ref no: apl/proj/formalin-ii/2019/1563 date:...

Ref No: APL/Proj/Formalin-II/2019/1563 Date: 13/07/2019

Corrigendum - 2

Name of Work: Transhipment facility works of APL at Boitamari, Assam

Tender Number: TCE.6842A-CV-3000-3003 dated 13th June, 2019

The modification / additional information of the above mentioned Tender

document is attached here.

Separate Corrigendum will be issued shortly with the revised Plot Plan, Piping &

Instrumentation Diagrams and Process Datasheets.

Sd/-

Managing Director

SPEC.NO.

TCE-6842A-CV-3000-3003

TATA CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP

ADDENDUM 1 FOR TRANSHIPMENT FACILITY WORKS

SHEET 1 of 4

FILE NAME: Addendum-1_Transhipment facility.doc

Proprietary rights of the information contained herein belong to Tata Consulting Engineers Limited (TCE). This information is intended to be used for the mentioned purpose/project only. In case of misuse of information

and any claim arising thereof, cost and consequence will be on the party misusing the information.

TCE FORM NO. 329 R6 FILE NAME: F-329-Rev-R6.docx

ISSUE R0

ADDENDUM - 1

ENQUIRY NO.: TCE.6842A-CV-3000-3003

TENDER: TRANSHIPMENT FACILITY WORKS

OWNER : ASSAM PETROCHEMICALS LIMITED

PROJECT : 500TPD METHANOL AND 200TPD FORMALIN PLANT

LOCATION : BOITAMARI, BONGAIGAON, ASSAM

CONSULTANT : TATA CONSULTING ENGINEERS LIMITED

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ADDENDUM - 1

I / We certify that I / We have read Addendum No - 1 and the same has

been considered while submitting the tender.

Signature of Tenderer:

For:

Address:

Date:

Seal of the Company

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ADDENDUM - 1

1.0 SCOPE OF THIS ADDENDUM

1.1 This Addendum for Enquiry No.: TCE.6842A-CV-3000-3003 Rev. R0, is

issued to provide details regarding revisions in various volumes of enquiry

document and for clarifying techno-commercial queries raised by bidders.

1.2 Except for details mentioned herein, all other details contained in the Enquiry

No.: TCE.6842A-CV-3000-3003, Rev. R0 shall remain applicable and

unchanged.

1.3 Bidder should submit the signed & stamped copy of this Addendum and

attached documents along with their Offer.

1.4 Bid Validity: Bids shall remain valid for 6 months from the due date for bid

submission. .

Sl. No.

Volume Section Clause as per RFQ

document Additions / Deletions / Modifications /

Revisions

1.0 Volume I - General & Commercial

A

Scope of Works for Civil and Structural, Sheet 2 of 3, Clause 2.7 e

Sr. No List of structures/work

1. Disperse building

2. Methanol pump station

3. Methanol Tank farm

4. Security office

5. Driver Rest room

6. Truck parking area (40nos)

7. Weigh bridge (2 nos.)

8. Loading/Unloading Gantry (9bays)

9. Pipe rack

10. Roads and Drains

11. Underground facilities

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Revisions

2.0 Volume-I A

Scope of Electrical works, TCE.6842A-CV-3000-3003-01_4, clause No: 1.1.1

All the electrical equipment located in hazardous area should be suitable are suitable for hazardous class as specified in tender.

3.0 Volume-I A

Scope of Electrical works, TCE.6842A-CV-3000-3003-01_4, clause No: 2.1.12

All the electrical panels will be located in disperse building.


A Instruction to bidders, Sheet 2 of 22, Clause 2.8

Earnest Money Deposit (EMD): INR 51,86,550/- (Rupees Fifty One Lakhs Eighty Six Thousand Five Hundred Fifty Only) in the form of Demand Draft (DD) (from Nationalised Bank) in favor of “Assam Petrochemicals Limited” at the State Bank of India, Namrup Branch, Namrup, Pin- 786623 or non-revocable Bank Guarantee (BG) from Nationalised Bank as per the APL format (annexure-I). EMD shall not bear any interest.


A Instruction to bidders, Sheet 3 of 22, Clause 3.1.1

Average Annual Financial Turnover during the last 3 years, ending 31st march, of the previous financial year, should be at least INR 16.36 Crores.


A Instruction to bidders, Sheet 3 of 22, Clause 3.2.1

a) Three similar completed works, each costing not less than INR 21.81 Crores or

b) Two similar Completed Works, each costing not less than INR 27.26 Crores or

c) One similar completed work costing not less than INR 43.62 Crores


A

Instruction to bidders, Sheet 21 & 22 (Annexure - I: Proforma for EMD)

Proforma for EMD to be revised by bidder as per the correct EMD amount (Revised EMD -51,86,550/-)

8.0 Volume-I- A- Scope for Mechanical Works, Clause no. 1.6.2

Weigh Bridge quantity shall be two (2) numbers instead of one number

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Revisions

9.0 Volume-I A-

Scope for Mechanical Works, Clause no. 1.6.4.I.(C)

Administration building is deleted. New DISPERSE room is added. It contains Conference room, Control room , UPS room, Battery room, Storage Area, Electrical panels (MCC panel and Lighting transformer). Truck Driver rest room is also added. Air conditioning shall be provided. For all the indoor conditions and type of system shall remain same.

10.0 Volume-I A-

Scope for Mechanical Works, Clause no. 1.6.4.I.(C)

Weigh Bridge Cabin shall be 2 nos instead of One number.

11.0 Volume-I A- Scope for Mechanical Works, Clause no. 1.6.4.II

Ventilation system shall be provided for Toilets. Workshop, DG + Boiler building, MCC room shall be removed from the scope.

12.0 Volume-I A Scope for Mechanical Works,

Details added Instrument air: Instrument air generation is in the scope of Formaldehyde plant package Vendor and the line will be routed up to the battery limits. From the battery limit further distribution inside the Transhipment area is in the scope of Transhipment vendor. For Battery limits refer Drawing no. TCE.6842A-CV-3019-SI-3003,P0 (Conceptual Plot plan of Transhipment facility)

13.0 Volume-I A Scope For Mechanical Works

Details added Steam: Steam generation system is in the scope of Formaldehyde plant package Vendor and the line will be routed up to

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Revisions

the battery limits. From the battery limit further distribution inside the Transhipment area is in the scope of Transhipment vendor. Similarly, Condensate return line shall route up to the battery limits by Transhipment vendor. For Battery limits refer Drawing no. TCE.6842A-CV-3019-SI-3003 (Conceptual Plot plan of Transhipment facility)


A Instruction to bidders

New clause added: Clause No. 34: Completion period shall be six months from the date of issue of LOI/PO.

15.0

Volume-I A Scope For Piping Works amended

Piping routing and isolation valves required to transfer Methanol from Transhipment tank farm to formaldehyde plant shall be provided by Transhipment vendor up to battery limit/tie-point. Piping routing and valves required for ETP/STP lines shall be provided by Transhipment vendor till battery limit/tie-in points. Piping and valve data sheets/ specifications required for residual piping shall be prepared by Transhipment vendor.


E Information of bidders

Revised document attached

17.0 Volume-II D Mechanical data sheet

TCE.6842A-CH-2027-DS-001, Rev P1, Revised mechanical data sheet due to change of capacity.

18.0 Volume-II D Process data sheet TCE.6842A-CH-2027-DS-001, Rev P1

Revised process data sheet due to change of capacity.

19.0 Volume-II D Mechanical Specifications added

M4-102-25-Rev-R6_Davit for side manhole

M4-102-26-Rev-R6_Davit for Top manhole

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Revisions

M4-102-27-Rev-R6_Manhole with hinged cover

M4-102-34-Rev-R5_gussets for nozzles

M4-102-56-Rev-R2

M4-102-60-Rev-R1-1_Std Bolt Hole Orientation

M4-119-01-Rev-R5_Storage tanks

M4-119-51-Rev-R6

M4-119-54-Rev-R2

M4-119-58-Rev-R1_Drain outlet for ST

M4-186-03-Rev-R5

M4-186-42-Rev-R3

20.0 Volume - IV C Annexure-III

Conceptual Plot plan is revised and attached as drawing no. TCE.6842A-CV-3019-SI-3003 Rev. P1

21.0 Volume - IV C Annexure-IV

Concept note for Architectural works is revised document no. TCE.6842A-AC-1023-BS-04 Rev. R0

22.0 Volume - IV C Annexure-V

Revised Design basis report for Transhipment Facility civil, structural and infrastructural works Document no. 6842A-CV-3000-DC-03 Rev. R1

23.0 Volume IV C Annexure VII,

Process Design Basis TCE.6842A-CH-2026-BS-01 is revised to R1

24.0 Volume-IV C Annexure-VIII

TCE.6842A-CH-2026-PF-20001 Methanol Storage Tank PFD, Rev. P1

TCE.6842A-CH-2026-PF-20002 Methanol Loading & Unloading PFD, Rev. P1

25.0 Volume-IV C Annexure-IX TCE.6842A-CH-2026-LS-20002

Electrical Load List PFD Rev. P1

26.0 Volume-IV C Annexure-IX

TCE.6842A-CH-2026-PI-20001 Storage tank P&ID, Rev. P1

TCE.6842A-CH-2026-PI-20002 Methanol Unloading P&ID, Rev. P1

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Revisions

TCE.6842A-CH-2026-PI-20003 Methanol Loading P&ID, Rev. P1

TCE.6842A-CH-2026-PI-20005 Effluent collection pit P&ID, Rev. P1

27.0 Volume-IV C Annexure-XI TCE.6842A-CH-2026-LS-20001

Equipment Load List , Rev. P1

28.0 Volume-IV C Annexure-XII TCE.6842A-CH-2026-GA-20001

GA drawing of Methanol Storage tank , Rev. P1

29.0 Volume-IV C Annexure-XIII TCE.6842A-CH-2026-GA-20002

GA drawing of Gantry , Rev. P1

30.0 Volume-IV C Annexure-XV

TCE.6842A-CH-2027-DS-003 Methanol loading Pump PDS, Rev. P1

TCE.6842A-CH-2027-DS-002 Methanol Unloading Pump PDS, Rev. P1

31.0 Volume-IV C Annexure-XVI TCE.6842A-CH-LA-PDS-001

Loading Arm PDS, Rev. P1

32.0 Volume-IV C Annexure -XIV TCE.6842A-CH-2027-DS-001

Methanol storage tank PDS, Rev. P1

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TATA CONSULTING ENGINEERS LIMITED SECTION: E

INFORMATION ABOUT BIDDER

(To be furnished by the bidder) SHEET 1 OF 15 OF 4

FILE NAME: E3 - INFORMATION ABOUT BIDDER

ISSUE

R0

TCE FORM NO. 329 R5

Bidders Information Form B

Applicant:

COMPANY DETAILS ________________________________________________________________________

1. Firms are required to attach a copy of Articles of Association.

2. Firms are required to indicate main lines of Business, as indicated below (1) Since (2) Since (3) Since (4) Since (5) Since (6) Since (7) Since (8) Since (9) Since (10) Since

3. Type of Organization of Applicant ____________________________________________________________

4. Establishment Year and Country of Incorporation (Copy of Notarial Act to be attached) ____________________________________________________________

5. Local Office (India) Address: ____________________________________________________________

____________________________________________________________

Tel. No: ________________ Telex No. ______________________

Fax. No. :________________

6. Head office

Address: ____________________________________________________________

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____________________________________________________________

Tel. No: ________________ Telex No._____________________

Fax. No. :________________

7. If the applicant is a subsidiary of or linked with any other company: 1) Describe the relationship with the associate or holding company 2) Identify common directorships 3) Identify the legal limits of liability of the company 4) Provide an organization chart(s) showing the Company or Group structure

8. List by name the owner and all executive directors of the company; include nationality, responsibility area, years of experience, years with the company.

Attach additional pages as necessary for identifying each appropriately.

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Bidders Information Form D

Applicant:

FINANCIAL STATUS: ANNUAL STATEMENT

1. Audited Financial Statements

Single companies and each member of the Joint venture are required to submit audited

financial statements for the last three years.

2. Submission of this Form by all Participants duly completed is mandatory. Noncompliance will result in Disqualification.

3. Summary of Assets and Liabilities

A summary of assets and liabilities derived from the audited financial statements and

converted to Indian Rupees (Rs) as shown in the following:

Financial Standing Rs

Year 2017-18

Rs

Year 2018-19

Rs

Year 2019-20

Currency Conversion

Rate

Date of Currency

Conversion

a. Current Assets

b. Fixed Assets

c. Other Assets

d. Short-term debts

e. Long-term debts

f. Net worth

g. Working capital

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4. The annual value of works undertaken for each of the above mentioned years is shown in the following:

Category of

Work

Amount (Rs. Lakh)

Year 2016-17 Year 2017-18 Year 2018-19

Currency Conversion Rate

Date of Currency Conversion 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

(Signed and Stamped,

Authorized representative of applicant)

__________________

Date:

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Qualification Requirement Form D (Contd)

Applicant:

FINANCIAL STATUS: CREDIT FACILITIES

Banking details of applicant and Bank reference.

1. Please provide the name and address of the established Bank or financial institution that is providing your credit line:

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

2. Total amount and type of credit line. This must be stated in a clear and unequivocal terms on regular Bank letterhead and signed by own authorized representative of the Bank.

3. Each applicant shall provide a reference signed by an authorized representative of an established Bank.

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Bidders Information Form E

Applicant:

MANPOWER

List by category, the total number of employees of the company and the employees resident in

India. List by name and complete the biodata as required, including English language

capabilities of the personnel with relevant experience, detailed CV’s of available personnel are

to be included in Form J:

1. Total number of currently employed personnel

Category Total Employees

Executive Directors

General Management

Administrative

Technical/Management

Permanent v/s Contract

Contracts Management

Semi-skilled/ Skilled Personnel (Civil, M &E)

Site Agent

Site Supervisory staff

(Civil, M & E)

Permanently Established Groups

(e.g. Process / Plant design etc.)

Others

2. Available personnel with relevant experience for this project

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Category Name Qualification Years with

Company

Relevant

experience

Including contract

values

Executive Directors

General

Management

Administrative

Technical /

Management

Permanent

Employee

Contract Employee

Contracts

Management

Semi-skilled / Skilled personnel (Civil, M&E)

Site Agent

Site supervisory

staff (Civil, M&E)

Permanently

Established

Groups (eg.

Process/ Plant

Design etc.)

Others

Attach additional pages as necessary identifying each appropriately.

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Bidders Information Form G

Applicant :

EXPERIENCE RECORD: SIMILAR TYPE OF WORKS AS COVERED IN SCOPE OF WORKS.

Country

/

Location

Name of

Project /

Employer

Project

Details

Value

in

Crore

Rs.

