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EM- L - 004
ENGINEERING MANUAL
FOR
PIPING LAYOUT
The present document or drawing is property of TECHNIP INDIA Ltd., and shall not, under any circumstances, be totally
or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent,
for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed
upon right of use.
01-10-08
AM
JKR
BVR
23-11-98
PP
JKR
JKR
Rev
Date
DD/MM/YY
STATUS
WRITTEN BY
(name & visa)
CHECKED BY
(name & visa)
APPROVED BY
(name & visa)
DOCUMENT REVISIONS
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Sections changed in last revision are identified by a vertical line in the right margin
PIPING LAYOUT
CONTENTS
PART I
PIPING AND PIPING SPECIALITIES
PAGE
3
PART II
EQUIPMENT PIPING
18
PART III
INSTRUMENT PIPING
55
PART IV
OFFSITES PIPING
69
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PART I
PIPING AND PIPING SPECIALITIES
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PART I
PIPING AND PIPING SPECIALITIES
PAGE
1.0
PIPE RACKS
2.0
PIPE SPACING
11
3.0
13
4.0
LIST OF DRAWINGS
16
4.1
803-ES-L-172
6 Sheets
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4.2
803-ES-L-034
4 Sheets
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4.3
803-ES-L-174
3 Sheets
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SECTION 1
PIPE RACKS
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SECTION 1
1.0
PIPERACKS
1.1
1.1.1 On completion of the routing diagram, the pipe rack width/tier ratio at
selected line density locations can be determined by either:
a)
0.50N
W = -------T
W = Approximate width in metres for the installed rack.
N = Number of lines given at the early stages of the
project.
T = Number of rack levels or tiers contemplated.
The above empirical formula allows for the following, when rack lines are
an average of 150NB size.
0.50 x 24
------------ =
2
12 metres
------------- = 6000mm wide pipe rack
2 levels
1.1.2 Sections X-X and Y-Y on figure 1.1 indicates locations selected by
observations, where the number of tiers required may be subject to
adjustment.
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1.3.1 Special consideration must be given to the Flare or Relief Header. This
line should slope in the direction of the flare knockout Drum and should
not be pocketed, See Section 11 of engineering manual EM/L/003 for
details.
1.3.2 Locate Flare Header at the edge of the rack to accommodate any flat
expansion loops that may be required
1.3.3 Locate Flare header to allow for safety valves and discharge piping to be
positioned above it without pockets and in to the top of the header.
1.3.4 Connections in to the header can be laterally at 45 Deg if pressure drop is
critical within the system. See Figure 1.4 Sht 3 of 6.
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1.4
1.4.1 Preliminary flexibility analysis takes place during the early stages of the
piperack development. Line temperature and insulation thickness if
known, should be indicated on lines to assist the Engineer.
1.4.2 Expansion loop nests should be located by the piping engineer relative
to the assumed location of anchors, See Figure 1.5. The loops will
generally rise to the established take-off level.
Figure 1.6 indicates typical steam / condensate loop arrangement. Note
that provision should be made for drip legs on inlet side of steam header
loops.
1.4.3 Lines of extreme temperature hot or cold, process or utility, which travel
long distances on the rack must be examined for adequate flexibility and
clearances with adjacent lines.
1.4.4 All branch lines that join headers in the rack should be checked for
adequate flexibility relative to the thermal movement of the headers, See
figure 1.7.
1.4.5 Line spacing should be checked for expansion clearance at changes of
direction, See figure 1.8.
1.4.6 See engineering manual EM/L/005 for additional information relating to
piping flexibility.
1.5
1.5.1 Lines crossing battery limits will normally be valved requiring platform
access, See P&I diagrams for extent of valving.
1.5.2 Figure 1.9 shows a typical single level piperack where the elevation is to
be maintained across the battery limit. The walkway will be elevated to
clear the largest anticipated line and located to suit the largest valve.
1.5.3 Valves will be staggered on either side of walkway and be provided with
extension stems as required. Battery limit line locations are normally an
early priority.
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1.5.4 Where lines cross the battery limit at grade, valves will be located as
indicated in Figure 1.10.
1.5.5 Figure 1.11 shows a two level piperack the Battery Limit valves accessible
from a single platform.
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SECTION 2
PIPE SPACING
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SECTION 2
2.0
PIPE SPACING
The Drawing 803ESL034 ( 4 Sheets ) were developed for use by
piping design personnel to determine the minimum distance required
between adjacent runs of piping.
2.1
803ESL034 SHT 1 of 4 is used for spacing 150# and 300# bare pipe
to flanged bare pipe. Dimension A is given in the form of a chart.
2.2
2.3
2.4
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SECTION 3
STEAM TRAP PIPING
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SECTION 3
3.0
3.1
STEAM TRAPS
There are various types of steam traps used in process plants.
Table 1 in Drawing 803-ES-L-174 SHT 1 of 3 gives data on Traps and
additional information, relative to the application of the steam traps
under various operating and climatic condition.
Check with process design department for the type of steam trap to be
used for to be used for the specific project.
3.2
3.2.1 All valves shown on the details on sheets 2 of 3 & 3 of 3 are gate valves
3.2.2 The drip pocket valve and blind flanges is to be used for periodically
blowing down. For safety, the valve should be piped to a drain or grade
3.2.3 A valve downstream of trap is required when the discharge to a header.
( See sheet 2 of 3 for collected condensate system and sheet 3 of 3 for a
drained condensate system ).
3.2.4 A strainer would be fitted in the line before the trap to prevent any particles
from interfering with the performance of the trap. However, in some cases
the strainer is an integral feature of the trap.
