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1. GENERAL
1.1 Introduction

Proposed ULO re-refining facility is spread over an area of around 23 acres and has an annual
capacity of producing 60,000 MT of refined lube oil base stock out of used lube oil in first phase.
This facility covers a process plant, utilities building, loading and unloading bay, hydrogen
generation unit, waste water treatment unit, lube oil blending unit, drum storage area, firefighting
area, electrical room, control room, a well-e quipped lab (for testing the feed and product
specifications periodically), cooling tower, DM water and soft water generation area,
maintenance shop & chemical storage area, a spacious admin building with parking lot and
open space for future expansion of process plant, utilities are and tank farm.

A major tank farm (with tanks to store feed oil, products, intermediate products and by-products
of the process) should be installed to store feed & products in bulk. However process
intermediate tank will be located close to process plant area.

1.2 Scope of work

This document describes the civil and structural design basis for the facility’s structures and
general civil works. All civil/structural works will be designed in accordance with applicable
codes, industry standards and local and state regulations.

1.3 Units of Measurement

All units of measurement shall be based on the Metric System of Measurement. The following un
its shall be used:

Sr. No. Application Unit of Measurement

1 Temperature °C or K
2 Pressure, gauge bar-g ,
3 Pressure, absolute bar-a OR mbar, mmWC
4 Pressure Drop Bar
5 Vacuum mbar
6 Mass kg
7 Volume – Liquids / Solids m3 OR Lt(Liter)
8 Volume – Gases (or at flow condition) Nm3
9 Liquid Flow rates – Mass Kg/hr
10 Liquid Flow rates – Volumetric m3/hr
11 Gases Flow rates – Mass Kg/hr
12 Gases Flow rates – Volumetric Nm3/hr
13 Steam flow rate kg/h
14 Heat Kcal
15 Heat Transfer Coefficient Kcal / m2.hr.oC
16 Latent Heat Kcal/Kg
17 Sensible Heat Kcal/kg
18 Specific Heat Kcal/kg. °C
19 Fouling Factor m2-hr- °C/Kcal
20 Heat Duty Kcal/hr
21 Power kW
22 Dynamic Viscosity cP
23 Kinematic Viscosity cSt
24 Liquid density kg/m3
25 Vapor density kg/m3
26 Equipment dimension mm
27 Length m
28 Pipe Diameter / Pipe Size NB
29 Thickness mm
30 Area m2
31 Velocity m/s
32 Nozzle sizes NB
33 Noise Level dB
34 Stresses N/mm2
35 Force N
 36 Flange Rating lbs. or #
37 Current A
38 Level indication in control room % Or mm
39 Electrical Resistance ohm
40 Electrical conductivity µs/cm
41 Vibration mm/s
42 Product concentration ppm (w or v) or wt.%
43 Frequency Hz
44 Voltage V
45 Specific Heat Gas Ratio Cp/Cv
46 Gas Constant J/Kg.K
47 Molecular Weight gm/mol

2. SITE CONDITIONS
2.1 Plant layout and Access

The facility will be laid out to accommodate the spaces required to service equipment as well as
to maintain and operate the plant. Access aisles and clearance will be provided for safe
operation, maintenance, inspection, and equipment removal. Provisions will be made for
personnel walkways including, doors, stairs, landings, ladders, and other approved access
means.

Personnel and plant maintenance equipment access to plant equipment, piping and their related
features will include the following:

 In plant equipment areas, personnel access aisles for operation and maintenance
activities will nominally be 1.20 m wide and 2.30 m high.
 The plant will be subdivided into separate fire areas as determined by a Fire Risk
Evaluation for the purpose of limiting the spread of fire, protecting personnel, and limiting
the resultant consequential damage to the plant.
 Adequate clear space will be provided above equipment to ensure that foundation bolts
or other devices do not obstruct removal.
 Plant fire protection and life safety features will be considered in the plant layout and be
designed in accordance with local codes, permits, and insurance requirements.
2.2 Site work

