KOC-L-028

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ST ND RDS

UBLICATION

KOC

RECOMMENDED PRACTICE

FOR

PLAJVT

LAYOUT

DOC.NO.KOC L 028

STANDARDS

TEAM

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DOC NO

KOC La28

Page f

Rev.

KUWAIT OIL COMPANY K.S.C.)

STANDARDS PUBLICATION

KOC RECOMMENDED PRACTICE

FOR

PL NT LAYOUT

INCLUDING SPACING.CHARTS)

DOC.

NO.

KOC-L-028

STANDARDS TEAM

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Rev

KOC

RECOMMENDED PRACTTCE

FOR

PLANT

LAYOUT

INCLUDING SPACING CHARTS)

DOC. NO. KOC L 028

ISSUING

AIMWORITY:

STANDARDS TEAM

Task Force

lss~re s

KOC R

I TF L P 2

I

Description Prepared By

Snr. Engm. Sids

eam

LeaderStandards

Tel. 6115f

Tel. 61896

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age

3

sf

33

Rev.

1

TABLE

OF

CONTEMTS

PAGE

NO.

5

SCOPE

APPLICATION

TERMINOLOGY

3.1 Definitions

3.2

Abbreviations

REFERENCE STANDARDS, CODES AND SPECIFlCATONS

4.1 Conflicts

4.2 List of Standards Codes

and

Specifications

ENVIRONMENTALCONDITIONS

HEALTH

SAFETY

AND

ENVIRONMENT

LAYOUTOFPLANT-SITE

7.1 eneral

Philosophy

7.2 Site Layout

7.3

Plot Layout

7.4 Access Ways

Implant

Roads

7.5 Construction

Maintenance

Considerations

LAYOUT OF EQUIPMENT

AN5

PLANT BUILDINGS

8.9

Equipment Layout

8.2

Buildings Layout: Office, Control and Other Buildings

8.3 Air

Intakes

and

Discharges

8.4 Primary

Area

Substation

8

PlantSubstation

8 6

Utilities

8.7 Fire-Water

Tanks and

Pumps

8.8 Process Vessels

8.9

Shell

and Tube Exchangers

8 lO

Gas Compressor

Process Pumps

8.72 Air-Cooled Exchangers

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Fired

Heaters

Storage

Tanks

for Petroleum

Pres sur~ elief Devices

Other Potenfiel

Sources

of

Hazard

Flare S h c k

Bum Pit

Manikdd

Offsite

Effluent Treatment Facilities

Overhaad

ElsctricalRowerlines

Plant Piping

9.0 PIPELINES

TRANSIT LINES

10.0 QUALlTf

ASSURANCE

SFACING CHART I

SPACING

6

EQUIPMENT

AND

ITEMS

LOCATED

WITHIN

KOC PLANT

GC

BS OTHER FAClhlillES)

3.PACIjjG CHART-;

SPACING O F

KOC

EQUIPMENT AND ITEM5

LOCATED

OUTSIDE OF KOC

PLANT GC

BS OTHER FACILITIES)

BUT WITHIN

KOC FENCED

AREA

SPACING CHART

3

SPAClYG

O KOC PLANT,

KOC

TANK FARM AND

OTHER

KOC ITEMS FROM KUWAlT GOVT

PRIVATE PUBLIC

WTILITIES

FACIILITI

ES

ETC

ACKNOWLEDGEMENT

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DOC. NO. KOC-L-028

FOREWOR

This document KOCRecommended

Practice

for Plant Layout1 s intended to serve

as a guide to the layout of plantsite nd offsite equipment and units items in KOC

onshore oil and ga s processing plant and facilities in Kuwa it.

This Recommended Practice (RP) has been approved by the Standards Team in

consultation with the Standards Techn ical Committee (STC) for cons istent use throughout

the corporate engineering and operational functions of Kuwait Oil Company (K .S.C.).

This RP sets out to achieve the following objectives:

> To outline KO C s basic philosophy regarding site developmen t and the layout of

Plant sites, equipment and piping.

i

To provide guidance during the design stage of a project regarding acceptable

equipmen t spacing, clearances, access for construction, operation, m aintenance,

safety and fire-fig h ing purposes.

i

To ensure facilities are constructed ~n ine with KOC s lnsurance provisions and

other recognized International Agencies and to allow the facilities to qualify for

favourable consideration from lnsurance Agents.

i

To utilize operational experience to avoid repetition of past problems and to

consolidate worthwhile and bene ficial design, operating and cost saving features.

>

To standardize facility site plan and layouts as much as possible.

>

To have future requirem ents included in the initial design of a facility.

> To set out minimum

technical requirements for monitoring compliance with

distances from the view points of operation, safety and maintenance needs.

feedback, comments or suggestions, derived from the application of this Recommended

Practice at any stage of design, engineering, purchase, manufacture, field installation,

operation and maintenance are encouraged, and should be directed to:

The Team Leader Standards

(Chairman, Standards Technical Com mittee)

Industrial Services Group, KOC

P.O. Box 9758, khm ad i 61008

State of Kuwait

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DOC NO.

KOC L 028

]

Page

of Rev

Task

Fq rm Res pons i b l e

for This

Recommended

Practice

The Preparation of this Recommended Practice was entrusted by Standards Technical

Committee (STC) to the Task Force No. (TF-LPl12) consisting of the following

members:

Mr. Faisal Mirza Standards Team

TF Leader Ex 61 151

M r. Mohsin Mirza Standards Team

Author Ex 61 371

Mr. N. Ram anathan Export Facil ity Proj Me mbe r Ex 66960

Mr. Mohd. Alam

Safety Team Member Ex 6641

5

Mr. Uppara Saibaba Safety Team

Member Ex 71837

Mr. T V. Valsan

Design Team

Member Ex 61659

Mr. Haytham H. 41-Habshi 0pns.T ech.Svcs . NK

Member Ex 23336

Mr. M ohd. Al-Ajmi

0pns.Te ch. Sevs. W K Member Ex. 20336

Mr. NA l-S atta r AIAI Salam Production Opns. SK Member Ex 22538

Mr. Mohd. Dashti Drlg. WIOver

Member Ex 71057

Mr. John O nderdonk

Field Development SK

Member Ex 22069

Mr. Sayed Al-Zalzalah

Hum an Resources SEK Mem ber

Ex 22145

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SCOPE

This Recommended Practice

RP)

For Plant Layout is a guideline for

spacing of equipment and items located within KOC plant GCIBSlother

facilities) such as office control buildings, plant substation, process vessel,

process pump, pipeways, gas compressor, exchanger, process heater,

desalter, separator, and manifold etc as well as KOC equipment and items

located outside of KOC plant GCIBSlother facilities) but within KOC fenced

area such as fire water tank, fire water pump, flare stack, burn pit, oil gas

wells, area substation, flowlines, temporary structure etc. For spacing details

refer to Chart-I and Chart-2 of Appendix-?of this RP.