3.2.5 A by-pass is normally provided to allow for the steam trap to be replaced.
3.2.6 Insulation is needed in a cold environment if there is a risk of freezing as a
result of shutdown or intermittent operation, or in any climate for personnel
protection.
3.2.7 An isolating valve may be provided at the point of entry into the header.
Check individual project requirements.
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3.2.8 Drip pockets should be provided at the following positions on steam lines
where condensate collects:a) At low points before or at bottom of risers i.e: expansion loops in a
piperack.
b) On straight run steam headers approx. every 46,000 mm (150-0)
prior to rises and at dead ends. Check individual project
requirements.
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SECTION 4
LIST OF DRAWINGS
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SECTION 4
4.0
LIST OF DRAWINGS
4.1
803-ES-L-172
6 Sheets
Rev 0
4.2
803-ES-L-034
4 Sheets
Rev 0
4.3
803-ES-L-174
3 Sheets
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PART II
EQUIPMENT PIPING
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PART II
EQUIPMENT PIPING
PAGE
1. 0
TOWERS
20
2.0
VESSELS
23
3.0
CIRCULAR HEATERS
25
4.0
CABIN HEATERS
31
5.0
REACTORS
37
6.0
40
7.0
PUMPS
46
8.0
CENTRIFUGAL COMPRESSORS
49
9.0
LIST OF DRAWINGS
53
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SECTION 1
TOWERS
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SECTION 1
1.0
1.1
1.2
1.3
900 mm is the preferred location. When not possible, keep within the
range of 750 mm minimum to 1250 mm maximum.
1.4
1.5
1.6
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1.8
1.9
For dimension from back of pipe or insulation to vessel shell, see Section
1.13 below.
1.10
1.11
For typical reboiler hookups, see Section 6. For Shell and Tube
Exchangers.
1.12
1.13
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SECTION 2
VESSELS
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SECTION 2
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
Valves in control set in the off-gas line to be orientated so that they are
accessible from top platform.
2.11
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SECTION 3
CIRCULAR HEATERS
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SECTION 3
3.0
3.1
HEATERS PARTS
The following component parts are to be read in conjunction with Figures
3.1 and 3.2 in Drg 803-ES-L-177 Sht 1 of 7 & 803-ES-L-177 Sht 2 of 7.
3.1.1 Radiant Section It is the large part utilizing heat radiating from burners.
The tubes are in a vertical position.
3.1.2 Convection section This is the heat transfer section located directly
beneath the stack. The tubes are in a horizontal position.
3.1.3 Burners These are located at the base of the radiant section. They are
usually designed to burn fuel oil and fuel gas. Fuel oil is used to start-up.
When the plant is operating normally, fuel gas is produced from the
process plant for burners on fired heaters. Adequate space must be
allowed for removal of burner gun.
3.1.4 Peep Doors These are located in convenient positions to allow easy
observation of burner flames. Valves in the burner piping are usually
manifolded and located such that flame adjustment can be achieved
simultaneously with flame observation from a platform local to the peep
door.
3.1.5 Explosion Doors - (If required) These are designed to relieve pressure
should an explosion occur within the heater.
3.1.6 Damper This regulates the burner draft. The control is normally by cable
or linkage, to allow manual adjustment from grade. The system can also
be designed to function automatically.
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3.1.7 Access Door This is a removal door, which allows access into the heater
for inspection of tubes and refractory lining. Access doors must be kept
clear of external and internal piping.
3.1.8 Snuffing Steam Connections These are used to extinguish the flames
inside a heater in the event of the fire. They are usually located in the
base of radiant section and at the header boxes.
3.1.9 Soot blowers These are usually specified for heaters that use oil for fuel.
They are used to clear the tubes of soot by blowing steam through a
projecting lance.
3.1.10 Crossovers This is the piping connecting the radiant section with the
convection section, and it may be located inside or outside the heater.
Crossovers are usually supplied by the heater vendor.
3.1.11 Instruments
Draft Gauge Connection Usually located just beneath the damper
and in the radiant section. A differential pressure instrument is
connected to these points to measure the burner draft.
Tube Skin Thermocouple These measure the tube temperature in
the heater.
Sample Connection Usually located just below the damper.
Temperature Connections These are usually located in the stack
and also just below the convection section. A thermocouple is usually
located at the lower radiant section.
3.1.12 Flame Failure Systems If such a system is built into the heater
allowance must be made for a local cabinet. Orientation of the scanners
must be such that the flame can be seen. An air system will be required
for purging the scanners. Extra peep doors may also be required if its a
positive system.
3.1.13 Heater Piping Loads The heater requisition should state that it is the
responsibility of the heater vendor to provide adequate platform framing
and steel work to accommodate all external piping loads.
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At the early stages of the heater piping study, an effort must be made by
the piping engineer to establish piping loads for all externally connected
piping. This study is to be forwarded to the heater vendor so that provision
can be made with the support of the heater tubes and in the design of the
heater steelwork to accommodate these loads.
Piping Engineer must coordinate external piping flexibility requirement
together with tube movements given by the heater vendor. Liaison may be
required with heater vendor to support internal piping to ease any
supporting and flexibility problems associated with external piping.
3.2
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3.4
3.5.1 Break joints shall be installed in the fuel piping to burners so that burner
can be withdrawn easily.
3.5.2 Fuel piping can be run horizontally or vertically to suit head height
requirements.
3.5.3 Fuel headers to be run underneath platforms to facilitate supporting of
pipe.
3.5.4 Piping to burner gun should designed and routed such load or moment is
transmitted on to the burner gun.
