Document cod: Design specification:

ED-A-03.00-I-02 GENERAL UNIT AND EQUIPMENT LAYOUT

Engineer Division Technical Department GENERAL DESIGN NOVEMBER 2010 Page 2 of 15

TABLE OF CONTENTS

1. GENERAL ..................................................................................................................................................3
1.1. Purpose ......................................................................................................................................................3
1.2. Definitions...................................................................................................................................................3
1.3. Measurement units .....................................................................................................................................4

2. OFF-SITES .................................................................................................................................................4
2.1. Distances required ......................................................................................................................................4
2.2. Roads, accesses and service areas ............................................................................................................6
2.3. Central control room (off sites) ....................................................................................................................7
2.4. Main power substation (off sites).................................................................................................................7
2.5. Flare stacks ................................................................................................................................................7
2.6. Service Buildings ........................................................................................................................................7
2.7. Fire Water pumps .......................................................................................................................................7
2.8. Cooling towers ............................................................................................................................................7

3. ON-SITES...................................................................................................................................................8
3.1. Equipment Arrangement .............................................................................................................................9
3.2. Requirements for maintenance and use of mobile equipment......................................................................13

4. PLOT PLAN DRAWING (PE-A-0300.01) ....................................................................................................14

5. STANDARDS AND SPECIFICATIONS OF REFERENCE ...........................................................................15

5.1. REPSOL standards and technical specifications .........................................................................................15
5.2. International standards. ..............................................................................................................................15

6. INDEX OF TABLES INCLUDED IN THIS SPECIFICATION.........................................................................15

TABLE OF CONTENTS
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1. GENERAL

1.1. Purpose

This specification establishes the general guidelines to be followed in the arrangement of units and group of
units in an Industrial Complex, in order to attain maximum safety and facilitate process maintenance, operation,
control and fire prevention.
The use of this specification does not exempt the Engineering Company from the obligation of applying its own
and better experience. Reasons may also arise from process requirements that may require some deviation
from the requirements herein set out. In every case any deviation to this specification requirements shall be
notified to REPSOL, for its approval.
Application of this specification includes the obligation of complying with the occupational safety and hygiene
Regulations, safety in refineries, tank farm regulations, and any other applicable regulation included in the local
legislation that may be applicable to REPSOL Industrial Complexes.
This document is part of the latest edition of the REPSOL technical specifications and also makes reference to
the latest edition of the mentioned and/or applicable Standards and Codes, and to the instructions of the ‘Basic
Design Data’ (BDD) that includes the specific aspects of each project.
In case of discrepancy between the documents indicated, the following order of priority shall apply:
• Applicable legislation (provided that more restrictive criteria is not specified in the data sheets, in the
requisition or in this specification regarding the criteria established in the legislation)
• BDD - Basic Design Data
• This specification
• Standard drawings
Any exception, variation or addition that may imply any change in these documents must be notified in writing
to REPSOL for its approval.

1.2. Definitions

Unit: The set of manufacture elements formed by one or more physical-chemical processes that constitute a
specific complete operation, except the piping that connect to other units and to the external installations. Each
unit receives the name of the process that is most characteristic or representative of its main function.
Integrated unit: For the purposes of this specification, integrated units are those that even having different
processes are attended from the same control room.
Free circulation roads: Main roads within the Industrial Complex where a special circulation permit is not
required.
Restricted circulation roads: Roads normally used for maintenance equipment access between units, where
special safety measures are required.
Service areas: Strips of land, paved or not, around each unit.
Equipment limit: Equipment limit shall be formed by the vertical projection of all equipment located in the
periphery of the unit, thus forming a polygon including all the equipment of the unit.
Pavement limit: Pavement limit is formed by a polygon surrounding the equipment limit at an external distance
of 1.5 meters, including also the maintenance zones (e.g. the bundles withdrawal zone).
Unit limits (U.L.): Unit limit is defined by a rectangle considering the maximum dimensions of the most
projecting points of the pavement limit. This rectangle borders on the service area.

1 GENERAL
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Hazardous area: Those sites where there are, or could be, flammable gases or vapors in sufficient amount to
produce explosive or flammable mixtures, classified in function of the degree of danger and the extension of
the danger zones (for further information see ED-A-07.00).
Flash point: The minimum temperature at which a liquid produces sufficient flammable vapors to originate
2 combustion in the presence of a foreign ignition source (spark, flame, etc.) under certain specific test
conditions.
Auto-ignition point (spontaneous ignition): The minimum temperature at which a substance (solid, liquid or
gaseous) has sufficient energy to initiate and maintain combustion without requiring a foreign ignition source.

1.3. Measurement units

The International Metric System (SI) shall be used for units of measurement. Particularly, dimensions shall be
indicated in millimeters (mm) and elevations and coordinates (referred to those of the Industrial Complex) in
meters, with three decimals.

