Piping Design and Plant Layout

Contents 1. Scope...............................................................................................................................................3 2. Codes and Standards.......................................................................................................................3 3. Design Conditions...........................................................................................................................4 4. Materials..........................................................................................................................................7 5. Pipe Sizing.......................................................................................................................................7 6. Piping Design and Layout................................................................................................................7 7. Valving..........................................................................................................................................10 8. Line Blinds.....................................................................................................................................13 9. Relief Valves and Vents.................................................................................................................13 10. Service Piping..............................................................................................................................14 11. Equipment Piping........................................................................................................................17 12. Equipment Layout.......................................................................................................................21 13. Elevation, Clearance and Access Requirements..........................................................................29 Platform, Stair and Ladder Access...................................................................................................29 14. Miscellaneous - Personnel Protection..........................................................................................30 Table 1...........................................................................................................................................34 Table 2...........................................................................................................................................35 Table 3...........................................................................................................................................37 Table 4...........................................................................................................................................39 Table 5...........................................................................................................................................40 Table 6...........................................................................................................................................41 Table 7...........................................................................................................................................42 Table 8...........................................................................................................................................43 Page 1 of 43 Table 9...........................................................................................................................................44 Table 10.........................................................................................................................................45 Page 2 of 43 1. 1.1. Scope This specification describes the requirements for spacing and layout of equipment, piping arrangement, and pressure piping design for Reliance Industries Ltd., Jamnagar Export Refinery Project. The spacing and layout of equipment shall comply with OISD Standard - 118 Layout for Oil and Gas Installations, GE Insurance Solutions, GAP. 2.5.2 plant layout recommendations, Indian Petroleum Act 1934, The Petroleum Rules 2001, safety, adequate allowance for hazard separation, and accessibility. The design of pressure piping shall comply with the codes and standards referenced herein and with accepted practices currently applicable to piping systems. The units of measure shall be metric except that pipe sizes, flange ratings and flange bolt diameters shall use imperial units. Dimensions and sizes quoted are not intended as literal conversions from one system to the other. Non pressurised underground drainage, domestic sewer piping and plumbing are excluded from the scope of this specification. 1.2. 1.3. 1.4. 1.5. 2. 2.1. Codes and Standards The Codes and Standards (latest Editions and Addenda) which are applicable to this specification are : • The Petroleum Act and Petroleum Rules • Staticand Mobile Pressure Vessel Rules. • The Indian Boiler Regulations, 1950 • • • • • • • • • • ASME B31.1 ASME B31.3 ASME B31.4 - Code for Power Piping Code for Process Piping Code for Liquid Transportation Systems for Hydrocarbons, LPG, Anhydrous Ammonia and Alcohols Code for Gas Transmission Distribution Piping Systems and ASME B31.8 NFPA 30 NFPA 58 OISD-STD-144 OISD-STD-116 OISD-STD-156 OISD-STD-118 - Flammable and Combustible Liquids Code Standard for the storage and Handling of Liquefied Petroleum Gas LPG Bottling Plant Operations Fire Protection Facilities for Petroleum Refineries and Oil / Gas Processing Plants. Fire Protection Facilities for Port Oil Terminals. Layout for oil and gas installations • OISD-STD-117 - Fire Protection Facilities for Petroleum Depots & Terminals Fire Precautions at Petroleum Refineries and Bulk Storage Installations Liquefied Petroleum Gas Large Bulk Pressure Storage and Refrigerated LPG Oil and Chemical Plant Layout and Spacing • IP Model Code of Safe Practice - Pt 19 • • IP Model Code of Safe Practice – Pt 9, Volume 1 • GE Insurance Solutions – GAP.2.5.2 • GE Insurance Solutions – GAP.2.5.2.A • 2 • • • API RP520 Part 1 & API RP521 API RP550 OSHA - Hazard Classification of Process Operations for Spacing Requirements Design and Installation of Relieving Systems in Refineries Pressure Guide for Pressure Relief and Depressuring Systems Installation of Refinery Instruments and Control Systems Occupational Safety and Administration Orifice Metering of Natural Gas Health • AGA Gas Measurement Committee Report No. 3 • UOP - Std Spec 9-51-2 2.2. - Typical Plot Plan Procedures Any requirements contained in the latest editions and amendments of local and National Codes and Standards, which are more stringent than the codes and standards listed in para 2.1, shall be adhered to. Other Requirements Separate specifications cover the special requirements for sewer and drainage systems. Special requirements in accordance with NFPA requirements apply to fire protection systems. Heating, ventilating, air and water systems serving buildings rather than plant or process areas may conform to applicable plumbing, heating, and ventilating, or refrigeration codes. 2.3. 2.4. Designation on Piping & Instrument Diagrams The P & I Diagrams are to show limits of the piping governed by the Boiler Code. They shall indicate which codes or requirements, other than Refinery Piping Code, apply to various parts of the piping systems. The extent of all package units are to be shown in full on P&ID's. 3. 3.1. 3.1.1. Design Conditions Operating conditions Normal Conditions Temporary conditions govern as design conditions only when there is clear evidence they definitely exceed time and severity limits in Paragraph 302. In addition.3. 3. Pump shut-off discharge pressure is pump differential pressure at shut-off or stalling conditions plus suction pressure and hydrostatic head.Normal design conditions of pressure and temperature are the most severe conditions expected to coexist under usual long-time operating conditions.2.1.4 of ASME B31.2.2. whichever is greater. 3.2.1 above. 3. Low Temperature Piping Design temperature for piping with a fluid operating temperature below minus 29°C.4 of the Process Piping Code ASME B31. adjusted for allowances per para.1. 3.1 above and is generally based on the design temperature of connected equipment. Design Temperature Definition Design temperature is the most severe sustained fluid temperature. 3. The design pressure for Boiler Code piping is to be established in accordance with the Code for Power Piping ASME B31. 3. DELETED. subject to conditions of section 3. 3. subject to conditions of Section 3. Design temperature of non-insulated components shall be in accordance with Paragraph of 301.3. design shall be suitable for the design pressure at 38°C. whichever is greater. ii. These usual operations include all manipulation and control functions such as throttling. whichever is greater.3. steamout or abnormal operation. blocking and by-passing likely to be used for operation and control.2. such as those incidental to start-up.3.2.1.3. 3.2. shall be the normal fluid operating temperature. Steam Traced Piping Design temperature for steam traced piping shall be the fluid temperature or 11°C below saturation temperature of tracing steam.3. 3. Pump Discharge Systems Design pressure for unrelieved piping systems subject to pump discharge pressure shall be either normal operating pump discharge pressure or pump shut-off discharge pressure.3. 302. shutdown. or The Indian Boiler Regulations 1950.2 ASME B31. Temporary Conditions Usual operating conditions do not include more severe temporary conditions. .3 Chemical Plant and Petroleum Refinery Piping.1. 3.2.1. Normal operating pump discharge pressure is the pump differential pressure plus normal suction pressure and hydrostatic head.3.2.3. Design Pressure Definition The design pressure is the most severe condition of internal or external fluid pressure.3.3. where: i. Vacuum Systems Design pressure for piping systems operating under vacuum shall be full vacuum. Refer to Piping Stress Analysis Procedure 3PS-PL008. to and including the second block valve.2. Loads Affecting Piping Stresses Allowable stress values apply to total loads imposed on piping materials. such line shall be rated at the higher rating (and shall be the same material as the line of the higher rating) to and including the first block valve or.3.3. ii. Design shall provide for all loading significantly affecting pipe material stresses. 