STANDARDS PUBLICATION

KOC RECOMMENDED PRACTICE

FOR

PLAJVT LAYOUT

DOC.NO.KOC-L-028

STANDARDS TEAM

DOC. NO. KOC-La28 Page I of 33 Rev. 7

KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOC RECOMMENDED PRACTICE

FOR

PLANT LAYOUT (INCLUDING SPACING.CHARTS)

DOC. NO. KOC-L-028

STANDARDS TEAM

I

Rev. 1

KOC RECOMMENDED PRACTTCE

FOR

PLANT LAYOUT (INCLUDING SPACING CHARTS)

DOC. NO. KOC-L-028

ISSUING AIMWORITY:

STANDARDS TEAM

--- Task Force

lss~red as KOC RP ITF- LP, ,2,

1 I'

Description Prepared By Snr. Engm. Sids. 1 Team Leader Standards 11

Tel. 6115f Tel. 61896 I

Page 3 sf 33 Rev. 1 -

TABLE OF CONTEMTS

PAGE NO.

5

SCOPE

APPLICATION

TERMINOLOGY 3.1 Definitions 3.2 Abbreviations

REFERENCE STANDARDS, CODES AND SPECIFlCATONS 4.1 Conflicts 4.2 List of Standards, Codes and Specifications

ENVIRONMENTAL CONDITIONS

HEALTH, SAFETY AND ENVIRONMENT

LAYOUT OF PLANT-SITE 7.1 General Philosophy 7.2 Site Layout 7.3 Plot Layout 7.4 Access Ways Implant Roads 7.5 Construction % Maintenance Considerations

LAYOUT OF EQUIPMENT AN5 PLANT BUILDINGS 8.9 Equipment Layout 8.2 Buildings Layout: Office, Control and Other Buildings 8.3 Air Intakes and Discharges 8.4 Primary I Area Substation 8 3 PlantSubstation 8.6 'Utilities 8.7 Fire-Water Tanks and Pumps 8.8 Process Vessels 8.9 Shell and Tube Exchangers 8"lO Gas Compressor I Process Pumps 8.72 Air-Cooled Exchangers

Fired Heaters Storage Tanks for Petroleum Pressur~ Relief Devices Other Potenfiel Sources of Hazard Flare Shck Bum Pit Manikdd Offsite Effluent Treatment Facilities Overhaad Elsctrical Rowerlines Plant Piping

9.0 PIPELINES I TRANSIT LINES

10.0 QUALlTf ASSURANCE

SFACING CHART-I SPACING 0 6 EQUIPMENT AND ITEMS LOCATED WITHIN KOC PLANT (GC I BS I OTHER FAClhlillES)

3.PACIjjG CHART-;! SPACING OF KOC EQUIPMENT AND ITEM5 LOCATED OUTSIDE OF KOC PLANT (GC I BS I OTHER FACILITIES) BUT WITHIN KOC FENCED AREA

SPACING CHART -3 SPAClYG OF KOC PLANT, KOC TANK FARM, AND OTHER KOC ITEMS FROM KUWAlT GOVT I PRIVATE / PUBLIC WTILITIES I FACIILITI ES ETC

ACKNOWLEDGEMENT

- DOC. NO. KOC-L-028

FOREWORD

This document "KOC Recommended Practice for Plant Layout1' is intended to serve as a guide to the layout of plantsite and offsite equipment and units 1 items in KOC onshore oil and gas processing plant and facilities in Kuwait.

This Recommended Practice (RP) has been approved by the Standards Team in consultation with the Standards Technical Committee (STC) for consistent use throughout the corporate engineering and operational functions of Kuwait Oil Company (K.S.C.).

This RP sets out to achieve the following objectives:

> To outline KOC's basic philosophy regarding site development and the layout of Plant sites, equipment and piping.

i;; To provide guidance during the design stage of a project regarding acceptable equipment spacing, clearances, access for construction, operation, maintenance, safety and fire-fig h ting purposes.

i; To ensure facilities are constructed ~n line with KOC's lnsurance provisions and other recognized International Agencies and to allow the facilities to qualify for favourable consideration from lnsurance Agents.

i; To utilize operational experience to avoid repetition of past problems and to consolidate worthwhile and beneficial design, operating and cost saving features.

> To standardize facility site plan and layouts as much as possible.

> To have future requirements included in the initial design of a facility.

> To set out minimum technical requirements for monitoring compliance with distances from the view points of operation, safety and maintenance needs.

feedback, comments or suggestions, derived from the application of this Recommended Practice at any stage of design, engineering, purchase, manufacture, field installation, operation and maintenance are encouraged, and should be directed to:

The Team Leader Standards (Chairman, Standards Technical Committee) Industrial Services Group, KOC P.O. Box 9758, khmadi 61008 State of Kuwait

DOC. NO. KOC-L-028 I] Page 6 of 33 11 Rev. I

Task Fqrm Responsible for This Recommended Practice

The Preparation of this Recommended Practice was entrusted by Standards Technical Committee (STC) to the Task Force No. (TF-LPl12) consisting of the following members:

Mr. Faisal Mirza Standards Team TF Leader Ex. 61 151 Mr. Mohsin Mirza Standards Team Author Ex. 61 371 Mr. N. Ramanathan Export Facility Proj Member Ex. 66960 Mr. Mohd. Alam Safety Team Member Ex. 6641 5 Mr. Uppara Saibaba Safety Team Member Ex. 71837 Mr. T. V. Valsan Design Team Member Ex. 61659 Mr. Haytham H. 41-Habshi 0pns.Tech.Svcs. NK Member Ex. 23336 Mr. Mohd. Al-Ajmi 0pns.Tech. Sevs. WK Member Ex. 20336 Mr. NAl-Sattar AIAI Salam Production Opns. SK Member Ex. 22538 Mr. Mohd. Dashti Drlg. & WIOver - ! Member Ex. 71057 Mr. John Onderdonk Field Development SK Member Ex. 22069 Mr. Sayed Al-Zalzalah Human Resources SEK Member Ex. 22145

SCOPE

This Recommended Practice (RP) For Plant Layout is a guideline for spacing of equipment and items located within KOC plant (GCIBSlother facilities) such as office & control buildings, plant substation, process vessel, process pump, pipeways, gas compressor, exchanger, process heater, desalter, separator, and manifold etc as well as KOC equipment and items located outside of KOC plant (GCIBSlother facilities) but within KOC fenced area such as fire water tank, fire water pump, flare stack, burn pit, oil gas wells, area substation, flowlines, temporary structure etc. For spacing details refer to Chart-I and Chart-2 of Appendix-?of this RP.