2. OFF-SITES

2.1. Distances required

In order to define the plot plan drawing, distance between units, tanks, flare stacks, LPG installations, roads,
loading bays, etc., shall follow the requirements of this specification, and specially the distances required in
Table I.

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TABLE I
Minimum safety distance guidelines between units and equipment
on the Off-Sites.
These distances are based on various international standards
BUILDINGS (OFFICES. WORK SHOPS.

A
LABORATORY. ETC.) (NOTE 7)

Y
MARITIME LOADING BAY (JETTY)

A
BOILERS

COOLING TOWER

MAIN POWER DISTRIBUTION

SAFETY BUILDING (FIRE BRIGADE)

BOILERS NM
MAIN WATER FIRE-FIGHTING PUMPS

BUILDINGS (OFFICES. WORK SHOPS.

30 NM
LABORATORY. ETC.) (NOTE 7)
SUBSTATION

COOLING TOWER 45 45 NM
LOADING PLATFORM FOR OTHER
LPG LOADING PLATFORM

MARITIME LOADING BAY (JETTY) 60 60 30 NM

(NOTE 7)

MAIN POWER DISTRIBUTION

PIPE RACKS OUTSIDE THE UNIT

30 NM 45 60 NM
SUBSTATION
(NOTE 6)

SAFETY BUILDING (FIRE BRIGADE)

30 NM 30 60 NM NM
(NOTE 7)
PRODUCTS

MAIN WATER FIRE-FIGHTING PUMPS

PROCESS UNIT LIMIT

PROPERTY LIMITS (NOTE 8)

NM NM 15 60 NM NM NM
(NOTE 6)

LPG LOADING PLATFORM 60 60 45 45 60 60 60 NM

HYDROCARBON PUMPING

LOADING PLATFORM FOR OTHER

60 60 30 60 45 45 45 60 NM
FLARE STACK (NOTE 3)

HYDROCARBON SEPARATION
PRODUCTS

PIPE RACKS OUTSIDE THE UNIT 4.5 15 4.5 4.5 7.5 4.5 4.5 15 15 NM
POOLS (API / CPI. ETC.)

SUBSTANCES W/LOW F.P.T. (F.P.T.

PROCESS UNIT LIMIT 45 60 30 60 45 45 45 60 45 4.5 15
STATION

PRESSURE VESSELS AND

ATMOSPHERIC STORAGE OF
PROPERTY LIMITS (NOTE 8) 45 NM 30 60 NM NM NM 60 45 4.5 60 NM

SUBSTANCES W/HIGH F.P.T. (F.P.T.

HYDROCARBON PUMPING STATION 45 45 15 15 45 45 30 30 15 4.5 20 45 NM

ATMOSPHERIC STORAGE OF
SPHERES

FLARE STACK (NOTE 3) 60 60 60 60 60 60 60 60 60 60 60 60 60 NM

HYDROCARBON SEPARATION POOLS

45 45 30 45 45 45 45 45 45 4.5 45 60 15 60 NM
≤37.8 °C)

REFRIGERATED STORAGE
(API / CP.I. ETC.)

PRESSURE VESSELS AND SPHERES 60 60 30 60 60 60 60 60 45 4.5 60 60 NM 60 45 1D

≥37.8 °C)

ATMOSPHERIC STORAGE OF
SUBSTANCES W/LOW F.P.T. (F.P.T. ≤37.8 45 45 30 45 45 45 45 60 45 4.5 45 60 NM 60 45 40 0.5D
°C)

ATMOSPHERIC STORAGE OF
SUBSTANCES W/HIGH F.P.T. (F.P.T. ≥37.8 30 30 30 30 30 30 30 30 30 4.5 30 45 NM 60 30 40 0.5D 0.5D
°C)

REFRIGERATED STORAGE 45 45 30 45 45 45 45 60 45 4.5 60 60 NM 60 45 30 30 30 1D

NOTES

1. THE DISTANCES RECOMMENDED IN THIS TABLE ARE SUBJECT TO THE MINIMUM VALUES REQUIRED IN THE OFFICIAL REGULATIONS WHEN THESE EXIST.
DISTANCES ARE INDICATED IN METRES ON THE HORIZONTAL PLANE.
2. MINIMUM DISTANCES BETWEEN BUILDINGS, PROCESS EQUIPMENT, FENCES, ETC. (MEASURED FROM ONE END TO THE OTHER)
3. DISTANCE FROM FLARE STACK TO ANOTHER INSTALLATION SHALL BE VERIFIED ACCORDING TO STANDARD API 521 OR LOCAL REGULATIONS.
4. THIS TABLE SHALL BE COMPARED WITH THE LOCAL STANDARDS BEFORE USING IT.
5. F.P.T. FLASH POINT TEMPERATURE
6. MINIMUM DISTANCE REQUIRED. TO BE CONFIRMED BY A RISK ANALYSIS.
7. MINIMUM DISTANCE REQUIRED. DISTANCES FROM OR TO OCCUPIED BUILDINGS SHALL BE CONFIRMED BY RISK ANALYSIS.
8. SAFETY DISTANCE TO FOREST AREAS SHALL BE ACCORDING TO COUNTRY LEGISLATION