Clearing, excavation, backfill, and grading will be performed as required to construct the
facility and achieve finished site grades as described in this section and dedicated
documents.
2.2.1 Site Clearing
The site will be cleared of trees, shrubs, and vegetation to the extent necessary to construct
the facility. Provisions for special features (i.e., trees, monuments, or other items) that are to
remain and be protected during construction shall be made.
2.2.2 Excavation
Excavation work will consist of the removal of earth, sand, gravel, vegetation, organic
matter, rock, boulders, and debris to the lines and grades necessary for construction.
Materials suitable for backfill will be stockpiled at designated locations using proper erosion
protection methods. Disposal of any excess uncontaminated backfill material will be to a
designated landfill area. Dewatering of excavations will be done if and when necessary to
support construction activities.
2.2.3 Backfilling
Backfilling will be done in uniform layers of specified thickness. Soil in each layer will be
properly moistened to obtain its specified density. To verify compaction, representative field
density and moisture-content tests will be taken during compaction. Structural fill supporting
foundations and other critical structures, and general site fill will be compacted in
accordance with the criteria specified by the Geotechnical Investigation Report.
2.2.4 Grading
Site grading design will comply with applicable land development regulations. Graded areas
will be smooth, compacted, free from irregular surface changes, and sloped to drain. Final
earth grade adjacent to equipment and buildings will be below finished floor elevations and
will be sloped away from foundations as necessary to maintain proper drainage.
2.2.5 Roads and Parking
Asphalt site roads and parking will be provided for access, operation and maintenance as
shown on the Site General Arrangement drawing. Alternative access, if required by local
regulations, will be provided as shown on the General Arrangement drawing.
2.2.6 Landscaping and Fencing
A detailed landscape design, fine grading, furnishing and placement of trees, shrubbery,
and/or grass, will be prepared. A single chain-link fence around the site boundary, with an
automatic slide main gate, having a keypad for vehicle use, located at the main entrance will
be provided.
 2.3 Climatic data

Olteniţa City is located in the south of Romania, on the left bank of the Danube and the Arges
River, near the confluence of them.
Geo-morphologically, Olteniţa City was developed at the extreme south-east of the Romanian
Field, placed in the Danube valley.
From geotectonic point of view, the region belongs to Moesia Platform.
The main problem area is danger of flooding at high flow rates, both on the Danube and the
lower course of the river. In Calarasi county average flow of the Danube is approx. 6500 m3/s,
while the average flow of the river is 50 m3/s (at P.h. Budesti).

Temperature Regime

Indicator Value Observations

Average annual temperature +11.350C

Absolute maximum temperature +41.40C
Absolute minimum temperature -26.00C
The average temperature in January -1.950C
The average temperature in July +230C
The maximum depth of frost 0.70 - 0.80 m

Atmospheric humidity

Average relative humidity 77%

Average relative humidity during 65%
summer

Rainfall

Annual average 400-500 mm

Maximum Rainfall 71.90 mm May - June
Minimum Rainfall 29.20 mm February - March
Wind Load Data

The average speed of wind 23.6 m/sec The dominant winds blow
from V (16,4%) and SV
(12,4%)
Reference value of wind dynamic qb = 0.4 kPa As per CR-1-1-4/2012
pressure (IMR = 50 years)
Snow Load Data
 Characteristic value of snow load on sk = 2.0 kN/m2 As per CR-1-1-3/2012
soil (IMR = 50 years)
Seismic Load Data

Design ground acceleration value (IMR ag = 0.25g As per P100-1/2013

= 225 years) - (m/s2)
Corner Period Tc = 1.0s
Important Factor Value I,e = 1.2

2.4 Geotechnical Report

Soils design parameters to be used for foundation design shall be based upon soil investigation
report has been performed by geo-technical consultant. The subsurface investigation shall
include soil boring, field observation, and laboratory testing sufficient to determine soil substrata,
elevation and characteristics.
The project equipment and structures foundations will be designed to the meet the requirements
of the Geotechnical Report that will be prepared during the plant development.

