GPA PLANT PROJECT AND DESIGN CHECK LIST

Initial Publication 1970 Revised 1982, 1997

Gas Processors Association 6526 E. 60th St. Tulsa, Oklahoma 74145

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FOREWORD
In late 1970 Section "A" undertook the development of a plant design check list based on the results of a questionnaire distributed in early 1970. A Task Force was assigned consisting of: W. T. Lawler, Chairman, Sun Oil Company W. A. Haliburton, Cities Service Oil Co. D. R. Raney, Lone Star Gas Producing Co. Later additions to the Task Force were Messrs. E. C. Cramp, Atlantic Richfield Co. and W. H. Schulz, Mobil Oil Corp. ~Task Force members developed the check list format and prepared several of the sections. Others that participated in preparing individual sections ,;vere: Peter Leathard B. H. Williams M. D. Atldns J. E. Raley A. B. Richert Joseph Shutz C. O. Miller Allen Tarbutton W. C. Hart O. P. Procter W. R. Fairchild W. L. Hamilton R. E. Porcher Marvin Miller Atlantic Richfield Co. Continental Oil Co. Cotton Valley Operating Co. Dorchester Gas Producing co. Dresser Engineering Co. Exxon Co. U.S.A. Getty Oil Co. Mitchell Energy Corp. Phillips Petroleum Co. Phillips Petroleum Co. Shell Oil Co. Sun Oil Co. Union Texas Petroleum Xcel Products Co.

The guidance and attention to details of Chairman Lawler, as well as the actual preparation of several sections, is particularly appreciated. In 1981 a major revision of this Check List was made by Section "A" Task Force composed of the following: Hubert C. Daugherty, HNG Petrochemicals, Inc. Charles B. Wallace, Shell Oil Co. Melvin W. Noe, Chairman, Texas Gas Exploration Corp. Charles Hamilton, Texas Gas Exploration Corp. In 1996 another major revision to the Check List was made by a Section "A" Task Force Chaired by Craig Wentworth and composed of the following people: Charles Coarsey, Chevron/Warren Naomi Orbeck, Colorado Interstate Gas Co. Carl Soderman, PanEnergy Field Services, Inc. John Harryman, Shell E & P Technology Craig Wentworth, T. H. Russell Co. Carolyn Smith, T. H. Russell Co. William Smith, Texaco Inc. Cesar Espino, Trident NGL, Inc. The thanks of the industry are extended to these persons as well as to others who contributed to various parts of the overall project. It is only through the wholehearted interest and participation of individuals within the industry that worthwhile projects as these can be undertaken and completed.

STATEMENT OF PURPOSE The Check List is designed to serve as a guide for project managers and others who are charged with planning and preparing job and equipment specifications. By referring to this list, those planning projects may be made cognizant of most of the major items that should be considered when the project is originated and during the progress of design and construction. This guide is prepared using categories normally required for a processing plant project. An effort was made to prepare the check lists in a manner to make them useful to project managers and engineers for new plants, plant revisions, and for either company engineered or contracted projects. The Project Planning Check List is designed to be used for preparing the job specifications and Articles of Agreement or Contract. The general categories for equipment and services should aid in the selection of appropriate equipment for a particular job leaving the actual specification requirements to the discretion of each company and its responsible engineer in charge. It is recommended that the following statement be included in each specification category to call attention to the fact that there are various governmental regulations and codes that are subject to change. "All and their appurtenances shall meet the latest applicable federal, state and local codes. The manufacturer and/or plant contractor shall be responsible for determining all such codes and complying with them."

TABLE OF CONTENTS
Introduction ....................................................................................................................................................... :! Statement of Purpose ........................................................................................................................................ :!! Table of Contents ............................................................................................................................................. 111 Patti A. B. Part II Plant Start-up ...............................................................................................Section 1 Foundation and Structural Design ...............................................................Section 2 Unfired Pressure Vessels ..............................................................................Section 3 Heat Exchangers ..........................................................................................Section 4 Pumps, Expanders, and Drivers ...................................................................Section 5 Piping, Valves, and Fittings .........................................................................Section 6 Compressors .................................................................................................Section 7 Instruments and Controls .............................................................................Section 8 Electrical ......................................................................................................Section 9 Gas Fired Turbines ......................................................................................Section 10 Insulation .....................................................................................................Section 11 Painting ....................................................................................................... Section 12 Boilers ......................................................................................................... Section 13 Process Heaters ...........................................................................................Section 14 Cooling Towers ...........................................................................................Section 15 Welding Fabrication and Testing ................................................................Section 16 Liquid Product Custody Transfer .............................................................Section 17A Gas Custody Transfer ...............................................................................Section 17B Pipeline Construction ..................................................................................Section 18 Buildings .....................................................................................................Section 19 Grading, Drainage, and Roadways .............................................................Section 20 Safety ........................................................................................................... Section 21 Environmental Protection ...........................................................................Section 22 Product Loading and Construction .............................................................Section 23 Aboveground Storage and Construction .....................................................Section 24 Underground Storage and Construction ......................................................Section 25 Appendix Specification Categories and Codes .........................................................................Appendix A Address List - Code and Standards Associations .....................................................Appendix B Government Codes and Regulations - Offshore .......................................................Appendix C Page 163 Page 166 Page 167 Project Planning ............................................................................................Section 1 Project Planning - Offshore ..........................................................................Section 2 Page 1 Page 10 Page 15 Page 19 Page 21 Page 25 Page 34 Page 40 Page 43 Page 49 Page 61 Page 69 Page 75 Page 79 Page 82 Page 86 Page 91 Page 95 Page 99 Page 104 Page 108 Page 118 Page 123 Page 130 Page 139 Page 144 Page 152 Page 157

PART I SECTION 1 - PROJECT PLANNING

Plant Location Type I. PLANT SITE A. Size Required B. Cost C. Surface Owner 1. Water Rights 2. Subsurface Obstructions D. Site Description 1. Survey 2. Elevation E. Site Preparation 1. Clearing 2. Grading 3. Drainage and Flooding 4. Security a. Fencing b. Safety 5. Soil Survey a. Bearing b. Characteristics c. Water Table F. Access Road 1. Type Surface 2. Width 3. Distance 4. Highway Number/Designation G. Parking Lot 1. Size 2. Surface 3. Lighting 4. Signs-Identification, Information and Warning H. Sidewalk 1. Width 2. Length 3. Type Surface I. Plant Layout and Spacing Requirements

Date

3. Railroad 1. Name of Railroad Spur a. Number of Tracks b. Length K. Access R/W 1. Roads 2. Pipelines 3. Utilities 4. Railroads L. Density Information 1. Population - Residential/Industrial
2. Development - Existing & Future

2.

3. II.

DOT Classification

ELECTRIC POWER A. Source or Sources B. Voltage, Cycles, and Phases C. Connected Load D. Purchase Power 1. Demand Cost 2. Operating Load Cost 3. Contract Type (Firm or Interruptible) 4. Contract Term 5. Outage Record, Including Voltage Dips 6. 7. 8. Transformer Capacity Standby Facilities Incoming Line Details a. Length

b.

Type

c. Grounding E. Generators 1. Type, Number, and KW Each 2. Standby Power

F. Co-generation

G. Uninterrupfible Power Supply 2

Ill.

INLET SEPARATION FACILITIES A. Gas Separation B. Slug Catchers C. Condensate-Water Separation D. Pigging Facilities E. Coalescing Filters F. Sock/Cartridge Filters GAS COMPRESSORS A. Type, Number, Driver and Horsepower B. C. D. E. Suction and Discharge Pressure Suction and Cooled Gas Temperature Lube Oil Storage Starting Air System

IV.

V.

DEHYDRATION A. Type B. Water and Hydrocarbon Dew Point 1. Inlet 2. Outlet C. Instrument Air. PROCESS HEATING AND COOLING A. Heating 1. Direct/Indirect Fired Heater 2. Heat Medium 3. Waste Heat Recovery. B. Cooling 1. Air 2. Water- Fresh and/or Sea 3. Water - Closed Cycle 4. Refrigeration

VI.

VII. PRODUCT STORAGE AND DISPOSITION A. Products - Liquid, Solid, or Gaseous 1. Storage - Type, Size and Number 2. 3. 4.
5. 6.

Rail Loading Truck Loading Barge and/or Tanker Loading Facilities Loading Rate Custody Transfer - Tank Gauge, Meter, Scales, Provers

B. Products to Pipeline 1. Accumulator Size 2. Type Pumps. 3. Continuous or Batch 4. Type Metering and Control C. Pipeline Connections 1. Residue Gas 2. Liquid or Gaseous Products a. Tender Size b. Rate D. Size of Tanker Truck, Rail Car, Barge, or Ship to be Loaded E. Switching Frequency of Railroad

VIII BUILDINGS A. Office, Size and Type B. Warehouse and Shop, Size and Type C. Compressor Building, Size and Type D. Control Building, Size and Type E. Personnel, Size and Type F. Miscellaneous, Size and Type

IX.

INSTRUMENTATION A. Pneumatic (Gas or Air) B. Electronic (Intrinsically Safe) C. Chromatograph Monitoring and Control D. Computer E. ESD Systems

X.

WATER SYSTEM A. Supply 1. Source 2. Quantity. 3. Number of Wells 4

4. Expected Depth 5. Treating Required 6. Storage B. Waste Water Disposal 1. Quantity, 2. Method of Disposal 3. Sewer System 4. Treatment Required C. Firewater System 1. Type of Pump 2. Capacity 3. Storage D. Drinking Water 1. Treatment 2. Storage E. Sanitary System

XI.

FLARE SYSTEM A. Vapor B. Liquid C. Stack or Ground Flare. D. Igniter E. Incinerator

XII. FEDERAL, STATE, AND LOCAL JURISDICTIONS AND REGULATION A. Water Disposal B. Air Pollution C. Liquid/Solid Waste Disposal D. Noise E. Safety E Zoning, G. Permit Requirements and Impact Statement H. Public Relations and Owner Requirements

I. Local Emergency Planning Commission

XIII. DESIGN DATA A. Inlet Gas 1. Type

2.

3.

Design Volume a. Maximum b. Minimum Composition a. Hydrocarbon b. Water c. H2s d. C02 e. Other Sulfur Compounds (CS2,COS,RSH) f. Nitrogen and Other Inerts g. Oxygen

4. 5. 6.

Pressure - Design, Operating, Range Temperature - Design, Operating, Range Percentage Recovery Each Component

B. Products 1. Identification 2. Specifications C. Residue Gas Delivery Requirements for Each Pipeline

1.

Quality.

2. Delivery Capacity 3. Control Mechanism for Multiple Deliveries D. Fuel 1. Types Interruptible Firm 2. Value 3. Conditioning 4. Storage

5.

Quality Variations

CLIMATIC DATA A. Design Summer Dry Bulb Temperature B. Design Summer Wet Bulb Temperature C. Minimum Design Winter Temperature D. Type of Winterizing E. Wind 1. Direction 2. Velocity By Months 3. Maximum Velocity 6

E Rainfall or Snow 1. Amount and Number of Days 2. Maximum 3. Duration G. Earthquakes H. Corrosive Atmosphere I. Frost Line XV. CONSTRUCTION CONTRACT A. Type of Contract 1. Turnkey 2. Shared Responsibility Cost Plus Fixed Fee Lump Sum a. Complete Plant b. Material Only c. Labor Only Bo Retainage (Hold Back) C. Penalty - Bonus Clause D. Performance Bond E. Guarantees 1. Product Recovery 2. Product Specification 3. Mechanical 4. Utility 5. Stream Time/Year F. Insurance Requirements Including All Risk G. Extra Work H. Items Furnished by Company or Contractor (Specify) 1. 2. 3. 4. Plant Site Plant Road, Sidewalks, and Piling Plant Fence Start-Up Supplies 3. 4.

5.

Operating Supplies

6.

Spare Parts

7.

Source of Power, Gas, and Water for Construction

8. 9.

Fire Fighting Equipment Firewater System

10. Fireproofing 11. Paint 12. BuiIdings 13. Laboratory Equipment 14. Plant Water Supply 15. Cathodic Protection 16. Instrument Air Compressors 17. Temporary Facilities 18. Communications Equipment I. Miscellaneous 1. Specifications

2. 3. 4.

Drawings Data Books Start-Up and Operating Manuals

5.

Cost Analysis

6.

Project Progress Reports

7.

Cash Forecast During Design and Construction

8.

9.

Testing a. Mechanical b. Performance Process Safety Management Team

10. HAZOP/PHA Schedule

PART I SECTION 2 - PROJECT PLANNING - OFFSHORE Plant Location Type I. PLATFORM DATA A. Type. B. Description C. Name, Number and Weight of Decks D. Wells Drilled 1. Initial How 2. Additional How E. Environment 1. Water Depth Miles From Shore 2. Nautical Coordinates 3. Mean High Water Clearance 4. Wave Load Criteria and Prevailing Currents 5. Wind Load, Direction, and Speed 6. Seismic Criteria 7. Max. Rainfall Rate 8. Min. Air Temperature 9. Min. Seawater Temperature 10. Suspended Solids 11. Dissolved Oxygen F. Pipelines 1. Incoming Lines and Risers 2. 3. Slug Catcher Outgoing Lines and Risers Date Jurisdiction

Snowfall Max Max

Pig Receiver

4. Pig Launcher G. Electric Power 1. Incoming 2. Outgoing H. Boat Landings I. Navigation Aids J. Communications K. Flare Booms L. Continuous; Vent 10

Levels Agency .Cranes Flare

M. N. O. P.

Emergency; Vent Protective Coatings Cathodic Protection Layout, Spacing, and Maintenance

Flare

Q. Workover Rig R. Helipad II.

Quarters

RESERVOIR AND PRODUCTION FORECAST A. Initial Reservoir Pressure Oil Gas Temperature Flow, B. Full Production Reservoir Pressure Oil Gas Temperature Flow, C. Abandonment Reservoir Pressure Oil Gas Temperature Flow, D. Shut-in Wellhead Pressure E. Initial Wellhead Pressure Flow Temperature F. Full Production Wellhead Pressure Flow Temperature G. Abandonment Wellhead Pressure Flow Temperature H. Time Forecast Wellhead Pressure, Temperature, Flow, and Composition of Gas, or Charts Attached)

Brine Brine Brine

Oil, and Brine (Table

III.

OIL, GAS, AND PRODUCED BRINE SEPARATION A. Primary Separation and Test Methods and Conditions

B. Primary Hydrate Inhibition C. D. E. E IV. Oil RVP Requirement Oil H2S Removal Required Oil CO2 Removal Required Other MaxBS & W

ELECTRIC GENERATORS A. Type No. Phases B. Type No. Phases C. Type No. Phases

Driver HZ Driver HZ Driver HZ 11

KW Fuel KW Fuel KW Fuel

Volts Volts Volts

D. LIPS Electric System E. Waste Heat Recovery F. Starting System V. GAS COMPRESSION PHASES (Pressure Maintenance) A. Initial Requirement B. 2nd Phase C. 3rd Phase D. Waste Heat Recovery E. Starting System

VI.

PRODUCED BRINE DISPOSAL Initial A. B. C. D. E. F. G. H. I. To Sea: Treatment: To Injection: Treatment: Pressure: Temperature: Flow: Pump Drivers: Effluent Max Hydrocarbon Content: Full Protection Abandonment

VII. GAS TREATMENT A. Type B. Hydrocarbon Dew Points Required 1. For Reinjection 2. For Fuel 3. For Pipeline Export C. Moisture Dew Point Required

VIII. PLANT COOLING A. Air B. (Sea) Water C. Treatment (In and Out) D. Closed Cycle

12

IX.

PLANT HEATING A. Direct Fired B. Heat Medium C. Waste Heat Recovery D. Winterizing, Hydrate Protection E. Other OUTLET STREAMS STORAGE, SURGE, DISPOSITION A. Stabilized Crude Oil to B. NGL to C. Residue Gas to D. Oily Waste to E. Sanitary Waste to E Barge/Tanker Mooring and Loading Facilities

X.

G. Loading Rates. H. Metering: Crude Oi! Injection Seawater Coolant Seawater XI. ANCILLARY SYSTEMS A. Storage, Transfer and Injection: 1. Methanol 2. Glycol 3. Solid Desiccant 4. Caustic 5. Bactericide 6. Pour Point Depressant 7. Oil Corrosion Inhibitor 8. Gas Corrosion Inhibitor 9. Demulsifier 10. Lubricants 11. Heat Medium Storage 12. Other B. Produced Water Clarification C. Runoff Water Clarification

NGL

Gas

13

D. Sump Disposal E. Sump Oil Skimming F. (Heavy Oil) Pipeline Water Displacement G. Pipeline Corrosion Protection H. Structure (Jacket) Corrosion Protection I. Fire Detection J. Fire Fighting K. Personnel Evacuation L. Other Safety Systems and Zone (Area) Classifications 1. Gas Detection 2. Hydrogen Sulfide Detection 3. Dry Chemical System M. Instrument Air Compression, Dehydration, Storage. N. Starting Air Compression, Dehydration, Storage O. Communications

14

PART II

SECTION 1 - PLANT START-UP Plant. Location Type I. DESIGN AND INITIAL CONSTRUCTION PHASE A. Assign Key Personnel 1. Supervisory 2. Engineering 3. Maintenance 4. Operations 5. Process Hazard Analysis Team (PHA) 6. Process Safety Management Team (PSM) 7. Pre-startup Safety Review (PSM) Date

II.

FULL CONSTRUCTION PHASE A. Select and Order 1. Fire Fighting Equipment a. Cartridge b. Spare Power 2. Safety Equipment, Personnel Protection 3. 4. 5. 6. 7. 8. First Aid Supplies Shop Equipment Hand Tools Shop Supplies Laboratory Equipment and Supplies Office Furniture, Supplies, and Equipment

9.

Warehouse Bins/Shelving

10. Spare Parts

15

11. Plant Vehicles B. Procedures, Manuals, and Logs 1. Plant Start-Up Procedures

2. 3. 4. 5.

HAZOP/PHA Review Schedule Emergency Procedures Operations Manual Preventive Maintenance Schedules and Guidelines

6.

Logs and Reports - Operational and Maintenance

7.

Pre-Start-Up Inspection Check List a. Vessels

b.

Piping

c.

Rotating Equipment

d.

Control System

8.

Process Safety Management a. Piping and Instrumentation Drawings b. c. d. e. Material Safety Data Sheets Specification Sheets for all Tagged Equipment Management of Change Procedures Process Flow Diagrams

C. Assign Remainder of Plant Personnel 1. Operational

16

2. 3. 4. 5.

Maintenance Clerical Technical Safety/Environmental

D. Initiate Training Programs 1. First Aid Course 2. Equipment Familiarization 3. Process Indoctrination. 4. On-Site Training E. Order Initial Charges Process Fluids, Chemical, and Supplies 1. Lubricating Oils 2. Antifreeze 3. Methanol 4. Amine 5. Glycol 6. Absorption Oil 7. Heating Oil 8. Refrigerant 9. Water Treating Chemicals 10. Desiccants 11. Catalysts 12. Spare Filters, Gaskets 13. Special Low Temperature, Corrosive Service, or Non-Standard Items

III.

END OF CONSTRUCTION A. List of Regulating Agencies, Federal, State, and Local with Address, Name of Person, Telephone No. (Include Night & Emergency)

B. Start-Up and Plant Personnel, Unlisted Numbers, If Available

C. Plant Equipment Manufacturers and Suppliers

17

D. Obtain Plant Equipment Books from Contractors/Suppliers

E. Secure Sufficient Insurance

IV.

START-UP A. Notify Just Prior To Start-Up 1. Power Company, if Purchase Power 2. 3. 4. 5. Company Product Sales Group Gas Purchaser Appropriate Regulating Agencies Manufacturers and/or Suppliers Start-Up Representatives

6.