3.7 of Process Piping Code for loadings. 302.4.5.2. Normal operating pump discharge pressure is the pump differential pressure plus normal suction pressure and hydrostatic head.3. Appendix C. Design pressure for relieved piping systems subject to pump discharge shall be either the normal operating pump discharge pressure or the safety valve set pressure.4 through 301. 301. Block valves on both sides of a control valve and the by-pass valve shall all be rated at the same specification as the line with the higher rating. Lines with Two Ratings Where a line with a lower rating connects to a pipe or equipment with a higher rating.4. See para. 3. in addition to fluid pressure which may affect piping stresses and chapter VIII for piping in category ‘M’ fluid services.3. Exception shall be taken where suitable protection against vacuum failure is provided. when double block valves are used.3.4 of ASME B31. Relief or safety valve set pressure is this pressure plus hydrostatic head below relief valve adjusted for allowances per para. whichever is greater. where: i.3. 3. . 2½".1. 4. Piping outside of main pipeways shall run parallel to main pipeways wherever possible. temperature and pressure services.3. Piping smaller than ¾ inch shall not be used except in instrument and steam tracing services.1. flange. but shall be calculated to suit specific line service conditions. 4. bolting. 5. Branch reinforcement is to be based on "limited" corrosion. 25194-3PS-PL-001.4. 5" and 9" are not to be used except where equipment connections are these sizes. Piping on elevated racks shall run at different elevations designated for north-south and east-west banks. 6. In such cases. and change elevation when changing direction.1. Pipe sizes 1¼".1. wall thickness shall be selected on the basis of calculations to suit individual line conditions.1.3.1. Provision for future increased capacity shall be made when specifically requested. Refer to Specification No.3. 4. 5. 4. other than that required for pressure and corrosion allowance.3. Corrosion Allowances Corrosion allowances shown in the Piping Materials Classes is the maximum for the respective service and material.1. 6. 3½". 6. Relative elevations of pipeways shall be set to provide sufficient clearance between lines at intersections.3. branch connection and other specific material requirements for various classes of fluid. fitting. For wall thicknesses not specified in the pipe classes. 4. where all excess metal in the pipe wall. Pipe Sizing Piping is to be sized for normal operating conditions.2. as follows: 6. 4.1. transitions to other commercial pipe sizes is to be made as close as possible to the equipment connection.3. preferably in established banks or pipeways. 5.2. . Materials Piping Materials Specification The Piping Material Classes shall list in detail the pipe. 5. Piping Design and Layout Piping Routing Piping is to be arranged in an orderly manner and routed as directly as practical.3. Wall Thickness and Reinforcement Wall thickness and branch connection reinforcement requirements shown in Piping Material Classes are to be suitable for use in the most severe pressure-temperature conditions within the class limits. 6. valve.2. is credited to branch reinforcement. Pipe wall thicknesses may not be specified for the full pipe size range within a class. gasket. All components listed in a Piping Class shall be suitable for use within the pressure/temperature limits of that class.2. All process piping within unit plot limits shall be carried overhead. should be grouped together so that the intermediate supports may be simplified. Flat turns at changes in direction are to be avoided on elevated pipe racks.1. 6.6.7.1. 6. Control valve sets and manifold sets. caustic or other corrosive services shall not have flanged joints located above access ways or platforms. the minimum sleeper height is to be 400mm above the bottom of the concrete trench. Overhead lines in acid.11. . Piping line size to be a minimum of 2" in pipeways / piperacks. Piperacks and sleeperways shall be sized to allow 20% spare capacity on completion of engineering.6. where practical. 6. the minimum sleeper height is to be 600mm.1.1.10.8. An additional 20% spare capacity shall be allowed at commencement of detailed engineering to allow for design development. e.1. Piping located in paved areas to be elevated 600mm to bottom of pipe. Where pipes are running at grade in graded areas the minimum BOP of pipes is to be 500 mm. 3" & 4".1.1.1.9. Where pipes are running through interconnecting corridor and anywhere else that the pipe runs over the ungraded natural contours of the terrain.4.1. 6. Small bore thin walled lines SCH 10S or less for 2".12.g. 6.1. Lines whose temperature can drop to such a degree that the moisture in the surrounding earth would freeze shall not be buried but carried overhead or run in trenches.1. Overhead flanged joints in these services shall be fitted with a plastic shield. 6. Where pipes are running in sloping trenches passing under roads. Lines requiring limited pressure drop shall be routed as directly as practical. 6. Offplot piping between units shall be run on sleepers at grade. Dead ends and pockets in line are to be avoided.5.14. 6.13. 6. 6. guides. Expansion loops shall be used to reduce thermal expansions and absorb excess stresses where the normal pipe routing is too stiff.2.2. or mechanical vibration (including wind) conditions exist. 002 and 003. Adequate spacing to be allowed for expansion / contraction between lines at loops and any change of direction. other than shoes. For strain sensitive equipment such as turbines. Piping without flanges to have 100mm clearance between bare pipes or between insulation. configuration. The exception to the above is that shoes welded to stress relieved lines shall be shown and dimensioned on electronic isometrics. Pipe Spacing Minimum spacing between pipes shall be based on staggered flanges with at least 25mm clearance between outside of bare pipe or outside of insulation. All pipe supports.. 6. Welded support attachments. . Piping shall be supported from below in preference to hanging from above.6.4. All piping shall be adequately supported and restrained so as to prevent undue vibration. mechanical strength. supports and restraints will prevent excessive stress.4. For details of pipe spacing refer to project standard drawing No’s 25194-P14JG000-001. Expansion bellows shall not be used without prior approval of the Engineering Manager. stops or guides shall be used to direct thermal expansion away from pumps and turbines etc. Piping Flexibility Piping shall be designed with sufficient flexibility to absorb any excessive stresses.2. 6. 6. stresses or loads on equipment.1. Pipe Supports. fluctuating temperature or pressure. lugs. shall be shown and located on electronic isometrics.2.3. to outside of bare flange or outside of flange insulation on adjacent line. vibration or noise. deflection. shoes etc. will be shown on the 3D PDS Electronic Model. Pipe Support Procedure shall be in accordance with Specification 25194-3PSPL-015. 6. 6. high velocity flow. etc. Consideration shall be given to the intermediate supporting of smaller lines from larger lines.4.2. flashing fluid. Anchors. pressure drop.3. All lines shall be designed in compliance with the relevant code requirements.1. Lines subject to dynamic loading shall be designed to ensure that its size. Anchors & Guides 6. such as trunnions. 6. piping may be supported by rigid / spring hangers to take benefit of low friction and to permit any size adjustments that may be required.2. Dynamic loading may be expected when pulsating flow (such as at reciprocating compressors). 2. 7. Lines from condensers to accumulators. 7.3.1.1.4.1. The need for wear plates or shoes shall be investigated for large diameter and thin wall alloy piping. Other piping shall be direct buried. 7. Pipe Shoes Horizontal lines 2" and larger with insulation shall be run on shoes as per spec. Unless specifically required for operation.6.3.2. shall be in trenches.1. No block valve shall normally be provided in lines or at vessel nozzles for services as follows: Vapour lines to condensers. 7. Multiple lines running below roads or railway lines shall be either sleeved or run in culverts dependant on the most economic installed cost.4.5.2. 7. 6.3. For all other services paragraph 9. Liquid and vapour lines to and from syphon reboilers.5. Consideration must be given to the drainage of culverts and the effect on the hazardous area layout. 7.1. Lines between exchangers in series. The use of pipe trenches shall be avoided.1. Valves shall be installed so that stems are not below the horizontal position except cryogenic valves with extended bonnets which shall not be less than 45° above the horizontal.5. 6. 25194-3PS-PL-019. 6. piping provided with protective heating and piping in services requiring inspection and servicing. where flammable heavier than air gases can collect. the bottom half of insulation is to be cut away a distance of 150 mm on each side of the support. 7. 7.1. 7. 7. Locked open or car . Block valves shall be provided at all 1-½″ and smaller connections at equipment. Bare lines shall be laid directly on the piperack beam or sleeper. 6. When located below grade. 7. Valving Valves Operating and block valves are to be provided in minimum quantity consistent with good design and operating practice. 7.1.4.2. 7.3.5.2.1.3.1.1.1. block valves shall not be provided at vessel nozzles when the following conditions exist: Line to or from the vessel can be blocked by a valve located within 12 metres horizontal radius from vessel surface. 6.5.3.2. Underground Pipes Direct buried Carbon Steel Pipe shall be coated and wrapped. On 1-½" and smaller horizontal lines shoes are not to be provided.1.2.5.3.1.3 applies.1. 7. No block valves to be placed upstream and downstream on steam and boiler feedwater service relief valves (requirements of Indian Boiler Regulations).1. No undrainable liquid pocket in the line between vessel and valve.4.5.3.1. Line vents and drains fall into two categories. 7. 