Cvc 01015

TECHNICAL CORRECTIONJune 2001

Process Industry PracticesCivil

PIP CVC01015Civil Design Criteria

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice hasbeen prepared from the technical requirements in the existing standards of majorindustrial users, contractors, or standards organizations. By harmonizing thesetechnical requirements into a single set of Practices, administrative, application, andengineering costs to both the purchaser and the manufacturer should be reduced. Whilethis Practice is expected to incorporate the majority of requirements of most users,individual applications may involve requirements that will be appended to and takeprecedence over this Practice. Determinations concerning fitness for purpose andparticular matters or application of the Practice to particular project or engineeringsituations should not be made solely on information contained in these materials. Theuse of trade names from time to time should not be viewed as an expression ofpreference but rather recognized as normal usage in the trade. Other brands having thesame specifications are equally correct and may be substituted for those named. AllPractices or guidelines are intended to be consistent with applicable laws andregulations including OSHA requirements. To the extent these Practices or guidelinesshould conflict with OSHA or other applicable laws or regulations, such laws orregulations must be followed. Consult an appropriate professional before applying oracting on any material contained in or suggested by the Practice.

This Practice is subject to revision at any time by the responsible Function Teamand will be reviewed every 5 years. This Practice will be revised, reaffirmed, orwithdrawn. Information on whether this Practice has been revised may be found athttp://www.pip.org.

© Process Industry Practices (PIP), Construction Industry Institute, TheUniversity of Texas at Austin, 3208 Red River Street, Suite 300, Austin,Texas 78705. PIP member companies and subscribers may copy this Practicefor their internal use. Changes, overlays, addenda, or modifications of anykind are not permitted within any PIP Practice without the express writtenauthorization of PIP.

PRINTING HISTORYJune 1999 IssuedJune 2001 Technical Correction

Not printed with State funds

TECHNICAL CORRECTIONJune 2001

Process Industry Practices Page 1 of 10

Process Industry PracticesCivil

PIP CVC01015Civil Design Criteria

Table of Contents

1. Introduction..................................21.1 Purpose ............................................. 21.2 Scope................................................. 2

2. References ...................................22.1 Process Industry Practices ................ 22.2 Industry Codes and Standards .......... 22.3 Government Regulations ................... 3

3. Definitions ....................................3

4. Environmental Protection ...........44.1 Groundwater Protection..................... 44.2 Surface Water Protection .................. 44.3 Public Safety...................................... 4

5. Geotechnical EngineeringInvestigations .............................4

6. Site Preparation and Grading .....5

7. Excavation and Backfill...............5

8. Erosion Control............................6

9. Railroad Work............................. 6

10.Roads, Paving, and Surfacing... 6

11.Curbs, Gutters, and Walks ........ 7

12.Underground Utility PipingSystems ...................................... 812.1 Pressurized Water Distribution ... 812.2 Natural Gas ................................. 812.3 Cathodic Protection..................... 8

13.Sewers ........................................ 813.1 General ....................................... 813.2 Storm Sewers and Drainage ....... 913.3 Sanitary Sewers .......................... 913.4 Process Sewers .......................... 9

14.Fencing ..................................... 10

15.Landscaping, Seeding, andSodding..................................... 10

PIP CVC01015 TECHNICAL CORRECTIONCivil Design Criteria June 2001

Page 2 of 10 Process Industry Practices

1. Introduction

1.1 Purpose

This Practice provides the civil engineer with criteria for the design of civil siteworkwithin process facilities.

1.2 Scope

These general criteria define the minimum requirements for the design of civilsitework of process industry facilities at onshore U.S. sites. Included is all workrelated to preparation of the site; such as grading, roads and railroads, undergroundutility and sewer work and related facilities, and all work related to finishing the site.This Practice is intended to be used in conjunction with PIP CVC01016, Plant Siteand Project Data Sheets.

2. References

Applicable requirements in the following PIP Practices, codes and standards, andgovernment regulations shall be considered an integral part of this Practice. The edition ineffect on the date of contract award shall be used, except as otherwise specified. Short titleswill be used herein when appropriate.