Insurance Inspectors

B. Make Specific Job Assignments, Tours, Etc.

C. Arrange Sleeping and Mess Facilities if Remote

D. Final Pre-Start Inspection 1. Fire Fighting Equipment in Place and Operational 2. 3. 4. 5. 6. 7. Personnel Protection in Place First Aid Supplies in Place Area Clear of Obstructions Construction, Testing, and Purging Complete PSM Review Pre-Start-up Safety Review and Walk-through

18

PART H SECTION 2 - FOUNDATION AND STRUCTURAL DESIGN

Plant Location Type I. FOUNDATION A. Load Limit for Soil B. Frost Level C. Type of Cement (Compatible w/Soil) D. Determination of "Heave" From Soil Moisture Change

Date

E. Concrete Strength Requirement

F. Type of Foundation 1. Piling a. Wood b. Concrete c. Steel 2. Undeream Pier 3. Floating Pier 4. Mat G. Design Requirements 1. Resonating Frequency Characteristics of Soil, Foundation and Structure

2.

Drainage for Moisture Control

3. 4. 5. 6.

Design Wind Velocity Seismic Forces Building Code Requirements Loading a. Operating

19

b. Test c. Erection d. Dynamic Reinforcing of Foundations a. Type of Anchor Bolt & Material b. Type of Rebar and Grade

H. Type of Grout 1. Cement and Sand 2. Epoxy II. STRUCTURES A. Type of Structure 1. Steel 2. Concrete 3. Other B. Fireproofing Required

20

PART II SECTION 3 - UNFIRED PRESSURE VESSELS

Plant Location Type I. GENERAL A. Applicable Codes - Stamp Requirements

Date

B. Configuration Preference, Horizontal or Vertical

C. Should All Vessels be Self-Supporting When Water Full D. Are Integral Separators Acceptable E. Design Pressure F. Operating Pressure G. Dimensions - I.D./O.D. and Tangent/Tangent

H. Weight Per Unit I. Service Requirements J. Design Temperature K. Operating Temperature L. Site Conditions 1. 2. 3. II. Minimum and Maximum Ambient Design Temperatures Seismic Zone Wind Load

DESIGN A. Material Grade and Minimum Thickness 1. Heads 2. 3. 4. Shell Nozzles Skirts, Saddles, Externals

21

5.

Internals

B. Stress Relieving Requirements C. Corrosion Allowance D. Cathodic Protection Requirements E. Impact Test Requirements/Exemptions E Radiography (RT - 1, 2, 3, 4 or None) G. Longitudinal Weld Joint Efficiency H. Nozzles, Manways, and Inspection Openings, Vents, and Drain Connections I. PSV Location J. Externals 1. Ladders and Platforms 2. Piping Supports 3. Insulation Supports 4. Supports, Skirt or Saddles Required 5. Skirt Openings Required 6. Lifting Lugs 7. Davits or Hinges 8. Foundation 9. Grounding 10. Fireproofing and Insulation 11. Painting and Galvanizing K. Internals 1. Mist Eliminators - Type 2. 3. 4. 5. Distributors Vortex Breakers Siphon Drains Impingement Plates and Baffles

L. Trays 1. Number and Type 2. 3. 4. 5. 6. Material and Thickness Spacing Support Weight Level Tolerance Self Draining 22

8. 9. 10. 11. 12. 13.

Weir Holes Weir Height Seal Pans Maximum Percent of Flood Shop or Field Installed Size of Tray Manways I.D. of Manway Through Which Parts Must Pass

M. Packing or Desiccant 1. Height, Type and Size 2. 3. 4. Distributors Supports Screens, Top and Bottom

N. Catalyst, Mol Sieve, Activated Carbon, Other

III. REPORTS AND RECORDS A. ASME Code U1-A Report B. Data Sheet and Fabricators "As Built" Drawings C. Location, Heat Numbers, Physical, and Chemical Properties 1. Shell 2. Head 3. Nozzles 4. Skirt. 5. Welded Attachment D. Non-Destructive Test Report, X-Ray, etc. E. Are Tests to be Customer Witnessed and Approved F. G. H. I. Mill Test Reports Material Certifications Stress Relief Charts Charpy Impact Test Results

IV. INSULATION AND PAINT A. Insulation Type and Thickness B. Paint and Surface Preparation

23

V.

TRANSPORTATION LIMITATIONS

VI.

FILTERS A. Filter Removal Efficiency and Basis B. Residence Time

24

PART H SECTION 4 - HEAT EXCHANGERS

Plant Location Type. I. GENERAL A. Type (TEMA Nomenclature) B. Code Requirements (API, TEMA, ASME) C. D. E. F. G. H. I. Number of Units in Parallel Number of Units in Series Maximum Tube Length Space & Weight Limitations Acceptable Noise Level Surface Preparation, Paint and Coating State if Alternate Quotations will be Considered

Date

J. Operating Temperatures and Pressures K. Design Temperature for Materials of Construction L. Shipment Considerations M. Multiphase Feed Considerations N. Heat Treatment Required O. Radiography Required P. Site Conditions 1. Minimum and Maximum Ambient Design Temperatures 2. Seismic Zone

3. Wind Load Q. Insulation II. SHELL AND TUBE A. Design Data (API 660 Data Sheet) 1. Shell Side Design Temperature & Pressure

25

2.

Tube Side Design Temperature & Pressure

B. C. D. E. F. G.

3. Corrosion Allowance Materials of Construction Maximum Shell Diameter Are Bonnet Type Channels Acceptable Minimum Tube Diameter Maximum Tube Diameter Tube Pitch (Square, Triangular, Etc.)

H. Size, Rating and Orientation of Nozzles I. PSV Location J. Type Gaskets K. Complete Set of Spare Gaskets Required L. Are U-Tube Bundles Acceptable M. Are Fixed Tube Sheet Bundles Acceptable N. Are Shell Expansion Joints Required O. Are Multipass Shells Acceptable P. Are Electric Resistance Welded Tubes Acceptable Q. Tube Hole Vs. Tube ID in Transverse Baffles R. Minimum Velocity in Chiller Tubes S. Maximum or Minimum Velocity in Water Coolers T. Type Weir Plates U. Type Impingement Baffles V. Type Anodes Required for Water Side W. Analysis for Tube Vibrations X. Seal Weld Tube to Tubesheet Joint Required m. PLATE AND FRAME H E A T EXCHANGER 26

A. Design Data (ASME Pressure Vessel Code, Sect.VIII, Div. 1) 1. Hot Side Design Temperature & Pressure (In/Out) 2. Cold Side Design Temperature & Pressure (In/Out) 3. Corrosion Allowance Are Upstream Strainer Screens Required Flow Arrangement Lifting Lugs Requirements Materials of Construction Size, Rating and Orientation of Nozzles Type Gaskets Complete Set of Spare Gaskets Required Mounting Pedestal or Side Angle

B. C. D. E. F. G. H. I.

IV. AIR COOLED A. Design Data (API 661 Data Sheet) 1. Minimum and Maximum Air Temperature 2. 3. Design Pressure and Temperature Corrosion Allowance

B. C. D. E.

4. Altitude Horizontal or Vertical Coil Ladders and Catwalks Required Drive Arrangement Materials of Construction

E Minimum Clearance Fan Shroud Above Grade G. Tube Supports to Prevent Vibration Caused by Pulsation H. Winterizing Requirements I. Are Hail Screens Required J. Are Shutters Required (Manual or Automatic) K. Method to be Used for Temperature Control L. Is Automatic Control for Varying Blade Pitch Required M. Vibration Shutdown Devices Required N. Fans and Drivers 27

1. 2. 3. 4. 5. 6.

Fixed or Adjustable Pitch Tip Speed Limitation Number of Fans. Requirements for Fan Shutdown Type Driver and Location (Hydraulic, Electric, or Gas Engine) Electrical Area Classification

N. Fans and Drivers (Continued) 7. Power Requirement (Voltage, Phase, Cycle) 8. Direct Connected or V-Belt

9. Horsepower Required 10. Variable Speed Driver O. Tube and Header Specifications 1. Type of Fins 2. Type of Fin Attachment 3. Tube and Fin Material 4. Tube Size and Gauge 5. Type Headers 6. Header Plugs (Material and Type) 7. Size, Rating and Orientation of Header, Nozzles P. Forced or Induced Draft Q. Air Recirculation R. Are Bug Screens Required S. Do Tubes Require Sloping T. Noise Requirements V. PLATE FIN A. Design Data(ASME Pressure Vessel Code, Sect.VIII, Div.1) 1. Hot Side Design Temperature & Pressure (In/Out) 2. Cold Side Design Temperature & Pressure (In/Out)

B. Is Upstream Filtering Required C. Flow Arrangement D. Lifting Lugs/Davit Requirements

28

E. Materials of Construction E Nozzle Orientation and Vent/Drain Connections G. Mercury Tolerant Design Required H. Mounting Pedestal or Side Angle I. Stress Analysis by Supplier or Customer

VI. INSTALLATION A. Mounting (Concrete Foundation or Platform) B. Area for Tube Bundle Removal C. Hoists Required D. Block and By-pass Valves Required E. Control Instrumentation E Pressure Gauges and Thermometers G. Vent and Drain Valves H. Back Wash Connections for Water Coolers I. Chemical Injection and Cleanout Nozzles J. Slide Hates VIII. DATA REQUIREMENTS FROM MANUFACTURER A. Complete Data Sheet B. Complete Shop Drawings C. Certified Dimension Prints D. Manufacturers Test Data E. Metallurgy Data F. Name Plate Rubbing s

29

G. ASME U1-A Report H. Mill Test Reports I. Material Certifications J. Are Tests to be Customer Wimessed and Approved

30

*HEAT EXCHANGER SPECIFICATION SHEET

Job No. Reference No. Prooosal No. Date Item No. Parallel Surf./ShellI~ft,~ s) Rev. Series Sq Ft

Customer Address Plant Location Service of Unit cI-Iori=onAal) ~ ~Vert=cat/ ~..onnecteaIn Type 6 Size Gross) Sq Ft~ Shells~Unit 7 Surf./Unit IEff.I PERFORMANCE OF ONE UNIT 8 Shell Side 9 Fluid Allocation 10 Fluid Name Lb/Hr 11 Fluid Quantity, Total Vapor (In/Out) 12 Liquid 13 Steam 14 Water 15 Nonconden sob le 16 oF 17 Temperature (In/Out) 18 Specific Gravity Cp 19 Viscosity, Liquid 20 Molecular Weight, Vapor 21 Molecular Weight, Noncondensable Btu/Lb I: 22 Specific Heat Btu Ft/Hr Sq FtF 23 Thermal Conductivity Btu/Lb@ F 24 ILatent Heat Pslg 25 Inlet Pressure Ft/S 26 Veloclty Psi 27 Pressure Drop, AIIow./Calc. 28 29 3O 31 32 33 34 35 36 37 38

Tube Side

Fouling Resistance (Min.) oF Btu/Hr L MTD (Corrected) Heat Exchanged Btu/Hr Sq Ft=P Clean Transfer Rate r Service Sketch (Bundle~Nozzle Orientation) CONSTRUCTION OF ONE SHELL Tube Side Shell Side / Design/Test Pressure Psig oF Design Temperature No. Passes per Shell In.I Corrosion Allowance Connections In Size & Out Retina In;=~,~ediate 39 In. 4 3 0 - ~ O ~ g o ~ 4 S In.; Length Ft; Pitch OD In.; Thk (Min/Avg) 40 Tube No. Material 41 Tube Type (Integ.) (Remov.) In. Shell Cover ID OD 42 Shell Channel Cover 43 Channel or Bonnet Tubesheet-F looting 44 !Tubesheet-Stat ionary Impingement Protection 45 iFIoating Head Cover %~ (DiamJ Spacing/: /c Inlet In. ~.ut ( & r ' " ' Baffles-Cross Type 46 Seal Type 47 Baffles-Long U-Bend Type 48 Supports-Tube Tube-Tubesheet Joint 49 Bypass Seal Arrangement Type 50 Expansion Joint Bundle Entrance Bundle Exit 51 p v 2- Inlet Nozzle Tube Side 52 Gaskets-Shell Side *Floating Head 53 54 Code Requirements 55 Weights/Shell-Shipping 56 Remarks 57 58 59 6O 61 *Courtesy of API Division of Refining, Standard 660 TEMA Class Bundle

Filled with Water

Lb

31

*AIR COOLED HEAT E X C H A N G E R SPECIFICATION SHEET

No.

Date

By

Sheet No.. Proposal No. Contract No. Date Item No. Purch. IncI. No. Purch. Ord__No. (Induced)(Forced) Draft ff2;Bare Tube

Manufacturer 1 C~..u.~omer ' . 2 LPlant Location 3~

,
5~ Tu.~be

oFBa,

6~
7 I Transfer Rate- Finned Tube
8

B,o~]MTD, Elf.

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
55 56 57

; Bare Tube, Service Clean Btu/h. P E R F O R M A N C E D A T A - T U B E SIDE Fluid Name Lethal Service (Yes) (No) IN OUT Total Fluid Entering Ib/h Density, Liquid Ib/ft3 IN OUT Specific Heat Capacity Btu/Ib-'F Temperature "F Cond. (Liq.)(Vap,) Btu/h.ft-'F Liquid Ib/b (Pour) (Freeze) Point ~F Vapor Ib/h, mol. wt. Bubble Point F Noncond. Ib,/h, moh wt. Latent Heat Btu/Ib Steam jb/h =Inlet P r e s s u r e (psig)(psia) Water Ib/h Pressure Drop, AIIow./Cel. psi Viscosity (l~.iq.) (Vap.) cP! Fouling Resist,lnslde h.ft2*'F/Btu P E R F O R M A N C E D A T A - AIR SIDE Air Quantity, Total (Ib/}l) (std.ft3/mln)jAItitude, above Sea Level ift'iJ .Air Quantity/Fan act. ft3/minlTemperature In (Design Dry Bulb) Actual Static Pressure in. wnterITemperature Out Face Velocity std. ft/min JMass Velocity (Net Free Area) Ib/h.ft2 JMinimum Design Ambient DESIGN - M A T E R I A L S - CONSTRUCTION Design Pressure psig Test Pressure psig Design Temperature *F TUBE BUNDLE HEADER, Type TUBE, Material Size Material (Seamless) (Weldnd) No./Bay No. Tube Rows No. Passes* Slope in./ft OD in. in. IMin. Thiak. Arranqement Pluq Material No./Bondle JLength ft Bundles In Parallel In Series! Gasket Material Pitch in.~ Bays In Parallel In Series Corrosion Allowance in. F IN, Type Bundle Frame No., Size Inlet Nozzle in. Material MISCELLANEOUS No. r Size Outlet Nozzle in. OD in. IStock Thick, in.: Struct. Mount. (Grade) (Piperack) c/c Special Nozzles in. No./in. IFin Design Temp. "FI Surface Preparation Ratinq & Facing Code*ASME Vlll,Div. 1 Stamp(Yes) (No) Louvers Auto Manual TI Pl SPECS. Vibration Switches Chem. Cleaning M E C H A N I C A L EQUIPMENT F A N , Mfr.& Model DRIVER, Type 'SPEED REDUCER, Type No./B=y rev/mln Mfr. Mfr. & Model Dia. ft No. Blades No./Bay I hp/Driver I No./Bay Pitch Adj. Auto. Angle rev/min AGMA Rating hpJ Ratio ] Material, Blade Hub Enclosure Support (Structure) (PedestaL) hp/Fan, Des. Minimum Arab. Volt; Phase;Cycle Control Action on Air Failure-Fan Pitch (Minimum)(Maximum)(L~ckup) I Louvers (Open) (Close) (Lo=kup) Degree Control of Outlet Process Temperature (Maximum Cooling) (~_ ~F) Recirculction (None) (internal) (External Over Side) (External Over End) ISteom Coil (Yes) (No) NOTES: * Give tube count of each pass when irrecjular.

Plot Area

ft21Proposal Drawing No.

JWeight.Bundle

Ib;Shipping

Ib

*Courtesy of API Division of Refining, Standard 661

32

O00000000000000000OOQO00

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PLATE FIN HEAT EXCHANGER DATA

Item No. _ Page ~ Client "-~0Ject or Plant 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 6 7
g
B Da,dlnrt

_ of

Location PROCESS D A TA

J.O. No. Est. No. Date

By

Service Stream Fluid Description Total Flow Mol Weight Conditions A t Vapor: Mass Flow Rate Mol Weight Compressibility Density Vol Flow Rate Liquid Mass Flow Rate Mol Weight Specific Gravity@60 u F Density Vol Flow Rate Temperature Pressure Heat Content Vapor Liquid Total Heat Content Decreases Heat Content Increases Vapor Condensed Liquid Vaporizes Dew Pt of Vapor/Bubble Pt of L,Iquld Avg Latent of Vapor/Liquid Avg Specific Heat of Vapor/Liquid A v g Thermal Cond of Vapor/Liquid Avg Viscosity of Vapor/Liquid Pressure Drop~ Maximum Allowable Total Heat Exchan~led ,, Number of Cores= In Parallel t Core Date Width In,Length Parting Shee: Th!ckness Stream Number of Passages Fins, Type Hel~lht Thickness Spacln~l EffectlvePassagesWldth Effective Passage Length Free Flow Area Fluid Velocity Inlet Outlet Pressure Drop, Calculated Fouling Resistance Heat Transfer Rate Heat Transfer Surface Design Temperature= Max/MIn Design Pressure Test Pressure~ Hydro/Pneu Connections= Inlet TSize and Rating Outlet~ Size and Rating

Lb/Hr Inlet Lb/Hr Lb/Cu Ft Cu Ft/Sec Lb/Hr Lb/Cu Ft Cu Ft/Sec UF PSIA Btu/Hr Btu/Hr Btu/Hr Btu/Hr Btu/Hr Lb/Hr Lb / H r UF Btu/Lb Btu/Lb. UF Btu/Hr.. Sq. Ft.= UF/Ft CP PSI Btu/Hr Outlet Inlet Outlet nlet Outlet Inlet Outlet
I nlet

Outlet

Inlet

3utlet

D.P.

B,P.

D,P,

B.P.

D.P.

B,P.

D.P.

B,P.

D.P.

B,P.

D.P.

B.P.

In Series= type IniHelght In I Number of passages In| Outside Sheet Thickness= In= Number o f Dummy Layers=

corrected L. M. T. D. PHYSICAL A N D M E C H A N I C A L D A TA Mounted

Horlz, Vert,

Pass Arrangement; Weight= Net= Lb. Full of Water

Lb. Shipping

Lb.

Remarks= In. I n. No/In. In. In. Sq. Ft. Ft./Sec, Ft-/-~c: PSI Hr. Sq. Ft.~ UF/Btu Btu/Hh Sq. Ft r UF Sq. F t . UF PSIG PSIG

SKETCH=

[2t

~3)

4)

PART II SECTION 5 - PUMPS, EXPANDERS, AND DRIVERS

Plant Location Type I. GENERATOR A. Type of Service, Continuous, Intermittent or Standby B. Spare Requirements C. Interchangeability of Parts D. Electrical Area Classification E. Electric Power Voltage, Phase, Frequency, Service Factor F. G. H. I. 3. K. II. Acceptable Noise Level Indoor or Outdoor Location Is Unit to be Skid Mounted Code Requirements Design Life, Years Dynamic Balance

Date

DESIGN DATA A. Centrifugal Pumps (API Standard 610 Data Sheet) B. Motors (API Standard 618 Data Sheet) C. Gas Engines (API Standard 618 Data Sheet) D. Steam Drivers (API Standard 612 & 618 Data Sheet) E. Gas Turbine Drivers (API Standard 616 Data Sheet) F. Gasoline/Diesel Drivers G. Gears (API Standard 613 Data Sheet)
H. Process Data 1. Type Fluid 2. Fluid Quantity, Maximum and Minimum

3.

