Contents

1. Scope............................................................................................................................................

2. Codes and Standards.....................................................................................................................

3. Design Conditions.........................................................................................................................

4. Materials.......................................................................................................................................

5. Pipe Sizing....................................................................................................................................

6. Piping Design and Layout.............................................................................................................

7. Valving.........................................................................................................................................

8. Line Blinds....................................................................................................................................

9. Relief Valves and Vents................................................................................................................

10. Service Piping.............................................................................................................................

11. Equipment Piping........................................................................................................................

12. Equipment Layout.......................................................................................................................

13. Elevation, Clearance and Access Requirements.......................................................................30

14. Platform, Stair and Ladder Access..............................................................................................

15. Miscellaneous - Personnel Protection..........................................................................................

Table 1...........................................................................................................................................34

Table 2...........................................................................................................................................35

Table 3...........................................................................................................................................37

Table 4...........................................................................................................................................39

Table 5...........................................................................................................................................40

Table 6...........................................................................................................................................41

Table 7...........................................................................................................................................42

Page 1 of 44

Table 8...........................................................................................................................................43

Table 9...........................................................................................................................................44

Table 10.........................................................................................................................................45

Page 2 of 44

1. Scope

1.1. 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.

1.2. 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.

1.3. The design of pressure piping shall comply with the codes and standards referenced herein and with accepted practices currently applicable to piping systems.

1.4. 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.

1.5. Non pressurised underground drainage, domestic sewer piping and plumbing are excluded from the scope of this specification.

2. Codes and Standards

2.1. 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 - Code for Power Piping

ASME B31.3 - Code for Process Piping

ASME B31.4 - Code for Liquid Transportation Systems for Hydrocarbons, LPG, Anhydrous Ammonia and Alcohols

ASME B31.8 - Code for Gas Transmission and Distribution Piping Systems

NFPA 30 - Flammable and Combustible Liquids Code

NFPA 58 - Standard for the storage and Handling of Liquefied Petroleum Gas

OISD-STD-144 - LPG Bottling Plant Operations

OISD-STD-116 - Fire Protection Facilities for Petroleum Refineries and Oil / Gas Processing Plants.

OISD-STD-156 - Fire Protection Facilities for Port Oil Terminals. OISD-STD-118 - Layout for oil and gas installations

OISD-STD-117 - Fire Protection Facilities for Petroleum Depots & Terminals

IP Model Code of Safe Practice - Pt 19

- Fire Precautions at Petroleum Refineries and Bulk Storage Installations

IP Model Code of Safe Practice – Pt 9, Volume 1

- Liquefied Petroleum Gas Large Bulk Pressure Storage and Refrigerated LPG

GE Insurance Solutions – GAP.2.5.2

Oil and Chemical Plant Layout and Spacing

GE Insurance Solutions – GAP.2.5.2.A

Hazard Classification of Process Operations for Spacing Requirements

API RP520 Part 1 & 2 - Design and Installation of Pressure Relieving Systems in Refineries

API RP521 - Guide for Pressure Relief and Depressuring Systems

API RP550 - Installation of Refinery Instruments and Control Systems

OSHA - Occupational Safety and Health Administration AGA Gas Measurement

Committee Report No. 3 - Orifice Metering of Natural Gas

UOP - Std Spec 9-51-2

- Typical Plot Plan Procedures

2.2. 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.

2.3. 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.

2.4. 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. Design Conditions

3.1. Operating conditions

3.1.1. Normal Conditions

Normal design conditions of pressure and temperature are the most severe conditions expected to coexist under usual long-time operating conditions. These usual operations include all manipulation and control functions such as throttling, blocking and by-passing likely to be used for operation and control.

3.1.2. Temporary Conditions

Usual operating conditions do not include more severe temporary conditions, such as those incidental to start-up, shutdown, steamout or abnormal operation. Temporary conditions govern as design conditions only when there is clear evidence they definitely exceed time and severity limits in Paragraph 302.2.4 of ASME B31.3 Chemical Plant and Petroleum Refinery Piping.

3.2. Design Temperature

3.2.1. Definition

Design temperature is the most severe sustained fluid temperature, subject to conditions of section 3.1 above and is generally based on the design temperature of connected equipment. Design temperature of non-insulated components shall be in accordance with Paragraph of 301.3.2 ASME B31.3.

3.2.2. Steam Traced Piping

Design temperature for steam traced piping shall be the fluid temperature or 11C below saturation temperature of tracing steam, whichever is greater.

3.2.3. Low Temperature Piping

Design temperature for piping with a fluid operating temperature below minus 29C, shall be the normal fluid operating temperature. In addition, design shall be suitable for the design pressure at 38C.

3.3. Design Pressure

3.3.1. Definition

The design pressure is the most severe condition of internal or external fluid pressure, subject to conditions of Section 3.1 above. The design pressure for Boiler Code piping is to be established in accordance with the Code for Power Piping ASME B31.1, or The Indian Boiler Regulations 1950, whichever is greater.

3.3.2. DELETED.

3.3.3. Pump Discharge Systems

3.3.3.1. 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, whichever is greater, where:

i. Normal operating pump discharge pressure is the pump differential pressure plus normal suction pressure and hydrostatic head.

ii. Pump shut-off discharge pressure is pump differential pressure at shut-off or stalling conditions plus suction pressure and hydrostatic head, adjusted for allowances per para. 302.2.4 of the Process Piping Code ASME B31.3.

3.3.3.2. 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, whichever is greater, where:

i. Normal operating pump discharge pressure is the pump differential pressure plus normal suction pressure and hydrostatic head.

ii. Relief or safety valve set pressure is this pressure plus hydrostatic head below relief valve adjusted for allowances per para. 302.2.4 of ASME B31.3.

3.3.4. Lines with Two Ratings

Where a line with a lower rating connects to a pipe or equipment with a higher rating, 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, when double block valves are used, to and including the second block valve. 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.

3.3.5. Vacuum Systems

Design pressure for piping systems operating under vacuum shall be full vacuum. Exception shall be taken where suitable protection against vacuum failure is provided.

3.4. Loads Affecting Piping Stresses

Allowable stress values apply to total loads imposed on piping materials. Design shall provide for all loading significantly affecting pipe material stresses. See para. 301.4 through 301.7 of Process Piping Code for loadings, in addition to fluid pressure which may affect piping stresses and chapter VIII for piping in category ‘M’ fluid services. Refer to Piping Stress Analysis Procedure 3PS-PL-008, Appendix C.

4. Materials

4.1. Piping Materials Specification

The Piping Material Classes shall list in detail the pipe, valve, flange, fitting, bolting, gasket, branch connection and other specific material requirements for various classes of fluid, temperature and pressure services. Refer to Specification No. 25194-3PS-PL-001. All components listed in a Piping Class shall be suitable for use within the pressure/temperature limits of that class.

4.2. Corrosion Allowances

Corrosion allowances shown in the Piping Materials Classes is the maximum for the respective service and material.

4.3. Wall Thickness and Reinforcement

4.3.1. 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. Pipe wall thicknesses may not be specified for the full pipe size range within a class, but shall be calculated to suit specific line service conditions.

4.3.2. For wall thicknesses not specified in the pipe classes, wall thickness shall be selected on the basis of calculations to suit individual line conditions.

4.3.3. Branch reinforcement is to be based on "limited" corrosion, where all excess metal in the pipe wall, other than that required for pressure and corrosion allowance, is credited to branch reinforcement.

5. Pipe Sizing

5.1. Piping is to be sized for normal operating conditions. Provision for future increased capacity shall be made when specifically requested.