3. STANDARDS, CODES AND SPECIFICATIONS

 CR 0-2012 – Design code. Basis of construction structure design
 CR 1-1-3/2012 – Design code. Evaluation of snow on buildings
 CR 1-1-4/2012 – Design code. Evaluation of wind on buildings
 SR EN 1992-1-1 &SR EN 1992-1-1/NB – Eurocod 2: Design of concrete structures.
Part 1-1: General rules and rules for buildings & National Annex
 SR EN 1993-1-1 &SR EN 1993-1-1/AC – Design of steel structures. Part 1-1: General
rules and rules for buildings
 SR EN 1993-1-8 &SR EN 1993-1-8/AC – Design of steel structures. Part 1-8: Design of
joints
 SR EN 1993-1-10 – Eurocode 3: Design of steel structures. Part 1-10: Choice quality
grades of steel
 P100-1/2013 – Code of structures design for eartquake resistance.
 NP112 – 04 – Normative for the structure design of directly founded
 STAS 3300-1/85, 2/85 – Foundation soil. General principles calculation. Calculation of
the foundation soil for directly founded
 NE 012-1/2007 – Code of practice for execution of reinforced concrete and prestressed
 NE 012-2/2010 – Standard for production and execution of concrete, reinforced and
prestressed works
 NE 013 – 2002 – Code of practice for execution of precast elements from concrete,
reinforced and pre-stressed
 STAS 767/0-88 – Civil, industrial and agricultural structures. Constructions of steel.
General technical quality
 STAS 767/2-78 – Civil, industrial and agricultural structures. Bolted and swaged
connections for steel structures
 SR EN 15048-1:2007 – Assembly with non-tensioned bolts for steel structures. Part 1:
General requirements.
 SR EN 10025-1/05 – Hot rolled products of structural steel. Part 1: Technical delivery
conditions
 SR EN ISO 5817/2008 – Arc welded connections of steel. Guidelines for acceptance of
faults levels
 SR EN 1090-1+A1/2012 – Execution of steel structures and aluminum structures. Part
1: Requirements for conformity assessment of structural elements
 C150-1999 – Normative about quality of welded connections for steel structures
 C56-1985 & C56-2002 – Standard for quality check and reception of construction works
and related equipment
 SR EN ISO 5817-2008 – Welded Connections. Quality Classes
 SR EN 10024/98 – I shape steel. Hot formed steel
 SR EN 10025-1:2005 – Hot rolled products of steel structures. Part 1: General
technical delivery conditions
 SR EN 10056-1-2000 – Angles with equal and unequal winged of steel for
constructions
 SR EN 10058-2004 – Hot rolled steel for general use. Dimensions and tolerances on
dimensions and form
 STAS 564-86 – U shape steel. Hot formed steel
 STAS 2350-91 – Anchor bolts for foundations
 SR EN ISO 2560/2010 – Welding. Coated electrodes for manual welding using electric
arc of non-alloy and with fine granulation
 C16/84 – Norms for the working in cold time and related facilities
 4. DESIGN LOADS
4.1 Dead Loads (DL)
Dead load (D) shall be considered as the weight of all materials forming a permanent part of the
structure. It shall include the weight of all permanent construction including, but not limited to,
fixed equipment, framing, piping, floors, walls, roofs, partitions, stairs, cable tray, and any other
structures, contents of tanks, etc.
1 Self-weight and Permanent Load
The permanent load shall be the self-weight of structure and foundation including backfiiled
earth material on the foundation. Typical unit weights of structural materials are as follows:
 Steel = 78.5 kN/m3
 Plain Concrete = 23 kN/m3
 Reinforced Concrete = 25 kN/m3
 Backfilled Earth = 19 kN/m3
 Water = 9.8 kN/m3

2 Buildings
All appropiate dead loads shall be included in the design of buildings and shall include the
followings:
 Framing, walls, floors, roofs, suspended ceilings, permanent partitions and stairs.
 Fixed service equipment, machinery, electrical feeders, heating/ventilating/air
conditioning, etc. wherever their loads are transmitted to structural elements.

3 Structures and Foundations

The following dead loads shall be included in the design of structures and foundations for
equipment:
 Self-weight of structural elements.. For steel structures, 10% shall be added to allow
for fixings, gussets, etc.
 Machinery, equipment, valves and piping where they permanently load the structure.