Composition, Molecular Weight, Viscosity, and Vapor Pressure 34

4. 5. 6. 7. 8.

Inlet Temperature and Pressure Outlet Temperature and Pressure Water and CO2 Content, if Turbo-expander Solid Particle Content, if Turbo-expander Liquid Quantity in Inlet, if Turbo-expander

I. Mechanical Data 1. Case Design Pressure 2. Inlet and Outlet Flange Size, Rating and Location 3. 4. 5. 6. 7. 8.
9.

Type Baseplate Type Thrust Bearing Type Mechanical Seals, Manufacturer and Metallurgy Operating Speed and Critical Speed Efficiency Seal Gas Provisions, if Turbo-expander Expansion Joints

J. Instrumentation and Control

III.

CENTRIFUGAL PUMPS A. Type of Pump - Vertical, Horizontal, Deep Well, In-line B. Performance Curve Characteristics C. Design Impeller Size Vs. Maximum Impeller Size D. Impeller Type E. Driver Horsepower Vs. Design Horsepower F. Driver Horsepower Vs. Maximum Horsepower G. Is Non-Overloading Driver Required H. Are Low or Zero-Leakage Seals Required I. NPSH Available 35

J. Materials of Construction 1. Case 2. Impeller 3. Shaft 4. Seals 5. Shaft Sleeve 6. Wear Rings 7. Other K. Detection Required for Primary Seal Failure?

IV.

RECIPROCATING PUMPS A. Type of Pump - Triplex, Multiplex B. Maximum Plunger Speed and Diameter C. Type of Lubricator D. Cylinder Liners - Bolted In or Pressed In E. Type of Valves and Seats F. H.P. Required to Start Under Full Differential G. Pulsation Dampeners Required H. Type Booster Pump I. NPSH Available J. Materials of Construction 1. Fluid End 2. Frame 3. Plungers 4. Connecting Rod 5. Valves and Valve Seats

V.

ROTARY P. D. PUMPS A. Type of Pump - Gear, Vane, Progressive Caity, Screw B. Pump Speed C. Driver Horsepower vs. Design Horsepower D. Driver Horsepower vs. Maximum Horsepower E. Fluid Viscosity E Entrained Solid G. Horsepower Required to Start Under Full Differential 36

H. NPSH Available I. Materials of Construction 1. Case 2. Rotor/Gears 3. Sliding Vanes 4. Shaft/Shaft Sleeve 5. Other VI. EXPANDERS A. Type of Expander - Turbo, Liquid B. Performance Curve Characteristics C. Is Methanol Injection Required, If Turbo-expander D. Materials of Construction 1. Case 2. Impellers 3. Shaft 4. Seals VII. ACCESSORIES A. Type Suction Screen and Mesh Size B. Type Lube Oil Pump C. Does Driver and Driven Equipment Have Common Oil System D. Type Lube Oil Heater E. Type Lube Oil Cooler F. Type Seal Oil Cooler G. Type Lube Oil Filters H. Type Lube Oil Reservoir I. Type Lube Oil to be Used (Mineral, Synthetic, Etc.) J. Type Couplings (Flexible, Magnetic, Spacer, Non-Spacer, Etc.) K. Coupling Manufacturer L. Type Gear 37

M. Gear Code Requirements N. Maximum Recommended Gear Speed O. Type Speed Control P. Type Overspeed Protection Device Q. Type Vibration Monitor and Shutdown R. Type Safety Shutdown Valve S. Instrument Air Pressure Required

VIII. DRIVERS AND DRIVEN EQUIPMENT A. Type of Driver or Driven Equipment B. Direct Connected, Gear or Belt C. Design Speed and Speed Range D. Design Horsepower IX. TESTS REQUIRED (SPECIFY SHOP OR FIELD) A. Hydrostatic B. Overspeed C. Torsional D. Efficiency E. Horsepower F. Other DATA REQUIRED FROM MANUFACTURER A. Certified Dimension Prints B. Installation, Maintenance, and Operation Instructions C. Parts List and Recommended Spare Parts

X.

D. Complete Data Sheet

E. Performance Curve or Chart

38

F. Statement of Mechanical Efficiency

G. Unit Serial Number H. Complete Description of Accessory Equipment.

I. Mechanical Seal Drawings J. Cross Sectional Drawing.

39

PART II SECTION 6 - PIPING, VALVES, AND FITTINGS

Plant Location Type. I. GENERAL A. Service and Location B. Fluid Characteristics (Design and Operating Conditions)

Date

1. 2. 3. 4. 5. 6. 7.

General Name Description Flow Rate Pressure Temperature Specific Gravity Corrosivity Viscosity

C. Unusual Conditions or Special Requirements (Cryogenic, Acid Service, Etc.)

D. Is Hydrogen Present E. Is Hydrogen Sulfide Present F. Are Hazardous Chemicals Present G. Applicable Design Standard

II.

PIPING A. O.D. or Nominal Size Range (i.e., 1/2 in. to 24 in.)

B. Wall Thickness or Schedule

40

C. Grade and Specification D. Construction - ERW, Seamless, Other

E. Material E End/Pickling/Purging Connections

G. Length of Joint H. Coating - Internal, External

III.

VALVES A. Body 1. Size 2. Type and Style 3. 4. 5. 6. Material Pressure Rating End Connection Fin and/or Extension

B. Inner Valve 1. Size 2. Type and Style 3. 4.

Material Top or Bottom Guided Pressure Drop Leakage Rate or Shutoff Class NACE Material Requirements

5. 6. 7.

C. Stem Packing D. Lubrication

41

E. Actuator F. Normal Open/Close G. Fire Safe IV. FITTINGS A. Size B. Pressure Rating C. Material D. Connections 1. Screwed Fittings - Type 2. Flanges a. Type and ANSI/API Flange Rating b. c. d. e. f. g. h. i.
3.

Face Weld or Thread Bore Gaskets - Type and Material Bolts - Type and Material Insulating Flanges Are Slip-On Flanges Permitted Gasket Surface Face Finish

Weld Fittings a. Type. b. Wall Thickness or Schedule Socket Fittings a. Type. b. Wall Thickness or Schedule Are Threaded or Socket Welded Connectors to be Used Largest Threaded or Socket Welded Connector that is Permitted

4.

5. 6.

42

PART II SECTION 7 - COMPRESSOR Plant. Location Type I. GENERAL A. Life of Project B. Type Equipment Desired. 1. Reciprocating 2. Centrifugal 3. Axial 4. High Speed or Low Speed 5. Skidded or Block Mounted C. Design Conditions 1. Gas Volume 2. Suction Pressure/Temperature 3. Discharge Pressure 4. Design Pressure of Cylinders 5. Estimated Gas BHP. 6. Gas Composition. 7. 8. Elevation Range (Max. and Min.) of Above Conditions Date

D. Driver 1. Gas Engine a. Integral/Separable b. Turbo Charged/Naturally Aspirated c. % Load at Design Conditions d. BMEP Limitations Diesel Engine Gas Turbine Steam Turbine Electric Motor Motor/Variable Speed Drive (VSD/ASD) Coupling Type Other Air Emission Requirements/Controls

2. 3. 4. 5. 6. 7. 8. 9.

43

II.

RECIPROCATING COMPRESSOR A. Design Data 1. Manufacturer and Model Number 2. 3. 4. 5. 6. 7. 8. 9. Operating RPM Piston Size, Rod Size and Stroke Length Each Cylinder Number of Stages Number of Cylinders Each Stage Compression Ratio/Stage Single Acting or Double Acting Is Lifted End Operation Required Pulsation Model - Digital

10. Valves a. Number of Suction and Discharge Valves Each End b. c. d. Type of Valve (Feather, Poppet, Combination Etc.) Effective Valve Lift Area Per Valve Valve Velocity

11. Cylinder Clearance a. Head End - in3 b. Crank End - in3 c. Cylinder Bore, Nominal - in3 d. Externally Added Clearance, (Bottle, Space Ring, Pockets) in 3 e. Variable Clearance Capability/Range 12. Internal Rod Load Capability in Tension, Compression 13. Materials for Cylinder Components Including Rod Packing 14. Loading Curves 15. Manufacturers Performance Data at Operating Conditions 16. Capacity Control 17. Foundation Requirements

44

18. Spare Parts List 19. Start-Up, Maintenance and Operating Instructions

20. Cylinder Lubrication System 21. Pulsation Analog 22. Start-Up Screens 23. Connections for Compressor Analyzer 24. Jacket Cooling. 25. Lube Oil 26. Inter-Stage Cooling/Condensation 27. API Standard 618

KI.

CENTRIFUGAL COMPRESSOR A. Design Data 1. Manufacturer and Model Number 2. 3. 4. 5. 6. Operating RPM Number of Internal Compression Stages Preliminary Impeller Tip Speeds Impeller Eye Relative Math Numbers Materials for Case, Rotor, Stage Impellers,Diaphragms, Shaft Seals and Labyrinths

7. 8. 9.

Seal and Bearing Losses Inlet and Exit Losses Preliminary Volume/Speed

45

10. Minimum Allowable Operating Temperature and Maximum Allowable Operating Pressure and Temperature

11. Shaft Horsepower at Each End of Compressor

12. Preliminary Performance Curves Including Curves for Future Design Conditions 13. Base Compressor Shaft Dimensions and Weight

14. Individual Impeller Weights and Diameters

15. Estimated First and Second Critical Speeds

16. Type of Radial Bearing 17. Seal Oil System 18. Surge Control 19. API Standard 617 20. Overhung or Beam Configuration 21. Type Seals (Dry Gas or Oil Wet) 22. Type of Thrust Bearing (Tilting Pad, Magnetic, Etc.)

IV.

INSTRUMENTATION AND SAFETY A. Design Conditions 1. Attended or Unattended Operation 2. . Instrument Power - Electric, Gas or Air Control a. Manual or Automatic with or without Load Share 46

b. c. 4. 5. 6.

Local or Remote Torque Control

Stand-by Power Requirements Filters and Dehydrators on Gas or Air Supply Fuel/Emission Monitoring

B. Shutdown Functions 1. Emergency Plant Shutdown

2.

Engine and Compressor Safety Shutdowns

3. 4. 5.

Explosive Atmosphere Monitors Fire Monitors Sour Gas Monitors

V.

SPECIAL CONSIDERATIONS A. Acoustic Design Requirements 1. Limitations on Noise Level 2. 3. 4. 5. Engine Muffler and Air Filter Relief Valve Silencer. Station Blowdown Silencer Acoustic Treatment of Compressor Building/Wall Thickness or Lagging

6.

Acoustic Treatment of Piping and Coolers

B. Treating of Compressor Fuel C. Specifications for Acceptance Test 1. 2. Capacity Emissions 47

D. Building 1. Is Building Required/Justified 2. 3. Totally or Partially Enclosed Crane Requirements/Component Removal

E. Crankcase - Special Requirements

48

PART II SECTION 8 - INSTRUMENTS AND CONTROLS

Plant Location Type I. GENERAL A. Applicable Code B. Area Electrical Classification C. Type Drawings Required

Date

D. Air Pressure Available E. Electronic or Pneumatic or Distributive Control System (DCS) Preference

F. Mounting 1. Local Direct Mount 2. Local Panel 3. Central Room G. Control Room Required 1. Location 2. Electrical Classification 3. Pressurization 4. Air Source 5. Instruments to be Located H. Controllers to be Located at Equipment for Start-Up

I. List Points That Require Trending

J. Electric or Pneumatic Chart Drives K. List Multipoint Temperature Indicators or Trends Required L. Is Intrinsically Safe Design Required M. Is Air Purging Acceptable for Hazardous Locations

49

N. Metallurgy in Contact with Process Fluids

O. Type Control Air Tubing P. Type Tubing Fittings Q. Dew Point of Instrument Air R. Air Duration on Loss of AC Power S. Standby Electric Power Required T. Method of Replacing Failed Equipment U. Local Filter Type in Air Supply to Remove Compressor Oil V. Total Plant Air Capacity Required, SCFH W. Fail Safe Loop Design Required X. Allowable Amount of Control Equipment That Can Fail at Once Y. Smart Transmitter Party Line Architecture is Acceptable II. FLOW INSTRUMENTS A. Type Primary Flow Elements (Orifice, Turbine Meter Etc.) B. Are Calibrated Meter Runs Required C. Do Orifice Plates Require Changing in Service D. Orifice Calculation Methods E. Is Remote Readout Required F. Type Manometers (Dry Type, Mercury, Etc.) G. Type Chart (Uniform or Square Root) H. Chart Time Span (24 Hours, 7 Days, Etc.) I. Transmitters 1. Transmitter Type 2. Transmitter Range 50

3. 4. 5.

Is Adjustable Range Required Is Full Pressure Range Required Is Adjustable Dampener Required

J. Controller Modes Required (Proportioned Band, Reset, Etc.) K. Are Pressure Pens Required for Gas Meters L. Type of Custody Transfer Meters Required M. Units to be Read on Instrument N. Meter Coefficients to be Even Numbers with an Odd Orifice Plant Bore Dimension or Coefficients to be Odd Numbers with Even Bore Orifice Plant Dimensions

O. Are Electronic Flow Recorders (EFR) Required P. Temperature Pen Required for Liquid Flow Q. Three or Five Valve Manifold R. Condensing Vapor Service S. Boiling Liquid Service T. High Viscosity or Solids Containing Service U. Frequent Re-Ranging Required V. Square Root Characterization in Transmitter W. Fluid Temperature Too Hot or Cold For Transmitter X. Is Local Indication Required IN. LEVEL INSTRUMENT A. Type Primary Elements (Displacement, DP Cell, Etc.)

B. Are Internal Floats Acceptable C. Float Lengths Required D. Is Remote Readout Required

51

E. Vessel or Gauge Column Mounting F. Liquid Suitable for Capacitance Measurement G. Type Level Switches (Float, Pilot Actuated, Etc.)
H Shall Level Switch be Independent of Primary Control Device

I. Tank Gauges 1. Type Gauge for Pressure Tanks 2. Type Gauge for Atmospheric Tanks 3. Is Remote Readout Required 4. Is Automatic Tank Switch Required J. Gauge Glasses 1. Type Gauge Glasses 2. Range of Vessel Height to be Covered 3. 4. 5. 6. 7. 8. Are Thru Vision Glasses Required Are Frost Protectors Required Are Frost Plugs Acceptable for Cryogenic Services Type Gauge Cocks Type Vent and Drain Valves Required Location of Top and Bottom Connections

K. Controller Modes Required (Proportional Band, Reset, Etc.) L. Condensing Vapor Service M. Boiling Liquid Service N. Remote Transmitter Seals Required If so, Acceptable Seal Fluids O. Expected Level Error Due to Fluid Gravity Change E Location of Yoke Assembly Bottom Tap on Tank to Prevent Plugging Q. Allowable Zero and Span Shift R. YokeAssembly Blow Down Connections To Flare Header Required S. Maximum Static Pressure Expected T. Calibrate in What Units, (%, Inches, Gallons, Etc.)

52

IV.

PRESSURE INSTRUMENTS A. Type Primary Element (Bourdon Tube, Bellows, Etc.) B. Controller Modes Required (Proportional Band, Reset, Etc.) C. Over Range Protection Required D. Type Pressure Gauges E. Type Pressure Switches F. Type Pressure Transmitters G. Re-Ranging After Start-Up Desirable H. Controller Without Measurement Indication Acceptable I. Must Controller Have An Auto/Manual Capability J. Do Atmospheric Pressure Changes Cause Enough Error to Require an Absolute Pressure Transmitter K. Should Transmitter be Equipped with Zero Shift Check Valves L. Local Indication Required

V.

TEMPERATURE INSTRUMENTS A. Type Primary Element (Thermocouple, Resistance Element Filled Systems, Etc.)

B. Controller Modes Required (Proportioned Band, Reset Etc.) C. Type Thermocouples D. Type Thermowells E. Transmitters 1. Transmitter Type 2. Transmitter Range 3. Transmitter Output F. Multipoint Indicator or Recorder 1. Instrument Range 2. Type Indicator (Tape or Digital) 3. Recorder Print Speed 4. Number of Points G. Type Thermometers 53

H. Allowable Measurement Error Due to Changing Ambient Temperature I. Re-Ranging Required After Start-Up J. Minimum Span Desired K. Local Indication Required L. Maximum Allowable Dead and Lag(s) Time Process

M. Test Equipment to Calibrate Temperature Transmitters

N. Must Controller Have Auto/Manual Capacity

VI.

COMPUTER/DISTRIBUTED CONTROL SYSTEMS A. Physical Environment for Computer/Distributed Control System Including Peripherals 1. Safety/Area Classification 2. 3. 4. 5. . Air Conditioning/Humidity Control Electrical Power and Other Utility Requirements Space Cables, Routing, Distances Remote Applications: a. Pipeline b. Gathering/Distribution Networks c. Terminal Loading Facilities

B.

d. Tank Gauging Type of Control Application 1. Closed-Loop Control and Optimization a. Direct Digital Control (Distributed, Etc.) b. c. Supervisory control (Set Points to Panel Board Instruments or Distributed Microprocessor Controllers) Batch Process Control (Sequential Function Processes; Start-up and Shut-down, etc.)

54

d.

Safety of Process Operation (Automatic Corrective Action, Alarming)

2.

Information System a. Operating Information

b.

Process Engineering Information

c. d.

Management Information Accounting Information

C. Scope of Control Application 1. Type and Number of Process Units and Equipment a. Reactors b. Absorbers c. Fractionators d. Pipeline e. Production Wells f. Gathering/Distribution Networks g. Compressors

h. Furnaces i. Dehydrators j. Acid Gas Removal k. Boilers D. Interface of Control System 1. Total Input/Output Signals for Instrumentation a. Analog Inputs (1) High Level (2) Low Level (Millivolt) b. c. d. e. Analog Outputs Digital Inputs Digital Outputs Pulse Inputs (from Turbine Motors, Etc.)

55

f. 2.

Pulse Outputs (to Stepping Motors)

Types of Process Instrumentation a. Pneumatic Instrumentation (Signal Transducers) b. c. d. e. f. Electronic Instrumentation Distributed Microprocessor Control System (First Level Control) Thermocouple Sensor-Based Peripheral Pneumatic Signal Multiplexing System Field Bus Instrumentation

3.

On-Line Process Measurement Devices a. Flow, Level, Pressure, Temperature, Etc. Process Stream Properties: (1) Calorific Value (BTU, Etc.) (2) Density, Specific Gravity c. Process Stream Composition Personal-Computer Interface a. Process Alarm Panel b. Process Operator Control Panel c. d. e. CRT Video Display Unit with Keyboard Printing Devices Remote Data Entry Terminal (For Lab Data Entry and/or Readout, Etc.) b.

Interface With Other Systems a. Functions of Other Systems (1) Back-Up System (Dual or Standby) (2) Host or Centralized Computer (3) Parallel System (Similar Computers on Other Process Units) (4) Slave, or Lower Level, System b. Method of Communication (1) Bus (For Back-Up Computer) 56

(2) Data Link (RS-232, Etc.) (3) Network Interface with Other Logical (Smart) Peripheral Equipment a. Thermocouple Multiplexing System b. c. d. Tank Level Gauging System Programmable Logic Controllers (PLC) Pneumatic Signal Multiplexing System

e. f. g. h.

