1、 IPS-E-PR-190This Standard is the property of Iranian Ministry of Petroleum. All rights are reserved to the owner. Neither whole nor any part of this document may be disclosed to any third party, reproduced, stored in any retrieval system or transmitted in any form or by any means without the prior
2、written consent of the Iranian Ministry of Petroleum. ENGINEERING STANDARD FOR LAYOUT AND SPACING ORIGINAL EDITION MAR. 1996 This standard specification is reviewed and updated by the relevant technical committee on June 2002. The approved modifications are included in the present issue of IPS. Mar.
3、1996 IPS-E-PR-1901CONTENTS : PAGE No. 0.INTRODUCTION3 1. SCOPE 4 2. REFERENCES4 3. DEFINITIONS AND TERMINOLOGY. 5 4. SYMBOLS AND ABBREVIATIONS. 7 5. UNITS 7 6. SOME KEY ISSUES RELATED TO LAYOUT . 7 6.1 Terrain 7 6.2 Safety and Environment. 8 6.3 Throughput 8 7. BASIC CONSIDERATIONS 8 7.1 General. 8
4、7.2 Blocking . 8 7.3 Location and Weather. 8 7.4 Prevailing Wind . 9 7.5 Layout Indication 9 7.6 Classification of Hazards . 9 8. PLANT LAYOUT. 9 8.1 Area Arrangement. 9 8.2 Roadways 10 8.3 Piperacks and Sleepers 10 8.4 Layout of Control Room and Electrical Sub-Station. 12 8.5 Fire Fighting Requirem
5、ents . 13 8.6 Building Requirements. 13 9. LAYOUT IN PROCESS UNITS. 13 9.1 General. 13 9.2 Process Requirements . 13 9.3 Safety Requirements 14 9.4 Basic Design Considerations 15 9.4.6 Erection and maintenance requirements 16 9.4 7 Operational requirements. 17 9.4.8 Economic requirements 17 9.4.9 Di
6、stances/Clearances requirements 17 9.5 Equipment Layout and Spacing. 18 9.5.1 Reactors . 18 9.5.2 Towers 18 9.5.3 Fired equipment. 19 9.5.4 Heat exchangers 19 9.5.5 Vessels and drums 20 Mar.1996 IPS-E-PR-19029.5.6 Pumps. 20 9.5.7 Compressors 20 9.5.8 Storage vessels/tanks. 21 10. LAYOUT OF PIPING. 2
7、2 10.1 General. 22 10.2 Requirements and Design Criteria 23 11. UTILITY LAYOUT AND SPACING. 23 11.1 Requirements and Design Criteria 23 11.2 Spacing 24 12. OFFSITE FACILITIES. 24 12.1 General. 24 12.2 Tank Farm 24 12.3 Loading and Unloading Facilities 24 13. FLARE. 25 14. WASTE TREATMENT FACILITIES
8、25 APPENDICES : APPENDIX A 26 TABLE A.1 NFPA CODES, STANDARDS AND RECOMMENDATIONS. 26 TABLE A.2 CODES AND STANDARDS AFFECTING MAINTENANCE REQUIREMENTS 27 TABLE A.3 OIA RECOMMENDED SPACING AT REFINERIES, CHEMICALS,PETROCHEMICALS AND GAS PLANTS FOR BUILDINGS . 28 TABLE A.4 OIA GENERAL RECOMMENDATIONS
9、FOR SPACING IN REFINERIES . 29 TABLE A.5 OIA GENERAL RECOMMENDATIONS FOR SPACING IN PETROCHEMICAL PLANTS . 30 TABLE A.6 OIA GENERAL RECOMMENDATIONS FOR SPACING IN GAS PLANTS 31 TABLE A.7 PROXIMITY OF REFRIGERATED STORAGE VESSELS TOBOUNDARIES AND OTHER FACILITIES 32 TABLE A.8 PROXIMITY OF ATMOSPHERIC
10、 STORAGE TANKS TO BOUNDARIES AND OTHER FACILITIES. 33 TABLE A-9 PROXIMITY OF ATMOSPHERIC STORAGE TANKS TO EACH OTHERS 34 TABLE A.10 PROXIMITY OF NON-REFRIGERATED PRESSURE STORAGE VESSELS/DRUMS TO BOUNDARIES AND OTHER FACILITIES. 35 Mar.1996 IPS-E-PR-19030. INTRODUCTION The Standard practice Manuals
11、titled as “Fundamental Requirements for the Project Design and Engineering“ is intended for convenience of use and a pattern of follow-up and also a guidance. These Standard Engineering Practice Manuals, also indicate the check points to be considered by the process engineers for assurance of fulfil
12、lment of prerequisitions at any stage in the implementation of process projects. It should be noted that these Iranian Petroleum Standards (IPS), as Practice Manuals do not profess to cover all stages involved in every process project, but they effect the stages that exist in general in process proj
13、ects of oil, gas and Petrochemical Industries of Iran. These preparation stages describe the following three main phases which can be distinguished in every project also all frame construction. 3.9 Pipe Rack The pipe rack is the elevated supporting structure used to convey piping between equipment.
