COMPLETE REVISION

February 2019

Civil

PIP CVC01015
Civil Design Criteria
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major industrial
users, contractors, or standards organizations. By harmonizing these technical requirements
into a single set of Practices, administrative, application, and engineering costs to both the
purchaser and the manufacturer should be reduced. While this Practice is expected to
incorporate the majority of requirements of most users, individual applications may involve
requirements that will be appended to and take precedence over this Practice.
Determinations concerning fitness for purpose and particular matters or application of the
Practice to particular project or engineering situations should not be made solely on
information contained in these materials. The use of trade names from time to time should
not be viewed as an expression of preference but rather recognized as normal usage in the
trade. Other brands having the same specifications are equally correct and may be
substituted for those named. All Practices or guidelines are intended to be consistent with
applicable laws and regulations including OSHA requirements. To the extent these
Practices or guidelines should conflict with OSHA or other applicable laws or regulations,
such laws or regulations must be followed. Consult an appropriate professional before
applying or acting on any material contained in or suggested by the Practice.

This Practice is subject to revision at any time.

© Process Industry Practices (PIP), Construction Industry Institute, The University of Texas
at Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP Member Companies
and Subscribers may copy this Practice for their internal use. Changes or modifications of any
kind are not permitted within any PIP Practice without the express written authorization of
PIP. Authorized Users may attach addenda or overlays to clearly indicate modifications or
exceptions to specific sections of PIP Practices. Authorized Users may provide their clients,
suppliers and contractors with copies of the Practice solely for Authorized Users’ purposes.
These purposes include but are not limited to the procurement process (e.g., as attachments to
requests for quotation/ purchase orders or requests for proposals/contracts) and preparation
and issue of design engineering deliverables for use on a specific project by Authorized
User’s client. PIP’s copyright notices must be clearly indicated and unequivocally
incorporated in documents where an Authorized User desires to provide any third party with
copies of the Practice.

PUBLISHING HISTORY
June 1999 Issued June 2007 Technical Correction
June 2001 Technical Correction January 2013 Complete Revision
February 2005 Complete Revision February 2019 Complete Revision

Not printed with State funds

COMPLETE REVISION
February 2019

Civil

PIP CVC01015
Civil Design Criteria
Table of Contents
1. Scope ...........................................2
2. References ..................................2
2.1 Process Industry Practices ...............2
2.2 Industry Codes and Standards .........2
2.3 Government Regulations ..................3

3. Definitions ...................................3
4. Requirements ..............................4
4.1 General .............................................4
4.2 Environmental Protection .................4
4.3 Geotechnical Engineering
Investigations ....................................5
4.4 Site Preparation and Grading ...........6
4.5 Excavation and Backfill ....................6
4.6 Erosion and Sediment Control .........6
4.7 Railroad Work ...................................7
4.8 Roadways, Area Paving, and
Surfacing ..........................................8
4.9 Curbs, Gutters, and Walkways .......10
4.10 Sewers and Drainage Systems ......10
4.11 Fencing and Security ......................23
4.12 Landscaping, Seeding, and
Sodding ..........................................23

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Civil Design Criteria February 2019

1. Scope
This Practice describes minimum requirements for design of civil sitework of process industry
facilities at onshore U.S. sites. This Practice covers all work related to preparation of site such as
grading, roadways and railroads, and sewer work and related facilities, and all work related to
finishing site. This Practice is intended to be used in conjunction with PIP CVC01017 and
PIP CVC01018, as applicable.

2. References
Applicable parts of the following PIP Practices, industry codes and standards, and other regulations
shall be considered an integral part of this Practice. The edition in effect on the date of contract
award shall be used, except as otherwise noted. Short titles are used herein where appropriate.

2.1 Process Industry Practices (PIP)

– PIP CVC01017 - Plant Site Data Sheet
– PIP CVC01018 - Project Data Sheet
– PIP CVE02350 - Roadway Design Guide (U.S. Customary)
– PIP CVE02350M - Roadway Design Guide (Metric)
– PIP CVI02350 - Roadway and Area Paving General Notes and Typical Details
– PIP CVS02010 - Geotechnical Engineering Investigation Specification
– PIP CVS02100 - Site Preparation, Excavation, and Backfill Specification
– PIP CVS02350 - Roadway and Area Paving Construction Specification
– PIP CVS02700 - Underground Gravity Sewers Specification
– PIP CVS02830 - Chain-Link Fence and Gates Installation Specification
– PIP PNE00003 - Process Unit and Offsites Layout Guide
– PIP STS03001 - Plain and Reinforced Concrete Specification
2.2 Industry Codes and Standards

• American Concrete Institute (ACI)

– ACI 330R - Guide for the Design and Construction of Concrete Parking Lots
• American Petroleum Institute (API)
– API 2610 - Design, Construction, Operation, Maintenance, and Inspection of
Terminal & Tank Facilities
• American Railway Engineering and Maintenance-of-Way Association (AREMA)
– AREMA Manual for Railway Engineering
• ASTM International (ASTM)
– ASTM A746 - Standard Specification for Ductile Iron Gravity Sewer Pipe
– ASTM D6391 - Standard Test Method for Field Measurement of Hydraulic
Conductivity Using Borehole Infiltration

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• American Water Works Association (AWWA)

– AWWA C151/A21.51 - Ductile-Iron Pipe, Centrifugally Cast
• National Fire Protection Association (NFPA)
– NFPA 30 - Flammable and Combustible Liquids Code
• Portland Cement Association (PCA)
– PCA SN298 - Guide for Roller-Compacted Concrete Pavements
2.3 Government Regulations

• U.S. Department of Justice (DOJ) / Americans with Disabilities Act (ADA)