Percentage

Participation

of Company

in Project

Completed

Contract

Period

at

Award

Start

Date

Comple

-tion

Date

Supervising

/ Consulting

Firm

Attach additional pages as necessary identify each appropriately

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Bidders Information Form H

Applicant :

EXPERIENCE RECORD: PROJECTS COMPLETED - “SIMILAR TYPE OF WORKS AS COVERED IN SCOPE OF

WORKS” IN THE LAST 5 YEARS

Country /

Location

Name of

Project /

Employer

Project

Details

Value

in

Crore

Rs.

Percentage

Participation

of Company

in Project

Completed

Contract

Period

at award

Start

Date

Comple

tion

Date

Design \

Supervising

Firm

1. India a.

b.

c.

d.

e.

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(To be furnished by the bidder) SHEET 10 OF 15OF 4


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Country /

Location

Name of

Project /

Employer

Project

Details

Value

in

Crore

Rs.

Percentage

Participation

of Company

in Project

Completed

Contract

Period

at award

Start

Date

Comple

tion

Date

Design \

Supervising

Firm

2. Other

Countri

es

a.

b.

c.

d.

e.

Attach additional pages as necessary identify each appropriately

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Bidders Information Form J

Applicant :

KEY PERSONNEL (Proposed for this Project)

The technical qualification and experience of key staff will form an important part of the

evaluation process. A CV should be attached for each of the staff categories.

The resume for each key person available to be assigned to the project should indicate the

following information. The key personnel shall be associated with this project for the entire

project duration. In case, replacement of key personnel is required, the key person of equivalent

capacity shall be made available with prior approval of Owner.

a. Proposed position : ____________________________________________________

b. Name : ____________________________________________________

c. Date of Birth : ____________________________________________________

d. Nationality : ____________________________________________________

e. Education : ____________________________________________________

(Enclose photocopy of diploma/certification)

f. Language capability: __________________________________________________

g. Years of experience:____________________________________________________

(State speciality)

h. Countries where : ____________________________________________________

Experience obtained

i. Relevant experience: ___________________________________________________

(State value of projects in Indian Rs., duration of works and position(s) held)

j. Employment history : __________________________________________________

(State year, company, position held, works description and responsibilities)

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Bidders Information Form K

PROJECT EXECUTION PLAN (PEP)

The applicant is required to furnish Project Execution Plan (PEP) in the following format. A brief

but clear PEP is required describing planning and programming of the works.

a. Project Strategy: Outline statement of the organisation and methods to be employed by the applicant to undertake the work.

b. Organization chart : Preliminary organization chart indicating relationship between the head / branch office, different departments/companies which are assigned specific areas of responsibility, the site management, the on site direct works operations, suppliers and the supervising PMC/Consulting Engineer.

c. Responsibilities of Key Personnel: Identify all key personnel with management responsibilities by activity or section of work.

d. Management System: Outline the management techniques used to identify, evaluate and control the technical elements and schedule of the work.

e. Quality Management System: Provide a description of the Quality Assurance/Quality Control System; Organization and Procedures in use and identify the accreditation authority.

f. Project Safety Plan: Provide a statement outlining the Health and Safety plan operated by the company.

g. Contractor shall indicate any permanently established groups within the organization which would provide specific functions in the execution of the contract.

h. Program/Bar chart showing major activities.

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Bidders Information Form L

Applicant :

EQUIPMENT & PLANT (Owned and Proposed for this Project)

Description Quantity

(Actual)

Capacity or

Output

Make and

Model

Year of

Manufacture

Owned

or

Leased

Present

Location

1. List of principal Plant / Equipment owned by the contractor

a) Tower Cranes

b) Cranes (Mobile),

c) Trucks,

d) Concrete Mixers,

e) Batching Plants,

f) Pumps,

g) Other (applicant to list)

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Description Quantity

(Actual)

Capacity or

Output

Make and

Model

Year of

Manufacture

Owned

or

Leased

Present

Location

2. List of Plant / equipment (owned, Leased, hired) which contractor considers necessary for this contract

a)

b)

c)

d)

e)

f)

Note: Attach copies of form as necessary

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Bidders Information Form N

Applicant :

ADDITONAL INFORMATION

The applicant is invited to include any other information that may further demonstrate his competence to perform the said project works.

TCE.6842A-CV-3000-DC-03

TATA CONSULTING ENGINEERS LIMITED SHEET i OF iii DESIGN BASIS REPORT FOR CIVIL, STRUCTURAL

AND INFRASTRUCTURAL FACILITIES

R1 26-06-2019 AMP ARK - - - - - SND

R0 21-05-2019 SD/- AMP SD/- ARK - - - - - SD/- SND

P1 18-03-2019 SD/- AMP SD/- SDW - - - - - SD/- SND

P0 14-03-2019 SD/- AMP SD/- SDW - - - - - SD/- SND

REV. NO.

DATE PREPARED BY CHECKED BY CLEARED BY APPROVED BY


ASSAM PETROCHEMICALS LIMITED

500TPD METHANOL AND 200TPD FORMALIN PLANT

DESIGN BASIS REPORT

FOR CIVIL, STRUCTURAL AND INFRASTRUCTURAL FACILITIES

OF TRANSHIPMENT FACILITY WORKS

FILE NAME: 6842A-CV-3000-DC-03-REV-R1

TCE. 6842A-CV-3000-DC-02

TATA CONSULTING ENGINEERS LIMITED SECTION: CONTENTS

DESIGN BASIS REPORT FOR CIVIL, STRUCTURAL AND INFRASTRUCTURAL FACILITIES

SHEET ii OF iii

FILE NAME: F-120-Rev-R3.docx TCE FORM NO. 120 R3

ISSUE R1

CONTENTS

1. INTRODUCTION ................................................................................................ 1

2. LIST OF MAJOR STRUCTURES / BUILDINGS ................................................. 1

3. CODES, STANDARDS AND SPECIFICATIONS ............................................... 2

4. MATERIAL OF CONSTRUCTION ...................................................................... 4

5. EARTHWORK .................................................................................................... 5

6. SANITARY DRAINAGE SYSTEM ...................................................................... 5

7. STORM WATER DRAINAGE SYSTEM ............................................................. 6

8. PORTABLE WATER SYSTEM ............... ERROR! BOOKMARK NOT DEFINED.

9. FACILITY ROADS ............................................................................................ 10

10. DESIGN LOAD .............................................................................................. 11

11. LOAD COMBINATIONS ............................................................................... 15

12. ANALYSIS AND DESIGN OF STRUCTURES .............................................. 17

13. FOUNDATION DESIGN ................................................................................. 17

14. PILES AND PILE CAP DESIGNING .............................................................. 18

15. STRUCTURAL DESIGN OF RCC STRUCTURES ......................................... 18

16. STRUCTURAL DESIGN OF STEEL STRUCTURES .................................... 21

17. DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS ...................... 23

TCE. 6842A-CV-3000-DC-02

TATA CONSULTING ENGINEERS LIMITED SECTION:

REVISION STATUS

DESIGN BASIS REPORT FOR CIVIL, STRUCTURAL AND INFRASTRUCTURAL FACILITIES

SHEET iii OF iii


ISSUE R1

REVISION STATUS

Rev. No.

DATE DESCRIPTION

P0 14-03-2019 For review and comments.

P1 18-03-2019 For review and comments after revision in scope by APL. List of buildings is revised.

R0 21-05-2019 For Design and Construction

R1 26-06-2019 For Design and Construction, List of structures updated and clause is revised as per MOM dated 14-06-2019

TCE. 6842A-CV-3000-DC-03


WRITE- UP

DESIGN BASIS REPORT FOR CIVIL, STRUCTURAL AND INFRASTRUCTURE FACILITIES

SHEET 1 OF 25


ISSUE R1

1. INTRODUCTION

1.1 Scope

Assam Petrochemicals Limited (APL), a public sector unit under the Govt. of Assam along with Oil India Limited, a Navaratna company of Government of India with 51% and 49% equity participation respectively, plans to set up an integrated plant for manufacturing of Methanol and Formalin Plant in the land area adjacent to existing Methanol producing unit at Namrup, Assam. The Transhipment Facilities is proposed at Boitamari, Bongaigaon, Assam for the transhipment of methanol.

This design basis report is intended to provide the basis for finalising the architectural, civil & structural design including piling, buildings, structures, sheds, roads and drains, underground facilities, selection of materials, preparation of engineering specifications and drawings for all non -plant buildings / structures, infra structures which shall form a part of the Transhipment Facilities at Boitamari, Bongaigaon.

1.2 Site Data

The site is located approx. Around 17 km from Bongaigaon town and district, Assam.

a) Wind Speed : 50 m/s as per IS:875(Part-3)

b) Seismic Classification : Zone V

c) Ave. Annual rainfall : 3150mm (per Soil investigation report)

1.3 Soil Investigation And Site Survey Reports

a) Topographical Survey Map for the Proposed 200TPD Formaldehyde Plant, refer dwg no: ACAD/APL/DR-1 to 4 dated 20.12.17

b) Geotechnical Investigation report issued by Consulting Services: Soil & Foundations dated January 2018.

2. LIST OF MAJOR STRUCTURES / BUILDINGS

The list of major structures covered under Transhipment Facility for 500TPD Methanol and 200TPD Formalin Plant is as follows: 1. Disperse Room 2. Security cabin 3. Methanol storage tank farm (Dyked area) 4. Methanol pump shed for loading and unloading pumps(2 numbers) 5. Methanol truck loading and unloading gantry 6. Weigh bridge + Weigh Bridge Cabins (2 numbers) (Pit less weight bridge) 7. Tanker Parking (for 40 numbers of tankers.) 8. Truck Driver‟s Rest Area 9. Roads and Drains 10. Pipe rack & pipe sleepers

TCE. 6842A-CV-3000-DC-03


WRITE- UP


SHEET 2 OF 25


ISSUE R1

11. All underground facilities like sanitary, cable trenches, pits, effluent drains etc. whatever necessary.

3. CODES, STANDARDS AND SPECIFICATIONS

Only latest editions of codes and standards shall be followed with latest amendments. In case of conflict between codes & standard and job specification, more stringent requirement shall prevail.

The facilities for which the Codes & standards are not mentioned, the contractor shall furnish relevant Indian and International Codes & Standards to Owner/Engineering Consultant for review before commencement of Job.

National Building Code of India SP 7: 2016

Code of practice for design loads (Part-1, 2, 4 &5) (Reaffirmed in 2013)

IS 875:1987

Code of practice for design loads (Part-3) (Reaffirmed in 2013) IS 875 : 2015

Criteria for earthquake resistant design of structures (Part-1) (Reaffirmed in 2012)

IS 1893 :2016

Criteria for earthquake resistant design of structures (Part-4) (Reaffirmed in 2010)

IS 1893:2015

3.1 Structural Steel

Code of practice for general construction in steel (Reaffirmed in 2012) IS 800 :2007

Code of practice for use of cold formed light gauge steel Structural

member‟s in general building construction (Reaffirmed in 2016)

IS 801 :1975

Code of practice for use of steel tubes in general building works (Reaffirmed

in 2013)

IS 806:1968

Dimensions for Hot Rolled Steel Beam, Column, Channel and Angle

Sections (Reaffirmed in 2014)

IS 808:1989

Hexagon Head Bolts, Screws and Nuts of Product Grade `C' (Part-1)

(Reaffirmed in 2018)

IS 1363:2002

Hexagon Head Bolts, Screws and Nuts of Product Grade `C' (Part-2 to 3). IS 1363:2018

Hexagon Head Bolts, Screws and Nuts of Product Grades A and B (Part-1

to 3 & 6).

IS 1364:2018

Hexagon Head Bolts, Screws and Nuts of Product Grades A and B (Part-4)

(Reaffirmed in 2018).

IS 1364:2003

Hexagon Head Bolts, Screws and Nuts of Product Grades A and B (Part-5)


IS 1364:2002

Hot Rolled Parallel Flange Steel Sections for Beams, Columns and Bearing

Piles - Dimensions and Section Properties (Reaffirmed in 2014)

IS 12778: 2004

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3.2 Reinforced Concrete, Geotechnical and Masonry Works.

Code of practice for plain & reinforced concrete (Reaffirmed in 2016) IS 456: 2000

Explanatory Hand Book on Masonry Design and Construction. SP 20(S&T): 1991

Hand Book of Concrete Reinforcement and Detailing. SP 34: 1987

Code of practice for design and construction of shallow foundations in soils

(other than raft, ring and shell) (Reaffirmed in 2016)

IS 1080: 1985

Specification for high strength deformed steel bars and wires for concrete

reinforcement (Reaffirmed in 2013)

IS 1786: 2008

Code of practice for design and construction of foundations in soils: general

requirements (Reaffirmed in 2015)

IS 1904: 1986

Code of Practice for Design and Construction of Pile foundations – Part-1

(Concrete Piles), Section 2 (Bored cast-in-situ concrete piles)


IS 2911: 2010

Code of Practice for Design and Construction of Raft Foundations – Part-1 :

Design (Reaffirmed in 2013)

IS 2950: 1981

Code of Practice for Design and Construction of Machine Foundations,

(Part-1) (Reaffirmed in 2013)

IS 2974: 1982



IS 2974: 1980



IS 2974: 1992



IS 2974: 1979



IS 2974: 1987

Code of practice for concrete structures for the storage of liquids (Part-1 & 2)


IS 3370: 2009

Code of practice for concrete structures for the storage of liquids (Part-3 & 4)


IS 3370: 1967

Code of practice for earthquake resistant design and construction of

buildings (Reaffirmed in 2018)

IS 4326: 2013

Code of practice for determination of bearing capacity of shallow foundations


IS 6403: 1981

Code of practice for ductile detailing of reinforced concrete structures

subjected to seismic forces (Reaffirmed in 2016)

IS 13920: 2016

3.3 For Road works

IRC: 15 – 2017 Code of practice for construction of concrete road

IRC: 44 – 2017 Guidelines for Cement Concrete Mix Design for Pavements

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IRC: 57 - 2006 Recommended practice for Sealing of Joints in Concrete Pavements

IRC: 58 – 2015 Code of practice for construction of rigid pavement

IRC: 74 – 1979 Tentative Guidelines for Lean-Cement Concrete and Lean-Cement Fly Ash Concrete as a Pavement Base or Sub-Base

IRC: 85 – 2015 Code of practice for accelerated strength testing & evaluation of concrete for road construction

IRC:119-2015 Guidelines for Traffic Safety Barriers

IRC:99-2018 Guidelines for Traffic Calming Measures in Urban and Rural Areas (First Revision)

MORTH Specifications for Road and Bridge Works 2013 (5th Rev)

Publication year 2016

National Building Code of India

IS:783: 1985 Code of practice for laying of concrete pipes (Reaffirmed in Jan 2012)

Note: The above list is suggestive and not exhaustive. Apart from these basic codes any other related codes shall also be followed wherever required.

4. MATERIAL OF CONSTRUCTION

Material of construction of buildings and shed structures shall be as listed below:

Sr. No.

