RP 44-7 PLANT LAYOUT

February 1996

Copyright The British Petroleum Company p.l.c.

Copyright The British Petroleum Company p.l.c.

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 organisation. None of the information contained in this document shall be disclosed outside the recipient's own organisation without the prior written permission of Manager, Standards, BP International Limited, unless the terms of such agreement or contract expressly allow.

BP GROUP RECOMMENDED PRACTICES AND SPECIFICATIONS FOR ENGINEERING Issue Date Doc. No.

February 1996

RP 44-7

Latest Amendment Date

Document Title

PLANT LAYOUT
(Replaces BP Engineering CP 3)

APPLICABILITY Regional Applicability: SCOPE AND PURPOSE

International

This Recommended Practice specifies BP general requirements for the layout of process plant, associated offsite facilities and their equipment and structures within onshore installations. It provides guidance on equipment spacing distances which would produce a cost effective safe layout design whilst maintaining operational and maintenance requirements. It also allows adjustment of any prescribed values on a risk based approach.

AMENDMENTS Amd Date Page(s) Description ___________________________________________________________________

CUSTODIAN (See Quarterly Status List for Contact)

Plant Layout
Issued by:-

Engineering Practices Group, BP International Limited, Research & Engineering Centre Chertsey Road, Sunbury-on-Thames, Middlesex, TW16 7LN, UNITED KINGDOM Tel: +44 1932 76 4067 Fax: +44 1932 76 4077 Telex: 296041

CONTENTS Section Page FOREWORD ..................................................................................................................... iii 1. INTRODUCTION........................................................................................................... 1 1.1 Scope ................................................................................................................ 1 1.2 Application of this Recommended Practice ................................................................ 1 1.3 General Philosophy.................................................................................................... 2 2. THE RISK BASED APPROACH ................................................................................. 3 3. SITE LAYOUT ............................................................................................................... 3 3.1 Introduction............................................................................................................... 3 3.2 Site Layout Philosophy .............................................................................................. 3 3.3 Concept Safety Evaluation......................................................................................... 4 3.4 Site Infrastructure...................................................................................................... 5 3.5 Site Buildings ............................................................................................................ 8 4. PLOT LAYOUT.............................................................................................................. 9 4.1 General ................................................................................................................ 9 4.2 Sections of Plant........................................................................................................ 9 4.3 Separation Distances.................................................................................................10 4.4 Process Units Enclosed Within Buildings ..................................................................10 4.5 Plot Drainage............................................................................................................10 4.6 Special Fire Risk Areas.............................................................................................11 4.7 Plant Scale Model.....................................................................................................11 4.8 Construction Considerations .....................................................................................11 5. ACCESSWAYS AND IN PLANT ROADS...................................................................12 5.1 Philosophy ...............................................................................................................12 5.2 Recommended Widths and Clearances ......................................................................12 5.3 Routing ...............................................................................................................13 5.4 Access to Platforms ..................................................................................................14 6. PIPING ...........................................................................................................................14 6.1 Pipe Routing.............................................................................................................14 6.2 Minimum Headroom.................................................................................................14 6.3 Piping Supports and Pipetracks.................................................................................14 6.4 Piperacks ...............................................................................................................15 6.5 Valve Operation .......................................................................................................15 6.6 Spades ...............................................................................................................15 6.7 Sample Points...........................................................................................................15 6.8 Isolation ...............................................................................................................16 7. EQUIPMENT.................................................................................................................16 7.1 Machinery ...............................................................................................................16 7.2 Fired Heaters and High-Temperature Lines...............................................................17

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7.3 Air-Cooled Heat Exchangers ....................................................................................18 7.4 Shell and Tube Heat Exchangers...............................................................................19 7.5 Air Intakes and Discharges .......................................................................................19 7.6 Pressure Relief Devices.............................................................................................20 8. ABOVE-GROUND BULK STORAGE AND TRANSFER AREAS............................21 8.1 General ...............................................................................................................21 8.2 Class I, II and III Liquids..........................................................................................22 8.3 Pressurised LPG Storage ..........................................................................................23 TABLE 1 ...........................................................................................................................24 SPACING OF TANKS FOR PETROLEUM STOCKS OF CLASSES I, II & III(2) 24 NOTES TO TABLE 1....................................................................................................25 APPENDIX A.....................................................................................................................26 DEFINITIONS AND ABBREVIATIONS .....................................................................26 APPENDIX B.....................................................................................................................29 LIST OF REFERENCED DOCUMENTS......................................................................29 APPENDIX C.....................................................................................................................31 PLOT LAYOUT SPACING OF EQUIPMENT..............................................................31 APPENDIX D.....................................................................................................................32 ESTIMATION OF HEAT INPUT TO EQUIPMENT ....................................................32 APPENDIX E .....................................................................................................................35 GUIDANCE ON SPECIAL FIRE RISK AREAS...........................................................35

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FOREWORD Introduction to BP Group Recommended Practices and Specifications for Engineering The Introductory Volume contains a series of documents that provide an introduction to the BP Group Recommended Practices and Specifications for Engineering (RPSEs). In particular, the 'General Foreword' sets out the philosophy of the RPSEs. Other documents in the Introductory Volume provide general guidance on using the RPSEs and background information to Engineering Standards in BP. There are also recommendations for specific definitions and requirements. Value of this Recommended Practice A study on some BP projects has indicated a significant saving in both costs and Land requirements is achievable by optimisation of the layout. This document provides a basis for achieving these potential savings without compromising maintenance, operations and safety of the plant. . Application Text in italics is Commentary. Commentary provides background information which supports the requirements of the Recommended Practice, and may discuss alternative options. It also gives guidance on the implementation of any 'Specification' or 'Approval' actions; specific actions are indicated by an asterisk (*) preceding a paragraph number. This document may refer to certain local, national or international regulations but the responsibility to ensure compliance with legislation and any other statutory requirements lies with the user. The user should adapt or supplement this document to ensure compliance for the specific application. Principal Changes from Previous Edition This edition provides guidance on the use of a risk based approach for site layout and specific separation distances for equipment separation within a plot. Feedback and Further Information Users are invited to feed back any comments and to detail experiences in the application of BP RPSE's, to assist in the process of their continuous improvement. For feedback and further information, please contact Standards Group, BP International or the Custodian. See Quarterly Status List for contacts.

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1.

INTRODUCTION 1.1 Scope This Recommended Practice specifies BP general requirements for the layout of process plant, associated offsite facilities, and their equipment and structures within onshore installations. It is specifically applicable to conventional 'outdoor' installations for processing, storing and handling flammable or toxic fluids, and should be used for units constructed on site or modules fabricated off the site.
Project costs tend to increase due to additional:(i) (ii) (iii) (iv) foundations and structural steelwork Piping Land requirements Energy requirements

Significant cost savings can therefore be achieved by minimising the plot area providing safety, operational and maintenance requirements are met.

It includes requirements for spacing between items of equipment or plants, clearances, and access for construction, operation, maintenance, safety and fire-fighting purposes. 1.2 Application of this Recommended Practice Layout is concerned both with the spatial arrangement of the process equipment (and its interconnections), the location of the plant area within the site and the location of the site relative to the surrounding environment and residential communities. This Recommended Practice 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). This document is applicable to all aspects of onshore layout, for Refineries and Petrochemical Works including:(a) Petroleum or chemical storage terminals operated by marketing organisations. Jettys. Onshore exploration and production well drilling sites for oil or gas.

(b) (c)

It is not applicable to:(d) Offshore facilities.

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1.2.1

Application to Existing Facilities This document is not retroactive but, as far as is practicable, should be applied to expansions and modifications on existing sites.

1.2.2

Local or National Requirements Where there are local statutory requirements on layout for the country in which the site is located, these must be complied with other than where this Recommended Practice is more rigorous than such statutory requirements.