– 2010 ADA Standards for Accessible Design
– Guidance on the 2010 ADA Standards for Accessible Design
• U.S. Department of Homeland Security (DHS)
– 6 CFR Part 27 - Chemical Facility Anti-Terrorism Standards; Final Rule
• U.S. Environmental Protection Agency (EPA)
– EPA 40 CFR - Protection of the Environment
• U.S. Department of Transportation (DOT)
– 49 CFR Part 213 - Track Safety Standards

3. Definitions
BMPs: Best Management Practices are techniques (buffers, silt fences, detention ponds, swales,
etc.), schedules of activities, prohibitions of practices, and maintenance procedures used to
prevent or reduce discharge of pollutants

constructor: Party responsible for supplying materials, equipment, tools, supervision, and labor
for installation of civil sitework in accordance with contract documents. The term constructor
applies also to constructor’s subcontractor(s) and vendor(s).

contract documents: Any and all documents, including codes, studies, design drawings,
specifications, sketches, practices, and data sheets, that purchaser or engineer of record has
transmitted or otherwise communicated, either by incorporation or reference, and made part of
the legal contract agreement or purchase order between purchaser and constructor.

covered facility (or covered chemical facility): A chemical facility determined by the Assistant
Secretary to present high levels of security risk, or a facility that Assistant Secretary has
determined is presumptively high risk under U.S. Department of Homeland Security 6 CFR Part
27 Section 27.200. Assistant Secretary shall mean the Assistant Secretary for Infrastructure
Protection, U.S. Department of Homeland Security or his designee.

DOT: Department of Transportation or equivalent government organization for state, province, or

country in which project site is located

engineer of record: Purchaser’s authorized representative with overall authority and responsibility
for engineering design, quality, and performance of civil works, structures, foundations, materials,

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and appurtenances described in contract documents. Engineer of record is licensed as defined by

laws of the locality in which the work is to be constructed, and is qualified to practice in the
specialty discipline required for the work described in contract documents.

geotechnical engineer: Professional engineer responsible for performing geotechnical

investigation and/or geotechnical consulting during construction of civil works

noncontact cooling water: Cooling water that does not have direct contact with process fluids or
materials. Cooling water may be recirculated or used only once and conveyed through gravity
drainage systems.

operator: Entity (generally company, corporation, etc) that has: (1) operational control of
construction project plans and specifications, including the ability to make modifications to those
plans, or (2) day-to-day operational control of stormwater compliance activities

owner: Party who has authority through ownership, lease, or other legal agreement over facility
wherein sitework will be used.

process sewers: Any waste collection/drainage system carrying materials (exclusive of sanitary
waste) requiring treatment before discharge

purchaser: Party who awards contract to constructor. Purchaser may be owner or owner’s
authorized agent

SWPPP: Stormwater Pollution Prevention Plan is a document that describes pollution prevention
practices and activities that will be implemented on the site. It includes information on the site
and of each major phase of the planned activity, roles and responsibilities of contractors, and
inspection schedules and logs. The SWPPP also serves to document weather events and
modifications to construction plans and stormwater pollution prevention activities.

4. Requirements

4.1 General
Owner or owner’s representative shall provide PIP CVC01017 and PIP CVC01018 Data
Sheets that document site specific data and design basis for the project.

4.2 Environmental Protection

4.2.1 Storage facilities and process infrastructure (e.g., process loading/unloading,
petroleum storage, and hazardous material storage) shall be designed to protect
against soil, groundwater and surface water contamination in accordance with
EPA 40 CFR, state, and local regulations. Examples of protection methods
include drip pans, paving, impervious layers or membranes and concrete
containment.
4.2.2 Diked areas shall be designed to contain 100% of largest tank volume.
Comment: To allow for volume occupied by tanks, capacity of diked area enclosing
more than one tank shall be calculated after deducting volume of tanks,
other than the largest tank, below the height of the dike.

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Comment: It should be noted that some owners and local jurisdictions may
require the dike to provide “freeboard” for foam application and
runoff from fire-fighting operations and precipitation requirements.
Comment: See API 2610 for guidance on design of terminal and tank facilities.
4.2.3 Facilities for storage, handling, and use of flammable and combustible liquids
shall be in accordance with NFPA 30.
4.2.4 Sewers that carry water that is not normally subject to contamination (noncontact
cooling water or stormwater) and that have potential to receive spills (e.g.,
potentially contaminated water) shall be designed to include monitoring and
diversion capabilities.
Comment: Stormwater from process, storage, and loading areas should be
segregated from stormwater from undeveloped and non-process
areas to minimize volume of water requiring treatment.
4.2.5 Building floor and roof drains and other areas not subject to process spills shall
connect to stormwater drainage system.
4.2.6 Additional Requirements for Toe Wall Enclosures, Dikes and Pits
[Link] Tops and sides of dikes shall be protected from erosion.
[Link] Tank pits and dikes shall be made resistant to percolation with a hydraulic
conductivity no greater than 3.9 x 10-7 inches/s (10-6 cm/s) as determined
by ASTM D6391, using methods approved by engineer of record.
[Link] Diked or toe wall enclosures, including tank dike areas, shall be drained
with at least one catch basin or pipe through the enclosure discharging to
a drainage system outside the dike or toe wall. For dike areas with
combustible storage tank dike areas, all discharges shall be provided with
a valve according to Section 4.10.8 below, located such that it is
accessible for operation from outside the enclosure.