Structures Material of Construction

1. Disperse building

(panel room area, storage room, utility room, weigh bridge control area, staff seating area etc )

RCC building with roof slab and brick infill

2. Security Cabin & Time office RCC building with roof slab and brick infill walls

3. Methanol storage tank farm RCC dyke wall and RCC tank foundation with internal paving.

4. Methanol pump house shed RCC foundation with steel super structure & roof

5. Methanol Truck loading/unloading gantry shed

RCC foundation with steel super structure

6. Truck Driver Rest Room Partially RCC building with structural steel roofing and Partial cladding.

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7. Pipe racks Structural steel with RC foundation

8. Weigh bridge (2 nos) + Weigh bridge Cabin

RCC foundation

9. Tanker Parking Paved open area

10. two Wheeler parking Paved area with covered roof

The list mentioned above is not exhaustive; the same shall be referred along with the conceptual plot plan & Architectural design basis report & conceptual plot plan.

For description of Buildings and facilities refer the Architectural Design Basis Report no. TCE.6842A-AC-1023-BS-04.

5. EARTHWORK

Grading shall be carried out at all facility areas to provide a relatively leveled area with good drainage. The site finished grade shall be sloped 1:1000 towards drain away from buildings and other facilities. All areas to be stripped, cut and filled shall be defined on the project grading drawings.

Finished ground level to be considered for the facilities such that there will be optimum cutting and filling envisaged. The level of the finished ground level shall be minimum 300mm above nearest metallic road or highest flood level whichever is higher. The finished level shall not be less than the level of surrounding plots which will cause low laying area. Highest flood level is at RL 39.086 as mentioned in the survey drawing.

For foundation work, soft pockets found during the excavation shall be removed and shall be filled with course grained material.

6. SANITARY DRAINAGE SYSTEM

Wastewater and sewage water from toilet area, floor drains, shower/bathing areas, kitchen, wash basin etc. shall be collected & conveyed through gravity system to sewage treatment plant.

The sanitary drainage system shall be designed to collect and carry the peak flow of wastes based on the manning data or occupancy of the respective buildings, shift duties etc.

The Sewage collection pit along with pumps shall be provided to collect the sewage from entire area and to transfer the same to STP of proposed Formaldehyde plant. Battery limit for the same shall be decided during detail engineering.

a) Sewer appurtenances

a) Manholes

Spacing of manholes shall be as specified below:

For sewers up to 12" dia maximum spacing shall be 30m.

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For sewers up to 12"-20" dia maximum spacing shall be 45m.

b) Location of Manholes

Manholes shall be located at

Junction of sewers

Dead end of mains

Change of grade or size of mains

Change of direction

c) Location of Clean Outs

Clean outs shall be located so that rodding can be carried out in directions of flow and shall be located at following locations.

Dead ends of sewers

Where a sewer is essentially in horizontal plane and makes a 90o turn in direction (except where a turn is within 3m of its d/s termination at manhole or catch basin).

Where a sewer is essentially in a horizontal plane and makes a 45o turn in direction and the u/s length of line exceeds 15m.

b) Cover for drainage pipes

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

a) For the sewer of sizes up to 6" from equipment drain points to nearest main header or manhole shall be 300mm.

b) For main headers having size 6" and above, when located such that there is no chance of truck movement or crane movement over them shall be 450mm.

c) For headers in open paved areas when crane or truck movement can be expected shall be 1200mm, (Alternatively Pipes can be encased with 150 mm thick concrete (M20)).

7. STORM WATER DRAINAGE SYSTEM

Site drainage layout requirements shall dictate the surface grading around the buildings and facilities. Drainage system shall be subdivided into separate drainage areas and slopes of the drains shall be consistent with the natural slope of the plot and shall align with road layout.

Drain slopes and directions shall conform to the existing topography and shall follow existing site drainage pattern if feasible. Drain sizes shall be checked for actual volume of rain water from the area covered by the respective drain. The discharges of rain water from roof areas shall also be considered in the nearest drains and provision for pipe connection from catch pit to the drain shall be kept while drain detailing.

Storm water drainage system shall also be capable to collect fire water run-off based on fire fighting demand. The effect of additional runoff, such as flows

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from watersheds above and outside of the site, passing through the design area, shall also be considered.

c) Drain sizing

The bedding slope of the drain and size of the drain shall be maintained to limit the velocity of water in the drain as mentioned below:

Minimum drain depth - 300mm

Minimum drain width - 300mm

Minimum free board - 150mm

In case of pipe, the drain shall be considered 2/3rd full.

Area drains, catch basins, and storm sewer piping shall be used only where necessary to maintain surface access across the drainage area and to maximize surface usage of the site.

d) Design Rainfall intensity

Design rainfall intensity for storm water drain design shall be considered 100 mm/hr or based on actual rain fall data whichever is more.

e) Run-Off Coefficient

The following run off coefficients can be selected for design of the storm water drain.

Area Run-off coefficients:

Paved area - 1.0

Unpaved area – 0.5

f) Type of Drain

RCC rectangular drains in and around plant boundaries and roads & paved

areas. Drains shall be covered with precast concrete covers unless noted. Wherever there is vehicular movement, precast covers shall be designed for the class-A vehicular movement loads as per IRC 6 : 2017. For rest of the area precast covers shall be designed considering the appropriate live load as per IS 875 (Part-2).

All drain walls shall be designed for minimum surcharge pressure of 10KN/sq.m., considering that the minimum 1m wide shoulders are provided between road and drain and the vehicle movement near the drain is not envisaged. In case the vehicular movement is envisaged around the drain, the

Minimum Maximum

Pipe 0.6 m/s 2.4 m/s

Open drain 0.6 m/s 2.0 m/s

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surcharge due to vehicle load shall be considered while designing the drain wall.

The 90 degree or sharp bend in the drains shall be avoided. Suitable bed slope shall be provided to drains to maintain smooth flow of storm water to maintain self cleaning velocity without scouring.

Pipe or box culverts shall be installed under roads, wherever required based on depth of drain below road level. Storm water drain outfall point shall be connected to the existing outfall point established during the survey. Storm water drain invert level at outfall point shall be kept well above the invert levels of nearby nallas or external water bodies around the plant area to avoid water lodging/back flow inside the plant.

g) Rate of rainwater run-off

The maximum rate of rainwater run-off shall be based on the following formula

AIC103.6

1Q1

6

Where

Q1 = Design quantities of runoff from area (m3/sec)

C = Runoff Coefficient.

I = Design Rainfall Intensity (mm/Hr.)

A = Catchment Area (m2)

h) Velocity Calculation

Velocity = V = (1/n) x R2/3

x S1/2

Where ‘n’ is Roughness Coefficient = 0.017

‘R’ is Hydraulic mean depth = Aw/Ap

‘S’ is bed slope

i) Hume Pipes for road crossings

Road crossings shall be RCC box culverts / RCC pipe culverts, designed for road traffic loads. The relevant lateral loads due to wheel loads on the soil adjacent to walls at crossing shall be considered.

150mm dia NP-3 class hume pipe with CI grill shall be provided to collect rain water from road area and connect the same to storm water drain parallel to road at every 3m c/c located along the length of the roads. The hume pipes shall be laid to correct slope and length suitable to the drain invert levels.

Hume pipes for underground road crossings for fire water piping and natural gas pipe line, ERC/IRC hume pipes, sanitary/OWS/effluent drain pipe crossing,

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any other underground facilitates etc shall be provided with correct levels and locations keeping clearance below storm water drains.

All pipe culverts for road crossings shall be RCC hume pipes of NP-3 class conforming to IS: 458 - 2003.

j) Hydrostatic pressure for drain design

The design ground water level shall be as considered at existing ground level as per the Geo-technical specifications/report/data and the hydrostatic pressure there from, shall be adequately accounted for in the drain cross section design. In addition, all possible combinations of lateral soil pressures, hydrostatic pressures, uplifts, surcharges from fixed/moving loads etc shall be considered in the design.

Allowable net bearing capacity of soil shall be based on the geotechnical investigation report

k) Material of construction

Unless otherwise specified minimum grade of concrete to be used for drains shall be of M25 conforming to IS: 456 using 20mm and down size graded coarse stone aggregate.

Unless otherwise specified 50mm thick PCC of mix 1:2:4 (by weight, using 20mm and down size grade crushed stone aggregate) shall be provided under drain base slab, pits sumps etc. The PCC shall extend 50mm beyond the drains/pits/sumps.

Unless otherwise specified Plum concrete of grade 1:5:10 (by weight, using 40mm and down size grade crushed stone aggregate) shall be used as filler material wherever loose sub grade exists by removing the loose soil/fill.

The following minimum cover shall be provided for drains unless otherwise specified.

Sr. No.

Type of Works Minimum Cover

a) Drain, pit, Cable/Pipe Trench walls 30 mm

b) Drain, pit, Cable/Pipe Trench Base Slab 50 mm

c) Precast concrete cover 25 mm

The following minimum thickness shall be provided for RCC works unless otherwise specified.

Sr. No.

RCC Works Minimum Thickness

a) Cable/Pipe Trench walls & Base Slab. 150 mm

b) Precast Trench Cover 75 mm

c) Underground pit (Walls & Base Slab) 200 mm

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8. FACILITY ROADS

General Requirements:

It is intended to provide easy access for personnel and vehicles to all buildings and yard equipment. Concrete roads shall be considered to provide access to all facilities within plot area and to facilitate fire tender movement.

Approach roads from buildings and facilities which are connected to building ramp/loading unloading areas, shall be connected to the nearest main plant road

Finished Road level (FRL) shall be minimum 300mm above finished ground level (FGL) and minimum 200mm below Finished Floor level/ Plinth level of nearby buildings. The road level shall be matched with the Formaldehyde plant roads located adjacent to this proposed plant.

Roads: The design parameters shall be considered based on the geotechnical investigation report attached in Annexure I of volume IV of the tender document.

Material of Construction:

Pavement Quality Concrete.

Minimum grade of concrete for roads shall be M35.

Road width:

Width shall be as per plot plan drawing approved by Owner.

Typically width of carriageway shall be 6m & 7.5m as indicated in the drawing.

The minimum turning radius of road curvature:

12.0m for 7.5m wide road

1.5 x road width for other roads

Design traffic intensity for roads:

1) For roads other than tanker loading/unloading area - 5 Million Standard Axles (MSA) for a design life of 20 years

2) For roads near tanker parking area and tanker loading/unloading area - 15 Million Standard Axles (MSA) for a design life of 20 years.

Road vehicle loading class:

IRC class A loading considering tanker movement/Fire tender movement.

Camber & Longitudinal slope:

2.5% of camber away from road center line to be provided.

Longitudinal slope if necessary shall not be steeper than 1:50.

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Shoulder and Kerb:

1) Shoulder – Minimum 1.0m wide on both side of the road with Interlocking M-35 grade paver blocks having minimum thickness of 75mm, confirming to IS 15658 and IRC SP 63:2004.

2) Kerb stone - precast concrete kerb stone of minimum 150mm thickness, 500mm long. Readily available precast kerb stone can be used with prior approval from OWER. Road kerb shall be painted alternately with yellow and black strip by approved painting conforming to MORTH technical specifications.

9. DESIGN LOAD

All Buildings and structures for this project shall be designed for the following loads.

9.1 Dead Loads (DL)

The dead load considered in the structural design shall consist of the full weight of all known fixed structural and architectural elements. The weight of piping in operational conditions, conduit, cable tray, ductwork, etc., permanently attached to the structure shall be considered in dead load. If piping weight is not indicated separately or included in the weight of the equipment, the same shall be taken as 10% of the weight of the equipment.

9.2 Live Loads (LL)

The following live loads produced by the use and occupancy of a building or structure shall be the minimum considered in the structural design as specified in IS 875: PART 2 : 1987 (Reaffirmed 2013).

Loading Area Load Intensity (kN/m2)

Roof

Accessible Roof 1.5

Inaccessible Roof 0.75

For Sloping Roof with slope greater than 10 degrees

0.75 kN/m2 less 0.02

kN/m2 for every degree

increase in slope over 10 degrees, subject to a

minimum of 0.40 kN/m2

Staircase

Process / Technological Structures 5.0

Service Platforms / Watch Tower. 2.5

Office 5.0

Platform

Operating Platforms 3.0

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Loading Area Load Intensity (kN/m2)

Maintenance Platforms 7.5 (or as specified by

machine vendor)

Isolated Platform (for valve operation) 2.5

Access way 2.5

Cross over 2.0

Floor

Ground Floor Live Loads unless noted 5.0

Typical floor slab 5.0 Unless Noted

Otherwise

Storage Area/Stores/Panel room 10.0

All building floor and grand level loading As specified in IS: 875 (Part

2) : 1987

* Note: All the equipment loads are considered in addition to Live loads if any.

9.3 Equipment Load (EL)

Equipment Loads shall be defined as per the following cases, according to the governing conditions of operating, empty and testing. Equipment loads along with attached piping and platform shall be taken as given in mechanical loading data.

a) Equipment Load Erection (ELe)

This shall mean the weight of equipment during erection and exclude the weight of internal fluids, solids within equipment, platforms, insulation and piping attached to the equipment.

b) Equipment Load Operation (ELo)

This shall mean the weight of equipment during normal operating conditions including the weight of internal fluids, solids within equipment and all materials permanently attached to the equipment such as platforms, piping and insulation.

c) Equipment Load Testing (ELt)

This shall mean the weight of equipment, piping during hydrostatic testing after erection / installation including the weight of water within the equipment piping and all materials permanently attached to equipment such as platforms, insulations and piping.

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

9.4 Wind Loads (WL)

All buildings and structures shall be designed to withstand the forces of wind pressure in accordance with the appropriate provisions of IS: 875 (Part 3) - 2015.

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The forces of wind pressure assumed in any horizontal direction shall be considered with no allowance for the effect of shielding by other adjacent structures.

a) Location of site: As given in “Project Information General”.

b) Basic wind velocity - 50 m / sec

c) k1, k2, k3, K4 and other factors as per IS: 875 (Part III).

d) Category 2 to be considered for design

Based on the above wind pressure and exposure of the building as per IS: 875 (Part 3), further load calculations will be carried out with respect to profile of buildings.

The design life span of all structures (units & offsite) shall be taken as 50 years. Temporary structures shall be designed for a design life span of 25 years.

9.5 Seismic Loads (SL)

a) All buildings, structures, foundations shall be designed to resist the effects of earthquakes in accordance with IS 1893 (Part 1) 2016, IS 1893 (Part 4) 2015 and IS 13920 - 2016.

b) All the buildings and structures shall be designed for Design Basis Earthquake (DBE).

c) All liquid storage tanks shall be designed to resist the effects of earthquakes in accordance with IS 1893 (Part-2) 2014.

9.6 Seismic Parameters

Seismic design forces shall be determined based upon the following parameters. Buildings of different materials of construction and lateral force resisting systems shall be investigated separately.