5.2. Piping smaller than ¾ inch shall not be used except in instrument and steam tracing services.

5.3. Pipe sizes 1¼", 2½", 3½", 5" and 9" are not to be used except where equipment connections are these sizes. In such cases, transitions to other commercial pipe sizes is to be made as close as possible to the equipment connection.

6. Piping Design and Layout

6.1. Piping Routing

Piping is to be arranged in an orderly manner and routed as directly as practical, preferably in established banks or pipeways, as follows:

6.1.1. Piping on elevated racks shall run at different elevations designated for north-south and east-west banks, and change elevation when changing direction.

6.1.2. Piping outside of main pipeways shall run parallel to main pipeways wherever possible.

6.1.3. Relative elevations of pipeways shall be set to provide sufficient clearance between lines at intersections.

6.1.4. Flat turns at changes in direction are to be avoided on elevated pipe racks.

6.1.5. Dead ends and pockets in line are to be avoided.

6.1.6. All process piping within unit plot limits shall be carried overhead.

6.1.7. 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.

6.1.8. Offplot piping between units shall be run on sleepers at grade, where practical.

6.1.9. Overhead lines in acid, caustic or other corrosive services shall not have flanged joints located above access ways or platforms. Overhead flanged joints in these services shall be fitted with a plastic shield.

6.1.10. Piperacks and sleeperways shall be sized to allow 20% spare capacity on completion of engineering. An additional 20% spare capacity shall be allowed at commencement of detailed engineering to allow for design development.

6.1.11. Lines requiring limited pressure drop shall be routed as directly as practical.

6.1.12. Piping line size to be a minimum of 2" in pipeways / piperacks.

6.1.13. Piping located in paved areas to be elevated 600mm to bottom of pipe.e.g. Control valve sets and manifold sets.

Where pipes are running at grade in graded areas the minimum BOP of pipes is to be 500 mm.

Where pipes are running in sloping trenches passing under roads, the minimum sleeper height is to be 400mm above the bottom of the concrete trench.

Where pipes are running through interconnecting corridor and anywhere else that the pipe runs over the ungraded natural contours of the terrain, the minimum sleeper height is to be 600mm.

6.1.14. Small bore thin walled lines SCH 10S or less for 2", 3" & 4", should be grouped together so that the intermediate supports may be simplified.

6.2. Piping Flexibility

6.2.1. Piping shall be designed with sufficient flexibility to absorb any excessive stresses. Anchors, stops or guides shall be used to direct thermal expansion away from pumps and turbines etc.

6.2.2. Expansion loops shall be used to reduce thermal expansions and absorb excess stresses where the normal pipe routing is too stiff. Expansion bellows shall not be used without prior approval of the Engineering Manager.

6.2.3. Lines subject to dynamic loading shall be designed to ensure that its size, configuration, mechanical strength, supports and restraints will prevent excessive stress, pressure drop, vibration or noise. Dynamic loading may be expected when pulsating flow (such as at reciprocating compressors), high velocity flow, flashing fluid, fluctuating temperature or pressure, or mechanical vibration (including wind) conditions exist.

6.2.4. All lines shall be designed in compliance with the relevant code requirements.

6.3. 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, to outside of bare flange or outside of flange insulation on adjacent line. Piping without flanges to have 100mm clearance between bare pipes or between insulation. Adequate spacing to be allowed for expansion / contraction between lines at loops and any change of direction.

For details of pipe spacing refer to project standard drawing No’s 25194-P14-JG000-001, 002 and 003.

6.4. Pipe Supports, Anchors & Guides

6.4.1. Pipe Support Procedure shall be in accordance with Specification 25194-3PS-PL-015.

All piping shall be adequately supported and restrained so as to prevent undue vibration, deflection, stresses or loads on equipment. Piping shall be supported from below in preference to hanging from above. For strain sensitive equipment such as turbines, piping may be supported by rigid / spring hangers to take benefit of low friction and to permit any size adjustments that may be required.

Consideration shall be given to the intermediate supporting of smaller lines from larger lines.

All pipe supports, guides, shoes etc. will be shown on the 3D PDS Electronic Model. Welded support attachments, other than shoes, such as trunnions, lugs, etc., shall be shown and located on electronic isometrics. The exception to the above is that shoes welded to stress relieved lines shall be shown and dimensioned on electronic isometrics.

6.4.2. Pipe Shoes

Horizontal lines 2" and larger with insulation shall be run on shoes as per spec. 25194-3PS-PL-019.

On 1-½" and smaller horizontal lines shoes are not to be provided, the bottom half of insulation is to be cut away a distance of 150 mm on each side of the support. Bare lines shall be laid directly on the piperack beam or sleeper. The need for wear plates or shoes shall be investigated for large diameter and thin wall alloy piping.

6.5. Underground Pipes

6.5.1. Direct buried Carbon Steel Pipe shall be coated and wrapped.

6.5.2. The use of pipe trenches shall be avoided, where flammable heavier than air gases can collect.

6.5.3. Multiple lines running below roads or railway lines shall be either sleeved or run in culverts dependant on the most economic installed cost. Consideration must be given to the drainage of culverts and the effect on the hazardous area layout.

6.5.4. When located below grade, piping provided with protective heating and piping in services requiring inspection and servicing, shall be in trenches. Other piping shall be direct buried.

7. Valving

7.1. Valves

7.1.1. Operating and block valves are to be provided in minimum quantity consistent with good design and operating practice.

7.1.2. Unless specifically required for operation, block valves shall not be provided at vessel nozzles when the following conditions exist:

7.1.2.1. Line to or from the vessel can be blocked by a valve located within 12 metres horizontal radius from vessel surface.

7.1.2.2. No undrainable liquid pocket in the line between vessel and valve.

7.1.3. No block valve shall normally be provided in lines or at vessel nozzles for services as follows:

7.1.3.1. Vapour lines to condensers.

7.1.3.2. Liquid and vapour lines to and from syphon reboilers.

7.1.3.3. Lines from condensers to accumulators.

7.1.3.4. Lines between exchangers in series.

7.1.3.5. No block valves to be placed upstream and downstream on steam and boiler feedwater service relief valves (requirements of Indian Boiler Regulations). For all other services paragraph 9.3 applies.

7.1.4. Block valves shall be provided at all 1-½ and smaller connections at equipment.

7.1.5. 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. Locked open or car sealed open valves will have accessibility from fixed or a rolling platform or scaffold and not from a fixed or portable ladder.

7.1.6. Globe valves shall be installed so as to close against pressure.

7.1.7. Where a locked open valve is required, a metal tag shall be attached to the valve: reading "This valve must not be closed without written permission from responsible authority".

7.2. Header Block Valves

7.2.1. Branch line block valves from pipeway headers shall be provided in primary branch lines serving groups of lines to equipment, except where the main header may be shut off without affecting unit operation in the event of failure in a branch line.

7.2.2. Branch line block valves must be located at edge of pipeway for access by portable ladder.

7.3. Unit Block Valves

7.3.1. 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. Drain valves shall be fitted on unit side of the block valve.

7.4. Double Block & Bleed Valves

7.4.1. For double block and bleed requirements see isolation philosophy document 25194-G98- JG000-001 and P&IDs.

7.5. Line Vents and Drains

7.5.1. Vents and Drains conforming to the following table shall be added to large bore lines. this will apply mainly to the pipeway between the Refinery and Marine Tank Farm and lines on the main interconnecting piperack.

