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Guidance On Practice For Plant Layout Compress
Guidance On Practice For Plant Layout Compress
GP 44-10
Applicability Group
Date 7 September 2005
GP 44-10
BP GROUP
ENGINEERING TECHNICAL PRACTICES
7 September 2005 GP 44-10
Guidance on Practice for Plant Layout
Foreword
This is the first issue of Engineering Technical Practice (ETP) BP GP 44-10. Guidance on Practice
(GP) is based on parts of heritage documents from the merged BP companies as follows:
British Petroleum
RP 44-7 Plant Layout (February 1996).
Amoco
A BD-ELO-00-E Basic Design—Equipment Layout and Spacing—Design Specification
(October 1997).
A BD-ELO-00-G Basic Design—Equipment Layout and Spacing—Guide (October 1997).
Copyright © 2005, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organization. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of Director of Engineering, BP Group, unless the
terms of such agreement or contract expressly allow.
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7 September 2005 GP 44-10
Guidance on Practice for Plant Layout
Table of Contents
Page
1. Scope .................................................................................................................................... 5
2. Normative references............................................................................................................. 5
3. Terms and definitions............................................................................................................. 6
4. Symbols and abbreviations .................................................................................................... 8
5. General.................................................................................................................................. 9
5.1. Application of this GP.................................................................................................. 9
5.2. Requirements ............................................................................................................. 9
5.3. Philosophy ................................................................................................................ 10
5.4. Maintenance access ................................................................................................. 10
5.5. Future equipment...................................................................................................... 11
6. Onsite plant/unit layout ........................................................................................................ 11
6.1. Philosophy ................................................................................................................ 11
6.2. Site infrastructure...................................................................................................... 12
6.3. Buildings ................................................................................................................... 15
7. Plot layout............................................................................................................................ 16
7.1. General..................................................................................................................... 16
7.2. Plant sections ........................................................................................................... 16
7.3. Separation distances ................................................................................................ 17
7.4. Process units enclosed within buildings .................................................................... 17
7.5. Plot drainage............................................................................................................. 17
7.6. Special fire risk areas................................................................................................ 18
7.7. Plant scale model...................................................................................................... 18
7.8. Construction considerations ...................................................................................... 18
8. Accessways and in plant roads............................................................................................ 19
8.1. Philosophy ................................................................................................................ 19
8.2. Recommended widths and clearances...................................................................... 19
8.3. Routing ..................................................................................................................... 20
8.4. Access to platforms................................................................................................... 20
9. Piping .................................................................................................................................. 20
9.1. References ............................................................................................................... 20
9.2. Routing ..................................................................................................................... 20
9.3. Minimum clearances ................................................................................................. 21
9.4. Piping supports and pipe tracks ................................................................................ 21
9.5. Pipe racks................................................................................................................. 21
9.6. Valve operation......................................................................................................... 22
9.7. Spades (blinds)......................................................................................................... 22
9.8. Sample points ........................................................................................................... 22
9.9. Battery limit isolation ................................................................................................. 22
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7 September 2005 GP 44-10
Guidance on Practice for Plant Layout
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7 September 2005 GP 44-10
Guidance on Practice for Plant Layout
1. Scope
This GP provides guidance on all aspects of the layout of process plant, associated offsite facilities,
and their equipment and structures within onshore installations. This GP is specifically applicable to
conventional ‘outdoor’ installations for processing, storing, and handling flammable or toxic fluids.
Examples include gas processing plants, refineries, chemical plants, marine loading/unloading
facilities, and field sites; offshore facilities are excluded. This GP should be used for units constructed
on site or modules fabricated offsite. This document is not retroactive, but as far as practicable, should
be applied to expansions and modifications on existing sites as well as the installation of temporary
facilities.
2. Normative references
The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to applies.
BP
GP 04-10 Guidance on Practice for Drainage Systems.
GP 04-20 Guidance on Practice for Civil Engineering.
GP 04-30 Guidance on Practice for Design of Buildings Subject to Blast Loading.
GP 12-01 Guidance on Practice for Power System Design.
GP 14-01 Guidance on Practice for Noise Control.
GIS 14-011 Guidance on Industry Standard for Noise Control.
GP 22-10 Guidance on Practice for Design of Fired Heaters to ISO 13705
(API 560).
GP 22-20 Guidance on Practice for Design of Flares (API 537).
GIS 22-201 Guidance on Industry Standard for Flares (API 537).
GP 24-10 Guidance on Practice for Fire Protection – Onshore.
GP 24-03 Guidance on Practice for Inherently Safer Design Concept Selection.