LEGEND:

NM = MEANS THAT NO PREDETERMINED MINIMUM SPACE IS REQUIRED, BEST ENGINEERING PRACTICES SHALL BE APPLIED.
D = OUTSIDE DIAMETER

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2.2. Roads, accesses and service areas

Service areas, free circulation roads and restricted circulation roads shall be established within the Complex.
(see standard drawing PE-A-0300.03)
Roads shall be preferably at higher elevation regarding the floor level of the units and shall have such a section
that may allow water runoff to the drains foreseen for this purpose. The curvature radius in crossroads shall be
studied by the Engineering Company for allowing an easy circulation of heavy vehicles and with a large
clearance, and shall be of at least 10 meters.

2 Maximum slope of the roads shall be 5%.

2.2.1. Service Areas

Service areas shall be whenever possible 10 meters wide, but never less than 6 meters wide, measured from
the unit limit (U.L.). All units shall have their service area.
The service area shall have at least two accesses from a free circulation road. These accesses shall be
2
located at points that are as opposite as possible, and shall be at least 5 meters wide. Any case, shall be
checked access wide is enough to maintenance machinery.
The service area and the free circulation road shall never coincide.
Between two “integrated” units, both service areas may overlap, in which case the minimum distance between
their units limits shall be 10 m.

2 Service areas shall be not paved except opposite shall be specified in the project scope or D.B.D indication.

2.2.2. Free circulation roads

Free circulation roads shall be at least 6 meters wide, and shall be constructed at least 20 meters away from
those sites classified as Zone 0 or Zone 1 (this distance shall be measured from the nearest border of the road
and at a minimum distance of 9 to 13 meters from the U.L. depending on the width adopted for the service
2
area).
These roads shall have on both sides a “sidewalk” at least 3 meters wide (See standard drawing PE-A-
0300.03).
If there is a free circulation road between two units, the minimum distance between their unit limits shall vary
between 24 and 32 m (depending on the width of the service area adopted).

2.2.3. Restricted circulation roads

Restricted circulation roads shall be at least 4 meters wide and shall be at a minimum distance that shall vary
from 6 to 10 m from the U.L. (depending on the width adopted for the service area). They shall be duly signaled
and if necessary they shall be closed by posts or barriers.
If between two units there is a restricted circulation road, where it is possible to “make a stop” apart from
maintenance purposes, the minimum distance between their U.L. shall be between 24 and 16 m (depending on
whether the service area is 10 or 6 m wide).

2.2.4. Overhead clearance

The overhead clearance to be respected by any element crossing service areas, accesses and roads shall be
5.75 meters.
The overhead clearance to be respected in crossings with public roads or railway shall be that required by the
applicable local regulations.

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2.2.5. Paving in off-site areas

In off-site zones, concrete pavement shall be used below any equipment containing hazardous and flammable
liquids that could spill during operations routine and maintenance functions, e.g. loading and discharge lines,
loading pumps, filters, water drainage, etc. The paved area shall be leveled and shall have a slope towards an
appropriate drainage system.

2.3. Central control room (off sites)

The safety distance to be kept between any equipment that could present an explosion or fire risk and the
2 control room is indicated in Table II. Risk analysis results shall be considered for fire and blast resistant design
as required by specification ED-A15.00.
The control room shall be located windward regarding the fired heaters and process areas.

2.4. Main power substation (off sites)

The safety distance to be kept in order to guarantee their correct operation, considering any equipment with
hydrocarbons that could cause an explosion or fire, is indicated in Table I.
These distances may be reduced if the substation is designed to support the pressure produced by the
2 (potential) expansion wave determined for the substation site.
Power transformers located outside power substation shall be situated near by side of the building farther of
risk of explosion process units and preferably windward inflammable substances equipments.

2.5. Flare stacks

Elevated flare stacks shall be installed leeward regarding the process units, in the direction of the prevailing
wind.
The distance between the stack and other equipment (and the height in the case of an elevated stack) is
determined by radiation heating intensity considerations (standard API 521) or local regulations. Other factors
must be considered, such as noise, atmospheric contamination and location of public places, which could have
an influence on the minimum distance values considered in Table I.

2.6. Service Buildings

Service buildings include offices, laboratories, shops, warehouses, cafeterias, restaurants, and hospitals shall
be situated near the entrance of the planta and be readily accessible to a public road to reduce traffic inside
2 the facility. Buildings shall be spaced from fire and explosión risk areas.
If it is possible building shall be located on the windward side of the plant.

