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com Training Seminar Section - V B: Defining Offsite Facilities for Process Plants Contributors (In alphabetical order): Jadeep Coudhary, Anita R. Legvold, James O. Pennock
Some have asked questions such as: "What is Balance of Plant?"; "What is Offsites?" What is OSBL?" and "What needs to be considered when a project includes Offsites." The term Offsites is a general term and does not mean the same for every project or every plant. A project may include extensive tankage for feed storage along with tankage for in-process product, intermediate product, rundown tankage, slops and finished product tankage. Another project may include none of this because they already exist. The point here is just because you are told that the project includes "Offsites" you need to ask a lot of questions to determine exactly what they mean and what will be required. The purpose of this document is to aid in answering this type of question. This document will not tell you how to design the Offsites or design any of the individual sub-items or equipment found on this list. That design guidance should properly be left up to you, your supervisors and your management. I do however intend to start a listing of major elements along with some minor key issues that should be considered. I invite others to submit their own thoughts and comments to add to and improve this list.
Section Subject 1 Definitions -- Offsite vs. Onsite 2 Codes, Standards, and Practices 3 Site Issues 4 Terrain, Grading, Roads, & Drainage 5 Tankage 6 Flares 7 Piperacks & Sleepers 8 Pipelines 9 Loading / Unloading Racks (Truck, Rail, Barge, and Ship) 10 Cooling Water Supply Systems 11 Hazardous Chemicals 12 Waste Treatment Facilities 13 Electrical 14 Buildings & Auxiliaries 15 Fire Protection & Safety 16 LPG Bottling Facilities 17 Solids Storage & Disposal
Offsite -- In a process plant (Refinery, Chemical, Petrochemical, Power, etc.), any supporting facility that is not a direct part of the primary or secondary process reaction train or utility block. Offsites are also called OSBL.
or highway right-of-way line (3). Codes. Site Issues . Setback or Setback Line -. 1981 Prentice-Hall (2) -. An easement is typically a strip of land within which overhead power lines or underground pipes are run. Easements -. walls and any other construction form. Off Property .A line established by law. Decimalized Water. or custom. State. road. City.. etc. (1) -.. for a specific purpose.) MSS (Manufacturing Standards Society) -NACE (National Association of Corrosion Engineers)-NFPA (National Fire Protection Association) OIA (Oil Insurers Association) PFI (Pipe Fabrication Institute) USCG (United States Coast Guard) Regulations 3.Any single or collection of inter-related and inter-connected process equipment that performs an integrated process function. Balance of Plant . Drawing Indexes. Plant Air. Instrument Air. Standards. etc.This is another term for Offsites and/or anything else other than the Onsite Units or the Utility Block.Onsite . (2) Defines the separation between what is recognized legally as Owner's land and non-Owner's or other land. deed restriction. On Property -. Setback is a clear area normally at the boundary of a piece of property with conditions and restrictions for building or use. & Practices ANSI (American National Standards Institute) API (American Petroleum Institute) ASME (American Society of Mechanical Engineers) ASTM . s street. Plant Water.Any land (On Property or Off Property) set aside and designated for a specific use or purpose.A single or multiple grouping of facilities that generate the support services required by the Onsite Process units to function.All land and or water inside the Property line shown on the property map or deed.American Society of Testing Materials AWS (American Welding Society)-AWWA (American Water Works Association) CFR (Code of Federal Regulations) Division of Weights & Measures -DOT (Department of Transportation) FAR (Federal Accounting Regulations) IRI (Insurance Regulators Institute) Local Permits (Country. The Battery Limit line is usually established early in the project and documented on all discipline documents such as Plot Plans.Line used on a plot plan to determine the outside limit of a unit. such right being held by someone other than the owner who holds the title to the land (2).Off property is any land (or water) outside of the Property line shown on the property map or deed. A Right-of-Way within a piece of property may also be designated for use by someone other than the property owner. Battery Limit -.A vested or acquired right to use land other than as a tenant. etc.Lamit. fixing the minimum distance from the property line of the exterior face of buildings.Construction Dictionary 2.A Property Line is the recorded boundary of a plot of land. Utility Block . Site Plans. Typically any Onsite Unit could be made to function independently of another Onsite Unit. This normally includes: Steam Generation. Right of Way (ROW) -. (1) Property Line -. Onsite Units are also called ISBL. Louis Gary.