GIS 24-233 Guidance on Industry Standard for Fire Water Pumps and System Design.
GP 26-10 Guidance on Practice for Heat Exchangers.
GP 30-55 Guidance on Practice for Control Rooms.
GP 30-85 Guidance on Practice for Fire and Gas Detection.
GP 34-00 Guidance on Practice for Machinery.
GP 42-10 Guidance on Practice for Design of Process Piping (ASME B31.3).
GP 44-30 Guidance on Practice for Event Modelling and Risk Based Evaluation.
GP 44-60 Guidance on Practice for API RP 500 Area Classification.
GP 44-65 Guidance on Practice for IP 15 Area Classification.
GP 44-70 Guidance on Practice for Overpressure Protection.
GP 44-80 Guidance on Practice for Relief Disposal Systems.
GP 76-01 Guidance on Practice for HSSE in Design and Loss Prevention.
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7 September 2005 GP 44-10
Guidance on Practice for Plant Layout
For the purposes of this GP, the following terms and definitions apply:
Accessways
Paved areas for either vehicular or pedestrian access within plot limits.
Administration Area
That part of the site containing the main office buildings.
Battery Limit
The boundary of a process unit enclosing all equipment and unit limit block valves.
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Guidance on Practice for Plant Layout
Complex
A group of units, the operation of which is interlinked, e.g. a group consisting of vacuum unit,
catalytic cracker, alkylation unit, and sulphur recovery unit. On a small site, the term ‘complex’ may
refer to all the process units on the site.
Depot
A storage area of capacity less than 5 000 tonnes (5 512 tons), with no processing facilities but with
import and export facilities.
Equipment
The individual items, e.g. heat exchangers, that may make up a section.
Flammable Vapour
A general term to describe a flammable vapour or gas.
In Plant Roads
Roads serving one or more units or sections (of units) within a plot.
Module
Any assembly of equipment items and their associated piping, instrumentation, electrical equipment,
structure, and fittings, combined into a transportable subsection of a process unit or offsite facility.
The definition includes all sizes and sources of assembly, including contractor or vendor pre-
assembled units, preassembled or dressed complex equipment items, e.g. towers or fired heaters and
pipe rack units.
Occupied Building
A building is considered to be occupied if any of the following criteria are met:
Offsites
The units and equipment that are not specifically part of the processing units, but which provide a
service to the processing units. Offsites includes utilities (except within a process unit) and tankage.
Pipe Track
A grouping of unburied piping at or slightly below ground level.
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Guidance on Practice for Plant Layout
Plant
A general term to describe any one or all the units on a given site.
Plot
An area of the site where a unit e.g. refinery CDU, chemical plant, or storage terminal is located.
Section
Part of a unit, e.g. the fractionation part of a catalytic cracker.
Service Areas
Workshops, stores, fire station, laboratory, or similar buildings.
Site
The land owned by BP or for which BP is responsible (i.e. the land within the perimeter fence).
Storage Terminal
A storage area with no processing facilities, but with import and export facilities. If the storage
capacity is less than 5 000 tonnes (5 512 tons), this is classified as a depot.
Tank Compound
An area containing one or more tanks.
Unit
A main production component or plant in a refinery or chemical complex, e.g. a catalytic cracker or
acrylonitrile plant. Note that ‘unit’ is the usual term in refineries whereas ‘plant’ is the usual term in
chemical factories.
Utilities
Steam and power generation and transmission; condensate, process water, and cooling water treatment
and supply; instrument and service air supply; effluent treatment and similar services.
For the purpose of this GP, the following symbols and abbreviations apply:
BI Business interruption
PD Property Damage
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7 September 2005 GP 44-10
Guidance on Practice for Plant Layout
5. General
5.1.1. General
Layout is concerned with the spatial arrangement of the buildings and process equipment (and
its interconnections) within the plant boundaries, the location of the plant area within the site
boundaries, and the location of the site relative to the surrounding environment and residential
communities. This GP makes a clear distinction between the layout of the various plants/units
on a site and the arrangement of process vessels or equipment etc. within the plant (or plot).
5.2. Requirements
a. Projects shall undergo a risk assessment to an appropriate level of detail as defined in
GP 44-30.
1. Calculations relevant to layout or concerning potential major releases of hazardous
materials shall be made available for such a review.
2. Less stringent exceptions to or variances from requirements specified in this GP shall
be supported and documented by a risk assessment.
b. New sites shall undergo a Project Security Review (PSR).