3.5.5 Valving to be local to peep doors.
3.6
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3.7.1 Soot blowers are specified for heaters that use oil for fuel and have a
convection section. As the oil is burned soot builds up on the exterior of
the convection tubes and reduces heat transfer. Soot blowers are then
used to clear the tubes of soot. Steam is blown through a lance, stroking
the outside of the tubes which dislodges the soot.
3.7.2 There are two basic types of soot blowers:
(a) Fixed Rotating
(b) Retractable Rotating
3.7.3 Access platforms are required for maintenance of soot blowers.
Retractable soot blowers require withdrawal space.
3.7.4 Slope steam piping away from inlet connection. Valving may be located
locally or manifolded at grade. Check requirements of soot blowing in
sequence. This may affect manifolding of soot blowers. See detail in
Drawing.
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SECTION 4
CABIN HEATERS
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SECTION 4
4. 0
CABIN HEATERS
The direct-fired heater is used in all distillation units, in many cracking
systems and in several processes such as Alkylation, Polymerization and
Reforming.
Most heaters are built with two distinct heating sections; a radiant section
which can receive heat directly from the flame and convection section
which recovers heat from the hot gases travelling to the stack.
The box or cabin type heaters are commonly used, as they are well suited
for large capacities.
The design of piping to and from the heater is generally conducted along
with stress analysis, particularly with regard to the process inlets and
outlets.
The heater manufacturer normally allows for inlet and outlet nozzle
displacement due to the expansion of tube supports within the heater
under hot or operating conditions. Also, to provide tube anchor within
close proximity of the nozzles together with tabulated allowable and
directional loading afforded by external piping.
Care should be exercised in designing the process outlets and transfer
Line, piping as they are sometimes subjected to somewhat turbulent
conditions. As for example, a heater is usually at higher temperature than
the fractionator vaporizer temperature, because self-evaporation occurs
as the fluid flows through the transfer line. The heat required for this
vaporization comes from the sensible cooling of the stock flowing in the
line. Also, if steam is present at the vaporizer a sizeable vaporization or
flashing occurs at the end of the transfer line, which causes a further
decrease in temperature. Efforts should be made, therefore, to maintain a
smoothness of flow in this piping.
An isometric sketch of the completed transfer line arrangement is usually
forwarded to the process design department for process requirement
clearance.
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4.1
HEATER PARTS
The following component parts are to be read in conjunction with Figure
4.1 (See Drawing 803-ES-L-179 Sht 1 of 6)
4.1.1 Radiant Section - This is the large part utilizing heat radiating from
burners. The tubes are in a horizontal position.
4.1.2 Convection Section - This is the heat transfer section, which is located
directly beneath the stack. The tubes are in horizontal position.
The rate of heat absorption tends to be high at the entrance to the
convection section because heat is delivered by both radiation and
convection. The feed, because it is cooler, is sometimes introduced
through tubes in this area, and in some instances steam is superheated or
water heated through these tubes.
4.1.3 Burners - These are located at the base of the radiant section. They are
usually designed to burn fuel oil and fuel gas. Fuel oil is used at startup.
When the plant is operating normally, fuel gas is produced from the
process plant for burners on fired heaters. Adequate space must be
allowed for removal of burner gun.
4.1.4 Peer Doors - These are located in convenient positions to allow easy
observation of burner flames. Valves in the burner piping are usually
manifolded and located such that flame adjustment can be achieved
simultaneously with flame observation from a platform local to the peep
door.
4.1.5 Explosion Doors - These are designed to relieve pressure should an
explosion occur within the heater. They are not always required.
4.1.6 Damper - This regulates the burner draft. The control is normally by cable
or linkage, to allow manual adjustment from grade. The system can also
be designed to function automatically.
4.1.7 Access Door - This is a removable door which allows access into the
heater for inspection of tubes and refractory lining. Access doors must be
kept clear of external and internal piping.
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4.1.8 Snuffing steam Connections These are used to extinguish the flames
inside a heater in the event of a fire. They are usually located in the base
of the radiant section and at the header boxes.
4.1.9 Sootblowers - These are usually specified for heaters that use oil for fuel.
They are used to clear the tubes of soot by blowing steam through a
projecting lance.
4.1.10 Crossovers - This is the piping connecting the radiant section with the
convection section, and it may be located inside or outside the heater.
Crossovers are usually supplied by the heater vendor.
4.1.11Instruments
- Draft Gauge Connection - Usually located just beneath the
damper and in the radiant section. A differential pressure
instrument is connected to these points to measure the burner
draft.
- Tube Skin Thermocouple - These measure the tube
temperature in the heater.
- Sample connections - Usually located just below the damper.
- Temperature Connections - These are usually located in the stack
and also just below the convection section. A thermocouple is
usually located at the lower radiant section.
4.1.12 Flame Failure Systems - If such a system is built into the heater,
allowance must be made for a local cabinet. Orientation of the scanners
must be such that the flame can be seen. An air system will be required
for purging the scanners. Extra peep doors may also be required if
positive draft system.
4.1.13 Heater Piping loads - The heater requisition should state that it is the
responsibility of the heater vendor to provide adequate platform framing
and steelwork to accommodate all external piping loads.
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At the early stages of the heater piping study, an effort must be made by
the piping designer to establish piping loads for all external piping. This
study must be forwarded to the heater vendor so that provision can be
made in the design of the heater steelwork to incorporate these loads.
Final piping loads with exact locations can be forwarded to the heater
vendor later.
Piping Engineer must study the external piping flexibility requirements
together with tube movements given by the heater vendor in assessing
external piping loads and method of supporting piping. Liaison may be
required with heater vendor to support internal piping to ease any
supporting and study flexibility associated with external piping.