Angle of repose .Sanitary Sewage . Secondary and by-products Seismic zone SHE (Safety.Grubbing (Tree and shrub removal) .Capacity (number of rail cars) .Storm .Location .Oily Water .Secondary . Roads.Level vs.Chemical .Location. Terrain.Right hand or left hand drive .In ground or On ground .Skimmers & Aerators .Vertical and Horizontal Clearance requirements . Sloping Geotechnical influences .Invert Elevation Basins & Ponds . source and method of delivery Future growth Grass Roots or Greenfield (New construction) Impact across the fence Power requirements and source Products.Other Ditches .Type and purpose of traffic .Number .Lined vs.Contours . Size.Finished Grading Roads .Primary .Grading .Width .Depth . Unlined (or Rip Rap) .Contaminated .Standards and jurisdiction of Rail company (Right of Way) Drainage systems .Elevation .Pipeway or Sleeper Crossings (Overhead Vs Ramp & Culvert) Rail Spurs (see Loading and Unloading for additional criteria) . Ditches & Drainage Terrain . Primary. potential for congestion . Type .Rough Grading .Type of soil .Slope Culverts . Health and Environmental) Utilities requirements 4.Brownfield (Revamp Existing) Climate (Wind Rose) Demolition Feed stock type. Grading.Roadbed & Ballast Details .Traffic pattern.
Floating Roof . Catwalks.Multiple Tank Group -. Jacketed.Existing or new . Multiple) .Water Spray Systems (Deluge Systems) Tank Nozzles & Appurtenance . Pressurized .Location & Elevation .Single Wall vs. Commodity Grouping & Spacing Criteria .Spheres .External Type .Metallic vs.Single Tank .Jet Types .Foundation Types .Atmospheric vs.Cone Roof .Fenced or Unfenced .Other (Used tank cars as storage) Tank Construction ..Internal Coil Type .Snuffing steam to V/PRV (Vacuum & Pressure Relief Valve) Tail Pipes .Primary Inlet & Outlet Connections (Single vs.Bullets .Unlined vs. non compatible) .Different Sizes Spill Containment .Spheroids .Earthen Berm (Dike) .Removal methods and clearance Fire or ignition suppression .Insulated.Containment Criteria .Wall (Concrete) .Support requirements . Stairs.Same Size .Internal Bayonet Type .Multiple Tank Group -. Heated.Material if new .Access .Settlement Tank Auxiliary Equipment .Overflows & Runoff .Commodity (Compatible vs.Heaters & Coolers .Foundation Details .Motor Driven Mechanical Types .Mixers . and Platforms .Material if existing .Combination Tank Supports and Foundations .Valve extension stem requirements 5.Access Stiles. Lined .Topography .Sloping Bottoms . Tankage Types & Purpose . Double Wall . Cooled. nonmetallic .
) Dike Penetrations (Piping) .Sleeves (U/G Protection & Grounding) .Steam .Internal Pipe Supports -.Cooling Water .Level Controller & Gage -.Primary access .entrance and exit .Condensate . Non-winterized) Instrument Connections (Flow.Natural Anchors (Dike Sleeves) .Tracing Fluids (Low Temp.Double Containment .- Vent Connections (Closed.Sumps . Open. Winterized.Glycol .Float & Target Board -.Plant Water .Nitrogen . Level. Accessibility) -.Sonar Heating Coil Connections (Inlet/Outlet) Mixer Mounting Nozzles Manholes Internal Nozzles -.Tank Edge Handrail Pumps .Slops Collection System Hot Oil Systems . and Platforms .Location of First Support . and Temperature) -.Safety .Avoid weld seams Ladders. Stairs.Radar type Level Instruments -.Differential Settlement .Instrument Air .Plant Air . or High Temp.Automatic (Tape Type) Tank Gage -. Clearance.Orientation .Types .Piping Elements Product Piping .Pressure Taps -.Internal Floating Roof Supports Orientation & Elevation Size & Rating Projection Recommendations -.Swing Lines (Winch.Location .Asphalt Tankage & Distribution Utilities Piping .Roof traffic Vs Formal Platform . Flame Arresters) Drain Connections (Closed.Gage Hatch -.Chilled Water .Ammonia .Internal Piping -.Casings .Potable Water .Thermowells -. Pressure.
