KLM Technology Group

Project Engineering Standard

www.klmtechgroup.com
Page : 1 of 54

Rev: 0 1 Feb 20 11
KLM Technology Group #03 12 Block Aronia, Jalan Sri Perkasa 2 Taman Tampoi Utama 81200 Johor Bahru Mala ysia

LAYOUT AND SPACING (PROJECT STANDARDS AND SPECIFICATIONS)

SYMBOLS AND ABBREVIATIONS 3 UNITS 4 SOME KEY ISSUES RELATED TO LAYOUT 4 BASIC CONSIDERATIONS 5 PLANT LAYOUT 6 LAYOUT IN PROCESS UNITS 15 LAYOUT OF PIPING 31 UTILITY LAYOUT AND SPACING 33 OFFSITE FAC ILITIES 34 FLARE 36 WASTE TREATMENT FACILITIES 37 APPENDICES 38 KLM Technology Group
Project Engineering Standard

LAYOUT AND SPACING (PROJECT STANDARDS AND SPECIFICATIONS)

Feb 20 11

SCOPE Wherever explosion or fire hazard exist, proper plant layout and adequate

spacing between hazards are essential to loss prevention and control. Layout relates to the relative positio n of equipment or units within a given site. Spacing pertains to minimum distances between unit or equipment. This Project Engineering Standard covers the basic requirements of the plant layout and spacing of oil & gas refineries, petrochemical and simila r chemical plants to ensure safety and fire prevention together with ease of operation and maintenance. DEFINITIONS AND TERMINOLOGY Boundary Boundary of the equipment is the term used in a processing facility, by an imaginary line that completely encomp assed the defined site. Dike Is an earth or concrete wall providing a specified liquid retention capacity. Diversion Wall Is an earth or concrete wall which directs spills to a safe disposal area. Fire Resistive Fire resistance rating, as the time in minutes or hours, that materials or assemblies have withstand a fire exposure as established in accordance with the test of NFPA 251. High Flash Stock Are those having a closed cup flash point of 55C or over (such as heavy fuel oil, lubricating oils, t

ransformer oils etc.). This category does not include any stock that may be stored at temperatures above or within 8C of its flash point. Low Flash Stocks Are those having a closed cup flash point under 55C such as gasoline, kerosene, jet fuels, some h eating oils, diesel fuels and any other stock that may be stored at temperatures above or within 8C of its flash point. Non Combustible Material incapable of igniting or supporting combustion. Pipe Rack The pipe rack is the elevated supporting struct ure used to convey piping between equipment. This structure is also utilized for cable trays associated with electric power distribution and for instrument tray. Plot Plan The plot plan is the scaled plan drawing of the processing facility. KLM Technology Group
Project Engineering Standard

LAYOUT AND SPACING (PROJECT STANDARDS AND SPECIFICATIONS)

Feb 20 11

Sleepers The sleepers comprise the grade level supporting structure for piping between equipment for facilities, e.g., tank farm or other remote areas. Tank Diameter Where tank spacing is expressed in terms of tank diameter, the following criteria governs: (a) If ta nks are in different services, or different types of tanks are used, the diameter of the tank which requires the greater spacing is used. (b) If tanks are in similar services, the diameter of the largest tank is used Tank Spacing Is the unobstructed dist ance between tank shells, or between tank shells and the nearest edge of adjacent equipment, property lines, or buildings. Toe Wall Is a low earth, concrete, or masonry unit curb without capacity requirements for the retention of small leaks or spills V essel Diameter Where vessel spacing is expressed in terms of vessel diameter, the diameter of the largest vessel is used. For spheroids, the diameter at the maximum equator is used. Vessel Spacing -

Is the unobstructed distance between vessel shells or be tween vessel shells and nearest edge of adjacent equipment, property lines, or buildings. SYMBOLS AND ABBREVIATIONS ANSI : American National Standards Institute API : American Petroleum Institute ASME : American Society of Mechanical Engineers BP : Bo iling Point HVAC : Heating, Ventilation and Air Conditioning IC : Incombustibles IRI : Industrial Risk Insurance LPG : Liquefied Petroleum Gas NFPA : National Fire Protection Association OD : Outside Diameter OGP : Oil, Gas and Petrochemical KLM Technology Group