7.5. Line Vents and Drains Vents and Drains conforming to the following table shall be added to large bore lines. Globe valves shall be installed so as to close against pressure. 7. Header Block Valves Branch line block valves from pipeway headers shall be provided in primary branch lines serving groups of lines to equipment. 7. 7. Unit Block Valves Block valves shall be fitted on the unit side of plot limits to all overhead and underground process lines entering or leaving a process unit.2.5. For double block and bleed requirements see isolation philosophy document 25194G98.2.2.7.1. 7. a metal tag shall be attached to the valve: reading "This valve must not be closed without written permission from responsible authority".2. The vent / drain connections shall be branch connections according to the relevant branch table complete with blind flange. operating and non operating.3. Valves shall be included in the MTO for drains only. except where the main header may be shut off without affecting unit operation in the event of failure in a branch line.sealed open valves will have accessibility from fixed or a rolling platform or scaffold and not from a fixed or portable ladder.1. Drain valves shall be fitted on unit side of the block valve.1. Pipe Size 10" 12" 14" 16" 18" 20" 24" 30" 36" 42" 48" Up to 150 m 2" 2" 3" 3" 3" 3" 3" 3" 3" 4" 4" Greater than 150 m 3" 3" 3" 3" 4" 4" 4" 4" 4" 4" 4" 7.1. 7.2.4.JG000-001 and P&IDs. . Where a locked open valve is required.6. 7.4.3. 7. Double Block & Bleed Valves 7. 7. this will apply mainly to the pipeway between the Refinery and Marine Tank Farm and lines on the main interconnecting piperack.1.3.5.1.5. Branch line block valves must be located at edge of pipeway for access by portable ladder. 7. For assembly details refer to Drg 25194-P14-JG000-027. Non operating valves are valves that are not essential for plant operation.1. Where a connection connects to a process line the tie in shall be made at the side or top of the line.8.8. Open drains shall be valved. 7. Yes Yes * * Yes Yes * * (See Para. All other valves shall have stems orientated in the vertical.1.8. Valves in Caustic and Acid Services Valves in vertical pipe runs shall be located at a maximum height of 1350 mm from grade or platform.6. incorporating a blind flange when venting to atmosphere. 7. Non-Operating Vents and Drains shall conform to the following: i) For all hydrocarbon and hazardous service lines.6 bar and 117°C do not require high point vent connections on piping.8.6. 7.2.3) Non Operating Valves (7.7. 7. . 8.3) Instrument Valves 7. (The vents and drains shall not be shown on Piping & Instrument Diagrams).5. Generally vents and drains are to be ¾" dia.6.1. inert gas.3.Instrument Access) * To be used if available.2) Non Operating Valves. Operating Vents for equipment and piping shall be valved.2. 7.2.7.8. ii) iii) All other services shall have vent and drain connections provided at the high and low points of the piping system to facilitate maintenance and hydrostatic testing.2. Length of sample piping to be kept to minimum.3.8. 10.6.7. Valves shall not be provided on such connections to eliminate the chance of leakage through the valve gland.8. 7.1.1) Operating Valves. 7. 7.1.3. Operating valves are valves that are essential for plant operation. 7. and steam not exceeding design pressure or temperatures of 9.8. Systems for air.5. 7. Small (7. 7 . non-operating vents and drains shall be closed with a cap and seal welded.8. Small (7. Sample Connections Sample connections shall be located for easy access from grade (preferred) or fixed platform. together with a blind flange. 7. Valve Access Type of Access Required Grade Fixed Platf Rolling Platf or Scaffold No No Yes Yes Fixed Port Ladder Ladder No Yes No Yes No No No Yes Operating Valves (7. the other holding a ladder and are normally 2" and smaller. 8. 8.3.3. All lines entering or leaving process unit limits shall be provided with operational blinds as follows: No blinds required on air.2. Special attention must be given to the line flexibility when ring joint blinds are used.2. either by use of a 90 degree spool piece or preferably by incorporation of an appropriately designed 90 degree flanged nozzle on the vessel. 8. Chain Operators Operating valves with bottom of handwheel over 2000mm above actual grade or platform shall be chain operated.7. Blinds shall be accessible from grade or platform.3.2.4.g.2. In cases such as sample points where one hand holds the container and the other the valve. 8.2. Blinds/spacer shall be provided where indicated on the flowdiagram. Blind and Spacer Installation on Vessel Top Nozzles Where possible all blind and spacer sets for overhead lines 14" and above should be located in the horizontal axis.3.1. For details of blinds refer to project standard drawing Nos.4. 8. Lifting shall be by mobile equipment. locked/car sealed valve or any valve 1½" and smaller. then a platform access is required. 9.2. 25194-P14-JG000-018 and 019. water and lines containing non-toxic materials.2. For handling purposes blinds are to be installed preferably in the vertical (between flanges in horizontal part of line). hitching point shall be provided. For details of jackscrews refer to project standard drawing No’s 25194-P14-JG000-020 and 021.6. 8.2. 8.8.1.8.2.2.7. All flanges 3″ and larger adjacent to blinds to be complete with jack screws. When possible.8. Line Blinds Operational blinds shall be provided where process requirements indicate that part of the unit may logically be idle during operation of balance of the unit. Chains shall not hang in walkways or access areas and shall terminate approx 1000mm above grade or platform. 8.1. If the blinds/spacer is not accessible. Lines below 14"which have high pressure flanges with ring type joints down to 6" dia should be considered in the same way. 8. 7. 8.3. Grouped flanges with blinds (e. 8.2. 8. Small valves are defined as valves that can be easily operated with one hand. install a blind in combination with flanged elbow sections. Provide blinds on unit side of block valve on all overhead and underground process lines and all lines containing toxic material. When binds/spacer exceeds 45 kg.5. steam. 8. Relief Valves and Vents . at battery limit) are to be staggered. 8. Chain operators shall not be used for screwed. 10.4.3. 9. Vents from manholes shall be elevated 3 metres above grade or platform within a radius of 4. For details of steam trap arrangements refer to Project Standard Drawing No.3. Relief valves discharging into a closed blowdown system shall be elevated to provide self draining of the discharge line into the blowdown system.1. 10. to prevent liquid accumulation. 10. Steam Traps Provide steam traps at low points and drip legs of steam lines.2. 9. 9. Provide valves on each side of trap for trap removal on closed systems. Refer also to para. protecting blocked-in process piping or equipment against fluid thermal expansion shall discharge to a suitable drain or closed blowdown system. shall be located to prevent hazard to personnel. and continuously operating vents. 9.6.2. Block valves located upstream of a relief valve shall be full bore and the valve noted as "Locked open" on the Piping & Instrument Diagram. 9. 10. 10.2. The discharge of steam.9.2.8. safety valves. or similar non-flammable vapours from relief valves. Discharge steam traps to a lower pressure steam or condensate system (All steam traps shall be accessible from grade or platform). All relief valves shall be accessible from fixed platforms with the exception of thermal relief valves which can be accessed by portable ladder. Block valves shall be installed in a horizontal run of each branch line to group of common users. Manhole vents shall not be located closer than 15 metres to fired equipment. A 6 mm diameter weep hole shall be provided in the bottom of tail pipes. 25194-P14-JG000011.2. Small relief valves. 10. Relief valve tail pipes discharging to atmosphere shall terminate not less than 3 metres above any platform within a radius of 7. 10.1. 9. Branch connections shall be made from the top of the headers. 9.5 of this document. 9.1. will be provided at the discharge of each relief valve.1. Drip legs shall be located such that they do not foul pipe support steel or rack structures due to expansion.9.1.2. 10. Drip legs shall be provided on all steam lines at all low points and dead ends.4. air.3.1.7. Lifting devices shall be provided for valves weighing more than 45 kg.1.5 metres. 10. Service Piping Steam Piping Piping shall be designed for complete condensate removal.2.4.2.1. . 7.1. Vents adjacent to piperacks shall be elevated a minimum of 3 metres above the top rack level. A guide and linestop which is capable of withstanding the relief valve reaction force.5. 10.5 metres. 10.3. Piping shall be designed to make use of sub-headers to serve an area of process equipment or groups of drivers. 10. consisting of air.5.1.2. Block Valves are normally line size. For details of steamout connections refer to Project Standard Drawing No. Steam Tracing Where process lines require steam tracing they are to be indicated by a dotted line on the Piping & Instrument Diagrams. 10.10. as required.5. 10. Air System Piping Air piping system shall be designed for good drainage.4. 10.5.3. Utility stations shall be installed such that they remain in operation during unit shutdowns.1. shall be located throughout the operating area of each process unit. 10. but where control valve is two or more sizes smaller than line size.1.8. 25194-P14-JG000008 to 010 inc. Instrument air headers within process units shall be provided with a valved connection every 6 metres for field routing of air supplies to instrument distribution manifolds. 10. 10.6.2. 10. Drains shall be provided on the dead end portion of lines. 10. 10. . 10.2.3. 10. Branch connection shall be taken-off from the top of the header.8.5. Instrument Piping Control Valve Manifolds Where required by the P & ID control valves shall be supplied with block valves located up and down stream of control valve and a by-pass. 10.8.1.3.2.4. Additional utility hose connections for air and steam shall be supplied at platforms for tower manholes and elevated structures.4.4. Steamout Connections Steamout connections are required for purging vessels and pipelines containing hydrocarbon and hazardous fluid.1.5. No extension of Nitrogen lines to utility hose stations.1. 