Microprocessor Based Chromatograph System Laboratory Operated Computer System Smart Transmitters Software Backup/Re-Boot Methods

VII. MISCELLANEOUS A. Analyzers 1. Type. 2. 3. 4. 5. 6. 7. 8. 9. Automatic or Manual Switch Number of Points Location of Recorder and Controller Size of Sample System Tubing Are Vaporizer Regulators Required Location of Analyzer Type Sample Manifold Required Type of Sampler

10. Method of Calibration 11. Maximum Time That Analysis Can Lag Process B. Annunciators 1. Number of Points 2. Location 57

3. 4.

Style (CRT or Window Based) Is Intrinsically Safe Unit Required

5. 6. 7.

Are test, Acknowledge and Reset Functions Required Is Annunciator to be Used for Shutdown and Remote Alarm Type Remote Alarm (Telephone, Radio, Etc.)

8. 9.

First Out Indication Can Annunciator Be Implemented In Distributed Control System Operator Station

10. Control Room Audible Alarm 11. Plant Yard Audible Alarm 12. Desire Alarm Sequence C. Mechanical Equipment Shutdown System 1. Type Systems (Pneumatic or Electronic) 2. 3. 4. 5. 6. 7. 8. 9. Is Explosion Proof Unit Required Are Oil Sealed Switches Acceptable List Shutdown Points Is Remote Shutdown Required Upon Shutdown is Signal Required for Remote Annunciation or Shutdown Is First Out Indication Required Location of Panel Fail Safe Design Required

10. Must Shutdown Systems Be tested With Equipment On-Line D. Fired Equipment Safety Shutdown System 1. Type System (Pneumatic or Electronic) 2. List Shutdown Points

58

3. 4. 5. 6. 7. 8.

Is Remote Shutdown Required Upon Shutdown is Signal Required for Remote Annunciation or Shutdown Is First Out Indication Required Location of Panel Fail Safe Design Required Must Shutdown System Be Tested with Equipment On-Line

E. Main Control Panel/Operator Stations 1. Size and Number of Panels/Operator Stations

2. 3.

Number and Type of Instruments/Displays Sketch Showing Location and Size of Cut Outs/Operator Station Placement

4. 5.

Location of Panel/Operation Stations Size and Number of Air Supply Connections and Filters

6. 7. 8. 9.

Power Supply and Switches Required Is Emergency Power Required Will Management Information Computer be Connected to System Panel Material and Coating Specifications

10. Is Graphic Panel/Operation Station Graphics Required 11. Are Separate Indicator Lights Required 12. Operator Station Update Rate

VIII. CONTROL VALVES A. Shutoff Pressure Differential

59

B. Shutoff Class C. Pneumatic or Electric Actuator D. Fail Open, Fail Close, Fail Last E. F. G. H. Stroking Speed Required Body and Flange Pressure Rating Packing Type Allowable Leakage to Atmosphere

I. Design Flow J. Maximum Flow K. Characterization to Best Linearize Loop

L. Positioner Recommended

60

P A R T II

SECTION 9 - ELECTRICAL Plant Location Type I. GENERAL A. Applicable Codes B. Area Classifications 1. Use of Air Purging/Intrinsically Safe/Non Incentive Design Date

C. Type Drawings Required D. Main Distribution System Voltage E. Utility Service Agreement 1. Interruptible/Non-Interruptible Service

F. Utility Rate Schedule 1. Expected Outages Per Year

G. Distance to Utility Power Lines H. Grounded or Ungrounded System I. Power Failure/Restart System J. Short Circuit MVA and Amperes at Each Bus

II.

TRANSFORMERS A. Oil Insulated or Dry Type B. Transformer KVA Rating C. Voltage Taps Required D. Automatic Tap Changers Required E. KVA Upgrade By Adding Fans E Lighting Arrestors Used on Primary 61

G. Type of Windings Primary/Secondary 1. Secondary Grounding System

UI.

GENERATORS A. Single or Multiple Units B. Spare Capacity Required C. Future Load Requirements D. Continuous or Intermittent Duty E. Power Factor F. Type Drivers G. Type Voltage Regulation H. Type Synchronization I. Type Protective Relay J. Speed, Voltage, Phase, and Cycle K. Ammeters, Voltmeter, Watt Hour Meters, Power Factor Meters, and Frequency Meters Required

L. Allowable Voltage Dip on Motor Starting M. Automatic Load Balancing N. Automatic Reactive Current Balancing O. Import/Export Power Control P. Driver Kilowatt Capacity Versus Generator Kilowatt Capacity IV. MOTORS A. Type Enclosures Required B. Voltage, Cycle, Phase and RPM, for Various Size Motors C. High Temperature Protection Devices Required

D. Ground Fault Protection

62

E. Vendor Furnished Data 1. Nameplate Data 2. . Dimensional Prints Parts List and Bearing Numbers

F. Service Factor G. End Thrust Bearing Requirement H. Motor Efficiency I. Motor Sized to Handle Maximum Flow Conditions.

J. Power Factor Correction Capacitors at Each Motor

K. Spare Heaters

L. Maximum Allowable Vibration

M. Require NEMA Insulation Rating

N. Power Requirement for Motor Horsepower (Horsepower, Voltage, Phase Requirement)

V.

MOTOR CONTROL A. Maximum Size Motors with Manual Starters

B. Largest Horsepower Using Across the Line Magnetic Starters C. Soft Start Required D. Variable Frequency Drive (VFD) E. Ground Fault Protection F. Ambient Compensated Overload Protection

63

G. Individual Motor Control Transformers H. Centralized or Distributed Control I. Ammeters Required J. Indicator Lights Required K. Type Enclosure L. Partitioning of Motors Among Feeders M. Motor Control Center 1. Enclosure Type, (Front, Front/Back) Construction 2. Manufacturer N. Motor Control Center Building.
o

2. 3. VI.

Size HVAC, Purge Requirements Conduit Bulkheads

LIGHTING A. Type of Area Lighting 1. Fixtures 2. 3. Poles Automatic Control, If Required

B. Type of Local Lighting C. Type of Building Lighting D. Voltages Required for Various Lighting Types

E. Illumination Intensifies for Various Plant Areas and Buildings E Type Panel Board Required G. Voltage Surge Suppressors, If Required H. Location of Panel Boards and Switches 64

I. Emergency Lighting J. Locations Requiring Color Recognition By Operators

VII. RECEPTACLES A. Type Receptacles for Various Areas B. Location and Voltage of Receptacles C. Welding Receptacles, If Required D. Ground Fault Circuit Interrupters Required

~O

CONDUITS, DUCTS, AND CABLE TRAYS A. Minimum Size Conduit or Cable Tray B. Type of Conduit C. Percent of Spare Conduits Required D. Amount of Covering for Underground Conduit E. Type of Conduit Fittings F. Type of Pull Boxes and Junction Boxes G. Type of Man Holes H. Vapor Seals Required I. Conduit Seals at Area Classification Boundaries J. Conduit Drains to Remove Water Required K. Type of Cable Tray (Open Ladder, Enclosed) L. Cable Tray Material (Aluminum, Galvanized)

65

M. Type of Cable Tray Cover Required N. Cable Tray Entry

IX.

WIRE AND CABLE A. Maximum Percent Loading of Conductors B. Maximum Voltage Drop in Conductors C. Minimum Wire Size D. Solid or Stranded Wire E. Type of terminal Connections F. Type of Wire Insulation 1. For Use in Conduit, Cable Tray, Direct Burial

2. 3. 4.

Below 600 Volt High Voltage Above 600V Control, DC, Instrumentation

G. Acceptable Pulling Compounds H. Acceptable Splicing Methods for Medium Voltage Cable I. Insulation Resistance Tests Required J. Is Overhead Line Wiring Acceptable Within Battery Limits

X.

GROUNDING A. List Equipment Requiring Grounds

66

B. Location of Ground Beds

1. Is A Grounding Grid Required 2. Is Ground Grid Bare or Insulated 3. Is Ground Grid Ties to Equipment Bare or Insulated C. Type Ground Beds

D. Maximum Design Ground Resistance

E. Type Ground Bed Connectors

E Wire Size for Grounding Grid G. Required Method for Attaching Ground Lugs to H. Shall Attachments to Equipment be Above Ground and Visible I. Grounding for Surge Arrestors

XI.

CATHODIC PROTECTION SYSTEM A. Type Ground Beds

B. Depth of Ground Beds

C. Location of Ground Beds

D. Power Source

E. Insulating Joints Required

F. Are Rectifiers Locatable Outside the Classified Area

XIIo LOAD CONTROL

A. Automatic Demand Control

67

B. Monitor Demand C. Load Shed on Partial Generator Loss

XIII. HEAT TRACING A. Self Limiting B. Local On/OffIndication C. Are Thermostats Required D. Area Classification Requirements for Heat Trace

68

P A R T II S E C T I O N 10 - G A S F I R E D T U R B I N E

Plant Location Type I. GENERAL A. Installation 1. Concrete Pad on Land 2. 3. 4. 5. 6. Off-Shore Platform Mezzanine Land Other Degree of Skidding or Prefabrication Required Type of Enclosure

Date

B. Winterization Required C. Site Conditions 1. Altitude 2. Dry Bulb Temperature, F Minimum Design Temperature 3. Wet Bulb Temperature, F Minimum Design Temperature 4. Dust PPM Greater Than 5. Corrosive Constituents 6. Salt Air 7. Ice, Fog D. Design Life, Years II. DRIVEN EQUIPMENT A. Type B. Driven Equipment HP at C. Gear Loss, HP D. Horsepower Tolerance E. Normal HP Required by all Driven Equipment

Maximum Maximum Microns

RPM

69

F. Maximum Starmp Horsepower

HP at

RPM

G. Auxiliary HP H. Maximum Available HP at Site Conditions I. Maximum Operating Speed Range as % of Design Speed to J. Lateral and Torsional Critical Speeds K. Horsepower Required Under Most Severe Condition Over Speed Range

IlL

MECHANICAL A. Design Data (API Standard 616 "Combustion Gas Turbines for General Refinery Services") B. Type of Gas Turbine 1. Simple Cycle 2. Regenerative

3. Single, Two or Three Shaft 4. Steam Injector 5. Helper Drive 6. Industrial or Aero Derivative C. Codes, Standards and Specifications 1. Turbine 2. Driven Equipment 3. Gears 4. Couplings 5. Pumps 6. Electrical 7. Vibration 8. Coating or Painting 9. Humidifier Water 10. Pollution 11. Noise 12. Process Gas 13. Inlet Air 14. Fuel Gas 15. Lube Oil D. Overhaul 1. Normal Operating Time Between Scheduled Overhauls 2. Maximum Downtime That Can Be Tolerated During Required Major Overhaul 3. Provisions for Space, Labor and Spare Parts Required for Overhaul 4. Nearest Reliable Machine Shop with Proper Balancing Equipment 70

5. 6. 7. 8. 9.

Availability of Major Spare Components such as Rotating Elements, etc. List of Manufacturers Recommended Spare Parts Does Manufacturer Have a Capable Service Organization Does Manufacturer Offer a Maintenance Service Agreement Lifting Equipment

10. Cradle E. Couplings 1. Grease Packed 2. Continuously Lubricated

3. Spacer Type F. Materials of Construction

IV.

AUXILIARY EQUIPMENT A. Fuel 1. Primary Fuel 2. Secondary Fuel 3. Fuel Consumption Rate. 4. Can Fuel be Switched During Operation 5. 6. 7. 8. Available Natural Gas Fuel Pressure During Startup and Operation Fuel Separator Fuel Filter Analysis of Fuel During Starmp and Operation

9.

Fuel Contaminants

B. Starters

1. 2. 3.

Starter Type (Pneumatic, Electric, Electro-Hydraulic, Diesel, etc.) Pressure and Temperature of Starting Medium Disposition of Starting Medium 71

C. Waste Heat Recovery 1. Turbine Back Pressure at Exhaust Flange. 2. 3. 4. 5. 6. Design Temperature of Exhaust Exhaust Gas Quantity Heat Medium Mass Flow and Composition Supplemental Firing

D. Electrical Power 1. AC Power Available Hertz 2. Electrical Area Classification 3. Reliability of Power Source

Volts Phase

E. Lube oil System 1. Separate or Common Lube Oil Facility for Train 2. 3. 4. 5. 6. 7. 8. 9. Cooling Water Availability and Temperature Humidifier Water Availability Type Primary Lube Oil Pump Driver Type Spare Lube Oil Pump Driver Lube Oil System Piping - Stainless or Carbon Steel Are Dual Filters Required Are Dual Oil Coolers Required Type Lube Oil (Mineral or Synthetic)

F. Instrument Air Availability 1. Pressure 2. Dew Point 3. Filter G. Noise Abatement 1. Inlet Air Silencer 2. Exhaust Silencer 3. Applicable Noise Limits to Turbine and Surrounding Area 4. Normal Exposure Time, Hours Per Week 72

5. 6.

OSHA Standards Manufacturers Noise Level Guarantee

7.

Method of Noise Determination

H. Inlet Air Filter 1. Automatic Rotating Element 2. Stationary Element 3. Inertial 4. Allowable Pressure Drop Through Inlet Duct and Filter, Inches of Water 5. Self-Cleaning Filter I. Inlet Air Cooling J. Thermal Recuperation or Intercooling K. On-Stream Cleaning Capability

V.

AUTOMATION A. Attended or Unattended Operation B. Remote Starting

C. Starting System 1. Manual 2. Semiautomatic 3. Automatic D. Location of Turbine Control Panel E. Location of Driven Equipment Panel F. Will Common Annunciator be Used G. Interlocks Between Turbine, Driven Equipment and Other Process Equipment H. Conditions That will Actuate Alarms and Shutdowns

I. Control System Type (PLC or DCS)

73

VI.

SPECIAL CONSIDERATIONS A. Is Unit Responsibility for Turbine and Driven Equipment Contemplated B. Will Torsional Analysis be Performed by Turbine Manufacturer or Driven Equipment Manufacturer

C. Weight and Space Limitations D. Tests 1. Turbine Shop Test Under Full Load 2. 3. 4. 5. Turbine Shop test Under Partial Load Turbine Noise Levels on Test Stand Driven Equipment Shop Test Field Tests

E. Delivery Time E Air Emissions 1. Emissions Monitoring (Continuous, Periodic, etc.) 2. Control Provisions (Water Injections, etc.)

74

PART H SECTION 11 - INSULATION

Plant Location Type I. GENERAL A. Specifications 1. By Owner 2. By Contractor

Date

B. Code Requirements C. Materials Furnished by Contractor

D. Labor Furnished by Contractor

E. Type Contract 1. Lump Sum 2. Cost Plus Fee. 3. Unit Price F. Specify Which Insulation is to be Shop Applied

II.

DESIGN A. Specify Equipment to be Insulated and Metal Jacketed 1. Vessels 2. Heat Exchangers 3. Pumps 4. Compressors 5. Turbines 6. Piping 7. Fittings 8. Valves 9. Flanges 10. Gauged Level Controls 11. Gauge Glasses 75

12. Turbine or Heater Ducts 13. Underground Piping 14. Other

B. Specify Equipment to be Fireproofed 1. Vessels

2. Piping

3. 4. 5. 6. 7.

Vessel Skirts and Supports Load Bearing Piping Structures Load Bearing Equipment Structures Building Structures Other

C. Insulation Requirements and Thickness 1. Hot Insulation Shall be Applied Above 2. Thickness Schedule for Hot Insulation 3. Cold Insulation to be Applied Below 4. Thickness Schedule for Cold Insulation 5. Personnel Protection to be Applied Above 6. Thickness for Personnel Protection 7. Fireproofing Shall be Applied to Prevent Metal Temperatures From Exceeding When Exposed to a Flame for 8. Thickness Schedule for Fireproofing 9. Double Layer Insulation Shall be Applied for Temperatures Exceeding or When Insulation Thickness Exceeds D. Materials 1. Hot Insulation 2. Cold Insulation 3. Fireproofing 4. Joint Sealers (Cold) 5. Insulating Cement 6. Bore Coating 7. Binding Wire 8. Metal Jacketing 9. Insulation Bands 10. Expander Bands 11. Metal Screws. 12. Vapor Barrier 13. Metal Jacket Cooler 76

oF oF oF

oF oF Hours

oF Inches

III.

APPLICATION A. Surface Preparation

B. Specify Insulation Supports and Clips

C. Specify Screws or Bands for Jacketing and Spacing Requirements D. Are Prefabricated Pipe Fitting Metal Jackets Required E. Hot Piping, Ducts, and Equipment 1. Specify Binding Wire or Bands 2. Bands or Bindings Center to Center Spacing

3. 4. 5. 6. 7.

Are Flanges to be Insulated, Removable, or Blanket Type Are Valves to be Insulated, Removable, or Blanket Type Are Manhole Covers to be Insulated, Removable, or Blanket Type Are Bottom Heads to be Insulated Specify Any Special Techniques Required

F. Cold Piping and Equipment 1. Specify Binding Wire or Bands 2. 3. 4. 5. Bands or Bindings Center to Center Spacing Is Bore Coating Required Is Surface Sealer Required Specify Special Techniques Required

6. 7.

Vapor Barrier Required Are Metal Screws Allowed

77

G. Fireproofing 1. Band Center to Center Spacing for Blocks 2. 3. 4. 5. 6. 7. Specify Troweling or Spraying for Refractory Is Bore Coating Required Is Surface Sealer Required Reinforcing Required for Refractory Is Metal Jacket Required for Refractory Surface Preparation

8.

Specify Any Special Techniques Required

IV.

INSPECTION A. Inspection Method

B. Inspection by Company or Consultant

C. Inspection Requirements Prior to Applying Insulation: 1. Inspect Surface Preparation 2. Inspect Heat Trace or Steam Trace 3. Ensure that Leak Testing has been Fulfilled D. Inspection Requirements Prior to Applying Metal Jacket

78

PART II SECTION 12 - PAINTING

Plant Location Type I. GENERAL A. Climatic Environment B. Code Requirements C. Special Equipment Required

Date

D. Items Furnished by Contractor

E. Surfaces to be Coated (Specify Shop or Field) Aboveground Steel Structures 2. Aboveground Steel Piping 3. Underground Steel Piping and Structures 4. Steel Vessels 5. Pumps 6. Compressors 7. Turbines 8. Motors, Starters, Switches 9. Instruments 10. Heaters, Boilers, Stacks and Mufflers 11. Concrete 12. Tank and Vessel Interiors 13. Wood 14. Wallboard and Masonry F. Company Systems Color Code G. OSI-IA Color Code H. Coating Manufacturers Supervision Required
.

I.

SURFACE PREPARATION A. Hand Cleaning B. Machine Tool Cleaning C. Commercial Blast D. White Metal Blast 79

E. Blast Roughening

F. Inspection Required After Surface Preparation G. Rust Inhibitor Required After Surface Preparation H. Maximum Time Between Surface Preparation and First Primer Coat

III.

APPLICATION A. Manufacturers Recommendation B. Protective Films and Tape Required C. Inspection Required After Application D. White Metal Blast E. Maximum Humidity for Application F. Maximum Time Between Successive Coats

IV.

SYSTEMS SCHEDULE A. Surface Categories 1. Urdnsulated Piping, Vessels and Steel Structures to (Non-Coastal Areas) . Uninsulated Piping, Vessels and Steel Structures above (Non-Coastal Areas) . Uninsulated Piping, Vessels and Steel Structures to (Coastal Areas) . Uninsulated Piping, Vessels and Steel Structures above (Coastal Areas) . Insulated Piping, Vessels and Steel Structures to (Non-Coastal Areas) . Insulated Piping, Vessels and Steel Structures above (Non-coastal Areas) . Insulated Piping, Vessels and Steel Structures to (Coastal Areas) 80

oF

oF

oF

oF

oF

oF

oF

8.