Earthquake Load to be considered as per IS: 1893 (Part-4) 2015

a) Seismic Zone: Zone V

b) Zone Factor „Z‟ : 0.36

c) Importance factor „I‟ : –Shall be considered as per IS: 1893 (Part-4) 2015

d) Category – Shall be as per table-6 of IS: 1893:2015 (Part-4): 2015

e) Response reduction factor : Shall be considered as per Table-4 of IS: 1893 (Part-4) 2015

f) Vertical acceleration – Shall be considered 2/3rd of Horizontal acceleration value

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The seismic analysis shall be performed for three orthogonal components of the earthquake loads as per clause no. 8.3.2.1.1 & 8.3.2.1.2.

Minimum lateral force as per the applicable zone shall be taken from table 2 of IS: 1893 (Part-4) 2015.

Irregularities in the building configuration shall be avoided as stated in clause no.7.1, 7.9, Table-5 & Table-6 of IS: 1893 (Part-1) 2016.

Contribution of permanent dead loads and live loads as specified in IS: 1893 (Part-1) 2016, shall be considered while calculating nodal masses. Live load on the roof shall be accounted in the calculation of nodal masses as specified in IS: 1893 (Part-1) 2016.

The contribution of live load to be considered in the seismic weight calculation shall be as specified in IS 1893 (Part 1).

9.7 Categorisation of Structures / Equipments:

Typical categorization of industrial structure for 500TPD Methanol and 200TPD Formalin Plant is as given below:

Sr. No.

Structures Category

1. Disperse building 2

2. Security cabin 4

3. Methanol storage tanks foundation 2

4. Methanol pump shed 2

5. Tanker Loading/Unloading gantry 2

6. Truck Driver‟s rest area 4

7. Pipe racks 2

Response spectrum analysis shall be carried out according to category of the structure as per IS 1893 (Part-4) 2016.

Simplified analysis as per clause-10.3 of IS 1893 Part - 4 shall be carried out for all structures of Category - 4.

9.8 Ductile Detailing

All the structures shall be designed and details in accordance with the IS: 13920-2016.

Ductile detailing shall be adopted even if the forces generated due to wind loads are higher than seismic loads. Please add this sentence.

Column & beam sizing shall be done in line with the requirements mentioned in clause nos. 5, 6 & 7 of IS 13920 – 2016. Relative strength of beams and columns at a joint shall be ensured as per clause no. 7.4 of IS 13920 – 2016 to consider the same as a part of lateral resisting system.

In steel structures, members and their connections shall be so proportioned that high ductility is obtained to ensure that premature failure due to elastic or

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inelastic buckling does not occur. Ductile detailing of steel structures shall be carried out as per the provisions of IS:800:2007.

9.9 Impact & Vibratory Loads

All structural framing and concrete foundations subject to vibration, impact, impulse, shock, etc., shall be designed to withstand the generated forces within the limits of acceptable stress, deflection, and/or amplitude of vibration. All structures subjected to impact or vibratory loads shall be designed as per the provisions of IS 875 : PART 2 : 1987 (Reaffirmed 2013).

All structures supporting moving or stationary equipment shall be designed for static loads plus appropriate impact factors as defined by the equipment manufacturer, IS 800, or as listed below:

Transverse and longitudinal forces due to EOT crane shall be considered as per the provisions of IS 875 : Part 2 & Part 5 : 1987 (Reaffirmed 2013).

Equipment Description Impact Factor

Monorails 25% Vertical

EOT Crane As per IS 875 (Part-2) :1987 (Reaffirmed 2013)

9.10 Construction Loads

Loads produced by the materials of construction plus the equipment required to construct the facility (crane loads, rigging loads, earth moving equipment, etc.) as applicable shall be considered. When the sequencing of construction will not permit the lateral force resisting system of the structure to be constructed first, the engineer shall make provisions for temporary lateral bracing and clearly identify these requirements on the design drawings and contract documents. The contractor shall coordinate the sequence of building erection and the types and quantity of construction equipment to be used.

All structures shall be checked and designed to satisfy the worst load combination that produces maximum forces and effects and maximum stresses.

9.11 Other Loads

All liquid retaining/storage structures shall be designed as per IS 3370 (Part 1) 2009 & as per IS 1893 (Part 2) 2014, assuming liquid up to the full height of wall irrespective of provision of any over flow arrangement. Pressure relief valves or similar pressure relieving devices shall not be made in underground water retaining/storage RCC structures.

10. LOAD COMBINATIONS

All buildings/structures shall be designed to resist the worst combination of the above loads. Few of the load combinations to be considered are listed below.

A. For Foundation Design:

LOAD CONDITION LOAD COMBINATION

OPERATING DL + LL + ELo

DL + LL + ELo ± WL

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DL + ELo ± WL

0.9 * (DL + ELo) ± WL

DL + ELo + LL ± SL

DL + ELo ± SL

0.9 * (DL + ELo) ± SL

ERECTION

DL + ELe

DL + ELe ± WL

0.9 * (DL + ELe) ± WL

TESTING

DL+ ELt

DL + ELe ± WL

0.9 * (DL + ELt) ± WL

B. For Concrete Design:


OPERATING

1.5 * (DL + LL + ELo)

1.2 * (DL + LL + ELo ± WL)

1.5 * (DL + ELo ± WL)

0.9 * (DL + ELo ) ± 1.5 * WL

1.2 * (DL + ELo + LL ± SL)

1.5 * (DL + ELo ± SL)

0.9 * (DL + ELo ) ± 1.5 * SL

ERECTION 1.5 * (DL + ELe)

1.5 * (DL + ELe ± WL)

0.9 * (DL + ELe) ± 1.5 * WL

TESTING 1.5 * (DL+ ELt)

1.5 * (DL+ ELt ± (25% WL))

0.9 * (DL + ELt) ± 1.5 * (25% WL))

C. For Structural Steel Design:

Load combinations shall be as per clause-3.5 of IS: 800:2007.

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11. ANALYSIS AND DESIGN OF STRUCTURES

a) All analysis and design work related with civil or structural steel shall be carried out using STAAD Pro V8i (select series 6).

b) Limit State Method of design as per IS 456:2000 shall be followed in the design of concrete structures unless otherwise specified elsewhere in this document for special structures.

c) Limit State Method of design as per IS 800:2007 shall be followed in the design of steel structures unless otherwise specified elsewhere in this document for special structures.

12. FOUNDATION DESIGN

12.1 Minimum Requirements

Type of foundation to be used, foundation design and Minimum depth of foundation for all structures shall be decided based on the recommendations provided in Geo-technical Investigation report.

12.2 NGL (Natural ground level) and FGL (Finished ground level) shall be marked on all drawings showing foundation/sub-structure details and related design documents.

12.3 The design ground water level shall be considered at finished ground level as per the Geo-technical specifications/report/data and the hydrostatic pressure there from, shall be adequately accounted for in the design. In addition, all possible combinations of lateral soil pressures, hydrostatic pressures, uplifts, surcharges from fixed/moving loads etc shall be considered in the design.

12.4 Allowable safe bearing capacity (SBC) of soil shall be considered as per the recommendations provided in Geotechnical Investigation report. SBC value provided in geotechnical report is presented for three cases; Bearing, local shear and general shear criteria. However, for designing, SBC to be selected which will give the most conservative structure.

12.5 For transient loadings, e.g. wind/seismic, settlement shall not be the design criteria and the SBC (safe bearing capacity) based on shear criteria shall be considered.

12.6 Permissible increase in SBC for earthquake load combinations shall be as per Table-1 of IS 1893 (Part-1) 2016.

12.7 Permissible increase in SBC for wind load combinations shall be as per IS 875 (Part-5) 1987 (Reaffirmed 2013) except for stack foundation where wind is the predominant load.

12.8 Foundation shall be so designed that the resultant of all loads placed upon them is as near as possible to the centre of gravity of the foundation.

12.9 Factors of safety against overturning and sliding shall be as per values given below. Component of soil backfill weight over foundation slab shall be appropriately covered as foundation dead load. For stability checks the weight of soil as overburden shall be considered as given below.

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Type of structure

Minimum factor of safety against overturning

Minimum factor of safety against sliding

% weight of over burden over projected plan area of footing

With wind or seismic

Without wind or seismic

With wind or seismic

Without wind or seismic

All structures, except listed below.

1.5 2.0 1.5 1.5 100

Pipe racks 1.5 2.0 1.5 1.5 50

Retaining wall 1.5 2.0 1.5 1.5 100

Overhead water tank

1.5*/2.0 - 1.5 1.5 50

(* Empty Condition)

12.10 Minimum factor of safety against UPLIFT shall be 1.2 for all structures. In case of sumps, lining weight shall not be included in UPLIFT load calculation.

13. PILES AND PILE CAP DESIGNING

13.1 Pile capacities shall be considered as per the recommendations provided in the Geotechnical Investigation report, the same shall also be verified through pile load tests as per specifications.

13.2 Pile length, pile cut off level, Minimum diameter of pile, shall be as mentioned in the Geotechnical Investigation Report. Bored cast in situ end bearing pile shall be considered as mentioned in the Geotechnical Investigation report.

13.3 The ground water table shall be considered at the top of pile for pile analysis.

13.4 All other requirements related to reinforcement spacing, minimum cover, minimum diameter of bars, embedment of pile etc. shall be confirming to IS 2911 (Part 1) Section 2 - 2010.

13.5 Pile embedment inside pile cap shall be minimum 150mm.

14. STRUCTURAL DESIGN OF RCC STRUCTURES

14.1 General

a) All RCC structures shall be designed as per IS 456 : 2000.

b) Limiting deflection for RCC members shall be 1/350 of the span or 20mm whichever is less or as defined in IS: 456 : 2000 except where wind is the predominant load. For predominant wind load condition, allowable deflection shall be L/500.

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c) All liquid retaining/storage RCC structures shall be leak-proof and designed as uncracked section as per IS 3370 (Part 1) 2009 & as per IS 1893 (Part 2) 2014. However, the parts of such structures not coming in contact with the liquid shall be designed according to IS:456-2000, 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.

d) 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.

e) Concrete surfaces subject to exposure to aggressive chemicals like acids/alkalis, provided with suitable lining.

f) Minimum cement content and maximum water cement ration shall be as specified in Table-5 of IS 456.

14.2 Environmental Exposure Condition

Environmental exposure condition shall be considered as moderate as per clause 8.2.2, Table-3 of IS 456: 2000.

14.3 Fire Rating

Unless otherwise specified all concrete structures shall have 2 hour fire resistance (refer: clause 21 of IS 456).

14.4 Concrete Mix

a) Reinforced Cement Concrete (RCC):

Unless otherwise specified minimum grade of concrete to be used for shall be M25 for all structures except for water retaining structure it is M30, conforming to IS: 456-2000 using 20mm and down size graded crushed stone aggregate.

b) Plain Cement Concrete (PCC):

Unless otherwise specified 75mm thick PCC of mix 1:2:4 (by weight, using 20mm and down size grade crushed stone aggregate) shall be provided under all RCC foundations. The PCC concrete shall extend 75mm beyond the foundation.

c) Plum Concrete:

Unless otherwise specified Plum concrete of grade 1:5:10 (by weight, using 40mm and down size grade crushed stone aggregate) shall be used as filler material wherever loose sub grade exists by removing the loose soil/fill.

14.5 Reinforcement Bars

High strength Deformed Thermo mechanically treated (TMT) Steel bars of minimum grade Fe 500 D, conforming to IS: 1786:2008.

Mild Steel round bars shall not be used as reinforcement.

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14.6 Grouting & Minimum Grout Thickness

The minimum thickness of grout shall be 25 mm and not more than 50mm.

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-days minimum cube crushing strength of 40N/mm2 . Ordinary cement sand (1:2) grout shall only be used under the base plates of crossover, short pipe supports (not exceeding 1.5 m height) and small operating platforms (not exceed in 2.0m in height) not supporting any equipment.

Epoxy grout shall be used for equipment foundations as per specifications provided by equipment vendor.

14.7 Expansion Joints

Expansion joints shall be provided as per relevant IS code requirements for different type of RCC structures. Joints in the super-structure shall be provided by means of gap between two consecutive structural members. The gap shall be based on the design requirements.

14.8 Minimum Cover to Main Reinforcement

The following minimum cover shall be provided for RCC works unless otherwise specified.

Sr. No.

RCC Works Top Bottom Sides

a) Pedestals &Column Above Ground / Below Ground.

- - 50mm

b) Foundation 50mm 75mm 50mm

c) Pile Cap 50mm 100mm 50mm

d) Plinth Beam 30mm 40mm 30mm

e) Other Beams 30mm 30mm 30mm

f) Slabs 30mm 30mm 30mm

g) Walls Above Ground & Below Ground 40mm 40mm 40mm

h) Water Retaining Structures 40mm 40mm 40mm

i) Equipment Foundation. 40mm 40mm 40mm

j) Trenches and Pits. 30mm 30mm 30mm

14.9 Minimum Thickness of Structural Concrete Elements

The following minimum thickness shall be provided for RCC works unless otherwise specified.

Sr. No.

RCC Works Minimum Thickness

d) Footings (All types including raft foundations without beams).

(Note: Tapered footings shall not have thickness less than

300 mm

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150mm at the edges Minimum average thickness shall not be less than 300mm.

e) Pile Cap. 600 mm

f) Slab thickness in raft foundations with beam & slab construction. 150 mm

g) Floor / Roof slab, Walkway, Canopy Slab. 125 mm

h) Cable/Pipe Trench/Launder walls & Base Slab. 125 mm

i) Parapet 100 mm

j) Precast Trench Cover / Trench cover Slab 75 mm

k) Liquid Retaining / Leak proof structure Walls & Base Slab. 150 mm

l) Underground pit / Reservoir Walls & Base Slab. 250 mm

14.10 Minimum Height of Pedestals

The minimum projection of pedestals supporting any steel structure/stanchion bases shall be 300mm for structures and that for indoor structure it shall be 150mm above the high point of pavement/ finished grade/finished floor level whichever is higher. The maximum projection of pedestals above FGL/FFL for staircase/ladder shall be 200mm.

14.11 Minimum Cover to Foundation Bolts

Minimum distance from the centreline of foundation / anchor bolt to edge of pedestal shall be the maximum of the following:

a) Clear distance from the edge of the base plate / base frame to the outer edge of the pedestal shall be minimum 75mm.

b) Clear distance from the face of pocket to the outer edge of the pedestal shall be 75mm.

c) Clear distance from the edge of the sleeve or anchor plate to the edge of pedestal shall be 75mm.

