<SECURITY LEVEL 2>

DESIGN SPECIFICATION FOR

CONCRETE CONSTRUCTION
FOR
HINDUSTAN PETROLEUM CORPORATION LTD.
VISAKH REFINERY

DHT PROJECT
JOB NO. :
DOCUMENT NO.

6261

: A-6261-110-002

TOTAL NO. OF PAGES: 18 (INCLUDING THIS PAGE)

16-11-2009

FOR APPROVAL

AGR

ST/UB

PVO

REV.

DATE

DESCRIPTION

MADE BY

CHECKED

APPROVED

TOYO ENGINEERING INDIA LIMITED

MUMBAI

INDIA

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 2 OF 18

INDEX
PAGE
1.

GENERAL

1.1
1.2.
1.3
1.4
1.5

Scope
Codes and Standards
Related Design Specifications
Units
Priority of Requirements

2.

MATERIALS

2.1
2.2

General
Design Strength of Concrete

3.

DESIGN BASIS

3.1
3.2
3.3
3.4
3.5
3.6
3.6.1
3.6.2
3.6.3
3.6.4
3.7

Design Loads
............................................. 7
Foundation Design Criteria
............................................. 8
Design Basis and Requirements
....................................... 8
Special Considerations for RCC structures.12
Foundations
... 12
Foundations for Rotating and Reciprocating Equipment
General
............................................. 14
General Requirements for Design
............................................. 15
Dynamic Analysis
............................................. 15
Evaluation of Dynamic Analysis
............................................. 15
Blast Proof Construction
.16

4.

DESIGN DETAILS

4.1
4.2
4.3

Anchor Bolts
Grouting
Covering for Pit / Basins

.........................................16
.............................................17
.............................................17

ATTACHMENT -1
Amplitude vs Frequency curve

...18

.............................................
.............................................
.............................................
.............................................
.............................................

3
3
5
6
6

............................................. 6
............................................. 7

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

1.

GENERAL

1.1

Scope

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 3 OF 18

(1)

This specification covers the requirements for design of concrete construction

such as buildings, pipe rack, equipment support, steel structure foundation,
equipment foundation, machine foundations, liquid retaining structures viz. pit/
basin, dike, trench, local foundation, etc.

(2)

Excluded from the scope of this specification are the design requirements for pile
and pre-stressed concrete structures.

1.2

Codes and Standards

The following codes and standards shall be applied to the Design of Concrete
Construction unless otherwise specified.
IS 383 - 1970

Coarse and fine aggregates from natural sources for

concrete.

IS 432 (Part-1) &

(Part 2) 1982

Mild steel and medium tensile steel bar and harddrawn steel wire for Concrete reinforcement (Grade I).
(For Mild steel bars of Anchor bolts, rungs, metal
inserts, grating etc.)
Part 1 Mild steel and medium steel bar.
Part 2 Hard -drawn steel wire.

IS 455 1989

Portland slag cement.

IS 456 2000

Code of practice for plain and reinforced concrete.

IS 1786 - 1985

High strength deformed(HSD) steel bars and wires for

concrete reinforcement.

IS 1893 - 2002

Criteria for earthquake resistant design of structures.

IS 2974(Part 1)
1982

Code of practice for design and construction of

machine foundations; Part 1 Foundation for
reciprocating type machine (hammer foundation).

IS 2974 (Part 2)
- 1980

Code of practice for design and construction of

machine foundations; Part 2 Foundation for impact
type machine.

IS 2974 (Part 3)
- 1992

Code of practice for design and construction of

machine foundations; Part 3 Foundation for rotary
type machine (medium and high frequency).

IS 2974 (Part 4)
- 1979

Code of practice for design and construction of

machine foundations; Part 4 Foundation for rotary
type machine of low frequency.

IS 2974 (Part 5)

Code of practice for design and construction of

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

- 1987

PAGE 4 OF 18

machine foundations; Part 5 Foundation for impact

type machine other than hammers (forging and
stamping press, pig breakers, drop crusher and jolter).