1. A PSR should be considered for expansions, revamps, and temporary facilities.
2. A regional security adviser can be located at:
http://gbcweb.bpweb.bp.com/bpsecurity/Contacts/FindYourRSA.asp
This review ensures that security risks such as terrorist activity and vandalism are
reviewed and mitigated by competent personnel.
c. Projects shall undergo a Concept Safety Evaluation (CSE) as described in GP 24-03.
GP 24 03 shall be referenced for inherently safer design guidance.
d. Environmental considerations shall be included in the plant layout design to ensure that
projects and developments strive to achieve the corporate goal of “no damage” to the
environment. Projects shall be in compliance with HSSE in design and loss prevention in
accordance with the GP 76-01.
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Guidance on Practice for Plant Layout
5.3. Philosophy
Plant layout is particularly important at the design stage because the potential for
subsequent modification to the layout is very low. Plant layout is a major driver of
the risk that must be managed throughout the lifetime of the facility.
Plant layout shall identify and adopt the safest cost effective layout that meets the requirements
of the process design, safe operation/maintenance, and emergency action.
a. Minimum spacing within plant shall be in accordance with:
1. Clause 11 for aboveground storage tanks.
2. NFPA 58 and API Std 2510 (or equivalent European standard) for LPG.
3. EN 1473 or NFPA 59A for LNG.
4. API 2001 for fire protection in refineries.
b. Separation distances shall satisfy the following:
1. Provide minimum access clearance for emergency response actions.
2. Allow safe access for operation and emergency evacuation.
3. Provide minimum access clearance for maintenance.
4. Give an economic design.
c. PIP PNC00003 offers separation distances for common items of equipment that satisfy the
aforementioned criteria.
1. These distances should be regarded as a maximum for economic layout purposes.
2. Separation distance adjustments either way may be justifiable if a change could
materially affect the hazard or risk or if unusual access or process reasons exist.
3. Any proposal to increase these separation distances should be subject to a cost benefit
analysis.
d. Separation distances are flexible and should be judged on a hazard and risk based
approach. Whilst a quantified risk based approach may be used for location of units,
buildings etc. within a site, such an approach is, in general, considered impracticable as a
basis for equipment layout within a unit.
Variations within practicable separation distances are likely to reduce the knock-on
potential. However, risk reduction within a plot is, in general, more effectively
achieved by measures such as inspection, maintenance, and protective systems (e.g.
fire protection, shut down systems, drainage etc.).
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Guidance on Practice for Plant Layout
6.1. Philosophy
a. The site area shall be divided into plots, and if possible the plots should be rectangular.
b. The area of a plot shall be no greater than 20 000 m2 (215 278 ft2) and no side should be
greater than 200 m (656 ft).
c. A single plot may contain more than one process unit or section.
d. Irrespective of whether process units are on the same or adjacent plots, spacing
requirements outlined in this GP shall be satisfied. Spacing between process units shall
take into account the following factors:
1. Exposure to possible fire radiation.
2. Exposure to possible explosion overpressure.
3. Maintenance requirements, including unrestricted hot work, of one unit while
adjacent units are in service.
4. Business interruption potential and relative value of the units involved.
5. Prevailing wind direction.
6. Access by emergency response equipment.
7. Future expansion.
e. Plant separation should consider the following:
Plant separation distances depend on the size and congestion of the plant unit.
Typically the height and the width determine the size of the separation distance. The
key issue is to limit escalation.
1. Maximum size of flammable gas cloud from one plant area does not significantly
intrude into adjacent areas.
2. The magnitude of a gas explosion is not significantly increased by proximity of
adjacent plant units.
3. Damage caused in one area does not lead to escalation in adjacent areas.
f. If there is flow between individual units, the layout of the units should be, as far as
economical, in a logical order of flow.
The increased cost of wide spacing of process units must be weighed against the
implied safety benefits in the event of a fire or explosion.
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g. Process units with hazardous inventories shall be located to minimise the risk of any
inadvertent release of fluid to personnel within the site, and also on activities outside the
site boundary. Topography, prevailing winds, personnel safety, and nearby population
centres shall be considered in selecting the most suitable location.
Project layout philosophy should be developed at an early stage to ensure its
consideration in the safety assurance reviews. See GP 44-30 for guidance on
assessing the risk of such a release.
h. Flammable material storage should be located on separate plots from process units.
Flammable material may only be stored on a process unit plot provided all other options
for separate plot location have been ruled out, additional risk reduction measures are
incorporated, and a comprehensive risk assessment has been conducted.