2.1 Process Industry Practices (PIP)

– PIP CVC01016 - Plant Site and Project Data Sheets - Introduction andReferences

– PIP CVC01017 - Plant Site Data Sheet

– PIP CVC01018 - Project Data Sheet

– PIP CVE02705 - Engineering Guide for Double Contained Sewers (Pipe inPipe Systems)

– PIP CVI02720 - Sewer Details

– PIP CVS02010 - Geotechnical Engineering Investigation Specification

– PIP CVS02100 - Site Preparation, Excavation, and Backfill Specification

– PIP CVS02700 - Underground Gravity Sewers Specification

– PIP CVS02831 - Chain-Link Fencing Construction Specification (in Process)

2.2 Industry Codes and Standards

• American Association of State Highway and Transportation Officials (AASHTO)

– AASHTO Standard Specification for Highway Bridges

• American Railway Engineering Association (AREA)

– AREA Manual for Railway Engineering

TECHNICAL CORRECTION PIP CVC01015June 2001 Civil Design Criteria


• American Society of Mechanical Engineers

– ASME B31.3 - Process Piping

• American Water Works Association (AWWA)

– AWWA Standards

• National Fire Protection Association (NFPA)

– NFPA 20 - Installation of Centrifugal Fire Pumps

– NFPA 22 - Water Tanks for Private Fire Protection

– NFPA 24 - Installation of Private Fire Service Mains and TheirAppurtenances

– NFPA 30 - Flammable and Combustible Liquids Code

2.3 Government Regulations

• Americans with Disabilities Act (ADA)

• U.S. Environmental Protection Agency (EPA)

– EPA 40 CFR - U.S. Environmental Protection Agency Regulations

• U.S. Department of Transportation (U.S. DOT)

– U.S. DOT Pipeline Safety Regulations

3. Definitions

For the purposes of this Practice, the following definitions apply:

Cathodic Protection: A technique used to prevent corrosion of a metal surface by makingthat surface the cathode of an electrochemical cell

Contract Documents: Any and all documents, including design drawings, that have beentransmitted or otherwise communicated, either by incorporation or reference, and made partof the legal contract agreement for civil structural work

DOT: The department of transportation for the state in which the project site is located orthe equivalent government organization

Non-Contact Cooling Water: Cooling water that does not have direct contact with processfluids or materials. Cooling water may be recirculated or used only once and conveyedthrough gravity drainage systems.

Owner: The owner of the proposed facilities

Process Sewers: Any waste collection/drainage system carrying materials (exclusive ofsanitary waste) requiring treatment before discharge

RCRA: Resource Conservation and Recovery Act



4. Environmental Protection

4.1 Groundwater Protection

4.1.1 Storage facilities and process infrastructure (e.g., process loading/unloading,petroleum storage, hazardous material storage) shall be designed to protectagainst groundwater contamination. Examples include drip pans, paving, andconcrete containment.

4.1.2 New tanks below grade shall meet underground storage tank regulations inEPA 40 CFR, Part 280 UST.

4.1.3 Tank farm areas for RCRA hazardous materials storage shall be floored anddiked with materials impervious to the stored material for spill containment.Diked areas shall be designed to contain 100% of the largest RCRA tankvolume plus runoff from a 25-year, 24-hour rainfall, and with 6 inches (150mm) of freeboard.

4.1.4 RCRA hazardous waste storage tanks shall be installed to meet therequirements of EPA CFR 40, Part 264 and Part 265.

4.2 Surface Water Protection

4.2.1 To facilitate the control of contaminants and minimize the mixture of flowconstituents, drainage and sewer systems should be segregated wherepossible. Optimally, provide complete segregation of clean storm, sanitary,process, fire water, and Non-Contact Cooling Water sewers.

4.2.2 Sewers that carry water not normally subject to contamination (Non-ContactCooling Water or storm water) and that have the potential to receive spillsshall have monitoring and diversion capabilities.

4.2.3 Building floor and roof drains not subject to process spills shall connect tothe clean storm water drainage system.

4.3 Public Safety

Facilities for the storage, handling, and use of flammable and combustible liquidsshall conform to NFPA 30.