This Recommended Practice (RP) For Plant Layout is a guideline for spacing of items such as KOC Plant, KOC Tank Farm and KOC Pipelines / Transit Lines highway I roads, residential area, mosque, hospital, school, farm, office, shop, factory, warehouse, and industrial plant etc that are either controlled / owned by Government of Kuwait, or by public or private sectors, For spacing details refer to Chart-3 of Appendix-lof this RP.

APPLICATION

This RP is intended as a guide for plant layout. However it should not be construed as substitute for detailed engineering & layout, engineering drawings, piping layout, equipment nozzle orientation, equipment specifications, isometrics and lateral hook-ups with equipment. The Contractor should develop on his own the detailed plant and equipment layout drawings using this RP as guideline and all such documents should be submit to KOC for review and approval.

The pliant equipment layout, plant piping etc should fully comply with all relevant technical and contractual requirements of specific project i.e. Scope of Work, Technical Specifications and Contract Documents of KOC.

This EP is not applicable for any offshore installation or any onshore warehcuse, storage facility or depot etc.

This RP should not be considered as retroactive but should be applied to new facility or expansions, substantial modifications and / or revamp of existing facilities. Any exceptions or deviations shall be subject to approval by KOC.

KOC may choose alternative options or waive any of the requirements of this RP depending on the nature of any specific project.

Compliance with this RP does not in itself confer immunity to Contractor from legal or statutory obligations.

DOC. NO. KOC-L-028 Rev. 1 --- A

For the purpose of this RP, the following definitions apply.

Access Ways

Paved 3r unpaved area for either vehicular or pedestrian access within the plot limits.

Administration Area

The part of the site intended for the main ofice building.

Battery Limit

The boundary of a process unit enclosing all equipment and unit limit block valves.

Contractor

The pErson, or persons, or a firm or a company contracted by KOC to undertake the execution of the Work defined by KOC Contract.

Equipment

The individual items which make up a process unit.

Flowlines

Flowlines transport production from the wellhead to a manifold at a gathering centre. For the purpose of this RP the flowlines are not to be considered as pipelines / transit lines.

KOC Controlling Team

Any KOC Team authorized to initiate a request for the execution of a project.

Module

A steel skid or platform having equipment and items installed on it and fully connected to each other with piping, instrumentation and t;lectriml gadgets and cable network as a complete unit and ready for transptation.

Offsites

The units and equipment that are not specifically part of the processing units, but which provide a service to the processing units. Off sites include utilities, tankage, flares, burn pits and oil-water ponds etc.

Pipelines / Transit Lines

A network of Iines generally transporting hydrocarbon fluids from one facility (such as GC and BS) to another facility, terminal or storage such as Tank Farm. For the purpose of this RP the pipelines / transit line are not considered as flowlines.

Plant

A gene-ai term to describe a processing 1 operational unit on a given site.

Plot

An area of the site containing one or more process units, offsite and/or tankage.

Quantitative Risk Assessment

A detaYled qualitative and quantitative analysis to evaluate / measure the potential likelihood and consequences of site-specific scenarios of risks and associated hazards leading to human death, or injury, environmental damage or economic loss and their magnitude and then to compare the findings with acceptance criteria.

Scenario

A scenario is a set of conditions that define the development of fire, the spread of combustion products, the reaction of the occupants and the effect of combustion productions.

Service Areas

Workshops, stores, fire station, laboratory or similar buildings.

Site

An area where a new facility or an extension to an existing facility is to be provided, The Site contains all the plots.

Abbreviations

BS E IA EPA ESDV GC HAZOP HSE HVAC KOC MCC ME I EW NPSHk OSHA PHA QRA VCE

Booster Station Environment Impact Assessment Environment Public Authority - Kuwait Emergency Shut Down Valve Gathering Centre Hazard and Operability Study Health, Safety and Environment Heating, Ventilation and Air Conditioning Kuwait Oil Company (K.S.C.) Motor Control Centers Ministry of Energy I Electricity and Water Net Positive Suction Head Available Occupational Safety and Health Administration Process Hazard Analysis Quantitative Risk Assessment Vapour Cloud Explosion

REFERENCE STANDARDS, CODES AND,.SPECIFICATONS

Conflicts

In the event of conflicts between this RP and the Standards I Code referenced herein, or other contractual requirements, the most stringent requirement shall apply. In case, further clarifications are required, the subject shall be brought to the attention of KOC Controlling Team.

List of Standards,,-Codes and Specifications

The latest edition of the following standards, codes and specifications shall apply:

Nationr.1 Standards and Codes

API RP 500 Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class I, Division 1 and Division2

API RP 521 Guide for Pressure-Relieving and Depressuring Systems

API RP 752 Management of Hazards Associated with Location of Process Plant Buildings

API 22'1 8 Fireproofing Practices in Petroleum and Petrochemical Processing Plants

ASME 331.3 Process Piping

ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids

ASME 831.8 Gas Transmission and Distribution Piping Systems

BS EN 14161 Petroleum and Natural Gas Industries-Pipeline Transportation Systems

DOT CrR Titie 49 Department of Transportation (USA), Code of Federal Regulations "Transportation of Natural and or Other Gases by Pipeline: Minimum Federal Safety Standards"

NFPA 221

NFPA 551

OHSAS 1800

Standard for Fire Walls and Fire Barrier Walls

Guide for Evaluation of Fire Risk Assessments

1 Occupational Health and Safety Assessment Standard

OSHA 29 CFR 1910.1 19 Process Safety Management of Highly Hazardous Chemicals

4.2.2 KOC Standards and Recommended Practices

KOC Recommended Practice for Engineering Design Basis of Civil and Structural Work