2 2.7. Fire Water pumps

Fire water pumps shall be sufficiently remote from processing, storage and loading areas to reduce the risk of
fire or blast damage to the pumps given any protective measures (e.g. Fire/blast resisting enclosure) installed.
The pumping facilities shall be capable to operate during the worst case scenario identified in the risk
assessment.

2 2.8. Cooling towers

The direction of the prevailing wind shall be considered in selecting the location of cooling towers. The towers
shall be located to minimise any nuisance, both within and outside the site, from water blow out, evaporation,
drift and ice formation.

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3. ON-SITES

TABLE II
Minimum distance between equipment inside units (on site)
These distances are based on different international standards

A
GAS COMPRESSOR

CENTRAL CONTROL ROOM

Y
UNIT CONTROL ROOM (NOTE 3)

A
GAS COMPRESSOR NM
AIR COOLERS

COOLING TOWERS

CENTRAL CONTROL ROOM 30 NM

UNIT SUBSTATION (NOTE 3)

HEAT EXCHANGERS, OP.T.>AIP°C

UNIT CONTROL ROOM (NOTE 3) 30 NM NM

HEATEXCHANGERS, OP.T.<AIP°c

AIR COOLERS 7,5 30 30 NM

VESSELS

COOLING TOWERS 15 30 30 15 NM

VESSELS NM 30 30 3 15 NM
PUMPS WITH FLAMMABLE LIQUIDS,
FIRED HEATERS

UNIT SUBSTATION (NOTE 3) 30 NM NM 30 30 30 NM

EQUIPMENT WITH NON FLAMMABLE
PUMPS, OP.T.>AIP°c

HEAT EXCHANGERS, OP.T.>AIP°C 7,5 30 30 4,5 4,5 4,5 30 NM

REACTORS, OP.T.>AIP°C, EXTERNALLY

HEAT EXCHANGERS, OP.T.<AIP°c 7,5 30 30 NM 15 1,5 30 NM NM

REACTORS, OP.T. <AIP°C, INTERNALLY
VAPOURS

FIRED HEATERS 22,5 30 30 15 30 15 30 7,5 15 NM

SUBSTANCES

PUMPS, OP.T.>AIP°c 7,5 30 30 4,5 15 NM 30 4,5 NM 7,5 NM

MAIN EQUIPMENT STRUCTURE

PUMPS WITH FLAMMABLE LIQUIDS,

7,5 30 30 3 15 NM 30 4,5 3 15 4,5 NM
INSULATED

VAPOURS

EQUIPMENT WITH NON FLAMMABLE

NM NM NM NM NM NM NM NM NM 4,5 4,5 NM NM
INSULATED

SUBSTANCES

REACTORS, OP.T.>AIP°C, EXTERNALLY

7,5 30 30 4,5 NM 4,5 30 4,5 4,5 5 5 4,5 4,5 NM
INSULATED

REACTORS, OP.T. <AIP°C, INTERNALLY

7,5 30 30 7,5 NM 7,5 30 7,5 7,5 7,5 7,5 7,5 4,5 NM NM
INSULATED
TOWER

PIPE RACKS IN UNIT

PURGE TANK

MAIN EQUIPMENT STRUCTURE 7,5 30 30 NM 15 NM 30 4,5 NM 15 3 1 NM 4,5 4,5 NM

TOWER 7,5 30 30 3 15 1,5 30 4,5 1,5 15 4,5 3 NM 4,5 7,5 NM NM

PURGE TANK 15 30 30 7,5 15 7,5 30 15 7,5 15 15 7,5 NM 15 15 NM 7,5 NM

PIPE RACKS IN UNIT 4,5 7,5 4,5 NM NM NM 4,5 NM NM 5 3 1 NM 4,5 4,5 NM NM NM NM

NOTES

1. DISTANCES IN INTERNATIONAL METRIC SYSTEM UNITS (METRES)

2. APPLICABLE MINIMUM SAFETY DISTANCES, CONSIDERED ON THE BASIS OF THE PLANIMETRIC PLANT, IN METRES, BETWEEN EQUIPMENT CENTRE LINE,
FENCE LINE, END OF PUMP SUPPORTS, CENTRE LINE OF COMPRESSOR SUPPORTS AND OF STRUCTURES.
3. REDUCE THE DISTANCE TO 15 M WHEN THE ELEVATION IS HIGHER THAN 0.6 M REGARDING THE FLOOR LEVEL.

LEGEND:

NM = MEANS THAT NO MINIMUM PREDETERMINED SPACE IS REQUIRED, BEST ENGINEERING PRACTICES SHALL BE APPLIED.
OP.T.= MEANS OPERATING TEMPERATURE
AIP= AUTOIGNITION POINT OF THE SUBSTANCE CONTAINED.