This Recommended Practice RP) For lant Layout is a guideline for

spacing of items s u h as KOC Plant, KOC Tank Farm and KOC Pipelines /

Transit Lines highway oads, residential area, mosque, hospital, school,

farm, office, shop, factory, warehouse, and industrial plant etc that are either

controlled / owned by Government of Kuwait, or by public or private sectors,

For spacing details refer to Chart-3 of Appendix-lof this RP.

PPLIC TION

This RP is intended as a guide for plant layout. However t should not be

construed as substitute for detailed engineering layout, engineering

drawings, piping layout, equipment nozzle orientation, equipment

specifications, isometrics and lateral hook-ups with equipment. The Contractor

should develop on his own the detailed plant and equipment layout drawings

using this RP as guideline and all such documents should be submit to KOC

for review and approval.

The pliant equipment layout, plant piping etc should fully comply with all

relevant technical and contractual requirements of specific project i.e. Scope

of Work, Technical Specifications and Contract Documents of KOC.

This EP is not applicable for any offshore installation or any onshore

warehcuse, storage facility or depot etc.

This RP should not be considered as retroactive but should be applied to new

facility or expansions, substantial modifications and

/

or revamp of existing

facilities. Any exceptions or deviations shall be subject to approval by KOC.

KOC may choose alternative options or waive any of the requirements of this

RP depending on the nature of any specific project.

Compliance with this RP does not in itself confer immunity to Contractor from

legal or statutory obligations.

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DOC

NO

KOC L 028

Rev 1

For the purpose o f this RP the following definitions apply.

Access W ays

Paved 3r unpaved area for either vehicular or pedestrian access within the

plot limits.

Adm inistration Area

The part of the site intended for the main ofice building.

Battery Limit

The boundary of a process unit enclosing all equipment and unit limit block

valves.

Contractor

The pErson

or

persons or a firm or a company contracted by

KOC

to

undertake the execution of the Work defined by KOC Contract.

Equipment

The individual items which m ake up a process unit.

Flowlines

Flowlines transport production from the wellhead to a manifold at a gathering

centre. For the purpose of this RP the flowlines are not to be considered as

pipelines

/

transit lines.

KOC Controlling Team

Any KOC T eam authorized to initiate a request for the execution of a project.

Module

A steel skid or platform having equipment and items installed on it and fully

connected to each other with piping instrumentation and t;lectriml gadgets and

cable network as a complete unit and ready for tra nsp ta tio n.

Offsites

The units and equipment that are not specifically part of the processing units

but which provide a service to the processing units. Off sites include utilities

tankage flares burn pits and oil-water ponds etc.

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Pipelines / Transit Lines

A network of Iines generally transporting hydrocarbon fluids from one

facility such as GC and BS to another facility, terminal or storage such as

Tank Farm. For the purpose of this RP the pipelines

/

transit line are not

considered as flowlines.

Plant

A gene-ai term to describe a processing operational unit on a given site.

Plot

An area of the site containing one or more process units, offsite and/or

tankage.

Quantitative Risk Assessment

A detaYledqualitative and quantitative analysis to evaluate / measure the

potential likelihood and consequences of site-specific scenarios of risks and

associated hazards leading to human death, or injury, environmental damage

or economic loss and their magnitude and then to compare the findings with

acceptance criteria.

Scenario

A scenario is a set of conditions that define the development of fire, the

spread of combustion products, the reaction of the occupants and the effect of

combustion productions.

Service Areas

Workshops, stores, fire station, laboratory or similar buildings.

Site

An area where a new facility or an extension to an existing facility is to be

provided, The Site contains all the plots.

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Abbreviations

BS

E A

EPA

ESDV

GC

HAZOP

HSE

HVAC

KOC

MCC

ME EW

NPSHk

OSHA

PHA

QRA

VCE

Booster Station

Environment Impact Assessment

Environment Public Authority Kuwait

Emergency Shut Down Valve

Gathering Centre

Hazard and Operability Study

Health, Safety and Environment

Heating, Ventilation and Air Conditioning

Kuwait Oil Company (K.S.C.)

Motor Control Centers

Ministry of Energy Electricity and Water

Net Positive Suction Head Available

Occupational Safety and Health Administration

Process Hazard Analysis

Quantitative Risk Assessment

Vapour Cloud Explosion

REFERENCESTANDARDS CODES AND,.SPECIFICATONS

onflicts

In the event of conflicts between this RP and the Standards Code referenced

herein, or other contractual requirements, the most stringent requirement shall

apply. In case, further clarifications are required, the subject shall be brought

to the attention of KOC Controlling Team.

List

o f

Standards -Codes

nd Specifications

The latest edition of the following standards, codes and specifications shall

apply:

Nationr.1 Standards and Codes

API RP 500

Classification of Locations for Electrical

Installations

at Petroleum Facilities Classified as Class

I

Division

1 and Division2

API RP 521 Guide for Pressure-Relieving and Depressuring

Systems

API RP 752

Management of Hazards Associated with Location of

Process Plant Buildings

API 22 18 Fireproofing Practices in Petroleum and

Petrochemical Processing Plants

ASME 331.3 Process Piping

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ASME B31.4 Pipeline Transportation Systems for Liquid

