Catch Basin:
♦ Minimum catch basin size (internal Dimension) shall be 900 mm x 900 mm
♦ The bottom level of catch basin shall be lower than 150 mm from the invert level
of the lowest connected pipe.
♦ The surface travel of the drainage prior to entering catch pit shall be limited to 15
m.
♦ The maximum area per catch pit shall be 250 to 300 m2.
♦ Cover for catch basin shall be of Galvanized gratings.
D. Storm water pond: Storage and disposal:
PCC/RCC at Bottom & PCC/RCC on sides of Pond shall be

Storage
done as per design & depending upon soil conditions.
Total Capacity As per requirement.

Overflow if any shall be connected to main disposal channel

as decided for the project.
(The disposal channel capacity, shall be taken to State
Disposal
Government authorities by NRL. Technical details/ overflow
from Storm water pond quantities shall be furnished by
Consultant)
E. Trenches:
a) Electrical Cable Trench:
♦ Sand filled R.C.C. trenches shall be provided with pre-cast RC covers.
♦ Wherever trench crosses storm water drains, trenches shall be taken below
drains.
b) Pipe Trenches:
♦ R.C.C. trenches shall be provided with pre-cast RC cover as per piping
requirement.
Cable trenches shall be filled with sand as indicated in relevant electrical drawings. If
trenches are filled with sand then no inserts plates shall be provided within the
trenches.
In paved areas, the top of cable trench will be flush with finished floor level. Covers
shall overlap walls and joints with paving shall be sealed to prevent water entry.
In unpaved areas, walls shall be raised above ground level by 100 mm.
Trench floors shall be provided with a nominal slope to drain pits, where any water
entering trenches can be collected and be drained to the nearest contaminated rain
water sewer / storm water sewer. The trench bed shall have a slope of 1 in 750 along
the run and 1 in 250 perpendicular to the run.
Trench covers shall be designed for the vehicle load relevant to the area where the
trench is located.
Cable trench shall be of leak proof construction (un-cracked design). All the
construction joints of cable trenches i.e. between base slab to base slab and the
junction of vertical wall to base slab shall be ensured for water tightness.
11. WATER SYSTEM:
11.1 Drinking water System:

1) Drinking water supply to building shall always be from overhead tank. Connection from
Direct pumping header shall not be allowed. Suitable instruments for water tank over
flow control to be provided.
2) Rate of water supply: 135 lpcd (litres per capita per day).
3) System: Underground ring main with D. I. (Ductile Iron) pipes and fittings for dia 8”
and above and G.I. pipes and fittings for dia 6” and below. All U/G GI pipes shall be
coated with anticorrosive black paint.

4) Drinking water piping network shall be laid U/G in a closed loop wherever possible.
Isolation valves shall be provided at junctions. Valve pit shall be provided for valves in
underground drinking pipes.
5) Min. Clear Cover: 600 mm in open areas and 1200 mm below road crossings.
6) Storage: Overhead tank of R.C.C. construction / PVC. In case of PVC tank, insulated
type (PUF) tanks shall be considered. Capacity - 12 hours, based on average daily
demand.
7) Disinfection Method: ClO2 based method shall be used.
8) Drinking water system capacity shall be such that leakage and wastage etc. are accounted
so that shortage of drinking water may not occur. It is suggested to keep 25% design
margin to take care of above losses.
11.2 Underground piping:
All underground process pipes if otherwise not specified shall be C.S. pipes and shall be
provided with corrosion resistance protection.
12. SEWERS:
Process drains shall be oily water sewers, closed blow down sewers or chemical sewers. These
shall be provided as per OISD 109 and as per Mechanical / Piping design basis. Sizing layouts,
Material Specifications, corrosion protection etc. will be as per Mechanical / Piping design basis.
a) Storm water drains shall not be combined with oily waste sewer (OWS)/
Contaminated Rain Water Sewer (CRWS)/ Sanitary Waste Sewer (SWS) / combined
sewer system.
b) OWS/ CRWS within process unit from the equipment and area around equipment pumps
(by providing curb wall) shall be collected and shall be sent to Effluent Treatment Plant
(ETP). OWS from tank farm and other off sites areas shall be sent to ETP by gravity.
c) Initial 15 minutes of contaminated rainwater from the process unit areas (where rain
is likely to get contaminated) shall be sent to ETP through separate sewer (CRWS).
After 15 minutes, it shall be routed to storm water open drain via oil catcher by using two
way valve system.
d) RCC drain with HDG grating shall be provided all around the unit pavement to
collect non-contaminated water. This drain shall b e connected to main plant drain
through double valve pit arrangement. In case of accidental contamination, in generally
non-contaminated areas, the flow can be diverted to CRWS via double valve pit.
e) Tank farm drainage shall be provided in such a way that the storm water discharge
shall be either sent to storm water open ditch or to the contaminated rain water sewer
(CRWS) by providing valve pit outside the dyke wall depending on its contamination.
The discharge from tank farm shall be a released to ETP through gravity sewer at
controlled rate to CRWS by operating two way valve system.
f) Configuration of sewer shall be done in such a way to have minimum depth of sewer.
The exact depth shall be decided during detailed engineering. Any primary treatment, as
required at Inside Plant Battery Limit (ISBL) as per Process licensor’s
recommendations/ process design package, shall be provided.

