PROJECT STANDARDS AND SPECIFICATIONS layout and sp

1 KLM TechnologyGroupProject :1of54 Rev: 01 Feb2011 KLM Technology Group#03-12 Block Aronia,Jalan Sri Perkasa 2 Taman Tampoi Utama81200 Johor BahruMalaysiaLAYOUT AND spacing ( PROJECT STANDARDS AND SPECIFICATIONS )TABLE OF CONTENTSCOPE2 DEFINITIONS AND TERMINOLOGY2 SYMBOLS AND ABBREVIATIONS3 UNITS4 SOME KEY ISSUES RELATED TO LAYOUT4 BASIC CONSIDERATIONS5 PLANT LAYOUT6 layout IN PROCESS UNITS15 layout OF PIPING31 UTILITY layout AND SPACING33 OFFSITE FACILITIES34 FLARE36 WASTE TREATMENT FACILITIES37 APPENDICES38 KLM TechnologyGroupProject engineering StandardLAYOUT AND spacing ( PROJECT STANDARDS ANDSPECIFICATIONS)Page2of54 Rev: 07 Feb2011 SCOPEW herever explosion or fire hazard exist, proper plant layout and adequatespacing between hazards are essential to loss prevention and control.

2 Layoutrelates to the relative position of equipment or units within a given site. Spacingpertains to minimum distances between unit or engineering Standardcovers the basic requirements of the plantlayout and spacing of oil & gas refineries, petrochemical and similar chemicalplants to ensure safety and fire prevention together with ease of operation AND TERMINOLOGYB oundary-Boundary of the equipment is the term used in a processing facility,by an imaginary line that completely encompassed the defined an earth or concrete wall providing a specified liquid retention Wall-Is an earth or concrete wall which directs spills to a safedisposal Resistive-Fire resistance rating, as the time inminutes or hours, thatmaterials or assemblies have withstand a fire exposure as established inaccordance with the test of NFPA Flash Stock-Are those having a closed cup flash point of 55 C or over(such as heavy fuel oil, lubricating oils, transformer oils etc.)

3 This category doesnot include any stock that may be stored at temperatures above or within 8 C ofits flash Stocks-Are those having a closed cup flash point under 55 C suchas gasoline, kerosene, jet fuels, some heating oils, diesel fuels and any otherstock that may be stored at temperatures above or within 8 C of it s flash incapable of igniting or supporting Rack-The pipe rack is the elevated supporting structure used to conveypiping between equipment. This structure is also utilized for cable traysassociated with electric-power distribution and for instrument Plan-The plot plan is the scaled plan drawing of the processing TechnologyGroupProject engineering StandardLAYOUT AND spacing ( PROJECT STANDARDS ANDSPECIFICATIONS)Page3of54 Rev: 07 Feb2011 Sleepers-Thesleepers comprise the grade-level supporting structure for pipingbetween equipment for facilities, , tank farm or other remote Diameter-Where tank spacing is expressed in terms of tank diameter, thefollowing criteria governs: (a) If tanks are in different services, or different typesof tanks are used, the diameter of the tank which requires the greater spacing isused.

4 (b) If tanks are in similar services, the diameter of the largest tank is usedTank spacing -Is the unobstructed distance between tank shells, or betweentank shells and the nearest edge of adjacent equipment, property lines, Wall-Is a low earth, concrete, or masonry unit curb without capacityrequirements for the retention of small leaks or spillsVessel Diameter-Where vessel spacing is expressed in terms of vesseldiameter, the diameter of the largest vessel is used. For spheroids, the diameterat the maximum equator is spacing -Is the unobstructed distance between vessel shells or betweenvessel shells and nearest edge of adjacent equipment, property lines, AND ABBREVIATIONSANSI:American National STANDARDS InstituteAPI:American Petroleum InstituteASME:American Society of Mechanical EngineersBP:Boiling PointHVAC:Heating, Ventilation and Air ConditioningIC:IncombustiblesIRI:Industr ial Risk InsuranceLPG:Liquefied Petroleum GasNFPA:National Fire Protection AssociationOD:Outside DiameterOGP:Oil, Gas and PetrochemicalKLM TechnologyGroupProject engineering StandardLAYOUT AND spacing ( PROJECT STANDARDS ANDSPECIFICATIONS)Page4of54 Rev: 07 Feb2011 OIA:Oil Insurance AssociationSIC:Sheathed IncombustibleTEMA.