1.3

General Philosophy The overall philosophy of this document is that separation distances are flexible but 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.
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.). There is unlikely to be any significant reduction on the knock-on potential by variations within practicable separation distances. Very small release scenarios e.g. small flange leaks or pump seal failures have a knockon potential of ca. 10 m. and therefore very large plot areas would result (also increasing the 'confined volume' ).

The criteria proposed for separation distance between individual items of equipment is based on access requirements (i.e. for firefighting, escape, maintenance and operation). Based on these criteria a chart of separation distances for common items of equipment has been developed. These distances should be regarded as a maximum for economic layout purposes. However, adjustments either way may be justifiable where a change could materially effect the hazard or risk or where unusual access or process reasons exist. 1.3.1 Separation Distances Separation distances shall be determined as follows:(1) To provide minimum access clearance for maintenance and firefighting allow safe access for operation and emergency evacuation To give an economic design

(2) (3)

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The separation distances given in Appendix C are considered to be sufficient to satisfy (1) (2) and (3) above. Any proposal to increase spacing should be subject to a cost benefit analysis. 2. THE RISK BASED APPROACH The risk based approach requires the consequence of events and the frequency at which they occur to be determined. The consequences of concern are either injury to personnel and/or damage to equipment. These can be calculated by relating the effect distance (i.e. thermal radiation level, overpressure, etc.) to the location of personnel or equipment. Frequencies of releases can be generally obtained using generic data. If generic data is unavailable, the frequency can be calculated using fault tree methodology. The principal steps in a risk assessment are:Identification of the hazards Evaluation of the extent of any harmful effects Consequence analysis Frequency estimation Assessment of the risks

Guidance on the above methodology and damage criteria is available in the BP Chemicals Hazard Assessment Manual. Guidance on the use of QRA and the development of risk criteria is contained in the BP Group document referenced in Appendix B.

3.

SITE LAYOUT 3.1 Introduction This Section of the Recommended Practice provides general guidance for any major development on a new or existing site. Any calculations relevant to site layout, or concerning potential major releases of hazardous material shall be made available for review. 3.2 Site Layout Philosophy The site area shall be divided into plots. The area of a plot is typically 20,000 m2 maximum and the length of a side normally not exceeding 200 m, and where possible, the plots should be rectangular. A single plot may contain more than one process unit or sections. The minimum spacing between units should apply, irrespective of whether the units are on the same or adjacent plots.

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Where there is a flow of material between individual units, the layout of the units should be, as far as economical, in a logical order of flow.
Wide spacing of units and equipment increases costs, and the expenditure must be considered against the risk associated with a fire or explosion and probable resultant damage.

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. The effect of local topographical features and prevailing winds, shall be considered in selecting the most suitable location. Separation distances from the site boundary or centres of population should be determined by a risk based approach.
The layout philosophy for a project should be developed at an early stage of the job, in time for consideration by any safety reviews. In certain circumstances, a detailed risk analysis by specialists in this type of work may be required.

Flammable Material Storage Flammable material storage, in particular storage of Class 0, I and II fluids as classified in 8.1, and any fluids more volatile, should in general be located on separate plots from process units. However, flammable material may be stored on a process unit plot provided that the risks are demonstrated to be acceptable.
It is inherently safer to keep on-plot storage to a minimum.

3.3

Concept Safety Evaluation At an initial stage in any proposed development a preliminary risk assessment (sometimes referred to as a Concept Safety Evaluation (CSE) ) should be carried out to ensure that the layout of the site (or the location of a new plot within the site) complies with national, industry or business defined criteria for personnel and economic risk. The CSE guidance on which is given in Group Safety Document GN/91/4 which is referenced in Appendix B should be carried out by a safety professional with input from the project process engineer(s). It is necessary to ensure that the level of detail of the risk assessment is appropriate to the situation considered. The CSE is used to evaluate the merits of various proposed locations in a quantitative manner. The following issues should be addressed;(a) Personnel Risk For new sites the risk levels experienced by individuals and populations in the following areas should be evaluated using a risk based approach:(i) Plant Workers and other onsite personnel, i.e. including those not directly associated with the plant e.g.. workers

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on adjacent plant and occupants of administrative, workshops and laboratory areas etc.. (ii) Construction workers and the construction area including the amenities. Offsite public i.e. those centres of population beyond the factory fence.

(iii)

(b)

For new plots within an existing operating site the incremental risk contribution from the new plot should be assessed to ensure that the risk levels of both individuals and the centres of population listed above remain acceptable. Economic Risk Business Interruption (BI) and Property Damage(PD). The CSE should further consider the implications of site layout on potential for Business Interruption and Property Damage from escalation. The following scenarios should be considered:(i) Escalation of events on the proposed unit to existing unit(s). Escalation of events on the existing unit(s) to the proposed unit.

(c)

(ii)

3.4 3.4.1

Site Infrastructure Site Roads The plots shall be separated by site roads. Major site roads shall be of minimum width 6 m and shall be not more than 400 m apart. The remaining (minor) site roads shall be of minimum width 4 m. Equipment shall be located so that the site roads are not classified as a hazardous area as defined in BP Group RP 44-6. Minor site roads shall not be in an area classified as Zone 0 or 1. Any minor site road or inplant road classified as Zone 2 shall have controlled access.

3.4.2

Utilities Except where they are an integral part of a process unit, site utility services should be grouped together in an area classified as nonhazardous. They 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 separation distance should be determined on a risk based approach such that essential utility supply functions can be maintained within an agreed reliability.

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The spacing between site utility services and process plant with the capacity to produce a major flammable vapour release (or explosion overpressure), is intended for large sites where the utilities serve more than one plant. Loss of the utilities in such a case could, therefore, affect several plants. Typical separation distances should be circa 100 m from any units with a capacity to produce a flammable vapour release.

Cables shall be routed in accordance with the requirements of BP Group RP 12-1. 3.4.3 Firewater Pumps Firewater pumps shall be sufficiently remote from processing, storage and loading areas to reduce the risk of fire or blast damage to the pumps given any protective measures (e.g. fire/blast resisting enclosure) installed. The distance should take account of the frequency and hence risk of the event causing damage. The pumping facilities shall be capable of operation during the worst case fire situation. Requirements for firewater supply and distribution are given in BP Group RP 24-1. 3.4.4 Cooling Towers The direction of the prevailing wind shall be considered in selecting the location of cooling towers. The towers shall be located to minimise any nuisance, both within and outside the site, from water blow-out, evaporation, drift and ice formation. The requirements of BS 4485 or equivalent national standard shall be met. 3.4.5 Offsite Effluent Treatment Facilities Contaminated water drainage from onsite and offsite areas will be routed to suitable treatment facilities as detailed in BP Group RP 4-1 or a particular project specification. The facilities should be located to maximise gravity flow. If flammable vapours are present, consider locating the effluent treatment facilities remote and downwind from sources of ignition, in the prevailing wind direction. 3.4.6 Flares The location, spacing, orientation and height of flares shall be determined, for the particular site, by a full assessment of the factors involved.
The following general principles on siting should be applied:(a) 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

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the closed relief header(s), whilst avoiding passage through special fire risk areas. (b) 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. They should also be well away from public occupied areas that are, or may be in the future, located adjacent to the site boundaries. A side-wind location from process facilities and similar sources of major release of flammable vapour is preferred. (c) Where 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. Minimum spacings of 60 m from above-ground facilities, for elevated flares, and 150 m for unshielded ground flares or burn-pits are suggested for general guidance 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 BP Group RP 44-3. A flare should be considered to be an elevated flare where the tip of the stack is, say, 15 m 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.

(d)

(e)

The design considerations and general principles that determine the type and location of flares, and the routes for closed relief systems are covered in BP Group RP 44-3 and BP Group RP 44-1. 3.4.7 3.4.7.1 Bulk Rail/Road Loading and Unloading Racks Location of Bulk Rail/Road Loading and Unloading Racks Where 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. This area should be well clear of roads, railways and concentrations of personnel, where any of these are not directly associated with the loading or unloading operations. The loading and unloading facilities should be downwind or crosswind from process units and sources of ignition based on the prevailing wind.

