Plant and Piping Layout Philosophy

Document No: A-PIP-PHL-000-30000

Revision 0

Revision History
Revision Changes

A Issued for Review & Approval

0 Issued for Design

This revision checked and signed off by:

Name Function or Job Title

Harshal Vyas (HV) Area Engineer

Sachin Gokhale (SG) Area Engineer

Dattatray Ghodke (DVG) Piping Lead

Muktar Haji (MH) Piping Lead

Timir Mehta (TAM) Engineering Manager

MT Siddiquie (MTS) Engineering Manager

Holds
Hold No. Location Description

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Contents

REVISION HISTORY 2
CONTENTS 3
ABBREVIATIONS 5
1 INTRODUCTION 6
1.1 Project 6
1.2 Purpose 6
2 REFERENCES 7
2.1 General 7
2.2 Codes & Standards 8
3 DEFINITIONS 8
4 ORDER OF PRECEDENCE 9
5 SCOPE 9
6 GENERAL SITE LAYOUT PRINCIPLES 10
6.1 Primary Design Considerations 10
6.2 Safety 10
6.3 Environment 11
6.4 Process 11
6.5 Operations and Maintenance 11
6.6 Fabrication and Construction 12
6.7 Appearance 12
7 DETAILED REQUIREMENTS 13
7.1 Plant Orientation 13
7.2 Hazardous Areas 13
7.3 Roads and Paving 13
7.4 Perimeter Fencing and Gates 14
7.5 Personnel Access/Escape 14
7.6 Buildings 15
7.7 Equipment General Layout 16
7.8 Columns and Vessels 16
7.9 Shell and Tube Exchangers, Printed Circuit Heat Exchangers and Plate
Exchangers 17
7.10 Air Coolers 18
7.11 Fired Heaters 19
7.12 Pumps 20
7.13 Compressors 20
7.14 Gas Turbines 21
7.15 Diesel Engines 21
7.16 Pig Traps 21
7.17 Flare Stacks and Major Vents 22
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7.18 Underground Services and Interfaces 22

8 GENERAL PIPING REQUIREMENTS 22
8.1 General 22
8.2 Permissible Pipe Sizes 23
8.3 Piperacks and Pipetracks 23
8.4 Valves 24
8.5 Check Valves 25
8.6 Relief Valves 25
8.7 Globe Valves 25
8.8 Vents, Drains 25
8.9 Branch Connections 25
8.10 Wellsites and Gathering System Manifolds 25
8.11 Utility, Instrument and Nitrogen Air Piping 26
8.12 Pressure Relief Piping 26
8.13 Open Drain Systems 27
8.14 Fire Protection System 27
8.15 Instrumentation 27
8.15.1 Control Valves 27
8.15.2 Flow Instruments 28
8.15.3 Level Instruments 28
8.15.4 Pressure Instruments 28
8.15.5 Temperature Instruments 28
8.15.6 Corrosion Monitoring Fittings 29
8.15.7 Pipe Stress Analysis and Pipe Support Design 29
8.15.8 Flow Induced Vibration of Piping 29
8.15.9 Clearances 29
9 FITTINGS, FLANGES AND SPECIAL ITEMS 30
9.1 General 30
9.1.1 Line Blinds (spectacle blinds, spades and spacers) 30
9.1.2 Isolation Spools/Sets 30
9.2 Strainers and Filters 30
APPENDIX A - GENERAL GUIDELINE CLEARANCES AND DISTANCES FOR
PIPING LAYOUT 31
APPENDIX B – ERGONOMICS/ACCESSIBILITY 33
APPENDIX C – SEGREGATION AND SPACING DISTANCES 35

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Abbreviations

CAD computer aided design

CCR Central Control Room (within the CPF)
CPF Central Process Facility (the main reception, processing, utilities and
storage systems)
FEED front end engineering design
P&ID piping and instrumentation diagram
QRA quantitative risk assessment
API American Petroleum Institute
LPG Liquefied Petroleum Gas
FERA Fire and Explosion Risk Assessment
OSBL Outside Battery Limit
ISBL Inside Battery Limit

Abbreviations for commonly used units of measurement are also used but are not defined
herein.

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1 INTRODUCTION

1.1 Project
Groupement ISARÈNE (the “COMPANY”) will develop the Ain Tsila gas field which is
located in the Illizi basin in the eastern part of the Sahara Desert in south-east Algeria,
south of the Grand Erg Oriental. The field was discovered within the Périmètre Isarène
(Blocks 228, 229a) in 2007 and has been appraised to hold approximately 65 billion
cubic metres (2.29 trillion cubic feet) of recoverable hydrocarbon reserves. The field lies
in the Sahara Desert, approximately 1,100km south-east of Algiers, 175km west of In
Amenas, 175km north- west of Illizi and 450km to the south-east of Hassi Messaoud.
Central Processing Facility (CPF) is designed to produce 10.3 MMSCMD sales gas.

A gathering system, comprising wellsites, wellsite systems, flowlines, manifold stations

and trunk pipelines to gather the produced fluids and transport them to the reception
facilities at the CPF. Raw gas will be treated in the CPF. Processing facilities comprising
pipeline reception facilities, slugcatcher(s), feed gas compression, mercury removal,
gas dehydration, gas conditioning (natural gas liquids extraction), export compression,
condensate stripper, LPG fractionation facilities, condensate and LPG export facilities
and associated utilities, storage and buildings (all located at the CPF). Fiscal metering
for sales gas, LPG and condensate, located at the CPF battery limit.

Sales quality gas will be delivered to SONATRACH TRC’s (TRC) sales gas pipeline
system at a tie-in point on a manifold next to the TFT compressor station. Liquefied
petroleum gas (LPG) will be delivered to TRC’s LPG pipeline system at a tie-in point
located at a block valve station west of the TFT compressor station. Stabilised
condensate will be delivered to TRC’s condensate pipeline system at a tie-in point
located at Méderba, approximately 165km north of Ain Tsila.

1.2 Purpose
The purpose of this document is to define the plant and piping layout requirements with
the objective of developing a safe, operable, maintainable and constructable plant,
designed in accordance with all applicable codes, standards and sound general
engineering practices.

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2 REFERENCES

2.1 General
A-TSE-PHL-000-30000 Safety Philosophy

A-CIV-BOD-000-30001 Civil and Structural Design Basis

A-PRO-PHL-000-30005 Drainage Philosophy

A-PRO-PHL-000-30001 Isolation Philosophy

A-ARC-PHL-000-30000 Architectural Design Philosophy

A-ENG-LST-000-00001 List of Codes and Standards

A-IMT-GLS-000-00002 Abbreviations and Units of Measurement

A-PIP-SPE-000-30008 Specification for 3D Modelling Requirement

A-PIP-SPE-000-30007 Specification for Piping Material Classes

A-PIP-SPE-000-30006 Standard Pipe Support Specification

A-PIP-SPE-000-30004 Specification for Piping Flexibility and Pipe Supports

A-PIP-SPE-000-30005 Specification for Equipment Nozzle Load Loading

A-PIP-SPE-000-30009 Specification for 3D Model Design Review

A-PIP-SPE-000-30000 Purchase Specification for Piping Bulk Items

A-PIP-SPE-000-30001 Purchase Specification for Valves

A-PIP-SPE-000-30002 Purchase Specification for Fasteners and Gaskets

A-PIP-SPE-000-30003 Purchase Specification for GRE & Components

A-PIP-SPE-000-00003 Specification for Pressure Testing, Flushing &
Reinstatement of Piping System

A-MTL-SPE-000-30008 Specification for Insulation of Piping & Equipment

A-MTL-SPE-000-30003 Specification for Painting

A-MEC-PHL-000-30125 Mechanical Handling Philosophy

A-TSE-SPE-000-30003 Human Factors Engineering Design Specification

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A-INS-SPE-000-30000 Specification for General Instrumentation

A-INS-BOD-000-30000 Control & Instrumentation Design Basis

A-CIV-SPE-000-30010 Specification for Roads and Paving

A-MTL-SPE-000-30036 Specification for Cathodic Protection System

A-HSE-REP-000-00004 FERA & QRA Report

2.2 Codes & Standards

Reference to any standard or code shall mean the latest edition of that standard or code
as of 24th December 2018.