Elevated -.Pilot Gas .Operations Issues .Wash Stations & Spray Wands 6.Location Criteria .Free Standing .Access (Mobile Equipment) . Flare.Flame Arrester Flare Stack Utilities .Location Criteria .Elevated -."Boil Over" Maintenance Issues .Fuel Gas .Location Criteria .Atomizing Steam .Fuel Gas .Atomizing Steam Thermal Oxidizers .Cleaning and Repair .Support .Pilot Gas .Collection System Incinerator Utilities ."Roll Over" .System Study Flare KO Drums .Cable Guided Flare Accessories .Derrick Supported . and Thermal Oxidizer Flare .Elevated -.Flame Arrester Drain Incinerators . Incinerator.Igniter Line .Utility Station Location & Access .Collection System Thermal Oxidizer Utilities .Housekeeping Pads (Spillage control) .Pump out Flare Number and Types .Prevailing Wind (Wind Rose) .Prevailing Wind (Wind Rose) .Pilot Gas .Number of Flare Stacks .Prevailing Wind (Wind Rose) .Igniter Line .Vertical/Stack base integrated .Fuel Gas .Horizontal .CIP (Clean in place) .Atomizing Steam .Ground Flare .Flare Header .Igniter Line .
location.Cross Country .Concrete .Slip Lining 8.Bridges Materials of construction .Steam Tracing .Shoes.Piping Loops .Changes in Direction (Flat Turn vs.Number of levels .Internal Cleaning requirements for piping systems . Anchors.Piping Loops . and access .Current Space Requirements .Span Auxiliary Piping Services & Systems . Pipelines Types and Purpose . Anchors.Cleaning connections (Maintenance) .Future Space Requirements . Elevated) .Height .Minimum Line Sizes .Shoes.Intra Plant Accounting Meters .Hydrotest Vents & Drains .Solar induced expansion .Number .Elevated (Overhead) Racks .Operating Temperature induced expansion .Location .Jacketed Piping .Inter Plant . & Guides Pipe Bridges .Utility Systems . & Guides Pipe Sleepers .Solar induced expansion . Piperacks and Sleepers Support Types .Maximum Spans .Combination Overhead Racks .Size.Sleeper Racks .Maximum Spans .Operating Temperature induced expansion .Future Space Requirements .Meter Provers .Process Vents & Drains .Future (space allowance) Miscellaneous Piping Details .7.Steel .Minimum Line Sizes .Height .Current Space Requirements .Height .
Flammable Liquid Hydrocarbon Products ..Top Loading .Loading Arms or Loading Hoses .Truck .Bottom Loading (Truck & Rail only) ."Bonded Zone" .Fencing and Security Pig Launchers & Pig Catchers (Receivers) .Ship Loading & Unloading Method .Package System . Barge.Number of shipments . Barge/Ship) .Fixed or Floating Dock . Rail.Types Special Valving Considerations .Loading Arm reach .Height and reach of swing-down platforms . Rail Car.Dry Products .Unloading time Loading Rack Size & Location Criteria .Vendor or Third Party Sub contracted .Non-flammable Liquid Chemical Products .Liquefied Petroleum Gas (LPG) Products Shipping method .Minimum distance between loading "Spots" .Vapor recovery criteria Shipping Plan .Loading Arm rest position .Size of Carrier (Truck.Support Special Instrumentation .Rail .Gas Products .SCADA .Minimum bend radius Slug Catchers .Stick build Pipe Line Pigging Criteria .Loading Arm Type .Stair and Ladder access and egress Barge & Ship only .Barge .Pig Signals (Pig Sig) 9.Access & clearance for Operators .Types .Outline of structure . Loading / Unloading Racks (Truck.NFPA Criteria . and Ship) Product Data .Liquid Products .Frequency of shipments .Loading time .
Deluge Systems .Fixed Screens . Summer.Meters .Foam Systems 10.Spill containment .Nitrogen (for blanketing) Safety & Fire Protection .Once through system .Lake . vessel full at low tide) Auxiliaries .Municipal Water Supply (City.Fire Blankets .Atmospheric (Flooded) System Water Source .Utility Steam .River . etc.Wells .Closed loop Cooling Tower system . Cooling Water Supply Systems Types .Natural Draft Prevailing Wind .River Intake .Breathing Air .Induced Draft .Ocean Intake . County. and Winter?) .Hydrants ..Surge Pond Water Intake & Outfall Structures .Plant Air .Force .Fire Extinguishers . Fall.In-ground .Timing (Spring.Direction (primary and secondary) .Tide & Current Data .Strainers and Filters .Shelters .Oceans & Bays Tower Types .ESD (Emergency Shut Down) System .Grounding Lugs .Rotating Screens .Maximum "Swing" envelope (Vessel empty at high tide vs.Plant Water .Monitors .) .Forced Draft .Duration Basin Design .Piping Utility Requirements .Under-ground .