4.2
4.2.1 Fuel and inlet control valve sets to be manifolded at piperack columns.
Inlet control valving may need further investigation as to location. Fuel
stop valves to be located 15000 mm ( 50.0 ) distance from heaters.
4.2.2 Removable spools may be required for decoking if shown on P&IDS.
4.2.3 Fuel piping to burners are usually placed along sides of heaters and may
not necessarily be accessible from peep doors.
4.2.4 If decoking line to collection box is located at grade, make sure these are
removable spools for crane access to heater.
4.3
4.3.1 Break joints shall be installed in fuel piping to burners so that burner can
be withdrawn easily.
4.3.2 Fuel piping can be run horizontally or vertically to suit head height
requirements.
4.3.3 Fuel headers to be run underneath platforms to facilitate supporting of
pipe.
4.3.4 Piping to burner gun should be designed and routed such that no load or
moment is transmitted onto the burner gun.
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4.5
4.5.1 Soot blowers are specified for heaters that use oil for fuel and have a
convection section. As the oil is burned, soot builds up on the exterior of
the convection tubes and reduces heat transfer. Soot blowers are then
used to clear the tubes of soot. Steam is blown through a lance, striking
the out side of the tubes which dislodges the soot.
4.5.2 There are two basic types of soot blowers:
( See drawing 803 ES L - 179 Sht 6 of 6 )
(a) Fixed Rotating.
(b) Retractable Rotating.
4.5.3 Access platforms are required for maintenance of soot blowers.
Retractable soot blowers require withdrawal space.
4.5.4 Slope steam piping away from inlet connection. Valving may be located
locally or manifolded at grade. Check requirements for soot blowing in
sequence. This may affect manifolding of soot blowers. See detail in
drawing.
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SECTION 5
REACTORS
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SECTION - 5
5.0
REACTORS
5.1
5.1.1 Platforms can be connected to reactor where welding to the vessel shell is
permitted. Consideration must be given to differential expansion between
adjacent shells. .
When welding to shell is not permitted, provide a separate platform
support structure.
5.1.2 Access can be by ladders and/or stairways or a combination of both. This
will depend on clients requirements for operation and maintenance.
5.1.3 The basic philosophy regarding catalyst handling ( mobile or built - in )
should be established during the planning phase of a project.
5.2
5.2.1 A top manway is provided for charging the reactor with catalyst. Outlet
piping is connected to this manway cover by a flanged elbow nozzle to
facilitate the removal of a portion of this piping when handling catalyst.
5.2.2 Provide adequate vertical clearance for temperature element removal.
5.2.3 Sidestep ladders are generally preferred.
5.2.4 Allow for heavy insulation thickness when running piping close to the
reactor.
5.2.5 A davit should be provided to facilitate the removal of piping and outlet
nozzle cover, when there is no monorai1.
5.2.6 Provision should be made for the temporary support of this piping during
catalyst filling.
5.3
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5.3.1 The catalyst unloading side of the reactors should be kept clear of all
obstructions at grade, including steelwork bracing.
5.3.2 Swing elbows should be used instead of valves and bypasses on the
process and regeneration piping. This eliminates some stress problems as
the hot and cold parts of the line are not tied rigidly together.
5.3.3 Locate thermowells between the reactor nozzle and the swing elbows on
the process and regeneration piping.
5.3.4 All valves on lines in hydrogen service should be "double blocked". This
includes operational drains, pressure instruments etc., as shown on P and
I diagrams.
5.3.5 Where ring joint flanges are used the piping must be arranged to allow for
valve removal.
5.3.6 In hydrogen service when the line is above auto-ignition temperature,
steam snuffing rings are usually provided around all flanges above 300
NB.
5.4
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SECTION 6
SHELL & TUBE HEAT EXCHANGERS
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SECTION 6
6.0
6.1
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VERTICAL REBOILER PIPING - ( Figure 6.2 in Drawing 803 ES L 181 Sht 3 of 4 & 4 of 4 )
6.2.1 If the vertical reboiler is mounted nozzle, to nozzle with the column,
instrumentation will have to be contained in the nozzles and the
orientation specified at an early stage of the layout.
6.2.2 Extend column platforms to include reboiler when access is required t o
nozzles for valving and blinds above 4.5 metres.
Below 4.5 metres, a portable ladder is usually sufficient.
When the column platforms cannot be extended, a separate structure may
be required. Avoid the welding of, platform clips to exchangers.
6.2.3 The piping must be adequately flexible to take care of the differential
expansion between equipment and piping during the different cycles of
operation.
6.2.4 Space should be given to allow for tube maintenance while the exchanger
remains in situ. This often means that the platforms on the column above
the reboiler must be omitted or made easily removable.
6.2.5 If the reboiler is to be nozzle to nozzle it is usually preferred to support it
from the column by locating point of support as close to nozzle as
possible. An alternate is to locate the point of support at the same
elevation as the bottom tangent line of the column to minimize the
differential expansion.
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6.4
6.4.1 The kettle type exchanger can be used as a heater or cooler/chiller etc.
Steam piping is shown, but this may not necessarily be the most common
source of heat.
6.4.2 This type of exchanger is occasionally used as a reboiler, where large
quantities of vapours are handled.
6.4.3 When the level instruments are above the normal accepted operating
height, additional platforms or ladders may be required for these
instruments only.
6.4.4 Locate the instruments and the level control valves adjacent, if possible,
as this simplifies manual operation of the levels through the control valve
bypass valve.
6.4.5 Ladder and platform requirements to be determined by elevation of
exchanger.
6.5
6.5.1 To ensure that each exchanger receives an equal flow, the reductions in
line size, and the piping must be run symmetrically. This requirement
should be indicated on P and I diagram.