Pipe Size Up to 150 m Greater than 150 m

10" 2" 3"

12" 2" 3"

14" 3" 3"

16" 3" 3"

18" 3" 4"

20" 3" 4"

24" 3" 4"

30" 3" 4"

36" 3" 4"

42" 4" 4"

48" 4" 4"

7.5.2. The vent / drain connections shall be branch connections according to the relevant branch table complete with blind flange. Valves shall be included in the MTO for drains only.

7.5.3. Line vents and drains fall into two categories, operating and non operating.

7.5.3.1. Operating Vents for equipment and piping shall be valved, incorporating a blind flange when venting to atmosphere. Open drains shall be valved, together with a blind flange.

7.5.3.2. Non-Operating Vents and Drains shall conform to the following:

i) For all hydrocarbon and hazardous service lines, non-operating vents and drains shall be closed with a cap and seal welded. Valves shall not be provided on such connections to eliminate the chance of leakage through the valve gland.

ii) Systems for air, inert gas, and steam not exceeding design pressure or temperatures of 9.6 bar and 117°C do not require high point vent connections on piping.

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. (The vents and drains shall not be shown on Piping & Instrument Diagrams). Generally vents and drains are to be ¾" dia. For assembly details refer to Drg 25194-P14-JG000-027.

7.6. Sample Connections

7.6.1. Sample connections shall be located for easy access from grade (preferred) or fixed platform.

7.6.2. Length of sample piping to be kept to minimum.

7.6.3. Where a connection connects to a process line the tie in shall be made at the side or top of the line.

7.7. Valves in Caustic and Acid Services

7.7.1. Valves in vertical pipe runs shall be located at a maximum height of 1350 mm from grade or platform. All other valves shall have stems orientated in the vertical.

7.8. Valve Access

Type of Access Required

Grade Fixed Platf

Rolling Platf or Scaffold

Fixed Ladder

Port Ladder

Operating Valves (7.8.1) Yes Yes No No No

Operating Valves, Small (7.8.1, 7.8.3)

Yes Yes No Yes No

Non Operating Valves (7.8.2)

* * Yes No No

Non Operating Valves, Small (7.8.2, 7.8.3)

* * Yes Yes Yes

Instrument Valves (See Para. 10. 8. 7 - Instrument Access)* To be used if available.

7.8.1. Operating valves are valves that are essential for plant operation.

7.8.2. Non operating valves are valves that are not essential for plant operation.

7.8.3. Small valves are defined as valves that can be easily operated with one hand, the other holding a ladder and are normally 2" and smaller.

In cases such as sample points where one hand holds the container and the other the valve, then a platform access is required.

7.8.4. Chain Operators

Operating valves with bottom of handwheel over 2000mm above actual grade or platform shall be chain operated. Chains shall not hang in walkways or access areas and shall terminate approx 1000mm above grade or platform. Chain operators shall not be used for screwed, locked/car sealed valve or any valve 1-½" and smaller.

8. Line Blinds

8.1. 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. For details of blinds refer to project standard drawing Nos. 25194-P14-JG000-018 and 019.

8.2. All lines entering or leaving process unit limits shall be provided with operational blinds as follows:

8.2.1. No blinds required on air, steam, water and lines containing non-toxic materials.

8.2.2. Provide blinds on unit side of block valve on all overhead and underground process lines and all lines containing toxic material. All flanges 3 and larger adjacent to blinds to be complete with jack screws. For details of jackscrews refer to project standard drawing No’s 25194-P14-JG000-020 and 021.

8.2.3. Blinds/spacer shall be provided where indicated on the flowdiagram.

8.2.4. For handling purposes blinds are to be installed preferably in the vertical (between flanges in horizontal part of line).

8.2.5. Blinds shall be accessible from grade or platform.

8.2.6. When binds/spacer exceeds 45 kg. Lifting shall be by mobile equipment. If the blinds/spacer is not accessible, hitching point shall be provided.

8.2.7. Grouped flanges with blinds (e.g. at battery limit) are to be staggered.

8.2.8. Special attention must be given to the line flexibility when ring joint blinds are used. When possible, install a blind in combination with flanged elbow sections.

8.3. Blind and Spacer Installation on Vessel Top Nozzles

8.3.1. Where possible all blind and spacer sets for overhead lines 14" and above should be located in the horizontal axis, either by use of a 90 degree spool piece or preferably by incorporation of an appropriately designed 90 degree flanged nozzle on the vessel.

8.3.2. Lines below 14"which have high pressure flanges with ring type joints down to 6" dia should be considered in the same way.

9. Relief Valves and Vents

9.1. Relief valves discharging into a closed blowdown system shall be elevated to provide self draining of the discharge line into the blowdown system.

9.2. Relief valve tail pipes discharging to atmosphere shall terminate not less than 3 metres above any platform within a radius of 7.5 metres. A 6 mm diameter weep hole shall be provided in the bottom of tail pipes, to prevent liquid accumulation.

9.3. Block valves located upstream of a relief valve shall be full bore and the valve noted as "Locked open" on the Piping & Instrument Diagram. Refer also to para. 7.1.3.5 of this document.

9.4. Small relief valves, protecting blocked-in process piping or equipment against fluid thermal expansion shall discharge to a suitable drain or closed blowdown system.

9.5. All relief valves shall be accessible from fixed platforms with the exception of thermal relief valves which can be accessed by portable ladder. Lifting devices shall be provided for valves weighing more than 45 kg.

9.6. Vents from manholes shall be elevated 3 metres above grade or platform within a radius of 4.5 metres. Vents adjacent to piperacks shall be elevated a minimum of 3 metres above the top rack level.

9.7. Manhole vents shall not be located closer than 15 metres to fired equipment.

9.8. The discharge of steam, air, or similar non-flammable vapours from relief valves, safety valves, and continuously operating vents, shall be located to prevent hazard to personnel.

9.9. A guide and linestop which is capable of withstanding the relief valve reaction force, will be provided at the discharge of each relief valve.

10. Service Piping

10.1. Steam Piping

10.1.1. Piping shall be designed for complete condensate removal. Drip legs shall be provided on all steam lines at all low points and dead ends. Drip legs shall be located such that they do not foul pipe support steel or rack structures due to expansion.

10.1.2. Branch connections shall be made from the top of the headers.

10.1.3. Block valves shall be installed in a horizontal run of each branch line to group of common users.

10.1.4. Piping shall be designed to make use of sub-headers to serve an area of process equipment or groups of drivers.

10.2. Steam Traps

10.2.1. Provide steam traps at low points and drip legs of steam lines.

10.2.2. Discharge steam traps to a lower pressure steam or condensate system (All steam traps shall be accessible from grade or platform).

10.2.3. Provide valves on each side of trap for trap removal on closed systems.

10.2.4. For details of steam trap arrangements refer to Project Standard Drawing No. 25194-P14-JG000-011.

10.3. Steamout Connections

10.3.1. Steamout connections are required for purging vessels and pipelines containing hydrocarbon and hazardous fluid, except for cryogenic or LPG systems.

10.3.2. Steamout connections shall not be less than 1NB.

10.3.3. Hoses serving steam out connections shall not exceed 15 metres in length.

10.3.4. For details of steamout connections refer to Project Standard Drawing No. 25194-P14-JG000-012.

10.4. Steam Tracing

10.4.1. Where process lines require steam tracing they are to be indicated by a dotted line on the Piping & Instrument Diagrams. Above ground liquid lines subject to freezing are to be steam traced if the liquid cannot be circulated.