g) Acidic waste shall be neutralized and discharged to Effluent Treatment Plant as per the
design requirement. Required treatment as per process data sheet and design data shall
be provided in Design Basis.
h) Lining/coating to be provided over concrete and steel surfaces to protect them from
the corrosive attack of chemicals in the form of leakages, spillages, overflows, washings
etc. Acid/Alkali proof floor/drain lining shall be provided within and around the Caustic
treatment/Handling/ Wash areas/ other chemical handling areas over RCC surface. The
entire area shall be curbed by RCC kerb wall.
i) All underground C.S. pipes shall be provided with corrosion resistance protection for service
temperature up to 60°C as per specifications. All CBD lines with service temperature more
than 60°C shall be provided with inorganic zinc silicate primer followed by HB coal tar epoxy
coating. In addition, the CBD lines with more than 60°C shall be laid in stone/gravel bed
minimum 300mm on either side on top & bottom. In no case these painted lines shall be
buried in soil directly.
j) Corrosion resistant protection given to underground CS pipe shall extend up to min. 500
mm. above/ beyond grade on both sides.
k) Transformer oil (for oil filled transformer of 2000 liter) shall be drained as per provisions
given in OISD 173.
l) The maximum depth of sewer (invert level) shall be kept minimum possible. the system
shall be suitably supplemented with a pumping system.
m) Where sewerage system is absent, holding tank shall be provided which shall be emptied at
regular intervals.
n) Design of septic tank shall be as per the provisions of IS: 2470 Part-I & Part- II.
o) If a s per site requirement pre-cast septic tanks are to be provided specifications of IS:
9872 shall be followed.
Notes:
♦ All RCC pipes shall have socket & spigot joints. Suitable concrete supports at all
socket/ spigot joints of underground piping shall be provided.
♦ OWS/CRWS of each process unit shall be collected in closed pit within the process
unit battery limit and shall be sent to ETP as per process design basis. OWS
system shall be kept sealed during construction period to avoid its use for drainage of
construction water.
♦ Any oil drain e.g. pump suction header drain shall be discharged to OWS even if
it is intermittent.
♦ All exchanger drain shall be routed to OWS or CBD as per process design
basis.
♦ For drainage philosophy refer document TP-1ZZZA-PR-BOD-0003.

p) Types of Sewers and Disposal Method:
The drains are collected through closed drain system

Oily sewer/ CRWS (funnel arrangement) and discharge shall be as per
process design basis.
Neutralization pit and finally to storm water System
Chemical Sewer
or ETP as per design requirement
This waste shall be neutralized and discharged to
Acidic and Alkali
ETP as per the design requirement.
Closed Blow Down To CBD Drum
Flare Blow Down To ETP through OWS
Shall be collected in Pit/ Sump/ Network
Sanitary Sewer
and subsequently pumped to existing ETP.
q) Underground Pipes:
♦ Underground pipes shall have a minimum diameter of 150 mm.
♦ Minimum depth of soil cover over sewer lines shall be 1200 mm from the Finished
Grade level to the top of pipe at road crossing and 600 mm at other areas.
♦ In case of minimum coverage is not kept at road crossing, alternative method like
encasing by reinforced concrete around pipe shall be provided with the condition of the
strength confirmation by structural calculation.
r) Manholes:
♦ Design consideration of manholes shall be as per IS: 4111 Part-I.
♦ Manholes shall be installed for underground oily sewer pipe and sanitary sewer pipes
at the junctions where the direction or slope is changed. The pipe shall be straight
between the manholes. The manholes shall be provided at the maximum interval of
30m for pipes with diameter less or equal to 12“(300mm), 75m for pipes with diameter
less or equal to 24" (600mm), and 100m for pipe diameter greater than 24” (600mm).
♦ All underground structures (manholes etc.) should have M30 grade (As per IS:456)
RCC concrete.
♦ Manhole construction shall be as follows:
For Oily Sewer Manhole 1000mm x 1000mm RCC M30 (minimum
size)with Heavy Duty type Cast Iron round
For Sanitary Sewer cover x 900mm RCC M30 chamber with CI
450mm
Manhole rectangular cover
♦ Top of manhole shall be as follows:
Flush with paving in paved area. 300mm

