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TechnicalInformationabouttheSpacingofEquipmentin
PetrochemicalPlants
March15,2012qdzung1comment

Equipmentspacingintheplantdesignandpipingdisciplineisoneareathatcontinuestoresist
automation.Surethereareinhouseandthirdpartyprogramsouttherethatassistdesignersin
developingplotplans.MostoftheseprogramsarejustoverlaysonCADDproducts.These2D/3DCADD
overlaysmaygivefeedbackoncostsofthearrangementorthese2D/3DCADDoverlaysmayspeedup
thedevelopmentoftheplotbyautomatingthegenerationofequipmentgraphicsandstructuralgraphics.
Howevertherearenotoolsouttherethatwillarrangeaplotplanautomatically.

Themainreasonforthislackofequipmentarrangementautomationistheinabilitytodeveloprulesthat
completelydefinehowalistofequipmentshallbearrangedonaplot.Thedifficultyindefining
equipmentarrangementrulesisduetothecomplexityinvolved.
Hereisapartiallistoftheequipmentarrangementdesignconsiderationsthatmustbeaddressedoneach
project.

Highhazardoperations
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Groupedoperations
Criticaloperations
Numberofpersonnelatrisk
Concentrationofpropertyandbusinessinterruptionvalues
Equipmentreplacementandinstallationtime
Interdependencyoffacilities
Criticalcustomerorsupplierrelationships
Marketshareconcerns
Fireandexplosionexposures
Corrosiveorincompatiblematerialsexposures
Vaporcloudexplosions
Sourcesofignition
Maintenanceandemergencyaccessibility
Drainageandgradesloping
Prevailingwindconditions
Naturalhazardsandclimate
Futureexpansions
Externalexposures

ThedesignconsiderationforVaporCloudExplosionsaloneisasubjectthatfillsbooks.Theanalytical
automationtoolsforstudyingBoilingLiquidEvaporatingVaporExplosions(BLEVE)arefewandare
proprietary.ThereisdocumentationonhowtoevaluateBLEVEimpactsusinghandcalculations,suchas
theTNTequivalencymethod.Howeveritisgenerallyacceptedthatthesehandcalculationmethodsdoa
poorjobofpredictingBLEVE.
AndBLEVEsarejustoneformofVaporCloudexplosions!Othertypesofvaporcloudexplosionsrequire
differentanalyticaltechniques.
Sowhatdoesthedesignerdo?Designerstheworldovergenerallyrelyontheircompanys(ortheir
clients)tablestandardthatlistshowfaronepieceofequipmentneedstobefromanotherpieceof
equipment.Thesetablesaretypicallygeneratedbasedonexperienceparticularlytheexperienceofthe
insuranceindustry.AsamplechartfromtheBausbacher/Huntbookisshownabove.
Thefollowingpagesaregoingtocompareanddiscussthevariousspacingcriteriaavailableinthepublic
domain.Wewillalsotrytopointoutwherethesecriteriaconflict,andwheretheymaybeweak.
Bytheway,thepicturetotherightisofarecentexplosioninaplantwherethespacingcriteriasatisfied
aninsurancegroupsrequirementsforequipmentspacing.Theinitialexplosioncausedadominoeffect
thatleveledthreeunits.

Categories:PlantLayoutTags:plantlayout,TechnicalInformation

PlantLayoutStorageTanks
March15,2012qdzung1comment

TableofContents
1.TankageGrouping
2.ClassificationofCrudeOilandItsDerivatives
3.TankageLayout
4.PumpAreas
5.FireProtection
6.RoadandRailLoadingFacilities

1.TankageGrouping
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Tankageareawillbesubdividedintovariousgroupsdeterminedbythecontentsofthetanksandthe
relativeshapeandareaoftheplotavailable,accessandfirefightingmustalsobeconsidered.Seebelow
tableAPItanksizeforlayoutpurposes.

2.ClassificationofCrudeOilandItsDerivatives
Crudeoilanditsderivativesarepotentiallyhazardousmaterials.Thedegreeofthehazardisdetermined
essentiallybyvolatilityandflashpoint.
TheInstituteofPetroleumhasspecifiedthefollowingclasses:

Class0 Liquifiedpetroleumgases(LPG)
ClassI Liquidswhichhaveflashpointsbelow21oC
Liquidswhichhaveflashpointsfrom21oC
ClassII (1) uptoandincluding55oChandled,below
flashpoint
Liquidswhichhaveflashpointsfrom21oC
ClassII (2) uptoandincluding55oChandled,ator
aboveflashpoint
Liquidswhichhaveflashpointsabove55oC
ClassIII (1) uptoandincluding100oChandled,below
flashpoint
Liquidswhichhaveflashpointsabove55oC
ClassIII (2) uptoandincluding100oChandled,above
flashpoint
Unclassified. Liquidswithflashpointsabove100oC

ForfurtherinformationseeIPrefinerysafetycodepart3.

3.TankageLayout
3.1General
Thelayoutoftanks,asdistinctfromtheirspacing,shouldalwaystakeintoconsiderationtheaccessibility
neededforfirefightingandthepotentialvalueofastoragetankfarminprovidingabufferareabetween
processplantandpublicroads,houses,etc.,forenvironmentalreasons.
Thelocationoftankagerelativetoprocessunitsmustbesuchastoensuremaximumsafetyfrompossible
incidents.
Primarilyrequirementsforthelayoutofrefinerytanksfarmsaresummarisedasfollows.

1.Intertankspacingsandseparationdistancesbetweentankandboundarylineandtankandotherfacilities
areoffundamentalimportance.(See3.2).
2.Suitableroadwaysshouldbeprovidedforapproachtotanksitesbymobilefirefightingequipmentand
personnel.
3.Thefirewatersystemshouldbelaidouttoprovideadequatefireprotectiontoallpartsofthestoragearea
andthetransferfacilities.
4.Bundinganddrainingoftheareasurroundingthetanksshouldbesuchthataspillagefromanytankcan
becontrolledtominimisesubsequentdamagetothetankanditscontents.Theyshouldalsominimisethe
possibilityofothertanksbeinginvolved.
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5.Tankfarmsshouldpreferablynotbelocatedathigherlevelsthanprocessunitsinthesamecatchment
area.
6.Storagetanksholdingflammableliquidsshouldbeinstalledinsuchawaythatanyspillwillnotflow
towardsaprocessareaoranyothersourceofignition.

3.2.SpacingofTanksforLPGStocksofClass0
Recommendations
Factor forLPGStoredin
PressureTanks
Onequarterofthe
sumofthe
1.BetweenLPGpressurestorage
diametersofthe
tanks
twoadjacent
tanks.
15Mfromthetop
2.ToClassI,II,orIIIproduct ofthesurrounding
tanks. ClassI,IIorIII
producttanks.
Onediameterof
thelargestlow
pressure
3.Tolowpressurerefrigerated
refrigerated
LPGtanks.
storagetanksbut
notlessthan30
M.
4.Tobuildingcontaining
flammablemateriale.g.filling 15M
shed,storagebuilding.
Relatedtowater
5.Toboundaryoranyfixed
capacityoftankas
sourceofignition.
follows:
CapacityUpto
135cu.MOver Distance15M
135to565cu.M 24M30M
Over565cu.M

Thedistancegivenintheabovetableareminimumrecommendationsforabovegroundtanksandreferto
thehorizontaldistanceinplanbetweenthenearestpointonthestoragetankandaspecifiedfeature,e.g.
anadjacentstoragetank,building,boundary.Thedistancesareforbothsphericalandcylindricaltanks.

3.3BundingandGroupingofLPGTanks
TheprovisionofbundsaroundLPGpressurestoragetanksisnotnormallyjustified.
Separationkerbs,lowtoavoidgastraps,maximum600mmhigh,maybelocatedtopreventspillage
reachingimportantareas,e.g.pumpmanifoldarea,pipetrack.
Groundundertanksshouldbegradedtolevelswhichensurethatanyspillagehasapreferentialflow
awayfromthetank.
Pitsanddepressions,otherthanthosewhichhavebeenprovidedascatchmentareas,shouldbeavoidedto
preventtheformingofgaspockets.
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PressurestoragetanksforLPGshouldnotbelocatedwithinthebundedenclosuresofClassI,IIorIII
producttankageoroflowpressurerefrigeratedLPGtankage.

Thelayoutandgroupingoftanks,asdistinctfromspacing,shouldreceivecarefulconsiderationwiththe
viewofaccessibilityforfirefightingandtheavoidanceofspillagefromonetankflowingtowardsthe
othertankortowardsanearbyimportantarea.

3.4SpacingofTanksforLowPressureRefrigeratedLPGStorage
Class0
RecommendationsforLow
Factor PressureRefrigeratedLPG
Storage
Onehalfofthesumofthe
1.BetweenrefrigeratedLPG
diametersofthetwoadjacent
storagetanks
tanks.
Onediameterofthelargest
2.ToClassI,II,orIIIproduct
refrigeratedstoragetankbutnot
tanks.
lessthan30M.
Onediameterofthelargest
3.Topressurestoragetanks. refrigeratedstoragetankbutnot
lessthan30M.
4.Toprocessunits,office
building,workshop,laboratory,
45M
warehouse,boundary,oranyfixed
sourceofignition.

Thedistancegivenintheabovetableareminimumrecommendationsandrefertothehorizontaldistance
inplanbetweenthenearestpointonthestoragetankandaspecifiedfeature,e.g.anadjacentstorage
tank,building,boundary.

3.5.BundorImpoundedBasinforRefrigeratedLPGStorage
AbundshouldbeprovidedaroundalllowpressuretankscontainingrefrigeratedLPG.Thetankshould
becompletelysurroundedbythebund,unlessthetopographyoftheareaissuch,eithernaturallyorby
construction,thatspillscanbedirectedquicklyandsafely,bygravitydrainageanddiversionwallsif
required,toadepressionorimpoundingbasinlocatedwithintheboundaryoftheplant.
Bundsshouldbedesignedtobeofsufficientstrengthtowithstandthepressuretowhichtheywouldbe
subjectedifthevolumewithinthebundedenclosurewerefilledwithwater.Theareawithinthebund,
depression,orimpoundingbasisshouldbeisolatedfromanyoutsidedrainagesystembyavalve,normally
closedunlesstheareaisbeingdrainedofwaterundercontrolledconditions.
Whereonlyonetankiswithinthebund,thecapacityofthebundedenclosure,includingthecapacityof
anydepressionorimpoundingbasis,shouldbe75percentofthetankcapacity.Wheremorethanone
tankiswithinthemainenclosure,intermediatebundsshouldbeprovided,soastogiveanenclosure
aroundeachtankof50percentofthecapacityofthattank,andtheminimumeffectivecapacityofthe
mainenclosure,includinganydepressionorimpoundingbasin,shouldbe100percentofthecapacityof
thelargesttank,afterallowingforthevolumeoftheenclosureoccupiedbytheremainingtanks.Itis
desirablefortherequiredcapacitytobeprovidedwithbundsnotexceedinganaverageheightof6footas
measuredfromtheoutsidegroundlevel.
Theareawithinthebundshouldbegradedtolevelswhichensurethatanyspillagehasapreferentialflow
awayfromthetank.
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NotankageotherthanlowpressuretankageforrefrigeratedLPGshouldbewithinthebund.Thelayout
andgroupingoftanks,asdistinctfromspacing,shouldreceivecarefulconsiderationwiththeviewof
accessibilityforfirefighting.

3.6PipingInstallationandFlexibility
Liquidandvapourpipelinesshouldhaveadequateflexibilitytoaccommodateanysettlementoftanksor
otherequipment,thermalexpansionorotherstressesthatmayoccurinthepipeworksystem.
Precautionmustbetakentopreventdrainorsamplevalvesfreezingintheopenposition.Theflow
diagramwillindicatethetypeofdoublevalvingtobeinstalled,withaminimumdistancebetweenthe
valvesof1meter.Donotallowliquidtrapsinventlines.

3.7SpacingofTankforPetroleumStocksofClassesI,IIandIII(2).
Factor
1.Withinagroupof
smalltanks
2.Betweenagroupof
smalltanksorother
largertanks.
3.Betweenadjacent
individualtanks(other
thansmalltanks).
4.Betweenatankand
thetopoftheinsideof
thewallofits
compound
5.Betweenanytankina
groupoftanksandthe
insidetopofthe
adjacentcompound
wall.
6.Betweenatankanda
publicboundaryfence.
7.Betweenthetopof
theinsideofthewallof
atankcompoundanda
publicboundaryfence
ortoanyfixedignition
source.
8.Betweenatankand
Typeof
RecommendedMinimum
Tank
Distance
Roof
Determinedsolelyby
Fixedor
construction/maintenance
Floating
operationalconvenience
10Mminimum,otherwise
Fixedor
determinedbythesizeofthe
Floating
largertanks(see3below)
Halfthediameterofthelarger
(a)Fixed tank,butnotthan10Mandneed
notbemorethan15M.
0.3timesthediameterofthe
largertank,butnotlessthan10M
(b)Fixed andneednotbemorethan15M.
(Inthecaseofcrudeoiltankage
this15Moptiondoesnotapply)
Distanceequaltonotlessthan
halftheheightofthetank.
Fixedor
(Accessaroundthetankat
Floating
compoundgradelevelmustbe
maintained)
Fixedor
Floating
Fixedor
Notlessthan30M
Floating
Notlessthan15M
Fixedor Notlessthan30M

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thebatterylimitofa Floating
processplant.
9.Betweenthetopof
theinsidewallofatank
compoundandthe Notlessthan15M
batterylimitofa
processplant

ThetableabovegivesaguidanceontheminimumtankspacingforClassI,IIandIII(2)storagefacilities,
thefollowingpointsshouldbenoted.

1.Tanksofdiameterupto10Mareclassedassmalltanks
2.Smalltanksmaybesitedtogetheringroups,nogrouphavinganaggregatecapacityofmorethan8000
m3.Suchagroupmayberegardedasonetank.
3.Wherefuturechangesofserviceofastoragetankareanticipatedthelayoutandspacingshouldbe
designedforthemoststringentcase.
4.Forreasonsoffirefightingaccessthereshouldbenomorethantworowsoftanksbetweenadjacent
accessroads.
5.Fixedroofwithinternalfloatingcoversshouldbetreatedforspacingpurposesasfixedrooftanks.
6.Wherefixedroofandfloatingrooftanksareadjacent,spacingshouldbeonthebasisofthetank(s)with
themoststringentconditions.
7.Wheretanksareerectedoncompressiblesoils,thedistancebetweenadjacenttanksshouldbesufficientto
avoidexcessivedistortion.Thiscanbecausedbyadditionalsettlementsofthegroundwherethestressed
soilzoneofonetankoverlapsthatoftheadjacenttank.
8.ForClassIII(1)andunclassifiedpetroleumstocks,spacingoftanksisgovernedonlybyconstructional
andoperationalconvenience.However,thespacingofClassIII(1)tankagefromClassI,IIorIII(2)
tankageisgovernedbytherequirementsforthelatter.
9.Fortypicaltankinstallation,illustratinghowthespacingguidesareinterpretedseebelowfigures.

Fordetailsofatypicalverticaltankfoundationseebelowfigures.

3.8TankFarmPipingandLayout
Pipelinesconnectedtotanksshouldbedesignedsothatstressesimposedarewithinthetankdesignlimits.
Thesettlementofthetankandtheoutwardmovementoftheshellunderthefullhydrostaticpressure
shouldbetakenintoaccount.Thefirstpipesupportfromthetankshouldbelocatedatasufficient
distancetopreventdamagebothtothelineandtotankconnections.Considerationmaybegivento
installingspringsupportsneartotankconnectionforlargeborepipework.
Aslargediametertankshaveatendencytosettleontheirfoundations,provisionmustbemadeinthe
suctionandfillingpipingtotakecareoftanksettlement.Thismayrequiretheuseofexpansionjoints,
victauliccouplings,oralapjointflangeinstalledasshowninseebelowfigure.
Thefollowingnotemustbeaddedtoallpipingdrawingscontainingstoragetanks:
Allpipingmustbedisconnectedfromtankduringhydrostatictestofstoragetank
Thenumberofpipelinesintankcompoundsshouldbekepttoaminimum.Theyshouldberoutedinthe
shortestpracticablewaytothemainpipetrackslocatedoutsidethetankcompounds,withadequate
allowanceforexpansion.
Flexibilityinpipingsystemsmaybeprovidedthroughtheuseofbends,loopsoroffsets.Wherespaceisa
problemsuitableexpansionjointsofthebellowstypemaybeconsideredforinstallationinaccordance
withmanufacturersdesignspecificationsandguides.Theseexpansionjointsshouldbeusedonlyin
serviceswherethefluidpropertiesaresuchthatpluggingofthebellowscannotoccur.Theyshouldbe
anchoredandguided,shouldnotbesubjectedtotorsionalloads,andshouldbecapableofready
inspection.
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Tankfarmpipingshouldpreferablyberunabovegroundonconcreteorsteelsupports.Groundbeneath
pipingshouldbesogradedastopreventtheaccumulationofsurfacewaterorproductleakage.Manifolds
shouldbelocatedoutsidethetankbunds.

Pipingshouldpassoverearthbundwalls,however,ifthisisimpossible,asuitablepipesleevewillbe
providedtoallowforexpansionandpossiblemovementofthelines.Theannularspaceshouldbe
properlysealed.Likewiselinespassingthroughconcretebundwallswillbeprovidedwithpipesleeves.
Pedestrianwalkwaysshouldbeprovidedtogiveoperationalaccessovergroundlevelpipelines.
Pipelinesshouldbeprotectedagainstunevengroundsettlementwheretheypassunderroadways,
railwaysorotherpointssubjecttomovingloads.

Buriedpipelinesshouldbeprotectedexternallybycorrosionpreventingmaterials,orbycathodicmeans.
Routesofburiedpipelinesshouldbeadequatelymarkedabovegroundandrecorded.

Piperackscarriedacrosspathsorroadsshouldhaveadequateclearancefromgrade.Adequateaccess
stairwaysorladdersandoperatingplatformsshouldbeprovidedtofacilitateoperationandmaintenance
attanks.Tanksmaybeinterconnectedatrooflevelbybridgeplatforming.

Allnozzles,includingdrainsonatankshell,shouldhaveblockvalvesadjacenttothetankshellorasclose
aspracticable.

3.9TankBundCompoundCapacities
AbovegroundtanksforClassI,II(1),II(2)andIII(2)petroleumliquidsshouldbecompletely
surroundedbyawallorwalls.Alternatively,itisacceptabletoarrangethatspillageoramajorleakfrom
anytankaredirectedquicklyandsafelybygravitytoadepressionorimpoundingbasisataconvenient
location.
Thedistancebetweentheedgeoftheimpoundingbasinandthenearesttankortheinsidetopofthe
nearestbundwallshouldbeaminimumof30M.Thedistancebetweentheedgeofthebasinandroad
fencebatterylimitofaprocessplantshouldnotbelessthan15M.
Theheightofthebundwallasmeasuredfromoutsidegroundlevelshouldbesufficienttoafford
protectionforpersonnelwhenengagedinfirefightingandthewallshouldbelocatedsothatareasonably
closeapproachcanbemadetoatankfiretoallowuseofmobilefirefightingequipment.Accessroads
overbundwallsintoverylargecompoundsarehelpfulincertainfiresituations.
Separatewallsaroundeachtankarenotnecessary,butthetotalcapacityofthetanksinonebundedarea
shouldberestrictedtothefollowingmaximumfigures:

Singletanks Norestriction
Groupsoffloatingrooftanks 120,000m3
Groupsoffixedrooftanks 60,000m3
Notmorethantwotanksof
Crudetanks greaterindividualcapacitythan
60,000m3

Thefiguresforb.andc.maybeexceededforgroupsofnotmorethanthreetanks,wheretherecanbeno
riskofpollutionorhazardtothepublic.
Intermediatewallsoflesserheightthanthemainbundwallsmaybeprovidedtodividetankageinto
groupsofaconvenientsizesoastocontainsmallspillagesandactasfirebreaks.
Buried,semiburiedormoundedtanksneednotbeenclosedbyabundwallexceptwhentheyarelocated
ingroundhigherthanthesurroundingterrain.However,considerationshouldbegiventotheprovisionof
smallbundwallsaroundassociatedtankvalves.
Thenetcapacityofthetankcompoundshouldgenerallybeequivalenttothecapacityofthelargesttank
inthecompound.However,areductionofthiscapacityof75%willprovidereasonableprotectionagainst
spillageandmaybeadoptedwhereconditionsaresuitable(e.g.wheretherecanbenoriskofpollutionor
hazardtothepublic).Thenetcapacityofatankcompoundshouldbecalculatedbydeductingfromthe

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totalcapacitya.thevolumeofalltanks,otherthanthelargest,belowthelevelofthetopthecompound
wallandb.thevolumeofallintermediatewalls.

Alowwallwhichneednotbemorethan0.5mhigh,shouldbeconstructedforClassIII(1)and
unclassifiedpetroleumproducttankagewhereconditionsaresuchthananyspillageorleakagecould
escapefromtheinstallationandcausedamagetothirdpartypropertydrainagesystems,riversor
waterways.

WherethereisapossibilitythattanksstoringtheseproductsmaybeinthefuturerequiredforClassI,II
(1)orIII(2),thenthecompoundwallsshouldbesuitableforthispotentialsituation.

4.PumpAreas
Pumpswillbelocatedoutsidebundareas.Thevesselspracticeistogroupthepumpsintobays.Keepthe
suctionlinesasshortaspractical.Thedischargepipingwillrunonlowleveltrackstotheprocessor
loadingareas.Thesetrackswillusuallypassunderroadsinculverts,butmaypassoveronapipebridge.
Longpiperunsmayrequireexpansionloopstoprovideflexibility.Consultwithstresssection.

5.FireProtection
Forstorageareasthemajorfirefightingeffortwillbeprovidedbymobileequipmentlayingdownlarge
blanketsoffoamand/orapplyinglargevolumesofwaterforcoolingpurposes.
Itisessentialtoprovideagoodsystemofallweatherroadstofacilitatethetransferoffireprotection
materialsandequipmenttothesceneofthefire.Theseroadsmustbeofadequatewidthand,wherever
possible,withnodeadends.
Itisimportantinthesitingoftanks,bundwallsandaccessroadsthatthetankscanbeprotectedby
coolingwaterorfoamappliancessituatedoutsidethecompoundwalls.Accountmustbetakenofthe
heightofthetankandthepossibleneedtocooltherooforprojectfoamontoatank.
Dryrisersforfoammaybeprovidedtothetopofstoragetankswiththeirconnectionsadjacenttoaccess
roads,fixedmonitorsmayalsobeemployed.Theflowdiagramwilldefinethesystemtobeemployed.

6.RoadandRailLoadingFacilities
Roadandrailloadingfacilitiesareusuallyassociatedwithstoragearea.Thesafelocationofthesein
relationtostoragetanksislaiddowninsection3.7.
Theroadorrailcarwillbefilledfromaloadingisland,thesupplylineswillbeeitherroutedunderground,
oronanoverheadpipebridge.Checkforclearances.
Belowfiguresshowsuchinstallations.
Ithasbecomecommonpracticetoprovideavapourcollectionsystemforthesaferemovalofvapours
duringtheloadingprocess.Thissystemwouldemployunloadingarmswhichareconnectedtoacollection
systemandpipedtoaventstackatasafelocation.
Whenlayingoutaloadingareaconsiderationmustbegiventothenumberofvehiclesorrailcarsper
hourtobeloaded.Asuitablemovementpatternmustbeestablishedforincomingandoutgoingvehicles
orrailcars.Weighbridgeswillberequired,thesystemofmovingrailcarsmustbedefined,building
housing,operationofficesandfacilitiesfordrivesetc.,mustbeprovided.
Figures:
APITANKSIZEFORLAYOUTPURPOSE
BasedonAPI650

Capacity
Diameter Height
Approximately

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USBarrels CU Meters Meters

Meters

500 75 4.6 4.9

1.000 150 6.4 4.9

1.500 225 6.4 7.3

2.000 300 7.6 7.3

3.000 450 9.2 7.3

4.000 600 9.2 9.3

5.000 750 9.2 12.2

6.000 900 9.2 14.6

7.000 1050 12.2 9.9

9.000 1350 12.2 12.2

10.000 1500 12.8 12.2

12.000 1800 12.8 14.6

15.000 2250 14.6 14.6

20.000 3000 18.3 12.2

30.000 4500 22.3 12.2

40.000 6000 26.0 12.2

50.000 7500 27.5 14.6

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90.000 12000 36.6 12.2

100.000 15000 41.0 12.2

120.000 18000 41.0 14.6

140.000 21000 49.8 12.2

180.000 27000 54.9 12.2

200.000 30000 54.9 14.6

300.000 45000 61.0 17.0

450.000 60000 73.2 17.0

600.000 90000 91.5 14.6

800.000 100000 105.0 14.6

3NOINTERTANKSPACINGREQUIREMENTS
OTHERTHANFORCONSTRUCTION/OPERATION/MAINTENANCECONVENIENCE.TANKS
D1&D2ARETANKSWITHDIAMETERSGREATERTHAN10m.,&WITHDIAMETEROFD2
GREATERTHAND1.
Intertankspacingsbetweensmallandlargertanks.
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FLOATINGROOFTANKSOFDIAMETERD1D2D3GREATERTHAN10m.WITHINTHESAME
COMPUND.D1GREATERTHAND2&D2GREATERTHAND3.
Figure3.

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FIXED&FLOATINGROOFTANKSWITHINTHESAMECOMPOUND.D1GREATERTHAND2,
D2EQUALTOD3.
Figure4.

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Intertankspacingsforfixedandfloatingrooftanks(greaterthan10mdiameter)
LapjointFlangeDetailforTankSettlement
Figure5.

Foundationforverticaltank
BasedonBS2654
Figure6.