6.5.2 Establish requirements at an early stage of layout for structural members
to support overhead vapor line.
6.5.3 When provision is made for a future exchanger, the piping must be
designed with a flanged branch connection to facilitate connecting piping
with the minimum of plant shut down time.
6.5.4 It is important to line up the supports of equipment in structures to
minimize the use of filler beams.
6.5.5 Where a number of exchangers are fed with a common service such as
steam or cooling water, a header system running below platforming should
be used.
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6.5.6 In some cases the piping between the exchangers and the drum will have
to be given a nominal slope to ensure free drainage.
6.5.7 When exchangers are located on the middle or ground floors of a
structure, permanent handling facilities such as runway beams, may have
to be built into the structure. The distance between floors may have t o be
increased to provide the extra headroom.
6.5.8 Piping should be routed clear of all handling facilities.
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SECTION 7
PUMPS
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SECTION 7
7.0
PUMPS
7.1
7.1.1 Ensure that rear of pump does not restrict access requirements under
pipeway and that minimum clearances have been provided.
7.1.2 Ensure that maximum projection from pump does not restrict minimum
operating aisle required at equipment.
7.1.3 Provide bootleg with manual drain and steam trap.
7.1.4 Provide support to avoid overstressing pump nozzle.
7.1.5 If drip rings are not used, provide drain between block and, check valves.
Alternative is to boss and tap check valve.
7.1.6 Keep length run and number of fittings in suction line to a minimum.
7.1.7 Piping to be designed to a1low for sufficient support and flexibility.
7.1.8 This height to be increased where pipe runs over pump.
7.1.9 The running of pipe over the motor is acceptable only if the line is high
enough for lighting equipment access.
7.1.10 When this dimension exceeds 600 mm beyond steelwork the swing check
valve on the discharge line should be placed in the horizontal position.
7.1.11 Horizontal suction lines shall be designed to avoid pockets resulting from
thermal expansion. Provide slope as required.
7.1.12 Typical routing for piping with small thermal growth.
7.1.13 Where pump suction and inlet line are same size, use long radius
elbow.
7.1.14 Arrange piping to enable pump to be broken out for maintenance.
7.1.15 Ensure overhead clearance is sufficient for pump liftout.
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7.2
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SECTION 8
CENTRIFUGAL COMPRESSORS
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SECTION 8
8.0
CENTRIFUGAL COMPRESSORS
An understanding of the relationship of piping configurations to the
compressor equipment arrangement essential to achieve an economical
and workable layout. Centrifugal compressors piping study in this
section will concentrate on piping items and their relationship to the overall
layout.
8.1
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8.1.9 Lube / Seal oil console is supplied as a package unit. Therefore, Vendor
supplied data as to space requirements and interconnecting piping
requirements should be reviewed early with the Package Units Design
Department.
8.2
8.2.1 *
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8.2.9 Check job / client instructions for requirements and type of suction
strainers. For compressor suction piping which are too small for manual
cleaning ( i.e.: under 750 NB ), a removable spool piece should be
provided to permit installation of the strainer at a convenient, accessible
location. Piping from strainer to equipment nozzle shall be noted for
special cleaning procedures.
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SECTION 9
LIST OF DRAWINGS
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SECTION 9
9.0
LIST OF DRAWINGS
9.1
803-ES-L-175
6 Sheets
Rev 0
2 Sheets
Rev 1
(Sht 2 of 8 & 3 of 8)
9.2
803-ES-L-176
3 Sheets
Rev 0
9.3
803-ES-L-177
7 Sheets
Rev 0
9.4
803-ES-L-178
3 Sheets
Rev 0
9.5
803-ES-L-179
6 Sheets
Rev 0
9.6
803-ES-L-180
4 Sheets
Rev 0
9.7
803-ES-L-181
4 Sheets
Rev 0
9.8
803-ES-L-182
5 Sheets
1 Sheet
(Sht 4 of 6)
Rev 0
Rev 1
9.9
803-ES-L-183
6 Sheets
Rev 0
9.10
803-ES-L-184
3 Sheets
Rev 0
9.11
803-ES-L-185
2 Sheets
Rev 0
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PART III
INSTRUMENT PIPING
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PART III
INSTRUMENT PIPING
PAGE
1.0
SAFETY VALVES
57
2.0
CONTROL VALVES
61
3.0
LEVEL INSTRUMENTS
63
4.0
LIST OF DRAWINGS
67
4.1
803-ES-L-186
4 Sheets
Rev 0
4.2
803-ES-L-187
7 Sheets
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4.3
803-ES-L-188
6 Sheets
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Page
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SECTION 1
SAFETY VALVES
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SECTION 1
1.0
SAFETY VALVES
1.1
1.1.1 Individual relief lines, blowdown lines and flare lines should be selfdraining from all safety valve outlets to the knock-out drum, flare stack or
to a point at the plant limit.
1.1.2 A pocketed relief line system is usually more expensive, because it
requires a condensate knock-out pot with instruments, piping, valves and
pumps.
1.1.3 To eliminate pockets, relief line headers are usually placed at a higher
elevation above the main piperack, supported on an extended piperack
column tee support.
1.1.4 For some non-condensing gas system, self-drainage is not so essential
(refer to appropriate P & I flow diagrams and project specifications).
1.2
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1.2.6
1.2.7 Safety relief valve should be installed in a location readily accessible for
maintenance.
1.2.8 Use ANSI B 31.1 Power Piping, latest edition, Appendix 2, in place of
API RP 520 Part 2 for non-mandatory rules for the design of safety valve
installations.
1.3
1.3.1 Provide a 6mm diameter weephole at elbow low point. For high pressure
steam, Pipe weephole to a safe location.