NFPA 30 Flammable and Combustible Liquid Code

API 2510 Design and Construction of LPG Installation

GAP 2.5.2 Oil and Chemical Plant Layout and spacing

GAP 2.5.2.A Hazard classification of Process Operations for spacing

requirements

ASME B31.3 Process Piping

3 DEFINITIONS

“COMPANY” means Groupement ISARÈNE (the operator of the Ain

Tsila Development
“CONTRACTOR” means the party, which carries out all or part of the
design, engineering, installation and commissioning,
procurement and construction applicable to this
specification
“shall” or “must” indicates that the specified action is mandatory (i.e. must
be done by the specified action party)
“should” indicates that the specified action is recommended but
not mandatory. However the action party will be
responsible for the consequences in the event that
he/she elects not to do it
“will” indicates a commitment by others or a statement of fact

“Purchaser” means the entity defined as such in the purchase order

or Contract

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“Seller” means the entity defined as such in the purchase order

or contract

“Sub-supplier” means the entity responsible for the supply of

components or services to the Seller
“Manufacturer” means the entity responsible for the manufacture of an
item ultimately supplied by the Seller to the Purchaser
“Goods” means the physical items delivered under the terms of
the purchase order or contract
“Services” means any services provided pursuant to the purchase
order or contract but not incorporated in the Goods

4 ORDER OF PRECEDENCE
Should any conflict occur as a result of applying data sheets and specifications, the
order of precedence shall be:
1. Algerian Legislation
2. Algerian Regulatory Authorities Regulations
3. International codes and standards
4. COMPANY Philosophy documents
5. Project technical specifications
In case of conflict between any of the above then the most stringent shall apply unless
a dispensation has been approved by the COMPANY.
Any conflicting requirements contained within the purchase order shall be referred to
the Purchaser in writing for clarification and resolution before manufacture or
procurement.
Compliance by the Seller with the provision of this specification does not relieve the
Seller of its responsibility to furnish items of a proper mechanical design suited to meet
the specified service conditions and compliant with all applicable Algerian codes.

5 SCOPE
The scope of this document includes the Central Processing Facility (CPF) and Base
Industrielle (which is located alongside) and also the remote well pads and field
manifolds.
Although Piping is the lead discipline responsible for producing the plant layouts, it is
recognised that multidiscipline input will be necessary to achieve the objectives, i.e. to
define equipment types and sizes, buildings and key safety criteria.

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6 GENERAL SITE LAYOUT PRINCIPLES

6.1 Primary Design Considerations

The plant layout shall consider (in order of priority):
• Safety
• Environment
• Process
• Operations and maintenance
• Cost and appearance
• Fabrication and construction
Where any of these characteristics conflict, sound engineering principles shall be
applied to provide optimisation and each eventual conflict resolution shall be confirmed
with the COMPANY’s Engineering Manager.

6.2 Safety
The plant layout shall be developed in accordance with the relevant codes and
regulations and those listed in section 2.2. In addition spacing tables and guidelines
are provided in the appendices of this document which shall be used to ensure
compliance with local regulations. Judgement shall be used where data/guidelines are
not available and any such (judgement) distances shall be agreed with the COMPANY’s
Engineering Manager.
A quantitative risk assessment (QRA) shall be carried out to establish the spacing
requirements for occupied buildings within the CPF and the Base Industrielle. The
laboratory and the Central Control Room (CCR) (both within the CPF) shall be located
far enough away from the process areas to reduce blast overpressure such that any
requirement for a “blastproof” design can be avoided.
The following shall be taken into consideration (not listed in order of importance):
• Segregating high and low risk units
• Locating the higher risk units away from the areas of regular personnel
occupation
• Locating lower risk units between higher risk units and areas of regular
personnel occupation, to provide a barrier/buffer
• Separating flammable inventory from sources of ignition
• Considering prevailing wind direction with respect to potential leaks of noxious
gases and/or hydrocarbon gases
• Hazardous equipment / units shall be located downwind or across wind from
regularly occupied areas
• Bunding shall be provided for hazardous liquids containment. Bunds shall
include a suitable liquid recovery system

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• Ensuring hydrocarbon gases cannot be trapped below ground level, e.g. in

drains, pits
• Locating equipment at a safe distance from the edge of roads
• Providing kerbing and sloped paving to minimise the spread of pool fires
• Providing clear and direct means of personnel escape from hazardous areas
• Providing a minimum of two routes of escape from each area, including from
any elevated platform longer than 12 metres. Dead ends shall not be longer than
7 metres.
• Providing a minimum of one staircase to each elevated structure, including the
upper floor of any building – ideally there should be two staircases but a vertical
ladder is an acceptable secondary means of escape where two staircases
cannot reasonably be provided
• Locating active fire protection facilities in locations which can be easily/logically
accessed
• Placing safety equipment in locations adjacent to evacuation routes
• Providing sufficient site and road access for emergency vehicles and equipment
• Providing additional “panic” gates in the perimeter fence to enable emergency
evacuation in the event of noxious/toxic gas escapes
• The open vents shall be kept at minimum possible elevation from tank roof or
vessel top just away from the platform as determined by HSE dispersion study.
Elevation shall not be less than 3m from grade. Vent flow shall be away from
equipment and walkways.
• Personnel protection shall be applied on all un-insulated lines with an operating
temperature higher than 60 °C or lower than -10 °C and within a range of 0.6 m
horizontal and 2 m vertical from any accessible location.

6.3 Environment
The layout shall minimise the potential for environmental damage by providing
containment and suitable disposal means for any spillage or accidental discharge of
pollutants. The layout shall include space and access to waste management facilities
to properly segregate, store, transport and dispose waste generated.

6.4 Process
Process requirements typically dictate the relevant locations of equipment, valves, etc.,
especially their elevations.
Equipment shall be located to streamline the process flow and simplify piping systems,
without compromising piping stress and support requirements.

6.5 Operations and Maintenance

Roads shall provide sufficient access for operation and maintenance vehicles, cranes,
etc.

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Satisfactory space and access shall be provided for operation and maintenance of
equipment, valves and instruments.
Layby areas shall be provided where loading/offloading (e.g. of chemicals) will regularly
occur.
Space shall be allocated for mechanical handling equipment, both permanent and
temporary.
Space shall be provided for loading and unloading of catalysts or adsorbents.
Laydown and access areas shall be provided for all equipment requiring regular
maintenance, e.g. turbine drivers – note: common laydown/access areas may be used
where simultaneous maintenance operations on adjacent equipment are not
anticipated.

6.6 Fabrication and Construction

The layout shall be developed such that large items of equipment (e.g. vessels, process
columns, packaged equipment) can be lifted into place, whether being delivered
complete or in sections for site assembly. Construction laydown areas, partial erection
of pipe racks, etc. shall be considered during the development of the layout.
Consideration shall be given to those items of equipment with potentially long delivery
times, where late site access to a particular area may be required.
Installation of future or mobile equipment (if necessary) must be considered as lifting
over ‘live’ plant must be avoided.

6.7 Appearance
As a general rule, equipment shall be laid out in straight lines as this will result in an
economically laid out plant. Preference should be given to having a single central pipe
rack with a minimum number of side branches, with equipment being laid out on either
side.
The appearance of the layout can be improved by grouping items of similar equipment
together, e.g. pumps, heat exchangers, etc., but this shall not compromise economical
pipe runs.
Structures and groups of equipment should form a neat, symmetrical balanced layout,
consistent with keeping the pipe runs to a minimum.
Columns and large vertical vessels of similar diameter shall be arranged in rows with a
common centre line. If the vessel diameters vary greatly, they should be lined up with
a common face. If adjacent to a structure (e.g. a pipe rack), the common face shall be
on the structure side.
The centre lines of pump discharge nozzles should be lined up, as should the nozzles
of exchanger channel ends.
Where there are duplicated streams, their layouts shall be made identical insofar as
possible. ‘Handed’ arrangements shall be avoided unless specifically required for
process reasons (e.g. mirrored pipework). This principle shall also be followed where
there are similar equipment sequences within a process stream, e.g. columns,

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exchangers and pumps, which could have their layout repeated for different columns,
but each group having a different process duty.
Identical plant arrangements for parallel streams or similar groups of process equipment
have significant advantages, not only in economies of design but also for fabrication,
construction and operations.
A simple layout appearance usually provides a simple operational and maintenance
situation.

7 DETAILED REQUIREMENTS
This section elaborates on the primary considerations for plant layout.

7.1 Plant Orientation

The prevailing wind shall direct plant flare/vent plumes and any potential hydrocarbon
gas discharge resulting from leaks away from both regularly occupied areas and local
infrastructure and away from any potential source of ignition.
The prevailing wind shall direct noxious smells from effluent treatment plant away from
both regularly occupied areas and local infrastructure.
The orientation of the plant with respect to the gathering system/export pipelines and
utility services shall also be considered to provide the most cost effective and best
technical solution, whilst not jeopardising safety from any possible hydrocarbon leaks
or the receipt of pipeline cleaning spheres etc.
The use of natural (or artificial) topography shall be considered with respect to gravity
systems such as drains and flares.
To reduce civil excavation costs, natural lows of the terrain shall be considered with
respect to drainage tanks/pits and lagoons.

