PIM-DU-5093

REFINERY PROCESS LAYOUT

This document can be downloaded from the following

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or fax (510-242-2157).

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CONTENTS

1.0 Scope ..........................................................................................................................3

2.0 Definitions ...................................................................................................................3
3.0 References ..................................................................................................................3
3.1 ......Industry Codes and Standards ............................................................................3
3.2 ......Company Specifications ...................................................................................3
4.0 General ........................................................................................................................4
5.0 Plant-to-Plant Spacing ...............................................................................................4
6.0 Access, Platforms and Ladders ................................................................................4
7.0 Roads and Paving ......................................................................................................5
8.0 Piping ..........................................................................................................................5
9.0 Buildings .....................................................................................................................6
10.0 Equipment and Instrument Access ..........................................................................6
10.1 ....Fired Heaters and Furnaces .............................................................................6
10.2 ....Heat Exchangers ..............................................................................................6
10.3 ....Pumps ..............................................................................................................6
10.4 ....Compressors and Auxiliaries ............................................................................7
10.5 ....Instrumentation .................................................................................................7
11.0 Cooling Towers ..........................................................................................................7
12.0 Storage Tanks ............................................................................................................7
13.0 Flares ...........................................................................................................................7

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1.0 SCOPE
1. This Specification provides requirements for the layout of Refinery Process Unit layout, inclu-
ding plot areas, equipment, pipe racks, piping, platforms, roads, and other miscellaneous items.
2. Refinery Process Unit layout includes equipment location, access and egress for personnel
safety, access for operations and maintenance, and provisions for operational housekeeping
and constructability.
3. Access and clearances for operation and maintenance on proprietary equipment or parts of
proprietary equipment shall be in accordance with the equipment manufacturer's standards.
4. This specification does not include:
a. Spacing and layout consideration for minimizing losses due to fire, and
b. LPG and terminals covered by API STD 2510 and STD 2610.

2.0 DEFINITIONS
For the purpose of this document, the following definitions shall apply:
Company—The Owner.
Designer—The person or organization in responsible charge of the engineering design.
Owner—Principal end user.
Purchaser—The Owner or the Owner's authorized agent.
Shall—A term which indicates that a provision is a requirement.
Should—A term which indicates that a provision is recommended as good practice but is not a
requirement.

3.0 REFERENCES
The latest edition of the following Specifications, Codes and Standards, including their references,
shall be considered an integral part of this Specification. Short titles will be used herein when
appropriate.

3.1 Industry Codes and Standards

American Petroleum Institute (API)
STD 2510 Design and Construction of Liquefied Petroleum Gas (LPG) Installations
STD 2610 Design, Construction, Operation, Maintenance and Inspection of Terminal
and Tank Facilities
RP 752 Management of Hazards Associated with Location of Process Plant Buildings
National Fire Protection Agency (NFPA)
NFPA 30 Flammable and Combustible Liquids Code
Code of Federal Regulation (CFR)
29 CFR Part 1910 Occupational Safety and Health Standards

3.2 Company Documents

Fire Protection Manual Section 1300, Layout and Spacing

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Appendix H, Building Siting Guidelines

Safety in Design Manual

4.0 GENERAL
1. Refinery Process Unit Layout shall satisfy law and statute of the prevailing Governing Authority.
2. All conflicts between the Company Specifications and the applicable codes, standards, laws
and statures shall be submitted in writing to Company for resolution.
3. Any and all exceptions to the Company Specifications shall be submitted in writing to Com-
pany for approval.
4. Refinery Process Unit layout shall satisfy the applicable requirements of Owner's Safety in
Design Manual.
5. Prevailing weather and site conditions shall be considered in the development of general plant
arrangements.
6. Plant equipment shall be located to minimize risk to the public and environmental habits.
7. The Process Unit shall be integrated within a common plant site such that independent operat-
ing and shutdown requirements for maintenance of other Process Units are not affected.
8. Facilities shall be provided for the isolation of a Process Unit when independent operation and
maintenance is required.
9. Plant and equipment layout shall provide exit routes in accordance with OSHA 29 CFR 1910
Subpart E and Owner’s Fire Protection Manual, Appendix H.
10. Layout shall permit full utilization of mobile handling equipment for construction, servicing,
and maintenance from roads through or adjacent to the Process Unit.
11. Spacing requirements shall be in accordance with the Equipment Spacing Charts located in
Owner’s Fire Protection Manual, Figures 1300-1 and 1300-2.