Though an inherently safer design of separate plot location is recommended for
flammable material storage and process units, it is recognized it may not always be
possible. In such situation, possible risk reduction measures to consider include
storage deluge system, remote emergency shutdown (ESD), passive fire protection,
blast protection, storage vessel orientation, etc.
i. Field fabricated towers, fired heaters, etc. should be located at unit limits for construction
convenience, if practicable. Exceptions may be taken in consideration of process design or
hazard management benefits.
j. Plant layout studies/ reviews should establish credible fire scenarios and the extent of
direct flame impingement/ thermal radiation produced by the fire.
1. This should be taken into account when finalising layouts.
2. Spacing between tanks and other items of plant can be relaxed with a higher degree of
fire protection.
For example, if passive fire protection (i.e. a fire wall) is provided between two
critical product pumps then greater separation may not be required. In some cases,
appropriate fire detection backed up by a rapid fire response (whether by fixed fire
fighting systems or by manual means) can allow relaxation.
3. In all cases, criticality of plant and equipment and implications of loss for asset
damage, business interruption and reputation should be considered, as well as those
for life safety.
6.2.1. Roads
a. Site roads shall separate plots. Refer to GP 04-20 for minimum width for site roads.
b. Equipment shall be located so that site roads are not classified as a hazardous area as
defined in GP 44-60 or GP 44-65.
1. Minor site roads shall not be in an area classified as Zone 0 or 1 (Class I Division 1).
2. Any minor site road or in-plant road classified as Zone 2 (Class I Division 2) shall
have controlled access.
6.2.2. Utilities
a. Site utility services shall be grouped together in a non-hazardous area with exceptions
being utility services integral to process unit operation.
b. Site utility services should be located so that essential utility supplies can be maintained
under emergency conditions (i.e. in the event of a flammable vapour release). The
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Guidance on Practice for Plant Layout
6.2.6. Flares
a. The location, spacing, orientation, and height of flares shall be determined, for the
particular site, by a full assessment of the factors involved. The design considerations and
general principles that determine the type and location of flares, and the routes for closed
relief systems are covered in GP 22-20, 44-70, and 44-80 and GIS 22-201.
b. The following principles on siting should be applied:
1. The flare(s) should, ideally, be located as close as practicable to the process units
served, so as to allow the shortest, most direct, route(s) for the closed relief header(s),
whilst avoiding passage through special fire risk areas.
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In practice, because they are a source of thermal radiation, and a possible source of
ignition, flares are generally located remote from process facilities, storage areas,
utility areas, and service/office areas, but well inside the property line.
2. They should also be as far as practicable from public occupied areas that are, or may
be in the future, located adjacent to the site boundaries.
3. Design of the flare location shall consider thermal radiation, noise, luminosity,
potential odour, potential ground level emissions, and ignition source related to the
flare.
4. A side-wind location (relative to the prevailing wind direction) from process facilities
and similar sources of major release of flammable vapour is preferred.
5. If more than one flare is provided, the location of each shall be based on operational
requirements. The locations of all flares should be determined by any need for
independent operation or maintenance of individual flares. This may require suitable
spacing of separate flare stacks, or a tower-mounted multi-flare stack system. The
latter should have facilities for lowering the stacks separately, to ensure that
maintenance on any one flare stack can be carried out while the remaining flare stack
system remains in operation.
6. Minimum spacing of 60 m (197 ft) from aboveground facilities for elevated flares and
150 m (492 ft) for unshielded ground flares or burn-pits are suggested to provide a
preliminary estimate for a restricted access zone around the flare-tip/stack. The actual
spacing shall be that resulting from design calculations as described in GP 44-80.
A flare should be considered to be an elevated flare if the tip of the stack is 15 m
(49,2 ft) or more above local grade. This is an arbitrary distinction, but is a height
above which dispersion of smoke and/or toxic gases would begin to improve due to
wind effects, and above which shielding of a single or multiple ground flare becomes
impracticable.
6.2.8.1. Location
a. If loading and unloading racks handle bulk flammable or hazardous raw materials or
products, these facilities should, preferably, be consolidated in a single remote area on the
periphery of the site but should be at a safe distance from any offsite population.
The term 'bulk' cannot be defined precisely, but is used if loading and unloading
facilities handle a large proportion of the raw material or product for a single
integrated operation, e.g. a refinery or chemical plant.
b. This area should be clear of roads, railways, and concentrations of personnel, if any of
these are not directly associated with the loading or unloading operations.
c. The loading and unloading facilities should be downwind or crosswind from process units
and sources of ignition based on the prevailing wind. If this is impracticable, the
loading/unloading area may be placed upwind at a prudent distance deemed by a thorough
hazard analysis.
d. For large sites containing several independent plants or units, loading and unloading racks
local to individual plants may be required.