7.2 Hazardous Areas

A hazardous area is an area where flammable gas or liquid is, or has the potential to
be present in sufficient quantities such as to require special precautions to be taken.
The extent of hazardous areas shall be taken into account when laying out equipment
- these areas shall not encroach onto roads and shall be at a safe distance from all
buildings and safe areas. Refer to the relevant code for the development and extent of
hazardous areas – also refer to spacing tables or FERA / QRA for distances between
hazardous and non-hazardous areas.

7.3 Roads and Paving

Plant roads shall be in accordance with Specification for Roads and Paving(A-CIV-SPE-
000-30010).
Roads shall be provided for general plant vehicular traffic, maintenance, operations and
firefighting access (notwithstanding that vehicular traffic within the CPF will be strictly
limited during normal operation).
Segregation between adjoining process units shall normally be achieved by the road
system, which will also reduce the risk of spread of localised fires.

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Perimeter roads should generally feed into the specific process unit roads (i.e. perimeter
roads will be the normal means of moving a vehicle from one process unit to another).
At least two sides of each process unit shall be provided with access roads, primarily
for firefighting purposes.
Perimeter and process unit roads shall not have dead ends, as these may cause
undesirable restrictions to traffic and personnel during emergencies.
Where regular vehicular traffic within the CPF is necessary, the required roads shall be
outside the hazardous areas.
All roads shall be designed to accommodate the largest anticipated vehicle that will be
allowed access into the CPF (typically a mobile crane or an articulated lorry). Facilities
for vehicle turning should also be considered.
Equipment must not be located on or near the edge of a road. Where equipment is
considered to be at risk from vehicular traffic, it shall be moved to a safer location or
guard barriers shall be provided.
Within the process areas, concrete paving shall provide walkways interconnecting all
major items of equipment, platforms, stairways and buildings. In addition, concrete
paving shall be provided around pumps and/or other machinery where liquid spillage is
likely to occur during normal operation.
For other items of equipment requiring infrequent maintenance, such as exchanger tube
bundles, column internals, etc., it should only be necessary to ensure that there is
adequate clear space for access purposes.

7.4 Perimeter Fencing and Gates

The CPF shall be bounded by a perimeter fence and a secondary inner fence sited on
top of a revetment with sloped site protection. Where national codes or the spacing
requirements herein do not dictate otherwise, the minimum distance from process
equipment to a perimeter fence shall be 15 metres.
A double leaf gate shall be provided for the primary road access between the Base
Industrielle and the CPF – this shall be provided with a security gatehouse (the “CPF
Gatehouse”) to control incoming and outgoing traffic and personnel. Double leaf access
gates may be provided elsewhere on the CPF perimeter (e.g. to facilitate entry of large
vehicles) – such gates shall normally be locked and do not require a gatehouse.
Additional personnel “panic” gates shall be provided strategically around the CPF
perimeter to allow easy and safe evacuation for site personnel in the event of an
emergency. Such “panic” gates shall only be operable from within the CPF.

7.5 Personnel Access/Escape

When designing the layout of the plant, good access must be provided for operations
and maintenance, whilst always considering safety. This can readily be achieved by
providing personnel access aisles under pipe racks and air coolers and beside
equipment located adjacent to the pipe racks.

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Secondary means of escape shall generally be located at the opposite end of a building
or structure to the stairway which provides the primary means of escape. At least one
of the means of escape shall lead away from the plant area towards safety.
Access platforms shall be continuous where it is logical for an operator to normally move
from one equipment item or process unit to the next. This will enable efficient operations
at height without the requirement for the operator to repeatedly climb up then down then
up to access adjacent equipment.
Where ladders are necessary, access to/from the ladder should be via a “side step off”
arrangement. Ladder cages shall be arranged such that fall protection is provided at
the interface of the ladder step off and any elevated platform.

7.6 Buildings
For information on the location and distance restrictions of various buildings, refer to
the equipment spacing charts in the appendices and the codes and standards as
defined in section 2.2 or the QRA, where the separation distances are not mentioned in
the equipment spacing charts of the appendices.
The Emergency/Medical Centre is of major importance to the operations (and especially
to dealing with any abnormal event), therefore it shall be sited in a safe area close to
the perimeter of the CPF and as a close as practical to the main fire pumps.
The building shall be protected from extreme environmental conditions, e.g. wind
damage, flooding.
The CCR and laboratory shall be located in a non-hazardous area within the CPF.
Electrical sub-stations and instrument rooms/buildings may potentially either be
integrated into buildings housing equipment such as compressors or main power
generators or standalone buildings local to the units they serve.
Good road access is necessary for the installation and maintenance of large heavy
equipment.
Transformer pens shall be located adjacent to the relevant electrical sub-station, be
provided with walls around three sides and a suitable foundation. The fourth side shall
be gated for personnel safety.
The CCR, local equipment rooms and sub-stations shall be located to minimise the
length of cable runs to the plant, whilst still complying with the required safety
requirements.
Analyser houses may be required and shall generally be sited centrally within the plant.
This enables the analyser connections to be of minimum length. If the houses are sited
inside a hazardous area they shall be pressurised, to prevent ingress of any hazardous
emissions.
Process gas compressors and air compressors shall be housed in a building or suitable
shelter with partial cladding, subject to evaluation.
Fire water pumps and the essential service generator, shall be provided with either a
suitable enclosure, house or shelter, as deemed necessary.

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7.7 Equipment General Layout

Whilst the sequence and/or elevation of equipment is generally defined by the process
flow requirements and unit considerations, limitations of pressure or temperature drop
in transfer lines may also decide the proximity of equipment.
Achieving maximum economy of pipework and supporting steel is an important factor
in the layout of the plant. Equipment shall be located to minimise runs of alloy pipework
and large bore pipe, without compromising piping flexibility and support requirements.
Consideration shall also be given to optimising the use of supporting structures by
designing them such that they service more than one item of equipment and ensuring
that access ways, platforms, etc. have more than one function.
When spacing equipment, consideration shall be given to whether it is handling low or
high flash point hydrocarbon products. Equipment items which could be considered a
possible source of hazard, should be grouped together and, where possible, located
separately from other areas of the plant, but this should not compromise economical
pipe runs. By careful positioning of equipment, hazardous area classifications may be
simplified, thus optimising the plot size.
The same criteria shall be applied to product/chemical loading and unloading areas.
Careful consideration must be given to equipment that may emit noxious fumes or
smells, e.g. waste treatment units; they shall not be located close to an area where
personnel will be working, or in the proximity of residential or catering units. These
items shall be sited where the prevailing wind will carry any noxious smells away from
sensitive areas.

7.8 Columns and Vessels

Generally this type of equipment shall be positioned in the process flow sequence, with
sufficient space allowed for operations and maintenance activities.
Columns shall be self-supporting without the need for external structures. Circular or
segmental platforms, with “side step off” ladders, should be supported directly from the
column shell.
Platforms on columns and vessels shall be provided for access to all valves which
require two handed operation, all hand valves 3” and above, all relief valves, all
instruments and/or transmitters, all manholes and all blinds and/or spades, unless they
are readily accessible from ground level. Small valves which can be operated with one
hand and indicating instruments may be accessed from a ladder. Where process
columns have internal trays, etc., manholes with permanent access shall be provided
at specific levels for tray and distributor removal. For ease of removal, the manholes
should be positioned in a common segment, preferably facing to the back of the vessel,
away from the plant and into an open lowering area. Manholes shall have davit arms
installed as part of the vessel to allow them to be swung into the open position without
requiring additional material handling equipment. The top section of a vertical column
may have items that require occasional removal - these shall be provided with a fixed
davit and platform on the head. Similarly, space must be provided for these items to be
lowered down to ground level, again at the back of the column into an open lowering
area.
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Horizontal vessels should be located at ground level, unless process considerations

dictate otherwise, and orientated with their longitudinal axis at right angles to the
piperack.
Access platforms on vessels shall be self-supported from the vessel using clips
wherever practical to avoid unnecessary steel work. Similarly, common platforms shall
be used, where practical.
The height of any column or vessel providing suction to pumps shall be given special
consideration to ensure that there is adequate height to cover the pump net positive
suction head (NPSH) requirements under all operating scenarios. Other factors which
shall influence the height of this type of equipment are headroom clearance under low
level piping connections to the pipe rack and allowances for low level drain connections.
Consideration should be given to the saving of plot space by changing vessels from the
horizontal position to vertical position, where process requirements allow. Approval of
this must always be obtained from the COMPANY’s Engineering Manager.
Vessels with agitators and motors shall be provided with adequate clearance and a
lifting facility, with laydown area, to allow the removal of both the motor and the agitator.
Nozzles, manholes, instrument connections, etc. shall be oriented to suit the
requirements of the process/mechanical data sheets and to avoid interference with
internal downcomers, baffles, trays, adjacent operating requirements, etc.
Nozzles and flanges required for isolation shall be accessible from permanent platform.
Nozzles only required for equipment isolation at major turn-arounds need not to be
accessible by permanent facilities but must be agreed with the COMPANY.
Manholes shall be provided, sized and located to allow safe entry inside vessel for
inspection and/or maintenance. The minimum required size shall be 24” diameter, or
large enough to get the largest single piece of internal fitting through, which may require
a large access way. Manhole elevations should be between 900mm and 1200mm
above platform levels. Lower clearance may be used by agreement with the
COMPANY. Manhole davits/hinges shall be provided and shall be oriented so that the
manhole cover opens away from the platform ladder and instrument access. Manholes
shall be located to give the best possible access to the column/vessel and tower drop-
out areas so that internals require minimum handling to the davit lifting tackle. On
horizontal and vertical vessels with a manhole elevation 4m or less above grade, no
platform is required.
For storage tanks access platforms shall be provided to manholes, operational valves,
draining valves and other equipment (foam pourer, heater etc.) not accessible from
grade. Roofs shall be strong enough to allow walking on top of them. Sample points
shall preferably be located at grade. If not possible shall be accessible by stair case.