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Categories:PlantLayoutTags:designguide,plantlayout,StorageTanks

PlantLayoutColumn
March15,2012qdzungLeaveacomment

TableofContents

1.General
2.Layout
3.Internals
4.Overheads
5.Reflux
6.Feeds
7.Instruments
8.ReboilerConnections
9.Platforms
10.Piping
11.TopHeadReliefValves
12.Clips

1.General
Thefractionationcolumncomprisesaverticalcylinderinterspacedatequalintervalswithtrays.Often
theseareintheformofsimpleperforateddisks,butmorecomplexarrangementsoccurdependingupon
columnfunction.Contentsareheatednearthebottomproducingvapourswhichriseupthroughthe
trays,meetingaflowofliquidpassingdownasaresultofcondensationoccuringatvariouslevels.
Itisessentialtoensuremaximumsurfacecontactbetweenvapourandliquid.Thelightestfractionsare
drawnfromthehighestelevations,theheaviestresiduebeingdepositedatthebottom.

2.Layout
Itisnecessarytoestablishwhethercolumnisworkingasasingleunitorinconjunctionwithothers
similar.Dependentuponprocessarrangementsflowmaybesequentialfromonetothenext.Thusfor
maximumeconomyorderofcolumnsmustbearrangedtogiveshortestpipingrunsandlowestpumping
losses.Considerationshouldbegiven,wherenecessary,tomaterialused,sincealthoughcorrectsequence
mayhavebeeneffectedunnecessaryexpensemaybeinvolvedwithalloylines.Suchcasesmustbetreated
ontheirmerits.
Columnisinterconnectedwithotherprocessequipmentsoitmustbelocatedadjacenttopiperackto
allowpipingconnectionstoruntoandfromtherackinorderlyfashion.Automaticallythismeansthat
manways(providedforerectionoftraysandmaintenance)shouldbelocatedontheoppositesideofthe
columnawayfromtheracktoprovidesuitableaccessforequipmentrequiredtoberemoved(seebelow
figures).Thisisnotmandatorysinceoccasionsarisewhenotherarrangementsarenecessary.

3.Internals
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Havinglocatedmanways,orientateinternaltraystoensureunimpededaccess.Dependinguponthetype
oftrayusedoneormoredowncomerpartitionsmayberequired.Iftheseareorientatedincorrectlyentry
willbeimpossibleviamanholeunlessthecolumnisexceptionallylarge.Preferablydowncomersare
arrangednormaltomanwayaccesscenterline.Processconnectionscanbelocatedinlogicalsequence,
startingfromthetopwhentrayorientationisestablished.

4.Overheads
Highestconnectionistheoverheadvapourlinewhichisusuallyconnectedtoacondensingunit.Anairfin
typeunitmaybelocatedontopofthepiperack.Alternativelyashellandtubeexchangertypecondenser
isusuallylocatedonastructureadjacenttothecolumn(asmayairfinunit).
Overheadvapourconnectionmayprojectverticallyfromtopofthecolumnfollowedbya90bendorit
mayemergefromthesideat45,usinganintegralprojectionextendingupalmosttothecentertopinside
thehead(seebelowfigure9).
Thelatterismoreeconomicinpipingsinceiteliminatesuseofsomeexpensivefittingsespeciallywhen
largediameteroverheadlinesareinvolved.Italsomakespipingsupportingsimplerasuseofa45elbow
enablespipetorundownclosetothecolumn.Disadvantageisgreaterrigiditymakingstressanalysis
moredifficult.
Oftenpermittedpressuredropbetweenoutletnozzleandexchangerislow(i.e.approximately0.5PSI)
thusitisessentialtoobtainstraightestandshortestrunpossible.Ifconnectionisfromthetopspecial
arrangementsmustbemadeforsupportingthelinewhichisoftenlargediameter.
Thecondenserisusuallyselfdraining.Oftensomeofthecondensedliquidisrequiredtobepumpedback
intothecolumn(reflux).Thusthecondensedliquidflowsbygravitytoarefluxdrumsituated
immediatelybelowtheexchanger.Thisdrumcanalsobemountedinthesamestructuresupportingthe
exchanger.Thisisimportantsinceifitwerelocatedelsewhereanadditionalpumpwouldberequiredif
theliquidhadtobeelevatedagainafterflowingfromthecondenser.
Furthermore,sincetheliquidintherefluxdrumhastobereturnedtothecolumnbyapumpitis
convenienttolocatethisunderneaththerefluxdrumatthebaseofthestructure.
Itfollows,therefore,thattheorientationoftheoutletofthevapourconnectionwillautomaticallyfixthe
locationoftheexchangerandtherefluxdrumorviceversa.Therefluxpumpdischargesbackintothe
towerusuallyatahighelevation,andsincethepipingshouldbestraightandasshortaspossible,itwill
probablycomeupatthesideasthevapourconnection.

5.Reflux
Traysarenumberedstartingfromthetop.Thefirstdowncomeristhereforeanoddone.Oftenthereflux
connectionislocatedabovethetoptray(seebelowfigure3).Thismeansthatorientationoftheoddand
eventrayscanbefixedsincetoutilizethetraycontactsurface,therefluxconnectionmustoccuronthe
oppositesideofthedowncomer.

6.Feeds
Themostimportantconnectionsarethefeeds(seefigures4and6).Thesemayoccurovertheoddoreven
traysoracombinationofboth.Theirelevationallocationisentirelyafunctionofprocessdesign.
Dependinguponthis,orientationofthenozzlewillfollow,butensurethatthenozzleisnotlocatedbehind
thedowncomerfromthetrayabove.Thiswouldresultinaliquidbuildupinthedowncomerrestricting
flowthroughthetraybelowandpreventingcorrectoperation.
Feedconnectionsareusuallylocatedinthetrayareabetweenthedowncomersinamannertoensure
maximumuseofthetrayareaaspossible.Oftenaninternalfeedpipeorspargerisusedtofacilitatethis.

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7.Instruments
Instrumentconnectionsmustbearrangedsothatpressureconnectionsareinthevapourspaceand
temperatureconnectionsareimmersedintheliquid.
Sometimesitisbettertoputthetemperatureconnectionsinthedowncomerpartofthetraysincethe
depthofliquidwillbegreateranditwillbeeasiertoobtaineffectivecoverage.
Probelengthandmechanicalinterferencemaypreventthis,ifsolocatethermowelloverthetrayitself.
Thisshouldbedoneonlyoninstallationswheretheliquiddepthonthetrayissufficient(seebelowfigure
8).
Thebaseofthetowercontainsalevelofliquidwhichiscontrolledbyhighandlowlevelcontrollers,liquid
levelalarmsandlevelgauges(seebelowfigure7).Careshouldbetakenwhenorientatingthese
instruments,thattheydonotobstructaccessontheplatform.Physicalspacethattheseinstruments
occupycanbeexcessive.Donotpositionimmediatelyadjacenttoladdersormanholes.

8.ReboilerConnections
Reboilerliquidandvapourconnectionsarelocatedeitherrelevanttoliquidhead(elevation)orstress
requirements,orboth.Twoconfigurationsarepossible:

1.Vertical
2.Horizontal

Forhorizontalreboilers,considerationmustbegiventoshortestmostdirectconnectionroutetoreduce
pressuredropwhichwillprobablygoverndesignlayout.Inbothcasestheremaybesupportproblems.
Usually,averticalreboiler(thermosyphonoperated)offerstheeasiestsolution.
Flexibilityisobtainedonthelowerconnectionwhereentryintothebottomofthetowercanbevariedas
requiredandsupportproblemsaresimplified.

9.Platforms
Alloftheaboverequiresaccessofsomekind.Tominimisecostminimumplatformingshouldbeprovided
consistentwithsafety.
Orientationarrangementsshouldbedesignedtoavoidneedfor360platforms.
Aplatformshouldnotextendalmostentirelyroundthecolumnsimplytoprovideaccesstoatemperature
connectionwhichcouldhavebeenlocatedontheopositeside.Whereseveralcolumnsmaybeworking
together,linkplatformsmayberequiredtomovefromonetothenext.Inthesecasesstrictconsideration
mustbegiventomaximiseeconomy.
Overallheightisgovernedbya.numberoftrays,b.pumpNPSHrequirementsand,c.staticliquidhead.
Thislatterheadnecessaryforthermosyphonreboilerestablishestheskirtheight.

10.Piping
Somecircumstancesrequireroutinglinespartiallyaroundthecolumn.Shouldtheselinescrossaplatform
sufficientheadroomclearancemustbeprovided.

11.TopHeadReliefValves
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Reliefvalvesvaryinnumberandsize.Locationcandependonwhetherdischargeistoatmosphereora
closedsystem.Ifdischargingtoaclosedsystem,locateataconvenientplatformdownthecolumnabove
thereliefheaderseebelowfigure5).Ifdischargingtoatmospherelocateontopofthecolumn,withthe
openendofthedischargeaminimumof3000mmabovethetopplatform.Formaintenanceremoval,
valveshouldbelocatedtoallowtopheaddavittopickitup.Dependentuponsizemultiplereliefvalves
mayrequireagantrystructureonthetophead.

12.Clips
Earlyorientationofnozzlesandroutingoflinesallowplatformsandpipesupportcliplocationstobe
passedtocolumnvendorquickly.
Itisbecomingmorearequirementthatclipsbeweldedoninthevesselfabricationshopparticularlyfor
alloysteels.
Whenlocatingplatformsandladders,themaximumladderlengthshouldnotexceed9Mwithoutarest
platform.
Platformsshould,wherepossible,beelevated900mmbelowmanways.
ManwaysDavitsorhingesshouldbepositionedtoavoidswingofcoverfoulinginstrumentsorother
connections.
Whenpositioningverticalpiping,tosimplifysupporting,attainacommonbackofpipedimensionfrom
columnshellof300mm.

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Figures18Incl.

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Categories:PlantLayoutTags:column,designguide,plantlayout

PlantLayoutCompressors
March15,2012qdzung1comment

TableofContents

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1.Introduction
2.ReciprocatingCompressors
3.CentrifugalCompressors
4.Drives

1.Introduction
Compressorsarethemechanicalmeanstoincreasevaporpressure,aspumpsareusedtoincreaseliquid
pressure.
Therearetwobasictypesofcompressors,reciprocatingandcentrifugal.Eachhasonespecificdutyto
intakevaporatlowpressure,compressitanddischargeitatahigherpressure.Thequantityofvaporto
bemovedanddischargepressureitusuallythedecidingfactorinthetypeselected.

1.1Reciprocatingcompressors
Reciprocatingcompressionistheforceconvertedtopressurebythemovementofthepistoninacylinder.
Thesemachinearegenerallyspecifiedforlowervolumesthancentrifugalcompressors.Ifseveralstagesof
compressionareemployed,extremelyhighpressuresmaybedeveloped.Becauseoftheirreciprocating
actionthesemachinescausepiping,ifnotproperlydesignedandsupported,topulsate,vibrateand
generatefatigue.

1.2CentrifugalCompressors
Centrifugalcompressionistheforceconvertedtopressurewhenagasisejectedbyanimpellerat
increasingvelocity.Centrifugalcompressorsarespecifiedforlargequantitiesofvapor.Pressure
differentialmaybesmallorlarge.Thesemachinesarenotsubjecttopulsationandthereforedonot
producevibrationaleffects.

1.3CompressorDrives
Driversfallintothreecategories,i.e.electric,steamandgas.
Electricaldriversrangefromsmallflameproofmotorstolargemotors,2000HPormore,requiringtheir
owncoolingsystems.Steamdriversarecomprisedofsingleormultistageturbines,eitherfully
condensingofbackpressure.Gasdriverscovergasturbinesorgasengines.

2.ReciprocatingCompressors
2.1TypesofMachines
Reciprocatingcompressorscanbeobtainedinavarietyofpatternsfromasimplesinglecylinderto
multicylindermultistagemachines.Seefigure1,2,3forthemostwidelyusedpatterns.
Figure1belowisasinglecylindermachine.Itwilloperateatlowspeed,maybesingleordoubleacting.
Figure2isabalancedhorizontallyopposedmulticylindermachine.Itwilloperateatlowspeed,maybe
singleordoubleacting,itcanalsobemultistage.
Figure3isagasfuelledangletypeengine.Thecompressioncylindersareallononesideoftheframe,

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cylinderdiametersandlengthsvaryaccordingtothecomposition,pressureandvolumeofgastobe
compressed.Dimensionsfromframecenterlinetocylindernozzleswillvarywithcompressionforces.

2.2TypesofCylinders
Figure3.Gasenginedrivenmachine(note:gasenginemaytakeVform)
Figures4,5fordetailsofcylinderarrangements.
Figure4:singleactingcylinder,havingonesuction,compressionanddischargeareapercylinder.
Figure5:doubleactingcylinder,havingtwosuction,compressionanddischargeareaspercylinder.
Multicompressionstages:numberoftimesthevaporiscompressedbygoingthroughaseriesof
compressioncylinderstoincreasepressure.
Gascompressionraisestemperature.Inareciprocatingmachine,compressionisviolentandheatriseis
great.Inlettemperaturesof40oCmayberaisedtoover100oCbytheactofcompression.Thecylinder
getshotanddependingonthevaporbeingcompressed,willneedsomeformofcooling.Thiswillusually
beintheformofcoolingwater,butforlowheatincreasesaglycolfilledjacketmaysuffice.

2.3CompressorFoundation,CylinderandSnubberSupports
ThefoundationforLPreciprocatingcompressorsmustbeindependentfromallotherfoundations.It
mustsupportthecompressorandallitsauxiliaryequipment.
Cylindersupportsaresuppliedbythevendoriftheyarerequired.
Theymustbeattachedtothefoundationconcrete.Likewisethesnubbersupportsmustbeattachedtothe
foundationconcrete,springswillbeusedlocallytosupportthesnubbers.

2.4CompressorLayout
Effectivecompressorlayoutresultsincostsavingsonprocessandutilitypiping,goodmaintenance
accessibilityandpossiblyreducedpulsationinsuctionanddischargepiping.Poorlayoutdoesthe
opossite.
SeebelowfigureTYPICALLAYOUTOFCOMPRESSORHOUSE&SUCTIONKNOCKOUTDRUM
Forangletypecompressors,locatethecrankshaftparalleltothesuctionanddischargeheaders.For
balancedhorizontallyopposedcompressors,thecrankshaftshouldrunatrightanglestothesuctionand
dischargeheaders.Compressorhousescontainingmorethanonemachine,particularlyiftheyarelong,
willprobablybeequippedwithatravellinggantrycranewhichwillbemanuallyorelectricallyoperated.
Thisfeaturecaninfluencetheoveralldimensionsofthehouse,asinadditiontothenecessarybuilding
andmaintenanceclearances,theverticalreactionsoftheloadedcranewillincreasefoundationsize.Since
thesemustnotbeconnectedtothemachinefoundations,thebuildingsizewillbeaffected.Itisusualfor
compressorvendorstoindicatetheoverallfoundationdimensionsontheirlayoutdrawings.(Theseshould
berequestedasearlyaspossible).
Thecompressorbuildingmustbesizedveryearlyinthelayoutstagewhenonlypreliminarydimensions
areavailable.Itmaybeknownthattheoveralllengthofthemachineis6metersandthewidthis4
meters.Tothesedimensionsmustbeaddedadequateclearanceformaintenancepluspossiblecontrol
valvestations,lubeoilequipment,localcontrolpanel,etc.Allow2metersallaroundtheoriginal
dimensions.Inpracticethis2meterallowancewillprovideawalkwayofonly12001500mmdueto
otheritemsoccupyingfloorspace.Withtwoormoremachines,allow2metersbetweencompression
cylinderstoallowforadequatepistonremoval.Alldimensionsmustbeconfirmedfromcertifiedvendor
drawings.
Allowamaintenanceareaatoneendofthebuilding.A6meterbayshouldbesufficient.Pits,trenches
andsimilargastrapsshouldbeavoidedingascompressorhouses.Largereciprocatinggascompressors
willusuallybeelevatedabovegradewithmezzaninefloorlevelwiththetopofthefoundationfor
operationandmaintenance.Theheightofthemezzaninefloorabovegradewillbekepttoaminimum
consistentwiththeadequacyofspaceforpipingandaccess,especiallytovalvesanddrains.
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2.5PipingLayout
Thepipinglayoutwillfollowtheplowdiagramsasissuedforthejob.Iftheyconflictwithanyofthe
followingnotes,theflowdiagramswillalwaystakeprecedence.Itisusualforthesuctionpipingtobe
routedtothetopofthecylinderanddischargepipingfromthebottom.Liquidsmustbepreventedfrom
enteringthecompressors.Asliquidsdonotcompress,extensiveprecautionsmustbetakentoensurethat
absolutelynoliquidentersthecompressorcylinderasmallquantitywoulddoextensivedamage.
Ifthereisanydoubtthatthevaporisnearitsdewpoint,thesuctionlinemustbesteamtracedbetween
thesuctiondrumandthecompressorinletorlocaltothecompressorinlet.ProcessDepartmentwill
advisetheextentanditwillbeshownontheflowdiagram.
Suctionanddischargeheaderswillbelocatedatgradelevelonsleepersuptothefirstpieceofconnecting
equipment,e.g.suctionKOdrumoraftercooler.Branchconnectionstothecompressorfromthesuction
headerwillbetakenfromthetopoftheheader.Suctionanddischargepipingwillbekeptasstraightas
possiblebetweenthecompressorsandheaders.Theuseofshortradiusbendsorteesandsimilar
installationsgivingopposedflowshallnotbepermitted.
Pipingshallnotbelessthancompressornozzlesize.Pipinglocaltocylindersshallclearthecylinderby
sufficientdistancetopermitpropermaintenanceonthecylindervalves.Whencompressorsareelevated
withamezzaninefloor,pipingandvalveswillnormallyrununderthefloor.
Whenmorethanonecompressorisemployedonthesameservice,allpipingtoandfromthecompressors
willbevalvedsothatanycompressormaybeshutdownandtakenoutofservice.Spectacleblindeswillbe
installedatthecompressorsideoftheisolatingvalves.
Startupbypassesaretobeinstalledbetweensuctionanddischargepipesofcompressorsandwillbe
locatedbetweenthecompressorandthelineblockvalve.Whennotfurnishedbythemanufacturer,a
reliefvalvewilltakebeinstalledbetweenthecompressordischargeandblockvalve.Thisreliefvalvewill
dischargeintothesuctionlinedownstreamoftheblockvalve.Thereliefvalvewillbeprovidedwitha
bypassforhandventing.
Distancepieceandpackingventpipingwillbemanifoldedintosystemsasindicatedontheflowdiagrams.
Thesesystemsareeitherventedtoatmosphereoutsidethecompressorhouseorconnectedtoacollection
system.
Utilitypipingwillcomprisecoolingwatersupplyandreturntolubeoilcooleralsotocylinderjackets.The
minimumlinesizeusedwillbe3/4.Sufficientventsanddrainswillbeprovidedsothatwaterlinesand
jacketsmaybecompletelydrainedatshutdown.Asteamorelectricalsupplymayberequirediflubeoil
heatersareprovidedforeitherthecompressororgearboxoil.Thissystemisusedpriortostartup.
Checkforlinesthathavetobechemicallyandensuredrawingsindicatethisrequirement.

3.CentrifugalCompressors
3.1TypesofMachine
Centrifugalcompressorscanbeobtainedinavarietyofpatterns.Seefigure8.CentrifugalRadial
Compressor
Centrifugalradialcompressors(figure8):thecompressionprocessiseffectedbyrotatingimpellersof
radialflowdesign(figure9RadialImpellor)infixedguideelements.
Centrifugalaxialcompressors(figure10):theforceisconvertedintopressurebyrotatingvanesbetween
fixedguidevanestheflowisaxial.

3.2SizeandPositionofNozzles
Centrifugalcompressormanufacturershavebasiccasedesignstheychangetherotorbladedesignto
meetvolumeandpressurerequirements.Forthisreasonsuctionnozzlesaresometimesmuchlargeror

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smallerthanthelinesizeforhydrocarbonprocessapplications.Forexample,a30suctionnozzlemay
havea20or24suctionline.Itwillbenecessarytoincreasethesuctionlinediameterlocallyatthe
compressornozzle.Donotuseareducingflangeasthiswillintroducefullvelocitytotherotorbladesata
turbulentcondition.Use30flangeandaconcentricreducerasaminimum.Itisbetterifapipelengthof
3diasof30pipecanalsobeaccommodated.
Suctionanddischargenozzlesareeitherontheundersideorthetopofthecompressor.Onmultistage
compressorstwoormoreinletnozzlesmaybeprovidedthesuctionlinesareconnectedtosuctiondrums
controlledtomaintainthevariousinletpressures.

3.3CompressorFoundations
(Seefig.10Centrigfugalaxialcompressors)
Thefoundationofeachmachinewillbecombinedwithitsdirectcoupleddrivesbutmustbeindependent
fromallotherfoundations,includingthelubeconsole.

3.4CompressorLayout
(Seefig.11,12,13below)
Centrifugalcompressorsareusuallylargecapacitymachines.Theyaredrivenbyelectricmotors,steam
orgasturbine,thedrivemaybeviaagearbox.Itisusualtomountsuchmachinesonatabletopabout4
metershighwithelevatedaccessallaround.Thelubeandsealoilconsolesforboththecompressorand
turbine,ifused,willbelocatedatgrade.Thesuctionanddischargeconnectionsofthecompressorwill
mostlikelybeontheundersidetheselinescanbeanchoredatgrade.Shouldtheseconnectionsbeonthe
topofahorizontallysplitcasecompressor,seefig13fordetailsofremovablespools.
Atypicalcompressorhouselayoutisshowninfigures11and12.Hereanelectricalmotoranda
condensingtypeturbinehasbeenused.Notethewithdrawalandmaintenanceareas,alsotheacoustic
hoods.Determinethetypeoftravellinggantrycrane,andensurethatpiping,etc.isclearofit.Notethe
lubeoilheadertanks,thesemustbeelevatedabovethemachines,ifthevendorhasnotstatedaminimum
elevationuse10metersabovethecenterlineofthemachines.
Theirpurposeisforemergencylubrication,andaretrippedinshouldthenormallubricationsupply
systemfail.Theysupplyoiltothebearingsuntilthemachinecomestoastandstill.
Thelubeandsealoilconsolesarecomprisedofthefollowingitems:oilstoragetank,filters,pumps,oil
cooler,sometimesanoilheaterforstartup,controlinstruments.
Interconnectingpipingmustbeinaccordancewiththeflowdiagram,allreturnlinesmustbefree
drainingfromthemachinestotheconsole.
Suctionanddischargepipingmustbesupportedsothatthenozzlesarenotoverloaded,usereducersnot
reducingflangelocaltosuctionanddischargenozzles.Makeprovisionforremovalofstrainersintheinlet
line.Silencersmayberequiredinboththesuctionanddischargepiping.
Acoustichoodsmayberequiredforboththecompressorandturbineensurethatthetabletopislarge
enoughtoaccommodatethem.Theymaybeofsectionalconstruction.Thetravellinggantrycranewillbe
usedtodismantlethemthismustbetakenintoconsiderationwhendeterminingtheelevationofthecrane
hook.
Maintenanceareamustbelargeenoughtoaccommodatetheacoustichood,turbineandcompressorhalf
casingrotors,etc.

4.Drives
4.1ElectricalMotors

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FlameproofmotorswillbeemployedforsmalltomediumHPmachines.
Ensurethatthecablescanberoutedtotheterminations,alsothatthereisspacebehindthemotorto
removetherotor.
LargeHPmachinestheirowncoolingsystemsthesefallintotwocategories:CACW(closeaircircuit
watercooledmachine)orCACA(closedaircircuitaircooledmachine).Thesetypesofmachines
mayrequireanareaof7mx7mand,therefore,determinethesizeofthecompressorhouse.
CACWmachines(seefig.14):maybemountedonatabletopwiththecoolerlocatedunder,inasealed
room.Thecoolingaircirculatingaroundthemotorisitselfcooledbywatercooledheatexchanger.
Provisionmustbemadeforremovalandserviceoftheexchanger.
Itispossibletoobtainmotorswiththecoolermountedaboveortoonesideofthemotor.
CACAmachineconsiderationmustbegivenregardingthesafelocationoftheairintake,whichwillbe
outsidethecompressorhouse.Ifafilterisrequiredintheintakesystem,provideaccessforreplacement
orcleaning.

4.2SteamTurbines
Twotypesofsteamturbinesmustbeconsidered,condensingandnoncondensing.Thenoncondensingtype
useshighpressuresteamandexhaustslowerpressuresteamtoastreamheader.Thecondensingturbine
exhauststoasurfacecondenser(whichisusuallyalargeexchangerwithhotwellattached,butmaytake
theformofanairfan)torecovercondensate.Surfacecondensersareoftengrademounteddirectlybelow
thecompressorsturbine.Thisarrangementemploysaturbinewithoutletnozzledirectlyconnectedviaan
expansionjointtothesurfacecondenser.(Seefig.16).Thesurfacecondensermaybemountedatgrade
alongsideagrademountedturbine.WitharrangementverylittleNPSHisavailable.
Ifanairfanisusedasasurfacecondenseritwillusuallybelocatedabovetheturbine,eitheronthe
compressorhouserooforoverapiperack.Ifthecondenseristheshellandtubetype,itwillmostlikely
beofthefixedtubeplatedesignandwillrequireaccessforroddingthetubes.Thecoolingwaterlines
associatedwiththecondenserarelargeboreandsomeconsiderationmustbegiventothepiping
arrangementandplacingofvalvestogivegoodoperationandutilizationofplotspace.
Thesteamsupplytotheturbinewillbetakenfromthetopofthesteamheader,abellowmayberequired
localtotheturbineandatemporarystrainerwillbeusedforstartup.
Theturbinewillrequiredasimilarlubeoilconsoletothatprovidedforthecompressor.Donotpocketthe
returndrains.Anelevatedlubeoilheadertankalsoberequired.
Noncondensingturbineassembliescompriseaturbine,lubeoilconsoleandheadertank.Thelowpressure
steamdischargelinewillbealargebore,abellowwillmostlikelyberequiredintheline,whichmustjoin
thetopoftheheader.Ifthelinehasalowpoint,asteamtrapanddrippocketmustbeprovided.
Maintenanceaccess:provisionmustbemadetodismantletheacoustichood,andremovehalfofthe
turbinecasingandtherotor.