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3.1. Equipment Arrangement

3.1.1. General

Distances between equipment within the units for carrying out the detailed plot plan shall comply with the
indications of Table II and standard drawing PE-A-0300.02. This standard drawing shows a process unit typical
distribution including the main requirements due to safety, operating and maintenance reasons.
Process equipment shall be arranged so that it implies minimal pipeline lengths when process condition
specified (transfer lines of columns, heaters and reactors) as such alloy steel lines), as well as the expansion
2 of the unit (if it is considered necessary) or the expansion of the piping line network if possible, with minimum
interference to operations.
Process equipment shall be aligned as far as possible on both sides of the pipe rack, respecting carefully the
required safety distance indicated in Table II. Towers and vertical vessels shall be lined up by their tangent
next to the rack, when their diameters vary substantially between them; when their difference is small, they
shall be aligned by their centerline.
Considering the prevailing winds in the zone, vessels, pumps, compressors, air coolers and other equipment in
2 which light flammable hydrocarbons are handled, shall be located leeward from the fired heaters according to
the direction of the wind, in order to minimize the possibility that their vapors may be transported by the wind
towards the fire.
Any permanent ignition point such as fired heaters, boilers, etc. shall be located at least 15 m away from any
equipment containing hydrocarbons or other flammable fluids and in a zone with abundant ventilation (or at a
2 larger distance if sufficient ventilation is not available). The external side of fired heaters shall be at least 1.5
meters away from the unit limit.
Equipment working with non-flammable products may be located up to 4.5 m away from fired heaters or
boilers.
For the reactors directly associated with fired heaters, their location shall be determined by the optimum design
of their pipelines with the fired heater and their catalyst load and discharge requirements; however, the
minimum distance to the fire heater shall not be less than 5 m.
In the case that two or more process sections may be operated separately within a same unit and one could be
in operation while the other one is stopped for maintenance, a distance of 6 meters shall be respected between
equipment of both sections containing hydrocarbons. However, this free space may be crossed by a pipe rack.
When equipment has to remain in service within a zone of equipment stopped for maintenance, special care
shall be taken with its location, in order to minimize the hazard.
The need of clearances within the unit shall be considered, both those required for disassembly and those
required for placing stand-by equipment or future equipment, if their installation has been foreseen. In general,
it is convenient to respect this criterion in all units, so that future expansions of the plant and of the units may
be feasible, even without knowing their specific details.
Special attention shall be paid to the layout of equipment in integrated units, which the maintenance shutdown does
not coincide, foreseeing space for the installation of provisional barriers between them, if so required during these
periods.
Normal elevations for foundations are indicated in specification ED-Q-02.00.

3.1.2. Minimum clearance for persons or mobile equipment transit

Minimum height for transit of persons shall be:

a) Piping and structural elements on the floor or in elevated zones
and any hot element (pipe, fired heater bottom, etc.) 2.20 m.
b) Piping in working areas, permanent or operation work but not transit 2.00 m.
c) In inclined ladders 2.20 m.
Minimum clearance width between any elements shall be 0.90 meters, except those specifically required such
as the clearance between pumps. When this width refers to equipment with a height exceeding 3 m, the
minimum clearance shall be 1.50 meters.

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An ample space shall be left between different equipment, allowing safe working conditions for operations and
maintenance personnel.
Equipment and heat exchanger insulation thickness shall be considered in order to define the minimum
clearances.
Vertical clearance in accesses for maintenance mobile equipment under pipe racks or other elements shall be
at least 3.5 meters, not limited to access from service area. The minimum width of this access shall be 3.0
meters.
The minimum vertical clearance between two pipe bents where the access from the maintenance way to the
2
area under the pipe rack is foreseen will be 3.5 meters too (i.e. below that height there will not be a spandrel
beam nor bracing between the columns that could block the way).
The zone adjacent to pumps, turbines and other mechanical equipment used for maintenance and access of
mobile equipment shall have a minimum vertical clearance of 2.5 meters over the floor. The clearance above
this equipment shall be sufficient to introduce the crane boom and pull out the piece to be disassembled. In
pumps, the pump, electric motor, turbine, etc. shall be capable of being extracted.
All piping that connect the pipe rack with lateral equipment, shall respect an access zone 1.5 meters wide and
2.5 meters high, required for the passing of the forklift or crane for the disassembly and transportation of
pumps and heads of heat exchangers.