1.3.2 Check extent of safety valve top works for davit clearances. Davits are
required for handling of safety relief valves 100 NB X 150 NB size and
above. Check davit swing or crane availability and access.
1.3.3 Snuffing steam if required ( locate block valve at grade ) See P & I
diagram.
1.3.4 Check with Process Design department for verification of inlet line size
when valve is not mounted directly vessel nozzle.
1.3.5 Safety valve discharge point should be positioned 3000 mm above the
highest working level of platform within a radius of 8000mm. It should be
noted that these dimensions may vary for different projects. Therefore
appropriate project specifications govern. In extreme cases, tail pipe may
need guiding or supporting.
1.4
1.4.1 Other platforms such as aircooler platforms could be used for access to
valves When they are located higher than flare / blowdown header.
1.4.2 Piping to Safety valve is to be free draining to drum without pockets.
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SECTION 2
CONTROL VALVES
Page
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SECTION 2
2.0
CONTROL VALVES
2.1
2.2.1 Check for adequate clearance between control valve diaphragm and
adjacent valve or pipe, etc. when fixing dimension X as a fixing make-up
dimension.
2.2.2 Pipe work in the control set has been arranged to accommodate the
removal of a spool piece between the block valve and control valve. This
allows for the control valve to be removed for maintenance purposes.
Trunion base plate under removable piece is normally designed as a
guided sliding support without bolting.
2.2.3 Use line size drip pockets on 200NB and smaller lines and reduced size
drip pockets on 250NB and larger lines.
2.2.4 + 2100 means 2100 above H.P. paving or platform.
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SECTION 3
LEVEL INSTRUMENTS
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SECTION 3
3.0
LEVEL INSTRUMENTS
This section relates to the installation of level and gauge instruments on
vessels together with access and clearance requirements.
These
instruments may be mounted on stand pipes (bridles) or directly
connected to vessel nozzles. Level displacer gauges may be vendor
supplied or field fabricated.
In this section, the level displacers are shown as vendor supplied units
directly connected to the vessels and the gauge glasses are shown
connected to a standpipe. The actual requirements for a project are
shown on the P & I diagram.
3.1
3.1.1 Level controllers are normally ordered and furnished as left hand mounted
units. The piping designer should make every effort to incorporate this
mounting in the development of the vessel nozzle orientation. If this
becomes an impossibility, then the information should be transmitted to
the Instrumentation & Controls Design Department as soon as known.
There are a total of eight (8) rotational positions commercially available
but it is preferred that position number 1 to used whenever possible. See
Mounting positions on Sht 1 of 6 of above drawing.
3.1.2 Where a level gauge is required, the preferred location should be adjacent
to or visible from level controller to enable the operator to check the
operation of level controller.
3.1.3 For maintenance and operation, the level controllers should be accessible
from grade or from ladders, platforms, structures, main operating levels,
etc.
3.1.4 Allow sufficient clearance in front of level controller for the opening of
transmitter case doors. Door swing requirements are shown as dimension
C on Drg No. 803ES-L-188 Sht 1 of 6.
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LEVEL GAUGES
( Drawings 803 ES L - 188 Sht 5 of 6 & Sht 6 of 6 )
3.3.1 Level gauges should be located so that they are easily read by operator
and accessible for maintenance.
3.3.2 Where a displacer level controller is required on a vessel, the level gauge
or Standpipe should be located in close proximity to enable a check to be
made on correct level controller operation.
3.3.3 Standpipes should be used where level fluctuations in a vessel and vessel
diameter requires more than one level gauge to show liquid level. This
arrangement cuts down the number of vessel nozzles and allows for
correct placement of gauges.
3.3.4 When more than one gauge is required an overlap should be provided to
give a continuous visible range.
a. For end connected gauges overlap should be 250 mm.
b. For side connected gauges overlap should be 90 mm
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SECTION 4
LIST OF DRAWINGS
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SECTION 4
4.0
LIST OF DRAWINGS
4.1
803 ES L - 186
4 Sheets
Rev 0
4.2
803 ES L 187
7 Sheets
Rev 0
4.3
803 ES L 188
6 Sheets
Rev 0
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PART IV
OFFSITES PIPING
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PART IV
OFFSITES PIPING
PAGE
1.0
OFFSITE TANKAGES
71
2.0
75
3.0
COOLING TOWERS
79
4.0
83
5.0
LIST OF DRAWINGS
87
5.1
803-ES-L-189
3 Sheets
Rev 0
5.2
803-ES-L-190
3 Sheets
Rev 0
5.3
803-ES-L-191
4 Sheets
Rev 0
5.4
803-ES-L-192
4 Sheets
Rev 0
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SECTION 1
OFFSITE TANKAGES
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SECTION 1
1.0
OFFSITE TANKAGES
1.1
1.1.1 Tanks with a height in excess of 4500 mm require stairways. These are
usually spiral and fixed to the tank walls. Start stairway so that the first
step is either facing the access ramp or next to the bund wall. Escape
ladders from tank interconnecting platforms should be similarly located.
1.1.2 Different types of tanks have different fixtures ( e.g.: fixed head water
spray, floating roof inert gas seal blanket ). Ensure that control or stop
valves are located outside bund walls.
1.1.3 Tank pad elevation is normally established at a height equivalent to the
as-settled position of the tank after hydrostatic testing. Allow sufficient
flexibility in pipe routing for differential settlement between tanks and bund
walls and between pumps and bund wall. The uses of flexible couplings
are suitable for services such as water but are not recommended for
hydrocarbons. Nozzle elevations shall be set by taking into account the
initial settlement.