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The term 'bulk' cannot be defined precisely, but is used where 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.

For large sites containing several independent plants, 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.

Access from the site boundary to and from the racks should, preferably, be separate from the main access to the site, and shall be located to minimise traffic through process areas. 3.4.7.2 Layout of the loading/unloading facility Loading/unloading areas for road transport shall have adequate space for access for filling, parking and manoeuvring. A drive-through rack arrangement is preferred. Loading/unloading areas for rail transport shall include adequate spur tracks for standing, filling, shunting and, may require a siding for unserviceable rolling stock. 3.4.8 Site Security All sites shall be within a perimeter fence. Admission to sites shall be through a security check point. 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 will require agreement with the local authorities. The location of buildings outside the site fence, e.g. offices, restaurants and club houses will depend 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.

3.5 3.5.1

Site Buildings Site Building Location A central control building (with or without satellite control buildings) for regulatory control and any 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 any parts of the site remote from the main processing area, e.g. a main tank farm or product loading facilities. All occupied buildings shall be provided with accessways and ideally should be located in an Area classified as safe (electrically). They shall not be located in any area classified as Zone 0 or Zone 1. They should not be located in an area classified as Zone 2, but where this is

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unavoidable the building should conform with the requirements of BP Group RP 44-6. 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 4.6) and should not pass through an area containing process plant. 3.5.2. Site building Blast Resisting Design Control buildings and other occupied site buildings shall be designed and located such that the risk to occupants is demonstrated to be acceptable. Further guidance is available in BP Group RP 4-6. 3.5.3 Site Building Toxic Hazard Considerations Where a unit could produce a major toxic release, the position of the building should be specified after taking into account the following:(a) (b) (c) (d) 4. PLOT LAYOUT 4.1 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 which can be subdivided into a number of sections. Where any such sections process flammable 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. (Refer to Appendix A for definitions). The design should consider areas required for lifting equipment, laydown and subsequent removal of equipment to off-plot maintenance facilities.

Pressurisation of the building. Prevailing wind direction. Escape routes. Other design factors.

4.2

Sections of Plant The meaning of 'sections' in this context must be clearly understood (see also the definition in Appendix A) It is not intended that there should be an additional spacing between equipment, for example, in a multiple reactor system with associated separation equipment when one of the reactors can be shut down for catalyst change with the remaining system in operation. In these cases, the space required depends on the operations to be carried out, any requirement for hot work, and the location of likely sources of release, e.g. sample points.

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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. Where equipment is grouped together, the arrangement should permit where possible, the use of common structures and maintenance equipment, e.g. a lifting beam. 4.3 Separation Distances In estimating adequate separation distances between the sections of a unit it is necessary to define probable maintenance and access needs and the effect of such activities on adjacent equipment.
Within the plot separation distances between individual items of equipment are generally determined by maintenance and emergency access requirements.

To meet this objective, and subject to the constraints imposed by other BP Group RPSEs - Appendix C provides data on recommended separation distances between items of equipment. The designer may reduce or extend the distances based on specific assessment of the risks involved. 4.4 Process Units Enclosed Within Buildings Process units or sections of units handling hazardous materials should not be located in fully enclosed in buildings.
If there is a specific need for weather protection, enclosure may be necessary, but equipment in a building should generally be minimised because of problems in dispersing any flammable vapour and providing access and escape, hazard potential is increased and therefore process plant and material storage should, where possible, be located in the open.

4.5

Plot Drainage The plot shall be graded so that any flammable liquid spills do not flow under or collect under process equipment. Grading and paving requirements are defined in BP Group RP 4-3, and drainage requirements are in BP Group RP 4-1. 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. For fired heaters refer to BP Group RP 22-1. Equipment containing strong acids or alkalis, or certain toxic or other corrosive chemicals should be grouped together, provided this is practicable and economical. Any such area shall be graded so that surface drainage can be segregated.

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4.6

Special Fire Risk Areas As a general principle, the need for special fire risk areas should always be reviewed to decide if improved equipment design justifies their reduction or elimination. See also Appendix E (of this document) BP Group RP 24-1 and BP Group RP 24-2.
Guidance on the specification of special fire risk areas, is given in Appendix E. Note that such a classification, in addition to influencing layout , also has requirements in the following BP Group RPSEs:BP Group RP 42-1 BP Group RP 24-1 BP Group RP 12-1 Piping systems. Fire protection onshore Electrical systems and installation.

4.7

Plant Scale Model Layout design may be aided by the use of 3 dimensional drafting packages and/or plastic models. The cost benefit of using these tools should be assessed.

4.8

Construction Considerations Where a plot being developed on (or major modification work is being carried out on an existing unit), or adjacent to, existing units, any interaction of the construction and commissioning of the unit(s) of the new plot, and interconnections between the existing units shall be considered. Measures shall be taken to achieve safe construction and commissioning of new plant, and to minimise disruption to, or stoppage of, existing units where this is necessary. Risks from construction activity should be considered and included in the CSE to compare the relative risk levels of location options.
Construction work on, or adjacent to existing operating facilities can cause additional problems in construction and in commissioning. Points to be considered at an early stage of development, and before the plot selection is frozen, include:(a Can the construction site be adequately separated from operating units, e.g. by a fence? Ideally the fence should be sufficiently far away to allow a blanket hot work permit to be issued daily. Consideration must also be given to escape from a fenced site in emergency. Use of temporary gas detectors can allow early warning for site evacuation. Can hot work be stopped and naked lights be extinguished rapidly on the construction site should a major gas release occur? For example, can all electric power be isolated from outside the construction site? Can site be evacuated if toxic release occurs. Is there a suitable access route to the construction site for the workforce and construction equipment, e.g. cranes? To avoid possible damage by bulky equipment, the route should avoid roads with overhead pipe crossings or obstructions. Because of the number of vehicles likely to be

(b)

(c)

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involved, the route should be away from areas with appreciable pedestrian traffic. (d) On most construction sites, amenity facilities e.g. canteens, washing and toilet facilities and a smoking area will be required. Can these be located away from operating units, and can a path between the site and the facilities be clearly defined? 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. Does the layout and plant location allow adequate access for operating, maintenance and fire-fighting to the existing and new units, and escape routes for emergency evacuation.

(e)

(g)

5.

ACCESSWAYS AND IN PLANT ROADS 5.1 Philosophy Accessways within each unit shall be provided for maintenance and for fire-fighting from the roads around the plot. There shall be at least pedestrian access for fire-fighting from all roads around the plot. Detailed access requirements for fire-fighting will depend on the fire protection system utilised. Concrete paving shall be provided in accordance with BP Group RP 43. 5.2 Recommended Widths and Clearances Minimum widths of accessways and clearances should be as follows:(a) (b) Vehicular accessways within plot limits Pedestrian accessways and elevated walkways within plot limits Stairways on tanks Footpaths in tankage areas Pedestrian accessways and elevated walkways receiving traffic from two or more routes. Maintenance access around individual items of equipment isolated from the main paved areas. 4.0 m 1.0 m

(c) (d) (e)

750 mm 600 mm 1.2 m

(f)

1.0 m

Note: All clearances shall be measured from the furthest projection on equipment, including associated pipework with its flanges and

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insulation boxes, filters, valves in their open position, drains, cabling, instruments etc., between grade and 2.0 m above grade.
Access to modules or pre-assembled units should be considered at an early stage in the project development. Because of the structural steel at the base of the modules, appreciable excavation would be required for the inside of the modules to be at the same level as the surrounding ground. This can also cause problems with the drainage system. Modules are often installed on raised concrete-filled or tiled plinths. Depending on the height of plinth, handrailing may be necessary, thus limiting access and escape routes. The operational and maintenance implications of elevated plinths should be examined.