7.9 Shell and Tube Exchangers, Printed Circuit Heat Exchangers and Plate
Exchangers
For heat exchangers with removable tubes or plates, piping must be routed to provide
adequate space for the withdrawal of the tube bundle or plates and for any tube pulling
equipment required to complete the tube bundle removal. Valves shall not be located

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directly on top of channel nozzles which would cause obstruction when removing
channel ends.
Connecting piping shall be provided with flanged break out spools to facilitate
maintenance requirements and shall be designed to minimise the requirement for
temporary pipe supports.
Whenever possible, exchangers shall be located at ground level, however up to three
shells may be stacked back-to-back, to minimise plot space.
Normally exchangers should be arranged so that the fixed end is at the channel end
but the actual location of fixed saddle & sliding saddle shall be finalised based on stress
analysis requirement.
Process or piping layout may fix the required height of horizontal exchangers; however
consideration shall also be given to venting and drainage of the equipment and
associated piping.
All shell and tube exchangers require clear space for rodding out and/or tube bundle
removal - even fixed tube exchangers will require some form of maintenance work, such
as tube plugging, etc. and will therefore require maintenance space. Space for tube
bundle removal shall be left free, the exchanger channels preferably pointing towards
an access area or road and an approach should be left for mobile lifting equipment.
Tube withdrawal for exchangers may be by crane, tube bundle pulling equipment or by
means of a pulling device or any combination thereof.
Where davits are supplied for head removal, adequate space and laydown area shall
be provided for full swing of the head.
Any exchanger containing hydrocarbons operating above 260°C shall not have process
equipment located above or below it.
Printed circuit heat exchangers shall be installed with removable spool pieces and
strainers on all inlets. The design shall incorporate an elbow in a break out spool to
allow for back puffing (flowing low pressure air to atmosphere for cleaning).
Plate exchangers are generally small and are normally used for corrosive fluids - these
require special consideration in terms of spillage. They shall normally be sited on a
concrete paved floor for wash down and containment of any spillage. Plates are
generally added/removed from the side of the unit and a minimum withdrawal space
equal to 120% of the unit width shall be allowed on the withdrawal side only.

7.10 Air Coolers

Air coolers shall either be positioned over pipe racks or, where advantageous, can be
supported from ground level or other structures. Whichever option is selected, access
platforms shall be provided to all motors and fans (dependent on whether units are
induced or forced units) and also provided for operator access to header boxes.
High level access walkways to air coolers located above pipe racks shall be provided
with stair towers till the Main Motor access Platform, with intermediate ladders to
provide escape if necessary. Ladder access from main Motor access Platform to
Header maintenance platform shall be provided.

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Where multiple air coolers are mounted along the length of the pipe rack, care must be
taken in positioning them relative to each other. If positioned too close to each other,
re-circulation problems may occur, where the exhaust air from one air cooler may be
sucked into the next air cooler’s inlet, i.e. the second unit will draw in heated air instead
of cooler air.
There may be instances whereby the number and size of air coolers dictate the overall
length of the pipe rack.
Space shall be considered for crane access to remove or maintain the bundles of air
coolers.
Equipment with contents with a low flash point shall not be located underneath air
coolers, unless additional fire precautions are taken.
Air coolers located above pipe racks shall have sufficient clearance from hot surfaces
to avoid drawing in hot air.
Equal flow or First in last out piping arrangements shall be provided at inlet & outlet of
air cooler as indicated on P&ID.

7.11 Fired Heaters

Fired heaters may be single units or grouped units sharing a common stack with the
exhaust gases being controlled by individual dampers. Since they are potentially
dangerous, they must be located at the extremities of the plot, with clear road access
from at least two sides.
The minimum spacing required between fired heater shells shall be 2 metres, or that
dictated by the appropriate safety code, with minimum headroom under the burner floor
of 2.2 metres. Vertical heaters are usually supplied with stub supporting feet and
additional steel or concrete legs may need to be designed to give the required height to
the heater.
Generally, a common platform for a group of heaters shall be arranged at the burner
operating level. Normally, all platforms associated with the heater are supplied by the
heater supplier.
The positioning of the heaters shall also be determined by the prevailing wind - they
shall be sited upstream of the process area to avoid any flammable vapours being
blown towards a source of ignition.
The floor around a heater shall be concrete paved and sloped to drain spillage away
from underneath the heater. No pits or trenches shall be allowed to extend anywhere
near or under the heater.
Heaters shall be arranged on a common centreline, wherever possible, and, when air
preheating is required, space shall be provided for the exchanger and fans, which will
be local to the heater.
Fuel isolation valves shall be readily accessible and located a minimum 15m away from
the heater in a suitable location.

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7.12 Pumps
Pumps shall be located at ground level, where practical, on prepared foundations within
a concrete paved area sloped to allow spillage to be washed away from the pumps.
Pumps located within a structure shall be provided with drip trays to collect any spillage.
Pumps shall be located close to and below the equipment from which they take suction
to satisfy net positive suction head (NPSH) requirements.
Pumps can be either located in groups (i.e. pump stations) or to the outside edge of the
pipe rack. All pumps shall be located using the centreline of discharge as the reference
and have their longitudinal axis at right angles to the pipe rack.
Maintenance space over each pump shall be provided to allow sufficient access for
either mobile equipment or a portable ‘A’ frame for removal of the pump casing and/or
motor. Where shelters or significant structures are provided over large pumps, a
runway beam shall be considered.
Pump suction and discharge pipework must be adequately supported to keep nozzle
loads and moments within acceptable limits.
To avoid cavitation pump suction line arrangement shall have a 5D straight length
(nozzle diameter) between the pump suction nozzle and eccentric reducer (API RP
686). In exceptional cases (e.g. due to space restrictions), a deviation is possible, but
this needs to be confirmed by the pump supplier in detail design.

7.13 Compressors
Suction and interstage knock out drums shall be positioned as close as practical to the
compressors, but outside the compressor building. The coolers shall be elevated to
allow them to drain towards their respective knock-out drums. The knock-out drums
shall be located to ensure suctions lines are not pocketed. Fall requirements from
recycle control valves shall be observed and access platforming provided as necessary.
Pipe support frames shall be provided to ensure allowable compressor nozzle loads are
achieved.
Pipework for reciprocating machines shall be supported from independent foundations,
with the design taking pulsation into account. During stress analysis, harmonic studies
shall be carried out, where necessary, to establish design suitability
Temporary strainers shall be located as close to the compressor as possible, unless
the piping and instrumentation diagram (P&ID) indicates otherwise, and piping
designed to enable the temporary strainer to be easily installed or removed without
springing the pipe or removing any of the pipe supports.
The straight length requirements local to the nozzles for suction and discharge piping
shall be confirmed with the compressor supplier.
Where pickling or chemical cleaning of compressor piping is required, it shall be noted
on the Line List.

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7.14 Gas Turbines

The air intake opening shall be located in a safe area and in such a position as to limit
the ingress of dust, moisture, hazardous gases, and hot gases from other exhaust
plumes, etc.
Exhaust ducts shall accommodate waste heat recovery units (WHRUs) for the hot oil
system and require careful consideration to achieve the best practical arrangement.

7.15 Diesel Engines

All pipework connected to diesel engines shall be arranged such that adequate flexibility
is maintained to effectively isolate the pipework from engine vibration. The use of a
flexible hose at the final piping connection to the machine shall be considered. Pipework
shall not be run directly over diesel engines where leaking fuel oil (e.g. from flange,
valve, flexible line and connections) can impinge on to exhaust piping or hot parts.
The elevation of the day tank shall be in accordance with the engine manufacturer’s
requirements.
Silencers, where required in the exhaust system, shall be located as close as possible
to the engine.
Exhaust piping shall discharge into a safe area and shall not prove hazardous to
personnel, nor foul air intakes to other equipment or heating, ventilation and air-
conditioning (HVAC) systems.