14、This structure is also utilized for cable trays associated with electric-power distribution and for instrument tray. 3.10 Plot Plan The plot plan is the scaled plan drawing of the processing facility. 3.11 Sheathed Incombustible or Incombustible (See Table A.3) Wood frame, incombustible sheathing. 3
15、.12 Sleepers The sleepers comprise the grade-level supporting structure for piping between equipment for facilities, e.g., tank farm or other remote areas. 3.13 Tank Diameter Where tank spacing is expressed in terms of tank diameter, the following criteria governs: a) If tanks are in different servi
16、ces, or different types of tanks are used, the diameter of the tank which requires the greater spacing is used. b) If tanks are in similar services, the diameter of the largest tank is used. 3.14 Tank Spacing Is the unobstructed distance between tank shells, or between tank shells and the nearest ed
17、ge of adjacent equipment, property lines, or buildings. Mar.1996 IPS-E-PR-19073.15 Toe Wall Is a low earth, concrete, or masonery unit curb without capacity requirements for the retention of small leaks or spills. 3.16 Vessel Diameter Where vessel spacing is expressed in terms of vessel diameter, th
18、e diameter of the largest vessel is used. For spheroids, the diameter at the maximum equator is used. 3.17 Vessel Spacing Is the unobstructed distance between vessel shells or between vessel shells and nearest edge of adjacent equipment, property lines, or buildings. 4. SYMBOLS AND ABBREVIATIONS ANS
19、I = American National Standard Institute API = American Petroleum Institute ASME = American Society of Mechanical Engineers BP = Boiling Point HVAC = Heating, Ventilation and Air Conditioning IC = Incombustibles IRI = Industrial Risk Insurance LPG = Liquefied Petroleum Gas NFPA = National Fire Prote
20、ction Association OD = Outside Diameter OGP = Oil, Gas and Petrochemical OIA = Oil Insurance Association SIC = Sheathed Incombustible TEMA = Thermal Exchargers Manufacturers Association UOP = Universal Oil Products. 5. UNITS This Standard is based on International System of Units (SI), except where
21、otherwise specified. 6. SOME KEY ISSUES RELATED TO LAYOUT 6.1 Terrain 6.1.1 In the first place, considerations should be given to the physical setting. It should not automatically be assumed that it is necessary to level the site. There may instead be ways that the process can take the advantage of
22、whatever slopes are present. 6.1.2 With respect to terrain, assess should be made, whether, there is adequate space in general. Mar.1996 IPS-E-PR-1908If not, ingenuity will be required to meet such requirements as those for flares. Available space can help to govern whether the plant can be located
23、on one floor or instead occupy several stories. The physical setting shall also be considered in light of the Transportation requirements for raw materials, products, wastes and supplies. 6.2 Safety and Environment 6.2.1 Familiarization with pertinent Environmental Regulations, (Local, National and
24、International), and how they might change is essential perior to conclusion of pre-project studies. 6.2.2 Attention shall be given to the pertinent safety regulations, including health and welfare needs. Hazardous and flammable materials require special handling, which can take up layout space. 6.2.
25、3 If the process fluids are especially toxic, layout is affected by the need for close chemical sewers and other protection measures. Security requirements may require special layout design when the plant produces a high-value product. 6.2.4 If a plant site is governed by particular building, piping
26、, plumbing, electrical and other codes, these can affect plant layout. Similar governing standards and regulation in plant site affects the layout concept. 6.3 Throughput 6.3.1 It is important not only to know the initial capacity but also to have a good feel for how much the plant might be expanded
27、 in the future, as well as how likely the process technology is to be modernized. These factors indicate how much space should be left for additional equipment. 6.3.2 Multiple processing lines (trains), are often required for the plant. Pairs of trains can either be identical or be mirror images. Th
28、e former option is less expensive. But the mirror image approach is sometimes preferable for layout reasons. Two such reasons are: a) For operator access via a central aisle. b) The need that the outlet sides of two lines of equipment (pumps, for instance) point toward each other so that they can be
29、 readily hooked to one common line. 7. BASIC CONSIDERATIONS 7.1 General The plant layout shall be arranged for: a) maximization of safety; b) prevention of the spread of fire and also ease of operation; c) maintenance consistent with economical design and future expansion. 7.2 Blocking The plant sit
30、e shall be blocked in consideration of hazards attendant to plant operation in the area. All blocked areas shall be formed as square as possible by divided access roads and/or boundary lines. 7.3 Location and Weather The plant layout shall be arranged in consideration of geographic location and weat
31、her in the region Mar.1996 IPS-E-PR-1909of the site. 7.4 Prevailing Wind Where the prevailing wind is defined, the administration and service facilities and directly fired equipment, etc., shall be located windward of process Units and storage tanks, etc. 7.5 Layout Indication The basic requirements
