Hindustan Petroleum

Corporation Limited

PROJECT REPORT

BLAST RESISTANT
BUILDING
Submitted by
Allu Leela Aravind Kumar,
Student Trainee,
Projects Department,
HPCL-VR.
CONTENTS

 ABOUT HPCL

 INTRODUCTION

 BLAST RESISTANT BUILDING

 FCCU-I FIELDROOM

 DRAWINGS

 SEQUENCE OF CIVILWORKS FOR FCCU-I

F/R

 QUALITY CHECKS DURING EXECUTION

 SAFETY AND PRECAUTIONS

 LEARNINGS
ABOUT HPCL
Hindustan Petroleum Corporation Limited (HPCL) was
incorporated on july5,1952 as Vacuum Refining Company of
India Limited. In 1974, it changed its name after the takeover and
merger if erstwhile Esso Standard and Lube India Limited by the
Esso(Acquisition of Undertakings in India) Act 1974. Caltex Oil
Refining (India) Ltd. (CORIL) was taken over by the CORIL-
HPCL Amalgamation Order 1978. Kosan Gas Company was
merged with HPCL in 1979 by the Kosangas Company
Acquisition Act 1979

Hindustan Petroleum Corporation Limited (HPCL) is an Indian

public sector undertaking in petroleum and Natural gas industry,
headquartered in Mumbai, and a subsidiary of the Oil and Natural
Gas Corporation (ONGC)’
Since 2018, Oil and Natural Gas Corporation has owned
majority of its stake. It is ranked 367th on the Fortuner Global
500 list of the world's biggest corporations as of 2016. On 24
October 2019, it became a Maharatna (PSU). HPCL has been
steadily growing over the years. The refining capacity increased
from 5.5 million metric tons (MMT) in 1984–85 to 14.80 million
metric tons as of March 2013. On the financial front, the net
income from sales and operations grew from ₹2,687 crores in
1984–1985 to₹2,06,529 crores in the 2012–13 financial year.
During the 2013–14 financial year, the company's net profit was
₹1,740 crores. During the 2021–22 financial year following the
COVID-19 Pandemic, HPCL's profit was ₹6,383 crore and its
revenue was ₹ 3,72,642 crore (its highest ever, up by 38%).HPCL
wholly owns two major refineries in India, one in Mumbai (west
coast) with a capacity of 9.5 million tons per year, and one in
Visakhapatnam (east coast) with a capacity of 8.3 million tons per
year (as per 2010).
Subsequently, during visakh refinery modernization project(VRMP)
in the year 2023, capacity of visakh refinery increased to 15 million
tons per year

Ongoing Projects
Visakh Refinery Modernization Project (VRMP)
 Production of MS & HSD with BS-VI specifications.
 Increase in Refining capacity from 8.33 MMTPA to 15 MMTPA
(almost doubling the capacity) by setting up various Process &
Utility Units.
 Refinery distillate yields improvement from 76% to 86%.

HPCL-VR
BLAST RESISTANT BUILDINGS

Definition:
Blast-resistant buildings are defined as buildings or other
structures capable of withstanding the effects of an accidental plant
explosion giving rise to the pressure/time effects. In resisting such
explosion, the building may suffer damage provided that this does
not result in collapse, danger to personnel or render control
equipment inoperable. However, capable of withstanding a static
overpressure of 3psi due to pressure/ time effects of explosion,
the building shall remain gas-tight for preventing ingress of
contaminated air following explosion.

REQUIREMENTS OF BLAST RESISTANT BUILDING AS

PER OISD-163

1. LOCATION

a. The building should be located in non-hazardous area

upwind of process plants / hydrocarbon storage and
handling facilities. It shall not be located on a lower
level than surrounding plants and tank farms. There
shall be no structure that would fall in the field room in
case of blast.
b. The location of building and its separation distances
from process units / block facilities shall be as per
OISD-STD-118 on “Layouts for Oil & Gas
Installations”.
c. Unless otherwise required from plant processing
considerations, the structural design of type-B building
shall be undertaken for a static overpressure of 3 psi.
2. CIVIL REQUIREMENTS