KOC Recommended Practice for Blast Resistant Design of Buildings

KOC-E-003 Part 1 KOC Recommended Practice for Design Basis, and Selection of Electrical Systems

KOC-G-002 KOC Standard for Hazardous Area Classification

KOC-G-007 KOC Standard for Basic Design Data

KOC-L-002 KOC Recommended Practice for the Protection of KOC Services: Clearance Requirements for Buried Pipelines & Piping, Cables, Underground Structures and Buildings

KOC-L-006 KOC Standard for Fire & Gas Detection Equipment

KOC Standard for Fire Protection and Safety Equipment

KOC-L-O f 7 KOC Recommended Practice for HAZOP Studies

KOC Standard for Layout, Spacing and Diking of Aboveground Petroleum Storage Tanks

- . - DOC. NO. KOC-La28

- Page 12 of 33

I I -

KOC-MP-027 Part 1 KOC Standard for Pressure Relief Devices: Design and Materials

KOC-MP-027 Part 2 KOC Recommended Practice for Pressure Relief Devices: sizing, Selection, Twinning and Installation

KOC-HSE Document

KOC.SA.018 HSE Procedure for Risk Assessment

KOC.SA.019 Guidelines for HSE Procedure for Risk Assessment

EV.KOC.003 Environmental Impact Assessment (EIA) Procedure

01 5 Series of Specifications

015-IH-1009 Flowlines

015 - LH - 1001 Piping Material Classes with Attachment 1

015 - LH -1002 Piping Design

015-NH- 7104 Plant / Equipment Noise Control

015-Y-I-1003 Loss Prevention Requirements

ENVIRONMENTAL CONDITIONS

Refer to KOC-G-007 "KOC Standard for Basic Design Data" which provides the detailed design information regarding the environmental, site and utility supply conditions prevailing throughout the KOC facilities.

HEALTH. SAFETY AND TNVlRONMENT

The plant layout should meet all the applicable Kuwaiti EPA Regulations and should conform to the relevant KOC HSE Guidelines with a view to protecting personnel and surrounding environment.

All relevant safety requirements of KOC Fire & Safety Regulations and KOC Health, Safety & Environment Management System (HSEMS) procedures and manuals as applicable shall be adhered to by the Designer / Contractor, while planning / implementing plant layout for KOC.

The Contactor shall carefully consider and address all environmental issues and impacts including NOx emission arising from layout, construction and / or operational activities as identified in KOC-HSE Environmental Impact Assessment (HA) Procedure EV.KOC.003.

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DOC. NO. KOC-L-028 Page '13 of 33 Rev. 1 -- LAYOUT OF PLANT-SITE

General Philosophy

This RP is intended to provide general guidance for a major development i.e. expansion of existing plant or construction of a new plant. KOC should specify and elaborate philosophy for any specific location or any specific processing unit(s), offsites facilities, control rooms and administration buildings etc for any project whenever required.

KOC philosophy and approach should be to provide a fit-for-purpose design that satisfactorily addresses the needs of HSE, operating and maintenance issues that will ensure a safe work environment, and will entail reasonable overall facility costs.

KOC intends to standardize as far as possible, the layout of the facilities and make use of common equipment designs that would facilitate inter-changes of equipment and operating personnel, and reduce spare parts, operations, maintenance, and training requirements.

The criteria for spacing between various equipment and items are based on requirements for process, operation, maintenance, and emergency evacuation, damages due to fire transfer & blast effects etc and sound engineering judgements etc. Based on these criteria Spacing Charts-I, Spacing Chart-2, and Spacing Chart-3 showing spacing for various equipment and items have been developed and included in Appendix-I of this RP.

The spacing shown in Spacing Charts in Appendix-I of this RP are optimum to satisfy KOC requirements. Any proposal to increase the spacing shown should be subject to a comprehensive cost-benefit analysis, and any proposal to decrease the given spacing (for process / operation or any other requirements) shall be subject to a comprehensive Quantitative Risk Assessment (QRA) by concerned KOC Team(s) or their appropriate nominated representative.

The total site layout and detailed layout of each plant shall be subject to approval of KOC. Any calculations relevant to the spacing of equipment or concerning potential major release of hazardous material shall be subject to review and approval by KOC.

All sites shall be generally within a perimeter fence. KOC should specify the site area and specify buildings that should be located inside or outside of the fence. The entrance to sites shall be through a security checkpoint.

I DOC. NO. KOC-La28 Page 14 of 33 I ' - 1 1 Rev. I

The consideration should be given that the overhead electrical power transm'ssbn lines do not cross-aver the plantsite. ft should be ensured that a minimum 60 meter horizontal distance is maintained between the edge of the right-of-way of overhead electrical power transmission line and the perimeter fence of the plant and its paraphernalia. For additional details on clearance from overhead power transmission lines refer to KOC-L-002.

The site layout should consider future expansion of the plant as additional space will be required for installation of equipment in future such as headers, process vessels, separators, desalter, pumps, compressors, heat exchangers, process / storage tanks, fire-water tanks, pipe rack and other equipment as listed it) Spacing Chart in Appendix-? of this RP. The site and plant layout shall be subject to approval by KOC.

Flammable material storage shall be located appropriately away from process units in compliance with KOC-L-027 "KOC Standard for Layout, Spacing and Diking of Aboveground Petroleum Storage Tanks".

Utility services should be grouped together in a non-hazardous area. They should be located so that essential utility supplies can be maintained under emergency conditions.

Firewater pumps shall be located appropriately away from the process storage and loading areas of the plant in order to reduce the risk of fire impact or blast damage to these pumps.

The location, spacing, orientation, height and separation distances of flares shall be determined by a full risk assessment and calculation of the factors involved.

Control buildings and other occupied site buildings shall be designed and located such that the risk to occupants shall be precluded or minimized.

Plant offices, workshops, laboratories and other similar buildings not directly linked to plant operation should not be located in the control building. They should be located separately in a safe and non-hazardous area / zone.