5. Geotechnical Engineering Investigations

5.1 Geotechnical engineering investigations shall be performed in accordance withPIP CVS02010 when sufficient geotechnical information is not available.

5.2 The design engineer shall provide the following technical information to thegeotechnical consultant when this information is available and appropriate:

5.2.1 Site plan showing proposed facilities and adjacent existing facilities

5.2.2 Topographic plan or relative elevations of existing grades and facilities toplanned grades of proposed facilities

5.2.3 Descriptions of proposed and existing facilities, including the following:



a. Types of structures

b. Anticipated design loads under various design cases, including staticcompression, uplift, horizontal shear, vibratory, dynamic, and blast

c. Any settlement sensitivity of structures or equipment

d. Any sensitivity to vibration from external sources, of both proposedand existing facilities

e. Special or unusual conditions: pits, basements, elevator shafts,reciprocating compressors, retaining walls, etc.

f. Elevations: building ground floor, bottom of pits, basements, elevatorshafts, walls, tanks, etc.

g. Proposed finish grade elevation adjacent to facilities

h. For tanks, load condition (empty, full, test, and operating weights);operating condition i.e., full most of the time, empty most of the timeplus time/duration when full, percentage full under operatingconditions, etc.); and settlement tolerances

i. Pavement loading and traffic data (when pavement recommendationsare needed)

j. Information regarding any known or potential soil/groundwatercontamination at the site

k. Drawings and other information for adjacent or on-site existingfacilities, including underground utilities and structures

6. Site Preparation and Grading

6.1 The design of site preparation activities, including clearing and grubbing, stripping,and general site grading shall be compatible with the requirements ofPIP CVS02100.

6.2 Excavation, fill, stockpile and disposal areas, and the extent of clearing and grubbingareas shall be defined in the Contract Documents. Consideration shall be given tobalancing the cut and fill for earthwork.

6.3 All demolition shall be specified in the Contract Documents.

6.4 Vehicular traffic detours shall be designed to provide a safe routing and asatisfactory means of controlling traffic.

7. Excavation and Backfill

7.1 The design of excavation and backfill shall be compatible with the requirements ofPIP CVS02100.

7.2 Areas requiring differing levels of compaction shall be noted on the drawings by theengineer. These areas include structure areas, roadways, railroad subgrades, paved



area subgrades, utility trenches, embankments and dikes, and general graded areasoutside the process or work areas.

8. Erosion Control

8.1 Due to the condition of the site based on forecasted construction activities, erosionand sedimentation controls must be given special consideration in design. Soilerosion control shall be designed to comply with federal, state, and local regulationsand shall be compatible with PIP CVS02100.

8.2 The need for erosion control permitting shall be identified and shall be submittedthrough the Owner.

9. Railroad Work

9.1 All railroad design shall be in accordance with the AREA Manual and the localoperating railroad requirements.

9.2 Railroads shall be standard gauge and meet design, condition, and maintenancerequirements for class II (minimum) track systems as defined by AREA.

9.3 No. 1 prime relay rail may be used.

9.4 The minimum turnout (frog number) shall be No. 8.

9.5 The maximum grade, unless otherwise required by local topography, shall be 2%.Loading stations should be designed level.

9.6 The maximum degree of curvature shall be 12 degrees 30 minutes.

9.7 The rail unit weight and rail type shall be selected to be compatible with the existingrail system and to provide the desired design life based upon the intended service andavailability.

9.8 A drainage system shall be designed to meet individual job requirements. Perforatedunderdrain systems with standpipes at 50-feet (15-m) intervals should be providedbetween parallel tracks and when adjacent grade is near the same elevation or higherthan the railroad track.

9.9 A geosynthetic material shall be installed between the subgrade and ballast whenrequired to prevent fouling.

10. Roads, Paving, and Surfacing

10.1 Roadways, parking areas, and paved areas shall be surfaced using materials specifiedin PIP CVC01017 and PIP CVC01018.

10.2 Roads shall have a vertical curve when the algebraic difference of the road gradientsis 2% or greater. The minimum length of a vertical curve shall be 100 feet (30 m).