For Oily Sewer Manhole
above ground in unpaved area.
For Sanitary Sewer
300mm above ground.
Manhole
♦ Sealed Manholes shall be provided at the following locations:

i. On unit oily sewer at unit battery limit, so that the unit area is cut off from any
fire in offsite area or vice versa.
ii. Within the unit area sealed manholes should be provided at locations such that
each sub-unit within the unit is isolated from the other areas. In case this
demarcation is difficult, one sealed manhole for every 25 to 30M length of the
main sewer should be provided.
iii. At change of direction of the line.
iv. At entry of branch line to manhole or mainline.
v. Sealed manhole with vent pipes, seal type, shall be used for CS pipes up to 24
Inch diameter. For CS pipes greater than 24 Inch diameter, double
compartment type sealed manholes shall be used.
vi. All sealed manholes shall have airtight covers and vents.
♦ Suitable Clean outs shall be provided at the ends and at the change of direction of
branch headers (where manhole is not provided) for cleaning of sewers as and when
required.
12.1 Design of contaminated rain water Sewer (Independent system):
The CRWS system collects contaminated rainwater, floor washings, condensate recovery drain,
firewater etc. This system consists of RCC catch basin, underground piping, RCC manholes,
vent pipes, flame arresters, CI manhole covers & frames, MS gratings, MS rungs, clean-outs
holding pits etc shall be provided by “contractor “as required to complete system. Drainage of
condensate steam from steam traps in plant area shall be properly designed.
Attempt shall be made to reduce the quantity of contaminated water by providing suitable means
of segregating the clean and contaminated areas.
Arrangement shall be made to collect the entire quantity of contaminated water emanating
from each plant area and install suitable means of physical separation of oil. The treated oil-free
water shall be discharged to the nearest storm water drain. This collection and treatment
system shall be suitable to take care of maximum rate of contaminated water either due to
rainfall or firefighting.
The contaminated rain water sewer shall be designed for the following combinations:
♦ Contaminated rain water or Fire water whichever is more. The quantities of contaminated
rainwater shall be worked out based on the contaminated process area in the unit block.
♦ Sewer shall be sized flowing full with peak flows taking future requirements or 2/3 full
without future requirements.
12.2 Design of process water sewer / OWS (Independent system):
The sewer shall be designed based o n the quantities o f process waste specified by process
department/ Licensor.
a) General considerations

Trenches shall be provided all around the Compressor, DG, TGs, IA/PA compressor &
other sources of oily water for collecting Oily floor wash with a Catch basin. The oily
water will be sent to a common pit through underground pipes, which would be
connected to the Oily Water Sewer system for disposal. The potential source of Oil
contamination i.e. Compressor, DG, TG, IA/PA Compressor will be located inside the
shed. So, rain water mixing is not envisaged.
For Storage Tanks, two-valve pit will be provided with connection to Storm Sewer &
OWS outside the dyke wall. If the water is contaminated with Oil, it will be sent to the
Oily water pit which would be connected to the Oily Water Sewer system for disposal.
Alternatively, Tank farm drainage shall be provided in such a way that the storm water
discharge shall be either sent to storm water open ditch or to the contaminated rain water
sewer (CRWS) by providing valve pit outside the dyke wall depending on its
contamination. The discharge from tank farm shall be a released to ETP through
gravity sewer at controlled rate to CRWS by operating two way valve system.
For pumps requiring Lubrication, a small curb wall with connection to OWS through
manholes will be provided.
For Hot Oil Storage, two-valve pit will be provided with connection to OWS & Storm
Sewer & if the spillage is substantial, Oil can be collected in the drums with a barrel
pump.
b) Discharge Data
The branch sewers from processing areas should be designed for the greater of the
following two situations,
i. Rainfall plus process waste water with the sewer flowing at 2/3 of full depth.
ii. Process waste water plus expected fire water runoff with sewers running full.
The design capacity of the trunk sewer should depend on the cumulative amount of used
cooling water and condensate from various processing areas and the storm drainage
from the paved areas and the largest tank dyke area. Trunk sewers generally drain large
water shed; therefore, fire water flows are not governing for their sizing. However, this
should be checked.
A PFD of the system shall be made identifying normal flow and design flow. The
normal flow shall be equal to average process flow. After the design flows shall be
identified, sewer shall be designed for running full.
c) Sewer Design
Minimum size of sewer shall be 150 mm.
All funnel drain shall be of minimum pipe size 100 mm dia. When 2 or more funnels
join together, the OWS size shall be 150 mm.
The main oily waste sewer header shall not be less than 200 mm dia. All connections
from funnel points shall be fire sealed.
Minimum velocity (at half full or running full) shall be 0.6 m/sec. If sewage consists of
large quantities of sediments the minimum velocity shall be 1.0 m/sec. subject to a
maximum of 2.4 m/sec.
d) Cover