Insulated Piping, Vessels and Steel Structures above (Coastal Areas) 9. Offshore Splash Zones 10. Tank and Vessel Interiors 11. Heaters, Boilers, Stacks, and Mufflers 12. Pumps, Engines, Compressors, and Turbines

oF

13. Electric Motors, Starters and Switches 14. Instruments and Gauge Racks 15. Concrete 16. Wood 17. Wallboard and Masonry Surface Preparation and Application for Each Category B. 1. Surface Preparation 2. Number of Primer Coats 3. Primer Type 4. Primer Dry Thickness 5. Number of Finish Coats 6. Finish Type 7. Finish Dry Thickness 8. Finish Color

81

PART H S E C T I O N 13 - B O I L E R S

Plant Location

Date

Type.
I. GENERAL SPECIFICATIONS A. Life Cycle Expectations B. Packaged or Field Erected C. Plot and/or Weight Limitations D. Electrical Area Classification E. Power Available F. Plot Orientation G. Housing H. ASME Boiler Code Volts Phase Hertz

II.

DESIGN CONDITIONS oF A. Lbs/Hr of Dry Steam at of Blowdown Steam Purity B. Superheat, No. of Degrees C. Operating Pressure D. Design Pressure E. Right or Left Hand E Altitude Ft. G. Ambient Air Temp. H. Feed Water Temp. to (Boiler)0Economizer I. Maximum Pressure Drop through Super Heater J. Maximum Heat Flux 1. Radiant 2. Convection K. Induced or Forced Draft Type of Fan Drive L. Air Heaters M. Refractory Material N. Type Burner O. Stack P. Burner System 82

.PSIG, at Non-return Valve, Plus

Lbs/Hr
oF

PSIG PSIG

F, Max

Min.,F oF

III.

COMBUSTION DESIGN CONDITIONS A. Type of Fuel (Dual or Single) B. Excess Air % C. Fuel Characteristics 1. Heating Valve, HHV 2. I-I/CRation (By Wt.) 3. Temperature at Burner 4. Fuel Pressure Available at Burner, PSIG 5. Sulfur Content, Wt.% 6. Gas Molecular Wt. 7. Gas Composition, and % 8. Liquid Fuels a. Chemical Analysis b. Viscosity c. Specific Gravity d. Atomization e. Filtering Requirements f. g. Storage Requirements System Pressure and Capacity Requirements

IV. WASTE HEAT BOILER A. Design Data (ASME Boiler and Pressure Vessel Code) 1. Gas Side Maximum Flow 2. Gas Side Maximum Temperature 3. Gas Side Maximum Pressure 4. Minimum Boiler Outlet Temperature 5. B. C. D. E. Steam Purity

Maximum Gas Velocity Are Inlet Baffles Required Access for Cleaning Vertical or Horizontal Tube Boiler Preferred

F. Minimum Water Velocity in Horizontal Tubes G. 100% Spare Pump for Forced Circulation Boiler H. Pumps Instrumented for Automatic Start-Up I. Material Present Which Cause Erosion 83

J. K. L. M.

Soot Blowers Required Minimum Tube O.D. for Convection, Economizer and Super Heater Sections Corrosion Allowance for Economizer Boiler Feed Water Bypass Around Economizer Required

N. Drain Connections for Economizer and Super Heater O. Super Heater Minimum Design Outlet Temperature P. Super Heater Design Outlet Temperature Q. Super Heater Header Outlet Vent Silencer R. Start-Up Cooling Steam Connections S. External Surface (Studs and Fins) Material T. External Surface Joining Method U. Metallurgy of Studs and Fins V. Minimum Fin Dimensions W. Maximum Fins Per Inch X. Minimum Casing Thickness V. FEED WATER AND CONDENSATE A. Percent Condensate Return Percent Makeup Water B. Water Analysis 1. Hardness, PPM 2. Silica 3. pH 4. Total Solids Suspended Solids 5. Other Contaminants C. Water Treatment 1. Deaeration 2. De-oiling 3. Type of Treatment 4. Blowdown - Manual or Automatic, Frequency

84

VI.

INSTRUMENTS AND CONTROLS A. Types of Controls (Integrated for Stand Alone)

B. Operating Controls

1. 2. 3. 4. 5. 6. 7.

Steam Pressure Feed Water Level Control (One, Two, or Three Element) Fuel Control Air Control Flue Gas Ignition (Burner System Interlocks) Emissions Monitoring,

C. Safety Controls 1. Steam 2. Water 3. Fuel 4. Air 5. Flue Gas 6. Flame Failure VII. GOVERNMENTAL CODES AND REGULATION A. Air Emission Requirements (Stack Height, Max/Min. Firing Emission Rates and Guarantees)

B. Water Disposal Requirements 1. Blowdown 2. Treating Chemicals C. Acoustic Design D. OSHA E. Inspection (and Testing)

VIII. MISCELLANEOUS A. Access Doors B. Soot Blowers C. Painting D. Drainage E. Delivery E Documentation Requirements

85

P A R T 1I S E C T I O N 14 - P R O C E S S H E A T E R S

Plant Location Type. I. GENERAL A. Life Cycle Requirements B. Type of Equipment Desired 1. Vertical-Cylindrical 2. 3. 4. 5. Horizontal-Rectangular Combination Radiant and Convection Direct-Heating or Indirect Waste Heat Recovery

Date

C. Service D. Shop-Fabricated or Field-Erected

II.

PROCESS DESIGN CONDITIONS A. Heater Sections and Service B. Heat Absorption MM BTU/I-I C. Fluid D. Flow Rate (Velocity Limitations) E. AUowable Pressure Drop F. Allowable Average Flux Density BTU/Sq.Ft./Hr. (Radiant/Convection) G. Inlet Conditions 1. Temperature, 2. Pressure, psig 3. Liquid Flow, Lb/Hr 4. Vapor Flow, Lb/Hr 5. Liquid - API or Sp.Gr. @ 60F 6. Vapor - Molecular Wt. 86

oF

7. 8.

Liquid Viscosity, CPS Distillation Data or Compositional Data

9. Sulfur Content of Fluid - Wt.% 10. Corrosion or Erosion Characteristics H. Outlet Conditions 1. Temperature, 2. Pressure, psig 3. Liquid Flow, Lb/Hr 4. Vapor Flow, Lb/Hr 5. Liquid - API or Sp.Gr.@ 60F 6. Vapor - Molecular Wt. 7. Liquid Viscosity, CPS I. Fouling Factor J. Minimum/Maximum Stack Temperature

oF

III.

COMBUSTION DESIGN CONDITIONS A. Type of Fuel (Single or Dual) B. Excess Air % C. Ambient Air Temperature _F(Max./Min.) D. Altitude - Ft. Above Sea Level E. Fuel Characteristics 1. Heating Valve, HHV 2. Specific Gravity 3. H/C Ratio by Weight 4. Temperature at Burner, F 5. Fuel Pressure Available at Burner, psig 6. Sulfur Content- Wt.% 7. Gas - Molecular Wt. % 8. Gas Composition- Molecular % 9. Liquid - ASTM Boiling Point G. Fuel Scrubber with High Liquid Level Shutdown Switch Ho Thermal Efficiency I. Waste Heat Source 1. Fluid 2. Mass Flow Rate 3. Allowable Pressure Drop 4. Inlet Temperature F 5. Minimum Outlet Temperature F

87

IV.

MECHANICAL DESIGN CONDITIONS A. Plot Limitations B. Tube Limitations C. Stack Limitations D. Structural Design Data 1. Wind Load 2. Seismic Factor E. Stack Draft Preventer E Wind Skirts G. Insulation H. Refractory I. Casing J. Hangers K. Type Burner L. Supplemental Firing K. Forced or Natural Draft COIL DESIGN CONDITIONS A. Heater Sections and Service B. Design Pressure, psig C. Design Fluid Temperature, F D. Corrosion Allowance, Tubes E. Corrosion Allowance, Fittings F. Stress Relieve G. Weld Inspection Requirements - X-Ray or Other H. Tube Material (ASTM Spec. & Grade) I. Plug Type Headers 1. Material (ASTM Spec. & Grade) 2. Location 3. Welded or Rolled J. Return Bends 1. Material (ASTM Spec. & Grade) 2. Location H. Terminals 1. Material (ASTM Spec. & Grade) 2. Location L. Crossovers 1. Welded or Flanged 2. Pipe Material (ASTM Spec. & Grade) M. Creep Value at Operating Temperature N. Weld Inspection & Hydrostatic Testing

V.

88

O. Coil Configuration

VI.

INSTRUMENTATION, CONTROLS, AND SHUTDOWNS A. Flame Failure Device B. Manual Emergency Shutdown C. Low Fuel Gas Pressure Shutdown D. High Fluid Temperature Shutdown E. Low Fluid Flow Shutdown F. High Fluid Flow Shutdown G. High Stack Temperature Shutdown H. Thermowells and Pressure Gauges on Inlet and Outlet Passes I. Check Valve on Outlet of Header J. Individual Pass Flow Measurement and Valves for Flow Control Required K. Stack Damper and Control L. Low Instrument Air Pressure Shutdown M. Fluid Temperature Control N. Ignition System O. Flue Gas Monitoring P. Combustion Controls Q. Other Special Controls

VII.

SPECIAL CONSIDERATIONS A. Acoustic Design Requirements B. Proper Spacing from Process and Storage Areas

89

C. Air Emission Requirements Guarantees D. Number of Drawings and Manufacturers Data E. Access Doors, Platforms and Ladders F. Painting G. Drainage H. Delivery. I. Inspection Ports. L Waste Heat Diverter/By-Pass K. Minimum Stack Height L. Structural

90

PART II SECTION 15 - COOLING TOWERS

Plant. Location Type I. GENERAL A. Type B. Arrangement C. Packaged or Field Erected D. Minimum Cells E. Plot and/or Weight Limitations F. Electrical Area Classifications G. Basin or Support H. Plot Orientation I. Industry Code Requirements

Date

II.

DESIGN CONDITIONS A. Flow Rate

B. Hot Water Temperature

C. Cold Water Temperature D. Ambient Wet Bulb Temperature E. Project Elevation F. Wind Velocity and Prevailing Direction

III.

DESIGN CONSIDERATIONS A. Structural Design Loads 1. Wind 2. Snow 3. Live 4. Seismic 91

B. Unusual Contaminants

1. Air 2. Water C. Design Restrictions 1. Maximum Drift Loss 2. Materials 3. Maximum Allowable Fan Tip Speed 4. Minimum Fan Stack Height 5. Noise Limitations 6. Type of Fan Driver 7. Winterization Requirements 8. Water Connections, Size and Number D. Economic Evaluation Configuration

IV.

MATERIALS A. Lumber 1. Species 2. Treatment

B.

C. D. E. F. G. H. I. J. K. L. V.

3. Lumber Code Hardware 1. Fasteners 2. Castings 3. Coating 4. Nails Casing Frame Fill Louvers Mechanical Equipment Support Stairways and Ladders Hot Water Distribution System Fan Stacks Drift Eliminators Fan Deck

MECHANICAL EQUIPMENT A. Fan Driver 1. Type 2. Vibration Control 3. Variable/Dual/Reversible Speed 92

B. Fan Design Noise Limitations C. D. E. F. Speed Reducers Driveshaft Assembly Handling Equipment Pump 1. Type 2. Pumping Head (Measured Above Basin Curb) 3. 4. Arrangement Sump and Trash Screens

5. Type of Pump Driver G. Water Treating 1. Type Make Up Water (Analysis) 2. 3. 4. 5. 6. 7. Quantity of Make Up Water Cycles of Concentration Chlorinator Acid Softener/RO Filters

H. Electrical 1. Wiring and Controls

2. 3. 4.

Type of Enclosures Power Capacity Power Characteristics (Volts, Hertz, Phase)

I. Fire Protection

93

VI.

INSTRUMENTS AND CONTROLS A. Fans B. Pumps C. Water Make-Up Controls D. Chemical Treatment E. Water Temperature

VII. SPECIAL CONSIDERATIONS A. Delivery. B. Performance Guarantee 1. Performance Curves 2. 3. Field Test and Cost Basis of Settlement

C. Documents 1. Drawings 2. Operating and Maintenance Manuals

3.

Spare Parts Lists

4.

Certified Lumber Treatment

D. Governmental Codes and Regulations

E. Water Disposal

94

PART II SECTION 16 - WELDED FABRICATION AND TESTING

Plant Location Type I. GENERAL AND DESIGN A. Applicable Codes and Standards B. Jurisdictional Regulations C. Metallurgical Considerations 1. 2. 3. 4. 5. Low Temperature Service Corrosive Service High Temperature Service Physical Properties Chemical Properties

Date

D. Operating Conditions E. Dimensional Tolerances F. Weld Repairs G. Branch Connections H. Material Protection from Damage and Environment 1. Welding Materials 2. Fabricated Pieces

II.

SAFETY PRECAUTIONS

95

HI.

WELD PROCEDURES A. Code Welding Procedure Specification

B. Code Procedure Qualification Record

C. Weld Variables 1. Process 2. Joint (Groove) Design 3. 4. 5. 6. 7. 8. 9. Base Metal Plate or Pipe Thickness Tolerances Electrode Selection Filler Metal Size or Rate of Deposit Weld Deposit Composition Positions

10. Ambient Conditions Suitable for Welding 11. Preheat 12. Post Weld Treatment 13. Shielding Gas/Electrode Coating/Flux 14. Electrical Characteristics 15. Welder Techniques 16. Line-Up Clamps/Back-Up Rings 17. Pipe Diameter Range 18. Heat Input

96

D. Supplemental Test

1.

Charpy V-Notch

IV.

WELDER QUALIFICATION A. Record of Performance Qualification Tests

B. Welding Performance Variable 1. 2. 3. 4. 5. 6. 7. 8. Welding Process Pipe or Plate Thickness and Size Joint Design Filler Metal Position Shield Gas Electrical Characteristics Technique (Uphill or Downhill)

C. Welder Identification D. Frequency of Qualification Tests E. Qualification Test Code Reference

V.

INSPECTION AND TESTS A. Welding 1. Visual 2. Mechanical 3. Radiographic a. Full b. Random 4. Ultrasonic 5. Hardness 97

6. Magnaflux 7. Dye Penetrant (PT) Testing. B. Pressure Testing 1. Hydrostatic 2. Pneumatic 3. Required Holding Time 4. Are Charts Required

98

PART II SECTION 17A - LIQUID PRODUCT CUSTODY TRANSFER

Plant Location Type I. GENERAL A. Applicable Codes/Standards/Specifications

Date

B. Area Electrical Classification 1. Heater 2. Flow Computer 3. Building C. Is Electric Power Required D. Is Skid Mounting Required E. Weather Proofing Required F. Type of Measurement, Mass or Volumetric G. Calculation Procedure H. Point of Delivery/Custody Transfer

I. Delivery Period J. Party Operating and Maintaining Metering Facilities

K. Source of Physical Data L. Method of Settlement Upon Failure of Equipment Meter/Sampler M. Is Flow Continuous or Batch N. Product Specifications

O. Correction of Errors

99

P. Insulation Requirements Q. Painting Requirements R. P & I D S. Mechanical/Electrical Drawings

II.

METERS A. Type of Meter B. Flow Range Min./Norm./Max C. Type of Fluid Metered-Lubrication Qualities

D. Is Ticket Printer Required E. Is Remote Transmission Required F. Maximum and Normal Operating Pressure G. Maximum Allowable Pressure Drop H. Vapor Pressure of Fluid I. Viscosity and Gravity of Fluid J. Maximum and Normal Fluid Temperature K. Back Pressure Required to Meter Fluid at Maximum Temperature L. Corrosiveness of Fluid M. Will Meter Accept Mechanical or Electronic Connection for Prover N. Will Flow Computer Drive a Continuous Sampler O. Will Type of Product Pump Affect Meter Selection R Is a Spare or Check Meter Required Q. R. S. T. U. V. W. Break in Time for New/Refurbished Meter ANSI Flange Rating/Face Battery Powered Totalizer Required Design for Capacity Increase/Decrease Flow Computer Printer Meter Tube and Meter Certification 100

Ill.

PROVERS A Type of Prover

B. C. D. E. F.

Is Prover Stationary or Portable Maximum Working Pressure Frequency of Calibration Test/Number of Tests Per Calibration Maximum Meter Factor Deviation/Proving Repeatability Allowed List Parties That are to Witness Calibrations

G. Type of Portable Prover Fluid Connections H. Method for Disposal of Fluid in Prover I. Is Contract Prover Company Acceptable to all Parties J. Method of Cleaning Portable Provers for Next Calibration K. Block and Bleed Requirements L. Prover Certification.

IV.

SAMPLING AND ANALYSIS A. Type of Sampler (i.e. Automatic) B. Frequency of Sampling or Sampler Transfer (Time, Flow Gate) C. Number and Volume of Samples Required D. Continuous or Spot Sampling E. Will Sampler Take Sample at Stream Conditions E Sampling Rate (Proportional to Flow) G. Type of Analysis H. Laboratory to be Used for Analysis I. Components Required From Analysis J. How Should Analysis be Reported (Mol%, Liquid Volume %, Weight %, etc.) K. Maximum Time for Reporting Analysis L. Maximum Deviation Allowed for Check Samples

101

M. Who Pays for Analysis Costs N. Period Referee Sample to be Retained O. Sampler Equipped to Prevent Product Vaporization P. Mixing Device Q. Sampling Method (i.e., GPA 2174) R. Analysis Requirements (i.e. GPA 2177) S. Sample Cylinders/Carrying Case(s) T. Scoops U. On-Line Chromatograph Vs. Sampler

V.

DENSITOMETERS AND GRAVITOMETERS A. Type of Instrument B. Continuous or Spot Reading C. Recording or Indicating D. E. F. G. H. Does Instrument Measure at Stream Temperature and Pressure Maximum Deviation Allowed Frequency of Calibration Are Separate Connections Required for Densitometer Checks/Calibration? Are Single or Dual (in/out) Thermowells Required on Desitometer Check Piping?

I. Restricting Orifice in Main Piping Parallel with Densitometer Check Piping?

VI.

ACCESSORY EQUIPMENT A. Is Temperature Recorder Required B. Is Pressure Recorder Required C. Back Pressure Valve Required D. Strainer or Filter Required E. Thermowells and Pressure Taps Required F. Is a Meter By-Pass Allowed G. Is Chemical Injection Required

102

H. Is Automatic Temperature Compensation Permitted I. Battery Powered Backup System J. Meter Building 1. Purged, HVAC 2. Back Up Power Supply (UPS) 3. Communications (Phone Line, Radio, Satellite, etc.)

K. Meter Building Heating, Air Conditioning, Lighting

L. Insulating Flanges and Other Insulating Devices M. Thermal Relief Devices N. Flow Computer 1. No. Analog Input 2. Storage Capacity 3. Battery Back Up 4. Communication Format 5. DI/DO Required

103

PART H SECTION 17B - GAS CUSTODY TRANSFER

Plant Location Type I. GENERAL A. Applicable Codes/Standards/Specifications

Date

1. 2. 3.

Meter Piping Electrical

B. Electrical Area Classification 1. Electronic Devices 2. Analyzers 3. Building 4. Communications Devices 5. Control Devices 6. External C. Is Electric Power Required D. Is Skid Mounting Required E. Calculation Procedure/Method F. Point of Delivery/Custody Transfer

G. Delivery Period H. Party Operating/Maintaining/Calibratingthe Metering Facilities I. Source of Physical Data J. Method of Settlement Upon Failure of Equipment Meter Recorder/Flow Computer, Analyzer, Sampler Plate

K. Gas Specifications 1. Delivery Pressure and Temperature Range 2. Gas Gravity/BTU Limitation/Dew Point

3.