5 Tubular Exchangers Manufacturers AssociationUOP:Universal Oil ProductsUNITSThis Standard is based on International System of Units (SI), except whereotherwise KEY ISSUES RELATED TO LAYOUTT errainIn the first place, considerations should be given to the physical setting. It shouldnot automatically be assumed that it is necessary to level the site. There mayinstead be ways that the process can take the advantage of whatever slopes respect to terrain, assess should be made, whether, there is adequatespace in general. If not, ingenuity will be required to meet such requirements asthose for flares. Available space can help to govern whether the plantcan belocated on one floor or instead occupy several stories. The physical setting shallalso be considered in light of the Transportation requirements for raw materials,products, wastes and and with pertinent Environmental Regulations, (Local, National andInternational), and how they might change is essentialperiodto conclusion ofpre- PROJECT shall be given to the pertinent safety regulations, including healthand welfare and flammable materials require special handling, which can takeup layout the process fluids are especially toxic, layout is affected by the need forclose chemical sewers and other protection measures.

6 Security requirementsKLM TechnologyGroupProject engineering StandardLAYOUT AND spacing ( PROJECT STANDARDS ANDSPECIFICATIONS)Page5of54 Rev: 07 Feb2011may require special layout design when the plant produces a a plant site is governed by particular building, piping, plumbing, electricaland other codes, these can affect plant layout . Similar governing standardsand regulation in plant site affects the layout is important not only to know the initial capacity but also to have a good feel forhow much the plant might be expanded in the future, as well as how likely theprocess technology is to be modernized. These factors indicate how much spaceshould be left for additional processing lines (trains), are often required for the plant. Pairs of trainscan either be identical or be mirror images.

7 The former option is less the mirror image approach is sometimes preferable for layout reasons. Twosuch reasons operator access via a central need that the outlet sides of two lines of equipment (pumps, for instance)point toward each other so that they can be readily hooked to one CONSIDERATIONSG eneralThe plant layout shall be arranged safety; spread easy operation and future projectBlockingThe plant site shall be blocked in consideration of hazards attendant to plantoperation in the area. All blocked areas shall be formed as square as possible bydivided access roads and/or boundary TechnologyGroupProject engineering StandardLAYOUT AND spacing ( PROJECT STANDARDS ANDSPECIFICATIONS)Page6of54 Rev: 07 Feb2011 Location and WeatherThe plant layout shall be arranged in consideration of geographiclocation andweather in the region of the WindWhere the prevailing wind is defined, the administration and service facilities anddirectly fired equipment, etc.

8 , shall not be located windward of process Units andstorage tanks, IndicationThe basic requirements to be met in the appropriate diagram when making apiping and equipment layout equipment, ladders, structures, davits, trolley beams, shall be be located and valving and hand wheel orientations shall be funnel locations for underground drains shall be electrical switch gear, lighting panels shall be sample systems shall be indicatedClassification of HazardsThe plant layout shall be determined in consideration of classified hazardousareas (specified inAPI RP-500 Recommended Practice for Classification ofLocations for Electrical Installations at Petroleum facilities )PLANT LAYOUTArea ArrangementClassifiedblocked areas, such as process areas, storage areas, utilities areas,administration and service areas, and other areas shall be decided on the basesof following road, rail access ways, and TechnologyGroupProject engineering StandardLAYOUT AND spacing ( PROJECT STANDARDS ANDSPECIFICATIONS)Page7of54 Rev: of pipelinesto and from of prevailing law and regulation which may affect the location of units and elevation for location of upstream / downstream units and equipment(such as feed and product storage tanks, wastewater plant, oil/ waterseparator, etc.)

9 And arranged as process area shall be located in the most convenient place foroperating the process Unit. Theunits shall be separated by roads. Majorroads shall have minimum width of 10 m., with maximum length of 400 minor roads shall have minimum width of 6 m. (Minor roads shall notbe in an area classified as zone 0 or 1). A plant may contain one orseveral process units. Where any unit processes flammable fluids andmay be operated independently ( one unit may be shut down withothers in operation ). The minimum spacing between equipment on thetwo adjacent units shall be at least 20 storage area shall be located as far as possible from buildingsoccupied by personnel at the site, but should be located near the processarea for ready operation of the feed stocks and product run utilities area shall be located beside the process area for ready supplyof utilities.

10 Except where they are an integral part of a process unit, siteutility units should be grouped together in an area classified as and unloading area shall be located on a corner of the site withcapable connection to public road directly, for inland areas for road transport shall have adequate space toprovide access for filling, parking and maneuvering. A drive through rackarrangement is preferred. The loading and unloading facilities should bedownwind or crosswind from process units and sources of ignition,basedon the direction of prevailing wind. For marine transportation, the areashall be located on the seaside or riverside in the plant administration and service area shall be located at a safe place on thesite in order to protect personnel from hazards.