IS 3370 (Part 1)
- 1965

Code of practice for concrete structures for storage of

liquids; Part 1 General requirements.

IS 3370 (Part 2)
- 1965

Code of practice for concrete structures for storage of

liquids; Part 2 Reinforced concrete structures.

IS 3370 (Part 4)
- 1967

Code of practice for concrete structures for storage of

liquids; Part 4 Design tables.

IS 4326 - 1993

Earthquake resistant design and construction of

buildings - code practice.

IS 4994 - 1968

Criteria for blast resistant design of structures for

explosions above ground

IS 8112 - 1989

43 grade ordinary Portland cement.

IS 6909 -1973

Sulphate Resistant Cement

IS 11089 -1980

Code Of Practice For Design And Construction Of

Ring Foundation; (Amendment 1), Reaffirmed 1995

IS 13620 -1993

Fusion bonded epoxy coated reinforcing bars.

IS 13920 -1993

Ductile detailing of reinforced concrete structures

subjected to seismic forces - Code of Practice.

SP 16 - 1980

Design aids for reinforced concrete to IS: 456 - 1978.

OISD STD-163

Control Room Safety (A publication of oil industry

safety directorate).

OISD STD-164

Fire proofing in oil and gas industry (A publication of

oil industry safety directorate).

OISD STD-173

Fire protection system for electrical installations.

National building code.

Building bye laws.

:
:

Factor rules
Licensors standard/ standard specification shall be
followed wherever applicable /available.
Design loads(other than Earthquake) for Buildings &
structures
Specification for supersulphated cement.

IS 875 -1987

IS 6909-1990

IS 1363 2002

Hexagon Bolts, screws & nuts of product grade (M5 to

M64)

IS 3138 1966

Hexagon bolts & Nuts(M42 to M150)

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 5 OF 18

IS 2062 2006

Steel for General structural purposes- Specification

IS 1904 1986

IS 2016 1967

Design & Construction of foundation in soil general

requirement
Specification for Plain washers.

IS 2911 (1979- :
1985)

Design & Construction of pile foundation.

IS 2950 1981

Design & Construction of raft foundation.

IS 4091 - 1979

Design & Construction for transmission line towers &

Poles

IS 4991 1968

Criteria for blast resistant design of structures for

explosives above ground

IS 4995 1974

Design of Reinforced concrete bins for storage

granular & powdery materials

IS 4998 1992

Design of Reinforced Concrete Chimneys

IS 5249 1992

Method of test for determination of dynamic properties

of soil.

IS 5410 -1992

IS 6403 1981

Cement Paint
Determination of Bearing Capacity of shallow
foundations

IS 8009 1980

1.3

1.4

Calculation of settlements of Foundations.

Related Design Specifications

A-6261-110-001

: Design Specification For Loads

A-6261-110-003

: Design Specification for Steel Structure

A-6261-110-004

: Design Specification for Buildings

A-6261-110-005

: Design Specification for General Civil

A-6261-110-006

: Design Basis for Foundation

Units
Unless otherwise specified MKS or SI units shall be applied as the measurement
system to the drawings and documents.

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

1.5

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 6 OF 18

Priority of Requirements
In case of any discrepancy among the codes/ standards, related Design
Specification and this specification, order of priority shall be as under:
(1)
(2)
(3)

This Specification
Related Design Specifications
Codes and Standards

(4)

Licensors standard/ standard specification shall be followed wherever

applicable /available.

2.

MATERIALS

2.1

General
Unless otherwise specified in the Drawings, material specifications shall conform
to the following.

(1)

Cement
Cement used for all concrete works both above and below ground shall be
Portland Slag cement-PSC conforming to IS: 455 and OPC-43 Gr conforming to
IS:8112, except for Sulphur pit, Sulphur Basin and Sulphur truck loading facility for
which Sulphate Resistant Cement SRC conforming to IS: 6909 shall be used.