a. The openings through walls shall not exceed seven

percent (7%) of wall area.
b. Area of each windows shall not exceed 0.25 sq.m.
c. Glass used for windows shall be toughened & shatter-
proof of 7 psi rating.
d. Window slits shall be vertical with slit width not
exceeding 0.30m.
e. The entry / exits to the control room shall face the least
hazardous area.
f. Any entry to field room building shall be protected
with baffle wall of blast-resistant construction with
suitable overlap on both sides against entry of direct
blast pressure wave. Baffles shall be at 45 degree / 90
degree to the access way.
g. Fire-resistant partition / isolation shall be provided
between various risks where fire protection is provided
to prevent spread f fire to the adjoining protected
areas. Doors, if provided between protected areas,
shall be fire check doors.
h. Wall thickness should be 150 mm (thick).
i. Concrete slab thickness should be 230 mm (thick).
j. All openings MCT’S should be in MCT’S

3. ELECRICAL REQUIREMENTS

a. Electrical fitting provided in the field room shall be in

line with OISD_STD_113

4. INSTRUMENTATION REQUIREMENTS

a. Adequate clearance between cabinets/ racks and

 wall of field room shall be provided for access to
the equipment during testing/ maintenance.
minimum distance of 1m between equipment to
wall of field room and minimum distance of 2m in
aisle is recommended.

5. AIR CONDITIONING:

 Separate supply and return air ducting shall be provided

for field room.
 Dampers shall be installed in ducts, where they
pierce fire walls or at the point the duct(s) emerge
from air conditioning plant room. These dampers
must have 90 minutes fire rating (resistance) and
may be of single blade/multi blade design
pneumatically operated and actuated by smoke
detector units.
 With operation of the automatic (smoke / hydrocarbon /
toxic gas) detector within the air duct, the supply and
return air ducts must be cut-off and the air conditioning
plant tripped.
 Field room is to be pressurized to 3-5mm WG, if it is
located within 16m from process plant or, lies with in
hazardous area classified as per OISD-STD-113

6. GENERAL REQUIREDMENTS:

a. Console room and Rack rooms

b. Computer room
c. UPS room
d. AC plant and AHU room
e. Battery room with battery charger sets
f. Clean agent cylinder room / Fire extinguishing system.
g. Offices for Officers-in-charge directly involved in
Operation & maintenance of plant. Sitting
arrangement for staff directly involved in operation
and maintenance of DCS.
h. Essential services such as instrument calibration
facility, Engineering Room and Optimization Room /
computers & advanced control room.
i. Essential amenities: Locker room, discussion room.
Record room, Dining room, toilet etc.
j. Field room shall cater for minimum essential
occupancy. Similarly, sub-station block when
combined with control room shall have space only
for essential requirement.
k. Field room shall cater for minimum essential
occupancy. Similarly, sub-station block when
combined with control room shall have space only
for essential requirement.
l. Field room / sub-station buildings shall not have any
provision for conference hall, library etc., where
assembly of people may take place. Personnel, not
related to essential functions of plant control, shall not
be stationed in the control room.
m. A set of emergency tools stored and displayed in a
wall-mounted cupboard with a glass cover for
using in emergency.
n. In case blast resistant design of field room,
adequate cable transit blocks with dummy blocks
shall be provided for future expansion.
o. Field room should be of one storey above grade
construction to facilitate quick evacuation in emergency
and shall cater for minimum essential occupancy.
p. Field Room entry shall have double doors.
q. The air curtain facility at the inner door may be
considered to prevent any dust entry inside the control
room.
 r. Toughened and shatter proof glass shall be used for doors/
windows in control rooms.
s. Minimum two exits shall be provided in such a way that
each has a different unobstructed escape route.
t. These routes shall be properly identified and displayed.
u. The emergency exist shall be properly identified,
displayed and shall be as per National Building code
of India and Factories Act.
v. Drainage system for control room building shall be
provides with suitable traps to prevent back-flow of
explosive vapours during plant upset or spills.
w. Floor level of the building (including the floor
supporting the false flooring) should be higher
compared to the grade level outside the building.
 SELECTION OF TYPE OF CONSTRUCTIONS
ADVANTAGES OF BLAST RESISTANT BUILDING:

1. Staff, equipment, and assets are protected during a

catastrophic event
2. Reduce liability, increase peace of mind
3. Reduce time lost to retrieve tools or other equipment
4. Reduce the amount of time exposed to hazards
5. Flexibility and modifications
6. Mobility
7. Built offsite
CODES USED:
 IS CODES

 IS 875 (Part-1,2,3) – Code of practice for design loads (except

earthquake loads).
 IS 1893 - code of practice of design of earthquake loads.
 IS 456 - code of practice for Plain and Reinforced concrete.
 IS 2911 – Design and construction of Piles.

 OISD Standards

 OISD-163 is used for construction of building

requirements and etc.
 OISD-113 is used for electrical
 OISD-STD-118 is used Layouts for Oil & Gas Installations.

FCCU-1 FIELD ROOM:

Type of Building:
As per OISD 163, FCCU-I field room is to be constructed
blast resistant building.

FACITITIES INSIDE FIELD ROOM:

Dimension (L*B in m)
 Shift in charge room - 3m*3m
 Change room for gents – 2.5m*4.2m
  Change room for ladies- 2.5m*4.2m
 Dining room - 3m*3.5m
 Store / Document room- 3m*3m
 Gents toilets - 4.5m*3m
 Ladies toilets - 3m*4.5m
COMPLYING TO OISD 163

DESCRIPTION Complying
to OISD
153
 The openings through walls shall not exceed
seven percent (7%) of wall area. Complied
 Area of each windows shall not exceed 0.25 sq.m. Complied
 Glass used for windows shall be toughened &
shatter-proof of 7 psi rating. Complied
Complied Complied
 The entry / exits to the control room shall face the
least hazardous area. Complied
 Any entry to field room building shall be
protected with baffle wall of blast-resistant
construction with suitable overlap on both sides
against entry of direct blast pressure wave. Baffles
shall be at 45 degree / 90 degree to the access way. Complied
 Fire-resistant partition / isolation shall be provided
between various risks where fire protection is
provided to prevent spread f fire to the adjoining
protected areas. Doors, if provided between protected
areas, shall be fire check doors. Complied
 Adequate ventilation will be maintained in the Complied
control room with a minimum of five to six air
changes per hour. Air intake to be properly
located.
 No equipment shall be placed on the roof other Complied
than air-intake system and exhaust stacks
 Wall thickness should be 230 mm (thick). 300 mm

 Concrete slab thickness should be 150 mm (thick). 175mm

 All openings MCT’S should be in MCT’S Complied

SEQUENCE OF CIVIL WORKS:

 Completion of Piling works: RCC 500mm pile cast-in-situ. Total
78 piles done. M35 grade used
 Completion of RCC walls: 230mm thick, Length: , Height: . M30
grade of concrete used.
 Raft thickness: 800mm thick
 Pcc:75mm thick.
 Plinth beams: plinth beams are two types. They are:
1. Dimensions: 400mm*300mm
2. Dimensions: 450mm*230mm
 Completion of Slab: 230mm thick double reinforced RCC slab
done. M30 grade of concrete used.
 Columns: total 21 columns
They are used two types of columns. They are
1. C1 – 13 columns with dimension: (450*600) mm.
2. C2 – 8 columns with dimension: (230*300) mm.
 Completion of Bricks partition walls: 230mm brick partition walls
are done as per drawings.
 height of partition walls 2.1m. Fly ash bricks were used.
 Completion of Flooring works: Earth filling was done till flooring
PCC level. PCC of 100mm done. 12mm thick, 600mm*600mm
vitrified tiles were used in shift in charge room and other rooms.
Granite tiles were used at entrance area. Anti-skid tiles were used in
Ladies and Gents Toilets.
 Electrical works
i) Electrical engineers within the refinery industry are tasked
with the intricate design, maintenance, and optimization of
power distribution systems.
ii) An electrical foreman typically oversees a team of
electricians or technicians that work on gas and oil pumps,
valves or other components

 Fire alarm system

i) It is having four types of categories
a. Water and foam fire suppression systems,
b. Fire extinguishers,
c. Fire alarms,
d. Fire safety training.