10.3 Roads shall be designed for AASHTO HS20 truck loading. Selection of materials ofconstruction shall be in accordance with DOT highway specifications. Thickness ofmaterials (concrete, or asphaltic, or granular bases and surfaces materials) shall be



designed according to the design traffic loading and geotechnical data of thesubgrade and conforming to DOT highway specifications.

10.4 Roadway shoulders, curbs, sideslopes, drainage ditches, and culverts shall bedesigned in accordance with DOT specifications where practical.

10.5 The maximum grade for roadways shall be 6%. The minimum cross slope forroadways shall be 2%.

10.6 The minimum inside turning radius shall be 50 feet (15 m) for tractor-trailers, 30 feet(9 m) for stake body trucks, and 25 feet (7.5 m) for passenger cars and pickup trucks.

10.7 The minimum sight distance shall be 200 feet (60 m).

10.8 Design of roadways shall include clearance and loads for construction andmaintenance equipment (e.g., cranes).

10.9 The roadway pavement design shall include a drainage system to prevent saturationof the base and subgrade.

10.10 Guide rails along roadway embankments shall be designed in accordance with DOTspecifications. Guide rails or bollards shall be designed to protect equipment (e.g.,electric substations, natural gas valves) along plant streets.

10.11 Minimum slope for Portland cement concrete and asphalt area paving shall be 1%.

10.12 Portland cement concrete area paving shall be a minimum of 4 inches (100 mm)thick.

10.13 Portland cement concrete area paving shall have contraction or construction joints ata maximum spacing of 25 feet (7.5 m) in both directions unless otherwiseengineered. Reinforcing required by design shall be provided across constructionjoints. Expansion joints are not required except at foundations and for other itemspenetrating through Portland cement concrete paving.

10.14 Asphalt area paving shall be designed for the anticipated traffic load in accordancewith AASHTO design requirements but shall not be less than 2 inches (50 mm)thick.

10.15 Gravel surfacing shall be placed to a minimum compacted thickness of 3 inches(75 mm).

11. Curbs, Gutters, and Walks

11.1 Walks shall be provided to interconnect the parking lot, gatehouse, administrationbuilding, cafeteria, process buildings, etc., to adjacent roadways for safe pedestriantravel.

11.2 The walkway subbase shall be in accordance with PIP CVS02100.

11.3 Walkway grades without steps shall not exceed 6%.

11.4 Finished grades shall be shown on the engineering drawings.

11.5 All curbs, gutters, and walks shall be designed to comply with ADA requirements.



12. Underground Utility Piping Systems

12.1 Pressurized Water Distribution

12.1.1 Water distribution systems shall be designed to supply adequate flow andpressure at all points of usage and shall meet requirements of AWWAStandards and local codes.

12.1.2 If the Owner has existing models of the systems, the models shall be utilizedto determine if adequate flow and pressure are available and to ensure thatother parts of the system will not be adversely affected.

12.1.3 Fire water distribution systems shall meet the requirements of NFPA 20,NFPA 22, NFPA 24, and the Owner’s insurer.

12.1.4 System design shall include sufficient restraint of pipefittings and valves toprevent movement during normal and anticipated water hammer conditions.

12.2 Natural Gas

12.2.1 Natural gas distribution systems shall be designed to supply adequate flowand pressure at all points of usage while operating at acceptable noise levels.

12.2.2 Valve spacing shall be such that a section of main can be shut down quicklyin the event of an emergency.

12.2.3 Systems shall be designed in accordance with the U.S. DOT Pipeline SafetyRegulations for outside of buildings and with ASME B31.3 for inside ofbuildings.

12.3 Cathodic Protection

12.3.1 Cathodic protection for corrosion control may be required on undergroundcarbon steel structures including piping. Cathodic protection of otherunderground lines in the area may be necessary at times to ensure theintegrity of the process lines.

12.3.2 External coatings shall be used in conjunction with cathodic protection.

13. Sewers

13.1 General

13.1.1 Sewers and drainage systems shall be designed to protect the atmosphere,soil, surface water, and groundwater from contamination and to provide safe,economical collection and flow of all sewage to treatment and/or holdingfacilities and subsequently to approved disposal.