10. 10.7.7.3.8. Hoses serving steam out connections shall not exceed 15 metres in length.2. so that a 15 metre length of hose can service any point in the area.4.3. 10.6. Steamout connections shall not be less than 1″NB.3. For details of steam tracing requirements refer to Project Standard Drawings No.7.5. the block valves may be one size smaller than line size.1. Provide drain valves and drip legs at the low points of systems. except for cryogenic or LPG systems.3. 10. Use of Nitrogen only through hard piping. 25194-P14-JG000-012.5. 10. steam and water.1. Utility Stations Utility stations at grade. Water System Piping 2″NB and below branch connections from cooling water headers shall be taken from the top of the line.1. Above ground liquid lines subject to freezing are to be steam traced if the liquid cannot be circulated. 10. 10. 10. 10. For “fail closed” valves. 10.8.RP. . Orifice Metering of Natural Gas. Piping subjected to these conditions shall be analysed and designed to ensure that its size and configuration downstream of the valve prevents excessive vibration and noise.3.10.5.8.8. Supports at control valve manifolds shall be located so that the assembly is self supporting when the control valve is removed.6.3.8. Orifice flanges may be located in horizontal or vertical lines.1.4. In case of high pressure drop.2.5. vendor shall be consulted for provision of a suitable diffuser. Their locations must be consistent with their function and with convenience of plant operation.8. 10. 10.8.1. 10. In general. they shall be located in sight of instruments or indicators showing the variables they control. 10. 10. the location of taps in steam flow shall be horizontal or at 45° upwards from the horizontal and in liquid flow shall be horizontal or at 45° downwards from the horizontal. 10.2. bleed valves shall be located upstream and downstream of the control valve between the control valve and block valve. For configurations of Control Valve Manifolds refer to Project Standard Drawing No.8. Refer to Systems Standard Drawing No 25194-J10-JG000-026.8.1. 10. Level Instruments Location Level instruments shall be accessible from grade.8.1. Bleed valves shall be located between upstream block valve and control valve for “fail open” valves.1. platform or ladder. Strong Backs Where strong backs are provided for external level instruments. high fluid velocities along with extreme noise levels can be expected.4.3. Location of Control Valves Control valves shall be located at grade or on conveniently accessible platforms.1. 10. Orifice Taps Orifice taps are to be located vertically upwards for gas flow on horizontal lines.7.8. 10.6. Their location is to be consistent with function and with convenience of plant operation. 10. By-pass valve and piping shall be same size as control valve.2.8. Provide sufficient clearance at orifice flanges for installation of instrument piping and seal pots where required. Control valves in flashing service shall be located as far downstream of the line as possible whilst complying with the requirements of 10.1. 10.1. and AGA Gas Measurement Committee Report No 3.8.8. 10.1.The assembly shall be suitably supported to avoid unnecessary movement due to expansion. 10. their minimum pipe size shall be 2". 25194-P14JG000-007.6.8. if the meter is located in piperacks.8.2.5.2.4.4. pipe nipples shall be seal welded. 10.1.8. and the minimum length shall be in accordance with API. Orifice Runs Horizontal meter runs are preferred. 550 PART I. High Pressure Drop at Control Valves Where high pressure drop conditions exist across control valves. 10. Block valves shall be provided at the vessel connections.8.2.8.1. 11.1. When vessel is insulated allow a minimum clearance of 150mm between back of pipe and insulation. Locate items such as bridles with level instruments at dead end of platforms if possible.8. Connections Inside Skirts .2. Over-head vapour lines and similar connections 18" and larger may have a welded connection to the vessel. Vertical lines down columns or vessels shall be suitably supported from vessel and have a minimum of 300mm clearance from the outside of shell to back of pipe. Cold pull piping shall not be used in piping between maintenance joints. thereby eliminating normal operator travel around such items. Client shall be consulted before using cold pull in any piping.1. 11.1. Manways and platforms shall be located on the access side. Type of instrument Access Required for Operation No Yes Yes Yes Yes Yes Access from Grade Portable Fixed Ladder Ladder Yes No No No No No Yes Yes Yes Yes Yes Yes and/or Fixed Platform Yes Yes Yes Yes Yes Yes Thermocouples & Resistance Bulbs Test Thermowells Dial thermometers Pressure Gauges Level Gauges/Level Transmitters Transmitters (blind or indicating including sensing element) Field Controllers & Recorders Field Switches (Alarm & Control) Control Valves & other final Control Elements Analytical & Other Special Instruments Orifice Flanges Yes No Yes Yes No No Yes No No Yes Yes Yes No Yes Yes Yes Yes Yes Yes Yes 11.7. except where flanges are required for maintenance or blinding.10. Equipment Piping Vessel and Column Piping Piping at columns shall be located radially about the column on the pipeway side.1. 11. Instrument Access Table Instrument Access requirements shall be provided in accordance with the following table. shall be provided on vertical vessels.2.1. Allowing sufficient flexibility for final fit up with equipment nozzles. so that discharge is plainly visible.2.1.1. 11. and on vessels not accessible by mobile crane. Exchanger Piping Piping to shell and tube exchangers shall be provided with break-out flanges to permit easy removal of shell covers. Vents and Drains A valved and blinded atmospheric vent shall be provided at vessel high points and/or overhead piping with platform access provided for valve operation. 11. Platforms shall be provided at manways above 3 metres above high point of finished surface.3.1 Water Lines 11.1 Piping is to be arranged where practical. 11.1.2 Thermowells .2. Davits shall be oriented to allow the lowering of appurtenances into the access area.5 metres from grade.5.1. Adjacent columns shall be provided with combined platforms and manways at common elevations whenever possible. 11.2.2. platform. channel covers.1. 11.. 11. Platforms or fixed ladder shall be provided at all nozzles which require blinding during maintenance periods. The interval between platforms shall not exceed 9000mm. The bottom of the manhole entry shall not be more than 1070 mm above the platform. 11.Valves and flanges shall not be located inside vessel skirts. with 760 mm preferred. Draw-off Boots Draw-off boots on elevated horizontal vessels may be extended a reasonable amount to place the centres of gauge glass and level controller not over 1.1.1. Vessel davits for handling internals. 11.4.5. When practicable. 11. connection shall be piped from the bottoms-out line. 11.4.2 Cooling water supply and return piping connected to underground headers shall be piped as directly as possible.1. Allow adequate clearance for mobile handling equipment. or ladder access. so that water remains in all units on loss of cooling water supply.1.1. 11.1.5. Drains provided at vessels shall run to underground systems with open connections terminating 50mm above the drain hub. 11.3. channels and bundles. relief valves.3.3. Hot piping shall be routed in such a way that line movement due to thermal expansion matches that of equipment it is connected to. Platforms shall be positioned so that the manhole centreline is not less than 610 mm above the platform. etc.2. or check valves properly located.2. Piping must be adequately supported such that bundles can be removed without use of additional temporary supports on piping.3.3.1. 11. 2. 11. Weight and Thermal Stress Where possible.4. they shall be installed on adjacent piping. Concentric reducers are preferred where size changes are necessary in pump suction lines. Air Cooled Exchanger Piping Inlet piping to a heat exchanger units made up of multiple bundles shall be designed to provide for balanced flow and pressure drop through the tubes. 11. If grade level supports are required at pumps.4. 11. (Forces and movements at nozzles shall not exceed those allowed by the equipment manufacturer).4. to avoid differential settlement. Pumps with side suction and discharge nozzles may require up to 7 diameters length of straight pipe before suction nozzle in accordance with manufacturers recommendations.3. such as at end suction pump inlets.4. Split Header Bundles Piping connections to split header bundles shall incorporate necessary flexibility to accommodate the anticipated movement produced by differential temperature within the bundle. Access to Pumps and Turbines Piping at pumps and turbines shall be arranged to avoid interference with operation or maintenance access.3. This will allow piping to be supported without the use of springs. 11.1.When thermowell connections cannot be provided on exchanger inlet & outlet nozzles. Pipe bends before suction nozzles to be positioned where possible in the same plane as the pump shaft. centrifugal compressors or turbines they shall be installed on an integral extension of the equipment foundation. . pump discharge piping to be brought down to pump centre line level with check valve and isolation valve located horizontally. 11. Pump and Turbine Piping Pump Suction Piping Pump suction piping shall be arranged with particular care to avoid unnecessary pressure drop and vapour pockets.3. Suction and Inlet Strainers 11.2. Consideration shall be given to piping configurations to minimise these stresses. (Forces and moments are not to exceed those allowed by the equipment manufacturers).3. Sources of disturbance such as bends and branches shall be minimised to avoid vortex formation and uneven velocity distribution.1. Grade level pipe supports at pumps are to be adjustable type. Pump suction and discharge piping shall be designed to be self supporting to permit maintenance without major piping and pipe support disassembly. Eccentric reducers with flat side top shall be used at all horizontal pump nozzles. Possible two phase flow must be considered. 