Hydrocarbons and Other Liquids

ASME 831.8

Gas Transmission and Distribution Piping Systems

BS EN 14161 Petroleum and Natural Gas Industries-Pipeline

Transportation Systems

DOT CrR Titie 49 Department of Transportation (USA), Code of

Federal Regulations Transportation of Natural and

or Other Gases by Pipeline: Minimum Federal

Safety Standards

NFPA 221

NFPA 551

OHSAS 1800

Standard for Fire Walls and Fire Barrier Walls

Guide for Evaluation of Fire Risk Assessments

1

Occupational Health and Safety Assessment

Standard

OSHA 9 CFR 1910.119 Process Safety Management of Highly Hazardous

Chemicals

4.2.2 KOC Standards and Recommended Practices

KOC Recommended Practice for Engineering

Design Basis of Civil and Structural Work

KOC Recommended Practice for Blast Resistant

Design of Buildings

KOC-E-003 Part

1

KOC Recommended Practice for Design Basis,

and Selection of Electrical Systems

KOC-G-002

KOC Standard for Hazardous Area Classification

KOC-G-007

KOC Standard for Basic Design Data

KOC-L-002 KOC Recommended Practice for the

Protection of

KOC Services: Clearance Requirements

or Buried

Pipelines Piping, Cables, Underground

Structures and Buildings

KOC-L-006

KOC Standard for Fire Gas Detection Equipment

KOC Standard for Fire Protection and Safety

Equipment

KOC-L-O 7

KOC Recommended Practice for HAZOP Studies

KOC Standard for Layout, Spacing and Diking of

Aboveground Petroleum Storage Tanks

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.

DOC

NO

KOC La28

-

Page 12 of

I

I

KOC-MP-027 Part 1

KOC Standard for Pressure Relief Devices: Design

and Materials

KOC-MP-027 Part 2

KOC Recommended Practice for Pressure Relief

Devices: sizing, Selection, Twinning and Installation

KOC-HSE Document

KOC.SA.018

HSE Procedure for Risk Assessment

KOC.SA.019

Guidelines for HSE Procedure for Risk Assessment

EV.KOC.003

Environmental Impact Assessment (EIA) Procedure

01 5 Series of Specifications

015-IH-1009 Flowlines

015

LH

1001

Piping Material Classes with Attachment 1

015 LH -1002

Piping Design

015-NH- 7104

Plant / Equipment Noise Control

015-Y-I-1003 Loss Prevention Requirements

ENVIRONMENTAL

ONDITIONS

Refer to KOC-G-007 KOC Standard for Basic Design Data which provides

the detailed design information regarding the environmental, site and utility

supply conditions prevailing throughout the KOC facilities.

HEALTH SAFETY AND TNVlRONMENT

The plant layout should meet all the applicable Kuwaiti EPA Regulations and

should conform to the relevant KOC HSE Guidelines with a view to protecting

personnel and surrounding environment.

All relevant safety requirements of KOC Fire Safety Regulations and KOC

Health, Safety Environment Management System (HSEMS) procedures and

manuals as applicable shall be adhered to by the Designer / Contractor, while

planning / implementing plant layout for KOC.

The Contactor shall carefully consider and address all environmental issues and

impacts including NOxemission arising from layout, construction and / or operational

activities as identified in KOC-HSE Environmental Impact Assessment (HA)

Procedure EV.KOC.003.

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DOC.

NO

KOC L 028

Page 13of 33

Rev

1

LAYOUT

OF

PLANT SITE

eneral Philosophy

This

RP

is intended to provide general guidance for a major developmen t i.e .

expansion o f existing plant or construction of a new plant. KOC should specify

and elaborate philosophy for any specific location or any specific processing

unit s), offsites facilities, control rooms and administration buildings etc for any

project whenever required.

KOC philosophy and approach should be to provide a fit-for-purpose design

that satisfactorily addresses the needs of HSE, operating and maintenance

issues that will ensure a safe work environment, and will entail reasonable

overa ll facility costs.

KOC intends to standardize as far as possible, the layout of the facilities and

make use of co mm on equipment designs that would facilitate inter-changes of

equipment and operating personnel, and reduce spare parts, operations,

maintenance, and training requirements.

The criteria for spacing between various equipment and items are based on

requirements for process, operation, maintenance, and emergency

evacuation, damages due to fire transfer blast effects etc and sound

engineering judgements etc. Based on these criteria Spacing Charts-I,

Spacing Chart-2, and Spacing Chart-3 show ing spacing for various equipment

and items have been developed and included in Appen dix-I of this

RP.

The spacing shown in Spacing Charts in Appendix-I of this

RP

are optimum

to satisfy KOC requirements. Any proposal to increase the spacing shown

should be subject to a com prehensive cost-benefit analysis, and any p roposal

to decrease the given spacing for process / operation or any other

requirements) shall be subject to a comprehensive Quantitative Risk

Assessment

QRA)

by concerned KOC Team s) or their appropriate

nominated representative.

The total site layout and detailed layout of each plant shall be subject to

approval of KOC. Any calculations relevant to the spacing of equipment or

concerning potential major release of hazardous material shall be subject to

review and app roval by KOC .

All sites shall be generally within a perimeter fence.

KOC should specify the

site area and specify buildings that should be located inside or outside of the

fence. The en trance to sites shall be through a security checkpoint.

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I DOC

NO

KOC La28 Page 14

of 33

I

ev

The consideration should be given that the overhead electrical power

transm'ssbn l ines

do

ot

cross aver the

plantsite

ft

should be ensured that a

minimum

60

meter horizontal

distance is

maintained between the edge of the

right-of-way of overhead electrical power transmission line and the perimeter

fence

of

the plant and its paraphernalia. For additional details on clearance

from overhea d pow er transmission lines refer to KO C-L-002.

The site layout should consider future expansion of the plant as additional

space will be required for installation of equipment in future such as hea ders,

process vessels, separators, desalter, pump s, com pressors, he at exchangers,

process storage tanks, fire-water tanks, pipe rack and other equipment as

listed i t ) Spacing Chart in Appendix-? of this RP. The site and plant layout

shall

be

subject to approval by KOC.

Flamm able material storage shall be located appropriately aw ay from process

units

in

compliance with KO C-L-027 KOC Standard for Layout, Spacing and

Diking o Aboveground Petroleum Storage Tanks .

Utility

services

should be grouped together in a non-hazardous area. They

should

be

located so that essential utility supplies can be maintained under

emergency conditions.

Firewater pum ps shall be located appropriately away from the process storage

and loading areas of the plant in order to reduce the risk of fire impact or blast

damage to these pum ps.

The location, spacing, orientation, height and separation distances of flares

shall be determined by a full risk assessment and calculation of the factors

involved.