4.3GasTurbines
Whenusingagasturbinetodriveacompressor,asimilararrangementtoasteamturbinecanbeused
thelubeoilconsoleandheadertankswillberequired.Inaddition,theexhaustsystemmustbe
consideredthiswillbecomprisedofductingtosomeheatrecoverysystem,eitherasteamraisingplantor
processheaters.
Combustionairtotheturbineburnermustbetakenfromasafelocationoutsidethecompressorhouse.
Inletsilencerandfilterwillmostlikelyberequired.Provisionforoperationandmaintenancetoall
machinerymustbeprovided.

4.4GasEngines
Gasenginesareusedtodrivereciprocatingcompressors,eitherdirectlyorthroughagearbox.The
machinemayhavebothcompressionanddrivecylinderattachedtoacommoncrankshaft.Thesetypesof
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enginesmaydevelop2,000HPormore.Ensurethatadequatespaceisallowedforremovalofcylinder
headsandpistons.Thelubeoilsystemmaybeintegralwiththeenginethatorintheformofaconsole.
Shouldthelatterbeused,ensurethattheengineisatsuitableelevationtoallowforfreedrainingoil
returnlines.(seefig.17)

Theengineandcompressorwillbemountedonacommonfoundationthatisindependentofallother
foundations.Duetothevibrationproducedbythesemachines,alargemassconcretefoundationwillbe
employed.

Thegenerallayoutofthecompressorhousewillenabletheuseofatravellinggantrycraneforall
maintenance,thereforewhenroutingpipingthismustbeconsidered.Itisnotlikelythatamezzaninefloor
willbeemployedlocaltothemachines,enablingmostofthepipingtobekeptlow.

Combustionairmustbetakenfromasafelocationoutsidethecompressorhouse.Ifanairfilterwillbe
required,arrangeformaintenanceaccess.Likewise,theexhaustmustbedischargedoutsidethebuilding.
Thissystemwillbefittedwithasilencerandflametrap.Utilitysystemswillcompriseastartupair
system,alsofuelgas.Theenginewillmostlikelyhaveaclosedcircuitjacketwatercoolingsystem.

Thiswillcompriseashellandtubeexchangeroranairfan.Iftheformer,coolingwatersupplywillbe
requiredandtheusualclearancefortubepulling,etc.willbeprovided.(seefig.18).

Figuresincl.

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Figure6:DETAILOFFOUNDATION
&SUPPORTFORCYLINDER&SNUBBERS

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Figure7:TYPICALLAYOUTOF
COMPRESSORHOUSE&SUCTIONKNOCKOUTDRUM

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FIG.11TYPICALLAYOUTFOR
COMPRESSORSONETURBINEDRIVENONEELECTRICMOTORDRIVEN

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Categories:PlantLayoutTags:Compressors,designguide,plantlayout

PlantLayoutExchangers
March15,2012qdzungLeaveacomment

TableofContents

1.UseofExchangers
2.TypesofExchangers
3.TypesofShellandTubeExchangers
4.LayoutofShellandTubeExchangersinBanks
5.AlterationsThatCanBeMadetoShellandTubeExchangers
6.EstablishingElevationsofExchangers
7.Piping
8.LayoutofExchangersOtherThaninBanks
9.TypesofAirFins
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10.LayoutofAirFins
11.Piping
12.FinTubeExchangers
13.Chillers

1.UseofExchangers
Heatexchangerstransferheatfromonemediatoanother.Inthepetrochemicalindustry,theycanbe
generallyclassifiedunderthefollowingheadings:
Exchanger:Heatsonestreamandcoolstheother.Thereisnoheatlossandphysicalchangeineither
flowingmedia.
Cooler:Coolsliquidorgaseswithoutcondensationappliesalsotointercoolerandaftercooler.
Condenser:Condensesvapourorvapourmixture.Canbewatercooledorbysufficientlycoldprocess
streamwhichrequiresheating.
Chiller:Usesrefrigerantforcoolingprocessstreambelowfreezingpointorbellowprevailingcooling
watertemperature.
Heater(nonfired)Heatsprocessstreamgenerallyuptoitsboilingpointwithoutappreciable
vaporization.Heatingmediumisusuallysteamappliesalsotopreheaters.
Reboiler:Reboilsthebottomstreamoftowerforthefractionationprocess.Heatingmediumcanbesteam
orhotprocessstream.Whenlargequantitiesofvaporhavetobeproducedthekettletypereboilerisused.
Wasteheatboiler:Useswasteheat,suchasinternalcombustionexhaustfromgasturbinesorsimilar
driversforsteamgeneration.
Steamgenerator:Usesheatofprocessliquidorgasforproducingsteam.
Vapourizer:Vapourizespartofaprocessliquidstreamasdoesanevaporator.

2.TypesofExchangers
Briefly,exchangers,etc.,canbedividedintothefollowingthreegroups:
Shellandtube:Whichcanbeverticalorhorizontalwiththehorizontalonessingleorstackedinmulti
units.Asthenamesuggests,theyconsistofacylindricalshellwithanestoftubesinside.
Fintube:Thisconsistofafinnedtubethroughwhichpassesonemediajacketedbyanothertubethrough
whichpassestheothermedia.Theycanbeusedassingleormultiunits.
Airfins:Comeintwoshapesflatboxunitsandaframeunits.Bothconsistofbanksoffinnedtubes
throughwhichpassesthemediatobecooled.Largefansblowairfromatmospherethroughthebanks,
thuscoolingtheflowingmedia.Thereareothertypes,suchasplateexchangers,carbonblockexchanger,
etc.,buttheseareusedinfrequently.

3.TypesofShellandTubeExchangers
Floatingheadexchangersareusedwhenthemediabeinghandledcausesfairlyrapidfouling,andthe
temperaturecreatesexpansionproblems.Tubescanexpandfreelychannelheadandshellcover
arrangementisconvenientforinspection,andthetubebundlecaneasilyberemovedforcleaning.
Utubeexchangersareusedwhenfoulingofthetubesontheinsideisunlikely.Thetubesarefreeto
expandandthebundlecanberemovedfromtheshellforcleaningontheshellsideoftubes.
Fixedheadexchangershavenoprovisionforthetubeexpansionandunlessashellexpansionjointis
providedcanonlybeusedforrelativelylowtemperatureservice.
Theendcoversareremovablesothattheinsideofthetubescanbecleanedbyroddingorothersimilar
tools.Thistypeofcleaningisusuallycarriedoutinsitusosomespaceshouldbeallowedinthepiping
layouttoallowforthis.

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4.LayoutofShellandTubeExchangersinBanks
Forgoodmaintenanceandsafeworkingconditions,itisnecessarytospaceexchangerssuchthat
surroundingareaisadequateandclear.Theymaybespacedapartandgroupedinpairs.Whenapart,a
clearaccesswayof750mmisconsideredadequate,thisbeingtheclearspacebetweentheshellsand/or
theassociatedpipeworkandinsulation.Forpairedexchangersasimilarconditionisrequiredbetween
pairsandadjacentsingles,butbetweeneachshellofthepairthismaybereducedto450mmbetween
headflanges.Exchangersshouldalwaysbearrangedsuchthattheideallythereisaminimumof150mm
clearattherearforremovalofthebonnetandspaceprovidedfordroppingitclearoftheworkingarea.
Atthefrontorchannelend,aminimumdistanceofthetubelengthplus2500mmisconsideredgood.This
latterdoesnotofcourseapplytoexchangerslocatedinstructureswereatotalof1500mmwouldbe
sufficient.
Pipingconnectedtoheatexchangersisgenerallysimple.Pipingeconomyandgoodengineeringdesign
dependlargelyonknowingwhatalterationscanbemadetoexchangers.Inotherwords,thepiping
designercaninfluencetheexchangerdesign.Forexample,thedirectionofflow,nozzlelocations,etc.
Alterationstoexchangersofcourse,shouldnotaffecttheirdutyandcost.
Moneysavedonsimplerpipingshouldnotbespentoncostlyalterationstoexchangers.The
accompanyingchartshowsthepossiblealterationsthatmaybeinstigatedbythepipingdesignersto
typicalshellandtubeexchangerswithoutaffectingthethermaldesign.Whencontemplatingsucha
changeitshouldberememberedthatgenerallytheheatedmediashouldflowupward,andthecooled
mediaflowdownward.Thisisparticularlyimportantifthereisaphysicalchangetakingplacewithinthe
exchanger,suchasvaporizationorcondensation.Typicalexampleofthisare:
Reboilerswheretheprocessstreamenterstheshellatthebottomsasaliquidandleavesatthetopasa
vapourafterflowingthroughthetubes,andstreamenterstheshellnearthetopofthetubesandleavesat
thebottomontheshellascondensate.
Condenserswheretheprocessstreamenterstheshellatthetopasavapourandleavesthebottomasa
liquid,whilstcoolingwaterentersthetubessideatthebottomandleavesatthetop.

5.AlterationsThatCanBeMadetoShellandTube
Exchangers
Interchange,flowingmediabetweenthetubeandshellside.Thischangeisoftenpossible,moresowhen
theflowingmediaaresimilar,forexample,liquidhydrocarbons.Preferablythehottermediashouldflow
inthetubesidetoavoidheatlossesthroughtheshell,orthenecessityforthickerinsulation.
Changedirectiononflowoneithertubeorshellside.Onmostexchangersinpetrochemicalplants,these
changesarefrequentlypossiblewithoutaffectingtherequireddutyoftheexchangerifthetubesarein
doubleormultipassarrangementandtheshellhascrossflowarrangement.
Inexchangerswherecounterflowconditionscanbearranged,changingofflowdirectionshouldbemade
simultaneouslyintubeandshell.Somepointstoconsiderwhencontemplatingaflowchangeare:
Shellleakage:Whenwatercoolinggases,liquidhydrocarbonsorotherstreamsofdangerousnatureitis
bettertohavethewaterintheshellandtheprocessinthetubes,sinceanyleakageofgas,etc.,will
contaminatethewaterratherthanleakingtoatmosphere.
Highpressureconditions:Itisusuallymoreeconomicaltohavehighpressureinthetubesthaninthe
shellasthisallowsforminimumwallthicknessshell.
Corrosion:Corrosivefluidsshouldpassthroughthetubes,thusallowingtheuseofcarbonsteelforthe
shell.
Fouling:Itispreferabletopassthecleanstreamthroughtheshellandthedirtythroughthetubes.This
allowsforeasiercleaning.Mechanicalchanges,suchastangentialorelbowednozzlescansometimes
assistsinsimplifyingthepipingorloweringstackedexchangers.

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6.EstablishingElevationsofExchangers
Whereprocessrequirementsdictatetheelevation,itwillusuallybenotedonthePandIdiagram.
Fromtheeconomicpointofview,gradeisthebestlocation,whereitisalsomoreconvenientforthetube
bundlehandlingandgeneralmaintenance.Exchangersarelocatedinstructureswhengravityflowis
requiredtothecollectingdrum,orwheretheoutletisconnectedtoapumpsuctionwhichhasspecific
NPSHrequirements.Toelevateexchangerswithoutspecificrequirements,thefollowingprocedureis
recommended:
Selecttheexchangerwiththelargestbottomconnectionaddtothenozzlestandoutdimension(center
lineofexchangertofaceofflange)thedimensionthruhubofflange,elbow(11/2dia),onehalftheO/S
pipediameterand300mmforclearanceabovegrade.
Nowsubtractthecenterlinetoundersideofsupportdimensionfromabove,andthedimension
remainingisthefinishedheightofthefoundationincludinggrout.
Itispreferableifthisfoundationheightcanbemadecommonforalltheexchangersinthebank.Ifthisis
impracticableduetoextremesofshelland/orconnectionpipesizes,thenperhapstwoheightscanbe
decidedupon.
Whenstackingexchangers,twoorthreehigh,itisdesirablethatoverallheightdoesnotexceed120
(3650mm)duetotheproblemofmaintenance,bundlepulling,etc.

7.Piping
Planwisetheexchangerbankshouldbelaidoutspacedasnotedpreviously,andallthechannelnozzles
onacommoncenterline.
Thisisparticularlyimportantifthecoolingwaterheadersareunderground,astheCWinletscanrise
intothelowerchannelnozzles.
Theendoftheexchangeradjacenttotherackwillnormallybethefixedend,iftheCWheadersare
undergroundthefixedendwillbecomethechannelend.
AllchangesproposedmustbediscussedfullywithProcessEngineerandClientEngineerorVessel
Department.
Linesturningrightintheyardshouldberightfromtheexchangercenterlineandthoseturningleft
shouldapproachtheyardonthelefthandsideofexchangercenterline.Linesfrombottomconnections
shouldalsoturnupontherightortheleftsideofexchangersdependinguponwhichwaythelineturnsin
theyard.Lineswithvalvesshouldturntowardstheaccessaislewithvalvesandcontrolvalvesarranged
closetoexchanger.Utilitylinesconnectingtoaheaderintheyardcanbearrangedonanysideof
exchangercenterlinewithoutincreasingpipelength.
Accesstovalvehandwheelsandinstrumentswillinfluencepipingarrangementaroundheatexchangers.
Valvehandwheelsshouldbeaccessiblefromgradeandfromaconvenientaccessway.Theseaccessways
shouldbeutilizedforarrangingmanifolds,controlvalvesandinstruments.
Inthepipingarrangement,provisionfortuberemovalaccessshouldbeprovided.Thismeansaspool
pieceofflangedelbowinthepipelineconnectingtothechannelnozzle.
Therequirementsofgoodpipinglayoutgenerallyapplytothedesignofheatexchangerpiping.The
shortestlinesandleastnumberoffittingstemperaturepermittingwillobviouslyprovidethemost
economicalpipingarrangement.Thedesignershouldavoidloops,pocketsandcrossovers,andheshould
investigate,nozzletonozzle,thewholelengthofpipingroutedfromtheexchangertosomeother
equipment,aimingtoprovidenotmorethanonehighpointandonelowpoint,nomatterhowlongthe
line.
Veryoftenaflatturnintheyard,analternativepositionforcontrolvalvesormanifold,changednozzle
locationontheexchanger,etc.,canaccomplishthisrequirement.
Avoidexcessivepipingstrainsonexchangernozzlesfromactualweightofpipeandfittingsandfrom
forcesofthermalexpansion.
Forvalvesandblindesthebestlocationisdirectlyattheexchangernozzle.Inthecaseofanelbownozzle
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onanexchangeritshouldbecheckedthatsufficientclearancesareprovidedbetweenvalvehandwheel
andoutsideofexchanger.Elevatedvalvesmayrequireachainoperation.Thechainshouldhangfreelyat
accessiblespotneartheexchanger.

Belowfigureshowssketcheshighlightingexchangerpipingdetails.Orificeflangesinexchangerpipingare
usuallyinhorizontalpiperuns.Theselinesshouldbejustaboveheadroom,andtheorificeitselfaccessible
withmobileladder.Orificesinaliquidlineandmercurytypemeasuringelementrequiremoreheight.At
gaslinestheUtubecanbeabovethelinewithorifice,consequentlytheheightisnotcritical.Lineswith
orificeflangesshouldhavethenecessarystraightrunsbeforeandaftertheorificeflangesrequiredin
specificationorstandards.
Locallymountedpressureandtemperatureindicatorsonexchangernozzles,ontheshellorprocess
lines,shouldbevisiblefromtheaccessaisles.Similarlygaugeglassesandlevelcontrollersonexchangers
shouldbevisibleandassociatedvalvesaccessiblefromthisaisles.Whenarranginginstrument
connectionsonexchangerssufficientclearancesshouldbeleftbetweenflangesandexchangersupport
betweeninstrumentsandadjacentpiping.Insulationofpipingandexchangersshouldalsobetakeninto
account.

8.LayoutofExchangersOtherThaninBanks
Processequipmentinmostplantsisarrangedinthesequenceofprocessflow.However,whateverlayout
systemisused,thegeneralevaluationregardingexchangerpositionsisverysimilar.
Inlayoutthefractionationtowersshouldbelocatedinpropersequencefirst,althoughoftenthe
arrangementofotherequipmentforexample,condensersdependdirectlyuponthetowerorientation,
andsometimesthedecisionwhethertouseastructureornotdependsuponthis.Thisrelativepositionof
exchangerscanbereadilyevaluatedfromflowdiagrams.Forexchangerpositionsinapetrochemical
plantthefollowinggeneralclassificationcanbemade.
Exchangerswhichmustbenexttootherequipment.Suchexchangersarethereboilerswhichshouldbe
locatedtotheirrespectivetowers,orcondenserswhichshouldbenexttotheirrefluxdrumsclosetothe
tower.
Exchangerswhichshouldbeclosetootherprocessequipment.Forexample,exchangersinclosedpump
circuitssuchassomerefluxcircuits.Overheadcondensersshouldalsobeclosetotheirtowertoensure
thatthelinepressuredropinminimal.Incaseoftowerbottomdrawoffexchangerpumpflow,
exchangersshouldbeclosetothetowerordrum,togiveshortsuctionlines.
Exchangerslocatedbetweendistantitemsofprocessequipment.Theseareforexample,exchangerswith
processlinesconnectedtobothshellandtubeside.Whereparallelrunistheideallocationforthistypeof
exchanger.Onthatsideoftheyard,wherethemajorityofrelatedequipmentisplaced.Otherlocations
willcostmoreinpiperuns.
Exchangerslocatedbetweenprocessequipmentandtheunitlimit.Suchexchangersareforexample
productcoolers.Thesearefrequentlylocatedneartheunitlimit.
Stackedexchangers.Afurtherstepinthelayoutistoestablishwhichexchangerscanbestackedfor
simplifyingpipingandsavingplotspace.Mostunitsinthesameservicearegroupedautomatically.Two
exchangersinseriesorparallelareusuallystacked.Sometimes,smalldiameterexchangersinseriescan
bestackedthreehigh.Twoexchangersindissimilarservicescanalsobestacked.Sufficientclearance
mustbeprovidedforshellandchannelsidepipingbetweenthetwoexchangers.Reboilersandsingle
condensersusuallystandbythemselvesbesidetheirrespectivetowers.Verticalthermosyphonreboilers
areusuallyhungfromthesideoftheirassociatedtower.

9.TypesofAirFins
Therearetwotypesofairfinconstruction:theboxtypeandtheAframetype.
Theboxtypecanbedividedintotwoforms:forceddraughtandinduceddraught.
Forceddraftairfinsarethemostcommonlyusedtype,possiblybecausemaintenanceofthefaniseasy
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fromanunderslungplatform.

Aframetypeairfinslesscommonthantheboxtype.

Theyoffertheadvantageofrequiringlessplotareathanboxtypeairfinsofthesamecapacity.Theydo,
however,presentafewproblems.Duetophysicalshapeofthem,i.e.triangularsectionwiththeapex
uppermost,theinletheaderislocatedattheapex,withthecollectingheadersatbothbottomcorners.
Thismeansthatcooledproductlinesarecomingoffbothsidesoftherackwhichcanpresentpiping
problems.Also,with60osidescontainingtheproduct,itispossibletogetunevencoolingduetothesun
beingononeside,ortheprevailingwindtendingtoblowintothetubebankagainstthefan.

10.LayoutofAirFins
Airfinsarelargecomparedwithshellandtubeexchangers,anditisnotuncommonforthemtooccupy
severalthousandsquarefeetofplotareaonaunit.
Ifthisplotareaisrequiredatgrade,therecouldwellbesitingproblems,butfortunatelymostprocess
usingairfinsrequireagravityfeedthroughthem,whichmeanstheymustbeelevated.
Themostcommonsatisfactorylocationisontopofthemainpiperack.Piperackwidthisinvariably
determinedbytubelengthofairfinunits.Intheabsenceofsufficientroomontherack,theymaybe
locatedontopofanysuitablestructure,oranelevatedstructuremaybebuiltforthepurpose.
Whenlocatingairfinsontheplotanumberofpointshavetobeborneinmind.
Airfinofagivencapacitycouldbemadeupofseveralunitseachweighingseveraltons.
Itisimportantthateachunitbereachedbythesitecraneforerectionandmaintenancepurposes.
Therefore,theoverallplotlayoutmustprovideforthiscraneaccess.
Asmostairfinswillbecondensingoverheadsfromtowers,itisimportanttoconsidertheexplanation
problemsoftheoverheadlinewhensitingtherelevantairfin,asairfinsareunsuitableforacceptinghigh
loadsonthenozzles.
Accessplatformsarealwaysprovidedeithersideoftheairfinforaccesstotheheaderboxes,and
underneaththeunitsforaccesstofansandmotors.Provisionmustbemadeforgradetoallthese
platformsatleastateitherend.
Itisagoodideatoinvestigateconnectingtheseaccesswaystoadjacentstructurestoprovideintermediate
escapeandforoperationalconvenience.

11.Piping
Therearefourmajorproblemswhenpipingupairfins:

1.Correctconfigurationsofpipingtogiveequalorasnearequaldistributionaspossibleoftheproduct
througheachunitofmultiunitairfins.
2.Makepipingfromtoweroverheadasshortaspossibletominimizepressuredrop.
3.Obtainingapipingsystemthatissufficientlyflexibletoavoidoverloadingtheunitnozzles.
4.Providingsufficientlysuitablepipesupportsandanchors.

Belowfigureshowsdiagrammaticallythreemethodsofpipingfordistribution:

1.Showinggooddistribution
2.Showinggooddistribution
3.Showingbaddistribution

Whendesigningthepipingforairfinexchangers,thebasicrulesofpipingstillapply,thatthepipingruns
shouldbeasshortanddirectaspossible,butatthesametimebesufficientlyflexibletoavoidoverloading
theairfinnozzles.Thebelowfigureshowstwomethodsofrunningproductheaderstoairfins:
Byrunningtheinletheaderdownthecenteroftheunits,theofftakestotheunitdropoutofthebottom

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oftheheader,runacrosstheunitsanddropintothenozzles.

Thus,wehaveaseriesofofftakessufficientlylongtoabsorbexpansion,atthesametimehavingthe
minimumofelbowsresultinginminimumpressuredrop.

Supportscanusuallybeattachedtothesteelmembersthatrunbetweenunitsandarethusshortand
minimal.Theheadermustbeflangedatintervalsalongitslengthtofacilitatetheremovalofunitsby
craneformaintenance.

Thepreferredpositionfortheheaderisdirectlyabovetheinletnozzles,keepingthebranchesasshortas
possible.Makesurethattheairfiniscapableofexceptingthemovementimposedontheheader.Support
fromtheracksteelisbetweentheheaderboxes.

Outletheadersarelessofaproblembecausethetemperatureislowerandthepipesizeusuallymuch
smaller.

Theycanusuallybesupportedofftheairfinlegsbeneaththeheaderboxplatform.

Anyvalvesrequiredtoisolateunitsarethebestlocatedontheunitnozzles.Sometimesairfinshandling
lighthydrocarbonsmayrequiresnuffingsteamsupply.

Theseshouldbetreatedinthesamewayassnuffingsteamtoheaters,insomuchasthevalvesshouldbe
locatedatleast15metersradiusplanwisefromtheperimeteroftheairfin.

Pipingrunsthatplaceloadsofanysortontheairfinstructuresshouldbeavoidedifpossible,or
communicatedtothevendorassoonaspossible.

12.FinTubeExchangers
Fintubeexchangersconsistofahairpinshapedinnertubewithheattransferfinsontheoutside,except
forthereturnbend.
Thetwolegsarejacketedwithlargerborepipe.
Theheatexchangeisachievedbythestreampassingthroughthehairpin,andtheotherpassingthrough
thejackets.Theymaybeusedsinglyorinmultiples.
Theprimaryusesareforheathersorcoolersthatis,theprocessstreampassesthroughtheinnertube
andeithersteamorcoolingwaterpassesthroughthejackets.Theyareusedmainlyasasourceoflocal
heatexchange,suchasoutletheatersfromthetanksanddrumstopumps,etc.
Ourimportantpointtorememberwhenlocatingfintubesisthatthehairpintubedrawsoutfromthe
backend,thatis,theoppositeendfromthenozzles,andsufficientroommustbeallowedforthispurpose.
Pipingdesignconsiderationsaresimilartothoseonshellandtubeexchangers.

13.Chillers
Chillersareusedwheretheprocessstreamrequirescoolingtolowertemperaturethanpossiblewith
coolingwater,andforthispurposeitisnecessarytousearefrigerant.
Dependinguponthesizeofthechillersinstallation,therefrigerantcaneitherbesuppliedbyaproprietary
packageunit,oracustombuiltjobusingLPG.Theconstructionissimilartofintube,insomuchasthe
tubewithinatubefeatureiscommon.
Chillersusuallyconsistofamultiunitbankwiththeprocessstreampassingthroughtheinnertubeand
therefrigerantpassingthroughthejackets.Onceagainspacemustbeallowedattherearfortube
withdrawal.Animportantthingtorememberwhenlayingouttheseexchangers,istheconsiderable
thicknessofinsulationrequiredonallthepipework,necessitatinglargerthannormalpipespacing.