5.3

Routing Accessways may be run longitudinally under piperacks, 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. The vehicular accessways shall be as straight as practicable and free of overhead structures except where piperacks, ducts and conveyors are located, and should not cross main drainage systems and cable trenches. Equipment shall not protrude into accessways. Site-run piping and cable trays shall be installed in such a way that they do not affect access. Where practicable, process equipment shall be located so that the accessways are not classified as being in Zone 0 or Zone 1 areas, as determined by BP Group RP 44-6. Access should take account of the clearance required by the proposed cranes or mobile handling equipment or where if there is an economic advantage in a layout which necessitates the use of special equipment. Where 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 piperacks, ducts and obstructions crossing these roads and accessways shall not interfere with such access. Where overhead piperacks, 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 piperacks, cables ducts or equipment. Minimum vertical clearances are given in 6.2. Should the above requirements be considered not economical and practicable, details of the equipment required to be removed for maintenance access shall be reviewed.

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5.4 5.4.1

Access to Platforms Access to platforms shall meet the requirements of BP Group RP 4-2. The multiple escape routes shall not be adjacent to each other, nor be adjacent to sources of hazard.

6.

PIPING BP requirements for process piping systems are covered in BP Group RP 42-1, which includes information on layout, access and pipetracks. Fire-break walls are referred to in BP Group RP 42-1 and BP Group RP 4-3. 6.1 Pipe Routing Within a process unit, pipe runs shall be grouped in overhead piperacks. The piperacks should be as straight as practicable. Crossings of accessways should be at right angles to the accessway and as far as possible from junctions and bends in the accessway. Where a pipe leakage during a fire could lead to a major increase in the fire intensity, such pipes should not be located in any special fire risk area (see 4.6). Such pipes shall include flare lines and pipes connected to 10 m3 or more of flammable liquid which cannot be remotely isolated. Where this is not practicable, the location of such pipes in the special fire risk area shall have external passive fire protection applied to meet the requirements equivalent to those specified in BP Group RP 24-1. 6.2 Minimum Headroom Piping systems shall be designed, and equipment laid out, to provide access by mobile equipment. Accessways shall be planned accordingly, and minimum headroom clearances for this purpose shall be:(a) 4.5 m over railways (top of rail), roads and accessways for mobile equipment. 5.5 m over the crown of roads and, where necessary, over accessways for heavy equipment. 2.0 m over walkways and platforms.

(b)

(c) 6.3

Piping Supports and Pipetracks Piping supports shall not block accessways nor interfere with access. Piping support layout should also allow for removal of pipework if expected to be necessary for maintenance of equipment. Outside the plot and in tankage areas, pipes should normally be in pipetracks at grade level.

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There should be not less than 1 m between the nearest edge of a pipetrack and the toe of a bund. 6.4 Piperacks An overhead piperack may contain more than one level of piping. Provided that replacement of any piping during a unit or section overhaul is feasible. In a multilevel piperack, pipes carrying corrosive fluids should be on the bottom level. Utilities should be on the top level of piping, with cable trays above. 6.5 Valve Operation All valve actuators and handwheels shall be located so that they may be conveniently reached when standing at ground level or from a permanent platform. Extended spindles or chain-operated valves may be used, but should be avoided where practicable. Any chains or extended spindles shall not hang nor be in the path of moving equipment, e.g. cranes. Valves with horizontal spindles shall be located with the spindle between 750 mm and 1.5 m above the ground or platform. For valves mounted with the spindle vertical, the preferred height of the handwheel above operating level is 1.1 m. The height shall not exceed 1.5 m nor be less than 1 m. 6.6 Spades All spading positions or other means of positive isolation, e.g. removable spool pieces, which require access during routine operation shall be accessible without any requirement for scaffolding. This includes spades which require swinging where normal start-up or shutdown routine operations, e.g. catalyst regeneration occurs frequently. Where economically practicable it should apply to other spading positions. Spading requirements are in BP Group RP 42-1. 6.7 Sample Points Sample points should be located or extended to 1 m above the level of the ground or an operating platform with stairway access. Detailed requirements for sample points and associated drains are specified in BP Group RP 42-1.
Sample points which are frequently used should preferably be located 1 m above the ground or a platform. However, in the case of infrequently used sample points, e.g. used on catalytic regeneration, where this length is not practicable, shorter sample lines can be considered in order to avoid long sample lines

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6.8

Isolation It shall be possible to isolate hydrocarbon and utility systems, including steam, instrument air, plant air, nitrogen, process water and cooling water at each plot without affecting the supply to any other plot. Where the plot contains more than one section, the isolation shall be provided for each section. The isolating valves shall be readily accessible, and not in an area of special fire risk (see 4.6). They would be isolated in a fire situation to limit hydrocarbon release to the fire and to prevent any loss of containment in a utility system depleting supplies essential to adjacent sections.

7.

EQUIPMENT 7.1 Machinery Pumps should generally be located in the open, at or near grade level. All pumps shall be accessible for operation and maintenance. Adequately ventilated shelters shall be provided for large machines requiring in situ maintenance (see BP Group RP 34-1). Adequate space for lifting and handling facilities for maintenance shall be provided. Due to asphyxiation risk nitrogen compressors shall be located in the open or in adequately ventilated houses. Pumps should be located and specified so that an acceptable NPSH can be obtained without undue elevation of suction vessels or columns. Pumps on flammable or toxic duties shall not be located in pits to meet this requirement. BP Group RP 34-1 specifies various pump seal arrangements, which have been selected according to the potential hazard in the event of leakage. Pumps meeting the requirements of BP Group RP 34-1 may be located close to the side of overhead piperacks, or underneath the piperacks, provided that access requirements have been met. Recommended distances from other items of equipment are provided in Appendix C. Firewalls or firescreens may be used to increase protection of adjacent or overhead equipment, piperacks or structures from the effects of a pump fire, provided that access for maintenance and firefighting is not compromised. It is recommended that these measures (in addition to other active and passive fire prevention/protection means) are supported by a cost benefit analysis.
Fire walls and firescreens 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.

The separation distances for pumps and compressors with respect to ignition sources shall be as shown in Appendix C

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Pumps and compressors on flammable fluid service should be located 15 m or more horizontally from any part of a fired heater, or any lines which may operate at a temperature of 650C or greater. For this purpose, and subject to approval by BP, liquids with a flash point above 100C and pumped at a temperature below the auto-ignition temperature may be regarded as non-flammable. For petroleum and petroleum products, the auto-ignition temperature shall be taken as 210C unless a more accurate figure is specified by BP. For pure chemicals, the value of the auto-ignition temperature published in 'NFPA Fire Protection Guide on Hazardous Materials' shall be used. 7.2 Fired Heaters and High-Temperature Lines A heater, or group of heaters, shall be located on the periphery of a plot and immediately adjacent to an unrestricted road. There shall be adequate access for fire-fighting from all sides of a heater and, in the case of a group of heaters, they shall be separated from the remainder of the unit(s) by vehicular accessways on the other three sides of the group. See also 3.3. The layout and design of heaters shall normally be such that the tube removal can be effected by mobile lifting equipment, for which there shall be proper access i.e. the crane location shall not obstruct emergency access roadways. Space requirements for operation and for withdrawal of tubes and burners shall be in accordance with BP Group RP 22-1. The following equipment and fittings which handle flammable fluids shall be considered to be potential sources of hazard, and shall be located 15 m or less if justified by Risk assessment horizontally from any part of a heater and any associated electrical equipment housed in industrial type enclosures:(a) Pumps and compressors on flammable fluid service as defined in 7.1. Air-cooled heat exchangers (but also see 6.3). Sample points. Hydrocarbon vents and drains open or opened to atmosphere during normal operation. This shall include drains from fuel and pilot gas knockout drums. However, outlets from vents and drains that are opened only during plant shutdown or infrequent maintenance may be less than 15 m from a heater, provided they are closed and plugged during normal operation. Control valves meters and filters on hydrocarbon gas, or low flash point hydrocarbon liquid duty.