4.3 Geotechnical Engineering Investigations

4.3.1 If sufficient geotechnical information is not available, geotechnical engineering
investigations shall be performed in accordance with PIP CVS02010.
4.3.2 If available and appropriate, the following technical information shall be
provided to geotechnical engineer:
a. Site plan showing proposed facilities and adjacent existing facilities
b. Topographic plan or relative elevations of existing grades and facilities to
planned grades of proposed facilities
c. Descriptions of proposed and existing facilities, including the following:
1) Types of structures
2) Anticipated design loads for various design cases including static
compression, uplift, horizontal shear, vibratory, dynamic, and blast
3) Any settlement sensitivity of structures or equipment

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4) Any sensitivity to vibration from external sources of both proposed and

existing facilities
5) Special or unusual conditions such as pits, basements, elevator shafts,
reciprocating compressors, retaining walls, etc.
6) Elevations such as building ground floor, bottom of pits, basements,
elevator shafts, walls, tanks, etc.
7) Proposed finish grade elevation adjacent to facilities
8) For tanks, load condition (empty, full, test, and operating weights);
normal operating level ranges, durations, and settlement tolerances
9) Pavement loading and traffic data if pavement recommendations are
needed
10) Information regarding any known or potential soil/groundwater
contamination at the site
11) Drawings and other information for adjacent or on-site existing facilities,
including underground utilities and structures

4.4 Site Preparation and Grading

4.4.1 Site preparation activities, including clearing and grubbing, stripping, and general
site grading, shall be in accordance with PIP CVS02100.
4.4.2 Excavation, fill, stockpile and disposal areas, and extent of clearing and grubbing
areas shall be defined in contract documents.
Comment: Consideration shall be given to balancing cut and fill for earthwork.
4.4.3 All demolition and disposal methods shall be defined in contract documents.
4.4.4 Vehicular traffic detours shall be designed to provide a safe routing and a
satisfactory means of controlling traffic.
4.4.5 All graded surfaces shall be sloped to provide positive drainage and to avoid ponding.
4.4.6 Final grade shall take into consideration the existing drainage from surrounding
areas if applicable.

4.5 Excavation and Backfill

4.5.1 Excavation and backfill shall be in accordance with PIP CVS02100.
4.5.2 Areas requiring differing levels of compaction shall be noted on design drawings.
These areas include structure areas, roadways, railroad subgrades, paved area
subgrades, utility trenches, embankments and dikes, and general graded areas
outside process or work areas.

4.6 Erosion and Sediment Control

4.6.1 Erosion and sedimentation controls shall be in accordance with local, state, and
federal regulations, including EPA, US Army Corps of Engineers, and project
specific permits. Soil erosion control shall be designed to comply with federal,
state, and local regulations and shall be in accordance with PIP CVS02100.

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4.6.2 Operator(s) shall develop and implement a Stormwater Pollution Prevention Plan
(SWPPP) and maintain all Best Management Practices (BMPs) during each stage
of the project in accordance with applicable regulations. SWPPP must be
available on-site for review during inspection.
4.6.3 Construction activities that expose soil due to clearing, grading, excavating, etc.,
affecting one or more acres, including smaller sites in a larger common plan of
development, require coverage under a National Pollutant Discharge Elimination
System (NPDES) permit for stormwater discharges. Operator(s) shall complete
the following steps, as applicable under the governing jurisdiction:
a. Develop and implement a Stormwater Pollution Prevention Plan (SWPPP).
Submittal is required in some states. SWPPP must be completed prior to
submitting the Notice of Intent.
b. Submit a Notice of Intent (NOI) to governing authority.
c. Submit a Notice of Termination (NOT) to governing authority.
4.6.4 Where required, erosion control permitting documentation shall be submitted to
owner.

4.7 Railroad Work

4.7.1 Railroad design shall be in accordance with AREMA Manual for Railway
Engineering and local operating railroad requirements.
Comment: See 49 CFR Part 213 Track Safety Standards for additional general
information.
4.7.2 Railroads shall be standard gauge and shall meet design, condition, and maintenance
requirements for yards and terminals track systems as defined by AREMA.
4.7.3 Loading, unloading, and scale stations shall be designed to be level.
4.7.4 Rail unit weight and rail type shall be selected to be compatible with existing rail
system and to provide desired design life according to intended service and
availability.
4.7.5 A drainage system shall be designed to drain ballast and subgrade. Flooding of
grades between parallel tracks shall be prevented.
4.7.6 A geosynthetic material shall be installed between subgrade and ballast if
recommended by geotechnical engineer to prevent fouling of ballast.
4.7.7 Ballast section shall remain level with top of tie between adjacent tracks to
provide level walking surface area.
4.7.8 Unless otherwise specified in PIP CVC01017 and PIP CVC01018, railroads shall
be designed in accordance with the following:
a. Railroad clearances shall be in accordance with PIP PNE00003.
b. Rail shall be AREMA Class 1 relay.
c. Unless otherwise required by the local operating railroad, turnouts on tracks
shall be No. 8 minimum.
d. Maximum grade, unless otherwise required by local topography, shall be 2%.

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e. Maximum degree of curvature shall be 10 degrees.

f. Ballast shall be size AREMA No. 5 material with properties meeting AREMA
limiting values.
g. Ballast depth shall be a minimum of 8 inches (200 mm) from bottom of tie.
h. Sub-ballast shall be in accordance with AREMA and geotechnical engineer’s
recommendations.

4.8 Roadways, Area Paving, and Surfacing

4.8.1 Roadways and area paving shall be in accordance with PIP PNE00003.
4.8.2 ADA accessible parking spaces shall be designed in accordance with 2010 ADA
Standards for Accessible Design.
Comment: Engineer can also refer to Guidance on the 2010 ADA Standards for
Accessible Design document for more information.
4.8.3 Roadways and Area paving shall be designed using materials and methods
specified in PIP CVC01017 and/or PIP CVC01018.
4.8.4 Surfacing for the following areas shall be as specified in PIP CVC01017 and/or
PIP CVC01018 data sheets or as otherwise designated by owner. See
PIP CVE02350, PIP CVE02350M and PIP CVI02350 for information on various
surfacing options.
a. Sidewalks
b. Roadways, streets, or drives
c. Process equipment areas
d. Maintenance areas
e. Loading or unloading areas
f. Parking or storage areas
4.8.5 Final grading and paving around plant buildings shall direct liquids away from
the buildings.
Comment: Directing drainage so that liquids flow away from buildings reduces
the risk of building involvement in a plant fire.
4.8.6 Roadways
[Link] Unless otherwise specified by owner, roads shall be designed in
accordance with PIP CVE02350 or PIP CVE02350M.
[Link] Design drawings shall show all pavement and road requirements
including location, width, thickness of base course and pavement,
pavement type, grades, geometry, joint types and locations, shoulder
details, curbs, signage, drainage features, and materials.
4.8.7 Concrete Area Paving
[Link] For concrete materials and construction, see PIP CVS02350 and
PIP STS03001. Unless specified otherwise in PIP CVC01017 and/or