(2)

Aggregates
Aggregates used in the concrete works shall be graded from locally available
gravel or crushed stone conforming to IS: 383.
Unless otherwise specified, the maximum size of aggregates shall be as follows:
For large foundations and : 40mm graded down (provided the pitch of
mass concrete
reinforcement is more than 100mm).
For others

: 20mm graded down.

(3) Reinforcement:
High strength deformed steel bars of grade Fe 415 conforming to IS 1786 with
protective Fusion bonded epoxy coating (as per IS: 13620) shall be used for all
building/Structures inside/outside the process units. PVC coated (extrusion
process) 18 gauge SWG wire shall be used for binding reinforcement bars
(4) Anchor Bolts
Anchor bolts shall be turned from M.S. round conforming to IS : 2062, Grade-B
Hexagonal Bolts & Nuts of Grade-C and Washers shall conform to IS : 1363 / IS:
3138 and IS : 2016 respectively.
(5) Insert Plates
Insert plates shall be of structural steel quality conforming to IS: 2062 and shall be
provided with mild steel lugs as per drawings/ standards. Mild steel lugs shall
conform to IS: 432.

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

2.2

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 7 OF 18

Design Strength of Concrete

Unless otherwise specified, the minimum design compressive strength of cast-insitu / Precast concrete at 28 days (conforming to IS: 456) shall be as follows:
Structural Concrete / Piles (M30)...: 30 N / mm2
Liquid Retaining Structures (M30). : 30 N / mm2
Trench/ Drainage (M30).. : 30 N / mm2
Paving (M25 or M30) : 25 or 30 N / mm2 (Resp.)
(Depending on the type of paving as mentioned in cl. No. 3.3.1 of doc. No. A-6261-110-005)

Grade Slab (M20) : 20 N / mm2

Levelling Concrete (1:3:6) for
Water Retaining Structures (M10) .: 10 N / mm2
Levelling Concrete (1:5:10) for
other RCC foundations (M5)..
: 5 N / mm2
Filling/Mass/Plum concrete (M5) : 5 N / mm2
Plain cement concrete of Grade (M20)
for all masonry wall foundations..
: 20 N / mm2
From Durability considerations the minimum cement content and maxi water ratio
shall be as under. However, the maxi. Cement content shall not exceed 450
Kg/m3
Type of
Remarks
Plain Concrete
Reinforced concrete
cement
mini. cement Maxi. water
mini. cement Maxi. water
contentcement ratio content
cement ratio
kg/m3
kg/m3
OPC-43
250
0.5
350
.4
Severe
Gr/PSC/SRC
exposure
condition
Plain cement concrete of grade M20 of mini. 40mm thickness shall be provided as
damp proof course at plinth level of all masonry wall and to be coated with 3 mm thick
bitumen emulsion
3.

DESIGN BASIS

3.1

Design Loads

(1)

Design loading shall be as per Design Specification for Loads and shall be applied
to the following:
-

Design Loads,
Loading Combinations,
Safety Factors for Stability,
Load Factors for Required Strength.

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 8 OF 18

(2)

The calculation of stability and soil contact pressure of foundation shall be carried
out on the basis of working load and allowable soil bearing capacity as per design
specification for Foundation.
(3) The resisting lateral force against the sliding of foundation shall generally be based
on the friction force between the foundation and its supporting subsoil with friction
factor as specified in foundation design basis.
3.2

Foundation Design Criteria

The foundation design criteria such as foundation depths, allowable soil bearing
capacities, foundation settlement and soil design parameters shall be in
accordance with Design specification for Foundation.

3.3

Design Basis and Requirements

(1)

Framing Systems shall be arranged so that the stiffness of structure can be well
balanced and the structural stability can be secured.

(2)

Expansion joints for the structure shall be provided every 45 m in the longitudinal
direction.

(3)

Structural analysis and section design shall be made in accordance with the
applicable codes, standards and specifications and by using the authorized and
approved methods.

(4)

In case of heavy and / or tall equipments installed on the reinforced concrete

structure, the floor and beam arrangement shall be planned so that the firm
anchoring and structural stability shall be assured.