15. DESIGN CONSIDERATIONS FOR STEEL STRUCTURES

15.1 General

a) The design of all structural steel work such as roof trusses, steel sheds, pipe racks, pipe bridges, tank supporting platforms, operating platforms, stairs, ladders, walkways etc. will be carried out in accordance with Limit State Design method as per IS 800:2007.

b) Design, fabrication and erection of all structural steel works shall be carried out in accordance with the relevant Indian standard codes as applicable to the specific structures. Basic consideration of structural framework shall primarily be stability, ease of fabrication / erection and overall economy satisfying relevant Indian Standard Codes of Practice.

c) Structural elements continuously exposed to temperatures above 215 deg.C shall be designed for reduced stress as per clause 16.4 (Fig. 24) of IS: 800:2007.

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d) Crane gantry girders shall generally be of welded construction and of single span length. Chequered plate shall be used for gantry girder walkway flooring.

15.2 Steel Grade

Structural steel shall be of Grade E250/E350, quality A/BR, conforming to IS: 2062 :2011 (Grade A) semi killed or killed for Rolled Sections & fully killed and tested for impact resistance for plates & flats.

High strength anchor bolts of 8.8 grade shall confirm to IS 1367 (Part-3) 2002. Plain washers shall confirm to IS 2016 - 1967 and Heavy washers shall confirm to IS 6610:1972

All cold formed sections shall confirm to IS: 801-1975 Cold formed light gauge sections.

For detailing and construction of welded connections all provisions of IS 9595- 1996, IS 816-1969 and specification pertaining to design, detailing and construction shall apply.

Irrespective of welding length indicated on the drawing, full contact length required between gusset plate and members shall be welded in all cases unless otherwise specifically mentioned.

15.3 Limiting Deflection

The limiting permissible vertical & horizontal deflection for steel structure/building shall be as specified in Table-6, IS 800-2007.

15.4 Minimum Thickness

a) The minimum thickness of tubes shall be as specified in IS: 806-1968.

b) Structural members exposed to marked corrosive action shall be increased in thickness or otherwise suitably protected against corrosion as per section 15 of IS: 800:2007.

c) The minimum thickness of structural components (except gratings & chequered plates) which are directly exposed to weather and inaccessible for repainting shall be 8mm) or as per IS: 800:2007.

15.5 Design Criteria for Steel Staircase, Ladders, Handrails and Gratings.

a) Steel staircases for main approaches to operating platforms shall have channels provided as stringers with minimum clear width of 1000mm and slope of app. 41 degree. The vertical height between successive landings shall not be less than 2.6m nor exceed 4.0meters.

b) Treads shall be minimum 300mm wide made spaced equally so as to restrict the rise to maximum 200mm. Maximum 12 number of risers can be provided per flight.

c) The minimum width of concrete staircase shall be 1250mm.

d) Ladders shall be provided with safety cages when the top of the ladder is more than 3.0 m above the landing level. Safety cages shall start 2.1 metres above the lower landing level. Ladders shall be of 450mm clear width with

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20mm diameter MS rungs spaced at 300mm (maximum). Ladders shall preferably be vertical. In no case shall the angle with the vertical exceed five degrees.

15.6 Connections

a) Welded connections shall be adopted in general, except for isolated cases where bolted connections are specifically allowed with prior permission from Owner/Owner‟s representative. All permanent and erection connections shall have at least two 20mm diameter and 16mm diameter bolts respectively, unless restricted by the member size.

b) Connection shall be designed as per section 12 of IS:800- 2007

c) All moment connections shall have class 8.8 bolts conforming to high strength bearing type bolt conforming to IS: 3757-1985.

d) Connection bolts for minor connection such as hand railing connection / ladder and fixing of floor grating and grating tread, etc. shall be ordinary strength bolt conforming to IS: 1367-2002 property class 4.6.

e) The ends of all tubes shall be scaled by using 6 mm thick plates welded all round.

f) Minimum two nuts shall be used for all anchor bolts.

16. DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS

16.1 Cable and Pipe Trenches

a) All the cable trenches as per electrical requirements shall be RCC with 6mm chequered plate for indoor trenches and with precast concrete covering for outdoor cable trenches. The sides of trench shall be designed to resist earth pressure, cable load and surcharge load. Surcharge load for outdoor cable trenches shall be 10KN/sq.m. & for indoor cable trenches it shall be equal to live load on the grade slab for that building.

b) Cable trench cover shall be designed for self-weight and live load for the cable trench inside the building.

c) Cable trench crossing the road shall be designed for Class A loading of IRC / relevant IS code.

d) The trench bed shall have a slope if 1 in 1000 along the run and 1 in 250 perpendicular to the run. Necessary sumps shall be constructed and sump pumps if necessary shall be supplied. Cable trenches shall not be used as storm water drains.

e) If trenches are outside the covered area, then top of trenches shall be kept at least 150mm above the high point of finish ground level or finish floor level. The top of the trench shall be such that the surface rainwater does not enter the trench.

f) All metal parts inside the trench shall be connected to the earthing system.

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16.2 Pipe rack

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

a) Vertical Loading:

Actual weights of pipes coming at each tier shall be calculated. In calculating the actual weight of pipe, the class of pipe material content and insulation, if any, shall be taken into consideration. Insulation density shall be taken as 2600 N/m3, minimum.

The total actual weight thus calculated shall then be divided by the actual extent of span covered by 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 uniformly distributed load obtained as above shall be

assumed to be spread over the entire span. However, minimum loading for any pipe rack shall not be less than 1.25 kN/sq.m. In case, the calculated loading is higher than 1.25 kN/sq.m this shall be rounded off to the nearest multiple of 0.25 (i.e. 1.50, 1.75, 2.0 kN/sq.m).

b) Friction Force (Longitudinal and Transverse):

Where the pipes are of similar diameter and service condition, the friction force at each tier on every portal, both in longitudinal and transverse directions shall be 10% of the design vertical loading of the pipes for four or more pipes supported on a tier.

For a single pipe or up to three pipes at a tier on pipe rack, tee supports, trestles, the frictional force shall be taken as 30% and 10% of the design vertical force acting simultaneously in transverse and longitudinal directions respectively.

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.

c) Anchor and Guide Force (Thermal Load):

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

d) Loading on Intermediate Beam at Tier Level:

Intermediate beam at tier level shall be designed for 25% of load on main portal beams in transverse direction. A reduction of 10% in vertical loading shall be considered for main portal beams if intermediate beams are provided. The friction force on intermediate beam shall be taken as 10% of the vertical load on tier beams. This force shall be acting in transverse and longitudinal direction simultaneously.

e) Wind load on pipes:

Basic wind pressure shall be considered as per IS: 875 (Part-3) 2015.

To calculate wind load in transverse direction of pipe rack, a projected height shall be taken as [diameter of largest pipe including insulation (m) +

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10% of width of pipe rack (m)]. This sum is multiplied by the length of the pipes to determine tributary area. The wind load calculated thus is inclusive of the solidity ratio and shall be multiplied by force coefficient for design wind load on pipes. Force coefficient “Cf” to be considered for wind load on piping shall be 0.7.

Wind loads on structural members shall be calculated in addition to wind load on pipes as per the IS: 875 (Part-3) 2015.

To calculate wind load on cable trays in transverse direction of pipe rack, a projected height shall be taken as [height of largest tray (m) + 10% of width of pipe rack (m)]. This sum is multiplied by length of the cable trays to determine tributary area. The wind load calculated thus is inclusive of solidity ratio and shall be multiplied by force coefficient for design wind load on cable trays.

Force coefficient “Cf” to be considered for wind loads on cable trays shall be 2.0 assuming the depth of cable tray is not more than 75mm. For cable trays having depth more than 75mm, force coefficient shall be calculated as per IS: 875 (Part-3) 2015.

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TATA CONSULTING ENGINEERS LIMITED

SHEET i OF iii DESIGN BASIS REPORT FOR

ARCHITECTURAL WORKS

R0 08-07-2019 CNB NSS AP NSS

P0 15-04-2019 CNB NSS AP NSS

REV. NO.

DATE PREPARED BY CHECKED BY CLEARED BY APPROVED BY


ASSAM PETROCHEMICALS LIMITED

500TPD METHANOL AND 200TPD FORMALIN PLANT

ARCHITECTURAL DESIGN BASIS REPORT

FOR TRANSHIPMENT FACILITY WORKS

FILE NAME: 6842A-AC-1023-BS-04-REV-R0

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DESIGN BASIS REPORT FOR ARCHITECTURAL WORKS

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CONTENTS

1. INTRODUCTION...................................................................................................1

2. LIST OF MAJOR STRUCTURES / BUILDINGS ................................................. 1

3. CODES, STANDARDS AND SPECIFICATIONS ............................................... 2

4. ARCHITECTURAL DESIGN DATA .................................................................... 5

5. ARCHITECTURAL FINISHES .......................................................................... 22

6. LANDSCAPE ................................................................................................... 23

7. INTERIORS ...................................................................................................... 24

8. STRUCTURAL AND CONSTRUCTION ELEMENTS ....................................... 24

9. MATERIAL OF CONSTRUCTION .................................................................... 25

10. FINISHES SCHEDULE………………………………………………………………..26

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REVISION STATUS

Rev. No.

DATE DESCRIPTION

P0 15-04-2019 For review and comments.

R0 08-07-2019 For design.

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FILE NAME: F-120-Rev-R3.docx

1. INTRODUCTION

1.1 Scope

Assam Petrochemicals Limited (APL), a public sector unit under the Govt. of Assam along with Oil India Limited, a Navaratna Company of Government of India with 51% and 49% equity participation respectively, plans to set up an integrated plant for manufacturing of Methanol and Formalin Plant in the land area adjacent to existing Methanol producing unit at Namrup, Assam. The proposal is to setup Transhipment Facilities and infrastructure facilities for the methanol plant at Boitamari, Bongaigaon, Assam.

This design basis report is intended to provide the basis for finalising the architectural, selection of materials, preparation of design specifications and drawings for all non -plant buildings / structures, infrastructures which shall form a part of the Transhipment Facilities at Boitamari, Bongaigaon.

1.2 Site Data

The site is located approx. 17 km from Bongaigaon town and district, Assam.

a) Wind Speed : 50 m/s as per IS:875(Part-3)

b) Seismic Classification : Zone V

c) Ave. Annual rainfall : 3150mm (per Soil investigation report)

1.3 Soil Investigation and Site Survey Reports

a) Topographical Survey Map for the Proposed 200TPD Formaldehyde Plant, refer dwg no: ACAD/APL/DR-1 to 4 dated 20.12.2017

b) Soil investigation report issued by Consulting Services: Soil & Foundations issued on January 2018.

2. LIST OF MAJOR STRUCTURES / BUILDINGS

The list of major architectural structures covered under Transhipment Facility for 500TPD Methanol and 200TPD Formalin Plant is as follows:

1. Disperse Building 2. Security Cabin 3. Truck Driver’s Rest Room

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3. CODES, STANDARDS AND SPECIFICATIONS

3.1. Codes and Standards

The design shall in accordance with established and latest editions of codes and standard as referred below shall be followed.

(1) National Building Code of India 2016

(2) OISD Standards

(3) Town and country department

(4) State Industrial Development Corporation’s bye-laws and documents for building approval

(5) Unified Building Byelaws 2016

(6) Factory Inspector of the State.

Note: The above list is suggestive and not exhaustive. Apart from these basic codes any other related codes shall be also followed wherever required.

3.2. Statutory Approvals

Approvals/Clearances Required

Department to be Approached and Consulted

Incorporation of Company Registrar of Companies

Registration/IEM/Industrial license

District Industry Centre for Small Scale Industries (SSI) /Secretariat of Industrial Assistance (SIA) for large and medium industries

Allotment of land State DI/State Industrial Development Corporation (SIDC)/Infrastructure Corporation/Small Scale Industrial Development Corporation (SSIDC)

No-objection from Divisional Forest officer (for industries based on forests)

Ministry of Environment, Forest and Climate Change (MoEF), Forest and Wildlife Department,

Approval of construction activity and building plan

a. Town and country planning, (Assam) b. Municipal and local authorities c. Chief Inspector of Factories d. Pollution Control Board

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e. Electricity Board

NOC and consent under Water and Air Pollution Control Acts

(Assam) Pollution Control Board

a) Declaration of land as non-agricultural under section ,143

b) Proceedings under section 154 of UP Zamindari Abolition Act.

Revenue Department

a) Approval prior to construction of factory building /use as a factory 1) For non-hazardous industries 2) For hazardous and major hazardous industries

Labour department

Sanction of Power Local Electricity Board

Use and storage of explosives

Chief Controller of Explosives

NOC relating to fire safety from Fire officer

Fire Department

Boiler Inspection Certificate

Chief Inspector of Boilers

a) Approval prior to construction of factory building /use as a factory 1) For non-hazardous industries

2) For hazardous and major hazardous industries.

Labour Department

Registration under States Sales Tax Act, and Central and State Excise Act

i. Sales Tax Department Central and State Excise Depts.

Extraction of Minerals ii. State Director of Mines and Geology,

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Weights and Measures Inspector of Weights and Measures

Code Number for Export and Import

Regional Office of Director General of Foreign Trade.

Note: The above list is suggestive and not exhaustive. List of approvals need to be verified by client’s liaisoning consultant, as it may vary state to state.

3.3. Units of Measurement:

Unless otherwise specified MKS or SI units shall be applied as the measurement system to the Drawings and Documents.

The following table indicates the internationally accepted units for common properties in each system of measurement.

MKS SI

Mass Kg Kg

Length M – mm M - mm

Area M2 M2

Volume M3 M3

Flow Rates

Liquid M3/hr M3/hr

3.4. Priority of Requirements – Order of Precedence

In case of any discrepancy among the Codes / Standards, related Design Specification and this specification, the priority order shall be as under:

(1) Statutory Regulations

(2) Codes and Standards

(3) This Specification

(4) Related Design Specification

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3.5. Plot Plan

Conceptual schematic plot plan shall be attached as an annexure to tender document.

PLANT STRUCTURES

SR.NO. LIST OF STRUCTURE APPROX SIZE

(MTR.)

1 Disperse Building 15 X 20

2 Security Cabin 05 X 05

5 Truck Driver’s Rest Rooms 16 X 10

3.6. Site Context & Surrounding

The proposed site in Assam is envisaged at Boitamari. The site is well connected by road network and rail network. The nearest railway station to the site is Bongaigaon Railway Station.

4. ARCHITECTURAL DESIGN CRITERIA

All buildings shall be aesthetically designed with modern materials. Materials requirements unspecified in engineering specifications shall conform to manufacturer’s standards.

4.1. Architectural Design

Architectural design of buildings/sheds shall be in accordance with this design basis and references as stated herein, to facilitate the intended functions. The various types of requirements to be considered are described further. In plant area no underground/basement shall be provided.

4.2. Building Requirements

4.2.1. Spatial Requirements

Spatial requirements inside a building/shed shall be decided based on activities to be performed in the building and consequent occupancy pattern, equipment layout etc. Spaces can be generally classified as functional spaces, circulation spaces, amenity spaces, utility spaces. These are elaborated further.