The risk assessment study and risk acceptance criteria shall be carried out by a third party or KOC safety consultant with inputs by KOC Controlling Team. Issues related to construction, operation, and maintenance besides safety issues should also be included in the risk assessment.

A roads should be provided around site perimeter fence to permit access and exit in all weather conditions.

DOC. NO. KOC-L-028 11 Page I 5 of 33 Rev. I '1

Plant Layout

A plant should be laid out in such a way that all equipments and items of the plant are accessible for vehicles and pedestrian through road network. Additimally the emergency evacuation exits should be located taking into account the locations of potential release and the prevailing wind direction.

The process units shall not be enclosed in a building,

The plant area should generally be completely paved for good housekeeping and for better plant operations. However if it is not possible then concrete paving should be provided around process units of plant to help vehicles and pedestrian to access equipment, buildings and maintenance areas and also help flow of surface drainage of these areas.

The plot shall be graded so that any flammable liquid spill does not ftow under or collect under process equipment and shall not migrate to another process I utility area under gravity action. In case of any specific toxic liquid KOC should specify the requirements.

Necessary drains shall be appropriately provided at the periphery of each unit to collect any spillage.

KOC should identify and specify the hazardous areas in the plant.

Appropriate catchment areas for drainage water of the plant units should be considered as a result of fire fighting and storm water.

Sandy areas and terrains should be adequately covered with tiles to prevent plant and vegetation growth and maintain grading of plot.

Access Wavs % In-Plant Roads

Access ways and in-plant roads shall be provided for movement of maintenance vehicles and for fire fighting from the roads around the plot. There shall be at least lsvo pedestrian access ways for fire fighting purposes from all roads around the plot.

The minimum recommended width for vehicle access ways shall be six (6.0) metres and for pedestrian access ways shall be one (1) metre in accordance with KQC-C-002 "KOC Recommended Practice for Engineering Design Basis of Civil and Structural Work.

Vehicle access ways shall be as straight as practicable and free of obstructions from any overhead structures and should comply with the minimum overhead clearances as specified in "KOC-C-002". Equipment and other structures should be located in such a way that they do not protrude into the access ways.

The process pipeways or site-run piping and cable trays should be installed in such a way that they do not obstruct the access-ways or in-plant roads.

Appropriate care should be taken with regard to the clearance height of pipeway that crosses over the access-ways or in-plant roads so that it will not cause m y obstruction or hindrance to large vehicles, cranes and other large size mobile equipment or hoist mounted truck deployed for plant / equipment maintenance.

Construction & Maintenance Considerations

Modularization is an increasingly acceptable construction method. This method should be considered early in the design period to determine if it will be economical lead to cost benefit and improved construction and quality control.

Maintenance issues that need consideration during plant layout should include access for maintenance of equipment and lay down areas for equipment that may be repaired in place such as compressors, columns and shell and tube exchangers etc.

Piping around equipment requiring routine servicing shall be arranged for easy access. Where equipment can be removed and repaired while the plant continues to run, piping shall be arranged so this task can be done efficiently and safely.

LAYOUT OF EQUIPMEMT AND PLANT BUlLDlNGS

Equipment Layout

The primary consideration in the arrangement of plant and equipment should be to p-ovide a safe operating facility that shall be economically designed and easy to operate and maintain. For spacing between various equipment and items refer to Spacing Charts in Appendix-7 of this RP.

The equipment layout shall consider provision of appropriate space for future needs and expansion of plant by KOC.

Equipment shall be located and orientated with due consideration to the effect of noise in the immediate vicinity of the equipment and on the general plant areas.

Stacking equipment should be avoided unless they are in the same basic service and process ftow path such as a contactor, reflux accumulator etc. When stacking equipment, the layout shall facilitate the maintenance of individual items including removal and inspections.

Buildings layout: Office, Control and Other Buifdinqs

- - .

All buildings shall be sited according to the requirements of OSHA 29 CFR 1910.119 "Process Safety Management of Highly Hazardous Chemicals (PSM)" and the methods as outlined in API RP 752. The hazards associated with the presence of oil and gas wells in proximity to the buildings shall be included in this study. For spacing between plant buildings and various equiprent / items refer to Spacing Charts in Appendix-? of this RP.

Page 17 af 33 -

Office, maintenance and control buildings as well as other occupied site buildings shall be designed and located such that the risk to occupants is precluded or minimized. Where high risks are envisaged due to process requirements, blast resistant construction shall be adopted in accordance with KOC-C-030 "KOC Recommended Practice for Blast Resistant Design of Buildings". The location of the control room and the requirement for blast resistant construction shall be determined based on KOC's operating and maintenance requirements and the results of Vapour Cloud Explosion (VCE) Analysis.

Rev. I

Control buildings shall be planned independently, depending on available plot size, as the single storied or double storied building, catering to all the requirements for operations of the plants (GC / BS etc). Adequate space for equipment and necessary space and facilities for operators and other essential personnel shall be provided for monitoring and control on twenty four (24) hours basis throughout the year.

-

-

Control buildings should include as a minimum the following facilities only:

a. Plant Control room b. Auxiliary / Marshalling rooms c. Telecom / LAN room d. Conference & Training rooms e. Rest rooms f. Toilets, Shower and Locker rooms g. 'Prayer room h. Par tg and Mess room i. Offkes j . Instrument room k. Eiectdcal room 1. Mechanical room (HVAC) m. Stme room(s) n, Other if any.

The control building should not be located unnecessarily far away from process plant since it requires continuous monitoring and frequent visits to process plant.

DOC. NO. KOC-La28

A Quantitative Risk Assessment (QRA) shall be conducted by the Contractor, or a third party Consultant approved by KOC to demonstrate the risk involved. The QRA used in deciding the location of the control room and the type of construction shall include a Vapour Cloud Explosion (VCE) Analysis for various release scenarios. The final layout and design of all buildings shall be subject to the approval of KOC.

Office I' maintenance 1 control building shall be located to allow unobstructed pedestrian emergency escape. The escape route shall not cross any fire risk area and should not pass through an area containing a process unit.