The minimum cover over pipes in unit areas shall be as below:

i. 300 mm: For the sewer of sizes up to 150 mm from equipment drain points to
nearest main header or manhole.
ii. 450 mm: For main headers having size 150 mm and above, when located
such that there is no chance of truck movement or crane movement over then.
iii. 750 mm: For headers in open paved areas when crane or truck movement
can be expected. (CS pipes shall also be encased with 150 mm thick concrete in
this case).
e) Vent Pipes
Sewers, in general, should be designed for gravity flow. In a tightly sealed system, a rise in
water level would reduce the vapour space causing obstruction to flow. Therefore, vents
shall be installed on the manhole to maintain atmospheric pressure in the sewer and to
release vapours to safe locations. Following shall be ensured during design stage to
ensure that accidental release of vapours do not create unsafe condition:
i. At least one vent shall be installed on manhole for every 100 meter in offsite
area,
ii. Vents shall not be located near furnaces etc.
iii. The vent of height shall be 3 metre above the nearest tallest structure within 15
metre radius.
iv. In critical locations, the vent pipes should be provided with steam snuffing
connections.
v. Vents should be connected to VOC control system to minimise VOC emissions.
12.3 Design of Sanitary Sewer:

The Sanitary Sewer system collects all sanitary wastes from buildings, toilets, lavatories, showers,
kitchens, etc. The sanitary wastes will be collected and drained off to the sewage treatment
package according to the requirements of the relevant codes and specifications.
The sanitary sewer shall be designed for 3 times the average flow flowing half full incase of lateral
sewer and flowing 2/3 full in case of Main Sewers.
12.4 Cover for Sewer Line:
♦ Minimum cover over sewer line shall be 600 mm.
♦ Under road, sewer shall be protected by concrete encasement and minimum cushion
shall be 1200 mm.
12.5 Manhole Seal:
For trapping of gas or prevention of spread of fire through CRWS/ oily sewer from one area to
another, a liquid seal of minimum 150 mm shall be provided in manhole along with suitable
vents. Location of sealed manholes shall be decided accordingly. All vent pipes of sealed
manholes shall be provided in line with OISD Guide lines.
12.6 Material of Construction for Sewers:

Oily Sewer- Within C.S. Pipes as per NRL requirement and relevant PMC
process units and Piping Material Specifications
Tankage areas
Oily Sewer- Offsite gravity C.S. Pipes / RCC Hume Pipe (Class NP2) and Road
sewer crossing location Hume Pipe (Class NP3) as per relevant
PMC Piping Material Specifications
Oily Sewer- Offsite Main C.S. Pipes as per relevant PMC Piping Material Specifications
Acidic and Alkali sewer HDPE (as per IS:4984)