13.1.2 When specified by Owner, open channel ditches and basins that potentiallyconvey or retain groundwater contaminants (e.g., fire water runoff) shall belined. Lining material shall meet Owner-specified permeabilityrequirements.



13.1.3 When specified by Owner, each sewer system shall be designed forincreased flow from future sewer extension or from changes in surfaces thatchange the runoff coefficients.

13.1.4 Existing systems to which new systems will connect shall be reviewed toverify service compatibility and to ensure that sufficient capacity is availableto accept the additional flow, unless the Owner has provided a written noticethat the downstream system can accommodate the additional flow.

13.1.5 Manholes shall be located at spacing intervals to facilitate maintenance,inspection, and cleaning. Manholes or cleanouts shall be provided at changesin horizontal direction. Maximum spacing of manholes shall be 200 feet(60 m) for sewers less than or equal to 12 inches (300 mm) in diameter, and500 feet (150 m) for sewers larger than 12 inches (300 mm) in diameter.

13.1.6 Sanitary and process sewers shall be designed to cross under potable waterlines. Provide at least 12 inches (300 mm) of vertical clearance and36 inches (900 mm) of horizontal clearance when sanitary or process sewersparallel the water line, unless otherwise required by local codes.

13.1.7 Minimum pipe sizes shall be 4 inches (100 mm) for laterals and 8 inches(200 mm) for main sewers.

13.2 Storm Sewers and Drainage

13.2.1 Design storm sewers to be compatible with PIP CVS02700 andPIP CVI02720.

13.2.2 Sewers and drainage structures shall be designed to carry runoff from a rainevent as defined in PIP CVC01018. Unless otherwise specified, maximuminlet times shall be taken as 15 minutes for process areas with catch basinspacing of approximately 100 feet (30 m). Inlet times for large undevelopedareas shall be determined for each project, with special consideration forfuture development, but shall not exceed 30 minutes unless otherwisespecified by the Owner.

13.2.3 Piping design flow depth shall not exceed 2/3 the pipe diameter.

13.2.4 The minimum design velocity shall be 3 fps (0.9 m/s) at design capacity.

13.3 Sanitary Sewers

13.3.1 Design sanitary sewer systems to be compatible with PIP CVS02700 andPIP CVI02720.

13.3.2 The minimum design velocity shall be 2 fps (0.6 m/s) with pipe flowing 1/2full at maximum flow rate.

13.4 Process Sewers

13.4.1 Underground process sewers shall be designed to protect againstgroundwater contamination. Underground process sewers shall be designedto prevent potential leakage caused by anticipated corrosion, surface loads,shifting soils, water tables, etc., for the Owner’s specified design life.



Underground process sewer joining systems shall be welded, fused, or gluedunless otherwise specified.

13.4.2 Design underground process sewers to comply with Owner’s health andenvironmental requirements and to be compatible with PIP CVS02700 andPIP CVI02720. If a double-contained pipe in pipe system is required, thendesign in accordance with PIP CVE02705.

13.4.3 Process sewer designs shall comply with regulations in EPA 40 CFR.

13.4.4 Sewers requiring vents shall be determined by Owner requirements or asrequired due to the properties of the chemicals contained in the sewers.Collection systems shall be trapped and sealed to prevent personnel exposureto emissions. Sewers and vents shall be designed to comply with regulationsdirected at the control of volatile organic compound (VOC) and hazardousair pollutant (HAP) emissions. Vents shall be located away from normaloperating areas and shall be equipped for secondary VOC emission disposal(e.g., scrubbed, flared, etc.) if required.

13.4.5 Design flow depth of gravity process sewers shall not exceed 3/4 of the pipediameter, with a minimum velocity of 3 fps (0.9 m/s).

14. Fencing

Chain-link fencing shall be in accordance with PIP CVS02831 (in process).

15. Landscaping, Seeding, and Sodding

15.1 Surface treatments shall be shown on the final earthwork drawings.

15.2 Seeding and sodding shall comply with DOT specifications.

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