The orientation and layout of the building and its ventilation should be considered in view of prevailing wind direction as a result of major toxic release.

No building under any circumstances shall be built over any existing underground service(s).

Other Aant buildings such as compressor house, pump house, chemical storagE building should preferable be made of structural steel with sheet claddings and the design shall be submitted to KOC for review and approval.

Air Intakes and Discharqes

Air intartes for HVAC systems, air compressors (for process air, instrument air, plant air and ventilation air) and to gas turbines shall be located away from areas where air contamination can occur due to dust, flammable or toxic material. They shall not be located in any area classified as Hazardous Area (Zone 0, 7 or 2) as defined in KOC Standard KOC-G-002, nor hated above or below an area classified as Zone 0 or Zone 1. For spacing between various equipment and items refer to Spacing Charts in Appendix-I of this RP.

The 1oc:ation of air intakes shall be determined after considering the effect of possible air contamination, additional safety systems, and reduced exposure constraints on personnel working in the area. The locations shall be subject to the approval of KOC.

The intakes should be located upwind of discharge location to prevent cross contamination by recirculation taking into account natural wind effects. The distance between the intakes and the discharges should not be less than six (6) metres.

Air discharges from HVAC systems from enclosed hazardous areas shalr Ex considered as a source of release and shall be sited accordingly.

Air discharges from HVAC systems, and blow-off facilities associated with air compressors and fans, shall be located in such a way that they will not cause a hazard or inconvenience to personnel nor affect the access to, and operation of, adjacent equipment.

W C . NO. KOC-La28 11 - Page 19 of 33 - il . - ,

Rev. I

Primary / Area Substation

Substation buildings should generally comprise switchgear rooms, control rooms, battery rooms and transformer bays and should be sized appropriately to accommodate all the electrical equipments with the necessary safety clearances from the walls and the adjacent equipment in compliance with KOC RP for Design Basis and Selection of Electrical Systems KOC-E-003 Part 1. For spacing between primarylarea substation and various equipment / items refer to Spacing Chart-2 in Appendix-I of this RP,

These facilities are normatly critical to plant operation. They shall be located in a non-hazardous area and shall be well separated from the process area and hydrocarbon pipelines.

Attention to grading of the site should be given to ensure sub-stations are at a higher elevation relative to process areas.

Pjant Substation

The plant substation should feed the power requirements of each facility and should be located in a non-hazardous area and its location should be optimized to provide the minimum length of cable runs within the plant. For spacing between plant substation and various equipment / items refer to Spacing Chart-I in Appendix-I of this RP.

If rooms like office / storage filing etc. are to be constructed attached to the substatilsn buifding, they shall be provided with independent entrance door from outside; and shall be completely isolated from the substation building by fire rated walls and doors.

Utilities

Utilities are vital for the operation of the plant and facilities. It should be placed suitably away from process areas keeping in mind the operation requirements. For spacing between various equipment / items refer to Spacing Charts in Appendix-I of this RP.

Firewater Tanks and Pumps

Fire-water pumps are critical equipment that shall be utilized in fire emergency situations. They should be located well away from areas of blast, explosion, and fire risk. For spacing between fire-water tank / pump and various equipment / items refer to Spacing Chart-2 in Appendix-I of this RP.

The fire-water tank and fire-water pumps shall be located at a safe location and shall be outside the fenced area. The fire-water pumps should be located suitabiy close to the fire-water tank to meet the optimum operation requirements.

Area around fire water tank and fire water pump should have no obstruction and shall permit free access for fire trucks.

DOC. NO. KQC-La28

Process Vessels

Vertical vessels shall be placed on a common centreline parallel to the main pipe way, unless process reasons dictate otherwise. For spacing between process vessel and various equipment / items refer to Spacing Chart-1 in Appendix-I of this RP.

Horizontal vessels shall be located to minimise piping runs and shall be lined up with the dished head on a common locating line on the pipe way side of the unit. Vessels and associated piping shall not encroach into established operating or access aisles.

Adequate space should be provided between process vessels to allow removal of components without obstructing normal operations,

Shell and Tube Exchanqers

Shell and tube exchangers shall be located with the channel nozzles away from pipeways to facilitate tube bundle removal. They shall be lined up with dished ends on a common line with vessels or shell on the pipeway side. For spacing between shell and tube exchanger and various equipment I items refer to Spacing Chart-I in Appendix-I of this RP.

Shell and tube exchangers shall be located so that when their tube bundles are withdrawn they do not project into an emergency escape route or any road with unrestricted vehicle access.

Shell and tube exchangers shall be arranged so that they can be readily dismantled for cleaning and maintenance.

The channel end of exchangers shall be clear of overhead structures for handling of channel end by mobile equipment.

Shell and tube exchangers shall be located to facilitate tube bundle removal using mobile equipment. Monorails shall be provided where access from mobile equipment is not possible.

Gas Compressor

Gas Compressors with gas turbine dr~ve shall be oriented with due consideration to the location of air inlets, exhaust ducts, and piping. The effects of noise and draught should also be considered. For spacing between gas co.npressor and various equipment / items refer to Spacing Chart-I in Appendix-1 of this RP.

Compressors shall be located under a shelter to provide protection to equipment and personnel from the effects of direct solar radiation.

Compressors are recommended to be elevated to permit piping and auxiliaries to be located below the operating platform. Small compressors may be mounted at grade with piping and auxiliaries arranged for convenient access and maintenance.

1

DOC. NO. KOC-La28 Page 21 of 33 -

A suitable bridge or gantry crane should be provided to help replacement of parts a i d components of compressor for maintenance.

Process Pumps

Process pumps should be located at or near grade level and under a sunroof. All pumps should be accessible for operation & maintenance and suitable lifting devices shall be provided for their maintenance. For spacing between process pump and various equipment / items refer to Spacing Chart-1 in Appendix-1 of this RP.

Pumps should be located and specified so that an acceptable NPSH can be obtained without undue elevation of suction vessels or columns. Pumps in flammable or toxic service shall not be located in pits to meet or satisfy NPSH requirements.