(5)

Pits and basins shall be designed to withstand the water pressure, earth pressure,
buoyancy and surcharge where required.
The parts of liquid retaining / storage structures not coming in contact with the
liquid may be designed according to IS : 456 except ribs of beams of suspended
floor slabs and counterparts of walls (located on the side remote from the liquid)
and roof which shall be designed as un-cracked section. No increase in
permissible stresses in concrete and reinforcement shall be allowed under wind or
seismic conditions for such structures.
Pits and Basins containing liquids shall be designed for both full and empty
conditions and partition walls between compartments shall be designed for
alternative liquid pressure on either side.
Dikes shall be designed to withstand the pressure of containing liquid for both full
and empty conditions.
Liquid retaining structures shall be designed as per IS: 3370.
In all liquid retaining structures, PVC water bars (230 mm wide, 5 mm thick) shall
be provided at each construction joint and embedded as per manufacturers
recommendation. The sequence of construction and location of construction joints
shall be clearly shown on drawing.

(6)

Finishing requirement of concrete surfaces/Fire proof surfaces:

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 9 OF 18

All concrete structures exposed to atmosphere shall be painted with two coats of
cement based waterproof paint as per IS: 5410.
All the fire proof surfaces shall be painted with 2 coats of micro-porous exterior
top coat, compatable to cement surfaces, of approved make & colour conforming
to IS specifications
All underground RCC surfaces in contact with soil shall be painted with three
coats of Coal Tar epoxy paint.
(7) Minimum Thickness of Structural Concrete and Concrete embedded Elements
Member sizes shall be as per Design Requirements. However, minimum
dimensions of structural members shall be as given below:
Pile cap. . : 600 mm
Levelling concrete below liquid retaining structures ......................: 100 mm
Levelling concrete for other RCC foundations ..: 75 mm
Footings (All types including raft foundations without beams )...:300 mm

Grade slabs..................................: 150 mm

Underground Pit/Reservoir (Below grd.water table) Walls & slab. :250 mm

Underground Pit (Above grd.water table) Walls & slab.. .. :200 mm

Columns & Pedestals length. ..:250mm width,

250 mm depth
Beams.....:250mm width,
300 mm depth
Floor/Roof slab,walkway

:150mm

Parapet wall

:100mm

Chajja

:100mm

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 10 OF 18

Cable/Pipe trench Walls & Base slab. :125mm

Precast trench cover

: 125mm

Insert plate... :12mm

Corner angle....:6mm

(8)

Minimum Height of Pedestals above Finished Grade Level

The minimum height of outdoor and indoor pedestals (supporting equipment /
structures) shall be 300 mm and 150 mm respectively above the highest paving
level/ finished floor level / finished grade level whichever is higher. The projection
of pedestals for staircase/ ladder shall be 200 mm.

(9)

Minimum Clear Cover to Main Reinforcement

The clear cover shall be considered over links/stirrups. Clear cover for foundation
and substructure shall be as mentioned below.

(a) Slab (roof & floor)..: 45 mm

Chajja, Waist Slab
(b) Beam except for Plinth
beam

: Top & Bottom.. : 50 mm

: Side.. : 50 mm
: Face in contact with earth. : 75 mm

(c) Column and pedestal.. : Super Structure.. : 50 mm

: Face in contact with earth. : 75 mm
(d) Retaining wall
Basement and Pit wall

: Face in contact with earth: 60 mm

: Free face. : 50 mm

(e) Liquid retaining. : Face in contact with liquid. : 50 mm

structure
: Face in contact with earth. : 60 mm
: Free face. : 50 mm
(f) Plinth beam... : Top & Bottom.. : 75 mm
: Sides : 50 mm
(g) Foundation : Top & Bottom.. : 75 mm
: Sides : 75 mm