1.1.4 Group pumps together, wherever possible, on a common foundation. This
should be compatible with Note 1.1.3 above and with the requirement that
pump suction lines should be as short as possible and without pockets.
1.1.5 Allow sufficient space for pumps to be serviced without interfering with
roadway traffic.
1.1.6 Allow sufficient space for fire-fighting equipment to be parked off
roadways. ( Note: Fire fighting equipment must have access to tankage
areas from two sides ).
1.1.7 For long pipe runs above ground which may be left full of liquid, and can
be blocked in at both ends for periods of time, consideration must be given
to thermal relief due to solar expansion and a safety valve added if
necessary.
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1.1.8 The first pipe support should be at sufficient distance away from tank to
allow for tank settlement. If settlement is considerable the first support
may need to be an adjustable or spring support. Consideration could be
given to supporting pipe from tank, with appropriate stiffening, if
necessary.
1.1.9 Distance normally chosen between pipe support sleepers is 6000 mm. If
intermediate support is required at 3000 mm for small bore piping, it is
preferable that these lines be grouped together for support from larger
uninsulated lines if possible or to minimize the number of additional
sleepers.
1.1.10 Intersecting pipetracks outside the bunded area must be at a different
bottom of pipe elevation. The differences in the elevations are to be
minimum, usually considering the largest pipe as the worst condition.
Flat turns are acceptable if all lines turn in the same direction.
1.1.11 Keep expansion loops in nests for economy of supporting.
1.2
1.2.1 Tank base elevation is set to suit pump suction and piping requirements.
1.2.2 Lower manhole should be located close to stairway start point and
preferably below stairway, roof manhole should be oriented approximately
180 from lower manhole for air circulation during maintenance. Steam out
connection or inert gas purge connection should be located local to lower
manhole. Locate top manhole local to top platform.
1.2.3 If a combined pressure relief and vacuum breaker is required it must be
located at the high point of the tank.
1.2.4 Drain or pump out nozzles can be either as indicated or mounted above
base plate with an internal pipe to a sump.
1.2.5 Level instruments on tanks are normally fitted with a float type indicator.
This should be local to top manhole for maintenance. High level if fitted
has to be accessible from platform or stairway. Low level alarm should be
located so that reach is not affected by outlet nozzle.
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1.2.6 Inlet and outlet nozzles should be located together and pointing toward
inside bund pipe rack for simplicity of piping layout and valve operation.
Tank nozzles can be radial or parallel.
1.2.7 Floating Roof Tanks: Tank nozzle layout is similar to fixed roof tanks
except that roof nozzles will be grouped in the tank centre and are usually
located by tank vendor.
1.3
1.3.1 Uninsulated lines through earthen bund walls with no roadway above shall
be coated and wrapped and buried with no sleeving. The protective
coating shall extend a minimum of 300 mm beyond earthwork at the low
point on both sides.
1.3.2 Lines requiring sleeving:
a. Insulated lines through bund walls with no roadway above.
b. Insulated and uninsulated lines through bunds with roadway
above.
c. Insulated and uninsulated lines under plant roads.
These sleeves are normally made of corrugated galvanised metal and
extend to a point 300 mm beyond earthwork at the low point on both sides
of the wall or road.
Seal all sleeves on inside of bund walls with cement grout.
Provide sleeve guides within 300 mm of each sleeve end and not
exceeding 6000 mm centers. These guides shall be fabricated in
accordance with the details shown in drawing 803-ESL-189 Sht.3 of 3 and
attached to pipe by welding.
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SECTION 2
OFFSITE LPG STORAGE
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SECTION 2
2.0
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2.1.1 Horizontal storage bullets are normally supported on two saddles and
installed with a normal slope of 1 : 200, to allow drainage of possible
entrained water or complete removal of test water.
2.1.2 Vessel low point should be elevated to a minimum of 1500mm above
grade to ensure free air circulation under to clear any possible spillage.
Elevation can be increased if required, for piping clearances. Special
attention should be given to the positioning of the drain connection in cold
climate installations to prevent freeze-ups.
2.1.3 All L.P.G storage vessels should be fitted with a pressure relieving device
located on the high point of the tank at the end furthest away from the
manifold area. When atmospheric vents are permitted, the open end shall
contain a rain cap or equivalent device with a drain connection on the low
point directed away from the top of the tank.
2.1.4 All nozzles other than pressure relief nozzles shall be fitted with block
valves (preferably connected to nozzle). Inlet and outlet nozzles can be
fitted to either the top or bottom of the vessel. A bottom connection is
preferable as it minimizes top plat forming and makes for a more readily
accessible.
2.1.5 When two or more vessels are required, a common continuous platform
should be provided. Stairway access is normally required for platform
higher than 4500 mm above grade. Dead ended platform lengths should
be avoided. Manhole covers can be used for mounting instruments (all
instruments should be in vapor space) to reduce the number of
connections on the vessel.
2.1.6 General requirements for pipe routing are the same as for atmospheric
storage tanks. See section 1 in this part.
2.1.7 Eye wash and safety showers are to be provided and located at operators
level and or at grade.
2.1.8 LPG storage vessels shall be completely surrounded by fire water mains
including hydrants, monitors or combination of hydrant / monitor.
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2.2
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SECTION 3
COOLING TOWERS
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SECTION 3
3.0
COOLING TOWERS
3.1
3.1.1 Figure shows a typical layout of horizontal cooling water pumps and
piping. Process consideration should be given to pit elevation as
pumps may be located below grade in a pit for pump priming conditions
( pumps flooded on start-up ). When pump elevation is established to
suit flooded conditions, the top of pump casing should be a minimum of
150 mm below water level.
All cooling towers have some form of water collection pit, regardless of
type, into which the cooling tower basin slopes.