Chemical Sewer HDPE (as per IS:4984) / cPVC Pipes
Sanitary Sewer- Toilet uPVC pipes (as per IS: 13592, 15328)/ CI pipes (as per IS:
block up to inspection 3486/1729)
chamber
Sanitary Sewer- PVC / uPVC pipes (as per IS: 13592, 15328)/Ductile Iron
Gravity main & lateral Pipes Socket and spigot, rubber joints (Suitable concrete
supports at all socket / spigot joints of underground piping
shall be provided)
Sanitary Sewer- Pressure G.I. Pipes
main
Manhole for acid/ alkali sewer shall be provided with Acid/ Alkali proof lining.
13. STORAGE TANK FOUNDATION AND DYKE WALL:
a) Foundation Type:
Storage tanks shall be supported either on open ring wall type foundations or sand pads in
accordance with the Geotechnical recommendations.
b) Anticorrosive layer:
Anticorrosive layer shall be provided as per specifications for tank pads of 50 thick premix
carpet over 50 thick bitumen sand mixed with additions of kerosene / oil as required.
c) Storage Tank Dyke Walls:
Dyke walls / Fire Walls shall be provided as per OISD 118. Dyke Walls shall be of RCC.
Concrete grade M25 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. It shall have minimum 750
mm wide walkway with hand railing (if required) at top of wall to enable persons to walk on
the wall top. Stair cases at suitable location shall be provided to approach the walkway. If
space permits, dyke walls shall be provided with ramps on both sides at suitable places, for
movement of vehicles for tank cleaning purpose. Fire walls, if required shall be of plastered
brickwork and shall be 600 mm high (min) or as drawings / as instructed. They shall only
retain spillage to prevent fire spread.
d) Cathodic Protection:
When Cathodic Protection is provided for the Tank bottom plate, the use of crushed stone
layer, anticorrosive (Asphalt) layer etc shall be avoided for the effective functioning of CP
system. In such cases, tank bottom plate shall directly rest on the Clean Compacted Sand
fill below.

14. FENCING AND BOUNDARY WALL:

♦ The wall shall be reinforced concrete column & plastered brickwork with topped concentric
coil. The wall shall generally be of 3.0m high from FGL with the barbed fencing / concentric
coil extending a further 750mm on top of the wall. Structural system shall be of shallow
foundation, column & plinth beams.
♦ Below FGL, the foundation shall be designed to withstand the earth pressure and
Surcharge load of 1 T/sq.m.
♦ If the difference in the Plot Level and the Surrounding area is greater than or equal to 1.0
m, the R.C.C Retaining Wall shall be provided upto FGL to cater the Earth Pressure along
with a Surcharge of 1 T/sq.m.
♦ Suitable provision of drainage system shall be made outside the plot to divert the natural
storm water drainage into the nearest existing drainage system.
♦ It shall be ensured that no part of construction shall extend outside the battery limits of plot.
♦ Expansion joints shall be provided in the boundary wall as per relevant IS code. Spacing
between two expansion joint shall not exceed 30m.
♦ Design of boundary wall shall be checked for full submerged soil pressure under choked
condition of weep holes.
♦ For purpose of protection of Land Acquisition Limit, 2.00m high barbed wire Fencing shall
be provided.
15. ENTRANCE GATE:

Manually operated / Mechanically Operated sliding M.S. Gate of 2500 mm high shall be provided
at the plant main entrance.
16. PIPE SLEEPERS:
The RCC sleepers for process piping and fire water lines shall be designed based on the soil
bearing capacity (to be ascertained by site survey) and the horizontal/vertical loads of the pipes
running full. The sleeper shall confirm to standard (minimum requirement). Firewater piping
sleepers shall be independent of process piping sleepers. Design of sleepers shall be done taking
into account soil conditions as per soil investigation carried out.
17. ELECTRICAL / INSTRUMENTATION CABLE ROAD CROSSING (ERC / IRC):
ERC/IRC road crossing: PVC pipe conformed to IS: 4998 encased in concrete.
RCC / brick masonry cable trenches shall be with precast cover designed to sustain the maximum
load envisaged. Buried cable trenches shall be made, as per electrical / instrumentation
standards. At crossings, electrical trenches shall be made below the instrumentation trenches.
Wherever, storm water drains crosses the trenches, cable shall be taken below drains with RCC
duct/pipe.
The cable crossing at roads & pipe way shall be either with group of PVC pipes (Min. dia. 150 mm
encased with PCC M20) or RCC ducts. Clear cover over top of PVC pipe shall be 1200 mm. In
case of less cover, RCC encasement shall be provided.