Pumps shall be grouped together for ease of operation, providing process requirements are satisfied. Suction lines shall be kept as short as possible.

Pumps handling flammable liquids shall not be located under overhead equipment, pipe rack or structure. A minimum horizontal clearance of 10 metres shall be maintained between pump and overhead equipment, pipe rack or structure etc.

The practice of using firewalls or fire screens to protect overhead equipment, pipe rack or structure, from the effects of a pump fire, shall not be generally acceptable. However, risk assessment may be utilized in cases approved by KOC.

All flammable or toxic vapours released from plant equipment or systems shall be appropriately discharged to the flare header or otherwise to a safe place as approved by KOC. KOC approval in writing shall be obtained in case of any deviation from this requirement.

The pump vent and drain lines should be piped to proper containment facilities.

Adequately ventilated shelters shall be provided for large machines requiring in-situ maintenance. Adequate space for lifting and handling facilities shall be provided. A bridge or gantry crane should be provided to help replacement of parts and components of pump for maintenance.

Crude export pumps shall be located inside a pump shelter. A bridge or gantry crane should be provided to help replacement of parts and components of pump for maintenance.

All flammable or toxic liquids released should be discharged into a closed and safe drain system. KOC approval in writing should be obtained in case of any deviation from this requirement.

_DO. NO. KOC-L-028 -1 Page 22 ~f 33 -- -

Air-Cooled Exchanqers

Air-cooled exchangers shall be located to provide safe and practical access for operation and maintenance. They may be located at grade or over pipe ways. Crane access shall be provided for tube bundle removal. For spacing between air-cooled exchanger and various equipment 1 items refer to Spacing Chart-1 in Appendix-1 of this RP.

The location of air-cooled exchangers shall consider the effect of air moverent on increased fire spread and the possibility of tube failure adding fuel to the fire.

Air-cooled exchangers shall be located so that the hot air emitted shall not cause hazard or an inconvenience to personnel, and does not impair the operation of adjacent equipment.

Air-cooled exchangers should be located away from the fired heaters to minimise the possibil~ty of circulation of heater exhaust through the exchanger. Preferably, they should be located downwind of furnaces and other sources of ignition.

Air coolers shall not be located above pumps or compressors handling flammable materials.

Fired Heaters

Fired !-eaters shall be located on the periphery of a plot and immediately adjacent to an unrestricted road. There shall be adequate access for fire- fighting from all sides of a heater and, in the case of a group of heaters they shall be separated from the remainder of the units by vehicular access ways on the other three sides of the group. For spacing between fired heater and various equipment I items refer to Spacing Chart-I in Appendix4 of this RP.

Fired heaters shall be located relative to process equipment and prevailing winds to minimise the risk of gas releases from the plant drifting into the heater.

The layout and design of heaters shall be such that the tube removal can be effected by mobile lifting equipment. Adequate dropout and swinging space shall be provided,

Blast doors shall be oriented away from plant and operating areas.

Surface drains, specifically of hydrocarbons, shall not be located or routed directly under a fired heater.

DOC. NO. KOC-L428 I' Page 23 of 33 I Rev. I -

Storage Tanks for Petroleum

Aboveground Petroleum Storage Tanks shall be located at a safe location within the plant. The layout, interspacing, and diking of storage tanks shall be in accordance with the requirements of KOC Standard KOC-L-027. For spacing of storage tank and various other equipment / items within the plant refer to Spacing Chart-I in Appendix-I of this RP and for spacing of KOC Tank Farm from other facilities and items refer to Spacing Chart3 in Appendix-I of this RP.

Pressure Relief Devices

All flammable and toxic vapours released should be appropriately discharged to the flare header. KOC approval in writing shall be obtained in case of any deviation from this requirement.

All flammable and toxic liquids released shall be discharged into a closed and safe drain system. KOC approval in writing shall be obtained in case of any deviation from this requirement.

For additional information for appropriate drainage of flammable and toxic liquids refer to KOC-MP-027 Part 2.

Other Potential Sources of Hazard

Any of the following fittings, which handle flammable fluids, shall be considered a potential source of hazard:

a) Sample points

b) \/ents and drains

c) F'ressure regulator vents

d) Heater fuel control valves and meters

e) Heater fuel gas and pilot gas filters

f) Chemical injection points

The source of hazard described in clause 8.16.7 above or other potential sources of hazard shall be located at least 15 metres or more horizontally away from any part of a fired heater or electrical distribution board, or other sources of ignition.

Flare Stack

The location, spacing, orientation and height of flare stack shall be determined by a full assessment of the factors involved and appropriate calculation for the heat radiation. For spacing between flare stack and various equipment / items refer to Spacing Chart-2 in Appendix-I of this RP.

Flares are a possible source of ignition; and shall generally be located remote from process facilities, storage areas, utility areas, and office / service areas but well inside the property line. They should be well away from public occupied areas (present or future) located adjacent to the site boundaries.

DOC. NO. KOC-L-028

Flares should also be considered a source of vapour release, as it is possible that the flame could be extinguished.

Rev. I

Where more than one flare is provided, the location of each shall be based on operational requirements. The locations of all flares should be determined by any need for independent operation or maintenance of individual flares.

)1 - - -

The flare should be located either on side wind location or upwind location from the process facilities and sources of a major release of flammable vapour.

Flares should be located as close as practicable to the process units served. However this spacing should be computed based on risk assessment and calculations for heat radiation and submitted to KOC for approval.

Flare stacks shall conform to the state regulations regarding height of installations close to airways. All state clearances shall be obtained before finalizing the site layout.

Burn Pit

Burn p'f shall be located so that smoke from the burn pit does not drift over operatiqg areas of the plant, control and other buildings, substation and also the gas / vapours released from plant equipment are not blown over the burn pit. Fo- spacing between burn pit and various equipment / items refer to Spacing Chart-2 in Appendix-1 of this RP.