10.4.2. For details of steam tracing requirements refer to Project Standard Drawings No. 25194-P14-JG000-008 to 010 inc.

10.5. Utility Stations

10.5.1. Utility stations at grade, consisting of air, steam and water, shall be located throughout the operating area of each process unit, so that a 15 metre length of hose can service any point in the area.

10.5.2. Additional utility hose connections for air and steam shall be supplied at platforms for tower manholes and elevated structures, as required.

10.5.3. Utility stations shall be installed such that they remain in operation during unit shutdowns.

10.5.4. No extension of Nitrogen lines to utility hose stations.

10.5.5. Use of Nitrogen only through hard piping.

10.6. Water System Piping

10.6.1. 2NB and below branch connections from cooling water headers shall be taken from the top of the line. Drains shall be provided on the dead end portion of lines.

10.7. Air System Piping

10.7.1. Air piping system shall be designed for good drainage. Provide drain valves and drip legs at the low points of systems. Branch connection shall be taken-off from the top of the header.

10.7.2. 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.

10.8. Instrument Piping

10.8.1. Control Valve Manifolds

10.8.1.1. 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.

10.8.1.2. Block Valves are normally line size, but where control valve is two or more sizes smaller than line size, the block valves may be one size smaller than line size.

10.8.1.3.10.8.1.4. By-pass valve and piping shall be same size as control valve.

10.8.1.5. Supports at control valve manifolds shall be located so that the assembly is self supporting when the control valve is removed.The assembly shall be suitably supported to avoid unnecessary movement due to expansion.

10.8.1.6. Bleed valves shall be located between upstream block valve and control valve for “fail open” valves. For “fail closed” valves, bleed valves shall be located upstream and downstream of the control valve between the control valve and block valve.

10.8.1.7. For configurations of Control Valve Manifolds refer to Project Standard Drawing No. 25194-P14-JG000-007.

10.8.2. Location of Control Valves

10.8.2.1. Control valves shall be located at grade or on conveniently accessible platforms. Their locations must be consistent with their function and with convenience of plant operation. In general, they shall be located in sight of instruments or indicators showing the variables they control.

10.8.2.2. Control valves in flashing service shall be located as far downstream of the line as possible whilst complying with the requirements of 10.8.2.1.

10.8.3. High Pressure Drop at Control Valves

10.8.3.1. Where high pressure drop conditions exist across control valves, high fluid velocities along with extreme noise levels can be expected. 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. In case of high pressure drop, vendor shall be consulted for provision of a suitable diffuser.

10.8.4. Level Instruments

10.8.4.1. Location

Level instruments shall be accessible from grade, platform or ladder. Their location is to be consistent with function and with convenience of plant operation.

10.8.4.2. Strong Backs

Where strong backs are provided for external level instruments, their minimum pipe size shall be 2". Block valves shall be provided at the vessel connections.

10.8.5. Orifice Runs

10.8.5.1. Horizontal meter runs are preferred, and the minimum length shall be in accordance with API.RP. 550 PART I, and AGA Gas Measurement Committee Report No 3, Orifice Metering of Natural Gas. Provide sufficient clearance at orifice flanges for installation of instrument piping and seal pots where required. Refer to Systems Standard Drawing No 25194-J10-JG000-026.

10.8.6. Orifice Taps

10.8.6.1. Orifice taps are to be located vertically upwards for gas flow on horizontal lines, 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, if the meter is located in piperacks. Orifice flanges may be located in horizontal or vertical lines, pipe nipples shall be seal welded.

10.8.7. Instrument Access Table

Instrument Access requirements shall be provided in accordance with the following table.

Type of instrument Access Required for Operation

Access from Portable Ladder

Grade

Fixed Ladder

and/or

Fixed Platform

Thermocouples & Resistance Bulbs

No Yes Yes Yes

Test Thermowells Yes No Yes Yes

Dial thermometers Yes No Yes Yes

Pressure Gauges Yes No Yes Yes

Level Gauges/Level Transmitters

Yes No Yes Yes

Transmitters (blind or indicating including sensing element)

Yes No Yes Yes

Field Controllers & Recorders

Yes No Yes Yes

Field Switches (Alarm & Control)

No Yes Yes Yes

Control Valves & other final Control Elements

Yes No No Yes

Analytical & Other Special Instruments

Yes No Yes Yes

Orifice Flanges No Yes Yes Yes

11. Equipment Piping

11.1. Vessel and Column Piping

11.1.1. Piping at columns shall be located radially about the column on the pipeway side. Manways and platforms shall be located on the access side. Over-head vapour lines and similar connections 18" and larger may have a welded connection to the vessel, except where flanges are required for maintenance or blinding. 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. 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, thereby eliminating normal operator travel around such items.

Cold pull piping shall not be used in piping between maintenance joints. Client shall be consulted before using cold pull in any piping.

11.1.2. Connections Inside Skirts

Valves and flanges shall not be located inside vessel skirts.

11.1.3. Platforms or fixed ladder shall be provided at all nozzles which require blinding during maintenance periods.

11.1.3.1. Platforms shall be provided at manways above 3 metres above high point of finished surface. The interval between platforms shall not exceed 9000mm.

11.1.3.2. Platforms shall be positioned so that the manhole centreline is not less than 610 mm above the platform, with 760 mm preferred. The bottom of the manhole entry shall not be more than 1070 mm above the platform.

11.1.3.3. Adjacent columns shall be provided with combined platforms and manways at common elevations whenever possible.

11.1.3.4. Vessel davits for handling internals, relief valves, etc., shall be provided on vertical vessels, and on vessels not accessible by mobile crane. Davits shall be oriented to allow the lowering of appurtenances into the access area.

11.1.4. 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 1.5 metres from grade, platform, or ladder access.

11.1.5. Vents and Drains

11.1.5.1. A valved and blinded atmospheric vent shall be provided at vessel high points and/or overhead piping with platform access provided for valve operation.

11.1.5.2. Drains provided at vessels shall run to underground systems with open connections terminating 50mm above the drain hub, so that discharge is plainly visible. When practicable, connection shall be piped from the bottoms-out line.

11.2. Exchanger Piping

Piping to shell and tube exchangers shall be provided with break-out flanges to permit easy removal of shell covers, channel covers, channels and bundles. Allow adequate clearance for mobile handling equipment. Piping must be adequately supported such that bundles can be removed without use of additional temporary supports on piping. Hot piping shall be routed in such a way that line movement due to thermal expansion matches that of equipment it is connected to.

11.2.1 Water Lines

11.2.1.1 Piping is to be arranged where practical, or check valves properly located, so that water remains in all units on loss of cooling water supply.

11.2.1.2 Cooling water supply and return piping connected to underground headers shall be piped as directly as possible. Allowing sufficient flexibility for final fit up with equipment nozzles.

11.2.2 Thermowells

When thermowell connections cannot be provided on exchanger inlet & outlet nozzles, they shall be installed on adjacent piping.

11.3. Air Cooled Exchanger Piping

11.3.1. 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. Possible two phase flow must be considered.

11.3.2. 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. (Forces and movements at nozzles shall not exceed those allowed by the equipment manufacturer).

11.4. Pump and Turbine Piping

11.4.1. Pump Suction Piping

Pump suction piping shall be arranged with particular care to avoid unnecessary pressure drop and vapour pockets. Sources of disturbance such as bends and branches shall be minimised to avoid vortex formation and uneven velocity distribution. Pipe bends before suction nozzles to be positioned where possible in the same plane as the pump shaft. Concentric reducers are preferred where size changes are necessary in pump suction lines. Eccentric reducers with flat side top shall be used at all horizontal pump nozzles. 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.