ContaminantLimitations: H2S, Inert, Water

104

L. Correction of Errors M. Temperature and Pressure Basis for Measurement N. Barometric Pressure Determination O. Calibration/Test Frequency

I.

METER RECORDER A. Dry Flow Meter 1. 2. 3. 4. 5. Type of Chart: Square Root or Direct Read Recorded Conditions Static Pressure, Temperature, Differential Pressure Frequency of Chart Rotation (Programmable Clocks) Elevation of Recorder with Respect to Meter Run Flow Range Requirements

B. Electronic Flow Recorder 1. 2. 3. 4. 5. Frequency of Data Collection Power Supply and Back Up Power Calculation Procedures Data Editing Applicable Standards

C. Other Recording Devices

III.

METER RUN A. Minimum Upstream and Downstream Length B. How Conditioning (Straightening Vanes) C. Type of Orifice Fittings (Simplex, Senior, Orifice Flanges)

105

D. Number and Location of Taps for Sampling and Measurement E. Smoothness Tolerances for Meter Tube F. Beta Ratio G. Permissible Diameter Range H. MultipIe Parallel Meter Runs I. Automatic Flow Range Control

IV.

SAMPLING AND ANALYSIS A. Type of Sample 1. Spot 2. Continuous Sampler (Time or Flow Gate) 3. Continuous Analysis

4. Continuous Sampling Collection: Scoops, Orifice Plate B. Type of Analysis 1. Laboratory to be Used for Analysis

2. 3. 4. 5.

Analysis Requirements: Components, Gravity, BTU Temperature and Pressure Basis for Analysis Period Referee Sample to be Retained Applicable Standards

C. Power Source (Self Contained or external) D. Sample Cylinder(s): Single Chamber, Piston Cylinder

V.

ACCESSORY EQUIPMENT A. Insulating Flanges and Other Insulating Devices

106

REFERENCES
. API Manual of Petroleum Measurement Standards (MPMS), American Petroleum Institute, Washington, D.C. a. b. c. d. e. f. g. h. i. . Chapter 1, Vocabulary Chapter 4, Proving Systems, Section 2, Conventional Pipe Provers Chapter 4, Proving Systems, Section 3, Small Volume Provers Chapter 5, Metering, Section 3, Measurement of Hydrocarbon Liquids by Turbine Meters Chapter 5, Metering, Section 4, Accessory Equipment for Liquid Meters Chapter 14, Natural Gas Fluids Measurement, Section 3, Orifice Meters Chapter 14, Natural Gas Fluids Measurement, Section 6, Continuous Density Measurement Chapter 14, Natural Gas Fluids Measurement, Section 7, Mass Measurement of Natural Gas Liquids Chapter 14, Natural Gas Fluids Measurement, Section 8, Liquified Petroleum Gas Measurement

Standards of the Gas Processors Association (GPA), Tulsa, Oklahoma: a. GPA Standard 8182, Standard for the Mass Measurement of Natural Gas Liquids b. GPA Standard 8173, Method for Converting Mass Natural Gas Liquids and Vapors to English Liquid Volumes c. GPA Standard 2145, Physical Constants for Paraffin Hydrocarbons and Other Components of Natural Gas d. GPA Standard 2174, Obtaining Liquid Hydrocarbon Samples for Analysis by Gas Chromatography e. GPA Standard 2186, Tentative Method for the Extended Analysis of Hydrocarbon Liquid Mixtures Containing Nitrogen and Carbon Dioxide by Gas Chromatography f. GPA Standard 2177, Analysis of Demethanized Hydrocarbon Liquid Mixtures Containing Nitrogen and Carbon Dioxide by Gas Chromatography g. GPA Technical Publication TP-16, Composite Pressure and Temperature Volume Correction Factor Table for Liquified Petroleum Gas (LPG) and Natural Gasoline h. GPA Technical Publication TP-17, Table of Physical Properties of Hydrocarbons for Extended Analysis of Natural Gases

107

PART H

SECTION 18 - PIPELINE CONSTRUCTION Plant Location Type. I. GENERAL A. Fluid Properties 1. Type of Fluid (Gas, Liquid, Other)
.

Date

3. 4. 5. 6.
7.

Specific Gravity Viscosity Pour Point Vapor Pressure and Temperature Composition (COz Content, HzS Content, Etc.) Water Content Corrosivity Gas Delivery Specifications (Tariff Limitations)

8. 9.

B. Volumes and Rates 1. Total Daily Volume 2. Design Rate 3. Maximum Rate 4. Minimum Rate C. Pressures 1. Operating 2. Design/MAOP 3. Maximum 4. Minimum 5. MAOP of Interconnecting Pipelines 6. Population Density (Class Location)

D. Design Codes

1. 2. 3.

ASME (ANSI) B31.8 (Gas Pipelines - DOT). ASME (ANSI) B31.4 (Liquid Pipelines - DOT) Others

108

E. Pipeline Facilities 1. Mainline - Size, Length, Material Grade, Wall Thickness, Yield Strength

2.

Lateral - Size, Length, Material Grade, Wall Thickness, Yield Strength

3. 4. 5. 6. 7. 8. 9.

Plant Connections/Future Tap Locations Block Valves and Blowdowns - Size, Location, ANSI Rating Scraper Launchers and Receivers - Size, Location, ANSI Rating Launcher/Receiver Designed for Smart Pig Scraper Bars in Side Taps Coating - Shop, Field Joint, Aboveground, Type, Thickness Coating Temperature Limitations

10. Cathodic Protection, Insulators 11. NACE Trim Valves 12. River Weighing Requirements 13. Casing Requirements (Crossing) 14. Crossing (Bore, Open Cut, Directional Drill) F. Related Facilities 1. Storage - Atmospheric, Pressure Tank, Salt Dome, Refrigerated 2. 3. 4. 5. Pumping Stations Compressor Stations Measurement Facilities (Orifice, Turbine, Rotary, Electronic, Chart) Power Service Available (Solar RTU, Battery Backup)

6. RTU Building (Permits) 7. Sampling Facilities (Chromatograph, Moisture, Oxygen, Etc.) 8. Separation Facilities (2-Phase or 3-Phase) 9. Filtering Facilities 109

10. Dehydration Facilities 11. Batching Facilities 12. Inhibiting and Cleaning Facilities (Methanol Injection) 13. Treating Facilities 14. Odorization Facilities (Storage Tank, Dike) 15. Regulation (Monitor, Relief) 16. Flow Control Facilities 17. Indirect Waterbath Heating Facilities 18. Land Requirements (Size, Location, Access, Fencing) 19. Bypass Piping 20. Isolation Valves for Blowdown G. System Operations 1. Manpower Requirements (Calibration Weekly or Monthly) 2. 3. 4. 5. 6. 7. Automation and Surveillance Safety and Personnel Training Environmental Effects Operations and Maintenance Manuals Emergency Procedures Manual Noise Abatement Requirements

H. Regulating Agencies 1. Dept. of Transportation 2. 3. 4. 5. County Highway Depts. (For Requirements in Crossing County Roads) State Highway Depts. (For Requirements in Crossing State Highways) Corps. of Engineers (For Requirements in Crossing Navigable Waterways) Levee Districts (For Requirements in Crossing Levees)
110

6.
7.

Bureau of Land Management (BLM)

BOR

8. 9. II.

US Forest Service Others

CONSTRUCTION A. Selection of Route 1. Optimum Route Survey - Aerial Photos, Tax Maps, Ownership Lists 2. Alternate Routes

3.

Topographical Survey a. Drip Locations b. Design

4. 5. 6. .

Archeological Survey Preparation of Alignment Sheets Preparation of Permit Plats Right-Of-Way Requirements a. Construction Width b. Permanent Width c. Stations, Storage d. Access Roads e.
.

Pump and Compressor Station

Right-Of-Way Acquisition a. Survey Permissions b. Legal c. Landowner Confirmation d. Tenant Identification, If Any e. Document Execution f. Recording of ROW Documents g. Prepare List of Landowner Restrictions for Owner's Inspector, Contractor

111

9.

Permits a. Public/Government Property

b.

Highways and Roads

c. d. e.

Navigable Waterways (Spoil Location TBD) Irrigation and Drainage Canals (Spoil Location TBD) Railroads

f. Levees g. State Historical Preservation h. NPDES (Hydrostatic Test Water) i. Erosion Control j. Other B. Right-of-Way Preparation 1. Stake ROW 2. Construct Gates and Fences 3. Clear ROW a. b. c. d. e. f. g. 4. 5. Cut Trees and Brush Stump Removal and Storage Off ROW Debris Kept Separate from Backfill Material Debris Disposal (Offsite Unless Landowner Permission Granted) Spoil Bank Location (Top Soil to be Returned as Top Soil) Top Soil Entire ROW or Only Ditch and Spoil Area Maintain Natural Drainage (Flue Pipes for Stream Crossing)

Provisions for Use of Explosives Silt Fence Installation

6. Strip Top Soil C. Material Delivery 1. Storage Sites Selected (Inside or Outside) 2. 3. Material/Pipe Availability Transportation of Pipe to Coating Yard 112

4.

Transportation of Materials a. Owner b. c. d. Contractor Suppliers or Other Inspection for Damage

5. 6.

Demurrage Costs Borne by Owner or Contractor

Protection from a. Theft b. Damage 7. Material Inventory by Owner 8. Owner to be Reimbursed by Contractor for and Materials not Accounted for upon Final Acceptance D. Stringing of Pipe 1. Owner's Inspectors Assigned to Project 2. 3. 4. Owner Approval of Equipment to be Used in Loading/Unloading Pipe Use of Buffers or Other Protection in Handling to Protect Coating and Bevelled Ends Allow for Livestock and Vehicle Passage

E. Trenching/Boring 1. One-Call System Notifications 2. 3. 4. Trenching and Excavation Safety Widths Specified Minimum Cover Requirements a. Normal

b. c.

Rock Swamp (Designated Wetland)

d.

Irrigated Land 113

5. 6.

Bored Crossings (Excavation Width, Bore Length) Hand Ditching Requirements (Notify Owners Prior to Construction) a. b. c. Foreign Pipelines Utility Crossing Drainage Tile

7. 8. 9.

d. Timber Shoring for Deep Trenching Double Ditch Provisions for Use of Explosives in Rock

10. Provisions for Earth Pad in Rock Trench 11. Provisions for Drainage F. Laying of Pipe 1. Pipe Joints Swabbed to Remove Dirt and Foreign Matter 2. Provisions for Keeping Pipe Clean for Drag Sections for Boring

3. 4.

Provisions for Field Bends and Induction Bends Railroad and Public Road Crossings a. Approval of Engineers or Other Authority Having Jurisdiction b. Cased Crossings Tested for Electrical Shorts

5. 6.

Adequate Slack in Trench Padded Slings for Handling Coated and Wrapped Pipe

G. Welding 1. API Standard 1104 2. 3. Welding Procedure Qualification Welder Qualification and Safety Orientation 114

H. Radiographic Inspection 1. API Standard 1104 (100% or 10%) 2. Radiographer's Certification

I. Lowering 1. Padded Slings 2. 3. Clear Ditch of Rocks and Debris Prior to Lowering Inspect for Coating Holidays

J. Cathodic Protection 1. Anodes and Rectifiers 2. Test Leads K. Backfilling 1. Repair of Any Damage to Protective Wrapper and Coating 2. Fill Material Not to Include Skids, Stumps, Trees, or Rocks 3. Hot Coating Applied Over Trench Not to Be Covered Until Enamel has Thoroughly Hardened

4. 5. 6.

Return Top Soil to Surface of Trench and Mound Loose Dirt over Trench Riprap Steep Banks Plant Seed per Landowner Requirements

L. Stream and River Crossings 1. Hydrostatically Test Before Installation 2. 3. 4. Riprap Banks to Prevent Erosion Remove Excess Earth to Prevent Interferences with Normal Flow Confh-m Conformance of Construction to Specifications and Special Requirements of Agencies Having Jurisdiction

5.

Spare Crossing Pipe

M. Testing 1. Run Scraper with Gauging Hate, Caliper Tool 115

2. 3. 4.

Test Medium and Source Test Pressure Range and Duration Monitor Test (Number of Test Sections Required)

N. Line Cleaning and Drying 1. 2. Displace Test Medium (Disposal Location, Permits) Nitrogen Drying/Dehydrated Air/Batch Pigging

3. 4.

Purging Procedures Notification of Pipeline In-Service

O. Clean-Up 1. Remove Paint Barrels, Skids, Defective Material, and Other Construction Debris 2. Remove and Dispose of Large Rocks and Stumps

3. 4. 5. 6. 7.

Restore Streams and Wetlands Compact Backfill and Smooth Ground Surfaces Suitable for Cultivation Repair Drain Tile Install Line Markers Secure Damage Releases from a. Land Owner

b. Tenant P. General 1. Include Owner Specifications a. Painting b. c. d. Protective Coating Welding Hydrostatic Testing 116

e. L g. h. i. j. k. 2.

Gas Testing Air Testing Cathodic Protection Launching and Receiving Facilities for Scraper Traps Meter Run Installations Block Valves with Vent Connections Gathering Line Drip Installations

Provide Qualified Inspectors for Every Construction Activity

3.

As-Built Drawings a. Pipelines (Weld Joint Locations, X-Ray Report) b. Facilities (OSHA PSM Requirements)

4.

Material Reports (Surplus Material)

117

PART H SECTION 19 - BUILDINGS Plant Location Date.

Type.
I. BUILDING SERVICE A. Type of Construction 1. 2. New Building Modifications to Existing Building.

B. Duration 1. Permanent 2. Temporary C. Uses 1. Office 2. Laboratory 3. Process Control 4. Warehouse 5. Maintenance Shop. 6. Personnel - Change Room/Company Holding 7. 8. Machinery (Pumps, Compressors, Etc.) Open or Closed Type Instrument and Electrical

9.

Water Treating

10. Chemical Storage 11. Measurement or Analytical Equipment

12. DCS Field Control Cabinets

13. Electrical Switchgear

14. Other

118

D. Occupied Areas (Essentially Full-Time Basis)

E. Unoccupied Areas (Part-Time or As-Needed Basis)

F. Location 1. Plant Entrance 2. 3. Inside Process Area Other

II.

GENERAL SPECIFICATIONS A. Space Requirements 1. Equipment 2. 3. 4. 5. 6. 7. Storage Work Area Walkways Stairs Personnel Areas (Washrooms, Kitchen, Break Room, Change Rooms) Number of Levels

B. Comfort Requirements 1. Cooling 2. 3. 4. 5. 6. 7. Heating Dehumidification Ventilation and Fume Removal Pressurization Sanitary Facilities Noise Abatement

119

C. Provisions for Expansion

IE.

DESIGN SPECIFICATIONS A. Foundations 1. Pier 2. 3. Slab Curtain Wall

B. Floors 1. Material 2. Floor Coverings

a. Skid Resistant b. Chemical Resistant c. Materials C. Framing 1. Type a. Self Framing b. c. 2. 3. Rigid Masonry

Wind Loading Provision for Crane

D. Walls 1. Exterior a. Material b. c. Insulation

Openings (1) Doors (2) Windows (3) Special Interior a. Framing

120

b. Covering c. Insulation d. Openings E. Roofs 1. Loading a. Live b. Dead 2. Materials a. Roof. b. Truss/Support 3. Insulation 4. Special Features a. Skylights b. Ridge Vents c. Gutters and Downspouts. F. Ceilings 1. Unfinished 2. Finished 3. Materials 4. Soundproofing G. Safety 1. Fire Protection a. Sprinklers b. Extinguishers c. Detectors/Alarms d. Deluge System 2. Fire Resistance 3. Electrical Area Classification 4. 5. Blast Proofing Chemical Eyewash and Shower Stations

H. Utilities 1. Water a. Hot. b. Cold c. Drinking Fuel

,

3. 4. 5.

Power Compressed Air Computer/Telephone/Modem Outlets/Jacks

121

6.

Other

I. LIGHTING 1. Type of Fixtures and Spacing 2. Lighting Levels

3. Emergency Lighting. J. Regulatory Requirements 1. OSHA 2. ADA 3. DOT 4. NFPA 5. Others K. Inspection Requirements 1. State 2. County 3. City 4. Other

122

PART II SECTION 20 - GRADING, DRAINAGE, AND ROADWAYS

Plant, Location Type. I. GENERAL A. Regional Topographic Map B. Plant Site Topographic Map C. Regional Aerial Survey D. Plant Site Aerial Survey E. Rainfall or Snow Data 1. Amount and Number of Days 2. Maximum Daily Rate 3. Maximum Hourly Rate 4. Critical Run-Off Rate F. Regional Stream Discharge Rate Data G. Regional Stream Water Quality Data H. Waste Water Disposal 1. Quantity 2. Subsurface Injection 3. Surface Drainage Volume I. Soil Survey 1. Bearing Capacity. 2. Soil Composition & Characteristics 3. Water Table J. Federal, State and Local Regulations 1. Water Effluent Requirements 2. Water Disposal Permits 3. Environmental Impact Studies 4. Public Relations 5. Burning Permits II. GRADING A. Clearing & Grubbing 1. Cutting 2. Removal 3. Burning 4. Grubbing Depth Requirements 5. Explosive Use

Date

123

6. 7. 8. 9.

Backfill Timber Disposition Outside Project Disposal Sites Loose Rock Removal & Disposal

B. Excavation

1. 2. 3. 4.

Topsoil Removal and Disposition Concrete Seal Slabs Dewatering Procedure & Equipment Existing Structure Protection

C. Transportation D. Deposition and Compaction 1. Fill Material Specifications 2. Fill Material Source 3. Maximum Layer Thickness 4. Compaction Requirements E. Backfill 1. Material Specifications 2. Compaction F. Final Grade Drawings

lII.

SURFACE DRAINAGE A. Drainage Pattern Drawings

B. Culvert Types

1. 2. 3. 4.

Rigid Sectional Pipe Flexible Pipe Rigid Box Mulfiplate Arch

C. Culvert Material 1. Corrugated Galvanized Steel 2. Corrugated Aluminum 124

3. Concrete 4. Clay Pipe 5. Structural Plate 6. Gasket Materials D. Bridges 1. Concrete Specifications 2. Steel Specifications 3. Wood Specifications 4. Piling Specifications 5. Static and Impact Loads 6. U.S.Coast Guard Permits for Navigable Waterway Bridges E. Construction Requirements for Culverts and Bridges 1. Excavation Details 2. 3. Bedding for Culverts Backfill Material

4. Compaction 5. Joint Material 6. Depth of Cover 7. Pipe Driving Details 8. Clean Up E Sewers 1. Storm Water 2. 3. 4. 5. Sanitary Combination Material Specification Manhole Detail

G. Open Ditches IV. SUBSURFACE DRAINAGE A. Soil Studies 1. Origin 2. 3. Soil Characteristics Subgrade Soil Classifications 125

4. 5. 6. 7. 8.

Ground Water Data Bearing Power of Soil Slope and Angle of Repose Subsurface Stabilization Soil Requirement Above Water Level

B. Construction

1. 2. 3. 4. 5. 6.

Drain Pipe Materials Perforation Detail Backfill Material Top Seal Outlet Covers Subdrainage Drawing

V.

ROADWAYS A. Detailed Drawings

B. Excavation Detail

1. 2. 3. 4. 5.

Top Soil Removal & Disposition Loose Stone Removal Fill Material Fill Layer Maximum Compaction

C. Preparation of Subgrade 1. Subgrade Material 2. Subgrade Thickness

126

3.

Lime Treating a. b. Type Lime Lime Concentration

D. Application

1. 2.

