STANDARD DESIGN BASIS

MODULAR STRUCTURES. 
Read this document in conjunction with the following docs.
STANDARD DESIGN BASIS.

STANDARD DESIGN PRACTICE.

1.0 SCOPE OF WORKS :

    This standard covers the minimum requirements for structural

engineering, design, materials, fabrication, & erection of modular
structures in steel. Modules are compact layout of equipments resting on
structural framing with minimum piping & electrical cabling. Modules are
fabricated under controlled conditions in factories, resulting in quality
product compare to structures fabricated at site. Once the modules are
complete they are transported to the proposed site & directly erected on
foundations.

2.0 CODES AND STANDARDS :

    All structural & miscellaneous steel shall be designed, fabricated, &

erected in accordance with :

    IS: 800 ........ Code of practice for General Construction in steel.

3.0 MATERIALS OF CONSTRUCTION:

    Structural steel quality shall be Mild steel, conforming to IS 2062.

    Bolts used in structural connections shall conform to IS 1367.

4.0 STANDARD STRUCTURAL CALCULATIONS :

  4.1 SOFTWARE :

    STAAD III / StruCAD  or any approved software, capable of performing

3D analysis.

  4.2 DESIGN LOADS :

    The structural design loads & forces used for design are specified as
below:

    DEAD LOADS :

    Dead loads are defined as the total weight of the module structure &
components fixed to the structure, such as empty vessels, equipment,
fire proofing, insulation, piping & electrical conduits.

    OPERATING LOADS :

    Operating loads are defined as Dead Loads + the weight of any liquids or
solids present within the vessels, equipment or piping.

    TEST LOADS :

    Test loads are defined as Dead Loads + the weight of any liquid
necessary to pressure test vessels, equipment or piping.

    LIVE LOADS :

    Live loads are defined as the weight of all movable loads such as
personnel, tools, miscellaneous equipment, movable partitions, hoist &
stored materials. Live loads shall also include unusual loading such as
may occur during regeneration, upset or mis-operation conditions.
    WIND LOADS :

    Wind loads are determined in accordance with IS: 875.

    EARTHQUAKE LOADS :

    Earthquake loads are defined as the horizontal & vertical static force
equivalent in their design effect to the dynamic loads generated by
ground motion during a earthquake. Structures are designed for
earthquake, when applicable, in accordance with IS:1893. Importance
factor (I) = 1.0

  4.3 LOADS COMBINATIONS :

    The structural design should consider the following load combination as a

minimum :

    LOAD
DESIGN LOADS
COMBINATIONS
DEAD LOADS.
ERECTION/ UN- IMPACT LOAD { 50% OF DL }
LOADING
DESIGN WIND OR EARTHQUAKE
LOAD. WHICHEVER IS GREATER.
TEST LOAD.
TESTING 50 % OF DESIGN LIVE LOADS.
50 % OF WIND LOADS.
OPERATING LOADS.
NORMAL LIVE LOADS.
OPERATION
DESIGN WIND OR EARTHQUAKE
LOAD, WHICHEVER IS GREATER.
LIFTING / DEAD LOADS.
LOADING IN
TRAILERS  LIFTING LOADS WITH IMPACT.
LIFTING LUGS WILL BE CAPABLE OF LIFTING THE
REQUIRED HEAVIEST LOAD + 50 % EXTRA AS IMPACT
LOAD. WHILE DESIGNING LUGS/HOOKS DUE ATTENTION TO
BE PAID TO ANGLE OF INCLINATION OF CABLE W.R.T. LUG
& MEMBER.

  4.4 ACCEPTANCE CRITERIA :

    Stress ratios of all beams shall be < 1.0

    Deflections of all beams shall be < 1ũ 240 of span.

    Center
of gravity { CG } of module & that of Lifting Mechanism should
coincide theoretically, so as to avoid any tilting of module during
lifting.
The matching of CG shall be re-checked after completion of module
& any
adjustment required to lifting mechanism/cables shall be made.
5.0 DESIGN & FABRICATION PRACTICES.