11.4.4. Suitable supports or anchors shall be provided so that excessive weight and thermal stresses are not applied to the casings. Removable spool pieces shall be provided as appropriate. 11. Removable spool pieces shall be provided at compressors where needed to permit maintenance without major piping disassembly. Diagrams.4. Direct Fired Heater Piping Inlet & Outlet Process Piping .2.1. Suction and discharge lines shall be supported independently of the compressor shelter. unless permanent strainers are specified. 11. the discharge valve being located downstream of the check.5.6. If this is not practical then knock-out equipment shall be installed as required by the P & ID. 11.2.4.2. Tariff Advisory Committee (TAC). Volume bottles may be provided as required.2. Compressor Piping Suction Piping 11.2. 11.5. Suction and discharge piping shall be run on sleepers at grade.1.5.1. Centrifugal Compressor Suction piping shall be designed to ensure that the configuration of the piping and the length of straight pipe at inlet nozzle is adequate and does not adversely affect the compressor performance.1. 11.5.1.4.2.3.1.2. This arrangement permits simple and effective supports of the lines to reduce vibration. Removable Piping for Maintenance 11. Piping shall be run to avoid the possibility of trapping of collecting liquid.1. 11. Firewater Pump valves and Relief valves shall conform to the requirements of NFPA 20. Suction valve to be located upstream of strainer.5. Particular consideration must be given to design of piping subject to vibration from dynamic loading associated with reciprocating compressors.1.5.4.Temporary strainers with a pipe spool shall be provided at all pump suction.5. 11. When a positive displacement pump is not equipped with a built-in relief valve. 11.6. Block valves shall be installed in the suction and discharge of all pumps. Pump Valves 11.5.3. These lines shall also be subject to an analog / digital study.5. 11.5. a relief valve shall be installed in the discharge piping between the pump nozzle and the first block valve and shall normally discharge into the pump Suction Line.3. Check valves shall be installed in the discharge line of each centrifugal and rotary pump. 11.5.5. 11. 11.1. Temporary conical strainers with pipe spool shall be installed in compressor suction lines between the block valve and suction flange and indicated on Piping & Inst. 11.5.5.3. Vibration (Reciprocating Compressor) 11.5. 11. between block valve and suction flange and turbine inlet nozzles.3. 11.2. Condensate legs. and of the same length. Space required for tube maintenance shall be kept free of all piping. General 12. . 11. Take-off connections shall be made from the top of the steam and gas headers and piping arranged for equal flow distribution. from the point where the flow splits at the heater inlets. Burner and Snuffing Steam piping at Fired Heaters Burner piping shall be kept clear of all access and observation openings. being symmetrical. Any further isolation valves required as per P & ID are to be located outside of the bund wall with access readily available.2. Snuffing steam manifold shall be located 15 metres minimum distance away from furnace. Storage Tank Piping 11. however non symmetrical piping may contribute to the uneven heating and possible coking up and overheating of tubes.1. with similar fittings. 12. and that minimum loads are transferred to the heater coil supports.2. Unless required for common operation or safety reasons. Burner pipe valving shall be accessible when viewing through peephole. 11. Process Units shall be located on high ground to avoid flooding. This will reduce the risk of refractory lining damage. equipment is to be located in process sequence to minimise interconnecting piping.6.6. Consideration shall be given to the Symmetry of heater outlet piping. Preference shall be given to the inlet piping to heater.6. 11.6.1. to provide for easy and convenient removal of burners for maintenance.1. knockout pots or other approved methods for the collection and elimination of condensate shall be provided. Equipment within process and offsite areas shall be arranged to satisfy safety. Tank isolation valve and first pipe support shall be preferably supported from tank foundation to avoid differential settlement and use of spring supports. 11. Adequate flexibility shall be provided in connecting piping so that the tank nozzles are not distorted if tank settlement occurs.2. 11.1.1. In general. operational. or other specified means.1.1.6. DELETED.2. burner piping is to conform to the following requirements: 11. maintenance and construction requirements.2. Equipment Layout 12.2. Equipment shall be spaced to allow for safe operation and maintenance with due consideration to construction space requirements.1. Storage tank isolation valves shall be located at the tank nozzles.7.7.7.6. 11.1. Piping to the burners shall be made using flanges. Symmetry of outlet piping from heater is not so critical. 12.2 Inlet /outlet piping shall be supported such that imposed loads on coil flanges are kept to the absolute minimum.2. Piping shall be located to maintain a minimum of 2 metres clearance under the heater. these and Utility Units shall be arranged to suit independent operation and shutdown. Pumps Pumps shall be located close to the associated equipment so that suction line lengths are minimised.Each unit shall have a rectangular shape of maximum size 183 meters by 92 meters recommended for fire fighting purposes. For Minimum Spacing required between Facilities and Units refer to Table 4.4.5 metres. down to grade for removal by mobile equipment.2.2. For petroleum depots and terminals refer to clause 4.1.3.2. or walls. recommendations. .4. Pumps handling flammable materials shall not be located below piperacks. Space for future expansion shall be provided where specifically requested by job specifications. Firestations shall be close to main entry gate with straight approach to critical areas. Control rooms and Switch rooms shall be in a non-hazardous area if located 30 metres from the nearest source of flammable hazard in a Process Unit.3.3.3.5(v) of OISD . by means of overhead lifting gear. 12. 12. from the centre line of piperack column or outside edge of cantilevers for pumps operating at 260°C or above.3. 12.4. and a minimum of 3000 mm for pumps operating at 250 °C or less. Buildings 12.1. 12. Administration buildings shall be grouped and located upwind of operating plant areas. as required by GE Insurance Solutions. Minimum edge to edge between pump foundations shall be 1. Buildings comprising of more than one floor. 12. 12.2.1. 12. are to be provided with adequate access openings in floors.3. Compressors shall be housed in shelters to provide protection for equipment and personnel. (GAP). Located adjacent to a roadway and downwind from Heaters. 12. but with sufficient space required to provide adequate flexibility.1. For Minimum Spacing required within Process Unit Layouts refer to Table 5. 12. 12.4. 12.3.4.3. They shall be of blast resistant and pressurised design.4. Compressors 12. Centrifugal Compressors shall be a minimum of 7.3.2.117. Firewater Storage and Pumps shall be located a minimum distance of 60 metres from Hydrocarbon Storage and Process Units.1. and Processing Units.6 metres from Reciprocating Compressors.2. to enable equipment from upper floors to be lowered. located at Unit periphery and adjacent to a roadway. Pumps shall be located such that the pump discharge is a minimum of 4500 mm min. Adequate parking facilities shall be provided at buildings which are normally occupied. 12. 12.2.2. Exothermic reactions with no flammable liquids or gases shall also be included in this hazard group. Reactors shall be located for ease of access during catalyst unloading and loading operations. Small compressors may be grade mounted with piping and auxiliaries arranged for convenient access and maintenance. Typical process examples include: • • Acetic anhydride (carbonylation of methyl acetate) Acetone (dehydrogenation of alcohol) . 12.5. that are not accessible by mobile equipment.5.4.5. Where necessary provision shall be made for the installation of temporary handling equipment during catalyst unloading. 12. Vertical vessels are to be placed on a common centreline parallel to the main pipeway. internals.5. Moderate This category shall include endothermic reactions and other operations.5. Horizontal vessels shall be located to minimise piping runs and where practical. 12. as to permit the lowering of this equipment to a clear drop out area at grade. 12. Permanent facilities will not be provided unless expressly required by the process licensor.4.4.4. 12. Davits shall be orientated in such a way. absorption.4. Vessels and associated piping should not encroach into established operating or access aisles.5.3.2. mixing and blending of flammable liquids. Vessels 12. 12. Space shall be allowed for cranes and storage of spent and new catalyst.5. Where possible all compressors in a process unit shall be grouped together and located in a single shelter to reduce the cost of structures and cranes. Compressors may be elevated sufficiently to permit piping and auxiliaries to be located below operating platform.6.12. A bridge or gantry crane shall be provided for removal of compressor components.5. 12.1. a drop area shall be provided at one end of compressor shelters. This includes combining different types of compressors where an economic shelter design can be achieved.1.5. Davits shall be provided on top of vessels to handle relief valves 4" and larger. Suction and Interstage Knockout Drums shall be a minimum of 4 metres from Compressors. 12. be lined up with their tangents on a common locating line on the piperack side of the unit. such as distillation.3. Provision shall be made for removal of such items via removable roof panels. There shall be three hazard groups for Reactors: • • Moderate Intermediate • High 12.5. etc.4. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Adiponitrile Amine Treating (ATU) Ammonia Butamer Coker Crude distillation CRU Platformer DEIC5 Dimethyl formamide Chloromethanes Ethanol (from methanol) Ethylene glycol Fluid cat Cracking (FCC) Formaldehyde (methanol oxidation) Heavy Naphtha Hydrotreater IC5 Extractive LMG Merox Methyl amines Methyl ethyl ketone (dehydrogenation of alcohol) Polypropylene (PP) Polypropylene Recovery (PRU) PSA H2 Sat.5.2. & Unsat. This category shall include slightly exothermic reactions.5. Typical process examples include: • • • • Acetic anhydride (from acetic acid) Alkylation (Refinery) Benzene (from toluene-xylene) Benzene-Toluene-Xylene (BTX) . LPG Merox & Dec3 Solvent extraction Sour Water Stripping (SWS) Styrene Sulphur Recovery (SRU) Tail Gas Treating (TGT) Urea VGO Hydrotreating • Visbreaking 12. Intermediate Processes or operations having an appreciable explosion hazard and a moderate fire hazard are included. 5.5. High This category includes highly exothermic or potential run-away reactions and high hazard products handling.• • • • • • • • • • • • • Cumene Cyclohexane DHDS Ethyl benzene Hydrogen Unit (HMU) Methanol (Reforming) Polyethylene HD (small units) Polypropylene Polystyrene Polyvinyichloride Reforming (Refinery) Scanfining Terephtalic Acid 12. Typical process examples include: • • • • • • • • • • • • • • • • • • • • • • Acetic acid Acetaldehyde (oxidation) Acetone (cumene oxidation) Acrolein Acrylic acid Acrylonitrile Butadiene (oxidation) Caprolactam Cumene hydroperoxide Dimethyl terephtalate Ethylene Ethylene oxide Hydrocracking (MHC & LCO) Maleic anhydride (butane oxidation) Methyl metacrylate Phenol (cumene oxidation) Phtalic anhydride Polyethylene LD (high pressure) Polyethylene HD (large units) Propylene oxide Vinyl acetate Vinyl chloride (VCM-EDC) .3. 3. 12. expensive alloy pipe runs must be minimised. Shell and tube exchangers shall be located with the backs of exchangers on a common line with horizontal vessels. Fired equipment on each process or utility unit shall be grouped together and common stacks provided wherever this is possible and economically viable.7. 12.8.12.6. 12. fans and drivers for air coolers located over piperacks shall be achieved by providing accessways. heater locations will be determined to provide the lowest risk of fire or explosion. 12. no equipment to be located above or below coolers. suitable for heavy craneage.1. 12.3.8.7. External piping shall be minimised at the tube pulling end of equipment. between process equipment on one side of the piperack. 12.8. If air coolers are located over piperacks platforms shall be provided for access to motors. Air Coolers Air coolers shall be located so as to provide for safe and practical access for operation and maintenance. These exchangers when grouped shall be located with their channel nozzles on a common centreline. 12.3. 12. They may be located in equipment areas or over piperacks. and header boxes.7. Within congested process areas. Exchangers Shell and tube exchangers shall be located with the channel end away from pipeways to facilitate tube bundle removal.2.8. A minimum clearance of 15 metres shall be provided between the shell of fired heaters and other hydrocarbon containing equipment with the exception of reactors and their feed effluent exchangers where high temperature. with a clearance length of 1 metre plus length of bundles. this area shall not encroach on plant roadways. with the largest exchanger setting the distance from the piperack in a similar manner as indicated above.6. 12.6.1.6. 12.8. For exchangers under drums or unit structures. Access for removal or replacement of tube bundles.7. where ever possible the channel end shall be clear of overhead structures for handling of channel end by mobile equipment. 12. Tube pulling shall be by mobile crane and adequate dropout and swinging space shall be provided.2.6.4 of this specification. 12. Fired heaters shall be located at one corner and upwind of process units and storage tanks to minimise the possibility of vapours being carried towards these ignition sources. with the exception of those having channel ends connected to an underground cooling water system. Fired Heaters and Boilers Furnaces and boilers shall be located at plot boundaries for ease of access.4.4. Stacked tube exchangers shall be limited to two units high.2. For major banks of air coolers this shall require a number of accessways which shall be located on either side of the piperack. . Access shall be provided by ladders consistent with para 14. 12.1. Tanks Containing Hydrocarbon Liquids: Hydrocarbon liquids are classified in the Petroleum Act: Class Petroleum • Class Petroleum • "A" "B" "C" Liquid which has a flash point below 23°C Liquid which has a flash point of 23°C and above but below 65°C Liquid which has a flash point of 65°C and above but below 93°C Class Petroleum • 12.2.9. Any tank shall have at least one side adjacent to a road within a distance of 90 metres.4. 12. 12.1. Tanks containing non-flammable liquids shall be located to suit their service requirements. Drainage shall have fire barriers between two different bunded areas to prevent the spread of fire.000m3 shall be arranged in single file.9. Tanks storing chemicals or non-contaminated water shall not normally require bunding for containment of the total volume of liquid stored unless any spillage would seriously impact the surrounding area affecting refinery operations.8.1.12. Tanks Containing Non Hydrocarbon Liquids 12. .9.2. or ecological damage could occur.9.9. Adjacent circular fired heaters shall be provided with interconnected firing platforms at a common elevation. Storage Tanks 12. Drainage from bunded areas shall be controlled so as to prevent hydrocarbon liquids entering the natural water course or rainwater drainage system where their presence would constitute a hazard. A minimum clearance of 3 metres shall be provided between the shell of fired heaters and access roads.3.1. 12.9.9.3.2. Fire water and foam storage tanks shall be located in a safe area with ease of access to fire fighting personnel.2. 2 sides minimum to road. Bund walls shall not exceed a height of 1800mm plus 200mm free board. Tanks larger than 50.1.2.1.2.9. 12.1. 12. i.3.4.9.e. 12. 12.9.9. Kerbed areas shall be provided around hazardous chemicals so as to minimise the impact of spillage on surrounding equipment and personnel.1.9. The spacing and bunding requirements for tanks containing hydrocarbon liquids shall be determined in accordance with the Petroleum Act and Tables 6 & 7.2.8.6. 12. Refrigerated Storage Tanks The spacing and bunding requirements for refrigerated LPG storage Tanks shall be determined in accordance with the Institute of Petroleum Model Code of Safe Practice Part 9 and OISD-Std-144. Drainage from such areas shall be designed to prevent harmful chemicals entering other drainage systems where corrosion. 12.5. chemical reactions. 12. Kerbed areas shall also be provided to prevent hydro-carbon spills/fires from spreading. Road Tanker Loading Facilities Road tanker loading facilities for product export shall be laid out to suit the smooth flow of traffic which avoids cross-flow. with aggregate capacity limited to 15000m3. . Parking areas shall be provided for both empty and full tankers consistent with planned operations.1.11.2. 12.13.10. All roads used for fire fighting shall be 6 metres wide minimum. Bullets shall be orientated such that they do not point towards process or administration areas.11. 12. 12.10.4. 12. The arrangement of spheres and bullets shall be to permit the free flow of air below the vessel.12. shipping and cleaning of empty railcars and handling of sick wagons. Loading racks shall be located at least 15 metres from the nearest running line or roadway or 30 metres for LPG.13.3. 12.2. 12. Road access for fire fighting equipment shall be provided around loading sidings. Spillage of LPG shall be directed by means of diversion walls to the containment area. 12.12. Facilities for loading LPG shall be segregated from those for other hydrocarbons. Sidings shall be provided for marshalling.2. Separate rail spurs shall be provided for LPG loading.2. Headroom requirements for all roads shall be as per Table 3. Each group of vessels shall be separated by 30 metres minimum.13. Each group shall have a maximum of 6 vessels.1. receiving.10. 12.3.3. Grading shall not permit any depressions and spillage from one vessel to flow under another.5. 12. Pressure Storage of LPG The spacing and bunding requirements for pressure storage of LPG shall be determined in accordance with the OISD-Std-144 and Tables 9 & 10. 12.10. A distance of 16 metres shall be the minimum distance between hydrocarbon equipment and a hard shoulder or edge of road if there is no hard shoulder.11. 12. The minimum height below the shell of such vessels shall be 1200mm. 12.13. 12.3. 12.1.13.12.4. 12. Roads separating units shall provide fire breaks and have facilities for fire fighting activities.12. Rail Tanker Loading facilities Facilities shall be provided for both solids and bulk liquid loading of railcars.1. 12. Roads Primary traffic roads in the installation shall be clear of hazardous classified areas.10.12.11. 12. LPG spheres and bullets shall be treated as separate groups and provided with curb wall a minimum of 30 cms and a maximum of 60 cms at shallow sump position.10. 12. materials handling and loading/unloading areas. clearances and access requirements shall be in accordance with the requirements contained in Tables 1 through 3 and the applicable notes. General The extent of platforms shall be the minimum consistent with safety. shell and tube heat exchanger tube bundles are to be removed with a mobile crane and tube bundle extractor.5.2. Clearance and Access Requirements 13. clear space for tube-bundle removal by mobile crane must be provided. both vertically and horizontally is to be provided under main pipeways for trucks or mobile equipment to service pumps. utility plants and offsite areas for maintenance and fire fighting access. Stair and Ladder Access 13. or to an air cooler header box catwalk. utility plants. Examples would include: provisions to move from a major structure to a platform on an adjacent tower in close proximity. Platforms with stair access shall be provided for the following: 1. Stairways shall be provided for access on storage tanks which exceed 4500 mm in diameter and 6 metres in height.8. Platforms which require operator attention more than once in an eight hour shift. 13.5 m. operation and maintenance. A clearance of 1 metre plus length of bundles in front of the exchanger measured from the tube sheet and extending 6 metres on at least one side is to be provided. Where required. 