Control buildings and other occupied site buildings shall be designed and

located such that the risk to occupants shall be precluded or minimized.

Plant offices, workshops, laboratories and other similar buildings not directly

linked to plant operation should not be located in the control building. They

should be located separately in a safe and non-hazardous area zone.

The risk assessment study and risk acceptance criteria shall be carried out by a

third party or KOC safety consultant with inputs by KOC Controlling Team.

Issues related to construction, operation, and maintenance besides safety

issues should also b e included in the risk assessment.

A roads should be provided around site perimeter fence to permit access and

exit in all weather conditions.

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DOC. NO

KOC L 028

Page I 5

of

Rev 1

lant Layout

A plant should

be

laid out in such a way that all equipments and items of the

plant are accessible for vehicles and pedestrian through road network.

Additimally the emergency evacuation exits should be located taking into

account the locations of potential release and the prevailing wind direction.

The process units shall not be enclosed in a building,

The plant re should generally be completely paved for good housekeeping

and for better plant operations. However if it is not possible then concrete

paving should be provided around process units of plant to help vehicles and

pedestrian to access equipment, buildings and maintenance areas and also

help flow of surface drainage of these areas.

The plot shall be graded so that any flamm able liquid spill does not ftow under

or collect under process equipment and shall not migrate to another process

utility area under gravity action. In case of any specific toxic liquid KOC should

specify the requirements.

Necessary drains sha ll be appropriately provided at the pe riphery of each unit

to collect any spillage.

KOC should identify and specify the hazardous areas in the plant.

Appropriate catchment areas for drainage water of the plant units should be

considered as a result of fire fighting and storm water.

Sandy areas and terrains should be adequately covered with tiles to prevent

plant and vegetation growth and m aintain grading of plot.

Access avs % In Plant

Roads

Access ways and in-plant roads shall be provided for movement of maintenance

vehicles and for fire fighting from the roads around the plot. There shall be at

least lsvo pedestrian access ways for fire fighting purposes from all roads

around the plot.

The minimum recommended width for vehicle access ways shall be six

(6.0)

metres nd for pedestrian access ways shall be one (1) metre in accordance

with

KQC-C-002

KOC Recommended Practice for Engineering Design Basis

of Civil

and

Structural Work.

Vehicle access ways shall be as straight as practicable and free of

obstructions from any overhead structures and should comply with the

minimum overhead clearances as specified in KOC -C-002 . Equipment and

other structures should be located in such a way that they do not protrude into

the

access

ways.

The process pipeways or site-run piping and cable trays should be installed in

such

a way

that they do not obstruct the access -ways or in-plan t roads.

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Appropriate care should be taken with regard to the clearance height of

pipeway that crosses over the access-ways or in-plant roads so that it will not

cause m y obstruction or hindrance to large vehicles cranes and other large

size mobile equipment or hoist mounted truck deployed for plant / equipment

maintenance.

Construction Maintenance Considerations

Modularization is an increasingly acceptable construction method. This

method should be considered early in the design period to determine

if

it will

be economical lead to cost benefit and improved construction and quality

control.

Maintenance issues that need cons ideration during plant layout should include

access for maintenance of equipment and lay down areas for equipment that

may be repaired in place such as compressors columns and shell and tube

exchangers etc.

Piping around equ ipment requiring routine servicing shall be a rranged for easy

access.

Where equipment can be removed and repaired while the plant

continues to run piping shall be arranged so this task can b e done efficiently

and safely.

L YOUT OF EQUIPMEMT ND PL NT

BUlLDlNGS

Equipment Layout

The primary consideration in the arrangement of plant and equipment should

be to p-ovide a safe operating facility that shall be economically des igned and

easy to operate and maintain. For spacing between various equipment and

items refer to Spacing Cha rts in Appendix-7 of this RP.

The equipment layout shall consider provision of appropriate space for future

needs and expansion of plant by KOC .

Equipmen t shall be located and orientated with due consideration to the e ffect

of noise in the immediate vicinity of the equipment and on the general plant

areas.

Stacking equipment should be avoided unless they are in the same basic

service and proc ess ftow path such as a contactor reflux accumu lator etc.

When stacking equipment the layout shall facilitate the maintenance of

individual items including removal and inspections.

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Buildings

layout: Office

Control

nd

Other

Buifdinqs

.

All buildings shall be sited according to the requirements of OSHA 29 CFR

1910 119 Process Safety Management of Highly Hazardous Chemicals

(PSM)

nd

the

methods

as outlined in API RP

752.

The hazards associated

with the presence of oil and gas wells in proximity to the buildings shall be

included in this study For spacing between plant buildings and various

equiprent / items refer to Spacing Charts in Appendix-? of this

RP.

Page

17

af 33

Office, maintenance and control buildings as well as other occupied site

buildings shall be designed and located such that the risk to occupants is

precluded or minimized. Where high risks are envisaged due to process

requirements, blast resistant construction shall be adopted in accordance with

KOC-C-030 KOC Recommended Practice for Blast Resistant Design of

Buildings . The location of the control room and the requirement for blast

resistant construction shall be determined based on KOC's operating and

maintenance requirements and the results of Vapour Cloud Explosion (VCE)

Analysis.

Rev

Control buildings shall be planned independently, depending on available plot

size, as the single storied or double storied building, catering to all the

requirements for operations of the plants (GC / BS etc). Adequate space for

equipment and necessary space and facilities for operators and other

essential personnel shall be provided for monitoring and control on twenty four

(24) hours basis throughout the year.

Control buildings should include as a minimum the following facilities only:

a. Plant Control room

b. Auxiliary / Marshalling rooms

c. Telecom / LAN room

d. Conference Training rooms

e. Rest rooms

f

Toilets, Shower and Locker rooms

g. 'Prayer room

h

Par

tg and Mess room

i.

Offkes

j Instrument room

k

Eiectdcal room

1 Mechanical room (HVAC)

m Stme

room(s)

n,

Other if any.

The control building should not be located unnecessarily far away from

process plant since it requires continuous monitoring and frequent visits to

process plant.

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DOC. NO KOC La28

A Quantitative Risk Assessm ent QRA) shall be conducted by the Contractor, or a

third party Consultant approved by KOC to demonstrate the risk involved. The

QRA used in deciding the location of the control room and the type of construction

shall include a Vapour Cloud Explosion VCE) Analysis for various release

scenarios. The final layout and design of all buildings shall be subject to the

approval of KO C.