Burn pits shall be spaced at a suitable distance away to allow maintenance work to be carried out in a safe radiation zone from an adjacent burn pit unless radiation zone calculations indicate a greater distance is required. Distances shall be measured horizontally from the burner tip.

The manifold(s) is intended to receive and collect the petroleum produced from the wells. The petroleum is then discharged through the manifold outlets to various batteries of separators located in the vicinity.

For spacing between manifold and various equipment / items refer to Spacing Chart-I in Appendix-1 of this RP.

'I DOC. NO. KOC-L-028 1, Page 25 of 33 -

Offsite Effluent Treatment Facilities

The plant contaminated water should be directed to flow through intended water channels to treatment facilities. The water treatment facilities should be graded to maximize gravity flow as much as practicable.

The effluent treatment facilities should be on downwind direction from sources of ignition and be located at an appropriate distance from sources of ignition based 3n risk analysis and calculations

Overhead Electrical Powerlines

The rrinimum horizontal spacing (distance) of petroleum (liquid or gas) pipelines from overhead electrical powerlines shall be as given in KOC-L-002.

For the purpose of safety and protection the KOC plant or facility shall not be located / constructed beneath the overhead electrical powerlines. As such the overhead electrical powerhe should be at least 60 meters away (horizontally) from the fence or boundary of the plant or facility.

Plant Piping

General

The ASME 631.3 and KOC 035 series of specifications as described in dause 4.2 of this RP should be referred to and applied in order to carryout appropriate design of plant piping systems and construction with due considerations for safety requirements and piping systems hydraulics.

Future expansion should be considered in the initial layout. Appropriate space should be kept available for the installation of future equipment, piping and cables. All piping layouts shall be submitted to KOC for review and approval.

P r e s s piping shall not be buried and shall be routed above ground on grade level pipe racks or on elevated pipe racks.

Consideration should be given in design and layout of flare lines relief and drain systems in order to meet necessary safety and operation requirements.

The isolating valves shall be located such that they are readily accessible and not located in an hazardous area of fire risk zone.

Fire Water Piping

Firewater piping may be installed below ground or otherwise as per the design requirements. In case the line is designed underground, all block valves should be located below ground in pits and shall be provided with loose extension spindles for operation aboveground.

8.22.3 Piping Design

Flowtine battery limit valves shall be located immediately adjacent to the plant fence line.

Inlet and outlet piping of Emergency Shut-Down Valves (ESDVs) shall be covered in the detail engineering design and rou ted/located appropriately.

Thermal relief valves, protecting blocked-in process piping or equipment shall discharge to a suitable drain or closed blow down system.

For the protection requirements of new and existing KOC services, refer to the relevant clauses of KOC RP KOC-L-002 for details.

Refer to other KOC Standards / RP and 015 Series of Specification as listed in ctauses 4.2.2 & 4.2.3 of this RP, for a more detailed specification regarding Piping Design and Layout.

PIPELINES / TRANSIT LINES

The nearest location of proposed or existing facility such as residential building, mosque, hospital, school, farm, office, shop, workshop, factory/industry, warehouse, permanent structure, industrial, non-industrial dwellings, private or public utilities and service units etc shall be 500 meter away from the existing or proposed pipeline I transit line corridors conveying hydrocarbon gas, crude oil, and gas condensate. For minimum spacing requirements of equipment and various items refer to Spacing Charts in Appendix-? of this RP.

The valve pits, metering stations and drain pits along the underground pipeways or pipehe corridor shall be fenced with 2.8 meter high barbed wire fence, and shall be fully inaccessible to the public or residents at all times.

Statutory warning signboards with danger signs shall be installed at every 100 meter intervals along the pipe-way corridor for at least 500 m distance on the either side of proposed inhabited buildings.

Under special circumstances where the above distances can not be maintaiwd, the nearest location of the proposed building from the existing underground pipe-way corridors shall be established after carrying out an extensive Quantitative Risk Assessment (QRA) and analysis.

DOC. NO. KOC-La28 (1 Page 27 of 33 - __ - -

QUALITY ASSURANCE

The Contractor shall operate a quality system preferably based on IS0 9000 series of standards to satisfy the requirements of this Standard. The Contractor shall demonstrate compliance by providing a copy of the accredited certificate of its quality manual. Verification of the Contractor quality syskm is normally part of the pre-qualification procedure and is therefore, not detailed in the core text of this Standard.

The Contractor shall also operate an Occupational Health and Safety Assessment Series-OHSAS-78001 series of Standards to meet KOC HSEMS requknents.

DOCUMENTATION

General

Documentation required are generally covered in the KOC Tender Documents. However the documentation requirements as mentioned below supplements the requirements in aas specified in the KOC Tender Documents.

All correspondence, instructions, data sheets, drawings or any other written information shall be in English language. In case of dual languages, one language shall be English.

All dimensions, units of measurement, physical constants etc. shall be in SI units uiless otherwise specified. (Nominal bore pipe sizes to be generally mentioned in inches).

All documents (text, data sheets, specifications etc.) shall be provided with electroriic files in the approved and widely used software (MS Word, Excel, Auto CAD etc.). All calculations shall be submitted in approved and widely used software(s) agreed upon by KOC.

The Ccntractor shall provide the necessary documents to KOC for review and acceptance as given below, but shall not be limited to the following only:

Btock Flow Diagram Process Flow Diagrams PRlDs Cause and Effect Tables Plot Layout G-ading Plans Drainage Plans Paving Layout Drawings Equipment Layout Drawings Piping Plans

SPACING CHART-I SPACWC OF EWPMENT AND ITEM8 LOCATED WtTHlN KOC PLANT (GC I BS / OTHER FAClLlTlES)

4 I ~ a i n Prow55 P i p m ~ y ~ 1 30 5 I ~ i ~ e w x ~ s for Non-Pflroleum Fluids 1 25

Sparing in Mcfcrs

Not*] For spaeinp a f Peltrskmn Storage Tank (inside thr pIan1) wirh c q u i p m i Ircrns [mi& 8 c mmt planil r d t r to KOC Stsndsrd KOC-G027. Notc-3 Fm infarma~ion rcgrding apacrnp crrlcrln rcfcr ro Cla~scs 7 1.4 and 7 1.5 of this IW.