18. BARRICADE:
Barricading shall be provided near construction area to prevent damage to existing facilities. The
barricade shall be within the plot plan.
The height of the barricade shall be; minimum two meters above the highest point of active work.
The barricade shall be properly designed/ constructed as per BIS codes. The barricade shall be
made out of steel framework with galvanized iron sheets. Steel framework and its foundations
shall be properly designed/ constructed as per BIS codes.
If required, the barricade shall also be provided with suitable piping arrangement to be connected
to a pressurized water source to provide necessary water curtain. After completion of the work,
barricading including its foundations shall be removed and the site made good.
19. SPECIFIC REQUIREMENT:
a) Preferably all Buildings shall be designed as Energy Efficient building.
b) Rain water harvesting shall be mandatory for all buildings. (Refer to Clause 2.6 (11) of Part
C)
c) Rain Water Harvesting systems shall be designed, operated & maintained in line with
guidelines provided in Manual published by Central Public Works Department & Central
Ground Water Board.
d) Rain Water Recharging well shall be provided for the non plant area for recharging the
ground water
20. REMOVAL / REROUTING OF OBSTRUCTIONS
All underground or aboveground structures / foundations which will cause obstruction to new
structures / foundations, and which can be removed without disturbing any function of the existing
plant, shall be removed by the Contractor.
All existing underground or above found facilities requiring rerouting due to fouling with new
facilities shall be rerouted by the contractor in such a manner that rerouted facilities keep on
functioning as before.
Note: Before finalizing the route connection to existing system, adequacies of existing system shall
be checked by the contractor.

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Total pages: 131

NUMALIGARH REFINERY LIMITED

NRL EXPANSION PROJECT

ENGINEERING DESIGN BASIS

D3 01/12/2021 Approved for Design TMB PKB KC

TECHNIP INDIA LIMITED Facility Area Code 1Z Common Document

NRL’s PO NO: 4300062833-AMA/16.06.2020 Document Type BOD Basis Of Design

PART-D ..................................................................................................................................................... 106

Page 3 of 131 TP DOC REF: 082176C-ZZZ-JSD-1700-0001_D3

NUMALIGARH REFINERY LIMITED (NRL) has awarded Project Management Consultancy

2 DEFINITIONS & ABBREVIATIONS

Abbreviation Definition /Expanded form

Page 4 of 131 TP DOC REF: 082176C-ZZZ-JSD-1700-0001_D3

4 CONFLICTS & DEVIATIONS

• Local regulatory and statutory requirement.

Page 5 of 131 TP DOC REF: 082176C-ZZZ-JSD-1700-0001_D3

Part Sections No. of sheets Pages

A CIVIL AND STRUCTURAL 57 07 to 64

Page 6 of 131 TP DOC REF: 082176C-ZZZ-JSD-1700-0001_D3

CIVIL AND STRUCTURAL

Page 7 of 131 TP DOC REF: 082176C-ZZZ-JSD-1700-0001_D3

2. REFERENCE STANDARDS AND PUBLICATIONS

Sl No. Description Code

1. Paving Bitumen – Specification IS:73

2. Mild Steel wire for general engineering purposes IS: 280

8. Code of practice for plain & reinforced concrete IS:456

10. Methods of test for strength of concrete IS:516

11. Code of practice for general construction in steel IS:800

16. Cold formed light gauge structural steel section IS:811

21. Common burnt clay building bricks specifications IS:1077

Page 8 of 131 TP DOC REF: 082176C-ZZZ-JSD-1700-0001_D3

Sl No. Description Code

23. Method of identification of natural building stone IS:1123

27. Steel tubes for structural purposes- specification IS:1161

29. Bitumen-Mastic for flooring- specification IS:1195

30. Methods of sampling and analysis of concrete IS:1199

34. Code of Practice for Pre-stressed Concrete IS:1343

37. Specification for portland pozzolana cement IS:1489

44. Fillers for expansion joints IS:1838

45. Criteria for earthquake resistant design of structures (Part 1 to 4) IS:1893

46. Design & Construction of Foundations in solids IS:1904

47. Code of practice for structural use of unreinforced masonry IS:1905

48. Specification for plain washers IS:2016

Page 9 of 131 TP DOC REF: 082176C-ZZZ-JSD-1700-0001_D3

Sl No. Description Code

50. Code of Practice for Water Supply in Buildings IS:2065

51. Specification for sand for masonry mortars IS:2116

52. Specification for concrete masonry units IS:2185

53. Code of practice for brick works IS:2212

56. Specifications for thimbles for wire ropes IS:2315

57. Bulldog grips- specification IS:2361

58. Methods of test for aggregates for concrete (Part-II) IS:2386

59. Methods for sampling of aggregates for concrete IS:2430

70. Specification for ballies for general purposes IS:3337

74. Crane Rail Sections IS:3443

75. Specification for masonry cement IS:3466

76. Methods of test of burnt clay building bricks IS:3495

Page 10 of 131 TP DOC REF: 082176C-ZZZ-JSD-1700-0001_D3