Project Engineering Standard

LAYOUT AND SPACING (PROJECT STANDARDS AND SPECIFICATIONS)

Feb 20 11

OIA : Oil Insurance Association SIC : Sheathed Incombustible TEMA : Tubular Exchangers Manufacturers Association UOP : Universal Oil Products UNITS This Standard is based on International System of Units (SI), except where otherwise specified. SOME KEY ISSU ES RELATED TO LAYOUT Terrain In the first place, considerations should be given to the physical setting. It should not automatically be assumed that it is necessary to level the site. There may instead be ways that the process can take the advantage of w hatever slopes are present. With respect to terrain, assess should be made, whether, there is adequate

space in general. If not, ingenuity will be required to meet such requirements as those for flares. Available space can help to govern whether the plant can be located on one floor or instead occupy several stories. The physical setting shall also be considered in light of the Transportation requirements for raw materials, products, wastes and supplies. Safety and Environment 1. Familiarization with pertin ent Environmental Regulations, (Local, National and International), and how they might change is essential period to conclusion of pre project studies. 2. Attention shall be given to the pertinent safety regulations, including health and welfare needs. 3. Hazard ous and flammable materials require special handling, which can take up layout space. 4. If the process fluids are especially toxic, layout is affected by the need for close chemical sewers and other protection measures. Security requirements KLM Technology Group
Project Engineering Standard

LAYOUT AND SPACING (PROJECT STANDARDS AND SPECIFICATIONS)

54
Rev: 0 7

Feb 20 11

may require spec ial layout design when the plant produces a high value product. 5. If a plant site is governed by particular building, piping, plumbing, electrical and other codes, these can affect plant layout. Similar governing standards and regulation in plant site affect s the layout concept. Throughput It is important not only to know the initial capacity but also to have a good feel for how much the plant might be expanded in the future, as well as how likely the process technology is to be modernized. These factors in dicate how much space should be left for additional equipment. Multiple processing lines (trains), are often required for the plant. Pairs of trains can either be identical or be mirror images. The former option is less expensive. But the mirror image app roach is sometimes preferable for layout reasons. Two such reasons are: 1. For operator access via a central aisle. 2. The 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 on e common line.

BASIC CONSIDERATIONS General The pl ant layout shall be arranged to : 1. maximize safety; 2. prevent spread fire 3. Facilitate easy operation and maintenance 4. Consider future expansion 5. Economize project Blocking The plant site shall be blocked in co nsideration of hazards attendant to plant operation in the area. All blocked areas shall be formed as square as possible by divided access roads and/or boundary lines. KLM Technology Group
Project Engineering Standard

LAYOUT AND SPACING (PROJECT STANDARDS AND SPECIFICATIONS)

Feb 20 11

Location and Weather The plant layout shall be arranged in consideration of geographic location and weather in the region of the site. Prevailing Wind

Where the prevailing wind is defined, the administration and service facilities and directly fired equipment, etc., shall not be located windward of process Units and storage tanks, etc. L ayout Indication The basic requirements to be met in the appropriate diagram when making a piping and equipment layout are: 1. All equipment, ladders, structures, davits, trolley beams, shall be indicated. 2. All instruments shall be located and indicated. 3. All v alving and hand wheel orientations shall be indicated. 4. Drip funnel locations for underground drains shall be indicated. 5. All electrical switch gear, lighting panels shall be indicated. 6. All sample systems shall be indicated Classification of Hazards The pl ant layout shall be determined in consideration of classified hazardous areas (specified in API RP 500 Recommended Practice for Classification of Locations for Electrical Installations at Petroleum facilities) PLANT LAYOUT Area Arrangement Classified

blocked areas, such as process areas, storage areas, utilities areas,

administration and service areas, and other areas shall be decided on the bases of following factors: 1. Soil characteristics. 2. Main road, rail access ways, and jetty.