3.1.3. Vessels and columns

a) Horizontal vessels
They shall be aligned by the tangential line to their head next to the pipe rack. These alignments shall respect
the access way between equipment and pumps located under the pipe rack.
The manhole in horizontal vessels with a diameter exceeding 1500 mm shall be located on the lateral side
coinciding with their centerline. Only exceptionally it may be placed at the vessel head that is nearest to the
service road. In vessels with a diameter of 1500 mm or less, the manhole shall be located in the top.
Elevation of the lower generatrix of horizontal vessels shall provide the NPSH (net positive suction head)
required to the pumps working with them. This elevation shall be indicated in the P&I diagram, according to
specification ED-A-02.00.
b) Towers or columns
It could occur that the P&I diagram does not establish a minimum height, in which case the piping designer is
free to place the equipment at the most convenient elevation. Here certain aspects shall be considered, such
as not interrupting the passage with some pipe coming from the bottom of the tower or respecting such
passage increasing the tower or vessel elevation. In certain occasions it may be attempted to place the pump
next to the vessel or tower in order to not interrupt any passage.
Towers or columns shall be oriented so that their internal components may be lowered to the floor in the
maintenance area foreseen for this purpose.
The elevation of the lower tangential lines of fractionating towers shall provide the NPSH required to the
suction pumps. This elevation shall be indicated in the P&I diagram, according to specification ED-A-02.00.
Access holes to the vertical vessel skirt shall be oriented towards the service area. Ventilation holes shall be
oriented in the opposite direction to the skirt access. See standard drawing PE-C-0100.03.

3.1.4. Heat Exchangers

In the heat exchangers located below vessels or structures, the ends of the headers shall be free from
obstructions so that they may be handled with crane. If this is not possible, permanent devices shall be
foreseen for their disassembly.
The shell and tube heat exchangers shall be located preferably at the floor level. A maximum of three heat
exchangers may be stacked for shell diameters up to 24" and if the diameter is larger, not more than two. The
lower shell of these stacked heat exchangers shall be placed at such an elevation so that any pipeline may
have a minimum clearance of 350 mm between its lower generatrix and the floor or normal operating level.

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Heat exchangers shall be located near to their adjacent equipment in the process flow sequence so that
minimum lengths must be obtained for the larger pipelines or those made of alloy steel taking into
consideration their cost, flexibility and special conditions if it is required by the process.
If a minimum elevation is required for heat exchangers, this shall be indicated in the P&I diagram.
Heat exchangers shall be aligned normally by the centerline of the distribution header, which shall be oriented
towards the service road or maintenance area.
The longest heat exchanger shall limit along the tangential line of the shell cover with the required access
between heat exchangers and pumps located at the side of the pipe rack.
Whenever this is possible heat exchangers that must be elevated shall be grouped in a common structure with
other equipment with this kind of process conditions.
Maintenance spaces shall be foreseen in the arrangement of heat exchangers in elevated structures, for
depositing the heat exchanger covers when these are disassembled. The piping designer shall notify this to
the civil department, in order to ensure that the structure may resist the overloads that may occur.
The minimum width between heat exchangers or other equipment without passage requirements, where
entrance is only required for painting, repairing the insulation or disassembling flanges and headers, shall be
preferably 0.90 meters although where there are space difficulties, this width may be reduced to 0.60 meters.
Vertical re-boilers next to towers require the access of mobile equipment for disassembling their components
and free space on the floor for setting these down.

3.1.5. Pumps

Pumps in general shall be installed outside of the pipe rack and the end of the pump support shall be located
2 at 1 m from the centerline of the rack pillars rack (See PE-A-0300.01, PE-A-0300.02, PE-L-0100.01).
However, the Engineering Company may, if necessary, locate them next to the equipment served, provided
there is no difficulty in the access to the pumps.
The need of access space must be foreseen for the crane required for disassembling the pump and its driver
2 (electric motor or turbine). Normally the pumps shall be aligned by the front of their concrete foundations, so
that the drainage pipe passing in front of them does not require changes in its alignment.
In large pumps (exceeding 150 kw), the Engineering Company shall study carefully and justify the requirement of
2 clearances for the operation of mobile machinery for their maintenance, deciding their location outside of the pipe rack
if necessary.
The minimum passage space between the most projecting parts of the pumps, between two of them, or
between a pump and structure pillar or any other element shall be 0.9 meters.
For the location of the pumps under air coolers, see 3.1.6.

2 TABLE III
DISTANCE FROM PUMPS TO CENTERLINE OF PILLARS RACK (MOTOR IS NOT INCLUDED)

Distance
from pump to
Product location
centerline of
pillars rack

Tª> AIP Under air cooler 3m

Tª< AIP Under air cooler 1m

Tª< AIP Rack 1m

Tª< AIP Rack 1m

AIP= AUTOIGNITION POINT OF THE SUBSTANCE CONTAINED.