Dry Placing Slurry Placing

E. Mixing 1. First Mixing a. Curing Time b. 2. Mixing Equipment

Final Mixing a. Pulverizing b. c. Sieve Analysis Maximum Open Air Time

E Compaction 1. Maximum Time After Mixing 2. 3. 4. 5. Moisture Content Layer Thickness Rolling Minimum Curing Time

G. Base Course Sand Stabilized Material

1. 2. 3. 4.

Layer Depth Total Thickness Compaction Shell and Sand Specifications

127

5. 6. 7. 8. 9.

Proportions Liquid Limit Plasticity Index Shrinkage Applicable State Equipment and Construction Manuals

H. Base Course Cement Stabilized Material 1. Shell Grading 2. 3. 4. 5. 6. 7. 8. Material Proportioning Mixing Samples Application Rolling Evenness Tolerance Rework

I. Asphalt Concrete Road 1. Tack Cost Material 2. 3. 4. 5. 6. 7. 8. Tack Coat Concentration Time Before Top Coat Top Coat Material Binder Course Thickness Wear Course Thickness Mixing Equipment Dumping Temperature 128

9.

Compaction & Rolling

10. Samples & Testing 11. Smoothness Requirement

J.

Native Gravel & Iron Ore Gravel Roads 1. Gravel Grading 2. 3. 4. 5. 6. Delivery Layer Thickness Compaction Total Base Course Thickness Smoothness Tolerance

129

PART II SECTION 21 - SAFETY

Plant Location Type I. PLANT LAYOUT A. Equipment Location B. Normal Wind Direction C. Drainage Contour Plot

Date

D. Roads

II.

EQUIPMENT SPACING (Maintenance, Operations, and Safety) A. Heat Exchangers 1. 2. Pull Tube Bundles Remove Heads

B. Process Pumps C. Major Process Vessels 1. Changing Catalyst or Packing.

D. Compressor Areas E. Electrical Switch Racks E Office G. Control Room H. Storage Area I. Open Flame

130

III.

HEIGHT OF PIPE RACKS A. Above Walkways B. Above Vehicular Traffic Lanes

IV.

ELECTRICAL CLASSIFICATION A. Presence of Flammable Liquids with Flash Point Under 70F B. Presence of Flammable Liquids with Flash Point Over 200F Handled at Temperatures Above Flash Point

C. Class I D. Class II E. Division 1 F. Division 2

V.

FIRE PROTECTION A. Firewater System 1. Location of Firewater Storage 2. 3. 4. 5. 6. 7. 8. 9. Capacity of Firewater Storage Location of Firewater Pump Number and Capacity of Firewater Pumps Firewater Pump Pressure Type of Firewater Pump Drivers Fuel Source of Firewater Pump Drivers Actuation Source to Start Firewater Pumps Location of Firewater System Loops

10. Location of Firewater System Block Valves

131

11. Number and Location of Fire Hydrants 12. Number and Location of Monitor Nozzles 13. Capacity of Monitor Nozzles 14. Range of Monitor Nozzles 15. Monitor Nozzle Drains 16. Location of Portable Monitor Nozzles 17. Type and Location of Foam Equipment 18. Location and Storage for Fire Hose 19. Size and Length of Fire Hose 20. Type of Hose Nozzles 21. Location of Water Spray Systems 22. Density of Water Spray Systems 23. TestRecord of All Automatic Systems 24. Building Sprinkler Systems 25. Record of Pump Tests 26. Proper and Adequate Firewater System Capacity with Connections to Permit Outside Assistance

27. Fire Water Main Pump 28. Jockey Pumps 29. Fire Loop Valving and System Control 30. Emergency Pump Start Sequences
B.

Fire Extinguishers 1. Size,Type, and Location of Hand Extinguishers 132

2.

Size, Type, and Location of Wheeled Extinguishers

C. Fireproofing 1. Type of Fireproofing Material 2. 3. 4. 5. Application of Fireproofing Material List and Location of Vessels Requiring Fireproofing List and Location of Pipe Supports Requiring Fireproofing Building Stanchions Requiring Fireproofing

VI.

EMERGENCY SHUTDOWN SYSTEM A. Total Plant Shutdown 1. Plan for Shutting Down Plant Segments 2. 3. 4. 5. 6. Number and Location of Shutdown Devices Location of Inlet and Outlet Block Valves Location of Plant Bypass Valve Location of Depressuring Block Valves List of Equipment to Remain in Operation

B. Individual Shutdown Systems

1.

Compressors a. High Jacket Water Temperature b. c. d. e. f. Low Jacket Water Level Low Lube Oil Pressure Low Lube Oil Level Engine Overspeed High Discharge Gas Temperature

133

g. h. i. j. k. 1. 2.

High Bearing Temperature High Exhaust Manifold Temperature Excessive Vibration High Separator Level Force Feed Lubrication Failure Remote Safety Shutdown

Heaters a. High Stack Temperature b. c. d. e. f. g. h. i. j. k. High Process Flow Low Process Flow Low Heater Pass Process Flow Low Fuel Pressure Power Failure Instrument Air Failure Flame Failure Remote Safety Shutdown and Location Delatching Fuel Valves Snuffing Steam

3.

Pumps a. Bearing Failure b. Seal Failure

4.

Aerial Coolers - Cooling Towers a. Excessive Vibration b. Fireproofing Supports 134

C. Miscellaneous Monitors or Shutdowns 1. Minimum Metal Temperature (Cryogenic Plants)

2. 3. 4. 5. 6.

Maximum Metal Temperature Combustible Gas Monitors Fire Monitors Building Pressurization Monitors Test Record of Shutdown Valves

D. ESD Systems 1. Fail Positions 2. 3. Backup Philosophy Testing Procedures and Frequency

VII. DRAINS AND VENTS A. Sanitary Sewers B. Hydrocarbon Drain System C. Surface Drains D. Hydrocarbon Classifier Sumps E. List Relief Valves Venting to Atmosphere F. List Relief Valves Venting to Flare System G. Single or Dual Relief Valves H. Relief Valve Inlet and Outlet Block Valves with Locking Devices I. Relief Valve Testing Devices J. Weep Holes in Relief Valve Discharge K. Type and Location of Flare and Seal Arrangement

135

L. Rupture Discs M. Cryogenic Flare System

VIII. PRODUCT LOADING FACILITIES A. Type and Location B. Type of Connections C. Electrical Grounding D. Vents E. Excess Flow Valves F. Remote Shutdown Stations G. Curbs and/or Drainage H. Wheel Chocks, Truck or Rail

IX.

ACID GAS FACILITIES (OSHA 1910.1000) A. Toxic Level Monitor B. Personnel Protection Equipment C. Safety Showers

X.

COLOR CODING (OSHA 1910.144) A. Safety

B. Process Identification (Stencil or Color) 1. Lines

2. 3. 4.

Vessels Mechanical Equipment Instrumentation and Electrical

136

XI.

PERSONNEL SAFETY A. Walking-Working Surfaces (OSHA 1910.21).

B. Ladders, Stairs, and Platforms (OSHA 1910.23, 1910.24 and 1910.27)

C. Scaffolding (OSHA 1910.28) D. Noise (OSHA 1910.95) E. Personal Protective Equipment (OSHA 1910.132)

E Eye and Face Protection (OSHA 1910.133) G. Respiratory Protection (OSHA 1910.134) H. Occupational Head Protection (OSHA 1919.135) I. Machine Guarding (OSHA 1910.212)

J. Personnel Protection at Hot Surfaces

XII.

MISCELLANEOUS A. Flammable and Combustible Liquids B. Storage & Handling of LP Gas C. Chemical Handling and Storage D. Building Materials of Construction E. Type of Window Glass F. Venting of Buildings G. Posting of Instructions, Such as Loading Rack Operation, High Noise Areas, and Location of Safety Showers H. Source of Building Pressurization Air

137

I. Dikes for Storage Tanks and Heaters J. Location of Control Instruments, Control Valves, Thermometers, Pressure Gauges, and Relief Valves

K. Location of Contractors Supplies, Equipment, and Buildings

138

PART II SECTION 22 - ENVIRONMENTAL PROTECTION

Plant. Location Type I. PLANT SITE A. Selection 1. Topography and Natural Drainage 2. 3. 4. 5. 6. 7. 8. 9. Prevailing Winds Contamination Survey Proximity to Private Citizen Housing Growth Restrictions Proximity of Testing of Protected Species Natural Occurring Radioactivity Anticipated Noise Levels Archaeological Clearance

Date

10. Endangered Species Review 11. List Agencies with Control Jurisdiction: EPA, States, Region, Local, BLM, MMS, 12. Check the Site's Designation for Pollutants: Gases, Particulates, CO, 03, NOx

13. Location Factors Pertinent to NP Discharge

B. Design and Construction

1.

Site Preparation a. Soil Conservation b. c. Surface Water Protection Subsurface Water Protection

139

d. e. 2.

Air Emissions Storm Water Regulations

Plant Layout

3. 4. 5. 6.

Disposal of Waste Material Container Management/Labeling Permits - Regulatory Agency Requirements Spill Prevention Control & Countermeasures (SPCC) Plan and Assoc. Containment

II.

PLANT OPERATIONS A. Start-Up Operations 1. Training in Environmental Management Policies, Guidelines, Activities 2. 3. Start-Up Equipment Tests Start-Up Survey of Protection Equipment

4. 5. 6. 7. 8. 9.

Waste Segregation Solid Waste Handling Disposal Liquid Waste Disposal Air Emissions from Process Equipment (Glycol Dehy. etc.) Noise Control Water Discharges

10. Container Management/Labeling

Ill'.

SURFACE STORAGE A. Capacity of Storage and Containment B. SPCC Plan

140

C. Inspection D. Maintenance E. Air Emissions from Process Equipment (Glycol Dehy. etc.) F. Water Discharges G. Paint H. Protection of Migratory Birds

IV.

SUBSURFACE STORAGE A. Solution Mined Underground Storage Chambers 1. Break Through Prevention 2. 3. 4. 5. Porosity and Permeability Pressure Test Brine Disposal or Containment Safety Features

B. Mechanically Mined Underground Storage Chambers 1. Break Through Prevention 2. 3. 4. Porosity and Permeability Zones Pressure Test Safety Features

V.

SPILL PREVENTION CONTROL & COUNTERMEASURES A. Process Area B. Stormwater Drainage from Process Areas C. Marine Unloading-Loading D. Tank Car and Tank Truck Loading-Unloading E. Bulk Storage

141

F. Pump and In-Plant Process and Transfer Pipeline

G. Security
H. Surface Pits

VI.

COMBUSTION EQUIPMENT: INCINERATORS, BOILERS, OTHERS A. Proximity to Plant B. Location Regarding Prevailing Winds C. Type of Material Burned 1. Degree of Conversion & Emissions 2. Pilot Flare D. Height of Exhaust Stack E. Governmental Regulations

VII.

FLARES A. Proximity to Plant B. Location Regarding Prevailing Winds C. D. E. E Height Above Ground Below Ground Steam Line, if Available

G. Starter Equipment

H. Smokeless I. Governmental Regulations

VIII. OTHER COMBUSTION EQUIPMENT A. Proximity to Plant B. Location Regarding Prevailing Winds C. Height of Exhaust Stack D. Governmental Regulations

142

IX.

GLYCOL DEHYDRATION A. Type of Dehydration: Glycol Mol Sieve B. If Glycol, How are Vapors Collected C. Governmental Regulations HYDROCARBON FUGITIVE EMISSIONS A. P & I Diagrams B. Governmental Regulations

X.

143

PART H SECTION 23 - PRODUCT LOADING AND CONSTRUCTION

Plant Location Type I. GENERAL DESIGN CONSIDERATIONS A. Product to Be Loaded B. Volume to Be Loaded (Per Product) 1. 2. 3. 4. Daily Average Volume Maximum Rate Pressure Available

Date

Vapor Retttm a. Available b. Required C. Source of Product 1. Storage Tanks 2. UGS Wells 3. Process Rundown 4. Other D. Loading Schedule 1. 24 Hrs./Day. 2. Limited Hours a. Daylight Only b. Concurrent with Main Facility Shift c. Other

7 Days/Week

E. Equipment to be Loaded 1. Railroad Tank Cars Trucks a. Transports b. Bob-tails 3. Barges/Ships F. Loading Personnel 1. Supplied by Main Facility a. Full Time 144 2.

b. 2. 3. 4.

Concurrent with Operating Duties

Truck Driver Attended Fully Automated Other

G. Measurement 1. Transport Vessel Strapping a. Percent of Capacity b. 2. 3. 4. 5. 6. Feet/Inches of Outage

Volumetric Meters Weight Scales Storage Facility Tank Strappings Mass Other

H. Vapor Handling Systems 1. For Incoming Vessel a. Purging b. c. . Blowdown Vapor Recovery System

For Product Displacement (Loading) a. Spray Loading b. Vapor Return (1) Equalization with Facility's Tanks Vapor Space (2) Separate Vapor Recovery System (3) Other

I. Applicable Regulations/Codes/Permits/Approvals 1. Federal 2. State 145

3. County/Parish 4. Local 5. Industry 6. Other J. GPA Guidelines 1. Tentative NGL Loading Practices RB-194 2. GPA 8186 - Measurement of Liquid Hydrocarbon by Truck Scales

II.

SITE LAYOUT/DESIGN A. Size and Configuration of Available Area B. Prevailing Wind C. Adjacent Facilities (Distance/Elevations) 1. 2. 3. 4. 5. Buildings Process Vessels Heaters or Other Fired Equipment Flares Electrical a. Switch Gear b. Exposed Lines Roads Railroad Tracks Pipelines Residences

. 7. 8. 9.

10. Other D. Adjacent Physical Features and Distances 1. Streams a. Navigable b. Other 2. Gullies/Ditches 146

3. Hills 4. Scenic/Historical E. Access/Egress 1. Rail Racks a. Direction of Switch Engine Service

b.

2.

3.

Personnel Access/Egress (1) Normal (2) Emergency Docks a. Prevailing Current and/or Tides (1) Direction (2) Magnitude b. Direction of Prevailing Loaded Tow/Ship Movements c. Personnel Access/Egress (1) Normal (2) Emergency Truck Racks a. Direction of Main Road Access b. c. Direction of Loaded Truck Egress

Personnel Access/Egress (1) Normal (2) Emergency F. Soil Conditions 1. Strengths 2. Drainage 3. Expected Settlement 4. Heaving IlL RAIl. CAR LOADING FACILITY A. Type 1. Individual Island 2. Single Sided Rack 3. Dual Sided Rack 4. Multiple Track B. Size 1. Size/Class Cars to be Loaded a. Length b. Tank Height c. Dome Height

147

2.

Number of Loading Spots a. Frequency and Interval of Switches b. Car Storage Area

C. Access to Car Domes 1. Slide-Back Ramps 2. Drop Ramps 3. Overhead Walkway 4. Other D. Connections 1. Hoses 2. Arms a. Counter Balances b. Swing . Provisions for Injecting Additives E. Safety Provisions 1. Overpressure and Thermal Relief 2. 3. . Excess Flow Devices Check Valves Grounding a. Independent b. Interlocked with Product Flow c. Tank Bonding Lighting Remote Shutdown Prevention of Car/Truck Movement During Loading. Overfill a. Protection Against b. Quick Drainage of Spilled Material c. 9. Containment of Spilled Material

6. 7.
.

Fire Fighting Equipment

10. Communication System 11. Emergency/Operating Manual

148

12. Other

IV.

BARGE/SHIP DOCKS A. Draft/Length of Vessels to be Loaded B. Height (Freeboard) of Vessels C. Range of Tide/River Crests D. Number of Vessels to be Loaded E. Type of Dock 1. Slip (Double/Single) 2. 3. 4. Pier (Finger/Boss/Tee/Other) Mooring Other

F. Connections 1. Hoses 2. Arms a. Counter Balanced b. Swing 3. Provisions for Injecting Additives G. Safety Provisions 1. Overpressure and Thermal Relief. 2. 3. 4. 5. 6. 7. 8. Excess Flow Devices Check Valves Grounding-Bonding Lighting Remote Shutdown Coast Guard/Harbor Authority Spec. Requirements Communication System 149

9.

Spill Containment Equipment

10. Fire Fighting Equipment 11. Personnel Flotation Devices 12. Emergency/Operating Manual 13. Other

V.

TRUCK RACKS A. Product Distribution and Number of Spots 1. Single Product Per Spot 2. Multiple Products Per Spot
B. Orientation

1.

Location of Truck Entrance a. Security Clearance into Facility b. Driver Instructions

Location of Parking Areas a. Unloaded Waiting Area b. Loaded Waiting Area 3. Type of Drive a. Drive Through b. Loop C. Drive and Rack Surfacing 1. Concrete 2. Asphalt 3. Shell 4. Limestone 5. Other D. Provisions for Injecting Additives 1. Odorization 2. Inhibitor 3. Others E. Safety Provisions 1. Overpressure and Thermal Relief 2. 3. Excess Flow Device Check Valves 150

2.

6. 7.
.

Grounding a. Rack b. Trucks Lighting. Remote Shutdown Procedure to Prevent Truck Movement While Loading Overfill a. Protection Against b. Quick Drainage of Spilled Material c. Containment of Spilled Material

9. Communication System 10. Fire Fighting Equipment 11. Emergency/Operating Manual 12. Other 13. Regulatory and Code Requirements (Coast Guard, OSHA, NFPA Etc:) a. Permits b. Construction Approval c. Inspection

151

PART II SECTION 24 - ABOVEGROUND STORAGE & CONSTRUCTION

Plant Location

Date

Type.
I. AMBIENT TEMPERATURE STORAGE A. Capacity and Layout Design 1. Holding Time Required by Contract of Each Product 2. Size of Each Product Tenders to be Shipped 3. 4. 5. 6. Frequency of Each Product Tenders Pumping Rate of Each Product Tenders Production Rate of Each Product into Storage Number, Type and Size of Tanks for Each Product

7. 8. 9.

Dikes Required Spacing Between Tanks, Buildings, and Property Lines Site Survey

10. Grading Requirements

B. Process and Mechanical Design 1. Maximum Operating Pressure 2. Maximum Operating Temperature 3. Maximum Design Pressure

4. 5. 6. 7. 8.

Relief Valves and Vacuum Breakers Vapor Recovery and Equalizing Systems Products Product Specifications NPSH Required on Pump Out

152

9.

Grade and Thickness of: a. Heads b. Shells c. Nozzles 10. Submerge Fill Line 11. Stress Relieving Requirements 12. Corrosion Allowance 13. Cathodic Protection Requirements 14. Nozzles, Manways, and Openings 15. Stairways, Ladders, and Platforms 16. Strapping 17. Foundation 18. Grounding 19. Gauging a. Guarded Glass b. Reflex c. Remote d. Float 20. Sampling and Temperature Connections 21. High and Low Level Alarms. 22. Painting and Fireproofing Structural Supports 23. Automatic Shutoff Devices

II.

REFRIGERATED STORAGE A. Type of Storage Tank Required B. Capacity and Layout 1. Holding Time Required by Contract of Each Product 2. Size of Each Product Tenders to be Shipped 3. Frequency of Each Product Tenders

153

4. 5. 6. 7. 8. 9.

Pumping Rate of Each Product Tenders Production Rate of Each Product into Storage Number, Type and Size of Tanks for Each Product Dikes Required Spacing Between Tanks, Buildings, and Property Lines Site Survey

10. Grading Requirements C. Process and Mechanical Design 1. Maximum Operating Pressure 2. Maximum Operating Temperature 3. Maximum Design Pressure 4. Relief Valves and Vacuum Breakers 5. Vapor Recovery and Equalizing Systems

6. 7. 8. 9.