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 11 OF 18

(h) Pile. : Sides : 75 mm

(i) Pile cap. : Bottom.. :100 mm
: Top & Sides. : 50 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
25mm.
(10) Minimum Bar Diameter (Except for Blast Proof Construction)
Piles Main Bars.. : 12 mm
Piles Ties. : 8 mm
Major Foundation.. : 10 mm
Block Foundation - Main Bars. : 10 mm
Block Foundation - Tie Bars : 8 mm
Minor Foundation (Local foundation etc.). : 8 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 - Main Bars : 10 mm
Slab - Distribution Bars : 8 mm
Wall - Main Bars : 10 mm
Wall -Distribution Bars.. : 8 mm
Minor elements such as Chajjas, Lintel beams ,etc. : 8 mm
(11)

Bar Spacing
Minimum and maximum bar spacing for Foundations, Slabs, Stirrups for Beams,
Ties for Columns, Pedestals, Walls etc. shall be 100 mm and 300 mm
respectively. Bar spacing shall be provided in multiples of 25 mm.

3.4

SPECIAL CONSIDERATIONS FOR RCC STRUCTURES

3.4.1

General/design methods

(1) All buildings, structures, foundations, machine/equipment foundations, liquid

retaining/storage structures, trenches, pits etc. shall be of RCC and designed

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

(2)
(3)

(4)

(5)

(6)

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 12 OF 18

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, 4995, 4991, 4998, 5249, 6403, 8009,13920.
Only limit state method as per IS: 456 shall be followed in the design unless
otherwise specified elsewhere in this document for special structures.
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) shall be of leakproof RCC construction using waterproofing compounds.
All liquid retaining/storage RCC structures shall be leak-proof and designed as
uncracked section as per IS: 3370. However, the parts of such structures not
coming in contact with the liquid shall 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 shall be designed as uncracked
section. No increase in permissible stresses in concrete and reinforcement shall
be made under wind or seismic conditions for such structures.
The walls and base slabs of liquid retaining/storage structures shall 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, 5mm
thick) shall be provided at each construction joint.
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) shall be designed as uncracked sections.

3.4.2 R.C.C Chimney Design :

R.C.C. chimney shall be designed as per requirements of IS:4998-1968.
3.5

Foundations

(1) Foundation design shall be as per Geo- technical report /data ( to be attached
after soil investigation)
(2)

Foundation shall be proportioned in such a way that the allowable soil bearing
capacity is not exceeded and the resulting settlement is within the acceptable limit
in case of shallow foundation. For pile foundations, load on pile shall not exceed
acceptable limit. For capacity of piles and shallow foundation, refer foundation
design basis.

(3)

Foundation sizes and depths shall be planned considering subsurface conditions

and surrounding underground constructions such as adjacent foundations,
underground pipes and cables, trenches, pits, roads as well as the slope of
ground.

(4)

Isolated footing shall be planned for each foundation. However, where adjacent
footings interfere with each other, combined footing may be provided.

(5)

Where applicable, the elevation of foundation / pedestal top shall be in

accordance with the process, mechanical and piping requirements.

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

ISSUED : 16-11-2009

PAGE 13 OF 18

(6)

Factor of safety against overturning and sliding shall be as per values given in
the Doc no. A-6261-110-006. Component of soil backfill weight over foundation
shall be appropriately covered as foundation dead load. For stability checks the
weight of soil as overburden shall be as per Doc no. A-6261-110-006.

(7)

The design ground water level shall be as per the Foundation Basis A-6261-110006 and the hydrostatic pressure shall be adequately accounted for in design.

(8)

Allowable net bearing capacity of soil shall be as per Geotechnical report.

Following settlement criteria for dead plus imposed load conditions shall be
applicable unless specified in Geotechnical Report.
Foundation in unit areas, utility areas
And foundations for Plant buildings.

25 mm settlement.

Non plant buildings.

40 mm settlement

Raft Foundations

40 mm settlement

Foundations for Storage Tanks:

a)

Cone/Dome roof tanks.

300 mm edge settlement

b)

floating roof tanks.