13. vertical clearance must be allowed for access of heavy lift cranes at road crossings.1. Platform. Platforms with Ladder Access . Care should be taken however to ensure that differential expansion will not cause problems. 13.7. walkways. Secondary roads shall be provided between process units.8.4. Permanent monorail structures are to be provided only where crane access is impractical. Clear access. 13. etc. Equipment. 2. A vertical clearance of 10M is required at identified major road crossings where there is a need for heavy lift crane access. the monorail is to extend far enough beyond exchanger channel end to permit full use of hoists to pull and lower tube bundle to grade.3. 3. A minimum of 7.1. Where built-in handling facilities are not provided. air coolers and major equipment parts not provided with built-in maintenance facilities. Plants shall be serviced by primary roads adjacent to processing units. should be provided between elevated platforms. Elevations. Platforms with Stair Access 13. 13.9. catwalks. structures.6. and piping are to be arranged to permit crane access to compressors.13. Elevation. Whenever possible. 13. Where practical. Platforms at elevated rotating equipment items. 13. accessways. 11. 4.10.2 (3) Exchangers with centreline located 3. instruments. 5. (Refer to OSHA for all other provisions of access/egress). 4. pressure safety valves.10.3 metres and under with internals.1. Platforms at fired equipment.Personnel Protection . ladders shall be arranged so the user faces toward the equipment. 3.5 metres or more above grade. 13. Front access ladders may be used with discretion. 13. 3. 3. Platforms with ladder access shall be provided for the following: 1. Miscellaneous . 14.9. removable heads. Dual Access/Emergency Egress Provisions for emergency egress must be provided per current OSHA guidelines as follows: 1.e. Maximum distance of unobstructed travel to any means of escape when two or more exist. with interconnecting walkways provided to service valving fan motors and instruments. (This does not apply to horizontal vessels less than 12m length). • • Points requiring operating access less than once in an eight hour shift.3 metres and under without internals.1. 2. Service platforms for manholes. when manway centreline elevation from grade is : 3. Storage tanks smaller than those in 14. at vertical reboilers. Any platform servicing two or more pieces of equipment which may be concurrently maintained. Ladder Requirements 1. 3. is 23 metres. i. including valves. Wherever possible. 13.13. Air coolers. Platforms are not required for manways. 2. 2.. 6. Any single ladder run may not exceed 9 metres in length without a landing or platform. When dead end is greater than 6 metres. etc. 1. 14. Eye wash and emergency showers shall be provided in areas where operators are subject to hazardous sprays or spills.2.14. . Consideration shall be given to incorporating breathing air stations in facilities handling extremely toxic gases. P. shall include an allowance for at least 25 mm of grout. All elevations shall be referred to the High Point Of Paving (H. Small size pumps such as proportioning. Furnace Floor Bottom of Floor Plate Blowers and Compressors Pipe Trenches and Pits Sewer Boxes Plinth for Skid Mounted Equipment Wall or Roof Fired Floor Fired U/S Baseplate Top of Cover Top of Cover Figures in parentheses refer to notes below.P.Table 1 UNPAVED ITEM (1) (2) AREAS (4) PAVED AREAS (4) BUILDINGS ENCLOSED (4) OPEN SIDED (4) Grade. NOTES TO TABLE 1: 1. . Final elevation of H. Floors and Paving Column Piers Pumps (3) Stair and Ladder Pads Vert. As required Flush with Paving Flush with Paving 150 mm 300 mm 150 mm 450 mm 450 mm 400 mm 400 mm N/A N/A N/A As required Flush with Floor Flush with Floor N/A 300 mm 150 mm 450 mm 450 mm 400 mm 400 mm N/A N/A N/A As required Flush with Floor Flush with Floor N/A Top of piperack column footings. 3. All concrete support levels shown for equipment and structural items. and other small gear pumps may have bottom of baseplates located at elevation 450 mm above H. Dimensions shown above are above high point of paving.150 mm N/A N/A As required 50 mm 50 mm 150 mm (above Grade) 000 -150 mm 300 mm 150 mm 150 mm 300 mm 150 mm As required.P. elevation shall be referenced to Mean Sea Level EL.P. injection.).000 on plot plans. 2.P.P. As required.P.P.00. H. to be determined when complete site terracing is finalised. 4. Vessels High Point Low Point U/S Baseplate U/S Baseplate U/S Baseplate U/S Baseplate N/A N/A 300 mm 150 mm 150 mm 300 mm . except stairs and ladders. passageways and working areas Headroom height for projections over platforms. 180-1000mm 750mm 450mm 1500mm 750mm 750mm 1200mm 9M 15° 230mm 680mm 900mm 1500mm 2000mm 1000mm 750mm 750mm Maximum vertical rise of operational ladders (Single run) Maximum Allowable slope of ladders from vertical Toe clearance from centreline of rung to any obstruction Clear climbing space for vertical ladders Clear climbing space for inclined ladders (9) Operation and Maintenance (13) Width of platform required at bonnet or channel end of exchanger Maximum elevation to the bottom of handwheel on valves 6" NB and smaller from platform or grade (14) Horizontal clearance between insulation on paired exchanger flanges Clearance below furnace raised floors (15) (10) (11) (12) Horizontal clearance required between paired exchanger flanges Figures in parentheses refer to notes table notes .M 600-1500mm 900mm 1*M'hole dia. passageways and working areas Headroom height over stairs Access Walkways Width of stairways (Inside stringers) Width of Landings Width of walkways (At grade and elevated) Maximum vertical rise of stairways (One flight) Maximum horizontal distance from any point on platform to a primary or auxiliary exit Maximum length of dead-end platform in escape route (1) Vertical Vessel Shell Platforms (3) (4) Vessel Top Head Horizontal Exchanger Vertical Exchanger Fired Heaters Ladders (5)(6)(7)(8) Distance of platform below vessel manhole centreline Width of manhole platform (Minimum)(2) Platform extension beyond centre line of manhole Distance of platform below face of manhole flange Width of platform from three sides of manhole Clearance from bottom edge of channel or bonnet flanges Maximum distance of platform below top flange of channel or bonnet Width of platform from three sides of flange Width of platform at sides of horizontal and vertical tube furnaces Width of platform at ends of horizontal tube furnaces For Access Main Access For Access Main Access DIMENSION 2150mm 2150mm 2100mm 750mm 1000mm 1200mm 750mm 1200mm 3040mm 23M 6.Table 2 ITEM DESCRIPTION Headroom over platforms. walkways. walkways. an individual might select an escape path which would lead to such a dead-end .1 metres to 4. 13. . Toe plates shall be provided on the edges of all platform areas and around openings. A height adjustable mobile stair stand shall be available for access to equipment. Ladders shall generally be arranged for side exit. 14.5 metres above grade.see 9. above grade shall be provided with top rail hoops only. because of confusion arising from an emergency or panic situation. Dead-end platforms greater than 6 metres long are prohibited where such dead-ends are in escape routes or where it may be reasonably anticipated that. 5. Standard handrailing shall be provided on all sides of all platform areas 1200mm or more above grade and stairways. Ladders which serve platforms less than 1500mm above grade do not require a top rail hoop. 10. 15. 11. and manholes located within 2. 3. or butterfly valves shall be positioned so that wrench and wrench movement arc is at no point higher than 2. 2. shall be furnished with chain operators or extension stems. Portable ladders shall be 4. and which cannot be located vertically within 2 metres of a platform or grade. Valves shall be installed in valve pits and not buried. Clear climbing space is defined as the climbing area clearance for caged ladders. Ladders which serve platforms from 1500mm to 2300mm. Except relief valves . Clearance specified applies to wall or roof fired furnaces. except at the platform entrance and exit locations.NOTES TO TABLE 2: 1. instruments. Adequate tube removal space shall be provided for all exchangers that require tube bundles to be removed. valves. ball. step-through ladders are permissible.5. 2300mm or more above grade shall be provided with safety cages. Horizontally installed wrench operated plug. and shall be provided throughout the length of the ladder. Manually operated valves which normally require manipulation during plant operation or in an emergency. 6. 4. 8. however.0 m max. 12. 9. Ladders which are located at. The clear climbing space required for ladders that deviate in pitch between 75 and 90 degrees. Check clearance required to open manhole covers. Self-closing gates and top rail hoops shall be provided across ladder openings at all landing except for ladders located at or less than 1200mm above grade. 7.3 metres above grade or platform. 0M 6.9M 6. b) Around catalyst containing vessels. e) f) Inside fully enclosed equipment buildings.0M 10. i. located outdoors. g) Around exchangers or other types of equipment in dirty service that require frequent turn around maintenance.0M 3.7M 6.0M 6. Surfacing (3) (4) (5) (6) (7) (8) (9) (10) Railways Freeboard height of bund walls Maximum drop in paving Maximum average height of bund walls above grade + 200mm freeboard Headroom over refinery railway lines (From top of rail) Headroom over public railways Clearance from track centreline to obstructions DIMENSION 8. A 1.e. 3. . under bottom oilfired or combustible liquid containing furnaces and elevated structures supporting coke drums. 