32、 to be met in the appropriate diagram when making a piping and equipment layout are: 7.5.1 All equipment, ladders, structures, davits, trolley beams, shall be indicated. 7.5.2 All instrument shall be located and indicated. 7.5.3 All valving and handwheel orientations shall be indicated. 7.5.4 Drip f
33、unnel locations for underground drains shall be indicated. 7.5.5 All electrical switch grears, lighting pannels shall be indicated. 7.5.6 All sample systems shall be indicated 7.6 Classification of Hazards The plant layout shall be determined in consideration of classified hazardous areas, specified
34、 in following Standard Specifications: - IPS-E-EL-110 “Electrical Area Classification and Extent“; - API RP-500A “Recommended Practice for Classification of Locations for Electrical Installations in Petroleum Refineries“ 8. PLANT LAYOUT 8.1 Area Arrangement Classified blocked areas, such as process
35、areas, storage areas, utilities areas, administration and service areas, and other areas shall be arranged as follows: 1) The process area shall be located in the most convenient place for operating the process Unit. 2) The storage area shall be located as far as possible from buildings occupied by
36、personnel at the site, but should be located near the process area for ready operation of the feed stocks and product run-downs. 3) The utilities area shall be located beside the process area for ready supply of utilities. 4) Loading and unloading area shall be located on a corner of the site with c
37、apable connection to public road directly, for inland traffics. For marine transportation, the area shall be located on the seaside or riverside in the plant site. 5) The administration and service area shall be located at a safe place on the site in order to protect personnel from hazards. It shall
38、 preferably be located near the main gate alongside the main road of the plant. 6) Flare and burn pit shall be located at the end of the site with sufficient distance to prevent personnel hazard. 7) Waste water treating Unit shall be located near at the lowest point of the site so as to collect all
39、of effluent streams from the processing Unit. Mar.1996 IPS-E-PR-190108) The process Unit to which the feed stock is charged first, shall be located on the side near the feed stock tanks, to minimize the length of the feed line. 9) The process Unit from which the final product(s) is (are) withdrawn,
40、shall be located on the side near the products tanks to minimize the length of the product run-down line. 10) Process Units in which large quantities of utilities are consumed, should be preferably located on the side near the utility center. 8.2 Roadways 1) Road and access ways shall offer easy acc
41、ess for mobile equipment during construction and maintenance, fire fighting and emergency escape in a fire situation. 2) Unless otherwise specified by the Company, the defined roads shall be made as stated in IPS-E-CE-160, “Geometric Design of Roads“. 3) Access roads shall be at least 3 m from proce
42、ssing equipment between road edges to prevent vehicle collisions. 8.3 Piperacks and Sleepers 8.3.1 In general, piperack for process Units and pipe sleeps for the off-site facilities shall be considered as the principals support of the pipe way. Run pipe lines overhead should be grouped in piperacks
43、in a systematic manner. 8.3.2 Pipe rack runs oriented in the same direction shall be at consistent elevations. Pipe rack runs oriented opposite to these runs shall be at other elevations to accommodate crossing of lines at pipe racks junctions and to accommodate branch line intersections. 8.3.3 Sing
44、le level pipe racks are preferred, if more than one level is required, the distance between levels oriented in the same direction shall be adequate for maintenance but not less than 1.25 meters. 8.3.4 Minimum spacing between pipe centerlines shall be in accordance with drawings number IPS-D-PI-102,
45、“Typical Unit Arrangement and Pipeway Layout“, and IPS-D-PI-103, “Pipeline Spacing“. 8.3.5 Maximum piperack widths shall be 10 m. If widths larger than 10 m are required, the piperack shall be designed to be of two stage. Actual widths shall be 110% of the required widths or the required widths plus
46、 1m. In cases where air fin coolers are to be placed on the piperacks, the piperack widths shall be adjusted based on the length of the air coolers. 8.3.6 Avoid flat turns. When changing directions, change elevation. 8.3.7 Allow ample space for routing instrument lines and electrical conduit. Provid
47、e 25% additional space for future instrument lines and electrical conduit adjacent to that required. 8.3.8 Provide 20% additional space on the pipe rack for future piping. This space shall be continued and clear on each level for the full length of the rack. The width allocation may be split in two
48、sections but not more than two. 8.3.9 Allow a continuous clear area of 4 meters high by 4 meters wide below main racks in process Units for maintenance access ways. 8.3.10 Pipe racks outside process areas shall have the following minimum overhead refinery/plant clearances: main roadway -5 meters , a
49、ccess roads -4.5 meters, railroads -6.7 meters above top of rail. 8.3.11 Typical layout of piperack, for process plants depending on the number of process Units incorporated and the process complexities are given in Figs. 1 through 4 with reference descriptions as follow: a) “Single Rack Type“ layout, is suitable for small scale process complex consisting of two-three process Units. It is economical without requiring any large area. Mar.1996 IPS-E-PR-19011Fig. 1 b) “Comb Type“ layout shown i