PVC .Insulating Flange Sets 11.Pipe Riser Location .Contaminated Collection Locations Collection and transfer methods .Portable crane .Storm Water .Sanitary .FRP .Vertical .Material .Oily Water .Horizontal (elevated above basin) Operations .Stand alone .Built-in lifting facilities Cooling Water Supply and Return Piping .Location (Above ground or below ground) Water Treatment Chemical piping .Type . Waste Treatment Facilities Types .Gravity to Sump & Pump to Treatment .Alloys Cathotic Protection .Safety Shower/Eye Wash Winterized (Tempered water system) 12.Gravity (only) to Treatment . Hazardous Chemicals Handling and Storage Commodities List MSDS (Material Safety Data Sheet) Unloading Facilities Storage Loading Handling Safety .Pump Types & Location .Chemical .Manned Maintenance .Horizontal (same level next to basin) .Stainless Steel .
Lab Gas -.Comfort Steam & Condensate -.Laboratory (Product QC) -.Chilled Water -.Chemical Waste -.Transformers Aboveground Distribution .Rail Facilities 14.Load Centers .Substations .Structures .House of Worship (Mosque) -.Switch and Starter Racks .Telephone Poles .Warehouse -Auxiliaries .Duct Banks (Concrete encasement) .Fire House -.Hot & Cold Water .Safety Center & Training -.Types of Treatment 13.Electrical Manholes .Contaminated Waste .First Aid -.Pipe Racks .Change House (Locker Room) -.Machine Shop -.Piping .Parking Lots .Power Poles .Truck Loading/Unloading Docks Utility Services .Administration .Direct Bury Cable .Roads .Push Button Stations .Potable Water -- .Transmission Towers Underground Distribution . Electrical & Instrumentation Equipment Types .Light Standards .Conduit Racks .Cafeteria -.Maintenance -. Buildings & Auxiliaries Buildings and purpose .Gate or Guard Houses -.Control (House) Center -.Cable Trays .Process Equipment .Chemical Storage -.Junction Boxes .Instrument Rack/Cabinets .Electrical Pull Boxes Clearance criteria Electrical to: .
FRP Piping .Fire Hose Carts Materials of Construction .Foam Stations (Number and Orientation) .Fire Water Loop (Mains and Laterals) .Contingency Plan Fire Water System .Size Shipping method .Truck scales (weighbridge) Lube Oil packaging facility .Ductile Iron .Truck .Full bottle storage .Sulphur . . Fire Protection & Safety Fire Protection & Safety Plan .Carbon Steel w/ Internal Lining & external coating .Foam Chambers (Number and Orientation) .Fire Hydrants and Monitors .Basic Safety Plan .Type .Sanitary Waste -.Type.Rail 17.Filling .Cement Lining .Location .Thrust Blocks & Anchors Fire Training Area .Carbon Steel w/ external coating .Storm Water -Piping Materials 15.Open.Nonmetallic Linings .Fire Water Pumps ..Bottle shipping . Solids Storage & Disposal Type .Facilities Fire Equipment 16.Empty bottle receiving .Fire Water Storage . sheltered.Fire Water Source .Enclosed .Fire Protection Manifolds (Pumper Connections) . Product packaging LPG Bottling Facility . enclosed .Sheltered .
James O.Truck . USA.Dry . Pennock is a former Piper with more than 45 years experience covering process plant engineering. design. .Off property Shipping method . She is now semi-retired and lives in Florida..Rail . pipe fabrication and construction.Barge .Open .Other Jaydeep R. and field activities. Chaudhary is a piping designer with 4+ years of experience with oil & gas projects working with Hyundai Heavy Industries.Treated waste Consistency .Semi-dry Storage . USA. training. Anita R. design. Legvold is a Piping Design Engineer with more than 35 years experience covering process plant engineering.On property . He is now retired and lives in Florida.Sheltered Disposal . Seoul South Korea.Coke .