 HAVC system
a. HVAC- Heating, Ventilation, and Air Condition.
b. To help maintain good indoor air quality(IAQ)
through adequate ventilation with filtration and
provide thermal comfort
 Water proofing
a. Forming a barrier over surface of foundations,
roofs walls and other structural members of
buildings to prevent water penetrations through
these surfaces.
 Anti-termite treatment
a. It is a chemical procedure carried out for soil,
masonry, wood, and electrical fixtures which
provided a prevent measure against subterranean
termites before and after the construction.
 Completion of Putty & painting works: 2 coat putty done and 2
coats of painting done with approved color done.
 Drain: 300mm width brick drain was constructed and connected to
existing drain.
QUALITY CHECKS DURING EXCEUTION:

 Checking and Ensuring concrete grade inline with the

approve design mix:
M35 grade is used for underground construction(substructure)
M30 grade is used for above ground construction(superstructure)
 Ensuring proper clear cover to reinforcements
1. Clear cover to Slab: (20 or 30)mm
2. Clear cover to Footing: 50mm
3. Clear cover to Beam: 20mm
4. Clear cover to Column: 40mm for d>12mm ,
25mm for d<12mm.

 Ensuring proper centering and shuttering to avoid concrete

leads
 To provide a good working surface and distribute the
load evenly
 Ensuring proper vibration during concrete
 By removing air pockets & packing the aggregate
particles together, it increases the density and
strength of the concrete.
 Ensuring casting of cubes inline with IS456 codes
1. Cube size: (150*150*150) mm
 Ensuring proper curing as per IS: 456 standards
1. Concrete should be allowed to cure for a minimum of
seven days while using ordinary Portland cement.
2. Concrete should be allowed to cure for a minimum of
ten days while using blended cement or concrete with
mineral admixtures.
 Ensuring De-shuttering with in the time period as per IS
 codes
 IS Code 456 specifies the removal of formwork for
different kinds of concrete elements.
 A list of various concrete elements and their formwork
removal time: vertical formwork of wall, column and
beam-16-24 hours.
 Ensuring proper leak test of slab
 Proper layer wise compaction and doing compaction test for
back filling of soil.
 Remove the soil from the mixer and place it in the
mold in 3 layers or 5 layers depending on the method
utilized (Standard Proctor or Modified Proctor).
 For each layer, initiate the compaction process with
25 blows per layer
 Ensuring removal of shuttering as per IS code
recommendations.
 Vertical formwork of wall, column and beam- 16-24
hours.
SAFETY AND PRECACUTONS
petroleum refinery being a sensitive area the safety
precautions in the field are strictly followed. Some of
them are:
 Refinery being sensitive to any flash and fire, Mobiles are
strictly prohibited in the refinery area, instead Walkie-
Talkies are used for communication inside the plant area.
 Work permits are allotted to the workers and renewed at
the start of every working day to formalize what work is to
be done where and when.
 As the machinery and pipes are all around in the refinery
area, Safety Shoes and Helmet are mandatory to enter the
field.
 Gloves are mandatory for people working near the CDU.
 Apron is to be worn by women at the working area.

LEARNINGS:
During the internship Period at the Refinery some Technical
learning outcomes are:
 Type of buildings to be used in refineries.
 Blast proof buildings recommendations by OISD.
 Reading and understanding of drawings
 Execution procedure for different civil works done during
construction of building
 Quality checks for civil works and precautions that are
taken to Control Quality During Construction.
 Onsite Test that are done for Quality Assurance of the
Project.
  Safety precautions to be taken mainly during excavation
and work at height.
Along with the Technical aspects the internship
duration helped me in:
 Learning Office work etiquettes.
 Work and Learn under Guidance of Experienced Work
Professionals.
 Practical observation of Theoretical subject that was learnt
in academic courses.