7.16 Pig Traps

Consideration shall be given to providing mechanical handling facilities for the different
types of pigs that will be used.
These facilities may include:
• Overhead hoists or runway beams
• Winching points for the withdrawal of intelligent pigs
• Cradles and trollies, as necessary
Centre line elevations of horizontal traps shall be approximately 1200mm above ground.
The traps shall have self-venting mechanisms that prevent opening of the door until the
internal pressure has been fully vented. The use of valve interlocks between isolation
valves and the pig trap door shall be utilised.
Methods to contain spillage during operations shall be developed during Detailed
Engineering.
The demarcation between pipeline code and piping code will be indicated on the P&IDs.
The pipeline ESD requirements shall be determined by the QRA requirements.
Pipeline bend radius shall allow for intelligent pigs and are expected to be typically a
minimum of 5D (radius).

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7.17 Flare Stacks and Major Vents

Vertical flare stacks shall be located remote from the process units, within a dedicated
sterile area. They shall be positioned to reduce the effect of noise in the CPF/Base
Industrielle and to minimise the possibility of flame carryover towards the plant and to
avoid unplanned gas releases from the plant being carried towards an ignition source.
The height of each stack and its radiation zone shall be defined in Detailed Engineering
but shall take into account serviceability of the flare tip with the site’s mobile crane.
Flare headers shall slope towards the flare knock-out drum (no pockets shall be
allowed) which shall be located outside the flare stack radiation zone. The flare line
from the knock out drum to the flare stack shall slope backwards to the knock-out drum.
Horizontal flares and burn pits shall be located well away from plant facilities and
enclosed within concrete walls. All other requirements are similar to those for vertical
flare stacks.
Open vents containing hazardous gases shall be assessed on a case-by-case basis
and the open end location defined and indicated on the hazardous area drawings.

7.18 Underground Services and Interfaces

Valve pits shall be provided for valves on the buried fire main.
Drain hub locations shall be located to suit equipment and avoid causing tripping
hazards.

8 GENERAL PIPING REQUIREMENTS

8.1 General
All piping shall be designed and detailed in the 3D CAD model.
Close co-operation and liaison shall be maintained at all times between the various
disciplines, especially where layout affects (or is affected by) the Safety Philosophy (A-
TSE-PHL-000-30000), working environment, operation of equipment, electrical and/or
instrument cable routing, ventilation ducting, structural steel requirements, equipment
sizes, underground layout and constructability.
The overall intent shall be to provide a sufficiently spacious layout to avoid the need to
consider excessive blast overpressures. Safety studies shall be carried out to assess
and define the risks and, if necessary, identify selected hydrocarbon, firewater and
essential services pipework which requires action so that stress analysis and pipe
supports are adequately designed.
Every effort shall be taken to avoid locating flanges or other leak sources on pipes
containing flammable or hazardous fluids above escape routes, access ways, cable
trays or electrical installations.
Pipes containing pressurised flammable liquids or gases and passing through non-
hazardous areas shall be avoided, when this is not possible, they shall be of fully welded
construction without flanges or similar leak sources and each such occurrence shall be
discussed with the COMPANY’s Technical Safety Engineer on a case-by-case basis.

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All piping shall be routed to provide a simple, neat and economical layout allowing for
adequate supporting and flexibility to meet slugging, thermal and dead weight loadings.
The use of fittings and flanges shall be kept to a minimum.
Stress isometrics shall be produced and analysed for all stress critical lines.
No Pocket and slope requirement shall be followed as per the notes in the P&ID.
Generally, pockets shall be avoided in lines, particularly those carrying corrosive
chemicals, slurries and/or materials that congeal or solidify at ambient temperature. In
gas process lines no pocket requirement shall be complied wherever indicated in the
P&ID.
Lines carrying solids or fluids of high viscosity, flare, vent and drain lines, shall be sloped
in the direction of flow. The slope shall be as specified on the P&ID.
Adequate flexibility shall be built into the piping layout to avoid the use of expansion
bellows.
Where possible, small bore piping shall be routed in groups for supporting on common
supports.
All equipment and piping shall be arranged to provide the specified headroom and
clearances for ease of operation, inspection and maintenance. Dismantling shall be
possible with minimum interference to equipment or piping and without removing any
block valves.
Particular attention shall be paid to clearances required for the removal of pump,
compressor or turbine casings and shafts, pump and fan drivers, exchanger bundles,
compressor and engine pistons, shaker screens, valves, valve actuators, orifice plates,
flow meters and corrosion monitoring and chemical injection access fittings. All these
volumes shall be modelled in the 3D model unless agreed with the COMPANY.
Piping shall be kept clear of manholes, laydown areas, access openings, inspection
points, hatches, davits, areas for instrument removal, tower dropout areas, access
ways, emergency escape routes, access ladders and platforms.

8.2 Permissible Pipe Sizes

Only the following standard pipe sizes shall be used for process and utility piping. Any
proposed exceptions shall be discussed with the COMPANY’s Piping Engineer.
½”, ¾”, 1”, 1½”, 2”, 3”, 4”, 6”, 8”, 10”, 12”, 14”, 16”,18”,20”,24”,30”, 36”
As an exception 34” Line size shall be used for the gas export line.

8.3 Piperacks and Pipetracks

Dependant on the type of process plant and the size and shape of the plot available,
various configurations of pipe racks may be applied, e.g. straight through type, T-type,
L-type, U-type or combinations thereof. The configuration of pipe racks shall generally
depend on the quantity and complexity of piping and the integral requirement to support
equipment such as air coolers and high level access platforms, etc.

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Pipe racks within process units shall be elevated and may link to other process units to
form a plant network. They shall carry a series of pipes between equipment, their
elevation may change at changes of direction and they may comprise multiple levels.
Where more than three levels are required these shall be agreed with the COMPANY.
Wherever possible, common support levels for pipework, ducting and electrical and
instrument trays shall be provided.
Large bore piping / Hot lines shall be located as close to the edges of the pipe rack as
possible. This will permit the loops in the hot lines to have the greatest width over the
pipe rack and make nesting the loops of various lines simpler.
Lines that require falls, such as flare headers, shall be positioned so that the elevation
can be designed to suit the required slope and flat expansion loops accommodated.
The location and elevation of flare lines and similar systems with fall requirements shall
be established and fixed as early as possible in Detailed Engineering and shall form an
integral part of the pipe rack studies.
Valves which have to be located on the pipe rack should be grouped together and a
suitable means of access provided.
Pipe tracks (i.e. ground level sleepers) shall not be used unless agreed with the
COMPANY. These may be considered for installations where it is not practical to
consider elevated structures.
Additional space shall be provided between any pipe rack and adjacent equipment to
allow for possible underground drainage lines.
Where orifice plates are located in racks, they shall be located as close as possible to
the edges of pipe rack to allow ladder access to the piping isolation valves and flow
elements.
Minimal pipe size in pipe tracks and main pipe bridges shall not be less than 2”.
A growth allowance of 25% shall be provided in sizing all pipe racks and pipe tracks at
start of detailed engineering to take care of any additions during course of detailed
engineering. It is critical that the pipe rack layout design shall be robust and not subject
to major rework. during detailed design and execution.

8.4 Valves
Valve types shall be in accordance with the Isolation Philosophy (A-PRO-PHL-000-
30001) and the Process requirements and the appropriate types shall be indicated in
the P&IDs.
Valves shall be located to be operable from either ground level or permanent access
platforms as per appendix B.
The preferred stem orientation shall be either vertical or horizontal, the exception being
cryogenic valves which shall not be orientated more than 45o from vertical.
Valves shall be arranged so that the operator is at the optimum height for ease of
operation which is typically between 700mm and 1600mm above standing level
(appendix B). Variations are possible subject to review in the 3D CAD model and
agreement with the COMPANY’s Piping Engineer.
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Valve stems/levers must not obstruct walkways, access ways, ladders, platforms or
manholes.
Chain operated valves shall not be used.

8.5 Check Valves

Dual plate check valves, with plates that open beyond the body, shall not be installed
adjacent to any item that prevents the valve from fully opening. Requirements for
straight piping upstream of Dual plate check valves shall be considered in order to
avoid chatter caused by turbulent flow.
If check valves are to be installed in vertical lines, the flow shall be upwards and the
designer shall ensure that the check valves specified are suitable for vertical operation.
A drain connection shall be provided above the valve.
Piston type check valves shall be installed in the horizontal.
Attention shall be given to bolt withdrawal requirements when using wafer check valves.
In gas compressor discharge piping where there is a possibility of reverse flow
conditions causing vibration or possible damage to the compressor, non slam type
check valves shall be used as indicated on the P&ID.