5.0 PLANT-TO-PLANT SPACING

1. Spacing between process units is based on the estimated hazard of one or both facilities.
2. High hazard facilities are those that meet any of the following criteria:
a. Contain flammable liquids at nominal >500 psig.
b. Contain combustible liquids heated above their flash point and at nominal >500 psig.
c. Contain LPG, butane, hydrogen, ethylene, acetylene at any pressure.
d. Contain highly reactive or toxic compounds such as hydrofluoric acid or anhydrous
ammonia.
3. Spacing between major process units shall not be less than 75 feet (23 m) between equipment
setback lines.

6.0 ACCESS, PLATFORMS AND LADDERS

1. Ladders, platforms, and handrails shall be designed in accordance with applicable Federal
Standards and Instructions of the Occupational Safety and Health Administration (OSHA).
2. Stairs shall serve as the primary access and egress to main operating levels in structures, build-
ings, and furnaces.

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3. Ladders should serve as the means of access to vessel platforms, air cooler walkways, relief
valves platforms, and all other areas not defined as main operating levels.
4. Access shall be provided where plant personnel are likely to pass through while carrying out
routine duties.
5. Stairways shall have sufficient clearance to permit unobstructed passage for plant personnel.
6. Platforms serving vertical and horizontal exchangers shall not interfere with removal of the
channel end or bundle.
7. Platforms around furnaces shall allow plant personnel unobstructed access at and around pip-
ing manifolds, instruments, and furnace appurtenances.
8. The distance between the edge of equipment and the pipe rack shall be set so that there is oper-
ator access to equipment and grade level instruments.
9. Stairs and ladders shall not obstruct access to instrumentation items.
10. Permanently installed stairs or other appropriate means of fixed access shall be provided for
electrical equipment and instrumentation not installed at grade.

7.0 ROADS AND PAVING

1. Primary (unrestricted) roads shall have a minimum of 25 feet clearance from flammable or
toxic release sources to permit the unobstructed travel of major vehicles.
2. Secondary (restricted) roads shall permit maintenance vehicles to gain access to less accessi-
ble equipment.
3. Access shall be provided as follows:
a. Under pipe racks as needed to permit crane access for routine maintenance and removal of
equipment.
b. To reactors as needed to permit catalyst transfer vehicles to reach the area near catalyst
unloading nozzles.
c. At compressors as needed to permit vehicles such as flatbed trucks to enter a dropout area
and remove components via mobile equipment or permanent handling facilities.
d. Around other equipment as required by owner.
4. Paving should extend as follows:
a. To the outside edge of the supporting column piers of such equipment as bottom oil-fired
or combustible-liquid-containing furnaces and elevated structures supporting coke drums,
etc.
b. Around catalyst-containing vessels.
c. Around groups of two or more pumps located outdoors.
d. Around compressors and their related servicing equipment (e.g., lube oil consoles).
e. Around equipment in dirty service that requires frequent turnaround maintenance
f. Around equipment handling toxic liquid.
5. Curbs required to retain spilled materials shall be at least 6 inches wide. Curb height shall be
specified to contain the required spill volume.

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8.0 PIPING
1. Where located at ground level, piping shall not obstruct maintenance, operational access, or
emergency egress/access.
2. Where crossing of walkways is unavoidable, the piping shall be provided with stiles.

9.0 BUILDINGS
1. Buildings shall be located in accordance with applicable zoning and building regulations.
2. Buildings shall be assessed for exposure of occupants to an incident in accordance API RP 752
and Owner’s Fire Protection Manual, Appendix H.
3. Where possible, buildings shall be upwind of process and flammable storage tank areas (based
on prevailing wind direction).
4. All drainage shall be directed away from buildings.