  5.1 The configuration of the modules shall be BOX type.

  5.2 The modular structure shall be all welded structure & constructed of MB,
MC, ANGLES OR BOX sections. Contractor should produce a composite
fabrication drawing of module after receiving all the structural, piping,
 electrical, instrumentation & equipment/vessel drawings from the
consultant. Fabrication of module should commence after review of
fabrication drawings by consultant.

  5.3 All modules shall have minimum of 4 lifting lugs/hooks, two on each side,
designed for two point lift with the help of spreader bar.

  5.4 The modular base is designed to receive a concrete fill so that the filled
base provides a smooth, easily maintained operating surface. The base
will be an integral part of the finished raft/mat foundation. Alternately
the foundation can be in the form of isolated footings connected with
grade framing beams. The grade beams are expected to take up major
operating equipment loads, located at grade level within the module &
transfer it to foundations. Grade can be left unfilled & walking surfaces
may be provided with galvanized grating, but concrete filled base is
preferable as it provides a smooth, easily maintained operating surface.
Foundation loading & anchor bolt details should be provided to others for
foundation design & construction.

  5.5 Primary pipe supports designed for the required load, are an integral part
of the skid & will be welded to the skid base.

  5.6 Platforms, with ladder access, will be provided for items 7 feet or more
above the operating surface which require operator attention atleast
once per day. Platforms shall be designed for 500 Kg/M2 live load.
Walking surfaces of elevated platforms shall be galvanized steel gratings.
All handrails, ladders, stair treads & channel etc. shall also be galvanized.

  5.7  Use standard grating details for platforms & elevated walkways.

  5.8  All modules shall have a drainage system. An all welded pipe header,
with riser for collection of all process drain points will be installed inside
the module base.

  5.9 All field connections shall be of welded type. Bolts can be used only for
erection/alignment  purposes.

  5.10 Gusset/end plates shall not be less than 10 mm thick.

  5.11 Dimensions of handrails & guard rails are as given in Standards.

  5.12 Welding shall conform to IS-816: Code of practice for use of metal arc
welding for general construction in mild steel.

  5.13 The structure shall be primed & painted  with one shop coat of red oxide
zinc chromate paint & two finish coats of enamel paint in approved shade
& color. The portion of structural steel requiring fire proofing shall not be
painted.

  5.14 For galvanized members the maximum length shall be restricted to the
size of locally available Galvanizing tank. Piperack to Module base
connection & the stringer to piperack connections are to be bolted
construction.
6.0 LIFTING OF MODULAR STRUCTURE :

  6.1 Modular structure can be lifted from the base frame or from the frame
available at the top of structure.

  6.2 Lifting can be carried out by using cables, spreader bar or  frames. One or
more cranes can be used for simultaneous lifting from multiple hook
points.

  6.3 In case shipper/transporter uses jacks instead of cables, then jacking

shall be done at hook locations only.

7.0 TRANSPORTATION / SHIPPING :

  7.1 Size of module & weight is restricted by statutory road regulations of that
country. It depends up on the available road width, clear height at
crossings, bridges & tunnels etc. & permissible class of loading on
highways. In INDIA the module size is restricted to 4.5 m x 4.5 x 20 m
length & weight less than 70 tons.

  7.2 Proper precautions shall be taken during loading, unloading & transit of
module. Suitable temporary horizontal & vertical bracings/props shall be
provided to connect various members of the structure & also the
projected vessel/ equipment, panel  parts as the safeguard against
mishap /impact or undue tilting of module.

  7.3 Modules shall be suitably enclosed by timber/plywood container to

safeguard against air, dust, rain & theft.

  7.4  All openings in pipes shall be plugged before transit.

8.0  FABRICATION YARD :

  8.1 All modules shall be fabricated on a hard standing construction on a firm

soil commensuration with expected weight of module.

  8.2 There shall be no settlement or sagging of base at fabrication yard.

Proper drainage shall be provided for the fabrication area.