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PIP CVC01018, roadways and paving shall be designed in accordance

with the following requirements:
a. Concrete area paving may be of the following types:
1) Jointed plain concrete paving (JPCP) (Section [Link])
2) Jointed reinforced concrete paving (JRCP) (Section [Link])
3) Roller-compacted concrete paving (RCCP) (Section [Link])
b. Rigid pavement shall be designed based on the modulus of subgrade
reaction (k) determined or calculated at top of base course.
c. See PIP CVE02350 or PIP CVE02350M for design procedures for
concrete pavements.
d. See PIP CVI02350 for pavement thicknesses and joint construction
and spacing information.
e. Area paving shall be curbed where needed to contain chemicals or
hydrocarbons. Containment curbs shall be a minimum of 6 inches
(150 mm) wide and as tall as required to contain the material.
f. Pavement shall be divided into sections or catchment areas.
Catchment areas shall be sloped to sewer inlets to provide rapid
removal of stormwater, firewater, or hydrocarbon spills. One catch
basin shall be provided for each 3000 ft2 (280 m2) of paved area and
5000 ft2 (465 m2) of unpaved area. Maximum surface runoff travel
distance to catch basins shall be 100 ft (30 m) in process areas.
g. Minimum slope for area paving shall be 1% unless otherwise
specified. Consider 2% for areas that are constantly wet.
Comment: For sewer system to provide adequate drainage during a
storm or fire event, limitations are placed on maximum
runoff travel distance, area and ground slope.
h. Pavement subject to chemical attack shall be designed with an
appropriate protective coating or special concrete mix design.
i. For additional information on area paving and parking lots, see
ACI 330R.
[Link] Jointed Plain Concrete Paving (JPCP)
JPCP is unreinforced and shall be designed according to methods and
procedures of PIP CVE02350 or PIP CVE02350M. Provisions of
Section 4.8.3 shall be applied to the design.
[Link] Jointed Reinforced Concrete Paving (JRCP)
JRCP is reinforced and shall be designed according to methods and
procedures of PIP CVE02350 or PIP CVE02350M. Provisions of
Section 4.8.3 shall be applied to the design.

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[Link] Roller-Compacted Concrete Paving (RCCP)

1. RCCP may be used for most of the applications listed in the previous
section for JPCP at owner’s option. RCCP should be considered for
area paving where heavy forklifts greater than 15,000-lb (6,800-kg)
capacity or other heavy equipment operate, such as in container yards.
2. RCCP shall be designed according to methods and procedures
described in PCA SN298.
4.8.8 Gravel or Crushed Stone Surfacing
1. For area paving around exterior electrical equipment enclosures and at other
locations that are not subject to leaks or spills, crushed stone or similar
locally available material may be used.
2. Gravel or crushed stone surfacing shall be placed to a minimum finished
thickness of 3 inches (75 mm).
3. Gravel or crushed stone surfacing shall be suitable for pedestrian traffic.
4.8.9 Asphaltic Concrete Roadway and Area Paving
Asphaltic Concrete shall be designed according to methods and procedures of
PIP CVE02350 or PIP CVE02350M. Provisions of Section 4.8.3 shall be applied
to the design.

4.9 Curbs, Gutters, and Walkways

4.9.1 Walkways and roadway crossings shall be provided to connect parking lot,
gatehouse, administration building, cafeteria, process buildings, etc., for safe
pedestrian travel. Accessible routes including curbs, gutters, walkways, and
roadway crossings shall be designed to comply with 2010 ADA Standards for
Accessible Design. Engineer can also refer to Guidance on the 2010 ADA
Standards for Accessible Design document for more information.
4.9.2 Walkway subbase shall be in accordance with PIP CVS02100.
4.9.3 Walkway grades without steps shall not exceed 6%.
4.9.4 Finished grades shall be shown on design drawings.

4.10 Sewers and Drainage Systems

This section covers design and installation of stormwater, sanitary and process sewer
wastewater collection systems. See also PIP CVS02700 for specifications related to
underground gravity sewers that are relevant to the design and installation of sewer
systems.
Comment: This section uses partial flows depth, seals and vents for safety to prevent
vapor buildup and transmission. Other systems in use by petrochemical
companies are flooded systems using weirs to prevent vapor buildup or
transmission.
4.10.1 General
[Link] Sewers and drainage systems shall be designed to protect atmosphere,
soil, surface water, and groundwater from contamination and to

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provide safe, economical collection and flow of all sewage to treatment