4.2.1.1. Functional Spaces

Functional area of any building/shed is constituted by the main activity for which the building is required. Various spaces/rooms shall be judiciously sized and shall be integrated logically to generate the total building plan taking into account the following parameters -

a) Activities, group of activities and consequent work-flow pattern

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b) Site conditions i.e., dimensions, contours etc

c) Climatic conditions vis-à-vis orientation

d) Safety regulations. (HSE)

e) Lighting and ventilation

f) Acoustics

g) Services

h) Security

i) Economy

j) Aesthetics

k) Any specific requirement pertaining to particular buildings

l) All other established architectural design parameters.

The objective of spatial arrangement shall be to satisfy functional requirements and physical comfort and safety regulations as well as aesthetics which has significant role in creating a favourable working environment.

4.2.1.2. Utility Spaces

Utility spaces are space requirements which materialize due to provision of services like air-conditioning, pressurization, firefighting, electrical, telephone LAN etc. Following are examples. These spaces shall be provided as per required building services.

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

j) Room for LAN System.

4.2.1.3. Circulation Spaces

Following spaces are classified as circulation spaces. These spaces shall be provided as per required building services, for integrating various types of spaces and as means of access/exit/escape.

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a) Corridors & passages

b) Staircases

c) Elevator (requirements as per NBC)

d) Entrance lobby/Foyer including Reception & waiting

e) Gangway/walkways

f) Equipment loading/unloading platforms

g) Emergency Exits

h) Parking: Demarcation of parking bays will be done by using textured paver tiles in between two bays and by proper signage required.

4.2.1.4. Sizes of Spaces

Sizes of various types of spaces shall be decided based on occupancy / equipment sizes/ panel sizes/furniture layout, clearance, maintenance-safety requirements, light-ventilation requirements.

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

Sr. No. Type of Room Description of Size

1 Minimum area of any habitable room 9.5 m2 with minimum dimension restricted to 3.0m

2 Minimum ht. of any habitable room 2.4 m for air-conditioned areas.

Headroom below beams min. = 2.5 m

3 Maximum ht. of habitable rooms As stipulated by the local bye-laws, scale of accommodation.

4 For industrial work spaces @ 14 m3 per occupants. (Maximum) clear height of such workspaces shall be 3.60m.

Heights above 4.25 m shall not be taken into

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account.

For air-conditioned area, minimum clear height shall be 3.0 m.

5 Parking space Car: 2.50 x 5.50m

Bike: 1.20 x 2.50m

Truck: 3.75 x 10m

Trailer Truck: 5.00 x 20.00m

4.2.1.5. Amenity Spaces

Following spaces are classified as amenity spaces -

a) Toilet (Gents & Ladies) and Toilet for physically challenged.

b) Drinking Water Facility

c) Locker & Change Room

d) Rest room/ Lunch Room

e) First-aid room

f) Wash room and space for drying clothes.

g) Pantry

Out of the above-mentioned areas, a) Toilet, b) Drinking water, c) First Aid enclosures shall be mandatory requirement for occupied buildings/sheds. Other facilities shall be provided as required.

4.2.2. Ventilation and Day Lighting

4.2.2.1 Ventilation

A. 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, Part-8; Section-1

b) IS: 3103 code of practice for industrial ventilation.

c) State Factories Rules

Natural ventilation shall also be supplemented by mechanical or electrical means of ventilation in all areas of habitation.

B. Mechanical Ventilation

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In addition to natural ventilation, if required mechanical or electrical ventilation shall be provided depending on the type of building and its use. Other relevant design basis shall be referred for its requirement and applications.

4.2.2.2. Day Lighting

Established level of illumination shall be maintained for all parts of the buildings by means of windows, ventilators, skylights, etc. Following references shall be adhered to in this regard.

a) National Building Code of India, Part-8; Section-1

b) Guide for day lighting of building IS: 2440; Code of practice for interior illumination.IS:3646 (Part-I, II);

c) State Factories Rules

d) Any other relevant rules / code etc.

e) IS-7662 (Part-1) Recommendations for orientation of buildings (non-industrial)

Following architectural norms shall be adopted:

a) Direct solar illumination shall not be considered and only sky radiation shall be taken as contributing to illumination of the building.

b) Openings shall be provided with shading devices to avoid glare. For the purpose of illuminations, day lighting shall also be supplemented by artificial illumination.

4.2.3. 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.

a) National Building Code of India Part 8 Section 4

b) State Factory Rules

c) Limitations on decibel level stated elsewhere, if any, in the bid document

d) Code of practice for noise reduction in industrial buildings IS 3483

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

a) Segregating noise sources by buffer zones

b) Dampening of noise levels by damping devices

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

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4.2.4. Safety Requirements

Safety from fire and like emergencies shall be considered in building/shed design.

Buildings/sheds meant for human occupancy shall be provided with exits enough to permit safe escape of occupants in case of an emergency. The exits shall be in terms of doorway, corridors, and passage ways to internal/external staircase or to areas having access to the outside. Following references shall be adhered to in this regard. Maximum distance to an exit from any point in a building shall not exceed 30 m. A minimum of two staircases and two exits per floor shall be provided in each building. Width of passage/ corridor shall not be less than 1500 mm.

a) National Building Code of India, Part-4

b) State Factories Rules.

4.2.5. Site Planning

Site planning of building shall consider aspects like inter-relationship of the buildings with the whole system, movement pattern, traffic and road network, safety regulations, service network, fire safety, climatic and environmental aspects. 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. Local climatic factors such as temperature, humidity, wind to be considered. Site conditions like site dimensions, contour, drainage, noise level, view, future expansion and visual aspect to be considered. The design should be based on environmental design principles.

The site planning of the non-plant building shall be considered as well.

4.3. Building Services

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

4.3.1. Water supply and Distribution, Sanitary Drainage Services including solid waste Management

This service is essential for all habitable buildings/sheds. All buildings with human occupancy shall have toilet and drinking water facility as per following references.

a) National Building Code of India, Part-9, Section 1 & 2

b) State Factories Rules

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Drinking water provisions shall be provided within an enclosure separated from the toilets. Space for janitor shall be provided in the toilets. All service pipes showing on the external wall shall be suitably concealed or shall be provided within a shaft.

Septic tank & soak pit shall be provided for each building as per NBC-Part 9.

4.3.2. Air conditioning and Heating

Areas of control room, spaces housing equipment/machinery/panels etc. Which require conditioned environment and certain specified areas like offices, specific office accommodation shall be suitably air-conditioned by window/split/package type units as per requirement with respect to HVAC Design Basis.

4.4. Aesthetics

Apart from the fulfilment of functional & safety requirement, aesthetic requirement of the Buildings/sheds shall be taken care of in the design. However, EPC contractor may consider aesthetic and built form of local architecture for designing the campus.

As specific guidelines for achieving required aesthetics are difficult to establish, following guidelines shall be followed:

a) 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.

i. Building/shed shape and features

ii. Canopies, overhangs & shading devices

iii. Gutters

iv. Entrance/exit steps, door

v. Window/Ventilator composition

vi. External wall location with respect to columns

vii. Colour scheme, grooves in plaster

viii. Spatial arrangement

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4.5. Building Elements

4.5.1. Roof

4.5.1.1. In case of reinforced concrete framed building, the roof shall be made of cast-in-situ reinforced concrete and shall be made completely waterproof. Proper slope shall be given towards outlets for drainage purpose.

4.5.2. Wall

4.5.2.1. Internal partition wall shall be 230 mm/ 115mm thk (Wire cut) depending on the overall length and height of wall.

4.5.2.2. The external / load bearing wall shall be made of bricks and shall be of Minimum 230 mm thick.

4.5.2.3. Fire walls (around transformers) shall be minimum 350 mm thick made of common bricks or 200 mm thick RCC as per electrical requirement. (OISD).

4.5.2.4. All Blast proof walls shall be minimum 230 mm thk. RCC wall.

Notes:

i. 115 mm thk. Partition walls shall be provided with RCC transoms and mullions for stability.

ii. Wherever conduits or pipes are required to be concealed within partition wall, the local wall thickness shall be increased suitably.

iii. All cut-outs in Masonry / wall shall be sealed with fire rated sealant.

iv. Wherever, bricks are not easily available, suitable alternative material shall be used after obtaining owner’s approval.

4.5.3. Floor on grade:

The floor-on-grade shall be of structural concrete and divided into various types depending on the facility and type of loading. Type wise floor on grade to be adopted shall be as per Cl.3.0

4.5.4. False / Cavity Floor:

False/cavity flooring, consisting of cement filled flooring sheets with antistatic lamination on the top. False floor shall be provided to accommodate under floor cabling in all areas. Extent of false/cavity flooring shall be as per functional requirements. False flooring shall be fire rated to the level of fire rating of the walls, doors and suspended ceiling in the compartment.

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4.5.5. Finished Floor Level (Plinth FFL)

In general, Plinth FFL of the buildings, sheds shall be determined with respect to top of approach road or pavement. Unless noted otherwise on the reference drawings, following schedule shall be adhered to for FFL of various buildings & sheds.

a. Sub Station Building

Cable cellar floor - Top level of approach road + 600 mm

Transformer bay with pebbles - Top level of approach road +300 mm

or as per Elect. Design Basis.

Single storey substation with - Top level of approach road +1000

trench Mm (without trenches) or as specified

depending upon cable trench depth

b. Vehicle, scooter, cycle shed - Top level of approach road+150mm

including fire tender bays, repair shop

c. False floor areas (Control Room - Top level of approach road + 150

Satellite Rack Room Building) +

Height of false flooring (min. 600 mm)

d. Loading, Unloading bays, platforms - Top level of approach road + 1100 mm

e. Electrical rooms - As specified in drawings subject to

minimum 600 mm above top level of

approach road.

f. Other Buildings/Shed - Top level of approach road + 600 mm

from surrounding ground

level.

Notes:

1) In case of approaches with different top levels, the highest top level of approach road / Pavement shall be considered.

2) FFL shall be same throughout in a building / shed. Split levels may be considered in exceptional cases due to ground terrain etc.

3) FFL of external loading / unloading bays / platforms, toilet, pantry, kitchen shall be 6 ~ 12mm lower than that of the building / shed’s FFL to check the ingress / spillage of water.

4) FFL of Warehouses, Stores may be kept lower than loading / unloading bays / platforms where forklifts etc. are used for internal movement of items. Adequate arrangement for negotiating the level difference shall be provided in that case.

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Building Plinth Height shall be minimum +450mm from FGL. / HPP.

4.5.6. Ceiling Height

Requirements of ceiling height shall be as per functional requirements and applicable factory rules.

The height shall be determined considering the clearance from equipment, bus duct, HVAC duct, lighting fixtures, etc.

However, for some of the building areas the following minimum ceiling height requirements shall be followed.

Sr. No. Description Minimum Ceiling Height*

1 Minimum height of any habitable room

3000 mm

2 Industrial work places 3600 mm

3 False ceiling from False Floor / FFL 3000 mm

4 Fire Station Building /Control Room 5000 mm

5 Other buildings/sheds As desired by equipment /crane vendor

*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.

4.5.7. Damp Proof Course

Plain cement concrete of mix 1:2:4 of minimum 40 mm thickness (using 10 mm & down size graded aggregates) shall be provided as damp-proof course at plinth level of all masonry walls. Waterproofing compound shall be added to the damp proof course to prevent dampness in superstructure due to capillary action of water.

4.5.8. False Ceiling:

4.5.8.1. False ceiling shall be provided normally in air-conditioned areas. False ceilings shall be provided for following purposes: -

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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 3000 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 has 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.

4.5.8.2. Suitable space shall be kept enabling suitable arrangement of service duct cable, piping and lighting fixtures.

4.5.8.3. Under deck Insulation

Under deck insulation below RCC roof and over false ceiling (both locations) shall be provided for air-conditioned office / space as per HVAC Design Basis.

4.5.9. Doors / Windows / Ventilators:

4.5.9.1. Doors

Doors shall be provided for access, security and safety to all rooms, functional areas in a building. Air tight door shall be provided in pressurized area and in gaseous protection area.

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 : 1500mmx 2500 mm (masonry

opening size)

d. W.C bath Cubicle door :800 mm x 2100 mm (masonry

opening size)

e. Minimum size of other doors : 1200 mm x 2100 mm (masonry

opening size)

Notes:

A. Entrance doors shall be provided covering full width of the entrance lobby. In that case the door shall be of composite type consisting of open able shutters & fixed panels.

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Entrance lobby shall be provided with elaborate canopy. Following general guidelines shall be applied:

(1) External doors shall be made to open outwards.

(2) Wooden windows / ventilators shall not be used.

(3) Fireproof doors shall be with two hours fire rating as per statutory requirement.

(4) Blast resistant Control room entry door shall be provided with blast resistant baffle wall in front of entry door and shall have 45°/ 90° overlap on both sides as per OISD-STD 163.

B. All aluminium sections shall be annealed/colour anodized/powder coated as specified /as per architectural requirement.

C. The pressed steel doors shall conform to IS: 4351.

D. All aluminium doors shall be glazed powder coated aluminium doors with closing devices. Doors shall have heavy duty locks.

4.5.9.2. Windows / Ventilators:

Windows/ventilators shall be provided in all areas for natural lighting, ventilation, and visibility at working level. For the purpose of ventilation, total open able area of the windows/ventilators shall be as per Factories Act subject to a minimum of 15% of the floor area to be ventilated. However, for control room and in office areas, etc. where visibility from inside is also important, increased window area shall be provided. Areas accommodating panels/equipment shall be normally provided with ventilators at high level for uniformly distributed lighting. Fire retardant sealants shall be provided at the junction of Door/ window frame & walls.

Notes:

i. Requirements of window/ventilation area as stipulated above is for maximum room height of 4000 mm. For heights more than 4000 mm, additional window/ventilator shall be provided in the same manner at every work area / platform at all levels.

ii. Wherever due to limitation of external wall area or other reasons, stipulated area of window/ventilator cannot be provided, suitable mechanical/electrical system shall be employed.

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

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

v. For structures like workshop/warehouse/compressor sheds with roof sheeting, suitable monitor may be added to provide proper ventilation.

vi. For blast resistant Control rooms, window openings through wall may be provided as per OISD-STD 163.

vii. Fire resistance windows shall be provided as per TAC, electrical, process, etc., statutory requirements.

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viii. External windows shall have P.C.C. (1:3:6) sills, 100 thk.

4.5.9.3. Rolling Shutters:

Rolling shutters shall be provided wherever area requirement of open able shutters exceeds 2500 mm x 2500 mm such as A.C. Plant, Switch gear Room etc.

Rolling Shutters of sizes upto 25 Sqm. shall be gear operated only and rolling shutters of sizes more than 25 Sqm. shall be motorized-electrically operated.

4.5.9.4. Partitions:

The partition shall be modular type, anodized aluminium framed with combination of pre-laminated board & glass or G.I. framed Gypsum board partition shall be provided as per approved vendor’s recommendation.