Office

I

maintenance 1 control building shall be located to allow unobstructed

pedestrian emergency escape. The escape route shall not cross any fire risk

area and should not pass through an area containing a process unit.

The orientation and layout of the building and its ventilation should be

considered in view of prevailing wind direction as a result of major toxic

release.

No building under any circumstances shall be built over any existing

underground service s).

Other Aant buildings such as compressor house, pump house, chemical

storagE building should preferable be made of structural steel with sheet

claddings and the design shall be submitted to KOC for review and approval.

Air ntakes

and

Discharqes

Air intartes for HVAC systems, air compressors for process air, instrument

air

plant air and ventilation air) and to gas turbines shall be located away from

areas where air contamination can occur due to dust, flammable or

toxic

material. They shall not be located in any area classified as Hazardous Area

Zone 0, or 2) as defined in KOC Standard KOC -G-002, nor h a te d above

or below an area classified as Zone 0 or Zone 1 For spacing between various

equipment and items refer to Spacing Charts in Appendix -I of this RP.

The 1oc:ation of air intakes shall be determined after considering the

effect o f

possible air contamination, additional safety systems, an d reduced exposure

constraints on personnel working in the area. The locations shall be subject

to the approval o f KOC.

The intakes should be located upwind of discharge location

to

prevent

cross

contamination by recirculation taking into account natural wind

effects.

The

distance between the intakes and the discharges should not be less than six

6 )metres.

Air discharges from HVAC systems from enclosed hazardous areas shalr

considered as a source o f release and shall be sited accordingly.

Air discharges from HVA C systems, and blow-off facilities associated

with air

compressors and fans, shall be located in such way that they will not cause

a hazard or inconvenience to personnel nor affect the access to, and

operation of, adjacent equipmen t.

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W C

O KOC La28

age

9

of

l

Rev

Primary / Area

Substation

Substation buildings should generally comprise switchgear rooms control

rooms battery rooms and transformer bays and should be sized appropriately

to accommodate all the electrical equipments with the necessary safety

clearances from the walls and the adjacent equipment in compliance with

KOC RP for Design Basis and Selection of Electrical Systems KOC-E-003

Part 1. For spacing between primarylarea substation and various equipment

/

items refer to Spacing Chart-2 in Appendix-I of thisRP

These facilities are normatly critical to plant operation. They shall be located in

a non-hazardous area and shall be well separated from the process area and

hydrocarbon pipelines.

Attention to grading of the site should be given to ensure sub-stations are at a

higher elevation relative to process areas.

Pjant

Substation

The plant substation should feed the power requirements of each facility and

should be located in a non-hazardous area and its location should be

optimized to provide the minimum length of cable runs within the plant. For

spacing between plant substation and various equipment / items refer to

Spacing Chart-I in Appendix-I of this RP.

If rooms like office

/

storage filing etc. are to be constructed attached to the

substatilsn buifding they shall be provided with independent entrance door

from outside; and shall be completely isolated from the substation building by

fire rated walls and doors.

Utilities

Utilities are vital for the operation of the plant and facilities. It should be placed

suitably away from process areas keeping in mind the operation requirements.

For spacing between various equipment / items refer to Spacing Charts in

Appendix-I of this RP.

Firewater

Tanks

and

Pumps

Fire-water pumps are critical equipment that shall be utilized in fire emergency

situations. They should be located well away from areas of blast explosion

and fire risk. For spacing between fire-water tank / pump and various

equipment / items refer to Spacing Chart-2 in Appendix-I of this RP.

The fire-water tank and fire-water pumps shall be located at a safe location and

shall be outside the fenced

area. The fire-water pumps should be located

suitabiy close to the fire-water tank to meet the optimum operation

requirements.

Area around fire water tank and fire water pump should have no obstruction

and shall permit free access for fire trucks.

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DOC NO. KQC La28

rocess Vessels

Vertical vessels shall be placed on a common centreline parallel to the main

pipe way unless process reasons dictate otherwise. For spacing between

process vessel and various equipment items refer to Spacing Chart-1 in

App endix-I of this RP.

Horizontal vessels shall be located to minimise piping runs and shall be lined

up with the dished head on a comm on locating line on the pipe way side

of

the

unit. Vessels and associated piping shall not encroach into established

operating or access aisles.

Adequate space should be provided between process vessels to allow

removal of components without obstructing normal operations

Shell

nd

Tube

Exchanqers

Shell and tube exchangers shall be located with the channel nozzles away

from pipew ays to facilitate tube bundle removal. They shall be lined up with

dished ends on a common line with vessels or shell on the pipeway side. For

spacing between shell and tube exchanger and various equipment tems

refer to Spacing Ch art- I in Appendix-I of this RP.

Shell and tube 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 un restricted vehicle access.

Shell and tube exchangers shall be arranged so that they can be readily

dismantled for cleaning and maintenance.

The channel end of exchangers shall be clear of overhead structures for

handling of chan nel end by mob ile equipment.

Shell and tube exchangers shall be located to facilitate tube bundle removal

using mobile equipment.

Monorails shall be provided where access from

mobile equipmen t is not possible.

as

Compressor

as Com pressors with gas turbine d r~ v e shall be oriented with due

consideration to the location of air inlets exhaust ducts and piping.

he

effects of noise and draught should also be considered. For spacing between

gas co.npressor and various equipment

/

items refer to Spacing Chart-I in

Appendix-1 of this RP.

Compressors shall be located under a shelter to provide protection to

equipment and personnel from the effects of direct solar radiation.

Compressors are recommended to be elevated to permit piping and

auxiliaries to be located below the operating platform. Sm all compressors

may be m ounted at grade with piping and auxiliaries arranged for convenient

access and maintenance.

5/20/2018 KOC-L-028

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DOC. NO KOC La28

Page 21 of

A suitable bridge or gantry crane should be provided to help replacement of

parts a i d com ponents of compressor for maintenance.

rocess

umps

Process pum ps should be located at or near grade level and under a sunroof.

All pum ps should be accessible for operation mainten ance and suitable

lifting devices shall be provided for their maintenance.