and/or holding facilities and subsequently to approved disposal. Sewers
and drainage systems shall prevent the spread of fire from one drainage
area to another.
Comment: Site drainage is designed to prevent the spread of fire from
one area to another in order to minimize hazards to
personnel and equipment and maximize effectiveness of
emergency response.
[Link] If specified by owner, open channel ditches and basins that potentially
convey or retain groundwater contaminants (e.g., potentially
contaminated flows, firewater runoff) shall be lined. Lining material
shall meet owner-specified permeability requirements.
[Link] If specified by owner, each sewer system shall be designed for
increased flow from future sewer extension or from changes in
surfaces that change runoff coefficients.
[Link] Unless owner has provided written notice that downstream system can
accommodate the additional flow, existing systems to which new
systems will connect shall be reviewed to verify service compatibility
and to ensure that sufficient capacity is available to accept the
additional flow.
[Link] Sewer system shall provide access for inspection and repair.
[Link] Sewer line inverts shall slope continuously downstream throughout the
system such that no low points or traps are created in sewer lines.
Comment: Low points or traps in sewer lines allow for collection of
hydrocarbons that can either initiate or contribute to a plant fire.
[Link] Sanitary sewers shall be designed to keep solids suspended and
transported to the treatment facility without stagnant pockets where
solids can settle out and collect.
[Link] Process and stormwater sewers shall be designed to settle and trap
solids as close to their source as possible.
[Link] A closed system (e.g., pipe) with seals and vents shall be used for all
wastewater collection in process areas:
1) that are normally subject to hydrocarbon/oil or chemical
contamination or:
2) from process equipment contains potentially hazardous or
flammable vapors or liquids or:
3) that are subject to rainwater runoff from areas subject to
contamination.
Comment: Hydraulic seals prevent potentially hazardous or
flammable vapors from back flowing from sewer system
through the process drains. Proper venting of sewer
system prevents loss of hydraulic seals by either a pressure

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buildup or siphoning during normal sewer operations and

allows vapors to be safely discharged.
[Link] Open ditches are acceptable for stormwater drainage outside process
areas that are not normally subject to hydrocarbon/oil or chemical
contamination and not subject to rainwater runoff from areas subject to
contamination.
[Link] Natural sheet runoff is acceptable from unused plant areas that are not
contaminated.
[Link] Process sewers shall be segregated from stormwater sewer as specified
in contract documents.
[Link] Pipe material, strength selection, and installation shall be based on the
following:
1. Minimum earth cover shall be at least 1 ft (300 mm) below frost
line and not less than the smaller of 3 ft (900 mm) or one nominal
pipe diameter below finished grade.
2. Superimposed wheel load shall be a minimum of 16,000 lbs
(7260 kg), and a 50% load increase for impact shall be applied.
3. For rigid pipe, a bedding factor based on the method and class of
bedding selected, pipe crushing strength based on the three edge
method, and a safety factor of 1.5 for the applicable ASTM pipe
material standard shall be used to establish the safe supporting
strength (design load) of the pipe.
4. For flexible pipe other than ductile iron, a bedding constant and
modulus of soil reaction based on the method and class of bedding,
a pipe stiffness based on a parallel-plate loading test, and a safety
factor of 2 applied to the critical deflection limit for the applicable
ASTM pipe material standard shall be used to establish the design
deflection limit of the pipe.
5. For ductile iron pipe, minimum pipe thickness/strength shall be in
accordance with ASTM A746 or AWWA C151/A21.51 for the laying
condition selected or shall be based on a maximum design deflection
of 3% and design ring bending stress of 48 ksi (330 MPa), using the
modulus of soil reaction and deflection and bending coefficients
based on the method and class of bedding selected.
6. High density polyethylene (HDPE) sewers may be used in areas
where maximum process stream operating temperature is less than
manufacturer’s limits.
Comment: Sustained high temperatures may damage or collapse an
HDPE pipe and ultimately reduce the effectiveness of
the sewer to drain away firewater. For HDPE sewer
lines exposed to constant elevated temperatures,
temperature limits should be as specified by Piping
Manufacturer.

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[Link] Pipe joints shall be specified on drawings and shall be suitable for the
service and wastewater properties. Where zero leakage over the life of
the sewer is required, welded/fused or flanged/mechanically locked
gasketed joints shall be used compatible with the type of pipe selected.
Where nominal infiltration/exfiltration over the life of the sewer is
permissible, push-on compression gasket joints may be used.
[Link] Sewer Proximity
1. Sanitary and process sewers shall be designed to cross under
potable water lines.
2. Unless otherwise required by local codes, a minimum of 24-inches
(600-mm) vertical clearance above the sewer and 48-inches
(1,200-mm) horizontal clearance shall be provided if sanitary or
process sewers parallel a potable water line.
3. If a potable water line crosses a sanitary or process sewer line, one
segment of the potable water line pipe shall be centered over
sanitary or process sewer line such that joints of the potable water
line pipe are equidistant and at least 9 ft (2.7 m) horizontally from
the sanitary or process sewer line. Potable water line shall cross at
least 24 inches (600 mm) above the sanitary or process sewer line.
[Link] Minimum pipe sizes shall be 4 inches (100 mm) for sewers that do not
receive surface runoff and have length of run less than 75 feet (20 m).
Minimum pipe size shall be 8 inches (200 mm) for all other lines.
Smaller sizes may be acceptable for condensate drains, equipment
drains, etc.
[Link] Cleanout plugs shall be threaded to piping. In vehicle traffic area,
cleanout plugs shall be recessed below grade and have a removable
cover suitable for traffic loads.
4.10.2 Surface and Stormwater Drainage
[Link] Stormwater sewers and drainage structures shall be designed to carry
normal daily process flow and runoff from the larger of a rain event or
firewater discharge as specified in PIP CVC01017 and PIP CVC01018
provided by owner or in contract documents.
[Link] Unless otherwise specified, maximum inlet times shall be taken as
15 minutes for process areas with catch basin spacing of approximately
100 ft (30 m).
[Link] Inlet times for large undeveloped areas shall be determined for each
project with special consideration for future development but shall not
exceed 30 minutes unless otherwise specified by owner.
[Link] Piping design flow depth shall not exceed 2/3 of pipe diameter.
[Link] Minimum closed system design velocity shall be 3 fps (0.9 m/s) at average
daily flowrate. When daily rate is negligible, minimum closed system
design velocity shall be 2.5 fps (0.75 m/s) at 20 % of design capacity.