4 Lateral Earth/Water Pressure Load

Underground structures such as basins and retaining/bund walls shall be designed considering
lateral earth/water pressure load. Lateral earth pressure load is governed by the strength of
ground and can be calculated as follows:
H = ½ × K × γ × Df2
Where:

 h = Horizontal Stress
 v = Vertical Stress = γ × Df
 h = K × v
 γ = Unit Weight of Soil
 Df = Depth
 K = Coefficient of Lateral Earth Pressure
o Ka = tan2(45 – Φ/2) – for active soil pressure coefficient
o Kp = tan2(45 + Φ/2) – for passive soil pressure coefficient
 Φ = Frictional angle of Soil

4.2 Live Loads (LL)

Live Load shall include uniform or concentrate floor area loads, equipment handling loads, truck
wheel loads, and other similar loads. The floor area live load shall be omitted from areas
occupied by equipment which weight has been included in the dead load – unless the floor area
live load is larger, in which case it shall be used.
Live load does not include wind load, snow load, earthquake load, or dead load. The minimum
live load design basis will be as follows:
1. Platform/ Floor Areas:
 All Concrete Slabs on Grade 12.0 kN/m2
 Control Room 5.0 kN/m2
 Switgear Room 12.0 kN/m2
 Electrical Equipment Room 12.0 kN/m2
 Battery Room 12.0 kN/m2
 Utility Rack Platform 2.5 kN/m2
  Storage – Light 6.0 kN/m2
 Storage – Heavy 12.0 kN/m2
 Laboratory Areas including Offices 5.0 kN/m2
 Vessel Platform 5.0 kN/m2
 Equipment Maintenance Floor 7.0 kN/m2
 Miscellaneous Platforms and Walkways 5.0 kN/m2

2. Building Roof Areas (LR) 1.0 kN/m2 or Snow, whichever is grater

3. Tank Roof Areas (LR) 1.0 kN/m2 or Snow, whichever is grater

Minimum floor loads, other than listed above shall be in accordance with the Romanian
Standards SR EN 1991-1-1:2004 – Eurocode 1: Actions on structures – Part 1-1: General
actions.
 4.3 Snow Load (SL)
Snow loading shall be calculated in accordance with CR 1-1-3/2012 – Design code. Evaluation
of snow on buildings. For data related to snow and snow roof see Attachment 1.

Attachment 1
Snow Load Design
The snow loading shall be calculated in accordance with CR 1-1-3/2012, taking the respective
location of construction site.

s = gIs•i• Ce•Ct•sk

Where:
 sk – characteristic value of the ground snow load for the relevant altitude
 i – roof shape coefficient
 gIs – importance factor – exposure of structures
 Ce – Exposure coefficient of construction site
 1. Determination of the snow load on the ground

The characteristic load of snow shall be, in accordance with CR 1-1-3/2012, Fig. 3.1 and Annex
A, equal with sk = 2.0kN/m2.

2. Exposure coefficient and thermal coefficient

The exposure of a structure or of a roof to wind effects as well as the thermal transfer from a
heated room through a non-insulated roof influences the accumulation of the snow. In order to
take into account these effects CR 1-1-3/2012 introduces the exposure coefficient Ce and the
thermal coefficient Ct. In general the exposure factor is chosen as Ce = 1,0. Only in case of
exceptional circumstances where the roof is located either in open terrain or in surroundings
which represent shelter the exposure factor should be adjusted.

Type of exposure Ce
Complete (Fill) 0.8
Normal 1.0
Low 1.2

The thermal coefficient is also set to Ct = 1.0 for the normal situation. Only where roofs of
heated buildings are not or poorly insulated (glass roofs / thermal transmittance > 1 W/m²K) it is
allowed to use a reduced factor Ct.

3. Roof shape coefficients

Low wind velocities are sufficient to blow snow accumulations from a roof or to cause a drift of
snow which could lead to a local enhancement of the snow load. Roof shape coefficients are
needed for an adjustment of the ground snow load to a snow load on the roof taking into
account these effects.