For spacing between

process pump and various equipment / items refer to Spacing Chart-1 in

Appendix-1 of this RP.

Pumps should be located and specified so that an acceptable NPSH can be

obtained without un due elevation of suction vessels or columns. Pum ps in

flammable or toxic service shall not be located in pits to m eet or satisfy NP SH

requirements.

Pumps shall be grouped together for ease of operation, providing process

requirements are satisfied. Suction lines shall be kept as sho rt as possible.

Pumps handling flammable liquids shall not be located under overhead

equipment, pipe rack or structure. A minimum horizontal clearance of 10

metres shall be maintained between pump and overhead equipment, pipe

rack or structure etc.

The practice of using firewalls or fire screens to protect overhead equipment,

pipe rack or structure, from the effects of a pump fire, shall not be generally

acceptable. However, risk assessment may be utilized in cases approved by

KOC.

All flamm able or toxic vapours released from plant equipment or systems shall

be appropriately discharged to the flare header or otherwise to a safe place as

approved by KOC. KOC approval in writing shall be obtained in case of any

deviation from this requirement.

The pump vent and drain lines should

be piped to proper containment

facilities.

Adequately ventilated shelters shall be provided for large machines requiring

in-situ m aintenance . Adequate space for lifting and handling facilities shall be

provided. A b ridge or gantry crane should be provided to help replacement of

parts and compon ents of pump for maintenance.

Crude export pumps shall be located inside a pump shelter.

A bridge or

gantry crane should be provided to help replacement of parts and

components of pump for maintenance.

All flammab le or toxic liquids released should be discharged into a closed and

safe drain system. KOC approval in writing should be obtained in case of any

deviation from this requirement.

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_DO

NO. KOC L 028

1

Page ~

Air Cooled Exchanqers

Air-cooled exchangers shall be located to provide safe and practical access

for operation and maintenance. They may be located at grade or over pipe

ways. Crane access shall be provided for tube bundle removal. For spacing

between air-cooled exchanger and various equipmen t items refer to Spacing

Chart-1 in Appendix-1 of this RP .

The location of air-cooled exchangers shall consider the effect of air

m o v e re n t on increased fire spread and the possibil ity of tube failure adding

fuel to the fire.

Air-cooled exchangers shall be located so that the hot air emitted shall not

cause hazard or an inconvenience to personnel, and does not impair the

operation of adjacent equipment.

Air-cooled exchangers should be located away from the fired heaters to

minimise the pos sibil~ty of c irculation of heater exhaust through the

exchanger. Preferably, they should be located downw ind of furnaces and

other sources of ignition.

Air coolers shall not be located above pumps or compressors handling

flammable materials.

Fired

Heaters

Fired -eaters shall be located on the periphery of a p lot and immediately

adjacent to an unrestricted road.

There shall be adequate access for fire-

fighting from all sides of a hea ter and, in the case of a group of heaters they

shall be separated from the remainder of the units by vehicular access ways

on the other three sides of the group. For spacing between fired heater and

various equipment items refer to Spacing Cha rt-I in Ap pe nd ix4 of this

RP.

Fired heaters shall be located relative to process equipment and prevailing

winds to minimise the risk of gas releases from the plant drifting into the

heater.

The layout and design of heaters shall be such that the tube removal can be

effected by mobile lifting equipment. Adequate dropout and swinging space

shall be provided,

Blast doors sha ll be oriented away from plant and operating areas.

Surface drains, specifically of hydrocarbons, shall not be located or routed

directly under a fired heater.

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DOC. NO KOC L428 I Page

3 of

Rev

Storage

Tanks for

Petroleum

Aboveground Petroleum Storage Tanks shall be located at a safe location

within the plant. The layout, interspacing, and diking of storage tanks shall be

in accordance with the requirements of KOC Standard KOC-L-027. For

spacing of storage tank and various other equipment / items within the plant

refer to Spacing Chart-I in Appendix-I of this RP and for spacing of KOC

Tank Farm from other facilities and items refer to Spacing Chart3 in

Appendix-I of this RP.

Pressure

Relief

Devices

All flammable and toxic vapours released should be appropriately discharged

to the flare header.

KOC approval in writing shall be obtained in case of any

deviation from this requirement.

All flammable and toxic liquids released shall be discharged into a closed and

safe drain system.

KOC approval in writing shall be obtained in case of any

deviation from this requirement.

For additional information for appropriate drainage of flammable and toxic

liquids refer to KOC-MP-027 Part 2.

Other Potential

Sources o f

Hazard

Any of the following fittings, which handle flammable fluids, shall be

considered a potential source of hazard:

a) Sample points

b \/ents and drains

c) F ressure regulator vents

d)

Heater fuel control valves and meters

e)

Heater fuel gas and pilot gas filters

f Chemical injection points

The source of hazard described in clause 8.16.7 above or other potential

sources of hazard shall be located at least 15 metres or more horizontally

away from any part of a fired heater or electrical distribution board, or other

sources of ignition.

Flare tack

The location, spacing, orientation and height of flare stack shall be determined

by a full assessment of the factors involved and appropriate calculation for the

heat radiation. For spacing between flare stack and various equipment

/

items

refer to Spacing Chart-2 in Appendix-I of this

RP

5/20/2018 KOC-L-028

25/34

Flares are a possible source of ignition; and shall generally be located remote

from process facilities, storage areas, utility areas, and office / service areas

but well inside the property line. They should be well away from public

occupied areas present or future) located adjacent to the site boundaries.

DOC

NO KOC L 028

Flares should also be considered a source of vapour release, as it is possible

that the flame could be extinguished.

Rev

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.

1

The flare should be located either on side wind location or upwind location

from the process facilities and sources of a major release of flammable

vapour.

Flares should be located as close as practicable to the process units served.

However this spacing should be computed based on risk assessment and

calculations for heat radiation and submitted to KOC for approval.

Flare stacks shall conform to the state regulations regarding height of

installations close to airways. All state clearances shall be obtained before

finalizing the site layout.

Burn

it

Burn

p f

shall be located so that smoke from the burn pit does not drift over

operatiqg areas of the plant, control and other buildings, substation and also

the gas

/

vapours released from plant equipment are not blown over the burn

pit. Fo spacing between burn pit and various equipment / items refer to

Spacing Chart-2 in Appendix-1 of this RP

Burn pits shall be spaced at a suitable distance away to allow maintenance

work to be carried out in a safe radiation zone from an adjacent burn pit

unless radiation zone calculations indicate a greater distance is required.