150 mm edge settlement

For transient loading, eg. Wind/seismic, settlement shall not be the design criteria and
the SBC (safe bearing capacity) based on shear criteria shall be considered.
(9) Permissible increase in SBC/ Pile capacities (for compressive, shear and
uplift/ tension) shall be as per relevant BIS codes if not otherwise mentioned in
the Geotechnical report.
(10) For blast (due to hydrocarbon explosion) load combinations the design
bearing pressure of soil shall not exceed twice the allowable static bearing
pressure of soil. Pile capacity shall be similarly increased in blast condition to
1.5 times the permissible capacity under compression, tension and shear
modes.
(11) Grade of concrete to be used in foundation shall in general be as per the
philosophy adopted for the entire structure. However, mini. Cement content,
type of cement and any remedial actions required for foundations due to
aggressiveness of sub soil water shall be as per the Geo-technical report.
(12) No anti termite treatment shall be provided inside the unit areas. Offsite
and utility buildings shall be provided with anti termite treatment as per
IS:8944 and IS:6313.

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
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ISSUED : 16-11-2009

3.6

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 14 OF 18

Foundations for Rotating and Reciprocating Equipment

3.6.1 General
(1)

Foundation for rotating and reciprocating equipments such as turbines, engines,

compressors, generators etc. shall be designed to secure the dynamic stability of
the foundation system, as well as the static stability.
The soil stress below foundations under Dead loads shall not exceed 80% of the
Allowable soil bearing capacity or Safe load on Piles, for static loading.

(2)

Dynamic stability for foundation supporting heavy vibrating equipments like the
following shall be secured by dynamic analysis in general:

(3)

- Heavy vibrating equipment,

- Equipment sensitive to vibration,
- Equipment causing large dynamic force
All foundations for dynamic equipments shall be isolated from floor or any other
static foundation by providing filler board all around foundation.
Clear air gap shall be provided in Superstructure to avoid transmission of vibration
to adjacent structures. Special note shall be given on the drawing in this respect,
and suitable details be shown as required. Unless otherwise specified foundation
design shall follow general criteria indicated below.
CRITERIA

Dynamic
analysis

Foundation
weight
control

APPLICATION

*Allowable amplitude,
Natural frequency of foundation

Rotating
: P 400 KW
Reciprocating : P 100 KW

Natural frequency of foundation

Rotating
: P 100 KW
Reciprocating : P 40 KW

More than 3 x equip. weight

Rotating

More than 5 x equip. weight

Reciprocating : P < 40 KW

: P < 100 KW

P = Rated Power output of equipment (unit KW).

*If the suppliers requirement is available, it shall be considered.

3.6.2 General Requirements for Design

Following minimum requirements shall be taken into account for foundation
design in principle.
(1)

Foundation for heavy vibrating equipment shall be kept independent of building

floors/ foundations and other adjacent foundations.

(2)

Foundation weight shall be at least three times the weight of the rotating
equipment and five times the weight of the reciprocating equipment.

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 15 OF 18

The weight of foundation slab shall not be less than the combined weight of the
structure and the machine.
(3)

Foundation shall be of uniform rectangular/ square shape. Beams and columns of

foundations shall 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 raft or centroid of the pile
group, shall be within 5% for block foundations and 3% for frame foundations.
However, in highly compressible soils no eccentricity shall be permitted.

(5)

The geometric layout of the foundation and structure shall be basically symmetric
with respect to the vertical plane passing through the rotational axis of the
equipment.

6)

Machine foundations shall satisfy the requirements of IS: 2974 and any other
parameter as per machine vendor.

3.6.3 Dynamic Analysis

(1)

General
Dynamic analysis shall be performed by suitable and approved method so that
dynamic feature can be evaluated correctly:
Following effects shall be taken into account:
- Dynamic features of subsoil
- Dynamic features of supporting foundation system
- Dynamic effect of the foundation system
- Dynamic forces of equipment

Data of dynamic load to be used for the dynamic analysis, shall be supplied by
Equipment Supplier and shall state unbalanced force due to:
- Eccentricity of dynamic mass of rotating equipment
- Different crank arrangement of reciprocating equipment
3.6.4 Evaluation of Dynamic Analysis
(1)