Figures
TYPICALEXCHANGERSSHOWSPOSSIBLEALTERATIONSFORBETTERPIPING

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AIRFINMANIFOLDLAYOUT

HEADERMOUNTINGSFORAIRFIN

Categories:PlantLayoutTags:designguide,Exchangers,plantlayout

PlantLayoutFiredHeaters
March15,2012qdzung1comment

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TableofContents

1.General
2.Location
3.Safety
4.InletandOutletPiping
5.BurnerPiping
6.DecokingandSootblowing
7.Instruments

1.General
1.1.Function
Theprimaryfunctionofafiredheateristosupplyallheatrequiredbytheprocessinoneformor
another.Afiredheaterutilizesgaseousorliquidfuelsoftenproducedasabyproduct.Thenormal
processfunctionisraisingtheprocessstreamtoitsrequiredtemperaturefordistillation,catalytic
reaction,etc.Sizesofheatervaryconsiderably,dependentuponthetypeofdutyandthroughput.

1.2Types
Therearetwogeneralbasicdesignsortypesoffiredheaters:
Boxtype
Verticaltype.

Eitherofwhichmaybeforcedornaturaldraft.
BoxTypeHeaters(Seebelowfigures2and3.)
Aboxtypeheaterisconsideredtobeanyheaterinwhichthetubesarehorizontal.Inthistypeofheaterit
ispossibletohavelocationsorzonesofdifferentheatdensities.Thezoneofhighestheatdensityisthe
&ldquoradiantsection&rdquo.Thetubesinthissectionarecalled&ldquoradianttubes&rdquo.
Theheatpickupintheradianttubesismainlybydirectradiationfromtheheatingflame.Insomeheater
designsshieldtubesareusedbetweenradiantandconvectionsection.Thezoneoflowerheatdensityis
the&ldquoconvectionsection&rdquo.Thetubesinthissectionarecalled&ldquoconvection
tubes&rdquo.Thisheatpickupintheconvectionsectionisobtainedfromthecombustiongases
primarilybyconvection.
Boxtypeheatersmaybeupfiredordownfiredwithgasoroilfiredburnerslocatedintheendor
sidewalls,floor,rooforanycombinationthereof.
UpfiredHeaters
Inthehorizontalupfiredheater,productsofcombinationintheradiationchamberpassupwardthrough
banksofrooftubesandafirebrickdiffuserintoaplenumorcollectingchamber.Fromtheplenum
chamberfluegasesarepassedthroughanoverheadconvectionsectionandthentoanoverheadstack.
Suchheatersmaybefiredverticallyupwardbypanels,mountedintheheaterfloororhearth,theheater
floorbeingelevatedtoprovideheadroombeneath.Alternatively,theseheatersmayalsobefired
horizontallybyburnersmountedintheheaterendwalls,inwhichcasetheheaterfloorisonlyelevated
abovegradetoprovideaircoolingconvectiontotheheaterfoundations.Thistypeofheatermaycontain
singleormultipleradiationchambersdischargingfluegasestoacommonconvectionsectionandstack.
DownfiredHeaters
Inthedownfiredheater,combustiongasesgeneratedintheradiantchamberpassdownwardsthrougha

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refractorycheckerhearthintoacollectingchamberbeneath.Fromtherethefluegasesflowupward
throughtheconvectionsectionandthenouttothestack.Thedownfiredheatersarebasicallyintendedto
fireonheavyresidualfuels,wherethefluegasesarecorrosiveandmayclogfluegaspassagesof
conventionalheaters.

Convectionsectionsarethusprotectedbyremovalofcombustionsolidsandareusuallyprovidedwith
inspectionports,sootblowingdevicesandtubefacilitiestokeepthecoilsclean.Burnersindownfired
heatersarealwaysmountedintheheaterendwalls.

VerticalHeaters(Seebelowfigures4,5and6)Verticalheatersareeithercylindricalorrectangular.They
mayhaveradiantsectiononlyorconvectionandradiantsections.Theradiantsectiontubeswillusually
bevertical,butsomecylindricalheatershavehelicalcoils.Theconvectionsectioncanbeeitherverticalof
horizontal.

TypesofHeaterFiring

Heaterscanbefiredfromanyposition,i.e.bottom,top,sideorend.

Byfarthemostcommonisbottomfired,mainlybecauseitismoreeconomical.Theburnerofabottom
firedheaterwillbelocated2.12.7Mabovegradeataheightwhichissuitableforanoperatortowork
underneath.Operatingfromundertheheaterismoredangerousthanothertypesoffiring,whichisthe
principlereasoncertainoperatingcompanieswillnotinstallabottomfiredheater.

Heatersarecommonlylightwithanelectricignitor.somerefineriesuseapropanetorchwhilesomestill
lighttheburnerswitharagsoakedinspiritsorkerosene.
ForcedorNaturalDraft

Considerationmustbegivenatthelayoutstagetoaccommodatetheadditionalequipmentassociatedwith
aforceddraftheater.Thiswillusuallycompriseanairinletductwithsilencer,forceddraftfanandanair
preheater.Theinletductmayrequireasupportstructure.

2.Location
Heatersarealwayslocatedatasafedistance15metersawayfromotherhydrocarbonbearingequipment
andpreferablyupwindhowever,onsomeprocessitispermittedforreactorstobewithinthisdistanceto
preventlightvolatilevaporsfrombeginblowntowardsanopenflame.
Spacemustbeallowedfortubereplacementforbothhorizontalandverticalheatersandthis,together
withampleaccessformobileequipment,shouldbeconsideredonpipinglayoutsanddrawings.Ample
accessisalwaysneededforfirefightingequipmentwithareasunderoraroundheatersusuallypavedand
curbed.
Nolowpointsinthepavingorgradingarepermittedastheseprovideexcellentsportsfortrapping
hydrocarbonliquidswhichcouldbeignitedbytheopenflamesoftheburners.

3.Safety

3.1SnuffingSteamStation
Seebelowfigure7.
Snuffingsteamconnectionsaresuppliedbytheheatermanufacturers,generallyinthecombustion
chamberandheaderboxes.
Thecontrolpointorsnuffingsteammanifoldisgenerallylocatedatleast15metersawayfromtheheater,
issuppliedbyalivesteamheaderandisreadyforinstantaneoususe.Smotheringlinesshouldbefree
fromlowpocketsandshouldbesoarrangedastohavealldrainsgroupednearthemanifold.
Collectedcondensate(apartfromfreezingandblockinglines)can,whenblownintoahotfurnace,result

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inseriousdamage.(Lowpointsshouldbedrilled10mmdiameterorprovidedwithspringopeningauto
drainvalves).

3.2MonitorNozzles
Somecustomersrequestthatturretormonitornozzlesbelocatedaroundtheheatersothatwaterfor
fightingafireisinstantlyavailable.Controlsforsuchnozzlesshouldbelocatedatleast15metersaway
fromtheheater.

3.3UtilityStations
Steam,airandservicewaterconnectionsshouldbeprovidedneartubeendsofheaters.3.4.Process
ControlStationsProcessfeedanddischargingblockvalvesandflowcontrolvalvesshallbelocatedata
distancefromtheheater,ifindicatedasnecessarybytheengineeringflowdiagramorinstructedbythe
PipingSpecialistEngineerorProjectDepartment.

3.5ExplosionDoors
Pipingshallnotobstructexplosiondoorsortubeaccessdoors.

4.InletandOutletPiping
Seebelowfigures8and9.
Flowdistributionthroughamultipassheaterisaffectedbytheinletandoutletmanifolding.Thepiping
arrangementattheinletofthefurnaceisthemorecriticalandrequirescarefulattention.

4.1InletPiping
Inletpipingshouldpreferablybesymmetricalandofthesamelengthfromthepointwhereflowsplitsto
theheaterinlets.Thisreferstothenumberofbends,elbowsandvalves,aswellasthenumberofstraight
runsofpipeandtheirlocation.pipingshouldavoiddeadendteebranchesandsharpturns.Unequalflow
throughanypartoftheheaterwouldresultindepositsofcokeandoverheatingoftubewalls.

4.2OutletPiping
Onoutletpiping,symmetryisnotascriticalasontheinlethowever,nonsymmetricalpipingmay
contributetopossiblecokingandoverheatingoftubes.Anonreturnandashutoffvalveisusualatthe
outletofthefurnacetoeliminateanyreverseinthecaseoftubefailure.

4.3Flexibility
Becauseofthehightemperatureinvolvedandlengthofpiperunsrequiredtoisolatetheheaters,piping
flexibilitymustbeexaminedcarefully.Someheatermanufacturerswillpermitalimitedamountoftube
movementtotakeallorpartofthepipingexpansion.Thispossibilityshouldbeinvestigatedin
conjunctionwiththeStressDepartment,bythePipingDesignOfficeduringthestudystage.Itis
generallynecessarytoanchorthepipingadjacenttotheheatertoremovestressesfromthenozzles.

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5.BurnerPiping
Seebelowfigures8and9.
Supplyoffueltoindividualburnersisadjustedbyindividualvalves.Theseshouldbesolocatedthatthe
burnerscanbeoperatedwhileobservingtheflamethroughpeepholesorburneropenings.
Allburnerleadsforgasandsteam(atomizing)mustbetakenfromthetopoftheheaders,andfuelgas
pipingshouldbesoarrangedthattherearenopocketsinwhichcondensatecouldcollect.Thefueloil
headermusthavefullcirculationundernoconditionshallitbeadeadendline.Noncirculatingbranches
toburnersshouldbeasshortaspossibleorinsulatedtogetherwithatomizingsteam.
Aringheaderaroundthefurnacemountedashortdistanceabovethepeepholes,havingverticalleads
adjacenttotheverticaldoorstotheburners,providesthegreatestdegreeofvisibilityfromtheoperators
pointofview.
Atomizingsteamtobeusedinconjunctionwithfueloilshallbetakenthemainsteamsupplyheaderator
neartheheater.Steamtrapsshallbeprovidedtodrainalllowpointsintheatomizingsteamsystem.
Separateleadstoeachburnershallbetakenfromthetopoftheatomizingsteamsubheader.Shutoff
valvesshallbesolocatedthattheycanbeoperatedwhileobservingtheflamesfromtheobservations
ports.

6.DecokingandSootblowing
6.1Decoking
(Seebelowfigure12)
Theinternalcleaningoftubesandfittingsmaybeaccomplishedbyseveralmethods.Oneistocirculate
gasoilthroughthecoilaftertheheaterhasbeenshutdownbutbeforethecoilsaresteamedand
waterwashedandpriortotheopeningandstartofinspectionwork.
Thismethodiseffectiveifdepositsinthecoilaresuchthattheywillbesoftenedordissolvedbygasoil.
Whentubesarecokedorcontainharddeposit,othermethodsmaybeused,suchassteamairdecoking
andmechanicalcleaningforcokedepositsandchemicalcleaningforsaltdeposits.Chemicalcleaningand
steamairdecokingarepreferableastheytendtocleanthetubetobaremetal.Thechemicalcleaning
processrequirescirculationofaninhibitedacidthroughthecoiluntilalldepositshavebeensoftenedand
removed.Thisisusuallyfollowedbywaterwashingtoflushalldepositsfromthecoil.Steamairdecoking
processconsistsoftheusesteam,thecoil.Steamairdecokingprocessconsistsoftheuseofsteam,airand
heattoremovethecoke.Themechanicsofdecokingare:
a.Shrinkingandcrackingthecokeloosebyheatingtubesfromoutsidewhilesteamblowscokefromthe
coil.
b.Chemicalreactionofhotcokewithsteam.
c.Chemicalreactionofcokeandoxygeninair.
Steamandairservicesarepermanentlyconnectedtotheheater.Theheateroutletlineincorporatesa
swingelbowwhich,duringthedecokingoperation,isdisconnectedfromtheoutletlineandconnectedto
thedecokingheader.Caremustbetakentoallowsufficientaccessandplatformingwhentheswing
elbowsarechangedover.Cokeiscarriedbythisheadertothedrumorsump.
InsomeinstancesitmayrequestedbytheProcessDepartmentorClientthatthedecokingmanifoldis
connectedtoallowforreverseflowduringthedecoking.

6.2SootBlowing
Insomeheaterstheconvectionsectioncontainstubeswithextendedsurfaceintheformofeitherfinsor
studs.Extendedsurfacetubesareusedtoincreasetheconvectionheattransferareaatlowcapitalcost.
Becauseofthetendencyofextendedsurfacetubestofoulwhenburningheavyoils,sootblowersare
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usuallyinstalled.

Sootblowersemployhighpressuresteamtocleanthetubeoutersurfacesofsootandotherforeign
material.Sootblowersmaybeeitherautomaticelectricmotoroperatedbyapushbuttonatgrade,or
manualrequiringoperationfromaplatformlocatedattheconvectionbanklevel.Caremustbetaken
thatsufficientclearanceisallowedforthewithdrawalofsootblowers.

Generallyheatersaresuppliedwithsootblowingfacilitiesintheconvectionsectionalthoughtubesmay
notbeoftheextendedsurfacetype.

7.Instruments
7.1Stack
a.Damper:Mechanicalorpneumaticallyoperatedtocontrolthedraftthroughthestack.
b.Draftgauge(PandI)
c.Fluetemperature(TI)
d.Orsat(O2COCO2analyzer).
Instrumentsb.,c.andd.areusedtoaccessthecorrectcombustionconditions.Steamissuppliedforthe
Orsatconnectioninthestack.WaterissuppliedtotheO2analyzer.Platformingfortheaccesstothestack
instrumentsissuppliedwiththeheater.

7.2HeaterBody
a.SkinthermocouplesortubewallTIs:toindicateoverheatingoftubes.
b.PIs:tomeasurethedraftpressurethroughthecombustionsectionoftheheater.

Figures111incl.Figure1.BOXTYPEHEATERPLAN

PROCESSPIPINGBOXHEATHER

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AFTERTUBESBECIMEHEADED,STEAMISINJECTEDATCONVECTIONINLETS,VALVES
1,2,4&5ARECLOSED3ISOPEN.
TOSTARTBURNING,STEAMFLOWISREDUCED.AIRISINTRODUCEDBYOPENINGVALVE
4.FORREVERSEFLOW,VALVES2,3,4&6ARECLOSED,1&5AREOPEN.
VALVE2ISOPENEDONLYIFREVERSEBURNINGISREQUIRED.WHILEPASS1ISBEING
DECOKED,STEAMISINJECTEDINTOPASS2TOKEEPTUBESCOOL.

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Categories:PlantLayoutTags:designguide,FiredHeaters,plantlayout

PlantLayoutPumps
March15,2012qdzungLeaveacomment

TableofContents

1.General
2.CentrifugalPumps
3.ReciprocatingPumps
4.RotaryPumps
5.PumpDrivers
6.PumpHarnessPiping

1.General
1.1Definition
Inthiscontextapumpisdefinedasamachineusedtogenerateapressuredifferentialinordertopropel
liquidthroughapipingsystemfromonelocationtoanother.

1.2TypesofPump
Thethreebasictypesofpumparecentrifugal,reciprocating,androtary.Seebelowfigures.
Centrifugalpumpsarethemostcommon.Theyaremoreeconomicinserviceandrequireless
maintenancethanothertypes.Rotationoftheimpellerbladesproducesareductioninpressureatthe
centeroftheimpeller.Thiscausesliquidtoflowontotheimpellerfromthesuctionnozzlethrown
outwardsalongthebladesbycentrifugalforceleavingthebladetipsviathepumpvolutefinallyleaving
thedischargenozzle,inasmooth,nonpulsatingflow.
Reciprocatingpumpsareusedwhereapreciseamountofliquidisrequiredtobedelivered,alsowherethe
deliverypressurerequiredishigherthancanbeachievedwithothertypes.Theliquidismovedbymeans
ofapistoninacylinderafterbeingdrawnintothecylinder,throughaninletvalve,asthepistonmoves
downthecylinder.Asthepistonmovesbackupthecylindertheliquidisdischargedatapresetpressure
controlledbydeliveryvalve.
Theliquidisejectedfromthecylinderintothepipingsysteminpulseswhicharetransmittedtothe
suctionanddischargepiping,thusholddownscouldberequiredonthepipingsystem.Rotarypumpsare
usedtomoveheavyorveryviscousfluids.Theseemploymechanicalmeanssuchasgear,camandscrew,
tomovethefluid.

2.CentrifugalPumps
2.1NettPositiveSuctionHead
Centrifugalpumpsmusthavetheirsuctionlinesfloodedatalltimes.
Thesuctionpipinghastobedesignedtoavoidcavitationorpreventvopourenteringthepump.
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Therefore,suctionlinesshouldfallcontinuouslyforasufficientheightfromoverheadsourcetopump.
TheminimumverticalheightrequiredfromsourcetopumpsuctioniscalledtheNettPositiveSuction
Head,(NPSH).Thisiscriticalforefficientpumpoperationandmustnotbereduced.Vesselelevationsare
oftendependentontheNPSHofitsassociatedpump.Seebelowfigures.

2.2PumpTypes
Therearethreebasictypesofcentrifugalpumps.Horizontaldriveshaftwithpumpdrivemounted
remotefromtheline,verticaldriveshaftwithpumpanddrivemountedontheline,verticalbarreltype
withdirectimmersionsuctionfacility.Ineachcasethetypereferstodriveshaftdirection.
Themostcommonisthehorizontalwithitsshaftinthehorizontal,verticalinlinepumpshavetheirshafts
verticalandthepumpisinstalledinthepipeline,asavalvemustbe.Verticalcanpumpsareusually
singlestage,buthorizontalandverticalcantypescanbemultistagedtoobtainhigherdeliverypressures.

2.3SuctionPipingforHorizontalPumps
LineSize
Suctionpipingisusuallyoneortwolinesizeslargerthanthepumpsuctionnozzlesize.Suctionpiping
morethantwosizeslargershouldbequeriedwithProcessDepartment.
SuctionNozzleOrientation
Centrifugalpumpsaresuppliedwithsuctionnozzlesontheendofpumpcasing,axiallyinlinewith
impellershaft,alsoontoporsideofpumpcasing.Usuallypumpsarespecifiedwithendortopsuctionfor
generalservices.Sidesuctionpumps,withsidedischargearefrequentlyselectedforlargewaterduty.
Alsosidesuctionsidedischargepumpscanbeobtainedinmultistageformforhigherpressure
differentials.Thesepumpstendtobecomeverylong,soifplotspaceistight,considerationshouldbe
giventopurchasingthepumpinverticalformwithasumpatgrade.Seebelowfigures.
FlexibilityofSuctionLines
Consistentwithgoodpipingpractice,pumpsuctionlinesshouldbeasshortaspossible,butwithenough
flexibilitytoabsorbanypipemovementcausedbytemperaturedifferentialsandtomaintainpumpnozzle
loadstowithinthosepermittedbypumpvendor.Forfurtherdetailsrefertosectiononpipingflexibility.
SuctionLineFittings
Duetosuctionlinebeinglargerthanthesuctionnozzles,reducersarerequiredintheline.Reducers
shouldbeascloseaspossibletonozzle.Eccentricreducerswillbeusedwiththeflatontopforhorizontal
pumps.Seebelowfigures.Forpumpswithsuctionanddischargenozzlesontopofcasing,caremustbe
takentoensurethattheflatsoneccentricreducersareorientatedsothatsuctionanddischargelinesdo
notfouleachother.Seebelowfigures.
TemporaryStartupStrainers
Allpumpsmusthaveatemporarystartupstrainerinthesuctionlinetopreventanypipedebris
damagingthepump.Strainerswillbelocatedbetweenpumpsuctionblockvalveandpump.Strainersare
availableinthefollowingstyles:flat,basket,conicalandbathorteetype.
Forbasketandconicaltypesaremovablespoolpiecemustbeprovideddownstreamofsuctionblock
valve,whichmustnotinterferewithlinesupports.Bothtypeshavetheadvantagethatthepipingisleft
undisturbedandstrainerelementcanberemovedsimplybyremovingtheblindflangeonthetee,thus
leavingthepipingandsupportsundisturbed.Seebelowfigures.

2.4DischargePipingforHorizontalPumps
LineSize
Generally,dischargepipingisoneortwosizeslargerthanthepumpdischargenozzlesize.
DischargeLineFittings
Duetodischargelinebeinglargerthanthedischargenozzleeccentricreducersarerequiredintheline.
Reducersshouldbeascloseaspossibletothenozzle,withtopsuctiontopdischargepumps,caremust
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betakentoensurethattheflatsoneccentricreducersareorientatedsothatthelinesdonotfouleach
other.

Apressuregaugeislocatedinthedischargeline,andshouldbeupstreamofthecheckandgatevalves
whichareusuallyflangedtogetherwithadripringbetweenthem.Whenalevelswitchforpump
protectionisinstalledinthedischargeline,upstreamofblockvalves,ensuregoodaccessformaintenance
ofswitch.

Toenablegoodaccesstovalvehandwheelsandeaseofsupporting,thedischargelineshouldbeturnedflat
afterreducer,andthelineangledawayfromthenozzletoenablethelinetobesupportedfromgrade.See
belowfigures.

Avoidsupportinglargelinesfrompiperackstructuresifpossible,thisenablesminimumsizebeam
sectionstobeusedandbetteraccessforpumpremovalandmaintenance.

2.5SideSuctionandDischargeHorizontalPump
Thistypeofpumpisusuallyinstalledinalargedutyservicewithlargeborelines.Neverconnectanelbow
flangefittingmakeuptothenozzleofsuctionlinecomingdowntothepump.Supplyastraightpieceof
pipetwopipediameterslongbetweenthenozzleandelbow.
Thetwodiameterpipelengthcanbeeliminatediftheelbowisinthehorizontal,onlyeliminatepipe
lengthifavailablespaceistight.Seebelowfigures

2.6VerticalPumps
Verticalpumps,alsocalledcantypeorbarreltypeareusedwhenavailableNPSHisverylowor
nonexistent.
VerticalInLinePumps
Thistypeofpumpismounteddirectlyintothepipeline,asavalvewouldbe.Forsmallersizes,thepiping
systemsupportsthepumpandmotor,thusitisessentialthatthelineissupportedlocaltothepumpto
preventthelinemovingwhenthepumpisremoved.Alsoensurethatthereisgoodaccesstopumpfor
maintenanceandwithdrawalwithnooverheadobstructionsforliftingoutpump.Largersizeinline
pumpshavefeetorlugsonthecasingforsupportingfromgradeorsteelwork.
VerticalCanorBarrelType
Usuallythistypeofpumpisinstalledincoolingtowerwatercirculatingservice,retentionponds,and
applicationswhereNPSHislowandsuctionistakenfromasumpbelowgrade.Inmostcases,thereisno
suctionpipingtobeconsidered,butthedischargelinemustberoutedtoensuregoodaccessforpump
maintenance,withnooverheadobstructionsforpumpremovalbyacrane.Seebelowfigures.

3.ReciprocatingPumps
3.1TypesofPumps
Therearethreeclassesofreciprocatingpumps,piston,plungeranddiaphragm.
Pistonpumpsaregenerallyusedwheremediumtohighdeliverypressuresarerequired,suchahigh
pressureflushingofvesselinteriors,etc.Thesecanbeobtainedinmulticylinderformandcanbesingle
ordoubleacting.Plungerpumpsareusuallyusedformeteringorproportioning.
Frequentlyavariablespeeddriveorstrokeadjustingmechanismisprovidedtovarytheflowasdesired.
Diaphragmpumpsareinvariablyairdrivenandverycompact,alsotherearenosealsorpackingexposed
totheliquidbeingpumpedwhichmakesthemidealforhandlinghazardousortoxicliquids.Theseare
oftenusedforsumppumpout.Seebelowfigures.

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4.RotaryPumps
4.1TypesofPumps
Therearetwomainclassesofrotarypumps,gearorscrew.
Gearpumpsareusuallyemployedtopumpoilsandnonabrasivefluids.
Screwpumpsareusuallyusedtopumpheavyviscousfluidsandnonabrasivesludges.Apartfrom
maintaininggoodaccesstopumpsforoperationandmaintenanceeachcaseshouldbetreatedonan
individualbasis.

5.PumpDrivers
5.1TypesofPumpDrivers
Thethreemostcommontypesofdriveraretheelectricmotor,dieselengine,andsteamturbine.
5.2Electricmotorsarethemostcommonpumpdriverandareofthetotallyenclosed,flameprooftype
suitableforzone1use.Theirsizesrangefromsmalltoverylargewhichrequiretheirowncooling
systems.
5.3Dieselenginesareusuallytobefoundasdriversforfirewaterpumpswhicharehousedinaseparate
buildingawayfromthemaincomplex.
5.4Steamturbinesusedforpumpdriversareussualysinglestageandthepumpthattheydriveare
invariablyforstandbyservice(spare).

5.4.1SteamNozzleOrientation

Thesteaminletnozzleisusuallyontherighthandsidewhenviewedfromthepumpcouplingendofthe
turbinewiththeexhaustonthelefthandsideasstandard.Turbinescanbepurchasedwithinletand
exhaustonthesameside.Thismeansthatthepipingdesignercanplacetheexhaustconnectioneitheron
thesameoroppositesidefromtheinlet.Generallyoppositesidelocationofnozzlesresultsinlesspiping
congestion.

5.4.2InletPiping

Steaminletsarefurnishedwithstrainersaspartoftheturbineforprotectionagainstpipedebris,
thereforeinletpipingmustbedesignedwitharemovablesectionforstrainerremoval.
Steamsupplytoturbinesmustbemoisturefreeatalltimes,otherwisedamagetotheturbinewilloccurif
condensateenterstheturbinewhileitisrunning.Toseparatecondensatefromsteamabootlegmustbe
installedupstreamoftheinletblockvalve.
Thetwobasicturbineinstallationsaremanualstartuporautomaticstartup.Themanualstartupwill
haveagatevalveinthesteamsupplyneartheturbineinlet.Upstreamoftheblockvalveabootlegmust
beinstalledwithconnectionsforblowdownandsteamtraptoremoveanycondensateinthesteam
supply.Forautomaticstartupthegatevalveisreplacedwithremoteoperatedcontrolvalve,thebootleg
andtrapsarestillrequiredupstreamasformanualstartup.
Steamtrapsshouldbeprovidedtokeeptheturbinecasingfreefromcondensate.Thesecanbeinstalledat
thecasinglowpointifaconnectionisprovidedor,ontheoutletpipingifthecasingdrainsintotheoutlet
system.
Notetheremustbeatrapbeforeanyverticalrisewhichcouldformapocketwherecondensatecould
collect.