(b) (c) (d)

(e)

Process or utility lines which operate at 650C or more including transfer lines to or from heaters, and gas turbine exhaust should be

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considered as permanent ignition sources and taken account of in any risk assessment. Insulation of lines above 650C should cover the lines completely, including flanges and joints. The effect of the lagging on flange bolt temperatures should, however, be checked, and the appropriate grade of bolting selected. Surface drains shall not be located directly under a heater. 7.3 Air-Cooled Heat Exchangers The location of air-cooled heat exchangers shall be specifically considered with respect to any areas of special fire risk (see 4.6). Such consideration shall include:(a) The effect of the exchanger on air movement and increased fire spread. The possibility of failure of exchanger tubes releasing more combustible fluid to the fire. The design (in particular sealing arrangements of pumps) and operating conditions of adjacent process equipment. The height above any surface which can support a pool fire. The Requirements of BP Group RP 44-1 (sect 4.9.3) detail the affect on the relief case.

(b)

(c)

(d)

Air cooled heat exchangers may be located at a minimum distance from pumps on hydrocarbon service with seals meeting the recommendations of BP Group RP 34-1. For pumps on hydrocarbon duty where seals do not meet the requirements of BP Group RP 34-1 a greater distance will be required by calculation of the range of a likely flammable release. The horizontal distance shall be measured at the pump or motor. Pumps should be located after considering overall piping and plot layout, pump NPSH availability, pump isolation, upstream and downstream inventories and the consequences of fire spread and air cooler failure. The use of flanged joints in piperacks under, or adjacent to, air-cooled heat exchangers should be avoided. Air-cooled heat exchangers shall be located so that the hot air emitted is not a hazard or an inconvenience to personnel, nor adversely affects the operation of adjacent equipment. Air-cooled heat exchangers should, where practicable, be at least 15 m horizontally from fired heaters, to minimise the possibility of circulation of hot air.

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7.4

Shell and Tube Heat Exchangers Shell and tube heat exchangers shall be located so that, when their tube bundles are withdrawn, they do not project into an emergency escape route or any road with unrestricted vehicle access. Shell and tube heat exchangers shall be arranged so that they can readily be dismantled for cleaning and maintenance. Also, the spacing between heat exchanger shells shall allow sufficient unobstructed clearance for access for the bundle withdrawal equipment, and to permit access for shell flange gasket renewal (BP Group RP 26-1 refers).

7.5

Air Intakes and Discharges Air intakes, including intakes to heating and ventilating systems, air compressors for process, instrument, plant and breathing air, and to gas turbines, shall be located as far as is practicable away from areas where air contamination by dust, or by flammable or toxic material can occur. They shall not be located in any area classified as Zone 0, 1 or 2 as defined in BP Group RP 44-6, nor located above or below an area classified as Zone 0 or Zone 1. Air intakes other than for breathing air may be located:(a) (b) (c) not less than 3 m above a Zone 2 area when the flammable vapour release is heavier than air not less than 3 m below a Zone 2 area when the flammable release is lighter than air in a zone 2 area provided a dedicated flammable gas detection and protection system is provided.

The density of the flammable vapour shall be assumed to be at the expected operating temperature.
Special process conditions may mean lighter than air materials behave heavier than air etc.

The location of air intakes shall consider the effects of:(a) Possible air contamination with dust, or with flammable or toxic material. Any additional safety systems, e.g. equipment trips on detection of flammable material in the air intakes. Reduced pressure on personnel working in the area.

(b)

(c)

Some air intakes can be tolerant of contaminants in the air. For example, a process air compressor discharging at relatively low pressure and temperature (below about 150C) into a process stream containing flammables. Time exists for remedial action in the event of gas detection in the intake. In these cases it may be acceptable to locate the intake closer to the boundaries specified above.

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However, there are cases when even a low level of contamination is unacceptable. In particular, the air intake for breathing air compressors must be sited where contamination is unlikely. The siting of breathing and instrument air compressors should consider possible expansion of the site, i.e. they should not be located where future processing plant may be constructed.

Intakes and discharges shall be separated to prevent cross contamination by recirculation, taking into account natural wind effects. The distance between intakes and discharges shall be not less than 6 m unless design provisions can be demonstrated to prevent recirculation. Air discharges from heating and ventilating systems from enclosed hazardous areas shall be considered as a source of hazardous release and shall be sited accordingly. Air discharges from heating and ventilating systems, and blow-off facilities associated with air compressors and fans, shall be located so that they will not cause a hazard or inconvenience to personnel nor affect the access to, and operation of, adjacent equipment. 7.6 Pressure Relief Devices General rules for atmospheric discharge of pressure relief devices are listed below. These should be followed unless rigorous dispersion calculation can demonstrate an acceptable alternative. (a) In processing installations, all pressure relief devices on hazardous duties shall discharge at a point not less than 3 m above any platform, equipment, or structure, within a horizontal radius of 30 m measured from the point of discharge. In processing installations, flammable vapour should discharge at a point not less than 30 m measured in a straight line from any permanent source of ignition. Vapour from LPG and other low boiling point storage vessels remote from process areas shall discharge to atmosphere not less than 2 m above the pressure relief devices, and not less than 2 m above any platform within a 6 m radius. In the case of storage of LPG and other low boiling point materials, there shall be no permanent source of ignition within the radii specified in BP Group RP 44-6 as measured from the discharge from a pressure relief device. Flammable vapour should, and toxic vapour shall, discharge at a level not less than 25 m above grade or any main operating floor.

(b)

(c)

(d)

(e)

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However, all flammable and toxic discharges shall comply with the conditions of BP Group RP 44-1, which may dictate modified distances. 8. ABOVE-GROUND BULK STORAGE AND TRANSFER AREAS 8.1 General Tankage areas should be laid out to meet the requirements of section 3.2.
With large storage tanks, it may not be practicable to keep within these plot sizes. Any proposal for larger plot sizes shall be subject to BP approval.

Model Code of Safe Practice in the Storage of Petroleum Products, Part 1: Operations classifies flammable liquids as follows:Class 0 Class I Liquefied petroleum gas (LPG). Liquids, other than Class 0, with a flash point below 21C. Class II Liquids with a flash point from 21C to 55C inclusive. Class III Liquids with a flash point above 55C up to and including 100C. Unclassified Liquids with a flash point above 100C. Note This is based on the closed-cup flash point.
Class 0 includes other similar liquefied flammable gases. Class II and III liquids shall be 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 shall be based on the maximum operating temperature to 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. Nonflammable liquids shall be regarded as unclassified.

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 or greater should be arranged in a single row.
The figure of 40 m 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 diameter in a single row.

Pumps associated with tankage operations shall not be located inside a bunded tank compound, and should preferably be grouped together outside the bund provided this is practicable and economical.
Normally, the spacing between pumps will be determined by access requirements. However, where 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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8.2

Class I, II and III Liquids Tank spacing shall comply with the requirements of Table 1 and the Notes to Table 1, or any applicable national standards, whichever is more stringent.
The more rigorous spacing and bunding requirements for large crude oil tanks (diameter of 48 m or greater) is due to the large value of the inventory, and the difficulty in extinguishing a fire in such a tank if it were to extend beyond the rim fire stage. This could lead to a 'boil over' if the heat wave reached water bottoms, resulting in the fire spreading to within the bund and increasing the risk to adjacent tanks. The recommended spacing should be regarded as a minimum, especially where the financial consequences of the fire affecting adjacent tanks would be especially severe, e.g. where loss of a second tank would result in a shutdown of production or processing operations. Greater spacing is also required on sloping ground. With a separate bunded compound for each large crude oil tank, the spacing between tanks is likely to be greater than the recommended minimum of 0.5 times tank diameter. With substantially symmetrical arrangements and typical bund heights, the tank spacing would probably be about 1 diameter or even greater. In some sites, ground availability is limited and it can be difficult to meet the requirements of this part of this Code of Practice. A deviation which may be acceptable, would be to size the capacity of the bunded compound for 75% of the tank contents, provided that any greater spillage flowed into an adjacent bunded compound, e.g. by having a common bund section lower than the remaining bund. With this arrangement it should be possible to achieve the spacing of 0.5 times tank diameter. Any spillage or 'boil over' would be contained within the two bunds or, if the affected tank was less than 75% full, would be contained within the bund around the affected tank.

