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This article should only be used as a guide. It’s intended purpose is to help the piping designer
who is responsible for placement of one specific item in a typical refinery, chemical or
petrochemical process plant or someone who may need help in developing a total plot plan for a
complex unit.
The guidelines given here are based on my many years of experience with one of the world’s
largest engineering, design and construction companies along with the U. S. OSHA Part 1910
and the NFPA (National Fire Protection Association) Code No. 30.
The latest editions of these codes and any other applicable national, regional and local codes
should be referred to and used because they may be more stringent.
The subjects covered in this article have been arranged in alphabetical order in the hope it will
make them easier to locate.
Compressors, Centrifugal
Locate centrifugal compressor as close as possible the suction source. Top suction and
discharge lines either should be routed to provide clearance for overhead maintenance
requirements, or should be made up with removable spool pieces.
Support piping so as to minimize dead load on compressor nozzles; the load should be within the
recommended allowance of the compressor manufacturer.
Centrifugal compressors should have full platforming at operating level. Heavy parts such as
upper or inner casing and rotor should be accessible to mobile equipment. Review the equipment
arrangement for access and operation.
Locate lube and seal oil consoles adjacent to and as close as possible to the compressor. Oil
return lines from the compressor and driver should have a minimum slope of 1/2 inch per foot to
the inlet connection of seal traps, degassing tanks, and oil reservoir. Pipe the reservoir,
compressor bearing, and seal oil vents to a safe location at least 6 feet above operator head
level.
Compressors, Reciprocating
Locate reciprocating compressors so suction and discharge lines that are subject to vibration
(mechanical and acoustical) may be routed at grade and held down at points established by a
stress and analog study of the system.
Accessibility and maintenance for large lifts such as cylinder, motor rotor, and piston removal
should be by mobile equipment if the installation is outdoors or by traveling overhead crane if the
installation is indoors (or covered).
Horizontal, straight line, reciprocating compressors should have access to cylinder valves.
Access should be from grade or platform if required.
Depending on unit size and installation height, horizontal-opposed and gas engine driven
reciprocating compressors may require full platforming at the operating level.
Control Valves
Locate control valve stations accessible from grade or on a platform. In general, the (flow, level,
pressure, temperature) instruments or indicators showing the process variables should be visible
from the control valve.
Cooling Towers
Locate cooling towers downwind of buildings and equipment to keep spray from falling on them.
Orient the short side of the tower into the prevailing summer wind for maximum efficiency. This
means that the air flow (wind) will travel up the long sides and be drawn in to both sides of the
cooling tower equally. When the wind is allowed to blow directly into one long side it tends to blow
straight through and results in lower efficiency. Locate cooling towers a minimum of 100 feet
(30m) from process units, utility units, fired equipment, and process equipment.
Furnace Piping
Locate snuffing steam manifolds and fuel gas shutoff valves a minimum of 50 feet (15m)
horizontally from the heaters they protect.
Burner Valving for a Floor Fired Furnaces: Combination oil and gas firing valves should be
operable from burner observation door platform. For those fired by gas only, the valves should be
near the burner and should be operable from grade.
Burner Valving for a Side Fired Furnaces: Locate firing valves so they can be operated while the
flame is viewed from the observation door.
Flare Stacks
Locate the flare stack upwind of process units, with a minimum distance of 200 feet (60m) from
process equipment, tanks, and cooling towers. If the stack height is less than 75 feet (25m),
increase this distance to a minimum of 300 feet (90m). These minimum distances should be
verified by Company Process Engineering.
Future Provisions
Space for future equipment, pipe, or units should not be provided unless required by the client or
for specific process considerations. When applicable this requirement should be indicated on the
plot plan and P&IDs.
Loading Racks
Locate loading and unloading facilities that handle flammable commodities a minimum of 200 feet
(60m) from away from process equipment, and 250 feet (75m) from tankage.
(Note: The piping isometrics should show the required tap orientations)
Personnel Protection
Locate eye wash and emergency showers in all areas where operating personnel are subject to
hazardous sprays or spills, such as acid.
Personnel protection should be provided at uninsulated lines and for equipment operating above
140 degrees F (60 C) when they constitute a hazard to the operators during the normal operating
routine. Lines that are infrequently used, such as snuffing steam and relief valve discharges, may
not require protective shields or coverings.
Pipe
Clearance between the outside diameter of flange and the outside diameter of pipe to the
insulation should not be less than 0′- 1″* (25mm)
Clearance between the outside diameter of pipe, flange, or insulation and structural any member
should not be less than 0′- 2″* (50mm)
*With full consideration of thermal movements
Platforms
Minimum width for ladder to ladder travel: 2′- 6″ (800mm)
Headroom: 7′- 0″ (2.1m)
Headroom from stairwell treads: 7′- 0″ (2.1m)
Minimum clearance around any obstruction on dead end platforms: 1′- 6″ (500mm)
Pressure Instruments
Locate all local pressure indicators so they are visible from grade, permanent ladder, or platform.
Those located less than 15 feet (4.5m) above high point of finished surface should be accessible
from grade or a portable ladder. Those located in a pipeway should be considered accessible by
portable ladder. Those over 15 feet (4.5m) above high point of finished surface should be
accessible from a platform or permanent ladder.
Process Units
The relation of units, location of equipment, and routing of pipe should be based on economics,
safety, and ease of maintenance, operation, and construction requirements. The alignment of
equipment and routing of pipe should offer an organized appearance.