8.6 Relief Valves

Relief valves shall be installed in the vertical position, as close to the pressure source
as practically possible, and shall be provided with permanent access platforms.

8.7 Globe Valves

Globe valves shall be orientated to close against the pressure.

8.8 Vents, Drains

All valved vents and drains shall be shown on the P&IDs,
Hydro-static test vents and drains shall be provided with blind flange and shall not be
permanently valved.
Where drains terminate at an open tundish the open end shall, wherever possible, be
visible from the drain valve.
If a flanged hose is to be connected to a drain line, the drain outlet shall be located to
provide sufficient space between the drain connection and grade or platform to allow
connection of the hose and complete draining of the line.

8.9 Branch Connections

The minimum branch connection size shall be 3/4” NB.

8.10 Wellsites and Gathering System Manifolds

Flowline piping local to the wellhead shall be designed to cater for proppant and
reservoir sand. It is unlikely that it will be feasible to quantify the potential quantities,
therefore the Detailed Engineering CONTRACTOR shall agree with the COMPANY the
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design features that will be employed to limit the risk of erosion and damage during
operations.
As a minimum, metal seated valves shall be specified together with 3D (radius) bends
or flanged target tees (or a combination of both) at all changes in direction and
consideration shall be given to the design of a ‘collection header’ at each wellsite with
the objective of trapping, and periodically allowing the removal of debris.
Manifold piping arrangements shall ensure easy access for operational and
maintenance personnel and handling of intelligent/cleaning pigs, etc.

8.11 Utility, Instrument and Nitrogen Air Piping

Air piping shall be designed to be self-draining, with valved drain connections provided
at all low points in the system. Branches shall be taken from the top of headers.
Air supply distribution manifolds shall be located in the vicinity of the users they serve.
Utility Stations:
Utility stations shall be provided which normally include water, plant air and nitrogen.
The hose connections shall be arranged in a consistent order.
Each station shall be numbered and located such that working areas can be reached
with a maximum 15 metre length of flexible hose. All hose connection points shall point
45 degree downwards.
Where required on columns, it may be feasible to combine hoses to provide 30 metre
coverage. Else dry risers may be provided. This shall be discussed and agreed with
the COMPANY’s Piping Engineer.
Hose connection type shall be unique to each service so that flexible hoses may only
be used for their intended duty. Such hose connections shall be defined in the Special
Piping (SP) Item Index and corresponding SP item data sheet.
Utility stations shall be provided with colour-coded utility hose reels for each utility. The
number of hose reels required shall be as shown on the P&ID.

8.12 Pressure Relief Piping

Relief headers shall fall towards the knock-out drum without pockets. The slope
required is 1:500 for unit and main headers and 1:200 for lead and tail sub-headers or
as per P&ID.
Relief valves serving flammable liquids or vapours shall discharge into a common
header and exhaust to a suitable blowdown system as shown on the P&IDs.
The outlet pipe of relief valves discharging to the atmosphere (upwards) shall have a
6mm weep hole drilled in the lowest point in the line, after the relief valve. Process shall
confirm any requirement to run a drain line from the weep hole to a drain system.
Unless specifically noted otherwise on the P&ID, all branch connections on relief and
blowdown systems shall be at 90º to the run pipe. Special requirements for particular
branches to enter a header at 45º shall be highlighted by Process on the P&ID (e.g. 2-
phase flow or very high velocity).

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Pressure relief valve inlet piping shall be kept as short as possible and must drain back
to the protected equipment.
Relief valve inlet and discharge piping and blowdown valves shall be designed to
withstand reaction forces and moments caused by the valve discharging. Piping stress
shall be checked such that reaction forces and moments exerted on the vessels or
piping nozzles during discharge do not generate stresses above the levels permitted by
the governing code. Where necessary, additional pipe supports shall be provide to
reduce loads transmitted to equipment.

8.13 Open Drain Systems

The drain system shall have slope. The required slope shall be indicated in the P&ID.
Branch connections shall enter the header at 45º.
Flushing/rodding out points in open drain systems shall be provided at the end of
headers and after total changes of direction equalling 135°.
90° turns shall preferably be achieved using 2 x 45° elbows with an intermediate straight
section not less than 200mm long.
Hazardous open drain should not accumulate under the pipe rack. Hazardous open
drain should be covered where it crosses the pipe rack to avoid any damage to pipe
rack due to fire underneath.

8.14 Fire Protection System

Process units shall be provided with a suitable underground firewater ring main system,
Reference shall be made to the relevant National Fire Prevention Association (NFPA)
local and international codes.
Firewater tanks and fire pumps shall be located in a non-hazardous area.
Deluge/sprinkler nozzles shall be located to ensure complete coverage of the protected
areas. Spray pattern obstructions such as horizontal piping and cable trays, etc. shall
be avoided.
All fire protection equipment, deluge/sprinkler valves, CO2 skids, etc. shall be located
so as to be easily accessible in emergency conditions and for maintenance.
Firewater deluge sets shall be located away from the area they are protecting,
preferably in a safe area.
Valves on ring mains and headers shall have extended spindles when buried.
For all firewater piping systems, care shall be taken to avoid "dead legs" - where these
are unavoidable, flanged ends shall be included to allow removal of debris. Branch
"take-offs" for sprinkler systems shall be in the vertical position from the top of the
header to prevent debris from blocking the branch.

8.15 Instrumentation

8.15.1 Control Valves

All control valves shall be installed in a horizontal line and the actuator in a vertical
position.
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All control valves shall be easily accessible from ground level or a permanent access
platform and conveniently located for ease of operation and full maintenance. They
shall be sited so that instrument technicians can locate any associated local indicator
whilst having a view to both the control valve and its by-pass valve.
Control valves shall be located with a minimum clearance of 300mm below the valve,
and 300mm minimum above the actuator, or as specified by the vendor, to allow
removal of the actuator in-situ.
Where control valves are less than line size, the reducer shall be placed adjacent to the
valve. Spools or reducers between flanged block valves and control valves shall be
made long enough to permit bolt removal and for supports where required.

8.15.2 Flow Instruments

Sufficient clearance shall be allowed between orifice flanges and the adjacent horizontal
line to enable sufficient space for the tappings and valve arrangement.
Piping material supplied for use in metering tubes shall be in accordance with
dimensional tolerances stipulated by the instrument supplier. Special consideration
shall also be given to the internal smoothness of any circumferential welds associated
with the metering tube, including the adjoining pipework interface flange.
All flow meter runs upstream/downstream dimensions shall be as per Piping &
Instrument interface document.
Space shall be allowed for the withdrawal of insertion type flow meters.
Vertical meters shall not be used for fiscal measurement services. Vertical meters may
be used in other services, subject to the COMPANY’s approval. When using orifices in
vertical liquid lines the flow must be upwards. For dry air and gas the flow must be
downwards.

8.15.3 Level Instruments

Typical details of assemblies for all level Instruments and standpipe details shall be
shown on the P&IDs.
Standpipes and direct mounted instruments shall be accessible from ground level,
access platforms or permanent ladders.

8.15.4 Pressure Instruments

All pressure gauges shall be visible from, and be located for easy access from, ground
level, access platforms or permanent ladders.
Orientation of gauges in horizontal lines in gas service shall be upwards and for liquid
services, tapping point shall be horizontal with 90 Deg. elbow.

8.15.5 Temperature Instruments

For thermowell connections in line sizes less than 4"NB, the line shall be locally
enlarged to 4’’ minimum to accommodate the thermowell, using bottom flat eccentric
reducers in horizontal lines.

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Thermowell location shall be a minimum of 10 pipe diameters downstream of a junction

of two streams with different temperatures, or as indicated on the P&IDs.
All temperature instrument locations shall have clearances in which the temperature
element and thermowell may be withdrawn without interference. The minimum
clearance above the temperature instrument shall be 600mm.

8.15.6 Corrosion Monitoring Fittings

Corrosion monitoring devices shall be fitted into proprietary flanged branch fittings and
space must be allowed for attaching and operating the withdrawal tool. The location of
these devices shall be agreed with the CONTRACTOR’s metallurgy/materials
specialists but should generally be on the bottom of the pipe for process liquids.

8.15.7 Pipe Stress Analysis and Pipe Support Design

Engineering shall be carried out to fix the shape of all stress critical lines highlighted in
the Stress Critical Line List. Stress sketches shall be produced and marked up to
indicate pipe support locations. The location of the pipe supports shall also be identified
in the 3D CAD model to demonstrate they are in practical locations.