Class III(1) and unclassified liquids should be stored in a separate tank compound from Class I, II or III(2) liquids. Aboveground tanks for Class I, II and III(2) liquids shall be completely surrounded by a bund or bunds. Requirements for the construction of bunds are specified in BP Group RP 4-3.
The height of the bund as measured from outside ground level shall be sufficient to afford protection for personnel when engaged in fire-fighting, and the bund shall be located so that approach can be made to a tank fire to allow use of mobile firefighting equipment. The bund shall not restrict ventilation in the tankage area.

For tanks of diameter less than 48 m, individual bunded compounds are not required. Unless otherwise specified by BP, a separate bunded compound shall be provided for each tank with a diameter of 48 m or greater. In no case shall the number of tanks in any bunded compound exceed 6, or the total capacity exceed 60000 m3, either for floating or fixed roof tanks.

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Intermediate walls of lesser height than the main bunds may be provided to divide tankage into groups of a convenient size, to contain small spillages and act as firebreaks.

The net capacity of a bunded tank compound shall be equivalent to the capacity of the largest tank in the compound. The net capacity of a bunded tank compound shall be calculated by deducting from the total capacity:(a) The volume of all tanks, other than the largest, below the level of the top of the bund. The volume of all intermediate bunds.

(b)

For Class III (1) and unclassified liquids a low wall, which need not be more than 500 mm high, shall be constructed for tankage where conditions are such that any spillage or leakage could escape from the installation and cause damage to property, drainage systems, rivers or waterways.
Civil engineering requirements may require tank spacing to be increased above the minimum.

8.3 *

Pressurised LPG Storage LPG storage shall be laid out in accordance with UK Health and Safety Executive Guidance Note No. CS5 dated May 1981 (Paras 15 to 29 excluding Para 24), except that vessel separation will be specified by BP. In this context the word 'should' in the Guidance Note shall be interpreted as meaning 'shall'.
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 from the Custodian. The Institute of Petroleum Model Code of Safe Practice (Part 9) deals with LPG. A major revision is planned and, when the revised document is issued, this is likely to be preferred, by BP, to UK Health and Safety Executive Guidance Note No. CS5 (May 1981).

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.
As general guidance in the absence of formal risk calculations thermal radiation at the 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. The radiation may be calculated using the method in API Recommended Practice 521 Guide for Pressure-Relieving and Depressuring Systems (Appendix A in Second Edition September 1982) and assuming that:Fraction of heat liberated F = 0.3 Wind speed

m/s

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(a) (b)

(c)

Within a group of small tanks. Between a group of small tanks and another group of small tanks or other larger tanks. Between adjacent individual tanks (other than small tanks).

Type of Tank Roof Fixed or floating

Minimum Distance Determined by construction/ maintenance/operational convenience. 10 m, otherwise determined by the size of the larger tanks (see (c)), or Note 6. 0.5 times the diameter of the larger tank, but not less than 10 m and need not be more than 15 m. For crude oil tanks with a diameter of 48 m or greater, 0.5 times the diameter of the larger tanks. For smaller tanks containing crude oil, or all tanks containing other liquids, 0.3 times the diameter of the larger tanks, but not less than 10 m. It need not be more than 15 m unless the tank contains crude oil. Distance equal to not less than half the height of the tank. (Access around the tank at compound grade level shall be maintained). Not less than 15 m.

Fixed or Floating

(i)

Fixed

(ii) Floating

(d)

Between a tanks and the top of the inside of the wall of its compound. Between any tank in a group of tanks and the top of the inside of any adjacent compound wall. Between a tank and a public boundary fence. Between the top of the inside of the wall of a tank compound and a public boundary fence or to any fixed ignition source. Between a tank and the battery limit of a process plant. Between the top of the inside of the wall of a tank compound and the battery limit of a process plant.

Fixed or floating Fixed or floating Fixed or floating -

(e)

(f) (g)

Not less than 30 m. Not less than 15 m.

(h)

Fixed or floating -

Not less than 30 m. For high-hazard flammable release, not less than 100 m. Not less than 15 m.

(j)

TABLE 1 SPACING OF TANKS FOR PETROLEUM STOCKS OF CLASSES I, II & III(2) This table is based on the recommendations of the Institute of Petroleum Model Code of Safe Practice Part 3 (3rd Edition October 1981) Note: It may be appropriate in certain circumstances to modify these distances based on calculations relevant to the specific site scenarios.

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NOTES TO TABLE 1

(1) (2)

Tanks of a diameter up to 10 m are classed as small tanks. Small tanks may be sited together in groups, no group having an aggregate capacity of more than 8000 m3. Such a group may be regarded as one tank. Where future changes of service of a storage tank are anticipated, the layout and spacing shall be designed for the most stringent case. Where fixed roof and floating roof tanks are adjacent, spacing should be on the basis of the tank(s) with the most stringent conditions. For Class III(1) and unclassified liquids, spacing of tanks is governed mainly by constructional and operational convenience, but shall be a minimum of 3 m. However, the spacing of Class III(1) tankage from Class I, II or III(2) tankage is governed by the requirements for the latter. Where the aggregate capacity of a group of small tanks is greater than 5000 m3, the spacing shall be increased to 15 m. (This is an addition to the IP requirements). Tanks with internal floating roofs may be regarded as floating roof tanks (National Fire Protection Association NFPA 30).

(3)

(4)

(5)

(6)

(7)

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APPENDIX A DEFINITIONS AND ABBREVIATIONS Definitions Standardised definitions may be found in the BP Group RPSEs Introductory Volume. For some layout terms which may be open to misinterpretation, the following definitions apply:accessways: paved areas for either vehicular or pedestrian access within plot limits that part of the site containing the main office buildings the boundary of a process unit enclosing all equipment and unit limit block valves 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 a storage area of capacity less than 5000 tonnes, with no processing facilities but with import and export facilities the individual items, e.g. heat exchangers, which may make up a section a general term to describe a flammable vapour or gas 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 piperack units 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 a general term to describe any one or all the units on a given site

administration area: battery limit:

complex:

depot:

equipment:

flammable vapour: module:

offsites:

plant:

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plot:

an area of the site where a unit e.g. refinery CDU, chemical plant, or storage terminal is located the main network of thoroughfare serving all plots within a site other site roads serving one or more plot within the site. Roads serving to one or more units or sections (of units) within a plot part of a unit, e.g. the fractionation part of a catalytic cracker workshops, stores, fire station, laboratory or similar buildings the land owned by BP or for which BP is responsible for (i.e. the land within the perimeter fence) an area containing one or more tanks a storage area with no processing facilities, but with import and export facilities. If the storage capacity is less than 5000 tonnes, this is classified as a depot 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

major site road: minor site road: in plant roads:

section: service areas: site:

tank compound: storage terminal:

unit:

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

Abbreviations API BI CSE LPG NGL NFPA NPSH PD QRA SI American Petroleum Institute Business Interruption Concept Safety evaluation Liquefied Petroleum Gas Natural gas liquid National Fire Protection Association Net positive suction head Property Damage Quantified Risk Assessment Systeme International d'Unites

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APPENDIX B LIST OF REFERENCED DOCUMENTS A reference invokes the latest published issue or amendment unless stated otherwise. Referenced standards may be replaced by equivalent standards that are internationally or otherwise recognised provided that it can be shown to the satisfaction of the purchaser's professional engineer that they meet or exceed the requirements of the referenced standards.