The increase of 'within-site' road and/or rail traffic inherent in such a layout must
also receive full consideration.
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Guidance on Practice for Plant Layout
e. Access from the site boundary to and from the loading and unloading racks should,
preferably, be separate from the main access to the site, and shall be located to minimise
traffic through process areas.
6.2.8.2. Layout
a. Onshore loading/unloading and transfer areas shall be located on level ground.
b. Loading/unloading areas for road transport shall have adequate space for access for filling,
parking, and manoeuvring. A drive through rack arrangement is preferred.
c. Loading/unloading areas for rail transport shall include adequate spur tracks for standing,
filling, shunting, and may require a siding for unserviceable rolling stock.
d. Loading/unloading areas for container transport (e.g. bags, drums, crates) shall have
adequate space for lifting and manoeuvring. Space may also be required for temporary
placement of multiple containers during transfer.
e. Loading/unloading areas for marine transport shall include adequate space for accessing
transfer lines, docking, and positioning.
f. For loading and unloading areas with potentially high risk to life, there shall be at least two
independent escape routes for emergency egress.
g. For additional guidance on the layout of material transfer facilities, refer to API Std 2610.
6.2.8.3. Security
Sites shall be within a restricted access perimeter fence. Admission to sites shall be through a
security checkpoint. Some buildings, e.g. amenity buildings, may need to be located outside the
fence.
Location of units on a site relative to buildings, the boundary, and surrounding
areas may be governed by local regulations and require agreement with the local
authorities. The location of buildings outside the site fence, e.g. offices, restaurants,
and clubhouses depends on the local conditions, especially security. Buildings used
by site personnel during normal daytime working hours should normally be located
within the fence to minimise the number of people leaving and entering the site.
6.3. Buildings
6.3.1. Location
a. A central control building (with or without satellite control buildings) for regulatory
control and online optimisation may be used for all units in a process complex.
Alternatively, dedicated control buildings may be required for individual process units or
for parts of the site remote from the main processing area, e.g. a main tank farm or product
loading facilities.
b. Occupied buildings shall be provided with accessways and ideally should be located in an
area classified as electrically safe.
1. Occupied buildings shall not be located in any area classified as Zone 0 or Zone 1
(Class I Division 1).
2. If it is unavoidable that an occupied building be located in an area classified as
Zone 2 (Class I Division 2), it should conform to the requirements of GP 44-65
(GP 44-60).
c. Control building shall be located away from noise sources and on prevailing upwind side
of process and ignition/open flame areas, taking into consideration location of existing
units.
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Guidance on Practice for Plant Layout
d. Control buildings shall be located to allow unobstructed emergency pedestrian escape off
the plot. The escape route shall not cross any special fire risk area (see 7.6) and should not
pass through an area containing process plant.
e. Refer to GP 04-30 for occupied buildings including occupied portable buildings such as
those used during construction, startup, commissioning, and turnarounds.
f. For further location guidance for process plant buildings, refer to API 752 or equivalent
industry standard(s).
7. Plot layout
7.1. General
The plot layout shall be an economical design to meet the process and licensors’ objective
reflecting the need for safety to life and property, and allowing adequate access for
maintenance, operation, and emergency action.
A plot may contain a process unit that can be subdivided into a number of sections.
If such sections can process flammable and/or toxic fluids and may be operated
independently (i.e. one section may be shut down with the other in commission), the
spacing between equipment shall be sufficient to permit simultaneous normal
maintenance on the shut down section. The design should consider areas required
for lifting equipment, lay-down and subsequent removal of equipment to off-plot
maintenance facilities. For additional guidance on layout methodology, refer to
AIChE “Guidelines for Facility Siting and Layout”.
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2. This does not apply to fired heaters with a common stack. It is acceptable to group
together the heaters from more than one section, provided that individual heaters can
be positively isolated from each other and any common stack.
This layout also has the advantage of collecting the permanent ignition sources
together in one part of a plot.
b. If equipment is grouped together, the arrangement should permit, if possible, the use of
common structures and maintenance equipment, e.g. a lifting beam.
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c. The location of spillage collection areas depends on the likely spillage, volatility of the
liquid and position of permanent ignition sources (i.e. the probability of ignition), and the
effect of a pool fire on the equipment. Refer to GP 22-10 for additional requirements for
fired heaters.
d. Equipment containing strong acids or alkalis, or certain toxic, or other corrosive chemicals
should be grouped together, provided this is practicable and economical. Such areas shall
be graded so that surface drainage can be segregated.
e. Equipment containing incompatible or highly reactive chemicals should be segregated,
provided this is practicable and economical. Such areas shall be graded such that surface
drainage from both areas can be isolated from one another.