Pumps
Locate pumps close to the equipment from which they take suction. Normally, locate pumps in
process units under pipeways.
Design piping to provide clearance for pump or driver removal. Similarly, on end suction pumps,
piping should permit removing suction cover and pump impeller while the suction and discharge
valves are in place.
Arrange suction lines to minimize offsets. The suction lines should be short and as direct as
possible, and should step down from the equipment to the pump. Suction lines routed on
sleeperways may rise to pump suction nozzle elevation.
Orient valve handwheels or handles so they will not interfere with pump maintenance or motor
removal. Valve handwheels or handles should be readily operable from grade.
Maintenance and operating aisles with a minimum width of 2′-6″ (800mm) should be provided on
three sides of all pumps.
Pump Strainers
Provide temporary conical type strainers in 2 inch (50mm) and larger butt weld pump suction lines
for use during startup. Arrange piping to facilitate removal.
Use permanent Y-type strainers on 2 inch (50mm) and smaller screwed or socket weld pump
suction piping.
Railroads
Headroom over through-railroads (from top rail) 22′- 6″** (7m)
Clearance from track centerline to obstruction 10′- 0″** (3m)
(** Verify conformance with local regulations)
Roads
Major process plants normally have three classes of roads. They might be called Primary roads,
Secondary roads and Maintenance access ways.
(*) Normally secondary plant roads may be used as tube pull areas.
Safety Access
Provide a primary means of egress (continuous and unobstructed way of exit travel) from any
point in any building, elevated equipment, or structure. A secondary means of escape should be
provided where the travel distance from the furthest point on a platform to an exit exceeds 75 feet
(25m).
Access to elevated platforms should be by permanent ladder. Safety cages should be provided
on all ladders over 15′-0″ (4.5m)
The need for stairways should be determined by platform elevation, number of items requiring
attention, observation and adjustment, and the frequency of items.
Ladder safety devices such as cable reel safety belts and harnesses, may be investigated for use
on boiler, flare stack, water tank, and chimney ladders over 20 feet (6m) in unbroken lengths in
lieu of cage protection and landing platforms.
Sample Connections
Locate all sample connections so they are readily accessible from grade or platform.
In general, where liquid samples are taken in a bottle, locate the sample outlet above a drain
funnel to permit free running of the liquid before sampling.
Hot samples should be provided with a cooler.
Spectacle Blinds
Locate spectacle blinds to be accessible from grade or platform. Blinds located in a pipeway are
considered accessible. Blinds that weigh over 100 lbs (45kg) should be accessible by mobile
equipment. Where this is not possible, provide davits or hitching points.
Closely grouped flanges with blinds should be staggered.
Steam Traps
Locate all steam traps at all pocketed low points and at dead ends of steam headers. Also,
provide traps periodically on excessively long runs of steam piping, for sufficient condensate
removal, and to ensure dry quality steam at destination. Steam traps should be accessible from
grade or a platform. Steam traps located in pipeways should be considered accessible by
portable ladder.
Tankage
Locate any tankage containing hydrocarbon or other combustible fluids or gasses a minimum
distance of 250′-0″ (115m) from any process unit, rail loading facility or truck loading facility.
The minimum spacing of offsite storage tanks and dike requirements should be in accordance
with the latest edition of the National Fire Protection Association, Code No. 30, and OSHA part
1910.106 (b), where applicable.
Temperature Instruments
Locate temperature test wells, temperature Indicators and thermocouples to be accessible from
grade or a portable ladder. Those located in a pipeway should be considered accessible by a
portable ladder. Those located over 15 feet (7m) above high point of finished surface should be
accessible from a platform or permanent ladder.
Locate all local temperature indicators (TI) should be visible from grade, ladder, or platform.
Utility Stations
Provide and locate utility stations with water, steam, or air as indicated below:
All areas should be reachable with a single 50 foot (20m) length of hose from the station.
Provide water outlets at grade level only, in pump areas, and near equipment that should be
water washed during maintenance.
Provide steam outlets at grade level only in areas subject to product spills, and near equipment
that requires steaming out during maintenance.
Provide air outlets in areas where air-driven tools are used such as at exchangers, both ends of
heaters, compressor area, top platform of reactors, and on columns at each manway.
Hose, hose rack, and hose connections should be provided by the client or be purchased to
match the clients existing hardware.
Valve Operation
Locate operating valves requiring attention, observation, or adjustment during normal plant
operation (noted on the P&IDs) so they may be within easy reach from grade, platform, or
permanent ladder as follows:
- 2″ (50mm) and smaller may be located reachable from a ladder.
- 3″ (80mm) and larger must be reachable and operable on a platform
Operating valves with the bottom of handwheel is over 7 feet (2.1m)above high point of finished
surface or operating platform may be chain-operated.
The centerline of handwheel or handles on block valves used for shutdown only, located less
than 15 feet (4.5m) above high point of finished surface, and those located in pipeways, may be
accessible by portable ladder.
The centerline of handwheel or handles on block valves used for shutdown only and located over
15 feet (4.5m) above high point of finished surface, except those located in pipeways, should be
operable from permanent ladder or platform.
In general, keep valve handwheels, handles, and stems out of operating aisles. Where this is not
practical, elevate the valve to 6′- 6″ (plus or minus 3 inches) clear from high point of finished
surface to bottom of handwheel.
Walkways
Walkways should have a 2′-6′ (1m) horizontal clearance (not necessarily in a straight
line) and headroom of 7′- 0″ (2.1m)