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3.1.6. Air coolers

In the case of air coolers resting directly on the floor, the minimum height indicated in standard drawing PE-L-
0100.01 shall be considered as a guideline for the air flow to the fan. This detail shall be verified with the heat
exchanger designer.
For air coolers resting on structures or pipe racks, it shall be necessary to check carefully the height between the air
fan and the pipelines below it, to guarantee that the air flow area and the temperature of the pipelines do not have a
negative influence on the performance of the air cooler. A minimum clearance of 3 m shall be considered.
Air coolers shall be located in such a way that there is an easy and safe access for the maintenance as
2 required by this specific equipment. To gain access to the air cooler fans/motors, a continuous platform will be
provided. The platform shall be of the same width of this equipment.
They may be located over other equipment or over the main pipe rack, provided there is sufficient access to
allow the withdrawal or replacement of the bundles, fans and drivers. Care shall be taken to not locate air
coolers over potential fire sources such as light product pumps or hot oil pumps with product at/over its self-
ignition point. The end of the pump support shall be located 3 m away from the centerline of the rack pillars
and the pumps with products below their auto-ignition point shall be located at a distance of 1 m. Care shall
also be taken in keeping the hot lines without heat insulation or other hot equipment away from the air intake of
the air coolers. It shall be checked carefully that the weight and dimensions of the tube boxes are within the
capacity range of the crane foreseen to be used for disassembly.

3.1.2 Fired equipments – fired heaters and boilers

Equipment exposed to fire shall be grouped as far as possible, so that the use of common stacks may be
compatible with economic and operating factors. The individual ducts shall be provided with blocking or closing
systems regarding the common stack. The previous study shall be submitted to the approval of REPSOL.
All fired heater tubes shall be capable of being extracted or replaced generally by a mobile crane, so sufficient
2 space shall be available for their withdrawal and rotation. The external piping shall be minimized on the tube
withdrawal side of the horizontal fired heaters, and platforms and flue gas ducts shall be considered for vertical
fired heaters.
Space for adequate maintenance of fired heaters auxiliary equipment (pre heaters, air blowers, etc) shall be
considered in the unit design.
Fired heaters shall be located near unit limit.

3.1.3 Compressors

Compressors shall be installed preferably in the open air, and the use of mobile cranes shall be considered in
their maintenance studies for defining the plot plan. The construction of closure buildings and the installation
of bridge cranes shall only be performed with the specific approval of REPSOL, based on the environmental
conditions of the site, weather conditions, etc.
In the split casing centrifugal compressors, sufficient space shall be left for disassembly and withdrawal of all
their components.
In reciprocating compressors sufficient space shall be left for the withdrawal of pistons and shafts, without having to
disassemble the cylinders.

3.1.7. Control room / substation (within units)

The minimum distance between the on-site control room / electric substation and any release source
(originating a hazardous area), is indicated in Table II.
This distance may be reduced to 20 m., if the elevation of the building floor is 0.6 m higher than the level of the
2
surrounding ground, and the cable entrances are sealed.

3.1.8. Analyzers shelter

Analyzers cabin shall be located inside the unit at a place where the sampling shall be connected. A minimum
2 distance of 15 m shall be kept between the cabin and Hazardous Areas (Zone 0 and Zone 1).

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3.1.9. Shelter cabins

‘Shelter cabins’ may be required, depending on the distance to the central control room, percentage of time
that the operating personnel must remain in the zone, weather conditions and importance of it. Shall be
installed out of Hazardous Areas if it is possible.

3.1.10. Pipe bents, pipe racks

The distance between pipe rack bents shall normally be 6 m, which may be extended to 7 m with the prior
approval of REPSOL.
The distance between the maximum projection of the pillar center line of the pipe rack up to the pump valves,
control valves, etc., shall not exceed 2.5 meters, except for the pumps located 3 m away from the rack. This
plus the free passage of 1.5 meters, gives the distance of 4 meters at which the equipment and structures shall
be located away from the pipe rack. This distance of 4 m may be increased in function of the pump location.

3.1.11. Platforms

The need of platforms and dimensioning criteria are stated in specification ED-L-01.00.
Requirements for design of platforms, structures, scales, metallic ladders, etc are included in the specification
ED-M-01.00.

3.2. Requirements for maintenance and use of mobile equipment

The use of mobile equipment is preferable, if it is economic and if it reduces the number and cost of the
permanent hoisting structures.
In each project, the Industrial Complex shall facilitate information regarding the equipment available for
maintenance and shall analyze with the Engineering Company applicable criteria for it.
As a guideline, the following summarize an economic combination of mobile equipment and permanent hoisting
structures:

3.2.1. Space for air coolers maintenance.

Consider cranes for handling tube bundles. It shall be verified that the crane required for disassembling the
equipment according to its weight, may be able to circulate freely in the accesses and may be able to perform
the necessary turns once it is set down.

3.2.2. Monorail for air coolers fan motors.

The monorail for fan motors shall be required if the air coolers are mounted on pipe rack or other structures
that impede lowering the electric motor vertically from its operation position and if the weight of the electric
2 motor exceeds 80 kg. In every case it must be guaranteed that this monorail goes along a path free of
obstacles and that at one of its ends, or at both ends if the length exceeds 10 meters, there is sufficient vertical
space for lowering the motor to the floor. This will be replaced by mobile machinery whenever possible.