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operating units, and a path between the site and the facilities should be clearly
defined.
5. The movement of construction equipment and especially operation of cranes and
lifting gear near operating units can be a hazard. Pedestrian and vehicular access
should be kept separate.
6. The layout and plant location should allow adequate access for operating,
maintenance and fire fighting to the existing and new units, and provide for escape
routes for emergency evacuation.
8.1. Philosophy
a. Accessways within each unit shall be provided for maintenance and for fire fighting from
the roads around the plot. The design of the road layout should consider the plant
complexity and the type(s) of fire-fighting appliances (i.e. fire-fighting trucks) likely to be
utilized during an emergency.
Road widths, gate widths, clearance heights, turning circles and axle loadings for
the various types of vehicles likely to be used during the hazard are items for
consideration. These could include such vehicles as fire-fighting appliance (i.e. fire-
fighting truck), heavy bulk foam and/or carbon dioxide carriers.
Roads or access over firm ground should be provided to allow fire appliances to approach
within reasonable operating distance of the hazard. Access should be kept free of
obstruction. In certain circumstances, railway lines may impede access for fire appliances.
b. Emergency vehicle access points should be reviewed, including means of gaining entry
where unattended or remotely-operated secure entry systems exist. There shall be at least
pedestrian access for fire fighting from all roads around the plot. At least two road
approaches shall be wide enough to allow access by emergency equipment to process
areas. If access is only possible from two sides, these should, wherever possible, be the
longest opposite sides. Normally accessways should be arranged in a rectangular grid
pattern so that fire fighting can take place from two opposite sides.
Detailed access requirements for fire fighting depend on the fire protection system
utilised.
c. Concrete paving shall be provided in accordance with GP 04-20.
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8.3. Routing
a. Accessways may be run longitudinally under pipe racks, provided that all relevant
clearance factors have been considered. However, this shall not apply to roads or an
accessway from a road to a unit.
b. Vehicular accessways shall be as straight as practicable and free of overhead structures
except where pipe racks, ducts, and conveyors are located, and should not cross main
drainage systems and cable trenches. Equipment shall not protrude into accessways.
c. Site-run piping and cable trays shall be installed in such a way that they do not affect
access.
d. Process equipment shall be located so that the accessways are not classified as being in
Zone 0 or 1 (Class I Division 1) areas, as determined by GP 44 65 (GP 44-60).
e. Access should take account of the clearance required by the proposed cranes or mobile
handling equipment or if there is an economic advantage in a layout which necessitates the
use of special equipment.
f. If practicable and economical, the layout shall permit unrestricted access over minor roads
and vehicular accessways for deployment of the largest crane and any other mobile
equipment required for maintenance purposes and emergency services. Overhead pipe
racks, ducts, and obstructions crossing these roads and accessways shall not interfere with
such access.
g. Where overhead pipe racks, ducts, cables, conveyors, and other obstructions cross a road
or accessway, the space available horizontally at grade shall permit access of the largest
crane as required for maintenance purposes, so that the crane can be manoeuvred to the
required position. When the crane is being used for maintenance work, it shall be possible
to raise and extend the jib to the required position without obstruction from overhead pipe
racks, cables ducts, or equipment. Minimum vertical clearances are given in Annex A.
h. Should the above requirements be considered not economical and practicable, details of the
equipment required to be removed for maintenance access shall be reviewed.
9. Piping
9.1. References
Requirements for process piping systems are covered in GP 42-10 that includes information on
layout, access, pipe clearances, and routing. Firebreak walls are referred to in GP 42-10 and
GP 04-20.
9.2. Routing
a. Within a process unit, pipe runs shall be grouped in overhead pipe racks.
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10. Equipment
10.1. Philosophy
If available, published equipment spacing tables (such as PIP PNC00003) may be used for
guidance, but should be regarded as default values subject to thorough risk and hazard
assessments. Further considerations for equipment spacing risk assessments may be found in
Guidelines for Facility Siting and Layout by CCPS an AIChE industry technology alliance.
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Guidance on Practice for Plant Layout
d. Pumps should be located and specified so that an acceptable NPSH can be obtained
without undue elevation of suction vessels or columns. Pumps in flammable or toxic
service shall not be located in pits to meet this requirement.
e. GP 34-00 specifies various pump seal arrangements that have been selected according to
the potential hazard in the event of leakage. Pumps meeting the requirements of GP 34-00
may be located adjacent to the side of overhead pipe racks, provided that access
requirements have been met.
f. Recommended distances from other items of equipment are provided in PIP PNC00003.
g. Firewalls or fire screens may be used to increase protection of adjacent or overhead
equipment, pipe racks, or structures from the effects of a pump fire, provided that access
for maintenance and fire fighting is not compromised. It is recommended that these
measures (in addition to other active and passive fire prevention/protection means) be
supported by a cost benefit analysis.