Distances shall be measured horizontally from the burner tip.

The manifold s) is intended to receive and collect the petroleum produced

from the wells. The petroleum is then discharged through the manifold outlets

to various batteries of separators located in the vicinity.

For spacing between manifold and various equipment / items refer to Spacing

Chart-I in Appendix-1 of this

RP

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I

OC.

NO

KOC L 028

1 Page 25 of

Offsite Effluent Treatment acilities

The plant contaminated water should be directed to flow through intended

water channels to treatment facilities. The water treatment facilities should be

graded to maximize gravity flow as much as practicable.

The effluent treatment facilities should be on downwind direction from sources

of ignition and be located at an appropriate distance from sources of ignition

based 3n risk analysis and calculations

Overhead Electrical Powerlines

The rrinimum horizontal spacing distance) of petroleum liquid or gas)

pipelines from overhead electrical powerlines shall be as given in KOC L 002.

For the purpose of safety and protection the KOC plant or facility shall not be

located constructed beneath the overhead electrical powerlines. As such the

overhead electrical powerhe should be at least 60 meters away horizontally)

from the fence or boundary of the plant or facility.

Plant Piping

General

The

ASME

631.3 nd

KOC

035

series

of specifications as described in

dause

4 2

of

this

RP

should

be

referred to

and

applied in order to

carryout appropriate design

of

plant piping systems and construction

with due considerations for safety requirements and piping systems

hydraulics.

Future expansion should be considered in the initial layout.

Appropriate space should be kept available for the installation of

future equipment, piping and cables. All piping layouts shall be

submitted to KOC for review and approval.

P r e s s piping shall not be buried and shall be routed above ground

on

grade level pipe racks or on elevated pipe racks.

Consideration should be given in design and layout of flare lines relief

and drain systems in order to meet necessary safety and operation

requirements.

The isolating valves shall be located such that they are readily

accessible and not located in an hazardous area of fire risk zone.

Fire Water Piping

Firewater piping may be installed below ground or otherwise as per the

design requirements. In case the line is designed underground, all block

valves should be located below ground in pits and shall be provided with

loose extension spindles for operation aboveground.

5/20/2018 KOC-L-028

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8.22.3 Piping Design

Flowtine battery limit valves shall be located immediately adjacent to

the plant fence line.

Inlet and outlet piping of Emergency Shut-Down Valves ESDVs) shall

be covered in the detail engineering design and rou ed/located

appropriately.

Thermal relief valves, protecting blocked-in process piping or

equipment shall discharge to a suitable drain or closed blow down

system.

For the protection requirements of new and existing KOC services,

refer to the relevant clauses of KOC RP KOC-L-002 for details.

Refer to other KOC Standards

/

RP and 015 Series of Specification as

listed in ctauses 4.2.2 4.2.3 of this RP, for a more detailed

specification regarding Piping Design and Layout.

PIPELINES

TR NSIT

LINES

The nearest location of proposed or existing facility such as residential building,

mosque, hospital, school, farm, office, shop, workshop, factory/industry,

warehouse, permanent structure, industrial, non-industrial dwellings,

private

or

public utilities and service units etc shall be 500 meter away from the existing or

proposed pipeline transit line corridors conveying hydrocarbon

gas,

crude oil,

and gas condensate. For minimum spacing requirements of equipment and

various items refer to Spacing Charts in Appendix-? of this RP.

The valve pits, metering stations and drain pits along the underground pipew ys

or pipehe corridor shall be fenced with 2.8 meter high barbed

wire

fence, and

shall be fully inaccessible to the public or residents at all times.

Statutory warning signboards with danger signs shall be installed at every 100

meter intervals along the pipe-way corridor for at least 500 m distance o the

either side of proposed inhabited buildings.

Under special circumstances where the above distances can not be maintaiwd,

the nearest location of the proposed building from the existing underground

pipe-way corridors shall be established after carrying out an extensive

Quantitative Risk Assessment (QRA) and analysis.

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DOC NO. KOC La28

1

Page

7 of

QUALITY

ASSURANCE

The Contractor shall operate a quality system preferably based on IS0 9000

series of standards to satisfy the requirements of this Standard. The

Contractor shall demonstrate compliance by providing a copy of the

accredited certificate of its quality manual. Verification of the Contractor

quality syskm is normally part of the pre-qualification procedure and is

therefore, not detailed in the core text of this Standa rd.

The Contractor shall also operate an Occupational Health and Safety

Assessment Series-OHSAS-78001 series of Standards to m eet KOC HSEM S

r e q u k n e n t s .

DOCUMENT TION

General

Documentation required are generally covered in the KOC Tender

Documents. However the documentation requirements as mentioned below

supplements

the requirements in aas specified in the KOC Tender

Documents.

All correspondence, instructions, data sheets, drawings or any other written

information shall be in English language. In case of dual languages, one

language shall be English.

All dimensions, units of measurement, physical constants etc. shall be in

S

units u il es s otherwise specified. Nom inal bore pipe sizes to be generally

mentioned in inches).

All documents text, data sheets, specifications etc .) shall be provided with

electroriic files in the approved and widely used software MS W ord,

Excel,

Auto CAD etc.). All calculations shall be submitted in approved and widely

used software s ) agreed upon by KOC.

The C cntractor shall provide the necessary docum ents to KOC for review and

acceptance as given below, but shall not be limited to the following only:

Btock Flow Diagram

Process Flow Diagrams

PRlDs

Cause an d Effect Tables

Plot Layout

G-ading Plans

Drainage Plans

Paving Layou t Drawings

Equipmen t Layout Drawings

Piping Plans

5/20/2018 KOC-L-028

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5/20/2018 KOC-L-028

30/34

SPACING

CHART-I

SPACWCO EWPMENT AND ITEM

LOCATED

WtTHlN KOC PLANT GC BS / OTHER FA

~ a i n row55 P i p m ~ y ~

3

5

~ i ~ e w x ~ s

or Non Pf lro leum Fluids 25

Sparing in Mcfcrs

Not ]

For spaeinp

a f Peltrskmn

StorageTank inside thr pIan1

wirh

c q u i p m i Ircrns [mi

c mmt

planil r d t r o KO

Notc 3 m nfarm a~io n cgrd ing apacrnp crrlcrln rcfcr ro Cla~scs 1.4 and 1.5 o this IW.