11.4.2. Access to Pumps and Turbines

Piping at pumps and turbines shall be arranged to avoid interference with operation or maintenance access. Removable spool pieces shall be provided as appropriate, such as at end suction pump inlets. Pump suction and discharge piping shall be designed to be self supporting to permit maintenance without major piping and pipe support disassembly.

11.4.3. Weight and Thermal Stress

Where possible, pump discharge piping to be brought down to pump centre line level with check valve and isolation valve located horizontally. This will allow piping to be supported without the use of springs.

Suitable supports or anchors shall be provided so that excessive weight and thermal stresses are not applied to the casings. Consideration shall be given to piping configurations to minimise these stresses. (Forces and moments are not to exceed those allowed by the equipment manufacturers). Grade level pipe supports at pumps are to be adjustable type.

If grade level supports are required at pumps, centrifugal compressors or turbines they shall be installed on an integral extension of the equipment foundation, to avoid differential settlement.

11.4.4. Suction and Inlet Strainers

Temporary strainers with a pipe spool shall be provided at all pump suction, between block valve and suction flange and turbine inlet nozzles, unless permanent strainers are specified.

11.4.5. Pump Valves

11.4.5.1. Check valves shall be installed in the discharge line of each centrifugal and rotary pump. Block valves shall be installed in the suction and discharge of all pumps, the discharge valve being located downstream of the check. Suction valve to be located upstream of strainer.

11.4.5.2. When a positive displacement pump is not equipped with a built-in relief valve, 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.

11.4.5.3. Firewater Pump valves and Relief valves shall conform to the requirements of NFPA 20, Tariff Advisory Committee (TAC).

11.5. Compressor Piping

11.5.1. Suction Piping

11.5.1.1. 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.

11.5.1.2. Piping shall be run to avoid the possibility of trapping of collecting liquid. If this is not practical then knock-out equipment shall be installed as required by the P & ID.

11.5.1.3. 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. Diagrams.

11.5.2. Vibration (Reciprocating Compressor)

11.5.2.1. Particular consideration must be given to design of piping subject to vibration from dynamic loading associated with reciprocating compressors. Volume bottles may be provided as required. These lines shall also be subject to an analog / digital study.

11.5.2.2. Suction and discharge piping shall be run on sleepers at grade. This arrangement permits simple and effective supports of the lines to reduce vibration.

11.5.2.3. Suction and discharge lines shall be supported independently of the compressor shelter.

11.5.3. Removable Piping for Maintenance

11.5.3.1. Removable spool pieces shall be provided at compressors where needed to permit maintenance without major piping disassembly.

11.6. Direct Fired Heater Piping

11.6.1. Inlet & Outlet Process Piping

11.6.1.1. Preference shall be given to the inlet piping to heater, being symmetrical, and of the same length, with similar fittings, from the point where the flow splits at the heater inlets.

11.6.1.2. Symmetry of outlet piping from heater is not so critical, however non symmetrical piping may contribute to the uneven heating and possible coking up and overheating of tubes. Consideration shall be given to the Symmetry of heater outlet piping.

11.6.2. Burner and Snuffing Steam piping at Fired Heaters

Burner piping shall be kept clear of all access and observation openings. Space required for tube maintenance shall be kept free of all piping. Piping to the burners shall be made using flanges, or other specified means, to provide for easy and convenient removal of burners for maintenance. Piping shall be located to maintain a minimum of 2 metres clearance under the heater. In general, burner piping is to conform to the following requirements:

11.6.2.1. Take-off connections shall be made from the top of the steam and gas headers and piping arranged for equal flow distribution. Condensate legs, knockout pots or other approved methods for the collection and elimination of condensate shall be provided. Burner pipe valving shall be accessible when viewing through peephole.

11.6.2.2 Inlet /outlet piping shall be supported such that imposed loads on coil flanges are kept to the absolute minimum, and that minimum loads are transferred to the heater coil supports. This will reduce the risk of refractory lining damage.

11.6.2.2. Snuffing steam manifold shall be located 15 metres minimum distance away from furnace.

11.7. Storage Tank Piping

11.7.1. Adequate flexibility shall be provided in connecting piping so that the tank nozzles are not distorted if tank settlement occurs.

11.7.2. Storage tank isolation valves shall be located at the tank nozzles. Any further isolation valves required as per P & ID are to be located outside of the bund wall with access readily available. Tank isolation valve and first pipe support shall be

preferably supported from tank foundation to avoid differential settlement and use of spring supports.

12. Equipment Layout

12.1. General

12.1.1. DELETED.

12.1.2. Process Units shall be located on high ground to avoid flooding, these and Utility Units shall be arranged to suit independent operation and shutdown. Equipment within process and offsite areas shall be arranged to satisfy safety, operational, maintenance and construction requirements. Unless required for common operation or safety reasons, equipment is to be located in process sequence to minimise interconnecting piping. Equipment shall be spaced to allow for safe operation and maintenance with due consideration to construction space requirements.

Each unit shall have a rectangular shape of maximum size 183 meters by 92 meters recommended for fire fighting purposes.

12.1.3. Space for future expansion shall be provided where specifically requested by job specifications.

12.1.4. For Minimum Spacing required between Facilities and Units refer to Table 4. For Minimum Spacing required within Process Unit Layouts refer to Table 5.

12.2. Buildings

12.2.1. Administration buildings shall be grouped and located upwind of operating plant areas. Adequate parking facilities shall be provided at buildings which are normally occupied.

12.2.2. 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, and Processing Units. They shall be of blast resistant and pressurised design, located at Unit periphery and adjacent to a roadway.

12.2.3. Firestations shall be close to main entry gate with straight approach to critical areas. Firewater Storage and Pumps shall be located a minimum distance of 60 metres from Hydrocarbon Storage and Process Units. For petroleum depots and terminals refer to clause 4.3.5(v) of OISD - 117.

12.2.4. Buildings comprising of more than one floor, are to be provided with adequate access openings in floors, or walls, to enable equipment from upper floors to be lowered, by means of overhead lifting gear, down to grade for removal by mobile equipment.

12.3. Pumps

12.3.1. Pumps shall be located close to the associated equipment so that suction line lengths are minimised, but with sufficient space required to provide adequate flexibility.

12.3.2. Pumps handling flammable materials shall not be located below piperacks.

12.3.3. Pumps shall be located such that the pump discharge is a minimum of 4500 mm min. from the centre line of piperack column or outside edge of cantilevers for pumps operating at 260C or above, and a minimum of 3000 mm for pumps operating at 250 C or less, as required by GE Insurance Solutions, (GAP), recommendations.

12.3.4. Minimum edge to edge between pump foundations shall be 1.5 metres.

12.4. Compressors

12.4.1. Compressors shall be housed in shelters to provide protection for equipment and personnel. Located adjacent to a roadway and downwind from Heaters.

12.4.2. Centrifugal Compressors shall be a minimum of 7.6 metres from Reciprocating Compressors.

12.4.3. Suction and Interstage Knockout Drums shall be a minimum of 4 metres from Compressors.

12.4.4. A bridge or gantry crane shall be provided for removal of compressor components. Provision shall be made for removal of such items via removable roof panels, a drop area shall be provided at one end of compressor shelters.

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

12.4.6. 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. This includes combining different types of compressors where an economic shelter design can be achieved.

12.5. Vessels

12.5.1. Vertical vessels are to be placed on a common centreline parallel to the main pipeway.

12.5.2. Horizontal vessels shall be located to minimise piping runs and where practical, be lined up with their tangents on a common locating line on the piperack side of the unit. Vessels and associated piping should not encroach into established operating or access aisles.