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[Link] Flow velocity for closed sections shall not be more than 10 fps (3 m/s)
for the maximum design flow rate.
[Link] Unlined ditches shall be designed for a maximum velocity of 2 fps
(0.6 m/s). In lined ditches, there are no restrictions on maximum velocity.
[Link] Freeboard for open channels or ditches shall be a minimum of one
velocity head (V2/2g).
[Link] Runoff coefficients shall be determined for each area. Unpaved areas
designated for future development shall be considered paved unless
otherwise specified by owner.
[Link] Where deferred stormwater runoff is specified, it shall be excluded
from cumulative stormwater quantities where release is through a
fully closed outlet. Where release is through an open flow restriction
outlet, the maximum discharge of the outlet shall be included in
cumulative flows in sizing the system.
[Link] Firewater for sewer branches collecting effluent from individual inlets
such as drains and catch basins shall be a minimum of 500 gpm
(110 m3/h).
[Link] Firewater for lines collecting effluent from two or more inlets
discharging to manholes on mains within process and loading areas
shall be the cumulative firewater flow from the catch basins served.
The cumulative flow shall be based on the specified firewater
application rate, which may be less than 500 gpm (110 m3/h) per catch
basin, or 1000 gpm (230 m3/h), whichever is greater.
[Link] Sewers outside process units receiving combined flow from tank
areas, process units, street drains, etc. shall be designed for the largest
single quantity of firewater discharging into the main from any one
facility or process unit, but not less than 2000 gpm (450 m3/h).
Process and/or stormwater flow in combined mains may be greater
than the design firewater flow and could therefore set the sizing.
[Link] Firewater flows for tank area shall be 500 gpm (110 m3/hr) for tank
diameters less than 40 ft (12 m), 750 gpm (170 m3/hr) for tank
diameters between 40 ft (12 m) and 65 feet (20 m) and 1000 gpm
(230 m3/hr) for all tank diameters greater than 65 ft (20 m).
4.10.3 Sanitary Sewers
[Link] Sanitary waste from toilet facilities, lavatories, floor drains in wash
rooms and rest rooms, etc., shall discharge to sanitary sewers. Effluent
from floor drains shall discharge to the sanitary sewer downstream of
the septic tank, if used.
[Link] Sanitary sewers shall form a separate system into which no
hydrocarbons/oil or other process waste may be discharged.
Comment: Risk associated with process waste should be isolated to
only process sewers to minimize the effect of sewer fires
and explosions on occupied buildings. Discharging
hydrocarbons or process wastes into sanitary sewers prior to

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treatment can reduce effectiveness of sanitary waste

treatment. If biological treatment is not included in the
treatment system, sanitary wastes would not receive
adequate treatment prior to discharge.
[Link] If facilities for treatment of raw sanitary waste are not available in a
plant or municipal sewer system, then sanitary sewers shall discharge
into septic tanks, meeting local codes and the following:
1. Tanks shall be designed for the anticipated structural loads,
including adjacent service by a vacuum or septic pump-out truck.
2. Tanks may be constructed of concrete block, precast or cast-in-
place concrete, polyethylene, or "fiberglass."
3. Capacity shall be based on 50 gallons (0.2 m3) of sewage per
person per day with a minimum capacity of 500 gallons (1.9 m3).
4. Tanks shall operate at a minimum level of 4 ft (1200 mm).
[Link] If septic tanks are used, then absorption beds shall be provided to
handle discharge from the septic tanks.
[Link] If an adequate absorption bed cannot be provided for a septic tank, then
effluent may be discharged to the process sewer if approved by
engineer of record and provided the following requirements are met:
1. All regulatory requirements for sanitary wastewater handling,
disinfection, and conveyance shall be met.
2. Outlet from septic tank shall be hydraulically sealed
3. A vent shall be provided on septic tank or on the line between
septic tank and house trap.
4. Septic tank effluent shall discharge downstream of the oil/water
separation part of the process wastewater treatment plant but
upstream of the secondary (biological) treatment facilities.
Comment: Installation of a hydraulic seal prevents the transmission
of flammable vapor from the process sewer into the
sanitary system. Proper venting prevents loss of
hydraulic seals by either a pressure buildup or
siphoning during normal sewer operations. Connecting
the sanitary system downstream of the separation
facility reduces risk of involvement in a process sewer
system fire or explosion.
[Link] Minimum design velocity shall be 2 fps (0.6 m/s) with pipe flowing
half full at maximum flow rate.
4.10.4 Process Sewers
[Link] Underground process sewers shall be designed to protect against
groundwater contamination.

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[Link] Underground process sewers shall be designed to prevent potential

leakage caused by anticipated corrosion, surface loads, shifting soils,
water tables, etc., for owner’s specified design life.
[Link] Underground process sewer joining systems shall be welded, fused, or
glued unless otherwise specified.
[Link] Underground process sewers shall be designed in accordance with
owner’s Process Safety Management (PSM), environmental, and health
requirements.
[Link] Process sewer designs shall be in accordance with regulations in
EPA 40 CFR.
[Link] Acidic or caustic waste lines shall in no case be connected to
stormwater or sanitary sewers.
[Link] Acidic or caustic waste lines shall not discharge to process sewers
unless waste has first been neutralized or treated to be compatible with
the process sewer materials and non-reactive with the process waste.
Method of neutralization or treatment is as specified.
Comment: Method of neutralization is dependent on the type of waste
present and must be specified on a case-by-case basis.
Acids and caustics can impact the treatability of certain
wastewaters and can also result in the evolution of
hazardous materials (e.g., sulfides) in the sewer and
wastewater treatment units, with potential air quality and /
or personnel exposure issues. pH extremes can impact the
integrity of sewer pipes, thereby increasing risk of sewer
pipe leakage to soil/groundwater.
[Link] Corrosive chemical floor drains and catch basins shall be piped to a
chemically resistant sump or chemical sewer. Floor drains and catch
basins shall have acid-resistant slotted covers or grates. Floor drains
shall have a strainer composed of acid-resisting material to prevent
refuse from clogging the drains. See Section 4.10.7 for requirements to
neutralize or treat acidic or caustic waste before discharge to process
sewers.
[Link] Design flow depth of gravity process sewers shall not exceed 2/3 of the
pipe diameter with a minimum velocity of 3 fps (0.9 m/s).
[Link] Materials for drain system piping from refrigerated and pressurized
storage vessels, including valves outside the enclosure, shall be suitable
for the lowest temperature that may be encountered during a spill.
4.10.5 Seals and Vents
Comment: Hydraulic seals prevent potentially hazardous or flammable vapors
from back flowing from the sewer system into the drained area.
Proper venting of sewer system prevents loss of hydraulic seals by
either a pressure buildup or siphoning during normal sewer operations
and allows vapors to be safely discharged.