Firewalls and fire screens may impair access through the plant and increase
confinement in the event of a flammable release. These increases in risk must be
taken into consideration in any cost benefit analysis.
h. Pumps, compressors, and blowers in flammable fluid service should be located 15 m
(49 ft) or more horizontally from any part of a fired heater, or any process lines that may
operate at a temperature of 650°C (1 202°F) or greater.
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e. Process or utility lines that operate at 650°C (1 202°F) or more including transfer lines to
or from heaters, and gas turbine exhaust should be considered as permanent ignition
sources and taken account of in any risk assessment.
f. Insulation of lines above 650°C (1 202°F) should cover the lines completely, including
flanges and joints. The effect of the insulation on flange bolt temperatures should,
however, be checked, and the appropriate grade of bolting selected.
g. Surface drains shall not be located directly under a heater.
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a) At channel end:
• Longitudinal – tube length plus 3,1 m (10 ft).
• Overhead – 3,7 m (12 ft) for exchangers with centreline within 4,6 m (15 ft)
of grade.
• A clear overhead for exchangers with centreline more than 4,6 m (15 ft)
above grade.
b) At bonnet end:
• Longitudinal – 3,1 m (10 ft).
• Overhead – 3,1 m (10 ft).
2. Minimum clearances for exchangers with fixed tube sheets are the same as above,
except that longitudinal clearance may be provided at either the channel end or the
bonnet end.
3. Shell and tube exchangers shall not be stacked more than two high, except small
diameter exchangers if total height above grade/platform does not exceed 3,4 m
(11 ft).
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11.1. General
a. Layout and spacing of tanks within a tank farm shall take into consideration the following:
1. Characteristics of stored product.
2. Size of tank.
3. Maximum potential for fire radiation.
4. Boil over potential.
5. Business interruption consequences.
6. Prevailing wind direction.
7. Access of fire fighting equipment.
8. Distances from adjoining properties.
9. Future expansions.
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b. For additional guidance on the layout of storage facilities, refer to API Std 2610 and
IP 19).
c. Tankage areas should be laid out to meet the requirements of clause 6.1. Any proposal for
larger plot sizes shall be subject to BP approval.
With large storage tanks, it may not be practicable to keep within these plot sizes.
d. Bulk tanks storing hydrocarbons shall be located 76,2 m (250 ft), minimum, from any
process unit.
e. IP 15 classifies liquids as follows based on the closed-cup flash point (except for LPG):
1. Class 0 – Liquefied petroleum gas (LPG).
2. Class I – Liquids, other than Class 0, that have flash points below 21°C.
3. Class II (1) – Liquids that have flash points from 21°C up to and including 55°C,
handled below flash point.
4. Class II (2) – Liquids that have flash points from 21°C up to and including 55°C,
handled at or above flash point.
5. Class III (1) – Liquids that have flash points above 55°C up to and including 100°C,
handled below flash point.
6. Class III (2) – Liquids that have flash points above 55°C up to and including 100°C,
handled at or above flash point.
7. Unclassified – Liquids that have flash points above 100°C.
Class 0 includes other similar liquefied flammable gases. Class II and III liquids are
subdivided in accordance with the conditions under which they are handled.
Class II (1) or III (1) refers to flammable liquids in Class II or III handled or stored
at a temperature below the flash point. This is based on the maximum operating
temperature of storage. At a temperature above the flash point they fall into
Class II (2) or III (2) and shall be treated as a Class I liquid. Non-flammable liquids
shall be regarded as unclassified.
f. NFPA 497 classifies liquids as follows:
1. Class IA – Flammable liquids having flashpoints below 22,8°C (73°F) and having a
boiling point below 37,8°C (100°F).
2. Class IB – Flammable liquids having flashpoints below 22,8°C (73°F) and having a
boiling point at or above 37,8°C (100°F).
3. Class IC – Flammable liquids having flashpoints at or above 22,8°C (73°F) and below
37,8°C (100°F).
4. Class II – Combustible liquids having flashpoints at or above 37,8°C (100°F) and
below 60°C (140°F).
5. Class IIIA – Combustible liquids having flashpoints at or above 60°C (140°F) and
below 93°C (200°F).