European European Model Code of Safe Practice European Model Code of Safe Practice in the Storage and Handling of Petroleum Products Part 1: Operations Fire Protection Guide on Hazardous Materials Flammable and Combustible Liquids Code

NFPA NFPA 30

UK Health and Safety Executive Guidance Note CS5 (May 1981) British Standards BS 4485 IP Model Code of Safe Practice Part 3 (3rd Edition October 1981) American
API RP 521

The Storage of LPG at Fixed Installations

Water Cooling Towers Refining Safety Code

Guide for Pressure-Relieving and Depressuring System

BP Group Documents Safety Fire and Management Team, Shared Resource BP Chemicals BP Group RP 4-1 Risk HSE Guidance on the Use of Quantified Risk Assessment (QRA) and Development of Risk Criteria

Hazard Assessment Manual Acute Major Hazards Drainage Systems (replaces BP CP 5)

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BP Group RP 4-2

Plant Structures (replaces BP CP 6) Foundations and General Civil Works (replaces BP CP 4) Electrical Systems and Installation. (replaces BP CP 17 Pt 1) Fired Heaters (replaces BP CP 7) Onshore Fire Protection (replaces BP CP 15/16) Heat Exchange Equipment (replaces BP CP 9) Rotating Machinery (replaces BP CP 10) Piping Systems (replaces BP CP 12) Overpressure Protection Systems (replaces BP CP 14) Flare Systems (replaces BP CP 25) Area Classification (replaces BP CP 39) Group Safety Centre GN 91/4

BP Group RP 4-3

BP Group RP 12-1

BP Group RP 22-1

BP Group RP 24-1

BP Group RP 26-1

BP Group RP 34-1

BP Group RP 42-1

BP Group RP 44-1

BP Group RP 44-3

BP Group RP 44-6

Concept Safety Evaluation

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LEGEND
7.5 DENOTES MINIMUM HORIZONTAL DISTANCE IN METRES DENOTES REFER TO RELEVANT NOTE IN NOTES COLUMN DENOTES REFER ALSO TO RELEVANT NOTE IN NOTES COLUMN
U T R NIT A S N U SF B O ST RM A A E R TIO IR CO S) N (IN O LE CL RS .

SPACING CHART FOR PROCESS UNIT AREAS LANDBASED INSTALLATIONS

MINIMUM HORIZONTAL SEPARATION DISTANCES IN METRES NOTES
A. N/A DENOTES NOT APPLICABLE. B. MIN. DENOTES MINIMUM FOR OPERATION, MAINTENANCE AND CONSTRUCTION ACCESS. C. AIRCOOLERS MAY BE MOUNTED ON TOP OF PIPERACKS. D. AIRCOOLERS TO OTHER ITEMS OF EQUIPMENT, DISTANCES MUST ACCOUNT FOR UNDISTURBED AIR FLOWS THROUGH AIRCOOLERS.. E. PUMPS MAY BE PLACED UNDER PIPERACKS. F. SEPARATION DISTANCE IS TO OUTSIDE OF STORAGE TANK, WHERE A SPILLAGE AREA IS REQUIRED THEN THE SEPARATION DISTANCE SHALL BE FROM THE OUTSIDE OF RETAINING WALL. G. 2m DISTANCE FOR RECIPROCATING COMPRESSORS (CYLINDER HEADS) AND 3m DISTANCE FOR CENTRIFUGAL COMPRESSORS.. H. FOR COMPRESSORS WITH GAS TURBINE DRIVERS AND FOR DISTANCE TO OTHER COMPRESSORS IN THE SAME COMPRESSOR AREA REFER TO NOTE G. J. NOT USED. K. 1.5m TO DRUMS, 3m TO COLUMNS.. L. REBOILER EXCHANGERS TO BE MIN TO ASSOCIATED COLUMNS. M. NOT USED. N. 7.5m FOR HEATERS NOT HAVING THE SAME TURNAROUND REQUIREMENT, MIN FOR HEATERS HAVING THE SAME 13 TURNAROUND REQUIREMENT. P. 4.5m FOR EQUIPMENT DIRECTLY 14 ASSOCIATED WITH HEATER, 15m FOR EQUIPMENT NOT 15 ASSOCIATED WITH HEATER. 0. 7.5m FOR EXHAUST STACK 16 AND/OR FLUE GAS HEAT RECOVERY. 17 R. SEPARATION G IN MEASURED 18 IN FROM OUTSIDE OF TA N ES 19 COMPRESSOR HOUSE. CO BL T A EN M 20 M M IP A U FL EQ ON N

7.5 Z

1 2 3
OW DO W N

PLOT LAYOUT SPACING OF EQUIPMENT

4 5 6 7
PR OC

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

UNIT SUBSTATION (INCL. TRANSFORMERS AIR COOLERS FLARE AND BLOWDOWN DRUMS MS BELOW AUTO COLUMNS AND DRUMS ABOVE AUTO IGNITION COLUMNS AND DRUMS BELOW IGNITION DESALTERS FIRED HEATERS ISOLATION VALVES (PROCESS UNIT) PIPERACKS/TRACKS (PROCESS UNIT) PROCESS PUMPS ABOVE AUTO IGNITION PROCESS PUMPS BELOW AUTO IGNITION REACTORS ABOVE AUTO IGNITION REACTORS BELOW AUTO IGNITION SHELL & TUBE EXCHANGERS ABOVE AUTO IGNITION SHELL & TUBE EXCHANGERS BELOW AUTO IGNITION EQUIPMENT CONTAINING NON FLAMMABLES UNIT ATMOSPHERIC STORAGE TANKS GAS TURBINE DRIVER EDGE OF MAJOR ROADS

N/A 15 15 15 15 15 15 15 15 MIN 15 15 15 15 15 15 1.5 15 15 1.5 MIN D 3 3 3 3 4.5 15 7.5 3C MIN MIN 3 3 3 3 3/1.5 3F 15 15 1.5 3 3/1.5 3/1.5 4.5 15 7.5 3 3E 3E 3 3 1.5 1.5 1.5 3F 15 15

E AR MS FL RU D

C (H OM CO YD PRE RO S A L BO U CA SO V MN R RS E S A A BO U N TO D N) ( IG DR R) N UM IT IO S N

D AN

BL

G 3 3 4.5 15 7.5 3 3 3 3 3 3 3 1.5 3F 15 H 15

K K 4.5 15 7.5 3 3E 3E 3 3 K 4.5 15 7.5 3 3E 3E 3 3

1.5 15 9 4.5 4.5 E 4.5 E 4.5 4.5 3 3 1.5 4.5 15 15 N

7.5/15 N/A 15 MIN 15 15 P P P P 1.5 15 15 4.5

MIN 7.5 7.5 7.5 7.5 7.5 7.5 1.5 7.5 7.5 1.5

1.5 1.5 K&L K&L 1.5 1.5 K&L K&L 1.5 3F 15 15 1.5 3F 15 15

FI RE D IS H (P OL EA RO A TE TI PI CE O RS ( P PE SS N R O RA U VA N L C E CK PR IT V SS S A OC ) ES U U / TR TO ES PR N A S IT C A OC IG PU ) U K N M TO ES S R IT P S IO S IG P IG EA CT N UM N AB N IT IT O O IO PS V IO RS R E N B N A IG EA EL BO N CT O IT O SH V W E IO R A EL A BO L N SB U V & EL TO E TU SH O A B W U E B E EL TO E A LO L & X U W TO IG CHA T A UB N N U E IT GE TO EX IO R U N S IG CH S T NIT N AN IT G O A IO ER RA T G A N S G MO S E TU T A SPH ED RB N ER G K IN E S IC O E F D M RI A V JO ER R RO A D S