8.15.8 Flow Induced Vibration of Piping

The number of small branches to piping shall be minimised and the minimum small bore
connection size shall be 3/4”.
Bracing requirement for standalone branch connections for sizes less than 2”, shall be
based on AIV/FIV study recommendations to prevent fatigue from vibration. Details
shall be specified in the relevant specifications and assembly drawings.
On large bore critical lines, consideration shall be given to a minimum branch size of
2“.
Branches shall be avoided downstream of relief and blowdown valves. If this is not
possible, branches shall be located well away from these sources of vibration.
Branches shall not be located on pipe in areas of high stress or where large deflections
are predicted.

8.15.9 Clearances
To avoid rework, it is important that adequate clearances are allowed for in the 3D
model, for example, to allow for thermal movement between piping, insulation
installation/removal, stud bolt insertion/removal, etc.
It is anticipated that pipe insulation will be required, as a minimum, for all cold service
pipework, heat conservation for the hot oil system and acoustic insulation. It is
important that the correct thicknesses are allowed for in the pipe rack studies and 3D
modelling at an early stage.

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9 FITTINGS, FLANGES AND SPECIAL ITEMS

9.1 General
Weld neck flanges and standard fittings shall be used throughout all piping systems for
all sizes and pressure classes. Any equipment with flat face flange connections shall
have a flat face mating flange and full face gasket.
Where entrained proppant or sand is expected, target tees or pulled bends 3D (radius)
shall be considered in place of long radius (LR) elbows to minimise erosion.

9.1.1 Line Blinds (spectacle blinds, spades and spacers)

The position of all line blinds shall be designed to allow enough flexibility to spring the
line by means of jacking arrangements. On ring joint flanges, the flexibility allowance
must be sufficient to allow for the removal of the widest section of the ring whilst not
causing any overstressing of the piping.
Line blinds shall be located between two flanges, one of which may be a flanged
equipment nozzle or a flanged valve other than a wafer type.
Spectacle line blinds shall generally be used, providing the weight of the spectacle blind
does not exceed 50 kilogrammes.

9.1.2 Isolation Spools/Sets

The requirement for isolation spools/sets shall be identified on the P&IDs. Isolation
spools shall be shown at above ground to below ground interfaces or at changes of
metallurgy as required by materials selection.

9.2 Strainers and Filters

Depending on the type, strainers and filters (including temporary installations) shall be
arranged to provide clearance for basket removal or, in the case of a cone strainers
(witch’s hat), complete removal from the line.
In general, basket type or Y type strainers shall be used; to avoid disturbing the
alignment of pumps and compressors. Cone strainers (witch’s hat type) may be used
for temporary application (start-up etc) where agreed by the COMPANY’s Piping
Engineer.

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APPENDIX A - GENERAL GUIDELINE CLEARANCES AND DISTANCES FOR

PIPING LAYOUT

Personnel access Min. 915mm, exceptional 750mm wide x 2200mm

high for passageways
Min 1200mm wide x 2200mm high for main escape
routes
Min 1000mm wide x 2200mm high for secondary
escape routes
Platforms and break landings Min. 1000mm square
Stairway landings and half landings shall be a
minimum of 1500 wide and shall be designed to
accommodate a 4 person stretcher party
Stairs Nominally 1000mm wide tread width
Min. 750mm wide tread width
Max. of 4600mm single rise between breaks
Ladders Max. rise between platforms 6000mm
Min. ladder width 380mm
Road dimensions Main plant roads - min. 6000mm wide
Minor plant roads- min. 4000mm wide
Min. inside radius 7000mm
Major road radius 10000mm
Road overhead clearance Plant roads - min. 4500mm (Subject to specified
maintenance vehicles / cranes)
Process equipment Space between vessel face to face min. 2000mm
Vessel to boundary fence min. 15000mm
Manhole centreline from platform should be
between 900mm and 1200mm where possible,
alternative spacing may be used by agreement with
the COMPANY.
Exchangers Spacing for adjacent exchangers shall be min.
915mm clear between horizontal flanges including
insulation. Shell and tube exchangers shall not be
stacked more than two high, except for those with
small diameter shells providing the total height does
not exceed 3350mm from grade

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Standard transportable equipment 12mx2.5mx2.5m

sizes
Heavy/Oversizes transportable 17mx4mx4m
equipment sizes
(no special arrangements)
Process pipe rack Min 6000mm wide (for main process racks)
Yard bent spacing 6000mm min. 2000mm between
rack levels
Main pipe rack headroom clearance Min. 4500mm (road clearances as above)
Pipe rack headroom clearance Min 2800mm clearance for forklift truck access
within the process unit (maintenance from below the pipe rack)
Fired heaters Min. distance to process equipment 15000mm
Min. distance to burner management 15000mm
Min. stack height 6000mm above highest platform
within a 30000mm radius

Pumps Pumps handling combustibles shall not generally be

located under pipe racks
Min 1000mm between foundations for pumps
Storage tanks Dependent on service and capacity
Bund wall heights Max. 1200mm
Road loading bays Min. 15000mm between loading bay pumps
Sleepers Minimum clearance underneath lines supported on
sleepers from bottom of line to grade 400mm
Pipe to Pipe, pipe to insulation, 75mm
insulation to insulation
Flange to pipe, flange to insulation 30mm
Process drains Minimum clearance below drains 150mm
Handwheels Minimum clearance between handwheels and any
obstruction shall be 100mm

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APPENDIX B – ERGONOMICS/ACCESSIBILITY

ERGONOMIC VALVE POSITIONING

A = Preferred for operational valves

B = Acceptable for non operational valves
X = Not Acceptable

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APPENDIX B – ERGONOMICS/ACCESSIBILITY

Accessibility Requirements

Accessible From: Items;

From Grade or Platform Control Valves, On-Off valves
Safety Valves (except thermal relief)
Battery Limit Valves
Valves 3” and over.
Spectacle blinds
Manways on vessels higher than
4000mm above grade
Flow meters (except orifice and Venturi
type)
Sample collection points
Level instruments on towers and vessels
By Permanent Ladder Valves 2” and smaller
Pressure indicators
Temperature indicators
Handholes
Sample take-off points
By portable devices or scaffolding Orifice and Venturi type flow meters
(maximum 4000 mm above grade) Restriction orifices
Pressure connections (except indicators)
Temperature connections (except
indicators).
Manways on vessels

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APPENDIX C – SEGREGATION AND SPACING DISTANCES

The tables below includes both spacing requirements between process units/equipment and
safety distances from processing plant to third parties or offsite facilities and infrastructure.
Spacing shall also comply with the codes and standards as defined in section 2.2. The spacing
not indicated in the tables below shall be referred and complied to section 2.2.

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 EQUIPMENT SPACING CHART
A N/A DENOTES NOT APPLICABLE H FOR COMPRESSORS WITH GAS TURBINE DRIVES AND M 4.5M FOR EQUIPMENT DIRECTLY ASSOCIATED WITH
B MIN DENOTES MINIMUM FOR OPERATION, DISTANCES TO OTHER COMPRESSORS IN THE SAME HEATER. 15M FOR NON-ASSOCIATED EQUIPMENT.
MAINTENANCE AND CONSTRUCTION ACCESS AREA SEE NOTE G N 7.5M FOR EXHAUST STACK AND/OR FLUE GAS HEAT
C AIRCOOLERS MAYBE MOUNTED ON TOP OF PIPERACKS J 1.5M TO DRUMS, 3M TO COLUMNS RECOVERY.
D AIRCOOLERS TO OTHER ITEMS OF EQUIPMENT. K REBOILERS TO BE MIN TO ASSOCIATED COLUMNS O SEPARATION MEASURED FROM OUTSIDE OF
DISTANCES MUST ACCOUNT FOR UNDISTURBED AIR L 7.5M FOR HEATERS NOT HAVING THE SAME COMPRESSOR HOUSE
FLOWS THROUGH AIRCOOLERS MAINTENANCE SHUTDOWN, MIN FOR HEATERS HAVING
E PUMPS MAY BE PLACED UNDER PIPERACKS THE SAME MAINTENACE SHUTDWON
F SEPARATION DISTANCE IS TO OUTSIDE OF STORAGE
TANK
G 2M DISTANCE FOR RECIP COMPRESSORS (CYLINDER
HEADS) AND 3M FOR CENTRIFFUGAL COMPRESSORS

7.5 MINIMUM HORIZONTAL DISTANCE IN METERES

Y REFER TO RELEVANT NOTE
7.5 Z REFER ALSO TO RELEVANT NOTE

SUBSTATION (INC.
TRANSFORMERS)
1
FLARE AND
BLOWDOWN DRUMS

2 AIR COOLERS
1 SUBSTATION (INC. TRANSFORMERS) N/A

HYDROCARBON
COMPRESSORS (O)

3
2 AIR COOLERS 15 MIN (D)