Aluminium glazed partition to be used for Operation & Maintenance personal cabins.

If required partition shall be provided for flexible space arrangement in office spaces, partition shall be modular dismantle type of approved vendor.

4.5.9.5. Glazing:

All glazed partitions, doors, windows / ventilators shall be provided with 5.5 mm thick toughened glass. External glazing shall have 0.05mm thk (1.5mil) sun control film of approved make.

4.5.10. Hardware’s:

All hardware fittings and fixtures for doors, windows and louvers (e.g. hinges, bolts, locks, latches, stays, door-stops, door closers, floor springs) shall be heavy type matching to the size and weight of the door/ window/ ventilator shutters. These shall operate easily without hindrance secure properly without jamming; require nominal maintenance durable under prevailing site / weather conditions.

4.5.11. Steps / Ramps:

Steps / Ramps shall be provided for access to buildings, sheds for pedestrian /vehicular, equipment entry. Minimum 1200 mm wide platform shall be provided between Entrances door and ramps. Following dimensions of steps / ramps shall be followed:

(a) Tread: 300 mm (Minimum)

(b) Riser: 150 mm (Maximum)

(c) Slope of ramp: Not steeper than 1:10

(d) Ratio of tread and riser: 2 Riser + tread = 600 mm

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(e) Minimum width of steps / ramp: 1500 mm

All the flat roofs shall be accessible either by ladder or staircase for maintenance.

4.5.11.1. Staircases shall be provided in multi floor buildings for vertical circulation & emergency exits. Number of staircases shall be based on building/shed sizes, emergency exit requirements, and travel distances to exit points as per statutory regulations. More than 500 sq m ground covered area shall have at least two stairs in line with NBC-Part 4. Emergency exit requirements shall be as per safety distance requirement. At least one staircase shall be provided for access to the flat roof tops for maintenance.

Following dimensions for staircases shall be adhered to:

For Main Staircase:

a. Stairs width : 1500 mm minimum

b. Tread : 300 mm minimum

c. Riser : 150 mm maximum

d. Ratio of tread & riser : 2 Riser +Tread = 600 mm

e. Maximum no. of risers per flight : 12 Nos

For Emergency Staircase:

a. Stairs width : 1500 mm minimum

b. Tread : 300 mm minimum

c. Riser : 150 mm minimum

d. Maximum no. of risers per flight : 12 Nos

4.5.11.2. Passages/corridors

Passages/corridors shall be provided to integrate various spaces. Width of the passages/corridors shall be as per statutory requirement, subject to a minimum width of 1500 mm.

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.

4.5.11.3. Service Entry

Separate service entry shall be provided for service areas such as kitchen, air-condition/ pressurization plant room, electrical rooms. A common service entry may be provided depending on spatial arrangement.

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4.5.11.4. Air Lock Lobby

This shall be provided for all entries with centrally air-conditioned spaces.

4.5.11.5. 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 the movement subjected to the minimum requirement of 9 sq.m.

4.5.11.6. 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, and 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.

4.5.12. Canopy / Overhangs / Shading Devices:

4.5.12.1. Canopy / Overhangs:

Canopy / overhangs shall be provided at all entries and exits for rain and sun protection as per following requirements.

(a) For all type of buildings such as Laboratories, Administration, Canteen, Control Room, Substation, Security office, etc. Canopy shall be provided to all entrances.

(b) Canopy shall also be provided for stores / warehouses / storage sheds where regular movement of vehicle is anticipated.

(c) Size of canopy / overhang shall be decided based on vehicle parking, covered access to buildings / sheds, movement around the vehicle and aesthetics of building / shed.

(d) Overhangs shall be provided over all exits. Minimum 1200 mm overhang shall be provided.

4.5.12.2. Shading Devices:

Shading devices over windows / ventilators such as chajja shall be provided for rain / sun protection. These devices shall be in the form of horizontal

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projection, vertical projected fins or combination of both as per building facade treatment. Minimum projection of chajja shall be 600mm.

4.5.13. Parapet:

Parapets shall be of R.C.C for all building with minimum 600 mm high for non-approachable roof and 1000 mm high for approachable roof.

4.5.13.1. Railings:

Railings of 1000 mm high shall be provided in stairs and in all unprotected openings in slabs as a safety device. Railings in loading/unloading bay of Substations shall be of removable type to facilitate the purpose. Stainless steel railing of 1000mm high shall be provided in staircase and entrances for all buildings.

4.5.14. Plinth Protection:

All buildings / sheds shall be provided with 1000 mm wide plinth protection (150mm thick concrete over 150 mm thick compacted sand) all around buildings sheds. Level wise, it shall be 150 mm high above top of approach road level / surrounding finished surface, in order to avoid accumulation of water outside the buildings.

4.5.15. Roof gutter:

Roof gutter with rain water pipes shall be provided for all the buildings and sheds, shelters for roof water drainage. Gutters shall be of R.C.C. or pre-coated Galvalume sheet type depending on type of structure. Sizing of the gutter shall be based on areas to be drained and number of outlets.

4.5.16. Toilet:

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 for physically challenged people shall be provided as per statutory norms.

4.5.17. 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.

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4.5.18. Transformer Gate:

Steel gate of suitable size in front of transformer bays in substations building may be provided as per electrical requirement.

4.5.19. Internal/External Finishes:

Internal/External finishes shall be as per Cl 3.0

4.5.20. Waterproofing:

RCC roofs shall be provided with application of PU primer directly over it then application of Elastomeric membrane with min 600% elongation & Tensile Strength >6Mpa, by brush/roller/spray applied in 1.5mm thickness as per Manufacturer specifications Geotextile min 150 GSM over the cured membrane. Fibrated Screed concrete M20 grade to slope (avg 50 mm thicknesses), casted into panels of 2x2 m size and saw cut grooves of 6mm x 35mm filled with bituminous sealant. Top surface of shading devices (RCC) shall be finished with cement plaster mixed with water proofing compound laid in slope provided with drainage system.

4.6. Plumbing

4.6.1. Materials

4.6.1.1. Water Supply:

GI pipes/ CPVC pipes shall be used for water supply within building.

4.6.1.2. Rain water pipes:

UPVC Rain water pipes shall be provided to drain off the rain water accumulating on roof efficiently. Nos. and dia. shall be decided on area of roof, slope and rainfall intensity.

Rain water pipes shall be embedded in concrete /brick. GI spouts shall be used for drainage of chajjas and small canopies of ground floor only. Also refer General Civil Design Basis for design parameters. Rain water down take pipelines shall be aligned vertically so as to avoid cross Drainage over the RCC slabs.

4.6.1.3. Sewage System:

Sanitary sewer from the buildings shall be collected by inspection chambers and glazed stone ware pipe/ UPVC pipes and shall be connected to septic tank for treatment. Treated water shall be carried out to soak pit. Also refer General Civil Design Basis.

4.6.1.4. Storm Water Drainage System:

(1) Rain Water from the buildings shall be discharged into the storm water drain through roof gutters and down take pipes., Roof drainage shall be connected to rain water harvesting system as per NBC Part-9 section 1.

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(2) However, building surrounding areas shall also have the proper storm water drain arrangement.

(3) Unless otherwise specified, the oil contaminated water from buildings shall be connected to the oily sewer system of the plant. Refer General Civil Design Basis

5. ARCHITECTURAL FINISHES

All the building elements i.e. Floor, Wall, Ceiling, Roof, Doors, & Windows etc. shall be finished with architectural finishes as per following schedule.

Note:

1) All the architectural finishes shall be as per Specifications, Standards & Approved list of vendors.

2) Any Architectural finish for which no Specifications etc. is furnished, Contractor shall submit the appropriate Specification for Owner’s / PMC’s representative approval. The work shall be executed by the Contractor with such approved Specification without any extra time

& cost implication to Owner’s / PMC’s representative.

3) Colour scheme for all Architectural items shall be as approved by Owner’s / PMC’s representative.

5.1. Wall:

All bricks shall be of class designation 5.0 / wire cut.

5.2. Floor on grade

Types shall be as follows:

6. LANDSCAPE

The landscape design of the project is designed to check the pollution and also to beautify the area. The planting will be carefully done so as to

Sr. No. Facility Name Type of Construction

1

Disperse Building, Security Cabin, Truck Driver’s Rest Rooms

TYPE – I

RCC Structure

Floor finish as per architectural requirement. For Grade slab detail refer Standard Drawing

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decrease the environmental effects of the plant. The gathering spaces for the users should be easily accessible, create better living, recreational and interactive. The planting will be done to arrest the drifting dust, cut down the noise and reduce the air, water pollution.

As the site has various buildings like administrative, canteen and other buildings activities are planned based on the character of the building. Green belts, residential landscape, parking areas, traffic islands will have a formal character. The planting will provide ample shade and coolness to create respite from hostile hot interior of the factory. Careful Planting will create a micro climate which will reduce the temperature. Hardy shrubs can be used to make maintenance easy. Runoff on the site will be reduced with the use of permeable garden pavers, permeable roads, grass pavers etc. Zero runoff is to be achieved by means of water harvesting and sustainable techniques.

7. INTERIORS

Interior design of offices and other non-plant building’s concepts would be planned out with more functional and open office concept in general manner, keeping in mind APL as a global brand. A combination of workstations and closed cabins are planned in such a manner that they will have visual connectivity through the passages, members of middle management were permitted to use offices with doors, and individuals in higher-up positions such as CEOs were given wider, more type spaces with wonderful outdoor views.

These particular types of office spaces feature workspaces that are long in size, in which potentially a CEO and a new employee could end up working together side-by-side. The conference rooms are also essentially upgraded by featuring glass walls, though the spaces themselves are still enclosed. There are even some larger-sized businesses who have configured their building entrances in ways that would require all of their employees to pass through a large break room before ultimately moving on to their assigned departments.

The true benefit of all of this openness is to create communication in more articulated manner. Another wonderful benefit of open office interior design concept is the aspect of accountability, meaning that employees will be able to concentrate more on their assigned tasks.

8. STRUCTURAL AND CONSTRUCTION ELEMENTS

Please refer document 6842A-CV-3000-DC-03-REV-P1-Design Basis Report for Civil, Structural, Infrastructural Facilities.

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9. MATERIAL OF CONSTRUCTION

Material of construction of buildings and shed structures shall be as listed below:

Sr. No. Structures Material of Construction

1. Disperse Building

(includes panel room, UPS room, control room, battery room, storage room, workspaces for min. 10 people, toilets)

RCC building with RC roof slab and brick infill

2. Security Cabin RCC building with RC roof slab and brick infill

3. Truck Driver Rest Room RCC building with steel sloping roof and brick infill. Galvalume sheeting with adequate underdeck insulation treatment to be provided.

TCE. 6842A-AC-1023-BS-04 TATA CONSULTING ENGINEERS LIMITED

SECTION:

WRITE- UP


SHEET 25 OF 26


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TCE FORM NO. 120 R3

10.1 FINISHING SCHEDULE: DISPERSE BUILDING

10.2 FINISHING SCHEDULE: SECURITY CABIN

S.NO Room / Area / Location Flooring Wall (Interior) Ceiling Door/Windows/Ventilator

1 Entrance Lobby, Reception, Floor Lobby, Waiting Lounge

Staircase

Granite Stone Acrylic Emulsion Paint Grid Ceiling in Gypsum

Doors:

1. Solid core wooden flush doors 2. Hollow Metal Pressed Fire Rated Steel Door 3.Fully/ Partly Glazed Anodized Aluminium Framed Door Windows: Single Glazed Anodized Aluminium Framed Window

2 Storage Room, Panel Room, UPS Room, Battery Room

Kota Stone

Oil Bound Distemper

Oil Bound Distemper

3 Control Room Vitrified Tile Acrylic Emulsion Paint Grid Ceiling in Gypsum

4 Security Staff, Security Officer Vitrified Tile Acrylic Emulsion Paint Acrylic emulsion Paint

5

Toilets

Anti-skid Vitrified Tile

Ceramic Dado

Grid Ceiling in Perforated Metal

6

Passage

Vitrified Tile

Acrylic Emulsion Paint

Grid Ceiling in Gypsum

7

External ramps and staircase

Kota Stone

NA

NA


1 Staff and workers

Entry Lobby

Vitrified Tile


Acrylic Emulsion Paint Doors

1.Solid core wooden flush doors 2.Hollow Metal Pressed Fire Rated Steel Door Windows Single Glazed Anodized Aluminium Framed Window

2

Security Room

Vitrified Tile



3 Toilets


Ceramic Dado


4

Store Kota Stone

Oil Bound Distemper

Oil Bound Distemper

5 External ramps and staircase

Kota Stone/IPS

NA

NA

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WRITE- UP


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TCE FORM NO. 120 R3

10.3 FINISHING SCHEDULE: TRUCK DRIVER’S REST ROOMS

END OF REPORT


1

Driver’s Room

Vitrified Tile


Sheet Roofing on steel frame.

Doors: 1.Solid core wooden flush door for toilet. 2.PVC doors for WC and showers. Windows: 1. Ventilators for toilets. 2. No windows proposed to drivers’ rest room

area; it is proposed to be open between parapet wall and beam bottom.

2

Toilets


Ceramic Dado

NA

3

External ramps and staircase

Kota Stone/IPS

NA

NA

TCE.6842A-CH-2026-BS-01

TATA CONSULTING ENGINEERS LIMITED SHEET i OF iii PROCESS DESIGN BASIS

R0 08-07-2019 VK SS ABC REV. NO. DATE PREPARED

BY CHECKED BY CLEARED BY APPROVED BY FILE NAME: F-032-Rev-R3.docx TCE FORM NO. 032 R3

ASSAM PETROCHEMICAL LIMITED

TRANSHIPMENT FACILITY FOR 500 TPD METHANOL PLANT AT BIOTAMARI ASSAM

PROCESS DESIGN BASIS

DOC. FILE NAME: 6842A-BS-CH-01-Rev-R0.doc

TCE.6842A-CH-2026-BS-01 TATA CONSULTING ENGINEERS LIMITED SECTION: CONTENTS

PROCESS DESIGN BASIS SHEET ii OF iii

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TABLE OF CONTENTS

1.0 INTRODUCTION..................................................................................... 1 2.0 ABBREVIATIONS .................................................................................. 1 3.0 UNITS OF MEASUREMENT .................................................................. 2 4.0 CODES AND STANDARDS ................................................................... 3 5.0 PHYSICAL PROPERTIES ..................................................................... 3 6.0 FACILITY DESCRIPTION ...................................................................... 4 7.0 EQUIPMENT DESIGN CRITERIA ......................................................... 5 8.0 BATTERY LIMIT UTILITY CONDITIONS .............................................. 9 9.0 DESIGN PRESSURE PHILOSOPHY .................................................. 10 10.0 DESIGN TEMPERATURE PHILOSOPHY ........................................... 10 11.0 LINE SIZING CRITERIA ....................................................................... 10 12.0 SAFETY AND INSTRUMENTATION PHILOSOPHY .......................... 11 13.0 EFFLUENT COLLECTION AND DISPOSAL PHILOSOPHY ............. 12 14.0 HAZARDOUS AREA CLASSIFICATION ............................................ 12 15.0 NOISE ................................................................................................... 12

TCE.6842A-CH-2026-BS-01 TATA CONSULTING ENGINEERS LIMITED SECTION: REV.STATUS

PROCESS DESIGN BASIS SHEET iii OF iii

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REVISION STATUS SHEET

REV. NO. DATE DESCRIPTION P0 30-05-2019 ISSUED FOR REVIEW AND COMMENT R0 11-07-2019 ISSUED FOR APPROVAL

NOTE :- REVISED PORTION OF THE REPORT ARE HIGHLIGHTED IN YELLOW COLOUR.