12.5.3. Davits shall be provided on top of vessels to handle relief valves 4" and larger, internals, etc. that are not accessible by mobile equipment. Davits shall be

orientated in such a way, as to permit the lowering of this equipment to a clear drop out area at grade.

12.5.4. Reactors shall be located for ease of access during catalyst unloading and loading operations. Permanent facilities will not be provided unless expressly required by the process licensor. Space shall be allowed for cranes and storage of spent and new catalyst. Where necessary provision shall be made for the installation of temporary handling equipment during catalyst unloading.

12.5.5. There shall be three hazard groups for Reactors:

Moderate

Intermediate

High

12.5.5.1. Moderate

This category shall include endothermic reactions and other operations, such as distillation, absorption, mixing and blending of flammable liquids. Exothermic reactions with no flammable liquids or gases shall also be included in this hazard group. Typical process examples include:

Acetic anhydride (carbonylation of methyl acetate)

Acetone (dehydrogenation of alcohol)

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. & Unsat. LPG Merox & Dec3

Solvent extraction

Sour Water Stripping (SWS)

Styrene

Sulphur Recovery (SRU)

Tail Gas Treating (TGT)

Urea

VGO Hydrotreating

Visbreaking

12.5.5.2. Intermediate

Processes or operations having an appreciable explosion hazard and a moderate fire hazard are included. This category shall include slightly exothermic reactions. Typical process examples include:

Acetic anhydride (from acetic acid)

Alkylation (Refinery)

Benzene (from toluene-xylene)

Benzene-Toluene-Xylene (BTX)

Cumene

Cyclohexane

DHDS

Ethyl benzene

Hydrogen Unit (HMU)

Methanol (Reforming)

Polyethylene HD (small units)

Polypropylene

Polystyrene

Polyvinyichloride

Reforming (Refinery)

Scanfining

Terephtalic Acid

12.5.5.3. High

This category includes highly exothermic or potential run-away reactions and high hazard products handling. 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)

12.6. Exchangers

12.6.1. Shell and tube exchangers shall be located with the channel end away from pipeways to facilitate tube bundle removal, with a clearance length of 1 metre plus length of bundles, this area shall not encroach on plant roadways.

12.6.2. For exchangers under drums or unit structures, where ever possible the channel end shall be clear of overhead structures for handling of channel end by mobile equipment.

12.6.3. Shell and tube exchangers shall be located with the backs of exchangers on a common line with horizontal vessels, with the exception of those having channel ends connected to an underground cooling water system. These exchangers when grouped shall be located with their channel nozzles on a common centreline, with the largest exchanger setting the distance from the piperack in a similar manner as indicated above.

12.6.4. Stacked tube exchangers shall be limited to two units high.

12.7. Air Coolers

12.7.1. Air coolers shall be located so as to provide for safe and practical access for operation and maintenance. They may be located in equipment areas or over piperacks, no equipment to be located above or below coolers.

12.7.2. If air coolers are located over piperacks platforms shall be provided for access to motors, and header boxes. Access shall be provided by ladders consistent with para 14.4 of this specification.

12.7.3. Access for removal or replacement of tube bundles, fans and drivers for air coolers located over piperacks shall be achieved by providing accessways, suitable for heavy craneage, between process equipment on one side of the piperack. For major banks of air coolers this shall require a number of accessways which shall be located on either side of the piperack.

12.8. Fired Heaters and Boilers

12.8.1. Furnaces and boilers shall be located at plot boundaries for ease of access. Tube pulling shall be by mobile crane and adequate dropout and swinging space shall be provided. External piping shall be minimised at the tube pulling end of equipment.

12.8.2. Fired equipment on each process or utility unit shall be grouped together and common stacks provided wherever this is possible and economically viable.

12.8.3. 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. Within congested process areas, heater locations will be determined to provide the lowest risk of fire or explosion.

12.8.4. 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, expensive alloy pipe runs must be minimised.

12.8.5. A minimum clearance of 3 metres shall be provided between the shell of fired heaters and access roads.

12.8.6. Adjacent circular fired heaters shall be provided with interconnected firing platforms at a common elevation.

12.9. Storage Tanks

12.9.1. Tanks Containing Hydrocarbon Liquids:

Hydrocarbon liquids are classified in the Petroleum Act:

Class "A" Petroleum -

Liquid which has a flash point below 23C

Class "B" Petroleum -

Liquid which has a flash point of 23C and above but below 65C

Class "C" Petroleum -

Liquid which has a flash point of 65C and above but below 93C

12.9.1.1. The spacing and bunding requirements for tanks containing hydrocarbon liquids shall be determined in accordance with the Petroleum Act and Tables 6 & 7.

12.9.1.2. Bund walls shall not exceed a height of 1800mm plus 200mm free board.

12.9.1.3. Any tank shall have at least one side adjacent to a road within a distance of 90 metres. Tanks larger than 50,000m3 shall be arranged in single file, i.e. 2 sides minimum to road.

12.9.1.4. 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. Drainage shall have fire barriers between two different bunded areas to prevent the spread of fire.

12.9.2. Tanks Containing Non Hydrocarbon Liquids

12.9.2.1. Tanks containing non-flammable liquids shall be located to suit their service requirements.

12.9.2.2. Fire water and foam storage tanks shall be located in a safe area with ease of access to fire fighting personnel.

12.9.2.3. 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.

12.9.2.4. Kerbed areas shall be provided around hazardous chemicals so as to minimise the impact of spillage on surrounding equipment and personnel. Drainage from such areas shall be designed to prevent harmful chemicals entering other drainage systems where corrosion, chemical reactions, or ecological damage could occur. Kerbed areas shall also be provided to prevent hydro-carbon spills/fires from spreading.

12.9.3. 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.

12.10. Pressure Storage of LPG

12.10.1. The spacing and bunding requirements for pressure storage of LPG shall be determined in accordance with the OISD-Std-144 and Tables 9 & 10.

12.10.2. 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. Spillage of LPG shall be directed by means of diversion walls to the containment area. Grading shall not permit any depressions and spillage from one vessel to flow under another.

12.10.3. Each group shall have a maximum of 6 vessels, with aggregate capacity limited to 15000m3. Each group of vessels shall be separated by 30 metres minimum.

12.10.4. Bullets shall be orientated such that they do not point towards process or administration areas.

12.10.5. The arrangement of spheres and bullets shall be to permit the free flow of air below the vessel. The minimum height below the shell of such vessels shall be 1200mm.

12.11. Roads

12.11.1. Primary traffic roads in the installation shall be clear of hazardous classified areas. 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.

12.11.2. Roads separating units shall provide fire breaks and have facilities for fire fighting activities.

12.11.3. All roads used for fire fighting shall be 6 metres wide minimum. Headroom requirements for all roads shall be as per Table 3.

12.12. Road Tanker Loading Facilities

12.12.1. Road tanker loading facilities for product export shall be laid out to suit the smooth flow of traffic which avoids cross-flow.

12.12.2. Parking areas shall be provided for both empty and full tankers consistent with planned operations.

12.12.3. Facilities for loading LPG shall be segregated from those for other hydrocarbons.

12.13. Rail Tanker Loading facilities

12.13.1. Facilities shall be provided for both solids and bulk liquid loading of railcars. Sidings shall be provided for marshalling, receiving, shipping and cleaning of empty railcars and handling of sick wagons.