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[Link] Hydraulic seals and sediment traps shall be at catch basins, manholes,
or similar structures to provide direct access for cleanout.
[Link] Catch basin seals, where applicable, shall be as follows:
1. Seals shall provide a minimum 6-inch (150-mm) hydraulic seal at
zero flow level.
2. Seals shall be gas tight and accessible for cleaning.
3. Seals shall be bolted in place or otherwise installed so as to be
replaceable without demolition of the drain or catch basin.
4. Material shall be equal to or better than the sewer line, resistant to
atmospheric conditions and the wastewater constituents, and
owner-approved.
5. Seals shall include provisions for clear, easy opening to allow direct,
full diameter in-line access to the sewer line for periodic cleaning.
6. Seal shall be at either the outlet of the catch basin or the inlet to the
manhole, and shall preferably be located consistently throughout
the plant.
Comment: Detail requirements for seals are provided to ensure that
they remain effective in prevention of vapor
transmission from one area to another. Experience has
shown that seal material can fail, resulting in vapor
(reverse) migration into a catch basin.
[Link] Vents
1. Sewers requiring vents shall be specified by owner or shall be
required on the basis of the properties of chemicals contained in the
sewers or process area.
2. Collection systems shall be trapped and sealed to prevent personnel
exposure to emissions.
3. Sewers and sewer vents shall be designed to comply with
regulations for control of volatile organic compound (VOC) and
hazardous air pollutant emissions.
4. Vents shall be located away from normal operating areas and shall
be equipped for secondary VOC emission disposal (e.g., scrubbed,
flared, etc.) if required. Vent discharge location and elevation shall
be as follows, which may require an underground extension to a
safe location and attachment to a pipe support or other structure.
a) Vent discharge shall be at least 10 ft (3 m) above grade in a
safe, open area.
b) Vent discharge shall be at least 10 ft (3 m) above any
platform, elevated road/accessway, etc., located within a
horizontal distance of 25 ft (7.5 m).
c) Vent discharge shall be above any equipment, building, or
pipeway/rack located within a horizontal distance of 25 ft
(7.5 m).

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d) Vent discharge shall be at least 50 ft (15 m) above grade

when less than 100 ft (30 m) from a fired heater, substation,
switch rack, or similar ignition source, and shall in no case
be less than 50 ft (15 m) from such ignition sources.
e) Vent discharge shall be at least 3 ft (1 m) from any other
sewer vent of a different sealed section of sewer.
5. The highest manhole or highest point in each branch of each sealed
section of the sewer system shall be vented.
6. Vent piping shall be as follows:
a) Vent pipes shall be 4 inch (100 mm) maximum nominal pipe size.
b) Vent pipes shall be vertical at the discharge end and cut
horizontal to discharge upward.
c) Vent pipes shall be sloped to drain back to the manhole
without low points, which can trap liquid.
d) Vent pipes shall have at least one flanged joint above and
near grade to allow for cleaning access and
extension/replacement without welding.
e) Vent pipes shall be marked as specified by engineer of
record for easy field identification as a sewer vent.
Comment: The vertical direction of a vent helps aid in
dispersion. It also avoids flame impingement
issues if ignited. During staged civil work, the
flange is blinded to avoid soil/gravel falling into
the vent. Caps on open 4-inch (100-mm) vents
have not been successful. Vents are marked to
highlight locations where potential hazardous or
flammable gases may be present. Sites have
different identification systems that must be
specified on a case-by-case basis.
7. Vents shall be protected from damage by mobile equipment and
vehicles.
Comment: Damage can render a vent ineffective. The result
is a non-vented sewer/manhole. Without a vent,
vapor can "blow through" and out a catch basin,
resulting in a potential fire.
4.10.6 Drains
[Link] Use of open channel floor or pavement drains in process areas requires
owner's approval. Such drains shall be covered with grating.
Comment: Open channel drains are a potential source of spreading a
fire or creating a wall of fire. Additionally, open floor
drains pose a tripping hazard to workers.
[Link] Process drains discharging to the process sewer, including open
channel floor or pavement drains, shall discharge to the sewer system
through a minimum 6-inch (150-mm) hydraulic seal such as a self-