5/20/2018 KOC-L-028

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DOC. NO. KaC-1-028 I

Page 30

of

SPACINGCHART-2

SPACING OF KOC EQUIPMENT AND ITEMS LOCATED OUTSIDE OF KOC PLANT GC S OTHE

BUT

WITHIN KOC FENCED AREA

Tank+

R r : ~ c h h

Fire

Wwlrr

3

PM

RC RC 3

......

.

RC

RC

RC RC

RC RC RC

RC RC

P i p l i n c ~

Trrrnril

lints f l n t e - I )

3

3 RC

M

N

atr-2

8

Oil-Wstw

Separator ond

i

9 Oil .

G R ~

Vcll< N u W - ~ J

Now-1:

Thc

spacing is

of

pipclinc;

/

transit

l incs ( in

cnrridnrl

with

athsr

items as

shown.

T h ~ s

pacing

is not lntcndcd

fnr

the

Natc-2:

SP CING

ON HOLD.

Sparing

o f rhts it m is m hc prnvidcd by

PhDSS

? AM PADSSTtam

=

Produc~inn

h d

Xotc-3.

For i n foma l ion

r q a r d i n g

spacmg

crilcr~a r f i

o

CLauses

7.1 & and 7 t S o f h is RP.

5/20/2018 KOC-L-028

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DOC. NO KOC-L-028 Page 31 of 33

AP PENDtX-I Contd

.

SPACING CHART-3

SPACING

F

KOC

PLANT.

KOC

TANK

FARM AND

OTHER

KOC

ITEMS

f U O M

filJWAlT

GOV-i PKIVA

It PUl3LIC Ui LUTlES

AClLlT

I t 5 ETC

NOTE

:

For derails reg~rding pacins of

KOC Tank Fann

for

Petrolcum

Stom_cc with

olhcr

itcms rcfw

2 3 4

M RC

M

6

M

M RC

ARBREVIATJW45 IrSiED:

t

=

Cdcula tc

M

=

Dtrermmc appropriarc

spacing

hz;don Maintmance i crsonncl Access1Safcty INoisc Lcwl rtqu

N = No1

Controlled

by KOC

R =

Risk Anslys~s

X =

No

Mandator .

Rec]uiwmtnt

= Not Applicable

4

5

Hl:hwa

I R m d RC

Rr r l den

i

t r ca , Woqrrc.

Hmpital, Schc~ol,

arm,

5DOIRC

Oftire Shop. \ h r k h o p l

Srrcrnp. Wrrrhoutr

Err

Sr No -

l 1

60

300

S p r c ~ n gn Sletcrc

2

RC

5 1

RC

3

N

N

4

5/20/2018 KOC-L-028

33/34

DOC.

NO. KOC La28 Page 3 of

Rev. 1

ACKNOWLEDGEMENT

This RP has been approved by the Standards Technical Committee (STC) consisting of

the following:

Mr. NRedha AI-Haddad

Mr. Mohammad Emam

Mr. S. Kumar

Mr. Henry Hill

Mr. A. Unnikrishnan

Mr. Khalaf Harnada

Mr. N. Ramanathan

Mr. Ali Hassan Al-Failakawi

Mr. Daniel Pino

Mr. Abdul R. Al-Shammari

Mr. Khalid Al-Ahmad

Mr. AbdulAziz Akbar

Mr. Moataz Khalaf

Standards Team

Insp. Corr. Team (S E)

Standards Team

Opns. Tech. Svcs. Team (SK)

Standards Team

Design Team

Export Facilities Team

HSE Systems Team

Utilities Team

Insp. Corr. Team (N WK)

Gen. Projects Team

Project Mgmt. Team (NK)

Information Systems Team

Chairman

Deputy Chairman

Secretary/ Member

Member

Member

Member

Member

Member

Member

Member

Member

Member

Member

The draft of this

RP

had been circulated to the KOC User Teams for review and the

responses were received from the following:

ENGINEERING GROUP

EXPORT MARINE OPNS GROUP

Team Leader Design

Team Leader Export Services

AHMADI SERVlCES GROUP

HSE

GROUP

Team Leader Utilities

Team Leader Proj. Design

Team Leader 61dg Mgmt.

Team Leader HSE Systems

Team Leader HSE (TS)

Team Leader HSE (NK)

OPERATlONS

GROUP ISKl

MAJOR PROJECTS GROUP

Team Leader Maintenance

Team Leader Prod. Opns

OPERATIONS GROUP INK

Team Leader Project Support

DIVIDED ZONE

GROUP

Team Leader Opns. Tech. Svcs

Team Leader Proj. Engg. Facilities

GAS MANAGEMENT GROUP

Team Leader Gas Operations

Team Leader Consumers Networks

5/20/2018 KOC-L-028

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DOC.

NO

KOC La28 ] Page of 33 Rev.

1

This

KOC

RecommendedPractice or Layout o

Plantsite and

Offsite Facilities

IKOC-L-028 Rev.7 has been prepared by the Task Force TF-LPi12) comprisingof

ihe following members:

Mr. Faisal Mirza

Mr. Mohsin Mirza

Mr. N. Ramanathan

Mr. Mohd. Alam

Mr. Uppara Saibaba

Mr. T. V. Valsan

Mr. Haytham

H.

Al-Habshi

Mr. Mohd. Al-Ajmi

Mr. NAl-Sattar A/AI Salam

Mr. Mohd. Dashti

Mr. John Onderdonk

Mr. Sayed Al-Zaizalah

Standards Team

Standards Team

Export Facility Proj

Safety Team

Safety Team

Design Team

Opns.Tech.Svcs. NK

Opns.Tech. Sevs. WK

Production Opns. SK

TF Leader

Author

Member

Member

Member

Member

Member

Member

Member

Ex. 61 151

Ex. 61371

Ex. 66960

Ex. 66415

Ex 71837

Ex. 61659

Ex. 23336

Ex. 20336

Ex 22538

Human Resources SEK Member Ex. 22145

Drlg W/Over Member

Ex. 71057

Field Development SK

Member Ex. 22069