12.13.2. Road access for fire fighting equipment shall be provided around loading sidings.

12.13.3. Loading racks shall be located at least 15 metres from the nearest running line or roadway or 30 metres for LPG.

12.13.4. Separate rail spurs shall be provided for LPG loading.

13. Elevation, Clearance and Access Requirements

13.1. Elevations, clearances and access requirements shall be in accordance with the requirements contained in Tables 1 through 3 and the applicable notes.

13.2. Plants shall be serviced by primary roads adjacent to processing units, utility plants, materials handling and loading/unloading areas. Secondary roads shall be provided between process units, utility plants and offsite areas for maintenance and fire fighting access.

13.3. Equipment, structures, and piping are to be arranged to permit crane access to compressors, air coolers and major equipment parts not provided with built-in maintenance facilities.

13.4. Clear access, both vertically and horizontally is to be provided under main pipeways for trucks or mobile equipment to service pumps.

13.5. Whenever possible, shell and tube heat exchanger tube bundles are to be removed with a mobile crane and tube bundle extractor. Permanent monorail structures are to be provided only where crane access is impractical. Where required, 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.

Where built-in handling facilities are not provided, clear space for tube-bundle removal by mobile crane must be provided. 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.

13.6. A minimum of 7.5 m. vertical clearance must be allowed for access of heavy lift cranes at road crossings. A vertical clearance of 10M is required at identified major road crossings where there is a need for heavy lift crane access.

Platform, Stair and Ladder Access

13.7. General

The extent of platforms shall be the minimum consistent with safety, operation and maintenance. Where practical, walkways, catwalks, accessways, etc. should be provided between elevated platforms. Examples would include: provisions to move from a major structure to a platform on an adjacent tower in close proximity, or to an air cooler header box catwalk. Care should be taken however to ensure that differential expansion will not cause problems.

13.8. Platforms with Stair Access

13.8.1. Platforms with stair access shall be provided for the following:

1. Platforms which require operator attention more than once in an eight hour shift.

2. Platforms at elevated rotating equipment items.

3. Stairways shall be provided for access on storage tanks which exceed 4500 mm in diameter and 6 metres in height.

13.9. Platforms with Ladder Access

13.9.1. Platforms with ladder access shall be provided for the following:

1. Points requiring operating access less than once in an eight hour shift, including valves, instruments, etc.

2. Service platforms for manholes, pressure safety valves, removable heads, i.e., at vertical reboilers.

3. Storage tanks smaller than those in 14.2 (3)

4. Exchangers with centreline located 3.5 metres or more above grade.

5. Platforms are not required for manways, when manway centreline elevation from grade is :

3.3 metres and under without internals.

3.3 metres and under with internals.

6. Air coolers, with interconnecting walkways provided to service valving fan motors and instruments.

13.10. Dual Access/Emergency Egress

13.10.1. Provisions for emergency egress must be provided per current OSHA guidelines as follows:

1. When dead end is greater than 6 metres. (This does not apply to horizontal vessels less than 12m length).

2. Maximum distance of unobstructed travel to any means of escape when two or more exist, is 23 metres. (Refer to OSHA for all other provisions of access/egress).

3. Any platform servicing two or more pieces of equipment which may be concurrently maintained.

4. Platforms at fired equipment.

13.11. Ladder Requirements

1. Wherever possible, ladders shall be arranged so the user faces toward the equipment.

2. Front access ladders may be used with discretion.

3. Any single ladder run may not exceed 9 metres in length without a landing or platform.

14. Miscellaneous - Personnel Protection

14.1. Eye wash and emergency showers shall be provided in areas where operators are subject to hazardous sprays or spills.

14.2. Consideration shall be given to incorporating breathing air stations in facilities handling extremely toxic gases.

Table 1

UNPAVED PAVED BUILDINGS

ITEM (1) (2) AREAS(4)

AREAS(4)

ENCLOSED(4)

OPEN SIDED(4)

Grade, Floors High Point N/A 000 300 mm 300 mm

and Paving Low Point N/A -150 mm 150 mm 150 mm

Column Piers U/S Baseplate 300 mm 300 mm 450 mm 450 mm

Pumps (3) U/S Baseplate 150 mm 150 mm 450 mm 450 mm

Stair and Ladder Pads

U/S Baseplate 150 mm 150 mm 400 mm 400 mm

Vert. Vessels U/S Baseplate 300 mm 300 mm 400 mm 400 mm

Top of piperack column footings. .150 mm 150 mm N/A N/A

Furnace Floor Bottom of

Wall or Roof Fired

N/A As required. N/A N/A

Floor Plate Floor Fired N/A As required. N/A N/A

Blowers and Compressors

U/S Baseplate As required As required As required As required

Pipe Trenches and Pits

Top of Cover 50 mmFlush with

PavingFlush with Floor

Flush with Floor

Sewer Boxes Top of Cover 50 mmFlush with

PavingFlush with Floor

Flush with Floor

Plinth for Skid Mounted Equipment

150 mm (above Grade)

150 mm N/A N/A

Figures in parentheses refer to notes below;

NOTES TO TABLE 1:

1. All elevations shall be referred to the High Point Of Paving (H.P.P.). H.P.P. elevation shall be referenced to Mean Sea Level EL.00.000 on plot plans.

2. All concrete support levels shown for equipment and structural items, except stairs and ladders, shall include an allowance for at least 25 mm of grout.

3. Small size pumps such as proportioning, injection, and other small gear pumps may have bottom of baseplates located at elevation 450 mm above H.P.P.

4. Dimensions shown above are above high point of paving. Final elevation of H.P.P. to be determined when complete site terracing is finalised.

Table 2

ITEM DESCRIPTION DIMENSION

Headroom over platforms, walkways, passageways and working areas 2150mm

Headroom height for projections over platforms, walkways, passageways and working areas

2150mm

Headroom height over stairs 2100mm

Access Width of stairways (Inside stringers) For AccessMain Access

750mm1000mm

Walkways Width of Landings 1200mm

Width of walkways (At grade and elevated) For AccessMain Access

750mm1200mm

Maximum vertical rise of stairways (One flight) 3040mm

Maximum horizontal distance from any point on platform to a primary or auxiliary exit

23M

Maximum length of dead-end platform in escape route (1) 6.M

Vertical Distance of platform below vessel manhole centreline 600-1500mm

Vessel Width of manhole platform (Minimum)(2) 900mm

Shell Platform extension beyond centre line of manhole 1*M'hole dia.

Platforms Vessel Distance of platform below face of manhole flange 180-1000mm

(3) (4) Top Head Width of platform from three sides of manhole 750mm

Horizontal Exchanger

Clearance from bottom edge of channel or bonnet flanges 450mm

Vertical Maximum distance of platform below top flange of channel or bonnet

1500mm

Exchanger Width of platform from three sides of flange 750mm

Fired Width of platform at sides of horizontal and vertical tube furnaces 750mm

Heaters Width of platform at ends of horizontal tube furnaces 1200mm

Maximum vertical rise of operational ladders (Single run) 9M

Ladders Maximum Allowable slope of ladders from vertical 15

(5)(6)(7)(8) Toe clearance from centreline of rung to any obstruction 230mm

Clear climbing space for vertical ladders 680mm

Clear climbing space for inclined ladders (9) 900mm

Operation Width of platform required at bonnet or channel end of exchanger 1500mm

and Maintenance

Maximum elevation to the bottom of handwheel on valves 6" NB and smaller from platform or grade (14)

2000mm

(10) (11) (12) Horizontal clearance required between paired exchanger flanges 1000mm

(13) Horizontal clearance between insulation on paired exchanger flanges 750mm

Clearance below furnace raised floors (15) 750mm

Figures in parentheses refer to notes table notes

NOTES TO TABLE 2:

1. 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, because of confusion arising from an emergency or panic situation, an individual might select an escape path which would lead to such a dead-end .