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5.4.3WarmupBypass

Onautomaticstartupawarmupbypassmustbeprovidedaroundthecontrolvalve.Thisbypassis
usuallya1globevalve,andispartiallyopenedtoallowsteamtokeeptheturbineconstantlywarmand
slowlyturningtopreventtheshockofhotsteamenteringacoldturbine,andeliminatedamagetoturbine
blades.
Formanualstartupitisrecommendedthatawarmupbypassbeinstalled,butthejobflowsheetswill
govern.
Whenawarmupbypassisinstalledasteamtraponthecasingkeepsthesystemfreeofcondensate.See
belowfigures.

5.4.4ExhaustPiping

Turbineexhaustsareroutedeithertoaclosedexhauststeamsystemortoatmosphere.Whenexhaustisto
aclosedsystemtheremustbeablockvalvebetweenturbineandmainheader,thisblockisalwaysopen
duringnormalconditionsandonlyclosedforturbinemaintenanceorremoval.Thoughtshouldbegiven
tolocatingexhaustblockvalveonthepiperackimmediatelybeforelinesentermainheader,thiswill
preventaccidentalclosureofthisvalve.Iftheexhaustlineisroutedtoatmosphere,thesteamtrapon
turbinecasingwillnotbeinstalled,butreplacedbygatevalvepartiallyopentoallowcondensatetodrain
offfromcasing.Seebelowfigures.

5.4.5RotorWithdrawal

Mostsmallturbinecasingsaresplitalongtheirhorizontalaxisandenoughspaceabovetheturbine
shouldbekeptcleartoallowforthetopsectionofcasingtobeliftedclearofrotorbycrane.Seebelow
figures.

6.PumpHarnessPiping
Mostpumpsrequireexternalservicestobepipedtothemforbearingcooling,bearinglubrication,seal
flushing,ventinganddraining.
Theserequirementswillbeshownonutilityflowsheets,anditisthepipingdesignersresponsibilityto
ensurethattheactualgeographiclocationofpumpswithharnessesarecorrectlyshownontheflowsheets.
Thoughshouldbegiventorunningsubheaderstogroupsofpumpsthathaveharnessrequirements.
Thesesubheadersmustbesizedandmarkedonflowsheetmasters.Becausebranchlinestoindividual
pumpsaresmalldiameter,i.e.6mm,itisadvisabletotakebranchconnectionsfromthetopof
subheaders.Thiswilleliminatepipedebrisgettingintothebranchlineandintothepumpbearings,etc.
Careshouldbetakentoensureharnesspipingdoesnotinterferewithgoodoperationandmaintenance
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Theabovediagramsindicatecorrectandincorrectmethodsofattachingsuctionpiping.

Fig.1Showsairpocketformedalonguppersideofpipebysingconcentricreducer.
Fig.2(A)Horizontalelldirectlyintopumpsuctionresultsinanunbalancedthrustonpumpbearings.(B)
Usespoolpiece3pipediameterslongorlongradiusellwithcenterverticalvane.(C)Maybeinstalled
withorwithoutspoolpiecebut2pipediametersspoolispreferred.
Fig.3Showspropermethodofconnectingpumpsuctiontoasuctionheaderinordertoavoidairpockets.
Fig.4Representsacommonerrormadesuctionpipingtoacentrifugalpumpbyplacingpipingoveran
embankmentofareservoir,orotherobstruction.

SUCTIONPIPING:Thesuctionpipingshouldbeasdirectandshortaspossible.Ingeneralitshouldbe
oneortwosizeslargerthanpumpnozzle.Ifchangesfromonepipesizetoanotherarenecessary,standard
reducersshouldbeused.Correctandincorrectwaysareshowninthepicturereferredtoabove.

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AUTOMATIC
STARTUP

Categories:PlantLayoutTags:designguide,plantlayout,pumps

PlantLayoutReliefSystem
March15,2012qdzungLeaveacomment
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TableofContents

1.References
2.Scope
3.PressureReliefValveInstallations
4.ThermalReliefValveInstallations
5.RuptureDiskInstallation
6.VentingAtmosphericandLowPressureStorageTanks

1.References
Thedesignofareliefsystemisgovernedbythefollowing:
API.RP520designandinstallationofpressurerelievingsystemsinrefineries
BritishFactoryActs,inrelationtosteamraisingplants,ifapplicable
LocalauthoritiesandClientsrequirements
Goodengineeringpractice
Thedesignofatmosphericandlowpressureventingsystemsaregovernedbythefollowing:
API.RP2000Ventingatmosphericandlowpressurestoragetanks
LocalauthoritiesandClientsrequirements
Goodengineeringpractice

2.Scope
Thisguideisintendedtocovermethodsofinstallationforpressurereliefvalvesandtheirassociatedpipe
workandfittings.
Theinstallationofrupturedisks.
Ventingstoragetanks.

3.PressureReliefValveInstallations
Forgeneralrequirementsofreliefvalvesinstallationatvesselorpipework,seebelowfigures.
Reliefvalvesshouldbemountedinaverticalpositiononly.
Foroptimumperformancereliefvalvesmustberegularlyservicedandmaintained.Tofacilitatethis,
reliefvalvesshouldbelocatedtoenableeasyaccessandremoval.Sufficientplatformspacemustbe
providedaroundthevalve.Provisionofaliftingdeviceshouldbeconsideredforlargereliefvalves.For
typicalinstallationofreliefvalvesandpiping,seebelowfigures.
Thesysteminletandoutletpipingshallbedesignedtoprovideforpropervalveperformance.Tothisend
acompletereliefsystemisometricshowingtheinletanddischargepipingofallreliefvalvesincludedin
thesystemwillbeproduced.Belowfiguresshowspartofsuchasystem,overalldimensionsandlinesizes
shouldbeincluded.
ThesystemmustfirstbeapprovedbytheProcessDepartmentforpressuredrop,thenbytheStress
Sectionforstress.ShouldthepipingbereroutedduetostressrequirementsProcessDepartmentmust
reapprovethesystem.
Theinletpipingtoareliefvalveshallbedesignedsothatthepressuredropdoesnotexceed3percentof
thereliefvalvesetpressure,seebelowfigures.
Themostdesirableinstallationisthatinwhichthenominalsizeoftheinletbranchpipingisthesameas
orgreaterthan,thenominalsizeofthevalveinletflange,andinwhichthelengthdoesnotexceedtheface
tofacedimensionsofastandardteeandweldneckflangeoftherequiredpressureclass.The
configurationshownontheflowdiagrammustalwaysbefollowed.
Reliefvalvesystemsdesignedtodischargeagainstaconstantpressurecannottolerateabackpressure
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greaterthan10%ofthesetpressure.BalancedbellowsorBalansealtypereliefvalveswhichoperate
practicallyindependentofthebackpressuretolerateamuchhigherfigure,butgenerallythehigherthe
backpressurethelowerthecapacityofthereliefvalve.Duetothisthedischargepipingshouldbekeptas
directaspossible,seebelowfigures.

Theflowdiagramwilldetermineifthedischargeistoatmosphere,ortoacloseddischargeheader,see
belowfiguresfordetails.
Itispoorpracticetomountthereliefvalveattheendofalong,horizontalinletpipethroughwhichthere
isnormallynoflow
Foreignmattermayaccumulateorliquidmaybetrappedandmayinterferewiththeoperationofthe
valveorbethecauseofmorefrequentvalvemaintenance.
Processlateralsgenerallyshouldnotbeconnectedtoreliefvalveinletpiping,seebelowfigure4.
Proximityofothervalvesandequipment,therecommendationslaiddowninbelowfigures4,6and7
shouldbefollowedifpossiblefortheminimumnumberofstraightpipediametersbetweenthedevice
causingturbulenceandthereliefvalve.Theabovedoesnotapplytoreliefvalvesfittedwithstopvalves,
seebelowfigures.
Reliefvalvesdischargingintoareliefheadermustbelocatedatanelevationabovethereliefheaderso
thatthedischargelineisfreedraining.Undernocircumstancesmaythedischargelineortherelief
headerbepocketed.

4.ThermalReliefValveInstallations
Thermalreliefvalvesareprovidedoncoolingserviceswhereasystemcanbelockedinbyisolatingvalves.
Thedischargefromthereliefvalveshouldbepipedtogradeinoffsiteareas,tothenearestdrainin
processareas,followdetailsasshownontheflowdiagram.Seebelowfiguresforfurtherdetails.

5.RuptureDiskInstallation
Arupturediskdeviceisanonreclosingpressurereliefdeviceactuatedbyinletstaticpressureand
designedtofunctionbytheburstingofapressurecontainingdisk.Thediskmaybemadeofmetalor
carbongraphiteandhousedinasuitableholder.
Thepurposeofinstallingarupturediskupstreamofareliefvalveistominimisethelossbyleakage
throughthevalveofvaluable,noxiousorotherwisehazardousmaterialsortopreventcorrosivegases
fromreachingthereliefvalveinternals,seebelowfigure11.Typicalburstingdiskinstallationatarelief
valve.
Theinstallationofarupturediskmaybecalledfordownstreamofareliefvalve.Inthiscaseitspurpose
istopreventcorrosivegasesfromacommondischargelinereachingthereliefvalveinternals.
Rupturedisksmayalsobeinstalledasasolereliefdevice,seebelowfigure10.
Rupturedisksmustalwaysbeinstalledasshownonthevendorsdrawing.ForexampleofaConcave
installationseefigure10andaConvexinstallationseefigure11.

6.VentingAtmosphericandLowPressureStorage
Tanks
Determinationofventingrequirements
Inbreathingresultsfrommaximumoutflowofoilfromtank,orfromcontractionofvaporscausedby
maximumdecreaseinatmospherictemperature.Avacuumbreakingdeviceisfitteddirectlytothelineor

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vesseltopreventitscollapsewhentheinternalpressurefallsbelowatmospheric.Iftheadmissionof
oxygenintotheprocessishazardous,ainertgassupplyisconnectedtothevacuumbreakerviaapressure
reducingvalve.FollowthesystemdefinedontheFlowDiagram.

Outbreathingresultsfrommaximuminflowofoilintotanksandmaximumwhichresultfrommaximum
increaseinatmospherictemperature(thermalbreathing).Oneofthefollowingdevicesmaybespecified
ontheflowdiagram.

Reliefvalvemaybeusedeitherdischargingtoatmosphereorintoaclosedsystem.

Openventwithflamearrestingdevice.Manholeorgaugehatchthatpermitsthecovertolift.

Pressureandvacuumbreathingvalvesaredesignedtopreventevaporationfromstoragetanks,butto
allowbreathingwhenthepressureorvacuumexceedsthatspecified.Fordetailsseebelowfigures..

Figures18Incl.
RECOMMENDEDTYPICALRELIEFVALVEINSTALLATION(BASEDONAPIRP520)

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RECOMMENDEDTYPICALRELIEFVALVEINSTALLATIONS(EXTRACTEDFROMAPIRP520)

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RECOMMENDEDTYPICALRELIEFVALVEINSTALLATION

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RECOMMENDEDTYPICALRELIEFVALVEINSTALLATION

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RECOMMENDEDTYPICALRUPTUREDISKINSTALLATION

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TYPICALPRESSURE&VACUUMBREATHINGVALVE

Categories:PlantLayoutTags:designguide,plantlayout,ReliefSystem

PlantLayoutPipewayDesign
March15,2012qdzung2comments

TableofContents

1.General
2.InformationRequired
3.EvaluationofInformation
4.LineIdentification
5.PiperackWidth
6.PiperackElevation
7.LineLocationinPiperacks
8.PipingEconomyinPiperackanditsInfluenceonPlantLayout
9.PiperackGeneralArrangementChecklist
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10.Pipetracks
11.TrenchedPiping(CivilDepartment)
12.UndergroundPiping(byCivilDepartment)

1.General
Thepipewayconveysallmainprocesslinesconnectingdistantpiecesofequipment,reliefandblowdown
headers,alllinesleavingandenteringtheplant,utilitylinessupplyingsteam,air,coolingwaterandinert
gastotheplant.Electricalandinstrumentcabletraysareusuallyroutedinthepipeway.Pipewaysare
classifiedbytheirrelativeelevationtograde.

1.1Piperack
Overheadpipingsupportedonsteelorconcretebents.

1.2Pipetrack
Abovegroundpipingsupportedonconcretesleepersatgradelevel.(Offsiteareaswhereequipmentis
wellspacedout)

1.3TrenchedPiping(byCivilDepartment)
Belowgroundpipinglaidinconnectiontrenches.Costlyandusuallyundesirableunlesstrenchesare
wide,shallowandwellvented,heavygasesmaysettleandcrea
teafirehazardthroughthelengthofthetrench.Forthesereasons,onlypumpoutlines,chemicalsewers
orchemicaldraincollectionsystemsaresometimesplacedintrenchesandroutedtoapitorunderground
collectiontank.

1.4UndergroundPiping(byCivilDepartment)
Pipingdirectburiedbelowgroundlevel.Duetocostlymaintenanceandtheusuallycorrosivenatureof
soil,thismethodofroutingisgenerallyreservedforseweranddrainlines.Insomeplants,especiallyin
coldclimates,coolingwaterlinesareburiedbelowthefrostline.Thisshouldbedeterminedatthe
beginningofajob,isgenerallyaClientrequest.

2.InformationRequired
2.1JobSpecification
JobspecificationSP.C100containsdesigncriteria,agreedbetweenCompanyandClient,affecting
piperackdesign:

Batterylimit,valvingandspaderequirements.
Catwalk,platformandladderaccesstovalvesandreliefvalvesinpiperack.
Minimumheadroomandclearancesunderoverheadpipingorsupportingsteelwithinareas
Pipewaysandsecondaryaccessways
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Mainaccessroads
Railroads
Standardtobeusedforminimumspacingoflinesinpaperacks
Handlingandheadroomrequirementsforequipmentpositionedunderpiperacks
Operatingandsafetyrequirementsaffectingpiperackandstructuredesign
Locationofcoolingwaterlinesundergroundoraboveground
Trenchedpiping,ifany.

2.2ProcessFlowDiagrams
Processflowdiagramsshowmainprocesslinesandlinesinterconnectingprocessequipment.

2.3EngineeringFlowDiagrams
Engineeringflowdiagramsaredevelopedfromprocessflowdiagramsandshow:

Pipesizes.Pipeclasses,andlinenumber.
Valving.
Manifolding.
Allinstrumentation.
Equipmentandlinesrequiringservices,i.e.watersteam,air,nitrogenetc.

2.4UtilityFlowDiagrams
Utilityflowdiagramsshowtherequiredservices:

Steam
Condensate
Water
Air
Gas

Andanyadditionalservicespeculiartotheplantbeingworkedon,e.g.:

Caustic
Acid
Andrefrigerationlines,etc.

3.EvaluationofInformation
3.1InitialEvaluation
Useplotplanandprocessflowdiagramstomakeapreliminaryassessmentofwhichportionofprocess
lineswillbelocatedinpiperackandwhichlineswillinterconnectdirectlytonozzlesonadjacentitemsof
equipment.Drawlinestobelocatedonpiperacksonprintofplotplan.Someideaofutilitypiping
requiredmustbeestablishedandincludedcoordinatewithInstrumentandElectricalSectiontoassess
whatadditionalrackspacemayberequiredtoaccommodatecabletrays.Thisactionprovidesa
preliminaryvisualideaofthepiperackspacerequired.

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3.2Development
Withthereceiptofengineeringflowdiagramsandutilityflowdiagrams,amorecompleteandaccurate
assessmentofrackspaceispossible.Utilityheadersgenerallyrunthewholelengthofthepiperack,so
shouldbetakenintoaccountwhenestimatingadditionalspacerequired.ToassistProcessDepartmentin
sizingutilityheadersinthepipewayalineroutingonareprooftheplotplan,showingorderoftakeoffs
isrequired.

4.LineIdentification
Certaintypesofpipingrequirespecialconsideration:

4.1ProcessLines
Linesinterconnectingnozzlesonprocessequipmentmorethan6Mapart(closerspecedequipmentmay
bedirectlyinterconnectinginsidepipingareas).

Productslineswhichrunfromvessels,exchangersorpumptobattery/unitlimits
Crudeorotherchargelinesenteringtheunitwhichrunalongpiperackbeforeconnectingtoprocess
equipment,furnaces,exchangers,holdingdrumsorboosterpumps.

4.2ReliefHeaders
Individualrelieflines,blowdownlinesandflarelinesshouldbeselfdrainingfromallreliefvalveoutletsto
knockoutdrum,flarestackortoapointattheplantlimit.Toachievethis,lineswillconnectintothetop
oftheheaderandat45degreesindirectionofflow.Toeliminatepockets,andobtainrequiredslopeto
knockoutdrumsomereliefheadersmustbeplacedabovethemainpiperack.

4.3InstrumentandElectricalCableTrays
Ofteninstrumentandelectricalcabletraysaresupportedonthepiperacktrack.Spacemustbeallocated
toaccommodatethemfromtheoutset.Duetothepossibilityofinducedcurrentinterferenceinstrument
andcommunicationcabletraysmustbelocatedawayfromelectricalandpowercabletrays.Consultwith
Instrument/ElectricalDepartmentforseparationrequirements.

5.PiperackWidth
Thewidthofpiperackisinfluencedby:

Thenumberoflines
Electrical/instrumentcabletrays.
Spaceforfuturelines.

Thewidthofapiperackmaybecalculatedusingthefollowingmethod:Firstestimatenumberoflinesas
described.Addupthenumberoflinesupto18diameterinthemostdensesectionofthepiperack.
Thetotalwidthinmeters willbe:
W=(fxNxS)+Ameters
Wheref,safetyfactor=1.5,ifthelineshavebeenlaidoutasdescribedininitialevaluation.
Wheref,safetyfactor=1.2,ifthelineshavebeenlaidoutasdescribedunderdevelopment.
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N=numberoflinesbelow18diameter

S=averageestimatedspacingbetweenlinesinmillimeters.
UsuallyS=300mm

UsuallyS=230mm(iflinesinpiperackaresmallerthan10)
A=additionalwidthrequiredmetersfor:

Lineslargerthan18.
Futurelines.
Instrumentandelectricalcabletrays.
Anyslotforpumpdischargelines500mm1meter.

Thetotalwidthisthusobtained.IfWisbiggerthan9Musuallytwopiperacklevelswillberequired.
Note:Atthebeginningofajob,`W`shouldusuallyinclude3040%ofclearspaceforfuturelines.
Thewidthofthepiperackmaybeincreasedordeterminedbythespacerequirement,and/oraccessto
equipmentarrangedunderthepiperack.
Belowfigureshowstypicalpiperacksbentswithtabulateddimensions.Totalavailablepiperackwidthof
eachtypeofsupportisincluded.Thistablecanbeusedforselection.Themostcommonlyusedpiperack
supportsaretypes2,3,4and5.

5.1SpacingbetweenPiperackBents
Normalspacingbetweenpiperackbentsvariesbetween4.6Mto6M.
Thismaybeincreasedtoamaximumof8Mconsiderationmustbegivento:

Smallerlineswhichmustbesupportedmorefrequently(seeCompanydesignspecification
recommendedspanbetweenpipesupports)
Liquidfilledlinesrequiringshorterspanthangasfilledlines
Hotlineswhichspanshorterdistancesthancoldlinesofthesamesizeandwallthickness
Insulatedlinessmallbore,coldinsulatedlinesduetoweightofinsulationmustbesupportedat
relativelyshortintervals
Spacerequirementsofequipmentatgradecansometimesinfluencepiperackbentspacing.

6.PiperackElevation
Piperackelevationisdeterminedbythehighestrequirementofthefollowing:

Headroomovermainroad
Headroomforaccesstoequipmentunderthepiperack
Headroomunderlinesinterconnectingthepiperackandequipmentlocatedoutside.

Thesizeofsteelorconcretebeamsupportingoverheadpipingmustbetakenintoconsideration.
HeadroomrequirementsforeachjobaredetailedinCompanyspecificationno.C100andcoordination
procedure.

6.1ElevationatPiperackIntersection
Wheretwotwotierpiperacksmeet,itisessentialthatelevationsoflateralpiperacksslotbetween
elevationsofmainpiperack.
Figure2Aillustratesthisrequirement.Choiceoftopelevationoflateralpiperackmidwaybetweenthetop
anbottommainpiperackelevationallowsturningupordownattheintersection.
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Generally,linesrunningatrightanglestomainpiperackareassignedelevations500mmto1meter
higherorlower(dependingonheadroomrequirements)thanlinesrunninginmainpiperack.500mm
differentialbetweenpiperunsistheabsoluteminimum.

Figure2Bshowsapiperackintersectionwheretherespectivemainandlateralpiperackelevationsdonot
slotbetweeneachother.Thisdesigncomplicatesroutingoflinesfrompiperacktotheother,especially
wherelinesrunonthebottomlevelsofbothpiperacks.Avoidthisdesignatallcost.

Whereasingletierpiperackturnsthrough90,andalllinescanbekeptinthesamesequenceinboth
directions,noelevationdifferenceisnecessary.Whenlinessequencechanges,introduceanelevation
changeattheturn.Seebelowfigures.

7.LineLocationinPiperacks
7.1OneTierPiperacks
Belowfigureshowsacrosssectionofasinglelevelpiperack.Heavylines(verylargediameterlines,large
borelinesfullofliquid)regardlessofserviceareplacedoverornearthepiperackcolumns.Thissimplifies
steelworkorconcretepiperackdesign.Centrallyloadedcolumnandreducedbendingmomentonthe
beamwillresultinalighteroveralldesign.
Placeprocessandrelieflinesnexttothese.Linesservinglefthandareasofplantonleft,linesserving
righthandareasontheright.
Thecentralpiperackportionisreservedforutilitylineswhichmayservebothrightandlefthandareas
ontheplant.However,utilitylinesservingoneortwopiecesofequipmentshouldbeonthesamesideof
thepiperackastheequipmenttowhichtheyconnect.
Processlineswhichinterconnectequipmentonbothsidesofthepiperackshouldbeplacedclosetoutility
lines,andcanbeoneithersideofpiperack,dependinguponlocationofequipmenttheyserve.The
positionofproductlinesisinfluencedbytheirroutingafterleavingtheunit,right,(left)turninglines
shouldbeontheright(left)handsideofthepiperack.
Ifpossible,acentrallyplacedsectionofthepiperackisreservedforfuturelines.Thissectionshouldrun
thewholelengthofthepiperack.Shouldthisbeimpracticable,aseriesofsmallersections,runningthe
wholelengthofthepiperack,aretobeprovided.(seebelowfigure).

7.2TwoTierPiperacks
Wherethenumberoflinesdictatetheuseofatwolevelpiperack,utilitylinesareplacedonthetoplevel
andprocesslinesonthebottomlevel.Thisisnotarigidruleandwherepipingeconomydictatescertain
processlinesmayberoutedonthetoplevel.Linesequencearrangementshouldfollowthephilosophy
outlinedpreviously.

7.3PositionofHotLines
Itisadvantageousforpipesupportstogrouphotlinesrequiringexpansionloopstogether,preferablyon
sideofthepiperack.Horizontallyelevatedloopsoverthepiperackarecommonlyusedtominimizethe
effectsofexpansiononhotlines,thehottestandlargestlinebeingontheoutside.Seebelowfigures.

7.4LineSpacing
ForlinespacinguserecommendedpiperackspacingpertableinJobSpecificationC100.Itshouldbe
notedthatincertaincases,itisnecessarytodeviatefromthestandardsquotedabove,e.g.,seebelow
figuresatpointAduetopossibledifferentialexpansionlinespacingmayhavetobeincreasedtoallow
formovementoflinesatstartup.
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Todetermineexpansionofhotlines,useCompanyengineeringguide,Attachmentthermalexpansionof
pipematerials.

8.PipingEconomyinPiperackanditsInfluenceon
PlantLayout
8.1PiperackLayout
Plantlayoutdeterminesthemainpiperackpipingruns.Theshapeofpiperackistheresultofplant
arrangements,siteconditions,Clientsrequirementsandoverallplanteconomy.Seebelowfigures.
Pipingeconomydependsprimarilyonthelengthoflinesroutedinthepiperack.Belowfiguresshows
criticaldimensionswhichinfluenceoverallcost.Thesedimensionsdependonoverallplantlayoutand
shouldbecarefullyconsideredwhentheplotisarranged.
DimensionA,(seebelowfigures)isthetotallengthofpiperackandisgovernedbythenumberandsize
ofequipment,structuresandbuildingsarrangedalongbothsidesofthepiperack.Onaverage,3metersof
piperacklengtharerequiredperitemofprocessequipment,goodlayoutcanreducepiperacklength.
(Therebycosts).
Equipmentinpairs,stackedexchangerssupportedfromtowers,twovesselscombinedintoone,closely
locatedtowerswithcommonplatforms,processequipmentlocatedunderpiperackareexamples
whichhelpshortenpiperacklength.Inawellarrangedplant,averagelengthofpiperackperitemof
processequipmentcanbereducedto2.1metersto2.4meters.
CarefulselectionofdimensionsBandC,belowfigurewillminimizeinterconnectionequipmenton
oppositesidesofpiperack.Cisnormallynomorethan1.8metersto3meters.
DimensionsDandE,(seebelowfigure),minimize.Overgenerousdimensioningherewillincreasevertical
pipelengths.Maximizeuseofavailableplatformsforaccesstovalves.Whereairfinsarelocatedabove
thepiperack,useassociatedairfinmaintenanceplatforms,modifyingtheirextentifnecessary.This
methodwillbecheaperthanaddingspecialplatformsinthepiperack.