Foundations shall be so designed that natural frequency of the foundation system

shall not resonate with the following:
i) Operating speed of the motor.
ii) Operating speed of the machine.
iii) 2 times operating speed of the machine
(This condition shall be complied only when the manufacturer has furnished the
unbalanced forces related to 2 times the operating speed of the machine)
iv) Critical speed of the machine (for centrifugal machines).
Natural frequency of the foundation shall be 20% away from the above
mentioned frequencies. However, amplitudes of vibration of the
foundation
block shall always be checked to be within permissible limits

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

(2)

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 16 OF 18

Allowable amplitude due to dynamic load

Amplitude of the foundation systems for vibrating equipment shall be calculated
through dynamic analysis by using dynamic load supplied by supplier and the
allowable amplitude shall conform to suppliers requirement.
If suppliers requirement on amplitude is not specified, following criteria shall be
applied:
The amplitude of vibration of the foundation in any direction, at any point in the
foundation or structure shall be such that, it will fall down the zone ACC for the
specific exciting frequency as given in figure in Attachment - 1.

3.7

Blast Proof Construction

(1)

Minimum thickness of Reinforced Concrete Blast walls shall be 230mm to meet

the criteria of T.A.C. (Tarrif Advisory Comittee).

(2)

R.C.C. blast walls shall be taken upto 1.5m below FGL or upto top of footing
whichever is shallower, maintaining the wall thickness and reinforcement same as
in superstructure.

(3)

Members shall be designed for reversal of stresses.

(4)

Minimum reinforcement in wall in each face shall be 1% (as total in both

directions) of gross cross sectional area or as calculated from structural design
considerations. Maximum reinforcement in each face shall not exceed 2%.

(5)

Minimum reinforcement in roof slab in each face shall 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 shall be 12mm.

(7)

Maximum spacing of bars in walls and roof slab shall not exceed 150mm c/c.

4.

DESIGN DETAILS

4.1

Anchor Bolts

(1)

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.

(2)

Clear distance from the face of pocket to the outer edge of the pedestal shall be
100mm.

(3)

Clear distance between the edge of the base plate or base frame to the outer
edge of the pedestal shall be minimum 50 mm.

(4)

In general, anchor bolts for structural steel columns are embedded into the
pedestal. Clear distance from the edge of the sleeve or anchor plate to the edge
of the pedestal shall be minimum 100 mm.

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 17 OF 18

(5)

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.

(6)

All anchor bolts shall also be provided with additional lock nut.

4.2

Grouting

(1)

Unless otherwise specified by equipment manufacturers, top of foundations

except for local foundations shall be provided with an allowance for grouting as
specified below:

(a)
(b)
(c)

Foundation for large heavy duty compressors, generator, etc.. : 50 mm

Foundation for big towers (>20 m): 50 mm
Other foundation bases for columns, trusses, etc. : 25 mm

(2) Grouting under the column base plates/ shoe plates including sleeves and pockets
shall be done with non-shrink grout of free flow pre-mix type having compressive
strength (28 days) not less than 40 N/mm2 .
(3) Ordinary cement sand(1:2) mortar grout shall be used under the base plates
only for small, isolated structures e.g. operating platforms(not exceeding 2.0m
height) not supporting any equipment, cross-overs, stairs, ladders, short pipe
supports(not exceeding 1.5m height).
(4) In general , grouting work for anchor bolt pockets & base plates of equipments
a non-shrink grout shall be composed as per the specifications of the
manufacturer.
(5) Neat cement shall not be used for grouting under any condition.
(6)

4.3

Grouting requirement for machines and equipments are not covered here. The
same shall be governed by vendors requirement.
Covering for Pit / Basins

(1)

Open pits and basins without roofing or covering shall have safety railings.
Stepladders shall 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 shall be provided for pits and
basins with roofing.

DESIGN SPECIFICATION
FOR CONCRETE CONSTRUCTION
Toyo Engineering India Ltd.
HPCL, Visakh
ISSUED : 16-11-2009

ATTACHMENT -1

DOC. NO. A-6261-110-002

DIESEL HYDRO-TREATER UNIT(DHT)

PAGE 18 OF 18