2.0M 1200mm 200mm 150mm 1800mm 4.0M 1/40 16. Grading. d) Around compressors and their related servicing equipment.6M Figures in parentheses refer to notes below NOTES TO TABLE 3: 1.0M 6.. Around all equipment in process units. All roads shall be surfaced with tarmac.0 metres wide shoulder shall be provided each side of primary and secondary roads which is in addition to the widths stated. Walkways and the following areas shall be paved with concrete: a) Paving shall extend to the outside edge of the supporting column piers.7M 2.Table 3 ITEM DESCRIPTION Headroom for primary access and main plant access roads Headroom for electrical transmission lines Width of primary access roads Headroom for secondary access roads Width of accessways other than roads Width of secondary roads Access for heavy lift cranes Slope of road from centreline to edge Width of main plant access road Distance from pump foundation to edge of paving Paving. c) Around groups of two (2) or more pumps. lube oil consoles. All paving surrounding vessels. except as otherwise noted (note 6). These kerbed areas shall drain to a sump or area drain provided with a valve in the sewer outlet. manifolds. 11. 10.h) Around equipment handling potentially toxic liquids. The edges of paving adjacent to open sided buildings shall be at the same elevation as the edges of the floor of the building with paving sloping away from the building. General equipment areas within the unit limits. 9. 8.0 m including 200 mm freeboard. Bund walls shall provide sufficient volumetric capacity to contain the liquid that can be released from the largest tank in the enclosed area plus freeboard. 6. i) A 1. Maximum height 2.5 metres width of concrete pavement shall be provided either side of offplot piperacks to serve as both a walkway and a base support for control stations. with other contained equipment and tankage in place. to control the drainage. shall be sloped a minimum of 1/100 away from the container towards the drainage system located at the greatest practical distance from the tank. tanks. j) 4. 5. all parking. . The drainage system for bunded areas shall be provided with a valve on the outside of the bund wall. Accessways under main piperacks. Controlled drainage facilities shall be provided to recover spilled materials. etc. Kerbs and walls required only to contain limited spillage shall normally extend to a height of 150mm above High Point of Paving. All indoor and outdoor paving. or other equipment containing hydrocarbons which could reach the paving in a liquid state. shall be sloped for drainage. 7. and administrative areas shall be graded and surfaced with crushed stone. The floors of control rooms and switch gear rooms shall be level. 2.5 91.118) or UOP Standard 9-51-2 distances for compatible units are higher. these are included) Notes: Service Buildings Motor Control Centres and Electrical Substations Utilities Areas Cooling Tow ers Control Rooms Compressor Buildings Large Pump Houses Process Units Moderate Hazard Process Units Intermediate Hazard Process Units w ith High Hazard Atmospheric Storage Tanks Pressure Storage Tanks Refrigerated Storage Tanks Dome Roof Flares Unloading and Loading Racks Fire Water Pumps Fire Stations / / 15 15 30 30 30 30 61 122 76.5 90 15 30 15 30 30 30 30 30 61 76. GAP.5 61 15 30 / 30 30 30 61 91.5 15 61 90 Unloading and Loading Racks / / / Compressor Buildings Large Pump Houses Fire Water Pumps Service Buildings Cooling Towers Control Rooms Utilities Areas Fire Stations Flares .5 107 107 91.5 91.2 & 2.5 Process Units Intermediate Hazard 61 107 107 107 91.5.5 91.5.5 61 15 15 Motor Control Centres and Electrical Substations / 30 30 30 30 30 30 61 76.5 Process Units High Hazard T7 T7 T7 91.Table 4 Minimum Distance Between Facilities and Units as per GE Insurance Solutions.2a recommendations (If OISD Standard .5.5 for total Process Hazard examples.5 91.5 107 107 91.5 61 15 30 9 9 9 15 30 76.5 107 107 91.5 61 61 61 15 30 61 76.5 107 107 91.5 61 61 61 9 9 15 30 76.5 61 61 61 Process Units Moderate Hazard 30 61 91.5 76.5 107 107 91.5 107 Atmospheric Storage Tanks 107 T7 T7 122 107 107 107 Pressure Storage Tanks T7 122 107 107 Refrigerated Storage Tanks Dome Roof 107 Refer to paragraph 12. All Dimensions are in metres / = no spacing requirement T7 = refer to Table 7 / 91.5 107 107 91.5 76.5 61 15 15 / 15 15 15 30 30 30 30 61 76.5 61 91.5 107 107 91.5 107 107 91.5 91.5 91.5 107 107 91. 3 5 30.63 7.3 15.3 15.3 5 4 6 15.3 High Hazard Reactors 5 5 7.3 15.3 15.5 15.3 15.05 15.3 2 7 7 7 5 30. For total process hazard examples refer to paragraph 12. High Hazard Reactors include exothermic or run-aw ay reactions.3 15.3 Intermediate Hazard Pumps 15. Accumulators.63 30.3 5 7.63 7. Intermediate Hazard Pumps are all other pumps.5.3 5 5 6 15.3 5 3.3 Moderate Hazard Reactors 15.3 15.Table 5 Minimum Distance Between Equipment within Process Units as per GE Insurance Solutions.3 / / / Notes: All dimensions are in metres / = no spacing requirements High Hazard Pumps handle flammable. Drums Rundow n Tanks Fired Heaters Air Cooled Heat Exchanger Heat Exchangers Pipe Racks Unit Block Valves Analyzer Rooms 9. combustible liquids operating at 260°C or above and above 34.5 8 15.5 20 5 5 5 15. Drums 30.15 15. Intermediate Hazard Reactors High Hazard Pumps Unit Block Valves Heat Exchangers Analyzer Rooms Rundown Tanks Compressors Fired Heaters Pipe Racks .05 3.5.3 30. 2. Accumulators.3 15.3 15.15 9.5.63 7.3 15.05 6 15.5 30.3 30.3 2 2 7 7 7 4 30.5 bar.3 / 5 / 15. these are included) Compressors Intermediate Hazard Pumps High Hazard Pumps High Hazard Reactors Intermediate Hazard Reactors Moderate Hazard Reactors Columns.3 7.15 9.5 30.5 15. GAP. Also liquified flammable gases.5 15. Canned and magnetic have no specific requirements.3 / 15.5 15.15 15.5 30.5 15. Intermediate includes slightly exothermic reactions and moderate includes endothermic reactions.15 9.3 15.3 15.3 Air Cooled Heat Exchanger 15.5 18 5 3.3 15.2 & 2.3 7.5 30 9.63 7.2a (If OISD standard .5 30.63 30.5 30.3 2 4.63 30.5 15.3 15.5.118 or UOP standard 9-51-2 distances for compatible units are higher.5 30.3 Columns.63 15. Table 6 Minimum Distance between Storage Tanks and Offsite Facilities as per GE Insurance Solutions. GAP. these are included) This Table is applicable for installations.2 & 2. Filling Sheds Class 'A & B' Loading Area Class 'C' Loading Area Flame Proof Elec. where aggregate storage capacity of Class ‘A’ and Class ‘B’ petroleum stored above grade exceeds 5000 cu. metres or a tank diameter exceeds 9 metres. Filling Sheds .2a.( If OISD-118 or Petroleum Act and Petroleum Rules distances for compatible units are higher. 1 2 3 4 5 6 7 8 Non-flame Proof Elec. Pumps T7 T7 T7 15 15 15 15 15 15 Notes. Pumps NM Class 'A' Storage Tank Class 'C' Loading Area Class 'C. Pumps Non-flame Proof Elec. 2.5. T7 T7 15 15 15 15 8 15 Class 'B' Storage Tank T7 15 NM NM 8 8 15 NM 15 NM 8 NM 15 Class 'A' & B' Filling Sheds Clascc 'C' Storage Tank All dimensions are in metres. Pumps 9 1 2 3 4 5 6 7 8 9 Class 'A' Storage Tank Class 'B' Storage Tank Class 'C' Storage Tank Class 'A' & B' Filling Sheds Class 'C.5. NM = Minimum to suit operation or maintenance access T7 = Refer to Table 7 NM 8 NM NM NM NM NM 8 15 Class 'A & B' Loading Area NM NM NM NM 8 Flame Proof Elec. 2. Groups of spheres shall be limited to six. with an aggregate volume not to exceed 15.5.2 & 2.( If OISD-118 or Petroleum Act and Petroleum Rules distances for compatible units are higher. these are included) 1xD or 30M Min 1xD or 1xD or 30M 30M Min Min 2xD or 2xD or 60M 60M Min Min 2xD or 2xD or 60M 60M Min Min Floating Roof Tank Cone Roof Tank Spheres. Minimum distance between atmospheric storage tanks and pressurised or refrigerated storage spheres / tanks shall be 2 x diameter of the larger tank/sphere or 60 metres. Spheroids and Storage Vessels Cryogenic Tanks Spheres. Minimum distance between a tank shell and the inside of the bund wall shall not be less than one half the height of the tank. whichever is the greater.Table 7 As per GE Insurance Solutions. • • Cryogenic tanks .5.000m3 (as per Petroleum Act). GAP. whichever is greater TAC / LPA requirement). Interdistance between the nearest tanks located in two separate bunds as well as in the same bund shall be 30 metres or the diameter of the larger tank. Spheroids and Storage Vessels 1xD or 30M Min 2xD or 1xD or 60M 30M Min Min Floating Roof Tank Cone Roof Tank Notes Regarding Tanks and Spheres Spacing • • • Minimum spacing between groups of spheres shall be 30 metres (as per Petroleum Act).2a. 20) D. (min. Installation Minimum Distance from Boundary fencing around Installation D. (min. This table is applicable for facilities in a installation where total quantity of petroleum class A & B stored above ground in bulk exceeds 5000 cu. . Property beyond property line is deemed protected if it is within the jurisdiction of public Fire Brigade or plants’ own Fire Brigade.Table 8 Distances from Boundary Fencing As per OISD-118 or Petroleum Act and Petroleum Rules (higher of these are included). 4. metres or where the diameter of any such tank for the storage of petroleum exceeds 9 metres. All distances are in metres 2. 10) 15 10 20 10 Storage tank for Petroleum class ‘A’ Storage tank for Petroleum class ‘B’ Storage tank for Petroleum class ‘C’ Storage/filling shed for Petroleum class ‘A’ and class ‘B’ Storage/filling shed for Petroleum class ‘C’ Tank vehicle loading/unloading area for class ‘A’ and class ‘B’ Tank vehicle loading/unloading area for class ‘C’ Notes 1.diameter of larger tank. (min. Above table is based on the assumption that property beyond the boundary line is either protected or adequate green belt is provided as a safety buffer where no structure exists. 20) D. Notation: ‘D’ . 3. or UOP standard 9-51-2 distances for compatible units are higher. All dimensions are in metres. NM = Minimum to suit operation or maintenance access NA = Not applicable. Non LPG LPG Shed LPG Loading Gantry LPG/Other Rail Spur LPG Pump/Comp Hse Fire Pump House T7 T10 30 30 30 15 60 LPG Storage Vessel NA 30 30 30 30 NM Equip. T10 = Refer to Table 10 T7 = Refer to Table 7 50 30 60 LPG/Other Rail Spur NA 60 NA Fire Pump House 7 1 2 LPG Shed 3 4 5 .Table 9 Minimum Distances Between LPG Facilities (If OISD standard – 118. Petroleum act and Petroleum Rules. Static and Mobile Pressure Rules. these are included) LPG Pump/Comp Hse 6 1 2 3 4 5 6 7 LPG Storage Vessel Equip. Non LPG 15 30 30 15 60 50 50 30 60 LPG Loading Gantry Notes. . of each vessel (cu.mt of water) 10-20 21-40 41-350 351-450 Distance Cap. Minimum Distance between LPG Storage Vessels and Boundary/Property Line/Group of Buildings not associated with LPG Plant Capacity of each vessel (cu. of water) 451-750 751-3800 3801-above Distance 15 20 30 40 60 90 120 Note: All distances in metres.mt.Table 10 As per OISD-118 and Static and Mobile Pressure Vessel Rules (higher of these are included).