10.0 EQUIPMENT AND INSTRUMENT ACCESS

10.1 Fired Heaters and Furnaces

1. Space shall be provided for tube replacement.
2. Sufficient access and clearance shall be provided for removal of soot blowers, air pre-heaters,
burners, fans etc. and for operation of pressure relief doors.
3. Heater stacks shall be extended or heaters shall be located so that stack gases do not drift into
tall structures and columns where maintenance or operating personnel may be present.

10.2 Heat Exchangers

1. Clearance for tube bundle removal and channel or bonnet removal shall be provided.
2. Mobile access to air cooled exchangers for cooler removal/maintenance, fan motor mainte-
nance, and header box access shall be provided.
3. When possible, heat exchangers shall be located at grade and grouped.
4. Tubular heat exchangers shall not be stacked higher than 12 feet to the top unit centerline. If
locating exchangers beneath other facilities cannot be avoided, the channel shall be clear of
overhead obstructions for removal purposes.
5. Access shall be provided for exchanger cleaning and/or disassembly.

10.3 Pumps
1. Access to pump auxiliaries such as seal pots, starter button stations, motor conduit connec-
tions, etc. shall be provided.
2. Clearances for removal of pump, drivers, pump rods, impellers, and other parts shall be provided.
3. Access around and between pumps shall be provided.
4. Vertical pumps shall have appropriate overhead clearances for removal of drivers, shafts,
impellers and other parts.
5. Pumps operating at temperatures of 600°F (316°C) or higher or handling hydrocarbons above
either their flash point or auto-ignition temperature shall be located:
a. At least 40 feet (12 m) from positive sources of ignition including but not limited to fur-
naces, thermal oxidizers, and vapor recovery thermal combustion units.

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b. Five feet (1.5 m) apart minimum.

c. Ten feet (3 m) from equipment handling other flammables.
d. On the outer edge of the plot limit, outboard of columns and vessels, and with no equip-
ment installed overhead.
6. They shall not be located adjacent to critical, high value equipment, under or adjacent to over-
head fin fan coolers or under main instrumentation and electrical cable runs.

10.4 Compressors and Auxiliaries

1. Clearance shall be provided so that lube oil consoles, large castings, rotating elements, and
valves are readily accessible for maintenance.
2. Clearance and adequate lay down areas shall be provided for maintenance activity equipment
such as lifts for large compressor cylinders and pistons, casing and impellers for centrifugal
compressors, and rotors for large motors.
3. All air compressor intakes shall be located to preclude intake of contaminants.
4. Adequate space shall be provided for personnel on compressor decks and around compressor
auxiliaries.
5. Lay down areas on compressor decks shall be provided on elevated structures.

10.5 Instrumentation
1. Instrument mounting locations shall be selected with consideration of requirements for func-
tional operation and maintenance.
2. Instruments that require frequent calibration or maintenance shall be accessible from grade or
from a permanent platform.
3. Instruments including pressure gauges, dial thermometers, and gauge glasses shall be readable
from grade, platforms, or permanent ladders.
4. Instruments shall not protrude into or obstruct access ways so as to inhibit area personnel
egress.
5. Instruments shall be located to allow performance of routine services with unobstructed
access.

11.0 COOLING TOWERS

Cooling towers shall be located downwind or crosswind (based on prevailing wind direction) of
buildings, Process Units, and electrical substations and equipment.

12.0 STORAGE TANKS

1. Tank spacing and location shall comply with NFPA 30.
2. Equipment such as pumps and exchangers shall be located outside of diked storage areas.

13.0 FLARES
1. Radiation shall not exceed 500 Btu/hr/sq ft (1577.3 W/m2), excluding solar radiation, at any
location at which personnel may be continuously exposed, including proximity of plant prop-
erty lines.

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2. Flare stacks shall be located such that radiation from adjacent flares at flare tip maintenance
platform does not exceed 1100 Btu/hr/sq ft (3470.1 W/m2), excluding solar radiation.
3. Radiation at grade below flare shall not exceed 3000 Btu/hr/sq ft (9463.8 W/m2), excluding
solar radiation.

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