DOC. NO. KaC-1-028 I Page 30 of 33 Rev. I

SPACING CHART-2

SPACING OF KOC EQUIPMENT AND ITEMS LOCATED OUTSIDE OF KOC PLANT (GC I BS i OTHER FAClLITlESJ BUT WITHIN KOC FENCED AREA

Tank+ ( R r : ~ c h h j Fire Wwlrr)

1 30 PM RC RC 30 ...... .

.- RC RC RC RC RC RC RC RC RC

P i p l i n c ~ Trrrnril lints f lnte-I) 30 30 RC M N atr-2

8 I Oil-Wstw Separator Pond i 9 1 Oil .! G R ~ %Vcll< N u W - ~ J

Now-1: Thc spacing is of pipclinc; / transit lincs (in cnrridnrl with athsr items as shown. T h ~ s spacing is not lntcndcd fnr the dl$lrtbutron p~prng erc. Natc-2: SPACING ON-HOLD. Sparing o f rhts itcm is m hc prnvidcd by PhDSS ?%AM (PADSS Ttam = Produc~inn , h d Dril l ing Spa~ng S l r i t ~ "1 citnl)

Xotc-3. For infomalion rqarding spacmg crilcr~a r r f i to CLauses 7.1 .& and 7 . t . S o f this RP.

DOC. NO. KOC-L-028 Page 31 of 33 Rev. I -

AP'PENDtX-I Contd. . . . . . . . . . . . .

SPACING CHART-3

SPACING F KOC PLANT. KOC TANK FARM, AND OTHER KOC ITEMS fUOM filJWAlT GOV-i I PKIVA I t I PUl3LIC Ui LUTlES ! FAClLlT I t5 ETC

NOTE- 1 : For derails reg~rding 5pacins of " KOC Tank Fann for Petrolcum Stom_cc' with olhcr itcms rcfw la KOC S~andard KOC.

2 3 1 4 a --- - M RC 500 I RC -

M X 60 3D0 --- M X M RC 5MI IRC '

ARBREVIATJW45 IrSiED: t- = Cdculatc M = Dtrermmc appropriarc spacing hz;d on Maintmance i Pcrsonncl Access 1 Safcty INoisc Lcwl rtquirenienrs a5 applicable. N = No1 Controlled by KOC R = Risk Anslys~s X = No Mandator). Rec]uiwmtnt . = Not Applicable

' 4

5

Hl:hwa) IRmd RC Rrrlden ti111 , trca, Woqrrc. Hmpital, Schc~ol, Farm, 5DOIRC Oftire, Shop. \ h r k h o p l Srrcrnp. Wrrrhoutr Err

Sr. No. - l 1

6 0

300

Sprc~ng in Sletcrc

2

RC

5001 RC

3

N

N

N

N -I

4 5

DOC. NO. KOC-La28 ! 1 Page 32 of 33 Rev. 1 - -

ACKNOWLEDGEMENT

This RP has been approved by the Standards Technical Committee (STC) consisting of the following:

Mr. NRedha AI-Haddad Mr. Mohammad Emam Mr. S. Kumar Mr. Henry Hill Mr. A. Unnikrishnan Mr. Khalaf Harnada Mr. N. Ramanathan Mr. Ali Hassan Al-Failakawi Mr. Daniel Pino Mr. Abdul R. Al-Shammari Mr. Khalid Al-Ahmad Mr. Abdul Aziz Akbar Mr. Moataz Khalaf

Standards Team Insp. & Corr. Team (S&E) Standards Team Opns. Tech. Svcs. Team (SK) Standards Team Design Team Export Facilities Team HSE Systems Team Utilities Team Insp. & Corr. Team (N&WK) Gen. Projects Team Project Mgmt. Team (NK) Information Systems Team

Chairman Deputy Chairman Secretary/ Member Member Member Member Member Member Member Member Member Member Member

The draft of this RP had been circulated to the KOC User Teams for review and the responses were received from the following:

ENGINEERING GROUP EXPORT & MARINE OPNS. GROUP

Team Leader Design Team Leader Export Services

AHMADI SERVlCES GROUP HSE GROUP

Team Leader Utilities Team Leader Proj. Design Team Leader 61dg Mgmt.

Team Leader HSE Systems Team Leader HSE (TS) Team Leader HSE (NK)

OPERATlONS GROUP ISKl MAJOR PROJECTS GROUP

Team Leader Maintenance Team Leader Prod. Opns

OPERATIONS GROUP INK)

Team Leader Project Support

DIVIDED ZONE GROUP

Team Leader Opns. Tech. Svcs Team Leader Proj. Engg. & Facilities

GAS MANAGEMENT GROUP

Team Leader Gas Operations Team Leader Consumers Networks

q DOC. NO. KOC-La28 I] Page 33 of 33 Rev. I 1- - J

This KOC Recommended Practice for Layout of Plantsite and Offsite Facilities IKOC-L-028 Rev.7) has been prepared by the Task Force (TF-LPi12) comprising of ihe following members:

Mr. Faisal Mirza Mr. Mohsin Mirza Mr. N. Ramanathan Mr. Mohd. Alam Mr. Uppara Saibaba Mr. T. V. Valsan Mr. Haytham H. Al-Habshi Mr. Mohd. Al-Ajmi Mr. NAl-Sattar A/AI Salam Mr. Mohd. Dashti Mr. John Onderdonk Mr. Sayed Al-Zaizalah

Standards Team Standards Team Export Facility Proj Safety Team Safety Team Design Team Opns.Tech.Svcs. NK Opns.Tech. Sevs. WK Production Opns. SK

TF Leader Author Member Member Member Member Member Member Member

Ex. 61 151 Ex. 61371 Ex. 66960 Ex. 6641 5 Ex, 71837 Ex. 61659 Ex. 23336 Ex. 20336 Ex, 22538

Human Resources SEK Member Ex. 22145

Drlg, & W/Over - l Member Ex. 71057 Field Development SK Member Ex. 22069

J