S M N RU O D ITI D N N G A OI S N UT S M A ER LU O LOW LT C E A B ES D

ES

S UN IT

PLANT LAYOUT

10

AR

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11

EA

12

MIN MIN E

1.5

MIN E 1.5 3 3 3 3 3 3 3 3

1.5 3 3 3 3

1.5 3 3 3

1.5 3 3

1 1

MIN MIN 4.5 1.5

1.5 3

1.5 3

1.5 4.5 15 15

1.5 4.5 15 15

1.5

1.5

1.5

APPENDIX C

4.5 F 4.5 F 1.5 F 15 15 15 15 1.5 1.5

1.5 15 15

19 20

15 15

15 15

15 0

N/A

APPENDIX D ESTIMATION OF HEAT INPUT TO EQUIPMENT

A1

This Appendix provides a method of estimating the heat input to process equipment as a result of fire. From the heat input, the rate of metal temperature rise and the time to failure can be estimated. Types of fire can be divided into pool fires, jet fires and fireballs. It is necessary to:(a) Identify parts of the plant where each type of fire is likely to occur. Estimate the likely size of a fire. Estimate the heat input to equipment as a function of distance from a fire.

(b) (c)

The identification of the likely location of fires and the size of a fire requires experienced judgement, but the following notes may be used as a guide. A2. Fires occur after the inadvertent release of flammable material. When the release is of a liquid below its auto-ignition temperature, not released close to a source of ignition, and not likely to produce a vapour cloud, the liquid will drain to the low points of the plant and collect in the gullies or behind bunds. Ignition will result in a pool fire. When the release is above its auto-ignition temperature, released close to a source of ignition, or is a vapour or liquid likely to produce a vapour, the leak is likely to ignite and burn at the point of release as a jet fire. A3. Possible causes of release include:(a) (b) Vents to atmosphere. Drains to atmosphere used in normal operation, including sample points. Relief valves to atmosphere. Any breaches of containment, e.g. in spade changing on an operating unit.

(c) (d)

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(e) (f)

Single mechanical seals on pumps. Tube failure on a fired heater.

Judgement is required to assess possible release rates. Typically it should be assumed that valves on drain systems are fully open. In the case of seal failure, it may be assumed that the damaged seal will be a source of ignition. In spade changing, a release will normally be the non-drainable liquid between block valves. The effect of a passing valve should be examined assuming several possible flow areas. On fired heaters, the effect of different leak areas should be examined. The worst case is probably complete shearing of a tube, with a leak area of twice the cross-sectional area. A4. Estimation of the maximum heat flow into a vessel as a function of distance is complex. As a first approximation it may be assumed that:B x QR 4 x S2 x pi where K is the incident radiation on the vessel based on the exposed vessel area (kW/m2). For exposure to one side of a vessel only, this should be half of the total surface area. K= B is the fraction of heat received which is transmitted through external passive fire protection (typically B = 0.3). S is the minimum distance from the mid point of the flame to the vessel (m). QR is the heat radiated (kW) This simplified equation is valid only when the flame length is small compared to the separation distance S (typically < 0.15 S). Predictions by this method may be high. It is advisable in critical cases for a more sophisticated estimation to be made by a specialist. For a pool of burning liquid For LPG QR = 96 x pi x D2 kW. For other petroleum fractions QR = 70 x pi x D2 kW. D is the equivalent diameter of the pool in metres. For a circular pool D is the actual diameter. 4 x area For a non-circular pool D = . pool perimeter For a jet of burning fluid from a hole or open ended pipe QR = 0.3 x m x H kW. Where: m is mass of fluid in kg/sec H is the fluid calorific value in kJ/kg.

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For a pool fire, the centre of the flame is considered to be at a horizontal distance of 0.7D from the pool edge displaced in the direction of the wind, and at a height of 0.7D where D is the pool diameter. For a jet fire, the centre of the flame should be calculated using the method suggested for flares in API Recommended Practice 521 (Appendix A in Second Edition September 1982). A5. If a vessel fails due to external fire, the released flammable fluid (if above its atmospheric boiling point) may ignite and rise as a fireball of burning vapour. This will produce intense radiation for a short duration. Although this fireball radiation may injure personnel or ignite readily-flammable material in, e.g. administration buildings, it can be neglected in considering the temperature rise of process equipment because of its short duration. However, the effects of continuing combustion of any remaining contents must, of course, be fully considered.

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APPENDIX E GUIDANCE ON SPECIAL FIRE RISK AREAS E1. The following plant areas should be considered by BP to be of special fire risk:(a) Within a distance, (to be specified) of the following:(i) (ii) Fired heaters. Compressors on flammable fluid duty, and pumps other than those for which a single seal is recommended as first choice in BP Group RP 34-1. Vents, drains and sample points on systems containing more than 10 m3 of flammable liquid which, on escape, could flash to form an appreciable vapour cloud. This shall include liquefied petroleum gas (LPG), natural gas liquid (NGL) condensate, or liquid volatile at pumping temperature and atmospheric pressure. As a guide, other liquids should be considered volatile if the vapour pressure of the liquid exceeds 5 bar (abs).

(iii)

(b)

Within bunded and low-lying areas designed to contain flammable liquid, where that liquid will flash on release to give a substantial vapour cloud e.g. an LPG tank or in other areas where pool fires are possible. Where a potential leakage source of flammable vapour exists, and strong air movement could distort flames and attract hot combustion products, e.g. near air-cooled heat exchangers and air intakes. Where flammable material is being processed, and a potential leakage source exists within enclosed buildings or compartments.

(c)

(d)

Generally, areas subject only to potential fireball and flash fire need not be classified as special fire risk areas. E2. Fires which are likely to cause damage to structure or equipment are those resulting from significant release of flammable fluids due to equipment failure such as a major flange leak, pump seal collapse or broken pipe, or due to operational error or malfunction.

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The positions of possible pool fires are largely predictable as spilt liquids will flow to the low points of a slab drainage system, collect in gullies or be retained behind bunds (see BP Group RP 4-1). Damage from sustained pool fires will be due to radiation and contact with flame and hot combustion products. The former is directional and unaffected by wind, but flames which have low density and momentum are easily diverted by even low winds, and this can result in engulfment of adjacent equipment. In contrast, the positions of burning jets are not readily predictable, as they will arise from random failures. Where the positions are known, as for emergency vents discharging flammable vapour, shields should be fitted to protect adjacent cables and equipment. If a vapour cloud ignites, the initial fireball (duration a few seconds) flashes back to the source of the leak which will continue to burn as a pool fire or as a vapour jet at the point of release. Provided that the initial fireball or flash fire is of sufficiently short duration much equipment, including power and instrument cables, may still be capable of safe and effective operation. The protection concepts adopted for electrical apparatus reduce the likelihood of electrical apparatus being a source of ignition of vapour clouds, so that the more likely sources are hot surfaces of non-electrical equipment, fired heaters or maintenance activities. The following correspond to the numbered conditions in E1:(a) The probability of release will have been designed to be low and its quantity possibly limited; further control by isolation will also be available. Where the immediate control of such a vent or random leak is not possible by isolation, there will be a high risk of ignition and subsequent fire, and vital services should not be run through such an area. (b) The probability of a 'total' release in bunded areas may be very low, but smaller pool fires may occur; rapid fire-fighting action may be effective in extinguishing or controlling these. Remote stop controls and the incorporation of fusible links for air-cooled heat exchangers should limit this effect, but wind may be equally important in causing distortion of the affected area. The probability of minor releases and of ignition may be relatively high, but the quantity of release and the resultant duration of any fire may then be limited by operator or automatic response if the necessary shut-down controls are not affected. It can be assumed that a 5-minute response to a gas

(c)

(d)

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leak will be possible with all manual operation, and a 3-minute response with remote operation.

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