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TATA CONSULTING ENGINEERS LIMITED SECTION: WRITEUP PROCESS DESIGN BASIS SHEET 1 OF 12

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1.0 INTRODUCTION Assam Petrochemicals Limited (APL), a public sector unit under the Govt of Assam, is a multi-core petrochemical company situated at Namrup, Assam in the district of Dibrugarh. APL is setting up a transit storage facility in Boitamari, Assam for marketing / dispatch of Methanol. The Methanol product from Namrup plant will be transported directly to the terminal by road tankers. Methanol production capacity of Namrup plant is 500 TPD. Existing Formaldehyde plant, Namrup will consume 66 TPD of Methanol. Remaining 434 TPD will be available for sale in this transhipment facility. The yearly available saleable quantity of Methanol will be 14,3220 TPA. Methanol from road tankers will be unloaded into Methanol storage tanks. As per the business requirement Methanol will be marketed from the facility by road. APL entrusted TATA Consulting Engineers Limited (TCE) to provide PMC services for the integrated facility. This document provides the basis of process design for transhipment facility.

2.0 ABBREVIATIONS The following abbreviations are used throughout this document:

Table 1: Abbreviations API American Petroleum Institute IS Indian Standards OISD Oil Industry Safety Directorate E & I Electrical /Instrumentation TPD Tons per day BIS Bureau of Indian Standards MOC Material of Construction CS Cast Steel APL Assam Petrochemical Limited

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3.0 UNITS OF MEASUREMENT Table 2: Units of Measurement

PARAMETERS UNITS Area m² Corrosion Allowance mm Density kg / m³ Dimension (diameter, length) Mm, m Volumetric Flow rate (Gas) Nm³/h Volumetric Flow rate (Liquid) m³/h Mass Flow rate kg / h Mass kg, MT Frequency Hz Head NPSH (a) m Heat exchanged kcal / h Heat Transfer Coefficient kcal / m² h °C Latent Heat kcal/kg Electrical power kW Pressure (gauge) kg / cm² (g), mmHg, mm H2O Sound Power Level dB(A) Specific Heat kcal / kg °C Surface Tension mN/m (Dynes/cm) Temperature °C Time h, s, min. Thermal Conductivity kcal / m h °C Viscosity (Dynamic) cP Viscosity (Kinematic) cSt Velocity m/s, kmph Volume m³, litres (l)

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4.0 CODES AND STANDARDS Table 3: Codes and Standards

ITEM CODE/STANDARD Storage Tanks API 650 (12th edition) Centrifugal Pumps API 610 (11th edition) Pressure Vacuum Relief Valve API 2000 (7th edition) Electrical Equipment in Hazardous Area

API RP 500/ API RP 505 (2nd edition) or IEC code 60079-14

BIS IS 7444 (1974) API 682 4th ED, Jan 2014

Pumps-Shaft Sealing Systems for Centrifugal and Rotary Pumps

ASME B31.3, 2016 Process Piping OISD 118 Standard Layouts for Oil and Gas Installations

5.0 PHYSICAL PROPERTIES

Table 4: Methanol Properties

Colour Colourless, water white Boiling point 64.5 °C at 760 mmHg Density (kg/m3) 791 at 20 °C Hygroscopicity None Odour Pure material has a slight alcoholic

odour Flash point: Open cup 16 °C Close cup 12 °C Reactivity Not dangerously reactive Solubility Miscible in all proportions with

water

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Corrosivity Slightly corrosive to metals especially in presence of moisture. Exceptions – lead and aluminium

Freezing point (-) 97.6 °C Sp. Gravity (air=1) 1.11 Flammable limits, percent by volume in air at STP

7.3 to 36

Vapour pressure at 0 °C – 0.071 kg/cm2

at 20 °C – 0.131 kg/cm2 at 40 °C – 0.344 kg/cm2 Auto-ignition temperature 470 °C Refractive index at 20 °C 1.3312 Latent heat of vaporization 262.8 cal/g at 64.7 °C Latent heat of fusion 16.4 cal/g at (-) 97 °C

6.0 FACILITY DESCRIPTION

The facility consists of storage tanks (2 nos.) with a dyke wall, loading and unloading pumps and a gantry area. Gantry shall be provided with 8 nos. of bay. Four nos. of bays will be used for unloading methanol from road tankers to storage tanks and other four bays will be used for loading Methanol from storage tank to road tankers. A Batch controller with digital control valve and mass flow meter shall be provided to monitor and control the quantity of Methanol loaded into road tanker.

6.1. Facility Capacity The storage capacity for Methanol is calculated based on 10 days production of saleable Methanol which is 4340 tons (5487 m3). Two nos. of storage tanks, each of 2744 m3 working capacity are considered for storage of Methanol. Design Margin on working capacity shall be considered 10% while calculating the dimension of the tank

o One tank will be in receipt mode.

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o One tank will be in dispatch mode. 6.2. Road Tanker to Storage Tank Unloading

(Considering 6 working days in a week.) Basis: Quantity to be unloaded = 507 ton Road Tanker capacity = 20 m3

No. of hours for unloading = 6.5 h No. of Pumps = 2 W + 1S One Road Tanker unloading Time = 0.75 hrs Based on above criteria a) Pump Capacity with 10% Overdesign b) no. of road tanker required in day c) no. of bay required shall be calculated.

6.3. Storage Tank to Road Tanker loading Quantity to be loaded per day = 507 ton Road Tanker capacity = 20 m3

No. of hours for loading = 6.5 h No. of Pumps = 2 W + 1S One Road Tanker filling Time = 0.75 hrs Based on above criteria a) Pump Capacity with 10% Overdesign b) no. of road tankers required in a day c) no. of bays required shall be calculated.

7.0 EQUIPMENT DESIGN CRITERIA 7.1. TANK DESIGN

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7.1.1. Tank Dimensions Dimension of the tank shall be finalised based on below criteria.

7.1.1.1. Working Volume For the working capacity of tank, volume is considered between high liquid level and low liquid level and the gross capacity is calculated considering volume of the working capacity. All the storage tanks are internal floating with fixed roof tank.

7.1.1.2. Level Settings Low Low liquid level (LLLL) or trip level shall be set 300 mm above the landed roof height to prevent the roof from landing during normal operation. Typically, the roof lands at 1m from bottom of tank. LLLL should be set at a minimum 1300mm. The volume between LLL and LLLL shall be min of 15minutes (based on maximum out-flow) to allow for operator response. The volume between the LLL and High liquid level (HLL) is the working volume of the tank. The volume between HLL and High High Liquid Level (HHLL) shall be minimum of 15 minutes (based on maximum in-flow) to allow for operator response. The roof landing distance from the bottom of tank needs to be confirmed with the tank vendor for finalising the tank dimensions.

7.1.1.3. Roof Speed Recommended The roof velocities during inflow & outflow are normally restricted to 2m/h for mechanical constraints pertaining to the floating roof seal. The maximum roof velocity needs to be confirmed with the tank vendor.

7.1.2. Design Pressure The storage tanks are provided with Nitrogen blanketing of normal operating pressure of 70 mmWC. Breather valve set pressure =100 mmWC Breather valve overpressure = 100% Emergency relief hatch set pressure = 250 mmWC The design pressure of (-) 60 mmWC to 300 mmWC (g) shall be considered while designing the storage tanks.

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7.1.3. Design Temperature Methanol is to be stored at ambient temperature in the storage tanks. The design temperature of tanks shall be 65 ⁰C.

7.1.4. Corrosion Allowance As material of construction of tanks is considered to be CS, 3 mm corrosion allowance for shell, bottom, internal roof and internals of the storage tanks shall be considered while calculating the thickness of the tanks and corrosion allowance of 1.5 mm shall be considered for external roof. Cathodic Protection system is provided for tanks.

7.1.5. Drainage Tanks bottom plates shall be provided with draw-off sumps as per the design code API 650. The size of the draw-off sumps and the nozzle shall be as per the MDS of respective tanks. The slope of 1:100 shall be provided to the base plate for proper drainage to the drainage sump for storage tank. Drainage from two storage tanks shall be collected in CBD vessel of 10m3 capacity. From CBD vessel, fluid shall be pumped back to storage tank.

7.1.6. Manholes Floating roof tanks shall have at least one manhole on the roof for providing access to the tank interior and for ventilation when the tank is empty. Each tank pontoon is also individually provided with a 500 mm manhole with tight gasketed and bolted covers for access into the floating compartment. Shell manholes shall be provided to gain access into the tank for cleaning, inspection and repairs. The table below gives the minimum recommended size and number of manholes for floating roof storage tanks:

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Table 5: Number of manholes for floating roof storage tanks

Nominal Diameter of tank (m)

Number and size of Manholes

Shell Floating Roof No Size (mm) No Size (mm) Upto 18 1 600 1 900 1 900 >18 to 27 1 600 2 900 1 900 >27 2 600 2 900 1 600

For internal floating roof tanks, a manhole of minimum 600 mm ID should be provided on the fixed roof. A ladder shall be provided near the manhole for access from the roof to the internal floating cover. It shall be designed to accommodate the full travel of the floating roof.

7.1.7. Vents Vents with breather valve shall be provided in each of the storage tank. The overall capacities shall be determined in accordance with the provisions of API 2000. For normal operating condition breather valve is designed for out breathing case only and for inbreathing, nitrogen inflow to be considered. At emergency condition, in-breathing of air through breather valve to be considered.

7.1.8 Design Capacity 10% excess (overdesign) is considered while designing equipment and others. 7.2. ROAD TRAKER LOADING ARM DESIGN

Fluid Methanol Design Code API RP 1004

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Design Temperature 65°C Rating # 150 MOC CS

Based on section 6.3, no. of loading arm requirement, capacity and diameter shall be calculated.

7.3. PUMP DESIGN

FLUID Loading Pump Unloading Pump Design Code API 610 API 610

Type Centrifugal pump Centrifugal pump Sealing

Arrangement Double Mechanical Seal Double Mechanical Seal Qty Minimum one standby Min. one standby

Design Temp. 65 °C 65 °C Rating # 150 # 150

Corrosion allowance 3 mm 3 mm

MOC CS CS

7.3.1. Hydraulics For any pump designs and hydraulics calculations following design conditions are considered. - Margin on NPSH available shall be considered as 1 mlc. - Margin on differential head shall be considered as 5 mlc.

8.0 BATTERY LIMIT UTILITY CONDITIONS Utility pressure and temperature, as made available at battery limits of process unit, as indicated below:

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Table 6: Utility conditions at battery limit

Utility Operating Temperature @ Battery Limit (°C)

Operating Pressure @ Battery Limit Kg/cm2 (g)

Remarks

Nitrogen AMB More than 2 bar (g) Instrument Air -40 deg C ATM Service Water AMB More than 2 bar (g) Power Voltage 415 V, Frequency 50Hz, 3 Phase

9.0 DESIGN PRESSURE PHILOSOPHY For Tanks

The storage tanks are provided with Nitrogen blanketing of normal operating pressure of 70 mmWC. Breather valve set pressure = 100 mmWC Breather valve overpressure = 100%. Emergency relief hatch set pressure = 250 mmWC The design pressure of (-) 60 mmWC to 300 mmWC (g) shall be considered while designing the storage tanks.

10.0 DESIGN TEMPERATURE PHILOSOPHY For temp (operating) > 0°C and <50°C, design temp shall be 65°C.

11.0 LINE SIZING CRITERIA Recommended velocities considered for various services while doing line sizing are mentioned below

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Table 7: Line Velocities

SERVICE VELOCITY (m/s) Process Liquid 1.2-2 Pump Suction 0.3-1.52 Drain Lines 0.45-1.22 Nitrogen 15 (for blanketing) Compressed Air 15

Typical pressure drop range considered for line sizing and pump hydraulics calculations is as follows:

Table 8: Pressure Drop

LINE TYPE Typical allowable ∆P in line, (kg/cm2/100m)

Pump Suction 0.115-0.288 Pump Discharge 0.23-1.15 Gravity Flow 0.011

12.0 SAFETY AND INSTRUMENTATION PHILOSOPHY

a) Tank Instrumentation Both storage tanks are to be provided with the tank gauging system. In the tank gauging system, storage tank is provided with one servo and one radar type level transmitter, pressure transmitter and multi point temperature element measuring average temperature level. Additional float type local level instrument is considered for each storage tank. Pressure transmitter is to be provided to control the flow rate of Nitrogen from the control valve to maintain the pressure in the external roof area.

b) Safety Instrumentation Inert gas blanketing is used in external roof of the storage tanks to prevent

formation of explosive atmosphere within tank vapor spaces. Dry nitrogen is the preferred inert gas for blanketing.

The normal operating pressure of the Nitrogen blanketing is 70 mmWC.

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Breather valve is provided on the storage tank to avoid over pressuring or under pressuring of the tank. The breather valve is designed for set pressure of 100 mmWC and overpressure of 100%. The overall capacities of breather valve shall be determined in accordance with the provisions of API 2000.

Emergency relief hatch is provided for each tank at a set pressure of 250 mmWC which is designed for fire case.

c) Gantry instrumentation Each loading bay shall be provided with Batch controller with Digital control

valve. Mass flow meter shall be provided to monitor and control the quantity of Methanol into road tanker.

13.0 EFFLUENT COLLECTION AND DISPOSAL PHILOSOPHY 13.1. All the drains from equipment and pipe lines shall be done locally. 13.2. Effluent collection pit shall be used for surface drain. The collected effluent from

the collection pit will go to nearby effluent treatment plant. For sizing of effluent pit, first 10 min. of rain water from the dike is to be considered.

13.3. Vent & Pressure Vacuum Relief Valve discharge shall be provided upwards to the atmosphere at a safe location (minimum elevation of 3 meter from the highest point).

14.0 HAZARDOUS AREA CLASSIFICATION Dyke area and gantry area shall be classified as Zone 1, gas group II A and temperature class T1.

15.0 NOISE Noise level from all rotating equipment shall be < 85 dB (A) at 1 meter distance from the source of noise.