2. Check clearance required to open manhole covers.

3. Toe plates shall be provided on the edges of all platform areas and around openings, except at the platform entrance and exit locations.

4. Standard handrailing shall be provided on all sides of all platform areas 1200mm or more above grade and stairways.

5. Ladders shall generally be arranged for side exit; however, step-through ladders are permissible.

6. Ladders which are located at, 2300mm or more above grade shall be provided with safety cages. Ladders which serve platforms from 1500mm to 2300mm, above grade shall be provided with top rail hoops only. Ladders which serve platforms less than 1500mm above grade do not require a top rail hoop.

7. 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.

8. Clear climbing space is defined as the climbing area clearance for caged ladders, and shall be provided throughout the length of the ladder.

9. The clear climbing space required for ladders that deviate in pitch between 75 and 90 degrees.

10. A height adjustable mobile stair stand shall be available for access to equipment, valves, instruments, and manholes located within 2.1 metres to 4.5 metres above grade. Except relief valves - see 9.5. Portable ladders shall be 4.0 m max.

11. Adequate tube removal space shall be provided for all exchangers that require tube bundles to be removed.

12. Horizontally installed wrench operated plug, ball, or butterfly valves shall be positioned so that wrench and wrench movement arc is at no point higher than 2.3 metres above grade or platform.

13. Valves shall be installed in valve pits and not buried.

14. Manually operated valves which normally require manipulation during plant operation or in an emergency, and which cannot be located vertically within 2 metres of a platform or grade, shall be furnished with chain operators or extension stems.

15. Clearance specified applies to wall or roof fired furnaces.

Table 3

ITEM DESCRIPTION DIMENSION

Headroom for primary access and main plant access roads 8.0M

Headroom for electrical transmission lines 6.7M

Width of primary access roads 6.0M

Headroom for secondary access roads 6.0M

Width of accessways other than roads 3.0M

Width of secondary roads 6.0M

Access for heavy lift cranes 10.0M

Slope of road from centreline to edge 1/40

Width of main plant access road 16.0M

Distance from pump foundation to edge of paving 1200mm

Paving, Grading, Freeboard height of bund walls 200mm

Surfacing Maximum drop in paving 150mm

(3) (4) (5) (6) (7) (8) (9) (10)

Maximum average height of bund walls above grade + 200mm freeboard

1800mm

Headroom over refinery railway lines (From top of rail) 4.9M

Railways Headroom over public railways 6.7M

Clearance from track centreline to obstructions 2.6M

Figures in parentheses refer to notes below

NOTES TO TABLE 3:

1. All roads shall be surfaced with tarmac.

2. A 1.0 metres wide shoulder shall be provided each side of primary and secondary roads which is in addition to the widths stated.

3. Walkways and the following areas shall be paved with concrete:

a) Paving shall extend to the outside edge of the supporting column piers, under bottom oil-fired or combustible liquid containing furnaces and elevated structures supporting coke drums.

b) Around catalyst containing vessels.

c) Around groups of two (2) or more pumps, located outdoors.

d) Around compressors and their related servicing equipment, i.e., lube oil consoles.

e) Inside fully enclosed equipment buildings.

f) Around all equipment in process units.

g) Around exchangers or other types of equipment in dirty service that require frequent turn around maintenance.

h) Around equipment handling potentially toxic liquids. Controlled drainage facilities shall be provided to recover spilled materials.

i) A 1.5 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, manifolds, etc.

j) Accessways under main piperacks.

4. Kerbs and walls required only to contain limited spillage shall normally extend to a height of 150mm above High Point of Paving. These kerbed areas shall drain to a sump or area drain provided with a valve in the sewer outlet.

5. All indoor and outdoor paving, except as otherwise noted (note 6), shall be sloped for drainage.

6. The floors of control rooms and switch gear rooms shall be level.

7. General equipment areas within the unit limits, all parking, and administrative areas shall be graded and surfaced with crushed stone.

8. 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.

9. All paving surrounding vessels, tanks, or other equipment containing hydrocarbons which could reach the paving in a liquid state, 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.

10. 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, with other contained equipment and tankage in place. Maximum height 2.0 m including 200 mm freeboard.

11. The drainage system for bunded areas shall be provided with a valve on the outside of the bund wall, to control the drainage.

Table 4

Minimum Distance Between Facilities and Units as per GE Insurance Solutions, GAP. 2.5.2 & 2.5.2a recommendations

(If OISD Standard - 118) or UOP Standard 9-51-2 distances for compatible units are higher, these are included)

Table 5

Minimum Distance Between Equipment within Process Units as per GE Insurance Solutions, GAP. 2.5.2 & 2.5.2a

(If OISD standard - 118 or UOP standard 9-51-2 distances for compatible units are higher, these are included)

Table 6

Minimum Distance between Storage Tanks and Offsite Facilities as per GE Insurance Solutions, GAP. 2.5.2 & 2.5.2a.( If OISD-118 or Petroleum Act and Petroleum Rules distances for compatible units are higher, these are included)

This Table is applicable for installations, 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.

Table 7

As per GE Insurance Solutions, GAP. 2.5.2 & 2.5.2a.( If OISD-118 or Petroleum Act and Petroleum Rules distances for compatible units are higher, these are included)

Notes Regarding Tanks and Spheres Spacing

Minimum spacing between groups of spheres shall be 30 metres (as per Petroleum Act).

Groups of spheres shall be limited to six, with an aggregate volume not to exceed 15,000m3 (as per Petroleum Act).

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, whichever is greater TAC / LPA requirement).

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.

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, whichever is the greater.

Table 8

Distances from Boundary Fencing

As per OISD-118 or Petroleum Act and Petroleum Rules (higher of these are included).

Installation Minimum Distance from Boundary fencing around

Installation

Storage tank for Petroleum class ‘A’ D. (min. 20)

Storage tank for Petroleum class ‘B’ D. (min. 20)

Storage tank for Petroleum class ‘C’ D. (min. 10)

Storage/filling shed for Petroleum class ‘A’ and class ‘B’

15

Storage/filling shed for Petroleum class ‘C’ 10

Tank vehicle loading/unloading area for class ‘A’ and class ‘B’

20

Tank vehicle loading/unloading area for class ‘C’ 10

Notes

1. All distances are in metres

2. 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. metres or where the diameter of any such tank for the storage of petroleum exceeds 9 metres.

3. Notation:

‘D’ - diameter of larger tank.

4. 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. Property beyond property line is deemed protected if it is within the jurisdiction of public Fire Brigade or plants’ own Fire Brigade.

Table 9

Minimum Distances Between LPG Facilities

(If OISD standard – 118, Petroleum act and Petroleum Rules, Static and Mobile Pressure Rules, or UOP standard 9-51-2 distances for compatible units are higher, these are included)

Table 10

As per OISD-118 and Static and Mobile Pressure Vessel Rules (higher of these are included).

Minimum Distance between LPG Storage Vessels and Boundary/Property Line/Group of Buildings not associated with LPG Plant

Capacity of each vessel (cu.mt of

water)

Distance Cap. of each vessel (cu.mt. of water)

Distance

10-20 15 451-750 60

21-40 20 751-3800 90

41-350 30 3801-above 120

351-450 40

Note:

All distances in metres.