Products

Product Specifications NPSH Required on Pump Out

Grade and Thickness of: a. Heads b. Shells c. Nozzles 10. Submerge Fill Line 11. Stress Relieving Requirements 12. Corrosion Allowance

13. Cathodic Protection Requirements 14. Nozzles, Manways, and Openings 15. Stairways, Ladders, and Platforms 16. Strapping 154

17. Foundation 18. Grounding 19. Gauging a. Guarded Glass b. Reflex c. Remote d. Float 20. Sampling and Temperature Connections 21. High and Low Level Alarms 22. Painting and Fireproofing Structural Supports 23. Flare 24. Automatic Shutoff Devices D. Insulation 1. Type 2. 3. Thickness Vapor Barrier

E. Refrigeration System 1. Type Compressors 2. 3. 4. 5. 6. 7. 8.

9.

Type Refrigerant Ambient Temperature and Pressure Loading Rate Make Rate Tank Radiation and Convection Losses Refrigeration Load From Item 6 Chilled Product Temperature

Storage Temperature 10. Refrigeration Load from Cooling Product to Storage Conditions

155

11. Maximum Discharge Temperature Control Load 12. Total Refrigeration Load (7+10+11) 13. Total Number of Installed Units 14. Vaporization System to Allow Loading When Plant is Down 15. Air Fin or Water Cooling 16. Control System Ill. TESTING AND INSPECTION A. Confined Space Entry Procedure B. Isolation and Blinding Procedures C. Purging Procedure

156

PART

S E C T I O N 25 - U N D E R G R O U N D S T O R A G E AND C O N S T R U C T I O N Plant Location Type I. SOLUTION MINED CHAMBERS A. General Design Considerations 1. Products to Be Stored 2. 3. Desired Ultimate Individual Well Capacities Maximum Product Rates a. Injection b. Delivery Desired Development (Washing) Rates a. Direct b. Indirect Available Storage Site a. Size b. Configuration c. Survey Alternate or Co-Usages of Surface Area Applicable Regulations/Codes/Permits/Approvals a. Federal b. State c. County/Parish d. Local e. Offset Operators f. Other Geological Data a. Type Salt Structure b. Depth (1) Top of Cap (2) Top of Salt (3) Bottom Salt Section Geological Control Sources C. (1) Offset Storage Wells (2) Offset Oil Wells (3) Offset Water Wells (4) Published Data Date

4.

. .

157

Fresh Water Source a. During Washing b. During Operation 10. Brine Disposal/Storage a During Washing b. During Operation c. Pits (1) Permit Volume (2) Lined/Unlined (3) Leak Detection Method (4) Pumps Required Capacity Pressure d. Tanks (1) Volume (2) Lined/Unlined (3) Leak Detection Method (4) Pumps Required Capacity Pressure e. Disposal Wells (1) Permitted Injection Rate (2) Permitted Injection Pressure B. Site Layout Design 1. Wells Spacings a. Surface b. Subsurface . Property Requirements a. Offset b. Surface Ownership c. Subsurface Ownership . Existing Subsurface Facilities a. Pipelines b. Oil or Water Wells c. Relief Wells d. Monitor Wells e. Other . Existing or Proposed Surface Facilities a. Buildings b. Loading Racks c. Roads d. Rail Spurs e. Other 5. Expansion Plans 158

9.

Capacity Capacity Capacity Capacity

C. Storage Well Design 1. Number of Casing Strings Desired in Salt Section 2. Size Salt Section Strings for a. Washing. b. Product Handling Number of Surface/Conductor Strings Required a. Regulatory b. Company Policy Physical Casing String Design a. Collapse Pressures b. Internal Working Pressure c. Test Pressure d. Collar Type and Availability Cement Program Hydrostatic Test Program a. Surface/Conductor Strings b. Product String c. Salt Formation/Casing Seat

3.

4.

5. 6.

Christmas Tree Design a. Well Head + Hangers b. Outlet (Size + Working Pressure) (1) Product (2) Brine (3) Other D. Disposal Well Design 1. Flow Rate Pressure 2. Formation 3. Casing + Cement Program Requirements a. Regulatory b. Company Policy 4. Christmas Tree a. Working Pressure b. Configuration c. Material Specifications 5. Special Completion Methods Required 6. Physical Casing/Tubing Design a. Collapse Pressures b. Internal Working Pressure c. Test Pressure d. Collar Types e. Packer

.Type 159

E. Brine Storage Design 1. Capacity 2. Type 3. Physical Size 4. Leak Detection System 5. Pumping Requirements a. In (1) Rates (2) Sump + Suction Piping b. Out (1) Rates (2) Sump + Suction Piping 6. Corrosion Allowance 7. Pit Design a. Type Soil, Composition, Bearing b. c. d. Bottom and Side Slope Requirements Source and Type of Finished Surface Material Liner (1) Type and Thickness (2) Method of Installation (3) Leak Detection/Alarm e. Method of Disposal of Excess Soil

F. Fresh Water System Design 1. Rates Required a. Washing b. Operation 2. Pressures Required a. Washing. b. Operation 3. Source a. Wells b. Surface 4. Storage a. Type b. Capacity G. Safety Considerations 1. Adherence to Applicable Codes, Regulations, and Regulatory Agency Guidelines

160

Provisions to Protect for or Prevent a. Overfills (1) Brine Pressure Switches and String Weep Holes (2) Product Pressure Switches (3) Measurement System b. Overpressures (1) Well (2) Flow Lines Contingency Safety Equipment for a. Flow Line Failures b. Well Overfilling or Tubing Leaks/Breaks (1) Brine Degassing System (2) Gas Detectors

4.

5.

Fire Detection/Protection System a. Gas Detectors b. Fire Detectors c. Fusible Plugs d. Firewater Systems Cathodic Protection a. Flow Lines b. Well Strings

Mechanical Protection a. Well Heads b. Manifolds c. Pumps H. Environmental Considerations 1. Air Emissions a. Brine Degassing

6.

b.
2.

Piping VOC

Brine Handling a. Leak Containment b. Brine Piping Design

3.

Brine Pond (Pit) Solids a. Pond Cleanout Procedures

161

b. II.

Anhydride Disposal

MECHANICALLY MINED CHAMBERS

162

APPENDICES A - S P E C I F I C A T I O N C A T E G O R I E S AND C O D E S

PLANT START-UP Latest Revisions of OSHA and ERDA Regulations FOUNDATION AND S T R U C T U R A L DESIGN ASCE Guidance For the Seismic Evaluation and Design of Petrochemical Facilities ASCE Design of Anchor Bolts in Petrochemical Facilities ASCE Wind Loads on Industrial Structures - Survey of Industry Practices and Interim Guidelines ANSI/ASCE 7-88 - M i n i m u m Design Loads in Buildings and Other Structures ASTM D 1194 - Foundation Load Tests ASTM A82 - Reinforcement ASTM C39 - Compression Tests ASTM C78 - Flexure Tests ASTM C31 - Sampling and Curing ASTM D25 - Piling ASTM A7 or A373 - Anchor Bolts UNFIRED PRESSURE VESSELS ASME Boiler and Pressure Vessel Code Section VIII, Division 1, Rules for Construction of Pressure Vessels National Association of Corrosion Engineers - Standard MR-01-75 - Sulfide Stress Cracking Resistant Metallic Materials for Oil Field Equipment HEAT EXCHANGERS ASME Boiler and Pressure Vessel Code API Standard 660 - Shell and Tube Heat Exchangers for General Refinery Services API - Standard 661 - Air Cooled Heat Exchangers for General Refinery Services Standards of Tubular Exchanger Manufacturers Association Services
-

PUMPS, EXPANDERS, AND DRIVERS API - Standard 610 - Centrifugal Pumps for Refinery Services API Standard 615 - Mechanical Drive Steam Turbines for General Refinery Services Standards of the Hydraulic Institute
-

PIPING, VALVES AND FITTINGS ANSI B31.3 - Petroleum Refinery Piping ANSI B 16.5 - Steel Pipe Flanges and Flanged Fittings ANSI A40.8 - National Plumbing Code ANSI A13.1 - Scheme for the Identification of Piping Systems ASME B 16.47- Large Diameter Standards of the Hydraulic Institute API Standard 607 - Fire Test for Soft-seated Quarter Turn Valves National Association of Corrosion Engineers Standard MR-01-75 - Sulfide Stress Cracking Resistant Metallic Materials for Oil Field Equipment
-

COMPRESSORS API - Standard 617 - Centrifugal Compressors for General Refinery Services API Standard 618 - Reciprocating Compressors for General Refinery Services
-

163

INSTRUMENTS AND CONTROLS Instrument Society of American Standards API - Standard RP 500 - Recommended Practice for Classification of Locations for Electrical Installation At Petroleum Facilities API Standard RP 520 - Recommended Practice for the Design and Installation of PressureRelieving Systems in Refineries API Standard RP 550 - Manual on Installation of Refinery Ins~uments and Control Systems
-

ELECTRICAL ANSI/NFPA 70 - National Electrical Code API - Standard RP 500 - Recommended Practice for Classification of Locations for Electrical Installations at Petroleum Facilities API - Standard RP 540 - Recommended Practice for Electrical Installations in Petroleum Refineries ANSI/NFPA 497M - Manual for Classification of Gases, Vapors, and Dust for Electrical Equipment in Hazardous Classified Locations GAS FIRED TURBINES API
-

10.

Standard RP 616 - Combustion Gas Turbine for General Refinery Services

11. 12.

INSULATION PAINTING Systems and Specifications - Steel Structures Painting Council BOILERS ASME Boiler and Pressure Vessel Code

13.

14.

PROCESS HEATERS API Standard 665 - API Fired Heater Data Sheet API - Standard 530 - Recommended Practice for Calculation of Heater Tube Thickness in Petroleum Refineries API - Standard 630 - Tube and Header Dimensions for Fired Heaters for Refinery Services IRI Bulletin - Loss Prevention and Protection for Gasoline Plants (Formerly OIA Bulletin #301) NEPA 85b & 86b - National Fire Codes
-

15.

COOLING TOWERS CTI Code Tower - Standard Specifications W E L D E D FABRICATION AND TESTING ANSI/ASCE 7-88 - Minimum Design Loads in Buildings and Other Structures LIQUID P R O D U C T A N D CUSTODY TRANSFER PIPELINE CONSTRUCTION ASME DOT - Guide for Gas Transmission and Distribution Systems American Railway Engineering Associations
-

16.

17. 18.

164

19.

BUILDINGS ACI Standard 318 - Building Code Requirements for Reinforced Concrete ANSI/ASCE 7-88 - Minimum Design Loads in Buildings and Other Structures ASCE Design of Blast Resistant Buildings in Petrochemical Facilities
-

20.

GRADING, DRAINAGE, AND ROADWAYS State and Local Drains and Field Regulations SAFETY Industrial Risk Insurers BuUetin - "Loss Prevention and Protection for Gasoline Plants" (Formerly Bulletin #301) Industrial Risk Insurers Bulletin - "Minimum Spacing Standards" Industrial Risk Insurers Bulletin - "Truck Loading Rack Safety" ANSI A13.1 - Scheme for the Identification of Piping Systems API Guide for Inspection of Refinery Equipment OSHA Sections 1910.119, 1910.156, 1910-157, and 1910-158
-

21.

22.

ENVIRONMENTAL PROTECTION API - Publication - API Recommended Gas Plant Good Operating Practices for Protection of the Environment National environmental Policy Act & Land Regulations Industrial Risk Insurers Bulletin - "Loss Prevention and Protection for Gasoline Plants"(Formerly Bulletin #301) API Publication - Summary of State and Federal Pollution Control Laws and Regulations API Guide for Inspection of Refinery Equipment, API RP 525 American Association of Petroleum Geologists (Underground Waste Management and Environmental Implications) Environmental Protection Agency (Report to Congress on Hazardous Waste Disposal - June 30, 1973) (Also Report #5) OSHA 1910.95, API Guidelines on Noise (Medical Research Report No. EA 7301) Water Quality Act Amendment PL 92-500 OSHA Regulation - Section 1910.144 API Bulletin D 16 GPA RB-194 Tentative NGL Loading Practices Code of Federal Regulations (CFR) 40 CFR 261 Identification & Listing of Hazardous Waste 40 CFR 112 Requires a SPCC Plan 40 CFR 117 Clean Water Act (CWA) Requires NPDES Permit 40 CFR 1446 Regulation of Subsurface Disposal PRODUCT LOADING AND CONSTRUCTION GPA Publication RB-194 - Tentative NGL Loading Practices Industrial Risk Insurers Bulletin - "Truck Loading Rack Safety" (Formerly OLA-711) ABOVE GROUND STORAGES AND CONSTRUCTION API 650 - Welded Steel Tanks for Oil Storage

23.

4.

165

APPENDIX B - CODES, STANDARDS, AND ASSOCIATIONS American Concrete Institute Box 4754, Redford Station Detroit, Michigan 48219 American Institute of Steel Construction, Inc. 101 Park Avenue New York, New York 10017 American National Standards Institute 1430 Broadway New York, New York 10018 American Petroleum Institute 2101 L. Street, N.W. Washington, D.C. 20037 American Society of Mechanical Engineers 345 E. 47th Street New York, New York 10017 American Society for Testing and Materials 1916 Race Street Philadelphia, Pennsylvania 19103 Factory Mutual Engineering Corp. 1151 Boston-Providence Turnpike Norwood, Massachusetts 02062 Hydraulic Institute 122 E. 42nd Street New York, New York 10017 Instrument Society of America 400 Stanwix Street Pittsburgh, Pennsylvania 15222 Manufacturers of Standardization of Valve and Fittings Industry 1815 N. Fort Myer Drive Arlington, Virginia 22209 National Electric Manufacturers Association 155 E. 44th Street New York, New York 10017 National Fire Protection Assoc. 470 Atlantic Ave. Boston, Massachusetts 02110 Gas Processors Association 6526 E. 60th Street Tulsa, Oklahoma 74145 Industrial Risk Insurers 175 Wet Jackson Blvd. Chicago, Illinois 60604 Steel Structures Painting Council 4400 5th Avenue Pittsburgh, Pennsylvania 15213 Steel Tank Institute 20 North Weaker Drive Chicago, Illinois 60606 Tubular Exchanger Manufacturers Association, Inc. 331 Madison Avenue New York, New York 10017 Underwfiter's Laboratories, Inc. 207 E. Ohio Street Chicago, Illinois 60611 Cooling Tower Institute 3003 Yale Street Houston, Texas 77018 National Association of Corrosion Engineers 1440 South Creek Houston, Texas 77084

166

APPENDIX C - G O V E R N M E N T CODES & REGULATIONS - OFFSHORE

(SOURCE: API DOCUMENT RPI4C)

1.5 GOVERNMENT CODES, RULES AND REGULATIONS. Regulatory agencies have established certain requirements for the design, installation and operation of facilities on offshore production platforms. In addition to federal regulations, certain state and local regulations may be applicable. The following federal documents pertain to offshore oil and gas producing operations and should be used when applicable.
a.

Code of Federal Regulations (1) Title 30, Part 250 - Oil and Gas Sulphur Operations in the Outer Continental Shelf (2) Title 33, Chapter 1, Subpart N - Artificial Islands and Fixed Structures on the Outer Continental Shelf (3) Title 40, chapter 1, Sub-chapter D, Part 112 - Oil Pollution Prevention (4) Title 49, Part 192 - Transportation of Natural and Other Gas by Pipeline: Minimum Federal Safety Standards (5) Title 49, Part 195 - Transportation of Liquids by Pipeline National OCS Orders Notice to Lessees and Operators of all Federal Oil, Gas and Sulphur Leases in the Outer Continental Shelf.

b. c.

1.6 INDUSTRY CODES, STANDARDS AND RECOMMENDED PRACTICES. Various organizations have developed numerous standards, codes, specifications and recommended practices which have substantial accordance by government and industry. These documents are useful references for designing and installing surface safety systems on offshore production facilities. Referenced below are some of the more commonly used documents: a. American National Standards Institute (1) ANSI B31.3 - Petroleum Refinery Piping (2) ANSI B31.4 - Liquid Petroleum Transportation Piping Systems (3) ANSI B31.8 - Gas Transmission and Distribution Piping Systems (4) ANSI Z21.52 - Standards for Gas Fired Single Fire Box Boilers (5) ANSI Y32.11 - Graphical Symbols for Process Flow Diagrams (6) ANSI Z32.2.3 - Graphical Symbols for Pipe Fittings, Valves and Piping American Petroleum Institute (1) API RP 2G - Recommended Practice for Production Facilities on Offshore Structures (2) API RP 14B - Recommended Practice for Design, Installation and Operation of Subsurface Safety Valve Systems (2a) RP14C - Basic Surface Safety Systems on Offshore Production Platforms (3) API RP 500B - Recommended Practice for Classification of Areas for Electrical Installations at Drilling Rigs and Production Facilities on Land and on Marine Fixed and MobilePlatforms (4) API RP 520 - Recommended Practice for the Design and Installation of Pressure-Relieving Systems in Refineries - Part I and II (5) API RP 521 - Guide for Pressure Relief and Depressuring Systems (6) API RP 550 - Manual on Installation of Refinery Instruments and Control Systems - Part I (7) API RP 1111 - Recommended Practice for Design, Construction, Operation and Maintenance of Offshore Hydrocarbon Pipelines (8) API 6A - Specification for Wellhead Equipment 167

b.

(9) API 6D Specification for Pipeline Valves (10) API Spec 12F - Specification for Small Welded Production Tanks (11) API Spec 650 - Specification for Welded Steel Tanks for Oil Storage (12) API Spec 1104 - Specification for Welding Pipelines and Related Facilities (13) API Spec 2000 - Specification for Venting Atmospheric and Low Pressure Storage Tanks (14) API Guide for Inspection of Refinery Equipment, Chapter VI, Unfired Pressure Vessels (15) API Guide for Inspection of Refinery Equipment, Chapter IX, Fired Heaters Stacks (16) API Guide for Inspection of Refinery Equipment, Chapter XIII, Atmospheric and Low Pressure Storage Tanks (17) API Guide for inspection of Refinery Equipment, Chapter XV, Instruments and Control Equipment (18) API Guide for Inspection of Refinery Equipment, Chapter XVI, Pressure Relieving Devices
-

C.

American Society of Heating, Refrigeration and Air Conditioning Engineers (1) ASHRAE - Handbook and Product Directory, Systems Volume (2) A S H R A E - Handbook of Fundamentals American Society of Mechanical Engineers (1) ASME - Boiler and Pressure Vessel Code - Section I, Power Boilers (2) AS/vIE - Boiler and Pressure Vessel Code - Section IV, Heating Boilers (3) ASME - Boiler and Pressure Vessel Code - Section VIII, Pressure Vessels, Divisions 1 and 2 (4) ASME - Boiler and Pressure Vessel Code - Section IX, Welding Qualifications Factory Mutual Insurance Handbook of Industrial Loss Prevention, 2rid Edition, Chapter 38, Boiler Furnaces, Fuel Explosions Fire Insurance Association (1) Recommended Good Practices for Combustion Safeguards on Single Burner Boiler-Furnaces (2) Recommended Good Practices for Heat Transfer Mediums in Closed Systems Institute of Electrical and Electronic Engineers IEEE 45 - Recommended Practice for Electrical Installation on Shipboards Instrument Society of America (1) ISA-RP7.1 - Pneumatic Control Circuit Pressure Test (2) ISA-RP7.2 - Color Code for Tubing (3) ISA-RP20.1 and 20.2 - Specifications Forms for Instruments (4) ISA-RP42.1 - Nomenclature for Instrument Tubing Fittings (5) ISA-S5.1 - Instrumentation Symbols and Identification National Fire Protection Association (1) NFPA No. 70 - National Electrical Code (2) NFPA No. SPP-11A - Industrial Heating and Pressure Equipment

d.

e.

f.

g.

h.

i.

168