Table 3.1 Values of shape coefficients for snow load on the roof having a single slope, two
slopes and more spans

Roof Angle
00 ≤ a ≤ 300 300 < a < 600 a ≥ 600
0
a
μ1 0.8 0.8(60-a)/30 0
μ2 0.8 + 0.8 a/30 1.6 _
 4.4 Wind Load (WL)
The minimum basic wind speed will be considered in accordance with CR 1-1-4/2012, taking the
respective location of construction site. For data related to wind load design see Attachment 2.

The wind load on the structural frame shall be calculated applying the unit pressure to the
projected area of the framing members in the side exposed to the wind.

Attachment 2
Wind Load Design
The following relationship exists between the basic velocity and the basic pressure:
qb = ρ/2 · vb2
where: ρ = density of air (can be set to 1.25 kg/m3 )
As per CR 1-1-4/2012, Annex A, Table A.1, the reference value of wind dynamic pressure for
Oltenita city is:
qb = 0.4 kPa for IMR = 50years
The roughness factor related to a minimum height zmin for the calculation is:
cr(z) = kr • ln(z/z0) , for zmin < z ≤ zmax = 200 m
= cr (z = zmin), for z ≤ zmin
 kr = 0.19 • (z0/z0,II)0.07
where:
kr = terrain factor
z0 = roughness length
zmin = minimum height
The input parameters of the formulae above are defined in dependence of the relevant terrain
roughness:

The factors kr(z0) and kr2(z0)for different types of terrain categories:

Terrain category 0 I II III IV

kr(z0) 0.155 0.169 0.189 0.214 0.233
kr2(z0) 0.024 0.028 0.036 0.046 0.054

1. Determination of Wind pressure on surface

Design wind pressure on surface is given by formula:

 Pressure/wind suction acting on the outer surface of the structure:

we = Iw• cpe• qp(ze)

 Pressure/wind suction acting on the inner surfaces of the structure:

 wi = Iw • cpi • qp(zi)

where:
we – external pressure
wi – internal pressure
qb – basic value of velocity pressure
cpe(z) – external pressure coefficient
cpi(z) – internal pressure coefficient
ze; zi – reference height of the considered building
Iw – factor of importane – exposure to load wind
Both, external and internal wind pressure, are defined as acting orthogonally to the surface of
the building.

The values for factor of importane – exposure to load wind are the followings:
 Iw = 1.15, for constructions being part of classes of importance – exposure I and II
 Iw = 1.00, for constructions being part of classes of importance – exposure III and IV

Class of
Engineering
importance – Buildings
Structures
exposure
Main store Tank Farm Area
II Hydrogen Production
Cooling Tower
Unit
Process Unit - Lube Oil
Waste Water
Evaporation & Hydro
Treatment Plant
Treater

Non-process building
(concrete and steel), Flare and Fired
III
except of items Area
included in class I
Loading/unloading bay
facility Pipe Rack

Compressor H2
Process Pump
Foundation
DM Water
Generation System
Air Compressor &
Nitrogen Plant
 2. Determination of the Wind Induced Force
The wind force Fw acting on a structure or structural component may be determined as:
Fw = Iw • cd • cf • qp(ze) • Aref
Where:
Iw – factor of importane – exposure to load wind
qb – basic value of velocity pressure
cd – dynamic response coefficient of structure
cf – force coefficient for the structure or structural element
Aref – the reference area of the structure or structural element, perpendicular on wind
direction

3. Design Wind Loads on Enclosed Buildings

3.1 Wind Load acting on short direction of structure

 Distribution of pressure/suction on exterior walls

3.2 Wind Load acting on long direction of structure
Tank Foundations
The cylindrical vertical tanks will be supported on suitable foundations consisting of a ring-wall
foundation or a mat foundation depending on the size of the tank.

Transformer Foundations and Protection

Transformer foundations will be designed and constructed in accordance with the requirements
of local codes and regulations, and manufacturer’s recommendations. Spill containment will be
provided for the generator step-up transformer and unit auxiliary transformers, and will be
topped with galvanized steel grating. Reinforced concrete retention pits, with a low point sump,
will be provided for the transformers and will be sized to contain at least the full oil volume of the
transformer.