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sealing drain hub, "P" trap, or the line sealed (submerged) into a
junction box.
Comment: Hydraulic seals prevent potentially hazardous or flammable
vapors from backflowing from the sewer system through
the process drains.
[Link] Building drains shall be as follows:
1) Floor drains shall not be installed in control houses or electrical
substations except as provided for in [Link].
2) If floor drains are used in other buildings where they will handle
process wastewater, they shall be connected to the process sewer
through a seal.
3) Drains for sample rooms, laboratory sinks, and similar facilities
containing hydrocarbons/oils, but free of corrosive chemicals, shall
discharge through a seal to an oil collection facility or sump, and
then to a process (oily water) sewer system or other closed
collection system.
4) A running trap with double hub vented to the atmosphere shall be
installed in the sewer line at a point where the drain line leaves the
building.
Comment: In critical buildings, floor drains are not permitted to be
connected to the process sewer. This practice reduces the
chance of hydrocarbon vapors collecting through a leaking or
dry seal. In other buildings, where hydrocarbons are normally
present, hydraulic seals are provided to prevent vapor
transmission. The running trap provides a vapor seal to prevent
transmission of vapors from the sump to the building.
4.10.7 Catch Basins
[Link] Catch basins shall not be located beneath equipment, pipeways/pipe
racks or major piping, instrumentation or controls, structures, or
stairways or ladders, including their landings.
Comment: Catch basins are collection points for drainage. During a
fire, flammable liquid will pool at the catch basin,
increasing risk to any facilities located above it.
[Link] Catch basins shall not be located within 10 ft (3 m) horizontally of air
fin coolers, battery limit valve stations, or valves provided for the
purposes of emergency isolation, emergency shutoff, activation of
snuffing steam, activation of water spray/deluge systems, etc.,
[Link] Catch basins in process area or process service shall:
1) One catch basin shall not be connected to or flow through another
catch basin.
2) Discharge to the sewer through a minimum 6 inch (150 mm)
hydraulic seal. Where the seal is provided in the manhole, the line
from the catch basin shall be individually routed to the manhole

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Comment: To prevent transmission of a flammable material from one

area to another, catch basin to catch basin flow is not
permitted. Hydraulic seals prevent potentially flammable
vapors from being emitted from the sewer system through
the catch basin.
[Link] Catch basins in segregated stormwater sewer service may be connected
in series with engineer of record approval.
4.10.8 Valves
[Link] Valves shall be of an end-of-pipe style that is attached on only one side
and completely free on the opposite side (see Figure 1).

Figure 1. Example of Enclosed Area Drainage

[Link] For in-line service, valves shall be installed in a manhole or similar
structure, as approved by owner, which provides the means for
continuation of flow and that, provides access for maintenance and
replacement (see Figure 2).

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Figure 2. Example Valve for In-Line Service

[Link] Valves installed in manholes or other structures shall have a position

indicator visible from outside the manhole or structure.
[Link] Valves shall be bolted in place and shall be removable without cutting
or burning.
[Link] Valve components shall be of corrosion-resistant materials such as cast
iron, stainless steel, and galvanized steel.
[Link] Moving parts shall be designed to be non-binding and made of
materials, such as brass, that do not require frequent lubrication.
[Link] Valve stems shall have a suitable closure and packing to prevent vapor from
escaping at penetrations through lids or covers in closed sewer systems.
[Link] Valves that may be subject to an unseating pressure shall be capable of
resisting that pressure.
4.10.9 Manholes
[Link] Manholes shall be located as follows:
1. Manholes shall be located at spacing intervals to facilitate
maintenance, inspection, and cleaning.
2. Manholes or cleanouts shall be provided at changes in horizontal
direction.
3. Maximum spacing of manholes shall be 200 ft (60 m) for sewers less
than or equal to 12 inches (300 mm) in diameter and shall be 500 ft
(150 m) for sewers larger than 12 inches (300 mm) in diameter.
4. Manholes shall not be located beneath equipment, pipeways/rack or
major piping, instrumentation or controls, structures, or stairways or
ladders, including their landings.
Comment: During a sewer explosion, it is possible for the manhole
lid to be launched and cause damage to any facility

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above it. The subsequent fire may also increase risk to

any facilities located above it.
5. Manholes shall be installed where a sewer line from a process unit
connects to a sewer outside the unit.
Comment: Addition of a manhole provides additional isolation of
two process areas during a sewer explosion.
6. Manholes serving more than one integrated process unit or
integrated plant area shall not be located inside a process unit.
7. Manholes shall not be located inside tank dike areas except when
they receive drainage only from the tank and dike area within which
they are located.
[Link] The top of the outlet line shall be no higher than top of the lowest inlet
line, except for inlet lines submerged to form a seal.
Comment: The top of the outlet pipe must not be higher than the top of
the inlet pipe so that during a high flow situation the system
remains adequately vented.
[Link] Sealed manholes shall be provided as follows:
1. All sewers from process areas, storage areas, loading/unloading,
pumping, or other areas where hydrocarbons/oil or chemicals are
handled shall pass through sealed and vented manholes when tying
into a main plant sewer.
2. Integrated plants or large process areas shall be subdivided into
process areas of not more than 60,000 ft2 (5,600 m2) each separated
by a sealed manhole.
3. The sewer for an individual process unit or part of a unit located
within an integrated plant but designed to operate separately from
the entire plant shall be separated by a sealed manhole from other
units and shall discharge to a main that is isolated from other
process units by seals (see Figure 3).
4. The plant main sewer shall pass through a sealed manhole before
entering a separator to prevent a separator fire from traveling back
up the sewer into the plant.
Comment: Requirements for sealed manholes are provided to ensure
an adequate vapor separation between process areas.
Additionally, area limits are provided to reduce the size
of facilities that may be involved in plant fires.
[Link] Manhole vents shall be as follows:
1. All sealed sections of a sewer system shall be vented on both sides of
the seal to prevent blowing of seals by pressure buildup, as follows:
a) Manholes with baffle-type seals shall be vented on both sides
of the seal by separate vent pipes discharging to locations at
least 3 ft (1 m) apart.

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b) Where manhole seals are established by submerging inlet

connections, a vent shall be provided on both the sealed
manhole and the next manhole upstream.

Figure 3: Example Location of Sealed Manholes to Isolate Units in

an Integrated Plant

4.11 Fencing and Security

4.11.1 Chain-link fencing shall be in accordance with PIP CVS02830.
4.11.2 If a facility is deemed a “Covered Facility”, refer to Site Security Plan and
implement appropriately risk-based measures designed to satisfy performance
standards of Part III, U.S. Department of Homeland Security 6 CFR Part 27.

4.12 Landscaping, Seeding, and Sodding

4.12.1 Surface treatments shall be shown on final earthwork drawings.
4.12.2 Seeding and sodding shall comply with local DOT specifications.

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