3.2.3. Heat exchangers under structures

For heat exchangers under structures, monorail assisted by auxiliary crane is preferred to extract the tube
bundle and pull down to the ground. It is necessary to deduce carefully the height of the set of pulleys and the
2
height of the hook, in order to allow the hook to pass freely above the exchanger.
Foresee a removable handrail for the tube bundle extraction.
For heat exchangers installed in the higher elevations of structures where there is no obstacle overhead, so
that they are accessible for disassembling with mobile equipment, the monorail installation shall be waived,
unless REPSOL requests it specifically.

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3.2.4. Davit for towers

Davit shall be set up over the upper part of the towers for handling pressure relief valves and trays. They shall
be oriented so that the trays, internal parts of the tower, pressure relief valves, etc. may be lowered to the floor
over the equipment maintenance area.

3.2.5. Space for catalysts.

Adequate space shall be available for handling and storage of catalysts (new and spent), chemical products,
bottles of hydrogen, nitrogen, etc., including access for trucks where required.

4. PLOT PLAN DRAWING (PE-A-0300.01)

They shall be drawn normally to scale 1:100 and shall include all equipment contained in the P&I diagrams, of
the unit and the structures for piping or equipment perfectly identified and with their dimensions in their
planimetric position and/or indicating their coordinates regarding the Complex coordinates.
When the size of the unit avoids represent it in a single plane, the scale may be modified with the prior
approval of Repsol.
All structure pillars shall be numbered following the criteria used in the standard drawing PE-A-03.00-01, which
shows the way of representation and location of measures.
If there is overhead equipment placed over structures, partial plants shall be drawn stating their working
platform levels, dimensioning their position regarding the pillars of the structure and their complete elevation
from the floor level.
The Unit Limit shall be drawn, showing its coordinates. It shall also be the limit of the drawing, although, the
service area and adjacent roads shall also be represented if possible for information.
The Complex North orientation shall be drawn, as well as the true North and the direction of the prevailing wind
(for further information, see specification ED-A-10.00).
The starting point of all scales and ladders shall be drawn on the floor or elevated working levels. Showers,
eye-wash fountains, analyzers shelters, horizontal equipment supports, service stations, etc, shall be drawn as
well.
On the right hand side of the drawing a table shall be included showing the equipment items, elevation and
number of P&I diagram where each one may be found.
In the ELEVATION column an asterisk (*) shall be placed, leading to a note at the end of the table, defining the
point to which these elevations are referred for each equipment, according to the criterion followed in the
standard drawing.
2 The position of the crane provided for maintenance and escape routes shall be marked on the drawing.
The elevation of the unit floor shall always be 0.000 and shall be referred to the high point of the pavement.
The absolute elevation that corresponds to the 0.000 shall be stated in a note in the drawing. All elevations
used in project drawings and documents of the unit shall be referred to 0.000.

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5. STANDARDS AND SPECIFICATIONS OF REFERENCE

5.1. REPSOL standards and technical specifications

5.1.1. Design specifications

ED-A-02.00 Process and utilities piping and instrument diagrams for process units and off-sites.
ED-A-07.00 Hazardous areas classification procedure
ED-A-10.00 Requirements for preparation of drawings and documents for REPSOL Projects.
ED-A-15.00 Explosion risk analysis for new buildings
ED-L-01.00 Piping design for process and service units and auxiliary facilities.
ED-M-01.00 Steel structures.
ED-Q-02.00 Pavements and ditches.

5.1.2. Standard drawings

PE-A-0300.01 Unit plot plan drawing (example).

PE-A-0300.02 Typical layout in units. Equipment and clearances.
PE-A-0300.03 Distances between units and roads.
PE-C-0100.03 Skirt for vertical vessels.
PE-L-0100.01 Typical layout in units. Racks, equipment and piping.
Note:
Every REPSOL specification available in English language is identified in the Repsol index of Technical
Specifications ED-A-00.00 with the letter "I" as indicated in the following example:
ED-Y-XX.XX Spanish language
ED-Y-XX.XX-I English language

5.2. International standards.

• National Fire Protection Association:

NFPA 30 Flammable and combustible liquid code.
• International Electrotechnical Commission (IEC):
IEC 60079-10 Electrical apparatus for explosive gas atmospheres. Classification of hazardous areas.
IEC 61241-3 Electrical apparatus for use in the presence of combustible dust. Classification of areas
where combustible dusts are or may be present.

6. INDEX OF TABLES INCLUDED IN THIS SPECIFICATION.

Table I .................. Safety distances guideline between units and equipment (Off Site)
Table II ................. Minimum distances between equipment inside units (On Site)
Table 3 ................. Distance from pumps to centerline of pillars rack (motor is not included)

5 STANDARDS AND SPECIFICATIONS OF REFERENCE