9.PiperackGeneralArrangementChecklist
Criticallyreviewpiperacklayoutagainstlatestinformation.Somelinesshouldrequirereroutingfor
maximumpipingeconomy.Checkloopsrequiredfornesting.Asmanyloopsaspossibleshouldbe
combinedinaloopbayhavingdueregardtostressrequirements.

9.1VibratingLines
Avoidchangesindirection
Avoidlongoverhangingbendswithoutsupport
Usebendswherepossible(checkwithjobspecification)
Teestobeavoidedasfaraspossible,flowshouldenteralongrunofteeandneverinthebranch.

Lowpointpocketstobeavoidedinthefollowinglines:

Steam(trapanypocketsanddeadends)
Slurry
Blowdown(theselinesmustbeselfdraining)
Caustic,acidandPhenol(alltheseservicestobeselfdraining)
R.V.sbothinletandoutlet
Vapourtoknockoutpots
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Heavyproducts,bitumen,wax
Pumpsuctions
Lethalandtoxicsubstances

Highpointpocketstobeavoidedinthefollowinglines:

Pumpsuctions
Lightends
Vapour/liquidmixes(hottowerbottomsrefluxlines)
Crudelines

Onhotlines,checkshoerequirementsandclearancesatchangesofdirection(pipeexpansion).
Provideventsathighpoints.
Providedrainsatlowpoints.
Providesteamtrapsat:lowpoints,upstreamofloopsanddeadends,viacondensatedriplegs.
Onsteam,airandcondensateheaders,takeoffstobefromtopofheaders.RVheadershighorlow
elevation.BeforefinalizingelevationofRVheaderconsiderelevationofallRVdischargesandelevationof
knockoutdrumatflare.
Bends,ifused:(checkwithjobspecification).

Wherelineschangeelevationbendsmaybeusedprovidingdifferenceinelevationisadequateand
specificationpermits
Headertakeoffsinpiperacks,useelbows
Specialpiping:
Catalystlines5D(minimum).
Vibratingpiping5D.
Smallboreusuallybelow2(Clientpreferred).

Pipesetting:tobeavoidedinlargeborelines.Smallborelinestobesetonlywhereabsolutelynecessary.
PipeStressDepartmentwilladvisewhichpipingsystemsrequireformalstressanalysis.
Supports:avoidlongunsupportedoverhangs.
Steelworkclearances:checksteelworkclearancesforadditionoffireproofing(lowerelevationof
piperack),brackets,gussetsandthermalexpansionoflines.
Concretesupportclearances:checkforlocalthickeningofconcretecolumnsduetomethodoffabrication
adopted(i.e.corbels).
Valves:checkclearancesandaccessibility.Makefullofextendingplatformsforoperation(i.e.airfin
maintenanceplatforms).
Chainwheels:preferablydonotuse.However,ifnecessary,checkchainclearances.Spadingandvalving
atbatterylimit:checkforaccessibilityifnecessary,provideaccessplatform.

10.Pipetracks
Thistypeofpipewayisgenerallyassociatedwithoffsiteareaswhereequipmentiswellspacedout,and
landspaceisnotapremium.

10.1PipetrackWidth
Pipetrackwidthmaybeestimatedusingthemethoddetailedpreviouslyforpiperack.

10.2SpacingofPipetrackSleepers

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Pipetracksleepersarerelativelycheapthuspipingeconomyisdictatedbytherecommendedspanofthe
smallestlineinthetrack.
Wheresmallborelinesarefew,sleeperspacingmaybedeterminedbythepipespanoflargeborelines
providedsmallborelinesaresupportedoffthelargerlinesatadequateintervals.AnanglewithUbolts
issufficient(checkwithPipeSupportSection).
Forrecommendedpipesupportspans,useCompanystandard.
Onanaverageminimumspan=3meters
maximumspan=6meters
dependingonlinesizeandsubstancecarriedinpipes,(i.e.gasorliquid).
Alllinesmustbesupported.Atchangesofdirectionduetolongoverhangs,fornarrowpipetracksa
diagonalcornersleeperisrecommended.Onwidepipetracks,usealternativemethodoftwoshort
sleeperslocatednearcorner.Seebelowfigures.

10.3PipetrackElevation
Pipetrackelevationissetbymaintenanceaccesstopipingitemslocatedunderneaththepipetrack,i.e.
drainsandsteamtraps.Aminimumof12/300mmclearancebetweenunderneathoflinesandgradeis
recommendedwherenecessary,thismaybeincreasedto18/450mm.
Aspipetracksaregenerallysingletier,nochangeinelevationisnecessaryatchangesofdirection.Thisis
effectedbyuseofaflatturn.Seebelowfigures.
Forindividuallineelevationabovesleeper,useCompanyjobspecificationno.C4elevationofhot
insulatedlines.

10.4LineLocation
Linelocationwithreferencetoboreandweightisunnecessary,asallpipesaresupportedonsleepers
whichrestdirectlyontheground.Lineroutingisallimportant.Alllinesinterconnectingprocess
equipmentand/orstoragetankslocatedonlefthandsideofpipetrackareplacedtothelefthandside.
Similarly,alllinesinterconnectingequipmentlocatedonrighthandsideofpipetrackareplacedtothe
rightofpipetrack.Linesinterconnectingequipmentlocatedoneithersideofpipetrackareplacednear
thecenterofpipetrack.

10.5LineSpacing
UseCompanyjobspecificationno.C100recommendedpipetrackspacing

10.6RoadCrossings
Thestandardmethodistoprovideculvertsunderaccessroads.Elevatingpipingonacrossoverrackis
expensiveandintroducesunnecessarypocketsinthelinesthusrouted.Whendeterminingwidthand
heightofculvert,caremustbetakentoallowsufficientroomroundthepipeworkformaintenance,
insulationandpainting.Whereonlyoneortwolinescrossaroad,crossingmaybebymeansofsleevesset
underroadway.

10.7AccessWays
Inareasneedingfrequentaccess,platformsmaybeprovidedacrosspipetrack.

10.8Valves
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Wherepossible,theseshouldbegroupedattheedgeofanaccessplatformforeaseofoperation.Drain
valveswherepossibleshouldbebroughttooutsideofpipetrackforeaseofoperation.Thesameappliesto
steamtrapassemblies.

10.9ExpansionLoops
Horizontallyelevatedexpansionloopsabovepipetrackshouldbeprovidedwherenecessary.Groupallhot
linesrequiringexpansionloops,hottestandlargestlineontheoutside,ononesideofpipetrack.
(Generally,thesidechosenisthatsidewhichhasthehighestnumberoftakeoffsservingequipmenton
thatside).

11.TrenchedPiping(CivilDepartment)
Inmostplants,trenchesareavoidedduetoproblemsassociatedwiththistypeofpipeway:

Highinitialcost
Firehazard

Wheretrenchersareusedtoroutelinessuchas:

Pumpoutlines
Chemicalsewers
Chemicaldrains

Trenchersmustbeenoughtoallowsufficientclearancebetweentrenchwallandpiping.150mmbetween
outsideofpipeandinsideofwallistheminimumacceptableclearance.Thiswillallowforinstallationof
piping,paintingandfuturemaintenance.Seebelowfigures.Totalwidthoftrenchrequiredmaybe
determinedbyusingmethoddetailedabove.PipingDepartmentwilladviseCivilDepartmentof
requirements.

11.1LineSpacing
UseCompanyjobspecificationC100.recommendedpiperackspacing.
Linelocationinatrenchcarryinganumberoflinesshouldbecarefullychosenformaximumpiping
economyconsistentwithstressrequirements,ifany.
Opentrenchesrequiredrainstostopaccumulationofsurfacewater.Trenchbottomshouldbesloped
towardsdrainpoints.Inthiscase,pipesupportingisbymeansofanglesteelorIbeamssetintothewalls,
allowingbottomforfreedrainagetonearestdrainpoint.
Thismethodallowsdrainageofatrenchbyaminimumofdrainpointsbetweeneachpipesupportas
wouldbethecaseofsolidconcretepipesupportsbuiltupfromthetrench.Beforeproceedingontrench
drainagecheckwithcoordinationprocedureandCivilDepartmentforwatertablelevel.

11.2SafetyPrecautions
Mosttrencheshaveeitheracoverofconcreteslabsoragrating.
Whereflammableliquidsarecarriedintrenchedlines,afirebreakisprovidedatsuitableintervalsalong
atrenchandateachintersection.Thisgenerallyconsistsoftwoconcretewalls1M1.25Mapart,with
thespaceinbetweenfilledwithsand.Wherehighlyflammablegassesarecarried,thewholetrench,after
installationofpiping,isbackfilledwithsand.PipingwilladviseCivilDepartmentofrequirements.

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12.UndergroundPiping(byCivilDepartment)
Keepburiedpipingtoaminimum.Generallyonlysewerdrainlinesandfiremainsarelocatedbelow
ground.InsomecasesduetoClientorclimaterequirements,coolingwaterlinesarealsoburiedbelowthe
frostline.
Withfuturemaintenanceinmind,buriedlinesshouldbelocatedwellclearoffoundations,andifrunning
sidebyside,wellspacedout.Aminimumof300mmclearanceisnecessarybetweenfoundationsandlines
andbetweenthelinesthemselves.
Abovegroundsafedraintailswillenterbelowgrounddrainlineviaatundish(concentricreducer
normally)orifasealedsystemandcoolingwaterlinesbyaflangedstubraisedaboveground.
Flangedconnectionsshouldbeaminimumof300mmaboveprevalentgradelevel.Itisadvantageousto
setacommonlevelforallthesetakeoffsattheoutsetofthejob.Whenlocatingtieinconnectionsto
undergroundsystems,especiallyfromelevateddrainpoints,andadjacenttoequipmentplinths,ensure
adequateclearance.
Allburiedsteelpipesshouldhaveappliedacorrosionresistantcoatingandwrapping.
Deepvalveboxesforburiedlinesshouldbedesignedwithampleroominsidetheboxforamaintenance
mantobendoverandusewrenchesfortighteningflangesofrepackingvalves.Considerationshouldbe
giventotheuseofconcretepipeinlieuofsquareboxes.
Thecriteriaforagoodundergroundpipingdesignshouldbeeaseofmaintenance.Pipingshouldbeso
spacedastoalloweasydiggingoutandreplacementoffaultysectionsforthisreason,neverrun
undergroundpipingunderorthroughfoundations.

FiguresTable

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TYPICALPIPERANKBENTS

TOTAL
AVAILABLE
TYPE PIPERACK CANTILEVER NUMBER
WIDTHWIN
mm
WITHOUT WITH
No. WIDTHA WIDTHB OFELEV.
CANTILEVER CANTILEVER
1 3000 3000 1
6000TO
2 6000TO7300 9150TO10400 1500 1
7300
8500TO
3 8500TO9750 11600TO12800 1500 1
9750
6100TO
4 11900TO14300 13700TO16150 900OR1200 2
7300
8500TO
5 16800TO19200 18600TO21000 900OR1200 2
9750
6100TO
6 8500TO10400 11000TO12800 900OR1500 1.5
7300

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7 12200TO13400 14650TO15850 8500TO 900OR1500 1.5

9750

TYPICALPIPERANKINTERSECTION

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SINGLETIERRACKTURNINGTHROUGH90

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CROSSSECTIONOFSINGLELEVELPIPERACK

EXPANSIONLOOPS

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PIPERACKLAYOUTS

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PIPERACKLAYOUTS

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SPACINGPIPETRACKSLEEPERS

TRENCHEDPIPING

Categories:PlantLayoutTags:designguide,pipeway,plantlayout

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PROCESSDESIGNBASISSULFURDEGASSINGSECTION
March15,2012qdzungLeaveacomment

1.0INTRODUCTION

1.1SulfurRecoveryComplex

1.2SulfurDegassing

2.0PROCESSDESCRIPTION

2.1ProcessOverview

3.0SCOPEOFGAALICENSEPACKAGE
4.0FEEDSTOCK
5.0PRODUCTSTREAMS
6.0DESIGNCONSIDERATIONS
7.0PROCESSCONTROLPHILOSOPHIES

7.1ControlPhilosophyOverview

7.2DetailedControlPhilosophyDescription

8.0UTILITIES
9.0BATTERYLIMITCONDITIONS

1.0INTRODUCTION
1.1SulfurRecoveryComplex

DuetothehighersulfurcontentinCanadianextraheavycrude,theOperationCanadianCrude(OCC)Project
willincludeanexpansionofsulfurrecoveryprocesses,includingamineregeneration,sourwaterstripping,
elementalsulfurproduction,andtailgassulfurremoval.Revisedsulfurremovalcapacitywillbe1,220LTD.

TomeetpostOCCsulfurrecoveryrequirementsof1,220LTD,threeexistingsulfurrecoveryunit(SRU)trains
A,B,andCtrainswilloperatewithtwonewtrainsDandE.Undernormaloperation,SRUCwilloperateon
40%oxygenenrichmentwhileSRUAandSRUBwilloperateonaironlyandnewSRUDandSRUEwill
operatewithalight(22%)oxygenenrichment.Duringupsetconditions(SRUtrainortailgasunit(TGU)is
tripped),theunitwilloperateinmaximumoxygenenrichmentmodewithtrainCat40%O2andnewtrainsat
30%O2.

1.2SulfurDegassing

Theexisting600LTDDGAASSsulfurdegassingfacilitywillberelocatedandexpandedwithtwonew
identical575LTDtrainstodegastheproductsulfurpriortostorageandtransportation.Thedegassingsection
includesonedegassingcontactorandsupportingequipmentforeachnewSRUtrain.
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Therelocationoftheexistingdegassingtrainisnotpartofthedesignofthenewdegassingunits.Inthis
documentthenewunitsaredescribed.Refurbishingtheexistingdegassingunitandintegratingthethree
degassingunitswillalsobepartoftheoverallOCCscopebutisnottheresponsibilityofGoar,Allison&
Associates(GAA).

2.0PROCESSDESCRIPTION
2.1ProcessOverview

TomeetpostOCCsulfurrecoveryrequirementsof1,220LTD,theexistingSulfurDegassinghastobe
expandedwithtwonew575LTPDtrains,whichwilloperateinparalleltotheexistingoneandfedwithsulfur
fromSRUA,SRUB,andSRUCandthenewSRUDandSRUE.Undernormaloperation,alltrainsexcept
SRUCwilloperateasaironlywithaminimumoxygenflowtothenewunits.

Thenewdegassingtrainsincludeadegassingcontactorandsupportingequipment.

ExistingdegassingcontactorT394andsulfurcoolerE394willberelocatedadjacenttonewsulfurdegassing
contactorsT395andT396.Undegassedsulfurfromexistingandnewsulfurrecoveryunitswillbemanifolded
toallowdistributionofsulfurtothethreedegassingcontactors.Productsulfurfromdegassingcontactorswill
rundowntonewsulfurloadingtanks.DegassingventwillreturntoSRUD&SRUEtobeusedas
supplementalcombustionair.

ApreliminaryProcessFlowDiagramhasbeenincludedbelow.

2.2DetailedProcessDescription

Theliquidsulfurfromthesulfurlocksisdrainedviaacollectingheadertothesulfurcollectingdrumineach
SRU.Thevesselbreathesagainstthetailgasheader.Fromthisdrum,thesulfurispumpedtoasulfurcollection
header,feedingboththeexistingandthenewdegassingcolumns.BeforeenteringtheDGAASScolumn,the
sulfuriscooledusinghighpressurecondensate.

ThesulfurproducedintheClausunitscontainsnormallyabout250300ppmwtH2Swithamaximumof400
ppmwt.DegasificationreducestheH2Scontenttolessthan10ppmwt.Theprincipleofdegasificationis
injectionofpressurizedairintotheliquidsulfur,therebystrippingthedissolvedH2Sfromthesulfurand
convertingtheH2Sx(polysulfide)toH2SandSulfur.

Theactualsulfurstrippingtakesplaceinthecolumnpackingwherethesulfurisvigorouslyagitatedbybubbling
ofairthroughtheliquidsulfur.Thestrippingair,containingthereleasedH2Sisremovedfromthecolumnand
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reroutedviasulfurdegassingventknockoutdrum(thefeedvesseloftheexistingsulfurdegassingtrain),
operatedat25psig,tothefrontofoneofthenewSRUs.

ThesulfurlevelinthepumpingcompartmentsoftheSRUsulfurcollectingdrumsarekeptconstantbymeansof
levelcontrolleractingonacontrolvalveinthedischargeofthesulfurpump.Thesulfurfromeachstripping
columnisdischargedtosulfurbulkstorageonlevelcontrol.

AminimumflowrecyclelinefromthesulfurbulkstoragetankswillberoutedbacktoSRUA/B/C/D/Esulfur
pits.ThissulfurshallbereprocessedthroughthedegassingsystemalongwiththeundegassedSRUsulfurto
keepthesulfurintheliquidsulfurheadersflowing.Thislineisoutsidethescopeofthenewunits.

3.0SCOPEOFGAALICENSEPACKAGE

RequirementsforpostOCCSulfurDegassingwillbemetwithoneexistingtrainandtwonewidentical575
LTDtrains.

Therequiredstrippingairwillbedeliveredbycompressorsandairdryersthatwillfeedalldegassingtrains.
GAAwillindicatetheairrequirementsforthenewtrains.

TherelocationandupgradeoftheexistingtrainisnotpartoftheGAAlicensepackage.

4.0FEEDSTOCK
Designbasisforthesulfurfeedstreamtoeachdegassingtrainissummarizedbelow.

SRUSulfurfeedrate 575LTD

H2SandH2Sx(asH2S)inthesulfur
400ppmwt.max.
feed

Sulfurfeedpressure ByGAA

Sulfurfeedtemperature 342F

DryPurity,weight%minimum 99.5

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OrganicMaterial,weightppm 1,000
maximum

MineralAsh,weightppmmaximum 100

Acidity,weightppmmaximum 40

5.0PRODUCTSTREAMS
BrightYellow(at
Color ambient
temperatures)

Sulfurfeedpressure ByGAA

Sulfurtemperature ByGAA

DryPurity,weight%minimum 99.5

OrganicMaterial,weightppm
1,000
maximum

HydrogenSulfide,weightppm
10
maximum

MineralAsh,weightppmmaximum 100

Acidity,weightppmmaximum 40

6.0DESIGNCONSIDERATIONS
Objectiveistomakeprocessconfigurationofallthreedegassingunitsidentical.SulfurDegassingB(SDB)and
SDCshouldalsobeidenticalinequipment,instrument,andpipesizes.

NewsulfurcoolerswillhavesimilarconfigurationasexistingsulfurcoolerE394.Recycledsteamcondensate
willbeused.Incasecondensateistoocool,directsteaminjectionwillbeusedfortemperaturecontrol.Hot
waterreturnfromsulfurcoolerwillbereturnedtocondensateflashdrumD361togenerate10psigsteam.

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Thetotalventgasstreamfromthethreedegassingtrainswillbecombinedinoneheaderandhavethecapability
tobesenttoeitherSRUDorSRUE.

Protectiveinstrumentationwillbeprovidedtopreventliquidsulfurcarryoverinsulfurdegassingvent.An
additionalsafeguardistobeadded:ConvertexistingsulfurfeeddrumD394tosulfurdegassingventknockout
drum.ThedrumwillnolongerbeusedincurrentserviceasfeeddrumforT394.Withthisconfiguration,each
degassingcontactorwillhaveindividualbackpressurecontrol.VentfromD394willhaveabackpressure
controller,setat25psigtoensureadequatepressuretodrainsulfurcarryovertosulfurcollectingdrumsD278
orD288.

Mostclientsrequirepressurereliefdeviceforthedegassingcontactorevenalthoughtherearenoviable
contingenciestocauseoverpressure.Typicalsizingbasisistoratepressurereliefdevicefordesignsulfurflow
rate.ExistingsulfurdegassingcontactorT394usesarupturedisk.

ThenecessityofreliefdeviceshastobeevaluatedbyGAA.GAAisrequestedtoproposedalternativesolutions,
ifany.

7.0PROCESSCONTROLPHILOSOPHIES

7.1ControlPhilosophyOverview

SulfurDegassingUnitwillconsistoftwonewsulfurdegassingsections.Thefollowingisabriefprocess
overviewofeachnewequipmenttrain:

TheliquidsulfurfromtheSRUispumpedtothedegassingcolumnaftercoolingwithhighpressurecondensate.
ThesulfurproducedintheClausunitscontains250400ppmwtH2S.Degasificationbymeansofthe
degassingprocessreducestheH2Scontenttolessthan10ppmwt.Thestrippingair,containingthereleased
H2SisremovedfromthecolumnandreroutedtothemainSRUreactorburnerviaasulfurdegassingventknock
outdrum.Theliquidsulfurfromthestrippingcolumnisdischargedtoexistingstoragetanksonlevelcontrol.

MaincontrolobjectivesforeachnewSulfurDegassingUnitincludes:

Controlofthesulfurfeedflowtoeachdegassingunit.

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ControltemperatureoftheliquidsulfurbyadjustingtheflowrateHPcondensate.

ControlthetemperatureoftheHPcondensatebyadjustingthe(reduced)400#steamflowtothecondensate
steammixvalve.

Controltheflowofairtothedegassingcontactor.

Controlthelevelofliquidsulfurinthedegassingcontactorbyadjustingtheamountofsulfurtothestorage
tanks.

Backpressurecontroltheventgasoffthedegassingcontactor.

Backpressurecontroloftheventgasfromthesulfurdegassingventknockoutdrumatapressurehighenough
tofeedbacktotheSRUreactorburner.Similarly,thepressuremustbehighenoughsuchthatanysulfur
collectedinD394candrainbacktoeitherSRUDorEpits.

7.2DetailedControlPhilosophyDescription

TheliquidsulfurfromtheSRUispumpedtothedegassingcolumnaftercoolingHPcondensate.The
temperatureoftheliquidsulfurismaintainedattheoptimumtemperaturebyadjustingtheHPcondensateflow
rateattheoutletsideofthesulfurcooler.TheHPcondensateistemperaturecontrolledbyadjustingthe400#
steamflowtoensureproperheattransferbetweentheHPcondensateandliquidsulfur.

Toensureproperdegasification,air,whichisflowcontrolled,isinjectedintotheliquidsulfur,therebystripping
thedissolvedH2Sfromthesulfur.

TheactualH2Sstrippingtakesplaceinthecolumnwherethesulfurisvigorouslyagitatedbybubblingofair
throughtheliquidsulfur.Thestrippingair,containingthereleasedH2S,isremovedfromthecolumnbymeans
ofbackpressurecontrolandreroutedtothesulfurdegassingventknockoutdrum.Thedrumisalsokept
pressurizedbymeansofpressurecontrolhighenoughtobeabletodischargetheventgastomainreactorburner
intheSRUDorSRUE.ThisventgasstreamwillbemeasuredandviaaratiostationincorporatedintheSRU
burnercontrolsystem.

8.0UTILITIES
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Pressure
Pressure Pressure Temperature Temperature Temperature
Min
Utility Normal Design MinMax Normal Design
Max
PSIG PSIG F F F
PSIG

BoilerFeedWater 570840 675 925 225250 225 300

Condensate 4060 100 210

SteamLowPressure
921 17 46 240245 242 300
(10psig)

SteamLowPressure
4565 55 90 276296 287 308
(55psig)

SteamMedium
80121 98 146 340530 420 580
Pressure(100psig)

SteamHighPressure
340460 360 510 420505 440 555
(400psig)

85
CoolingWaterSupply 105125 120 150 6085 125
(ForHX
Design)

105110
CoolingWaterReturn 5570 60 95 120Max. 170
(ForHX
Design)

UtilityWater(Service
2732 30 57 3575 55 125
Water)

RefineryFuelGas 5058 53 125 30125 81 175

InstrumentAir 55150 71 100 20110 65 160

UtilityAir(PlantAir) 70150 85 175 20110 65 160

Oxygen
58142 118 167 20110 65 160

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Nitrogen 120180 150 205 20110 65 160

Hydrogen 200255 252 300 20110 65 160

NaturalGas 55120 100 150 20110 65 160

9.0BATTERYLIMITCONDITIONS

Normal Normal Design Design

FEEDSTREAMS SOURCE Pressure Temperature Pressure Temperature

(psig) (F) (psig) (F)

SulfurRecovery
LiquidSulfur ByGAA* 334342 ByGAA ByGAA
Units

DryCompressedAir SRCOffsites ByGAA ByGAA ByGAA ByGAA

Normal Normal Design Design

PRODUCT
DESTINATION Pressure Temperature Pressure Temperature
STREAMS
(psig) (F) (psig) (F)

SulfurRecoveryUnit
SulfurDegassingVent ByGAA ByGAA ByGAA ByGAA
D/E

LiquidSulfur SulfurStorage ByGAA ByGAA ByGAA ByGAA

*GAAtoconfirmsupplypressureforexistingrelocatedsulfurdegassingcontactor.

Categories:PlantLayoutTags:DESIGNBASIS,designguide,PROCESS

PlantLayoutGeneralRequirements
March15,2012qdzungLeaveacomment

TableofContents

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1.Process
2.HazardousandToxicAreas
3.EconomicConsiderations
4.AestheticConsiderations
5.Access
6.Safety
7.SiteConsiderations
8.ExternalInfluences
9.Clearances
10.Paving
11.Elevations
12.Insulation
13.ColumnsandDrums(Vertical/Horizontal)
14.Exchangers
15.FurnacesandFiredEquipment
16.Pumps
17.Compressors
18.Piping
19.AccesstoValvesandInstruments
20.ReliefValveSystems
21.MaintenanceandEquipmentHandling

1.Process
Equipmentshouldbelaidoutinasequencetosuittheprocessflow.Fluidflowrequirements,forexample
gravityflowsystems,pumpsuctionheadsandthermosyphonsystem,oftendictaterelativeelevationsand
provoketheneedforstructures.Limitationsofpressureortemperaturedropintransferlinesdecide
proximityoffurnaces,reactors,etc.