6. Class IIIB – Combustible liquids having flashpoints at or above 93°C (200°F).
7. Unstable Liquid – A liquid that, in the pure state or as commercially produced or
transported, vigorously polymerizes, decomposes, undergoes condensation reaction,
or becomes self-reactive under conditions of shock, pressure, or temperature.
8. Stable Liquid – Any liquid not defined as unstable.
g. Tanks shall be laid out to provide access for fire fighting. There should be no more than
two rows of tanks between adjacent access roads. Tanks of diameter 40 m (131 ft) or
greater should be arranged in a single row.
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The figure of 40 m (131 ft) diameter is somewhat arbitrary. Because fire fighting is
easier with a single-row tank layout, it may be considered preferable to group tanks
slightly smaller than 40 m (131 ft) diameter in a single row.
h. Pumps associated with tankage operations shall not be located inside a bunded (diked) tank
compound, and should preferably be grouped together outside the bund (dike) provided
this is practicable and economical.
Normally, the spacing between pumps is determined by access requirements.
However, if the pumps are on critical service, and failure would result in total
shutdown of a major facility, then additional spacing or separation may be
specified. An example of this critical duty is the main oil line (MOL) pumps on an
oil-producing site, or the booster pumps on a major pipeline.
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Acceptable spacing between LPG storage vessels depends on the method of fire
protection used. Practice in this field is under development, and specialist advice
should be obtained.
b. The risk to personnel (both onsite and offsite) from thermal radiation effects (e.g. from
torch fires, flash fires, pool fires and BLEVEs) should be assessed and compared with the
appropriate criteria.
c. As guidance in the absence of formal risk calculations thermal radiation at the plot
boundary, in the event of ignition of the leakage from a single relief valve or from a fire in
a spill-containment area, should not exceed 4,7 kW/m2 (1 490 Btu/hr-ft2). The radiation
may be calculated using the method in API RP 521 and assuming that:
1. Fraction of heat liberated F = 0,3
2. Wind speed = 2 m/s (6,6 ft/s)
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Annex A
(Normative)
Guidance on clearances
A.1. General
a. Items such as the following shall not block operating aisles or maintenance access.
1. Projecting piping.
2. Valve spindles (valve wheels).
3. Instrumentation.
4. Instrument air manifolds.
5. Local panels.
6. Transducer stations.
7. Pneumatic and electrical junction boxes.
8. Grouped steam tracing supply and condensate manifolds.
b. A minimum of 1 m (3,3 ft) clear working spaces shall be maintained around equipment
that requires frequent servicing such as pumps, exchangers, control valves, instruments,
tower manways, etc. Also refer to A.3.c for more stringent minimum horizontal clearances
for specific applications.
c. Horizontal and vertical clearances shall meet or exceed those recommended by equipment
suppliers for maintenance and operations.
A.2. Vertical
A.3. Horizontal
a. Main accessway horizontal clearance for mobile equipment shall be obtained from BP but
shall not be less than:
1. 6,1 m (20 ft).
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2. 3,1 m (10 ft) if mobile equipment is to service a specific piece of process equipment
and the mobile equipment can operate “straight-in” (no turns).
b. Minimum rail siding clearance for railroads must comply with national (i.e. federal) and
local railway clearances requirements as these vary from site to site.
c. Minimum horizontal clearance to piping, equipment, and instrumentation shall be as
follows unless otherwise approved by BP:
1. 1,5 m (5 ft) for aisles at equipment and machinery.
2. 1,2 m (4 ft) for operating and maintenance areas at grade.
3. 1,2 m (4 ft) for workspace on platforms servicing the heads of shell/tube exchangers
mounted on a structure. Also refer to clause 10.5.
4. 0,9 m (3 ft) for workspace on platforms servicing manways, in addition, the centre
line of the manway should be at an elevation of 1,5 m (5 ft) from the platform.
5. 2,1 m (7 ft) for workspace around compressors, turbines, and large motors shall be
provided for operating and maintenance clearances to handle casings, rotors,
crankshafts, flywheels, etc. This minimum spacing shall be validated by the
equipment supplier and approved by BP.
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Bibliography
[2] LASTFIRE Study (Large Atmospheric Storage Tank Fire Project) "Atmospheric Storage Tank Study
for Oil and Petrochemical Industries Technical and Safety Committee Singapore" by Technica (dated
1990) (link http://hse.bpweb.bp.com/hse/default.asp?subcat=394).
[3] "Guide to Fire Protection, Detection, Suppression and Emergency Response on BP LNG facilities" by
BP Group Technology (contact Richard Coates for document status).
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