COLUMNS AND DRUMS

ABOVE AUTO IGNITION

4
3 FLARE AND BLOWDOWN DRUMS 15 3 1.5

COLUMNS AND DRUMS

ABOVE BELOW IGNITION

5
4 HYDROCARBON COMPRESSORS (O) 15 3 3 G

6
5 COLUMNS AND DRUMS ABOVE AUTO IGNITION 15 3 3/1.5 3 J
7 DESALTERS

6 COLUMNS AND DRUMS ABOVE BELOW IGNITION 15 3 3/1.5 3 J J

ISOLATION VALVES
(PROCESS UNIT)

8 FIRED HEATERS

7 DESALTERS 15 4.5 4.5 4.5 4.5 4.5 1.5

PIPERACKS/TRACKS
(PROCESS UNIT)

8 FIRED HEATERS 15 15 15 15 15 15 15 L
PROCESS PUMPS ABOVE
AUTO IGNITION

10

9 ISOLATION VALVES (PROCESS UNIT) 15 7.5 7.5 7.5 7.5 7.5 9 7.5/15 N/A
PROCESS PUMPS BELOW
AUTO IGNITION

11

10 PIPERACKS/TRACKS (PROCESS UNIT) N/A 3C 3 3 3 3 4.5 15 MIN MIN MIN

REACTORS ABOVE AUTO
IGNITION

12

11 PROCESS PUMPS ABOVE AUTO IGNITION 15 MIN 3E 3 3E 3E 4.5 E 15 7.5 MIN E 1.5
13

12 PROCESS PUMPS BELOW AUTO IGNITION 15 MIN 3E 3 3E 3E 4.5 E 15 7.5 MIN E 1.5 1.5
S&T EXCHANGERS ABOVE AUTO
IGNITION

14 REACTORS BELOW AUTO IGNITION

13 REACTORS ABOVE AUTO IGNITION 15 3 3 3 3 3 4.5 M 7.5 3 3 3 1.5

S&T EXCHANGERS ABOVE BELOW
IGNITION

15

14 REACTORS BELOW AUTO IGNITION 15 3 3 3 3 3 4.5 M 7.5 3 3 3 3 1.5

16

15 S&T EXCHANGERS ABOVE AUTO IGNITION 15 3 1.5 3 1.5 J&K 1.5 J&K 3 M 7.5 3 3 3 3 3 1
16 S&T EXCHANGERS ABOVE BELOW IGNITION 15 3 1.5 3 1.5 J&K 1.5 J&K 3 M 7.5 3 3 3 3 3 1 1
17 EQUIPMENT CONTAINING NON FLAMMABLES 1.5 3/1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 MIN 1.5 1.5 1.5 1.5 1.5 1.5
18 ATMOSPHERIC STORAGE TANKS 15 3F 3F 3F 3F 3F 4.5 15 7.5 MIN 3 4.5 4.5 4.5 4.5 4.5 F
19 GAS TURBINE DRIVER 15 15 15 A5 H 15 15 15 15 7.5 4.5 15 15 15 15 15 15
20 EDGE OF MAJOR ROADS 1.5 15 15 15 15 15 15 4.5 1.5 1.5 15 15 15 15 15 15
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 MINIMUM DISTANCE BETWEEN UNITS
A
HYDROCARBON TRANSFER STATIONS A1,A2 101
HYDROCARBON TRANSFER STATIONS C1,D1 103A
HYDROCARBON TRANSFER STATIONS C7,D2 104A
101 TREATMENT UNITS P < 70 bar, T° < AUTO-IGNITION 111
101 20 (2) 103 TREATMENT UNITS P> 70 bar, T° > AUTO-IGNITION, COMPRESSION UNITS112
103 40 (2) 15 (3) 104 SECUNDARY UNITS; TRANSFER PUMPS OUTSIDE BUNDED AREA 121
(1) (1)
104 40 (2) 10 (3) 10 (3) 111 MAIN PIPE TRACKS (GRADE OR ELEVATED) 131
111 60 40 30 20 112 HYDROCARBON STORAGE TANKS A1,A2 (V>10m 3) 141
112 60 60 60 30 30 121 HYDROCARBON STORAGE TANKS C1, D1 (V > 30m 3) 143
121 30 20 20 20 30 10 131 HYDROCARBON STORAGE TANKS C2, D2 (V >50 m 3) 144
131 15 15 15 7.5 7.5 7.5 0 141 HYDROCARBON STORAGE TANKS C2,D2 (V>50m 3) 151
141 60 60 60 1,5d 1,5d 30 30 1,5d 143 VERTICAL FLARES h>30m 161AAA
143 60 60 60 1,5d 1,5d 30 20 1,5d d 144 GROUND FLARES AND BURN PITS h < 30 m 162AAA
144 60 60 60 1,5d 1,5d 20 20 1,5d d 0,8d 151 FIRE PUMPS, BUIDINGS & HYDRANTS 201
151 60 60 40 60 60 30 30 100 60 40 0 161 UTILITIES: POWER GENERATION, BOILER, AIRCOMPRESSOR, ETC 202
161 60 (4) 60 (4) 60 (4) 60 (4) 60 (4) 60 (4) 60 (4) 60 (4) 60 (4) 60 (4) 60 (4) 60 162 MAIN ELECTRICAL SUBSTATION 203
162 100 (4) 100 (4) 100 (4) 100 (4) 100 (4) 100 (4) 100 (4) 100 (4) 100 (4) 100 (4) 100 (4) 60 (4) 100 (4) 201 WORKSHOPS, WAREHOUSES, LABORATORIES, GARAGES 211
201 100 100 60 60 60 60 7.5 100 60 60 60 60 (4) 100 (4) 0 202 PERMANTLY MANNED CONTROL ROOM 212AAA

202 60 60 60 30 60 60 7.5 100 60 30 60 60 (4) 100 (4) 30 0 203 ADMINISTRATION BUILDINGS, PARKING 221
203 60 60 60 30 60 30 7.5 100 60 30 60 60 (4) 100 0 0 0 211 OUTSIDE AREA'S 222
211 60 60 30 30 60 60 7.5 100 60 30 30 60 100 (4) 0 0 0 0 212 PUBLIC BUILDINGS, HIGHWAYS, ROADS,RAILWAYS 301
(4)
212 60 (5) 60 30 30 60 (4) (5) 60 7.5 100 (4) (7) 60 30 30 60 100 (4) 0 (5) 0 (5) 0 0 0 221 PRODUCTION WELL (OIL, GAS) 401
221 60 60 30 30 60 60 15 100 60 30 40 60 (4) 100 (4) 0 (5) 0 (5) 0 0 (5) 0 0 222
222 60 60 30 30 60 60 7.5 100 60 30 60 60 100 0 0 0 0 15 0 0 301
301 100 100 40(5) 60(5) 100(5) 60(5) 15 100 (4) (7) 60 (4) 60 (4) 100 60 (4) 100 (4) 0 (5) 40 (5) 0 0 (5) 15 0 ND 0 401
401 150 150 150 100 100 100 100 300 300 150 100 150 150 300 150 150 150 150 150 150 150 50

NOTES

A: EXEMPTIONS FOR ROAD VEHICLES ARE POSSIBLE ( 1 ): EXCEPT IN THE CASE OF WELDING AT THE LOCATION d: DIAMETER OF TANKS
1,5 d WITH A MINIMUM 30 m
AA: MINIMUM DISTANCES ( 2 ): LATERAL DISTANCE, LONGITUDINAL DISTANCE = 1.5 x GREATEST LENGTH EXAMPLE:
141: INDICATED MINIMUM DISTANCE TO BE CONFIRMED
AAA: DISTANCES FIXED IN CASE OF AN OIL TREATMENT ( 3 ): LATERAL DISTANCE, LONGITUDINAL DISTANCE = 1.2 x GREATEST LENGTH 143: COMPULSORY DISTANCE
PLANT
IN THE CASE OF A GAS TREATMENT PLANT THE DISTANCE ( 4 ): DISTANCE TO BE CALCULATED AS A FUNCTION OF THE RATE OF RADIATION FROM FLARE AND THE ND: NOT APPLICABLE
SHALL BE CALCULATED. TECHNICAL BUILDINGS ARE DISSIPATION OF GASES IN AIR
EXCLUDED (NO OPERATORS PERMANTLY PRESENT), THEY THIS DISTANCE DOES NOT TAKE INTO ACCOUNT HARMFUL EFFECTS (LEVEL OF CRUDE,
SHALL BE LOCATED AS CLOSE TO THE UNITS AS POSSIBLE ( 5 ): ETC)
OUTSIDE THE HAZARDOUS AREA.
( 6 ): DISTANCE TO BE CALCULATED, MINIMUM 50m

( 7 ): DISTANCE TO BE CALCULATED, MINIMUM 100m

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