2.HazardousandToxicAreas
Equipmentitemsconsideredapossiblesourceofhazardshouldpreferablybegroupedandlocated
separately,ifpossibleandeconomic.
Examplesare:
Furnaces,flarestacks,orotherdirectfiredequipmentcontaininganopenflamerotatingormechanical
equipmenthandlingflammableorvolatileliquidswhichcouldeasilyleakorspill.
Equipmenthandlingacidsorothertoxicmaterialswhichcouldcausedamageordangerbyspillage,
shouldbegroupedandcontainedwithinabundedarea.

2.1LocateControlRooms
15metersormorefromequipmentwhichinoperationorduringmaintenancecancreateahazard.(Ifnot
practicable,pressurize).Ensuremaximumcableruntoanyinstrumentisnotmorethan90meters.

2.2LocateBuildings
Exampleoffices,firstaidrooms,cafeterias,garages,firestation,warehouses,gasholdersandworkshops
aminimumof30metersfromanyhazard.
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Unpressurisedsubstationandswitchroomsaminimumof15metersfromanyhazard.

DefinitionofdangerousareasandtheirsafetyrequirementsshallbeinaccordancewiththeInstituteof
PetroleumSafetyCodes,orwherethisisnotrecognized,totheapplicableNationalCode(s).

LocalbyelawsandFireOfficewhoserequirementsmaybemorestringentorspecificthantheabove
codesshalltakeprecedence.

3.EconomicConsiderations
Apartfromprocessrestrictions,positionequipmentformaximumeconomyofpipeworkandsupporting
steel.Ascompactalayoutaspossiblewithallequipmentatgradeisthefirstobjective,consistentwith
standardclearances,constructionandsafetyrequirements.
Minimizerunsofalloypipeworkandlargeborepipewithouttheintroductionofexpensiveexpansion
devices.
Optimizeuseofsupportingstructuresinconcreteorsteelbyduplicatingtheirapplicationtomorethan
oneitemofequipmentandensuringthataccessways,platforms,etc.,havemorethanonefunction.Space
savingcanbeachievedbylocatingequipmentoverthepiperack.Pumpsshouldingeneralbelocatedwith
theirmotorsunderneaththemainpiperack.

4.AestheticConsiderations
Attentionshouldbepaidtothegeneralappearanceoftheplant.Anattractivelylaidoutplantwith
equipmentinstraightlinesisusuallyeconomical.Preferenceshouldbegiventouseofasinglecentral
pipewaywithaminimumnumberofsidebranches,withequipmentlaidoutinrowsoneitherside.
Buildings,structuresandgroupsofequipmentshouldformneat,symmetrical,balancedlayout,consistent
withkeepingpiperunstoaminimum.
Towersandlargeverticalvesselswillbearrangedinrowswithacommoncenterlineifofsimilarsize,but
lineupwithacommonfaceifdiametersvarygreatly.Ifadjacenttoastructure,commonfacewillbeon
thestructureside.
Centerlinesofexchangerchannelnozzlesandcenterlinesofpumpdischargenozzlesshouldbelinedup.
Pipingaroundpumps,exchangersandsimilargroundlevelequipmentshouldberunatsetelevations,
onefornorthsouthandanotherforeastwestelevationswhereverpossible.(Similarforrackpipework).
Theseelevationsbeingtobottomofpipeorundersideofshoeforinsulatedlines.Thisshouldalsohelpto
achieveacommonelevationforofftakesfrompipeways.
Ifpossible,duplicatedstreamsshouldbemadeidentical.Handedarrangementsshouldbeavoided.Follow
thisprincipleforthissimilarequipmentsequenceswithintheprocessstream,forexample,fractionator
towerwithoverheadcondensers,refluxdrumpumpsandreboiler,etc.,isasystemwhichcouldbe
repeatedalmostidenticallyfordifferenttowershavingadifferentprocessduty.Advantagesaredesign
andconstructioneconomy,improvedmaintenanceandoperatingefficiency.

5.Access
Overallplantarrangementmustbereviewedforconstructions,operation,safetyandmaintenance.
Considerlargeitemsofequipmentortowersforwhichspecialliftinggearwillberequired.Provide
adequateaccesstolifttheseintoplace.Largeequipmentpositionedclosetoboundarylimitsmayrequire
erectionfromoutside.
Checktoascertainwhethersufficientspacewillbeavailableattheconstructionphase.
Operationandmaintenanceshouldbereviewedbytheeventualoperatingcompany.Giveconsiderationto
maintenanceaccesstoairfins,etc.,abovepipetracks.
Considerlocationofequipmentrequiringfrequentattendancebyoperatingpersonnelandrelative

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positionofcontrolroomtoobtainshortestandmostdirectroutesforoperatorswhenonroutine
operation.

6.Safety
Provide:Sufficientclearareabetweencriticalorhightemperatureitemsofequipment.Clearroutesfor
operatorswithtwoormoreescapeladdersorexitsatextremities.Clearroutesforaccessbyfirefighting
equipment.
DonotAllow:Areasclassifiedashazardoustooverlaptheplotlimitsorextendoverrailwayswhereopen
fireboxenginesarelikelytobeemployed.

7.SiteConsiderations
Ascertainsoilloadingconsiderationsandsitecontoursbeforefixingfinallayout.Considerablevariations
occurinallowablesoilloadsthroughoutsiteareas.Itmaybeadvantageoustolocateheavyequipmentin
thebestsoilloadingarea.Useexistingcontours,sothatthequantityofearthmovementduetocutandfill
maybesubstantiallyreducedbyintelligentpositioningoftheequipment.

8.ExternalInfluences
Stacksshouldpreferentiallybelocatedsothatprevailingwindsdonotblowsmokeovertheplant.Trynot
tolocatetheplantwhereitwillreceivedust,smoke,sprayoreffluentfromaneighboringplant.
Avoidusinglocationspollutedbycontinuousdriftofdust,smoke,etc.
Iftheplantistobelocatedinanexistingrefineryorfactorysite,lineupwithexistingroads,columns,
stacks.
Locationofexternalrailways,pipeways,cableways,sewersanddrains,etc.,mayalsoinfluencethefinal
orientationoftheplant.
Whenrailwayfacilitiesarerequired,avoidboxingintheplantbybranchlines.
Hazardousareasfromotherexistingplantsorequipmentmayextendovertheplantlimit.Thiscould
effectivelyreduceplotsizeandthusinfluencetheplantlayoutphilosophy.

9.Clearances
(SeeTableA)Clearancesbetweenadjacentplantsshouldatleastequalthoseforprimaryaccessroads.
Thespacebetweenedgeofanyroadandnearestequipmentmustnotbelessthan1.5meters.
Adequateroadaccesswithproperlyformedroadsmustbeprovidedforknownmaintenancepurposes:
e.g.,compressorhouse,largemachineryareas,reactorsorconverterswherecatalystremovaland
replacementmustbeeffected.
Equipmentrequiringinfrequentmaintenancesuchasexchangertubebundles,towerinternals,etc.,need
adequatelevelclearspaceforaccess/removalpurposes.Thegroundneednotbespecificallybuiltupto
takeloadsotherthanasurfacingofgranitechipsorsimilar,asduckboards,gratings,orothertemporary
materialcanbelaidatthetimewhentheplantisundermaintenance.

10.Paving
Withintheprocessareaminimalconcretepavingshouldbesuppliedforwalkwaysinterconnectingmajor
itemsofequipment,platforms,stairwaysandbuildings.
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Pavingshouldbesuppliedaroundpumpsorothermachinerylocatedintheopen,underneathfurnaces,
andanyotherareaswherespillageislikelytooccurduringnormaloperation.

Areascontainingalkalisacids,orotherchemicalsortoxicmaterialsshouldbepavedandbundedto
preventspillagespreading.Otherareasoftheplantaretobegradedandsurfacedwithgranitechipsor
similarmaterial.

11.Elevations
(SeeTableA)Allelevationsrefertoanominal100meters.Thepoint100elevationistakenasthehigh
pointofpavinginthepavedareas.Thisshouldbecommonthroughouttheplant.Equipmentelevations
referringtogradeelevationsof100metersareasshownintableA.

12.Insulation
Insulationmaybeappliedtovesselsupportsorstanchionsofstructuresforfireprotectionpurposes,thus
decreasingavailablefreespaceforaccess,sitingofpipework,instrumentsorelectricalequipment.
Inparticular,notethicknessofinsulationofveryhightemperatureorlowtemperaturepiping,whichmay
considerablyincreaseeffectiveo/dofpipetoberouted.Forlowtemperatureinsulation,additional
clearancemustbeprovidedaroundcontrolvalves,instrumentation,etc.Consideradditionalweightof
insulationandreducedcentersofsupportsnecessarytosupportheavilyinsulatedpipe.

13.ColumnsandDrums(Vertical/Horizontal)
Columnsareusuallyselfsupportingwithoutexternalstructures.Circularorsegmentalplatformswith
laddersaresupportedfromtheshell.Maximumallowablestraightrunofladderbeforeabreakplatform
shouldnotexceed9meters.
Factorsinfluencingcolumnelevationareprovisionofgravityflowsystemandinstallationoftherm
syphonreboilers.Dependingonplantarrangementcolumnsmayhavetobeelevatedtoaheightinexcess
ofthenormalrequirementstoallowforheadroomclearancefromlowlevelpipingofftakes.
Skirtheightofallcolumnsorvesselsprovidingsuctiontopumps,particularlyifhandlinghotorboiling
liquids,shouldbeadequateforpumpNPSHrequirements.
Provideplatformsoncolumnsforallvalves3andabove,instrumentcontrollersandtransmitters,relief
valves,manholesandblindsorspades.Otherwise,accesstosmallvalves,indicatinginstruments,etc.,is
acceptablebyladder.
Platformsforaccesstolevelgaugesandcontrollersshouldnotbeprovidedifundersideofsupporting
steelworkislessthannormalheadroomclearancefromgrade.Adjacentcolumnsshouldbechecked,so
thatplatformsdonotoverlap.Forlayout,2.0to2.5metersbetweenshells,dependinguponinsulation,
shouldsuffice.Allow900metersminimumclearancebetweencolumnfoundationandadjacentplinth.
Provideclearanceforremovalofinternalsandattachments,andfordavitsattopofcolumnifrelevant.
Centerlineofmanholeswillbe900mmaboveanyplatform.
Horizontalvesselsshouldbelocatedatgrade,withlongitudinalaxisatrightanglestothepipewayif
possible.Considersavingplotspacebychangingvesselsfromthehorizontalandbycombiningvessels
togetherwithaninternalhead.(Subjecttoprojectapproval).Sizeandnumberofaccessplatformson
horizontalvesselsshallbekepttoaminimumandarenottobeprovidedonhorizontalvesselsordrum
whenthetopofthevesselis2.5metersorlessfromgrade.
Channelendofvesselsprovidedwithinternaltubularheaterswillfacetowardsopenspace.Withdrawal
areamusttobeindicatedonstudies,GAsandPlotPlants.Internalagitatorsormixersaretobeprovided
withadequateclearanceforremoval.RemovalareamustbeindicatedonStudies,GAsandPlotPlants.

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14.Exchangers
Tubularexchangersusuallyhavestandardlengthtubesof2.5,4,5,and6meters.
Wheneverpossiblelocateexchangersatgradetofacilitatemaintenanceandtubewithdrawal.Twoor
moreshellsformingoneunitwillbestacked,orotherwisearrangedasindicatedontheexchanger
specificationsheet.
Exchangersondissimilarservicemaybestackedbutnevermorethanthreehigh,exceptforfintubetype
units.Horizontalclearanceofatleast900mmwillbeleftbetweenexchangersorexchangersandpiping.
Wherespaceislimited,clearancemaybereducedbetweenalternateexchangers,providingsufficient
spaceisleftformaintenanceandinspectionaccess.
Tubebundleremovaldistancewillbeminimumtubelengthplus900mm.Minimumremovaldistance
plus600mmwillbeleftbehindtherearshellcoveroffloatingheadexchangers.Whererearshellcoveris
providedwithadavit,allowclearanceforfullswingofthehead.Setoverheadvaporexchangersor
condensersatsuchelevationthatexchangerisselfdraining.
Arrangeoutletstoaliquidholdpotortrap,sothatundersideofexchangertubesisabovetheliquidlevel
inthetrap.Arrangeexchangerssothatfixedendisatthechannelend.Verticalexchangersshouldbeset
toallowliftingorloweringoftubebundle.ConsultVesselSectionastofeasibilityofsupportingvertical
exchangersfromassociatedtowers.
Spacefortubeorbundlewithdrawalshouldbeleftfree,exchangerchannelspreferablypointingtowards
accessareaorroad.Ifexchangerissituatedwellwithintheplot,leaveafreeareaandapproachfor
mobileliftingequipment.Preferablyairfinexchangersshouldbelocatedinaseparaterowoutsidethe
mainequipmentrow,remotefromthecentralpipeway.Considerlocationofairfinexchangersoverthe
centralpipewayifplotspaceifverylimited.

15.FurnacesandFiredEquipment
Locateatleast15metersawayfromotherequipmentwhichcouldbeasourceofspillageorleakageof
gas.
Nopitsortrenchespermittedtoextendunderfurnacesoranyfiredequipmentandifpossibletobe
avoidedinfurnaceareas.
Ensureampleroomatfiringfrontforoperationandremovaloftheburnersandforburnercontrolpanel
ifrequired.
Bottomfloorfiredfurnacesrequireadequateheadroomunderneaththefurnace.Wallfiredfurnaces
requireanadequateplatformwidthwithescaperoutesateachendofthefurnace.
Apartfromadequateplatformingandaccesstothefiringfront,otherstructuralattachmentsand
platformingaroundfurnacesshouldbekepttoaminimum.Peepholesshouldonlybeprovidedwhere
absolutelynecessary.Accessbymeansofstepladderissufficient.
Arrangeheatersoncommoncenterlinewhereverpossible.Provideunobstructedspaceforwithdrawal.
Operationandmaintenanceplatformsshouldbewideenoughtopermita1.0meterclearwalkway.
Escapeladdersshouldbeprovidedonlargeheaters.Verticalheatersareusuallysuppliedwithstub
supportingfeet,ensuredrawingsshowadequatesupportselevatedtorequiredheight.Headroom
elevationfromfloorleveltoundersideofheatershouldbe2.3meters,toprovidegoodfiringcontrol
operation.

16.Pumps
Locatepumpsclosetotheequipmentfromwhichtheytakesuctionpossiblyunderstructuresorwith
motorendsunderapiperackallowinganaccessaisleformobilehandlingequipment.Suctionlinesare
generallylargerthandischargelines,toavoidproblemsarisingfromlowNPSH.
Endsuction,topdischargeispreferableforpumpstakingsuctiondirectlyfromtanksorvesselslocatedat
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grade.Pumpsshouldbearrangedinrowswithcenterlineofdischargesonacommonline.Clearances
betweenpumpsorpumpsandpipingshallbeaminimumof900mm.

17.Compressors
Locatereciprocatingcompressors,anchorsandrestrainsforpipesinthecompressorsystemon
foundationsindependentofanybuilding,structureorpipetrestle.
Spacingvarieswithtypeandduty,payparticularattentionto:Withdrawalofengineandcompressor
pistons,camshaft,crankshaftandlubeoilcoolerbundlecylindervalvemaintenanceclearancewith
leastpossibleobstructionfrompipingsupports.
Compressorsaregenerallyprovidedwithadegreeofshelter,i.e.,asheetsbuilding.Keepthesidesupto8
feetabovegrade,openandventtheridgetoallowforescapeofflammablegaswhichmightleakfromthe
machines.Certaintypesofcompressors,owingtotheheightofthemassfoundationabovegradelevel,
requireamezzaninefloorofthegridconstructiontoavoidtrappinganygas,foroperationand
maintenance.

18.Piping
Allpipingwithinaprocessareashouldusuallyberunabovegrade.Trenchedpipingtobeavoided.
Piperacksandsupportstobeofthesimplestform.
Piperacksmaycontaintwolayersofpipework.Avoidtriplelayerofpipewaysexceptforveryshortruns.
Runpipingexternaltotheprocessareaatgradeonsleepers(300mmhigh).(Pipingatgradeischeaper
butliabletointerferewithaccess).
Locatelargeborepipingasclosetostanchionsaspossible.Linesrequiringaconstantfall(reliefheaders)
canberunoncantileversfrompiperackstanchionsoronverticalextensionstopipetrackstanchions.
Runhotlinerequiringexpansionloopsontheoutsideedgeofpipewaytopermitloopstohavegreatest
widthoverthepipewayandfacilitatenesting.Takeoffelevationsfrompipewaysshouldbeataconstant
elevationconsistentwiththerangeofpipesizesinvolved.
Changeelevationwheneverbanksofpipes,eithertogradeoronpiperackschangedirection.Elevationsto
theundersideofpiperackswillbeminimumforoperationandmobilemaintenanceequipmentand
consistentwithclearances.
Openpipetrenchesmaybeusedbetweenplantswherethereisnoriskofflammablevaporscollecting.It
issometimesconvenienttorunopentrenchesalongsideroadways.(Soilfromthetrenchcanbeusedto
builduptheroad).Whereapipewayorroadchangesdirection,thepipeisrunbeneaththeroad.
Occasionallyitispermissibletorunpipesintrenchestoovercomeadifficultpipingproblem.Such
trenchesshouldbeconcreted,drainedandcovered.Althoughtrenchedpipingistobeavoidedduetothe
expenseandhazardsassociatedwithopentrenches,undergroundburiedpipingisacceptableprovided
pipeisadequatelyprotectedandbelowthefrostline.
Sizingandarrangementofundergroundpipingshouldbefixedearlytoensurethatinstallationis
simultaneouswithfoundationwork.(Manydrains,sewersandcableways,whichdonotrequireattention,
arerunundergroundbelowthefrostline).Leavespacefordrawboxesoncableways,anchorson
undergroundcoolingwaterpipesandmanholesonsewers.Firemainsshouldbelocatedbetweenthe
perimeterroadandtheplant.

19.AccesstoValvesandInstruments
(SeeTableA)
Alloperatingvalves3andlargeraretobeaccessibleeitherfromgradeorsuitableplatformwith
maximum2.0metersaboveworkingleveltocenterofhandwheel.Smalloperatingvalvescanbereached
fromaladder.Valvesinstalledformaintenanceandshutdownpurposes(otherthanoperating)canbe
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reachedbyportableladder.Otherwiseextensionspindlesorsuitableremoteoperatinggearshouldbe
provided,butnotonvalves11/2andbelow.TheminimumaccesstobeprovidedisasshownonTableA.

20.ReliefValveSystems
Closedreliefvalvesystemsshouldbearrangedtobeselfdrainingandshouldnotcontainpocketswhere
liquidsmaycondenseandcollecttoprovideanybackpressure.

21.MaintenanceandEquipmentHandling
Handlingfacilitiesarelimitedtothehandlingofworkingpartsofequipmentwhichrequirefrequentor
routineserviceandwhichareinaccessibletomobilehandlingfacilitiesassumedtobeavailableatthe
plant.Thesefacilitiesarenotdesignedtohandleheavypartssuchasbedplatesofrotatingmachines,
rotatingequipment,compressorsbodies,machineryframes,etc.Thehandlingfacilitiesprovidedare
limitedasshownontableA
Thedesignandinstallationoftrolleybeams,overheadtravellingcranesandhoisttrestlesisbasedon
liftingthepartstobehandledandtransportingorloweringthemtospecifiedmaintenanceareasorto
grade.Fromthesepointstheyareexpectedtoberemovedbyskidsorhandtruckstootherareasmore
suitableformaintenance.

TablesA
ACCESSCLEARANCES

DESCRIPTION MINIMUM
ClearHeadroom ClearWidth OtherClearance
PrimaryAccessRoads
10.5Minsidecorner
(carryingmajor 6M 6M
radius
equipment)
4.5Minsidecorner
Secondary 5.1M 4.8M
radius
MinorAccessRoads 5.1M 3.6M
YardPiping 3M
Platform,walkways,
1Mworking
passageways,working 2.1M
platforms
areas,stairways
Manholecentre
Clearancefromfaceof
2.1M 1M Approx.1Mabove
manhole
platform
Railways Tosuitlocalcodes

ELEVATION

OpenAirPavedAreaHighPointofPaving 100.000M
Undersideofbaseplatesforstructuralsteel 100.150M
Stairandladderspads 100.075M
Undersideofbaseplatesvesselandcolumnplinths 100.300M
Topofpumpplinths 100.230M

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VALVEACCESS

MINIMUM
LOCATE
ITEM ACCESS
OVER
FROM
FIXED EDGEOF PLATFORM
SIZE
LADDERS PLATFORM ORGRADE
EXCHANGERHEADS ALL X
OPERATIONAL 2and
X
VALVES under
OPERATIONAL
over2 X
VALVES
MOTOROPERATED
all X
VALVES
CONTROLVALVES all X
R.V.s(Process) 2andover X
Accessibleby
BLOCKVALVES portable
ladder.
Edgeof
platform
accesswhere
BATTERYLIMIT
ALL ClientsSpec.
VALVESETC.
requests.
Otherwiseno
access.
PRESSURE
ALL X
INSTRUMENTS
TEMP.INSTRUMENTS ALL X
SAMPLEPOINTS ALL X
TRYCOCKS ALL X
GAUGEGLASSES ALL X
LEVEL
ALL X
CONTROLLERS
PROCESSBLINDS
ALL X
ANDSPADES
MANWAYS ALL X
HANDHOLES ALL X
Noaccess
NOZZLES ALL
Provided.
VESSELVENTS ALL X
LINEDRAINSAND Noaccess
VENTS Provided.

MAINTENANCEFACILITIES

EQUIPMENT PARTHANDLED HANDLINGFACILITIES

Reactors,Vesselsand Davitsorhingesfor
ManholeCovers
Columns. swingingopen.
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Internalrequiringregular
Trolleybeamsordavitsfor
removalorservicing.
loweringfromholesto
grade.
Thesewillbeprovidedas
Fixedbedreactors,catalyst speciallyspecifiedtoenable
change,etc. catalysttobeoffloadedand
loaded.
Allsuchexchangersare
providedwithjackboltsto
FloatingHeadExchangers. TubeBundles. breakjoints.Itisassumed
bundleswillbehandledby
mobileequipment.
ExchangerHeads,Channel
Nospecialprovision.
Cover,Bonnets.
Overheadtrolleybeamor
VerticalExchangers. RemovableTubeBundles.
davit.
Pump. Anypart. None.
Overheadtrolleybeamsor
CentrifugalCompressors. Rotatingparts.
cranes.
ReliefValves,2nominal Hitchingpointordavitfor
Piping.
boreandlarger. loweringtograde.
Overheadhitchingpointor
Blanks,blankflangesand
davitonlywhensubjectto
swingelbowweighing
frequentremovalfor
morethan300lbs(125kg).
maintenance.

ListingofInstrumentationWhichMayAssistInitialLayout

LikelyDevicesandProbableNumberFittedtoVariousTypesofEquipment.DevicesandDesignPoints
Affected.