3.1.2 Flume outlet spacing is dictated by pump and driver dimensions. If
cooling tower is of concrete construction then this information will be
required early in the job to allow early construction of tower and basin.
3.1.3 Although cooling water return to tower may be directly coupled, it is
advisable to use some form of flexible coupling to minimize the effects of
differential settlement.
3.1.4 To simplify the supporting of pipe and to reduce the number of small
access platforms, the cooling water return by-pass valve, make-up water
control valve and pond level controller should be grouped together for
access from a common platform may also be used in connection with
chlorination equipment.
3.1.5 Locate suction pit drain and overflow connections together ( if required )
to minimize underground pipe run.
3.1.6 Locate flume outlet valve directly on flume if flexible couplings are to be
used. Some cooling tower basins are fitted with adjustable weirs which
cab be used for shut-off instead of valves.
3.1.7 Discharge valve location : If a gate valve is used locate with check
valve in horizontal close to pump, so that the supports can be located on
pump foundation. If butterfly valve is used, locate in vertical, on
underground header flange.
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3.2.1 The shape of cooling towers will vary depending upon local
requirements such as ambient temperatures, prevailing wind strengths
and height limitations.
3.2.2 Vertical cooling towers can also be :
a. Semi-Forced Draft i.e. fitted with motor driven fans on the outside
usually between support legs.
b. Semi-Induced Draft i.e. fitted with fans on the inside, but with the water
distribution system on the outside. This makes for a very large
catchment pond but it has the advantage of limiting water loss.
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3.3
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SECTION 4
ROAD AND RAIL CAR LOADING
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SECTION 4
4.0
4.1
4.1.1 Loading arms can be ordered to suit different applications, and sizes and
can be for top or bottom loading. To determine the arc required, the
designer/engineer must first establish what type and size of tanker is to be
used, the speed and frequency of filling and the number of filling points on
that tanker to be serviced by one loading arm. Loading arm vendor should
be consulted as early as possible.
4.1.2 For top loading arms, a loading platform must be supplied. This platform
has a double function in providing access from the loading arm area to the
tanker top by means of some form of movable link platform and placing
the operator at the same or similar elevation to the tanker manhole
platform. Permanent access to tanker platform may also be required when
tanker loading is from the bottom.
4.1.3 Metering into tankers can be either local or remote mounted. This will be
governed by the client / local statutory body. If locally mounted, it should
be located where it cannot be accidentally damaged by incoming or
outgoing tankers.
4.1.4 Ideally, loading areas should be designed to have a through flow of
tankers and segregated parking facilities should be provided for incoming
and outgoing tankers.
4.1.5 If top loading arms are to be used, each loading platform should be
provided with two tanker standing areas for speed of tanker turnaround. If
bottom loading, only one standing area is needed and should be located
on the curb or pavement side of the tanker.
4.1.6 Some type of sprinkler or foam system is usually provided in this area and
correct location of this equipment is essential. Consult with project
engineering.
4.1.7 Tank car and truck vent lines shall be provided in accordance with the
requirements of the local governing codes.
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4.1.8 Roofed loading islands shall be provided with proper ventilation in roof
enclosures and an adequate roof drainage system.
4.1.9 Loading areas should be located within a reasonable and safe distance to
tankage supply, to plant perimeter road and to rail road ( R.R ) spurs off
the main R.R. right of way. They shall be controlled by a separate security
gate house and or enclosed with fencing as required by client security
procedures. A secured vehicle gate to the main plant area should be
considered.
4.1.10 Loading area should be equipped with the proper number of utility stations
for wash down and maintenance. Eye wash and safety showers area
normally provided and located at operators level and or at grade. See
utility P&I diagram for requirements.
4.1.11 An adequate drainage system shall be provided and located so as not to
spill liquids under the equipment being serviced.
4.1.12 Space should be allocated for future expansion of loading area when
future process areas are contemplated and shown on the overall plot plan.
4.1.13 Metering equipment, valves, filters and knock out drums to be located at
grade.
4.2
4.2.1 As dimensions of rail cars vary from country to country, the designer must
ascertain the size of rail car to be used so as to determine the center to
center dimensions for loading arms. Loading arm vendor should be
consulted as early as possible.
4.2.2 The loading bay of platform should be sufficiently far from the end of the
siding to allow for shunting of cars. Consideration should be given to a
through access R.R. siding rather than a dead ended track. If only one
product is to be loaded then one car length will be sufficient. If product
loading is multiple then consideration must be given to sequencing loading
arms to match preferred sequencing of rail cars. If one car is to be used
for various products, then some form of car flushing or purging may be
required.
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4.3.1 A more advanced type of rail loading installation is the automatic lance
operated rail loading. This entails a structure as basically outlined on
sheet 4 of 4. This type of operation gives a really fast turn around but is
expensive to install and a large demand for rail loading would have to be
anticipated to justify its installation.
4.3.2 On this type of installation and on the installation shown on sheet 3 of 4,
consideration should be given to having a double railroad system as the
cost of an extra track is small compared with the cost of a loading island.
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SECTION 5
LIST OF DRAWINGS
Page
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SECTION 5
5.0
LIST OF DRAWINGS
5.1
803 ES L - 189
3 Sheets
Rev 0
5.2
803 ES L - 190
3 Sheets
Rev 0
5.3
803 ES L - 191
4 Sheets
Rev 0
5.4
803 ES L - 192
4 Sheets
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SPECIMEN SIGNATURE
(FROM 01-OCT-2008)
S.
No.
Name
Signatory For
A.MARUTHAPPAN
Preparation
J.K.RAO
Checking
B V RAMANAKUMAR
Approval