LIST1)

DEVICESANDPROBABLENUMBEROF
EQUIPMENT
ITEMSFITTED
PSV(1)(PressureSafetyValve)
PIC(1)(PressureIndicatingController)
FRC(3)(FlowRecordingController)
TR(1)(Multipoint6channel)(Temperature
Recorder)TI(6)(TemperatureIndicator)
DISTILLATIONTOWER
PI(6)(PressureIndicator)
Analyser(1)(SingleStream)
LG(2)(LevelGauge)
LI(1)(LevelIndicator)
LIC(1)(LevelIndicatingController)
LG(3)(LevelGauge)
REFLUXDRUMSURGE LIT(1)(LevelIndicatingTransmitter)
DRUMBUFFERSTORAGE PI(1)(PressureIndicator)
FEEDTANKPRODUCT TI(1)(TemperatureIndicator)
TANK PSV(1)(PressureSafetyValve)
PIC(1)(PressureIndicatingController)
REACTOR PI(6)(PressureIndicator)
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REACTOR PI(6)(PressureIndicator)
TI(6)(TemperatureIndicator)
PSV(1)(PressureSafetyValve)
TR(1)(Multipoint50Channels)(Temperature
Recorder)
FIC(2)(FlowIndicatingController)
LIC(1)(LevelIndicatingController)
Analyser(1)
PIC(1)(PressureIndicatingController)
TIC(1)(TemperatureIndicatingController)

LIST1)

DEVICESANDPROBABLENUMBEROF
EQUIPMENT
ITEMSFITTED
PI(4)(PressureIndicator)
DPC(1)(DifferentialPressureController)
PIC(1)(PressureIndicatingController)
FR(1)(FlowRecorder)
COMPRESSOR(Axialflow) TI(1)(Multipoint12channel)(Temperature
Indicator)Vibration(2)
NRV(Dampedtopreventreverseflow)
ProgrammerandLogicSystem(1)
ShutdownSystem(1)
PI(4)(PressureIndicator)
COMPRESSORDRIVER FRC(1)(FlowRecordingController)
(Steamturbine) TI(4)(TemperatureIndicator)
ShutdownValve(1)
TRC(1)(TemperatureRecordingController)
TI(6)(TemperatureIndicator)
EXCHANGER PI(2)(PressureIndicator)
LG(1)(LevelGauge)
PSV(PressureSafetyValve)
FRC(4)(FlowRecordingController)
TRC(TemperatureRecordingController)
PIC(PressureIndicatingController)
FURNACES
FlameDetector(2)
LocalPanel
PI(12)(PressureIndicator)

LIST1)

DEVICESANDPROBABLENUMBEROF
EQUIPMENT
ITEMSFITTED
FURNACES(contd) TI(6)(TemperatureIndicator)
MultichannelTemperature(1)
O2Analyser(1)(OnlywhereBFWorsteamis
circulating)
pHAnalyser(1)
Conductivity
LG(3)(LevelGauge)
LIC(1)(LevelIndicatingController)
PSV(3)(PressureSafetyValve)
PCV(3)(PressureControlValve)
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PCV(3)(PressureControlValve)

Inlineinstrumentelements:FlowElements(Orifice,Plates,Venturi,Turbine,P/D,etc.).ControlValves
(Globe,Butterfly,Ball,etc.).ReliefValves.Thermowells.LIST2)

DEVICE TYPE DESIGNPOINTSAFFECTED

(FLOW)
PipeSectionwith
Fe1 Flangerating/size/overalllength/orientation
sensingelement
Fe2 PitotTube Location/straightlengthconnectionsize&type
Location/straightlengths/orientationFlange
Fe3 Orifice/Nozzle/Venturi sizeandrating.Position,sizetypeofinstr.
tappings
Size/endconnections/orientationstraight
Fe4 Elbow
lengths
Orientation/straightlengths/Flangerating/
Fe5 TargetMeterTransmitter
connections/insertionfacetoface
Orientation/straightlengths/Flangerating/face
Fe6 VortexMeter
toface/insertion
Fe7 HotWire ConsultInstrumentDepartment
Verticalonly/Flowupwardsonly.Orientationof
Fe8 VariableAreaMeter
connections,sizesandtype.
Overalllength/size/connections/verticalor
Fe9 MagneticFlowmeter
horizontal/nostraightlengths.
Straightlength/withorwithoutpipesection/
usuallyhorizontalendconnectionandsize.
Fe10 TurbineMeter
(Commontouseupstreamfilterandsometimes
degassing).
Orientationonewayonly/weight/nostraight
Fe11 PositiveDisplacement
lengths.Connectingaspervendorliterature.
Fe12 SonicFlowmeter ConsultInstrumentDepartment
Fe13 WeightRate ConsultInstrumentDepartment
Fe14 RadioActive ConsultInstrumentDepartment
Fe15 PhotoElectric ConsultInstrumentDepartment
Fe16 ChannelsandFlumes MostlyCivilEngineering.
Fe17 VaneType Spoolpiece=facetofaceendconnections.

LIST2)

DEVICE TYPE DESIGNPOINTSAFFECTED

TEMP
TE1 Thermocouple
Location/Increaseinpipedia/elbows,
TE2 ResistanceBulb
connectionsizeandtype.
TE3 FilledSystem
TE4 Thermistor
TE5 Radiation Locationofwindow/heatprotection.
FLAME
FAILURE
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Be Photo Locationofinstrumentandwindow.
Electrical/Colour
ANALYSER
Usuallywithbypasslinetodrainonback
DiverseMethods
toprocessonlyoccasionallyinline
An includingSGand
sometimescoaxialspoolpiece.Faceto
density
face/Flanges.
LEVEL
MEASUREMENT
An Capacitance SimilartotemperatureTe1.
Probe Conductivity Sometimescoaxialinspoolpiece.
PROXIMITY Feromagnetic) Nonintrusive
SWITCH Magnetic) Locationandmounting
a)Noninstrusive
Inductive)
b)Instrusive,typeTe1.
PRESSURE
BourdonTubes
Smalltapping/location/connections/size
DifferentialPressure CapsulesStrain
andtype
Gauge

LIST2)

DEVICE TYPE DESIGNPOINTSAFFECTED

GAUGE
GLASS
LEVEL
LG ALLTYPES Verticalonlynozzlespacing/connections
INTER
FACE
LEVEL
(GAUGEGLASS)
Verticalonlynozzlespacing
LG ALLTYPES
critical/connections
SPEED
MEASUREMENT Magnetic ConsultInstrumentDepartment.
ConsultInstrumentDepartment.Consult
StrobeTachiometer
InstrumentDepartment.
VALVES
Nominalbodysizeisdeterminedbyflow
criteria.Facetoface/connectionsizes
Operationelectrical
flangeratingoften300lbsminimumasa
hydraulic
PV,FV,TV,etcPVC standard.Axisofmovementoftopworks
pneumaticself
mustbeverticalallotherorientation
operated
prohibited.Facetofacedimensionsdonot
alwaysconformtoBS.
SAFETY
VALVES

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PSV Springopposed Freeorclosedventing.Multiplevalve

pressure relief.Gaugevalveswithsingleoperation
ofchangeoversingleisolationvalves
prohibitedminimumnozzlesizelaid
downinthecodes.Someinlet/outlet
flangecombinationsareexcludedin
standardmanufacturedependingon
application.

GENERALNOTE:Instrusiveelementsand/orspooltypeinstallationmaycallforflowlinesizedueto
changeduetoforcesonwettedparts,erosion,noise,depositionofsolidsincavitiesorviscosity.

Categories:PlantLayoutTags:designguide,plantlayout

PlantLayoutDesignguidescheckingPlotPlansandPlantLayout
March15,2012qdzung8comments

Designguides,CheckingofPlotplansandPlantlayouts.
Tableofcontent

1.Purpose
2.CheckingofPlotplans
3.RecordingofChanges
4.References
5.Attachments

1.Purpose
Thisprocedure,bytheapplicationofchecklists,describesthesafeguardingofqualityaspectsof
engineeringworkinthedevelopmentofplotplansandplantlayouts.Itcoverstherequirementstoensure
thattheapplicablespecifieddesignbasis,regulatoryrequirements,codesandstandardsarecorrectly
translatedintheirdevelopmentwithintheEngineeringDepartment.

2.CheckingofPlotplans
Theplotplansandplantlayoutsshallbeverifiedasaminimumagainstfourlists,asfollows:
2.1ChecklistforAdministration
Allchangesontheplotplansshallberecordedproperlyontherevisionlistsandthemarkedupissues
filed.Attachment1containschecklistthatcoverstheadministrativeaspectsofplotplancontrol.
2.2SafetyChecklistsforPlotplans
Allquestionsofthesafetychecklistshallbeverifiedagainsttheplotplan,seeAttachment2.
2.3ChecklistforTechnicalContentofPlotplans
Allquestionsofthechecklistwillbeverifiedagainsttheplotplandrawing,seeAttachment3.
2.4EquipmentClearanceGuidelineGenerally,clientshavetheirguidelinesonclearancesbetween
equipmentandorlocalregulationsexist.Inabsenceofthisdata,thefiguresmentionedinAttachment4
shallbeusedasaguide.

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3.RecordingofChanges
Therecordingofchangesandthefilingoftheassociateddocumentsshallbeinaccordancewiththe
relevantsectionsofref.4.4,4.3and4.4.Thesefilesshallbemaintainedaspartoftheprojectfile.Toeach
documentaListofRevisionsshallbeattached(ref.4.7).

4.References

Document
Title Level
Number

CMMA
4.1 101
TheNumberingofDocuments 2

CMMA
4.2 102
DocumentIssueCodeandChangeIdentification 2

4.3 CMPE504 TheProductionofEngineeringDocuments 2

4.4 CMPE110 ProjectFileCodingandMaintenance 2

4.5 BNDGC1 DesignGuideforPlantLayout 5

BNS
4.6 UK004
ChecklistDesignReviewTechnicalDisciplines(later) 5

BN
4.7 UE(I)10
ListofRevisions 4

5.Attachments

1.ChecklistforAdministration
2.SafetyChecklistforPlotplans
3.ChecklistforTechnicalContentofPlotplans
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4.EquipmentClearanceGuideline

1.CHECKLISTFORADMINISTRATION
1.Wasalistingpreparedofregulationstobefollowed?
2.Doesalistoftheplotplansexist?
3.Isthislistkeptuptodatewithnumberofdrawingsandissues?
4.Doanyalternativelistsexist?
5.Whatisthetypeoflist(Manual,Printout)?
6.Whatisfrequencyofupdatingofplotplan?
7.Dolargedeviationsexistinupdatingperiodsofeachunit?
8.Wasclientapproval

obtainedformally?
properlyrecorded?

9.Doesamarketupmastercopyexist?Isitkeptuptodate/
10.Arechanges

recordedonrevisionlists?
arerevisionlistsorderlyfiled?
properlyreferencedtoplotplan
referencedtopotentialchangeorder?

11.Aretheserevisionlistsorderlyfiled?
12.Isoriginofchangeandimpactproperlyindicatedonrevisionlist?
13.Aremarketupmastercopiesproperlyfiledinnumericalorder?
14.Arerevisionsproperlyindicatedonplotplan?
15.Authorizedsignatures?(Refertorelevantprocedure,ref.4.3).Locationforcertifiedsignature.
2.SAFETYCHECKLISTFORPLOTPLANS
CHECKLISTQUERIES
1.IdentifyCodesofPractice,StatutoryLegislationorClientsrequirementsdetermining.
1.1Overallplantlayout,proximitytopublicaccess,parkingplacesatsafelocations.
1.2Minimumspacingbetweenadjacentplants,interrelatedplantsandonplotequipment.
1.3Spacingandbundingofstorageareasandunits.
1.4Minimumspacingbetweenbuildingsandhazardousareas.
1.5LocationanddesignofControlBuilding.
1.6Atmosphericconditions,e.g.winddirection.
1.7Soilconditionsandtopography.Highpoints,slopes.
2.Identifypotentialhazardsfromhighlyflammableortoxic,orcorrosivematerials.Dotheseaffectlayout
orimposerestrictions?Identifyrequirements.
2.1Highorlowtemperatures.
2.2Highorlowpressures.
2.3Chemicalreactions.
2.4Flammableexplosivesubstances.
2.5Riskofdustexplosions.
2.6Toxiccorrosivesubstances.
2.7Radiationemission.
2.8Startupsituations(coveredinprocedures?).
2.9Shutdownsituations(coveredinprocedures?).
3.IdentifyCodesdeterminingFlareLocation(ifincluded).
4.Identifyfirefightingandprotectionrequirementstogetherwithapplicablecodesandlaws/reviewwith
localspecialistsrequired?
4.1Firewater,foam,drypowderlocation.

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4.2Fireandgasdetection,locationofequipment.
4.3Locationofutilitystations.
4.4Fireprotectionofstructuresandequipment.
5.Identifymeansofaccessandegress.
5.1Overallroadaccessrequirements.
5.2Fireaccessrequirements.
5.3Meansofescapefromareasatgradeandbunds.
5.4Meansofescapefromelevatedareas.
5.5Havealternativemeansofaccessandegressbeendevelopedwhereverpracticable?
6.Establishsafelocationofventsanddrains.
6.1Atmosphericreliefvalvedischarges.
6.2Steamandgasvents/drains.
6.3Continuousprocessvents/drains.

7.Noiseprofiles.

8.Constructionaspects.

9.Samplingandanalyzerpoints.

10.Drainage/collectinginsewer.Accessibilityofsamplepoint.
11.Plantsecurity.
12.Checksuitabilityofsafetyshowerlocation.Verifythatwatersupplycannotfreeze.
13.Specialplantsituations,e.g.offshore.
14.HasProcessDepartmentidentifiedandlistedallequipmentandlinessubjecttolethalortoxicrulesor
requiringspecialattentionforsafetyreasons?Emergencyshowersandeyewashersforeseen?
15.HasProcessDepartmentidentifiedandlistedallequipmentandlinesinvolvedinextremedesign
conditions?
16.Rulesforguardingofmovingmachinery?
17.Anyhazardstothepublic.(Releaseoftoxicgasesorwastes,fire,explosionundermisoperation,
malfunction,equipmentfailure?).
18.Areallopenpits,flooropeningsetc.fencedorprovidedwithguardrails?
3.CHECKLISTFORTECHNICALCONTENTOFPLOTPLANS
GENERAL

Nearestgeodeticstartingpointnoted?
Arebatterylimitsindicated?Blockvalvesforeseen?
Areaccessroadssuitable?Headroomclearance?Whatrules?
Accessroadtodischargeandloadingpointswalkwaysegregatedfromroadtraffic?
Supplypointsforchemicals,catalysts?Accessroadsforhazardouschemicals?
Isplotbrokenupinunits?Flowpatternbetweenunits?
Locationofinterconnectingpiperacks?Roomforfutureextension?
Havelocationsoffutureequipmentbeenindicated?
Whatrulesforequipmentclearance(refertoguideline)?
Locationofmaintenanceshop/accessroadsormaintenanceandequipmentreplacement?
Closewatchequipmentdefinedandlisted?

NOTE:
FollowingitemshavebeenlistedinsequenceoftheCompanyCostCode.

A.TOWERS.

1.Wasgroupingofdistillationtowersforeseen?
2.Overheadcondensersandreboilersgroupedoncommonstructure?
3.Verifysectionaldrawingsforelevation.
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4.Lightningprotection?

B.BUILDINGS

1.Useofsafetyglass(forwindows)?
2.Firestopsinpipepassagesthroughconcretewalls?Idemforcables?
3.Buildingscodeswrittenandlisted?
4.Protectionoflunchheatingdevices?
5.Typeofheating/airconditioning?
6.Ventilationandairintakepoints?
7.Sanitaryfacilities/firstaidfacilities?
8.Lightningprotection?
9.Exitsidentified/integratedinemergencylighting
10.Orientationofbuildings/sunshadesforeseen?

C.PIPING

Emergencyshutdownandisolationblockvalvestobecheckedforalllinesandplantlimits.Verifyuseof
ROVandaccessibility.Useofotherisolatingdevices?
Wherearespectacleblindstobeforeseen?
Locationofanchors/pipesupportstobeadequateforallowablestressandnozzleload/
Lockingdeviceoncriticalvalves?
Insulationforpersonnelprotection?
Protectionagainststaticelectricity?
Vibrationbracingforeseen/installed?
Locationofisolationpushbuttons?
Expensivealloypipinglayoutforminimumlength?
Firestopsforpipingpassingthroughconcretefloorsandwalls?

SafetyRelievingDevices

Layoutofflareheader/slope
Atmosphericrelease(steametc.)awayfromplatform.

D.STRUCTURES

Useofconcreteorsteel/fireproofing?
Useoffiredecks?
Rulesforstackingofequipment?
Standardsforstairs,platforms,laddersandhandrailings?Grating?
Lightningprotection?
Norexposedtoprocessequipment?
Stairs,platforms,laddersforaccesstooperatingvalves?
Useofnonslipsurfacesonstairs,platforms,accessways.

E.ELECTRICAL

1.Hazardousarea
classification Identificationofsourceofhazards.
Identificationofsubstancesreleased.
Establishmentofriskzones.
Establishmentoftemperatureclassandgasgroups.
Selectionofcertifiedequipment.
Criticalequipment Powersupply(transformers,switchgear)locatedseparately
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andprotected.Oilcontainmentdikesaroundtransformers.
2.Earthing Protectionagainstlightning
Dischargeofstaticelectricity.
Dispersaloffaultcurrents.
Limitingstepandtouchpotentialstosafelevels.
Protectionofearthingconductorsagainstcorrosion.
3.Cathodic
Protectionofburiedmetals.
protection
Interferencewithearthingsystem.
4.Fireprotection Firealarmcallpoints.
Firealarmbells/sirens.
Sprinkler/cloudsystems.
Fireresistanceofmaterials.
5.Area&road
Adequateillumination.
lighting
Lightscorrectlypositioned.
Avoidanceoftoomuchglareorreflection.
Adequateemergencylighting.
Possibilityofmaintenancelighting.
6.Cabling Compliancewithregulations.
Correctconductorsizing.
Adequateprotectionforcables.
7.Equipment Accessibility.
Easeofmaintenance
Emergencypower Isemergencygeneratorforeseen/locatedinsafearea?
Useofdieseldrives/turbines?
Powerconnections Distances.
Failureofelectricalcontrolstobeconsideredin
8.Controlfailure
design.Foreseefail/safeequipment
9.Switchgears Arelockoutfacilitiesforeseen?

F.FIREFIGHTING(seealsoK,item3)

Checksuitabilityoffirefightingequipment,locationofhydrantsandadequacyofwatersupply.
Checktoensurethatadequateaccessforfiretenderhasbeenprovidedtoallrelevantplantlocations.
Checkthatclearescaperoutesatgradehavebeenprovided.
Checkthatladdersandstairsarepositionedatgradeleadingtoclearescaperoutes.
Waterflooding/sprinklingforspheres.
Stairwaysmustbetheprimaryaccesstomainoperatingorserviceplatforms.
Auxiliaryexitsbyladderstobeprovided.
Nodeadendplatformtobelongerthan8meters.
Horizontalwalkingdistancetoprimaryorauxiliaryexitmustnotexceed25meters.
Checkonflametraprequirementsforventpipes.
Checkonventrequirementsforundergrounddrainagesystems.
Checkthatallventpipesandreliefvalvemanifoldsdischargingtoatmosphereareatleast3metersabove
anyplatformwithinaradiusof15meters.
Checkthatsuitableinterlockinghasbeencalledforatmultiplereliefvalveassemblies.
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Havesmokingregulationsbeendetermined?
DesignEngineeringSupervisorinconjunctionwithProcessandProjectshallchecksuitabilityofallrelief
systemarrangements.Particularattentionshallbegiventopossibilityofpockets/vaporlocksand
dischargerequirementsanduseand/orneedofclosedsystems.
Checklocationsofsniffersifprovidedontheplant.
Monitorsandhydrantsguardedagainstvehicledamage?
Reliabilityoffirewaterpumpincaseofpowerfailure.Auxiliarydrive.

G.GENERAL

Handlingdevicesrequiredforhandlingweightsover.kg.
Spaceformaterialstorage.
Haveweightandsizeofcontainersbeenconsidered/listed?Equipmentfoehandlingofcontainers,bins.
Loadingpiers:accessibilitytoemergencyshutoffvalves.
Communicationsbetweenshippingpumpandloadingpoint.
Flarewellsegregated?Areaprotectedagainstradiation.Extentofradiationzone.
Distancebetweenutilitystations.
Accessibilityofutilitystationsandcomposition.

H.HEATERS/BOILERS

Locatedinseparatearea.Wellsegregated.
Distancetoprocessunits:minimum15meterstohydrocarbonbearingequipment.
Sufficientinspectionopeningstoverifytheinternalsvisually.
Anchoringofinletandoutletlines.
Locatedupwindofoperatingunits.
Airintakelocations.
Remotelyoperated/accessibleshutdownvalvesonfuelsupplylines.
Whatincaseoftubeburst?
Accessforemergencyequipment?
Diversionwallsforeseen?

J.CIVIL

Haveundergroundservicesbeenmarked?
Markingalsoincaseofexcavation(warningstrips)?
Standardforroadways?
Considerriskofsettlementsoffoundations.
Areallopenpits,flooropeningsetc.fencedorprovidedwithguardrails?

K.CONTROLSYSTEMS
SpecificreferenceshallbemadetoChecklistDesignReviewTechnicalDisciplines,section9(ref.4.6)
andshallinclude:

1.Hazardousareas: Designphilosophy.
Selectionofcertifiedequipment.
Compliancewithareaclassificationdrawing
Installationtocodeandspecificcertificaterequirements
2.Earthing. Limitingtouchpotentialtosafelevels.
Protectionofearthingconductorsagainstcorrosion.
3.Fireprotection Firealarmbells/sirens.
Smoke/firedetection.(Instrumentequipment)
Shutdown,interlockandalarms.
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Fireresistanceofmaterials.
Operationalimplicationsofafire.
Firefightingsystem.(Instrumentequipment).
Highfireriskareas.
4.Fail/safedesign Shutdownsystems/emergencydepressurizingsystem.
Failsafefeaturesaffectingplantsafety.
Effectoffailureorlossofelectricity,andallutilities.
Burnermanagementsystems.
5.Safetyrelieving
Sizingcriteria.
devices
Safetyfactors.
Calculationsapproval.
6.Equipment
Maintenance
location
Accessibility
7.Cabling Compliancewithregulations.
Correctconductorsizing.
Adequateprotectionforcables
Segregations.
8.Electricalsupply
Correcttypeandsizingoffusesandcircuitbreakers.
system
Extentofequipmentofuninterruptablepowersupplysystem.
Alarms.
Overallpowerconsumption.
9.Airsupply Instrumentairconsumption.
Securityofsupply.
Operationalanddesignconditions.
Isanaudiblealarmincludedtowarnforreleaseofflammable
10.Alarming
vapors?Releaseoflethalgas.Firedheaterflamefailure.

M.VESSELS(TANKS)

Protectionincaseofleakage(bundwalls).
Lightningprotection.
Distancesbetweentanks/dikedareas.Whatrulestobefollowed?
Protectionagainststaticelectricity.
Specialrulesforcoldstoragedefined.
Accessibilityoftankgaugingdevice/suitableforpressureandtemperature.
Minimumflangedconnectionswithindikedareas.
Useofflowlimitingdevices.
Tankfarmsatlowerlevelthanprocessunits.
SitingoftanksingroupsconsiderAPIrules.
Icingprotectionforrefrigeratedstorageprotectionforspontaneouswarming.
Protectionofgasstoragetanksagainstsunradiation.

N.INSULATION

Resistanceofinsulationagainstfire.

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Personnelprotectioninsulationforeseen(verifyalongaccessroads).
Ifinsulationfoepersonnelprotectionisnotforeseen,protectbyopenguards,shields,railings.

P.PUMPS/COMPRESSORS

Locationseparatelyfornoiselimitation.Compressorsupwindfromfiredequipment.
Groupedunderpiperack(separaterows).Separatehighpressurepumps.
Possibilityofsprinklerinstallation/commonloops.
Accessibilityofrotatingequipmentforoperationandmaintenance(equipmentreplacement).
Allrotatingequipmentadequatelyguarded.
Noiseprotectioninrotatingequipment.Whatrulesimposed?
Airintakelocationforcompressors.
Whatisriskincaseofsealleakage?Whatprotectionforeseen?
Equipmentclearance/removalpossibilityofdefectiveequipment.
Installationofliftingequipment.
Lubricationpointsdefined.Accessibleforoperatingandmaintenancepersonnel?
Highpressurechargepumpstobeisolated.
Locationofsealoilunits.

Q.SEWERS

Checkareaclassificationforpitsandothercatchmentdevices.
Howissealingandventingofcatchbasinsdone?
Verifyremovalofreleasesanddripsfromunderequipment.
Consideruseofseparatesewerandtoxicsewer.Oilysewerrequired?
Pollutionrisk.Wastewatercollectionandtreatment.Locationofdischargepoint.
Specialprecautionsforhighlytoxichighlyflammableproducts.

T.EXCHANGERS

Accessibilityforcleaningrodding.
Spaceforbundlepullingdevice.
Locationofairfincoolers(nopumpsunderneath).
Arefiredecksforeseen?

4.EQUIPMENTCLEARANCEGUIDELINES
ITEMS

OverheadclearanceMeters
Equipment,structures,platforms,pipingandpipesupportsshallprovidethe
followingclearanceoverhead:

Railroads,topofrailtobottomofanyobstruction 7

Plantroadsformajormobileequipment 6

Secondaryroadsandaccesswaysformobileequipment 5

Gradesatpumprowaccesswayinsidebatterylimits 3

Walkways,passways,platformsandinsidebuildings
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Exchangersatgrade,shellcoverchannelend 1.5

Horizontalclearances

Betweenexchangers(aislesbetweenpiping) 0.9

Aroundpumps(aislesbetweenpiping) 0.9

Firedheaterstopumpshandlingflammablestocks 15

Firedheaterstootherflammablecontainingequipmentnotclosely
8
associatedwithheaters

Driverendofpumpswheretruckaccessisrequired 3

Driverendofpumpswheretruckaccessisnotrequired 1.8

Shellcoverendofexchangersatgradeforaccess 1.3

Betweenshellsofadjacenthorizontalvessels 1.2

Pipeberths

Underground,minimumcleargapbetweenpipes(300mm) 0.3

Aboveground,normal,betweenflangesandbarepipeorsurface
0.025
ofinsulationandplugs(25mm)

Equipmentspacing
Smallpumps,3.75kWorsmaller,mountedoncommonfoundations,center
suitable
tocenterdistance

Mediumpumps,22.5kWorsmaller,clearaisle 0.9

Largepumps,largerthan22.5kW,clearaisle
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0.9

Exchangersandotherequipmentonstructures,minimumclearaisle 0.9

Platforms
Vessels(verticalandhorizontal)andtowers

Sideplatformdistancebelowcenterlineofmanholeflange 0.91.05

Sideplatformwidthfrommanholecovertooutsideedgeofplatform 0.9

Sideplatformextensionbeyondcenterlineofmanhole 0.9

Headplatformdistancebelowundersideofflange 0.175

Headplatformwidthfromthreesidesofmanhole 0.75

Exchangers(horizontal)

Clearanceinfrontofchannelorbonnetflange 1.2

Exchangertubebundleremovalspace bundlelength

Minimumclearancefromedgeofflanges 0.3

Exchangers(vertical)

Distanceofplatformbelowtopflangeofchannelorbonnet 1.5

Furnaces
Widthofplatformatsidesofhorizontalandverticaltube
0.75
furnaces,minimum

Widthofplatformatendsofhorizontaltubefurnaces,minimum 1.0

Controlroom
Distanceofcontrolroomtoprocessequipment
25
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SUGGESTEDSPACINGSFORLPGSTORAGE

Minimum
distances
Vessel From Between
capacity buildings vessels
imp. cubic
feet meters feet meters
gallons meters
upto100 upto0.45
101500 0.452.3 10 3 3 1
5012,000 2.39.1 25 7.5 3 1
over2,000 over9.1 50 15 5 1.5

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