(BMPS) : Bapco Modernization Program Specifications

BAPCO MODERNIZATION PROGRAM SPECIFICATIONS
(BMPS)
PROJECT SPECIFICATION No.
BMPS-A4
REFINERY LAYOUT AND SPACING
The Bahrain Petroleum Company B.S.C. (Closed) Refinery Layout and Spacing
BMPS BMPS-A4
Bapco Modernization Program Specifications Revision 2, July 2018
I. GENERAL DESCRIPTION OF BMPS-A4

This specification covers the minimum technical requirements for Refinery Layout and Spacing.
II. CONFLICTS AND DEVIATIONS

It is Contractor’s (and Supplier’s / Subcontractor’s) responsibility to obtain all applicable specifications,
codes and standards, and to ensure compliance with the requirements contained therein. The word
‘should’ shall be replaced by ‘shall’ wherever it appears in these documents.
It shall be the Contractor’s (and Supplier’s / Subcontractor’s) responsibility to bring all conflicts and
deviations to the Owner’s attention in a timely manner and request a ruling interpretation or a resolution
in writing. The Contractor (and Supplier / Subcontractor) is not at liberty to assume which instruction
would govern. Refer Project Specification No. BMPS-A2 (Specifications, Codes and Standards) for
guidelines to manage conflicts and deviations.
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BMPS BMPS-A4
TABLE OF CONTENTS
I. GENERAL DESCRIPTION OF BMPS-A4 2
II. CONFLICTS AND DEVIATIONS 2

1. SCOPE 6
2. DEFINITIONS 6
3. REGULATIONS, CODES AND SPECIFICATIONS 6

3.0 International Standards 6
3.1 Owner Documents 6
4. LAYOUT CONSIDERATIONS 8
4.0 General 8
4.1 Efficient Design 10
4.2 Legal Requirements 10
5. LAYOUT OBJECTIVES AND BASIC REQUIREMENTS 10

5.0 Plant Datum 10
5.1 General 10
5.2 Consequence Analysis and Probabilistic Risk Assessment 11
5.3 Default Spacing 11
5.4 Separation from Adjacent Property 11
5.5 Separation of Facilities 12
5.6 Noise Control 13
5.7 Separation of Hazardous Plants 14
5.8 Protection of Critical Equipment 14
5.9 Protection for Utilities 14
5.10 Piping Arrangements 14
5.11 Utilisation of Topography 15
5.12 Drainage 16
5.13 Clearances and accessibility 18
5.14 Safety Showers/Eyewash Stations 18
6. BLOCK LAYOUT AND ROADS 19

6.0 General 19
6.1 Roads 19
6.2 Restricted and Unrestricted Roads 20
6.3 Paved Process Areas 20
7. PLANT SPACING 20
7.0 Plant-to-plant Spacing 20
7.1 Plant-to-building Spacing 21
7.2 Plant-to-offsites Facilities Spacing 21
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7.3 Spacing of Miscellaneous Facilities 22

7.4 Construction and Maintenance Considerations 22
7.5 Odour and Hazardous Waste Considerations 22
7.6 LPG Facilities 22
7.7 Tankage 23
7.8 Pump Stations 23
8. PROCESS EQUIPMENT LAYOUT AND SPACING 23

8.0 Basic Configuration 23
8.1 Main Piperacks and Adjacent Equipment Configuration 23
8.2 Onplot Piping 24
8.3 Power and Instrument Cabling 24
8.4 Vessels 24
8.5 Shell and Tube Heat Exchangers 25
8.6 Air-cooled Heat Exchangers 25
8.7 Fired Equipment and Heater Stacks 26
8.8 Pumps and Compressors 26
8.9 Cooling Towers 27
8.10 Packaged and Skid-mounted Equipment 27
8.11 Catalyst and Chemicals Handling 27
8.12 Equipment Servicing and Protection 28
8.13 Other Equipment Spacing Concerns 28
8.14 Location of Fire Fighting Equipment Inside Process Units 29
9. OVERHEAD PIPERACKS 29
9.0 Basic Requirements 29
9.1 Electrical and Instrument Cable Support 29
9.2 Allowances for Future Additions 29
9.3 Clearances 29
10. EQUIPMENT AND UNIT ACCESS 30

10.0 Access to Structures 30
10.1 Mobile Equipment Movement and Access 30
10.2 Satellite Operator Shelters 31
11. CLEARANCES FROM ATMOSPHERIC DISCHARGES 31

11.0 General 31
12. PITS AND PIPE TRENCHES 31

12.0 General 31
13. STORAGE TANKS 32

13.0 General 32
14. TANK TRUCK LOADING RACKS 32
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14.0 General 32
TABLE : ACCESS WALKWAYS, PLATFORMS, LADDERS AND MAINTENANCE 34
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1. SCOPE
This Specification provides guidelines and minimum requirements for the layout and spacing of refinery
process units, utilities, offsites and equipment items (including packaged plant). The Contractor shall
also consider this Specification in conjunction with the Owner’s other specifications referenced herein
(see Regulations, Codes and Standard). The Owner’s objective is to ensure safe and efficient operation
and maintenance, and fire prevention and control.
Certain provisions contained herein also apply to onshore marine terminals or other facilities outside the
refinery described in the Owner’s Specifications.
2. DEFINITIONS
Within this Specification the following definitions shall apply:
OWNER The Bahrain Petroleum Company B.S.C. (Closed).

The terms “Purchaser”, “Company” and “Owner” are interchangeable.
CONTRACTOR Company / Organisation responsible for detail engineering design,

procurement, construction and pre-commissioning of the facilities.
SUPPLIER Company / Organisation supplying equipment, materials or service.

The terms “Vendor” and “Supplier” are interchangeable.
SUBCONTRACTOR Company / Organisation contracted and managed by the Contractor.
3. REGULATIONS, CODES AND SPECIFICATIONS

3.1 International Standards
Latest editions of following Codes, including all their Addenda, shall be used in the development of the
detail piping design and equipment layout:
API RP 505 Recommended Practice for Classification of Locations for Electrical

Installations at petroleum Facilities Classified as Class 1, Zone 0,
Zone 1, and Zone 2
NFPA 30 Flammable and Combustible Liquids Code
3.2 Owner Documents
The primary reference project specifications (BMPS) and standard forms / drawings are listed below.
The complete list of Owner Documents is provided in BMPS-A2.
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BMPS BMPS-A4
SPECIFICATIONS
BMPS-A1 Basic Engineering Design Data
BMPS-A2 Specification, Codes and Standards
BMPS-A5 Safety in Design incorporating Human Factors Engineering
BMPS-A15 HAZOPs of Major Projects
BMPS-A18 Overpressure Protection
BMPS-A19 Design of Flare Equipment
BMPS-A20 Noise Limitations
BMPS-D5 Tankfarm Layout and Spill Control
BMPS-J1 Control System Design Basis
BMPS-L1 Refinery Piping

BMPS-L3 Piping Layout and Piping Design
BMPS-M1 Basic Civil and Structural Design Data
BMPS-M2 Concrete Structures

BMPS-M3 Steel Structures
BMPS-M6 Fireproofing
BMPS-P1 General Design Rules for Electrical System
BMPS-R3 Electrical Substation Building
BMPS-S1 Drainage Sewer Systems and Effluent Treating
BMPS-S3 Roads and Paved Areas
Loss Prevention Basis of Design, Fire Protection and Safety

BMPS-S5
System
BMPS-S6 Facilities for Pressurized Mounded Storage and Loading of LPG
STANDARDS FORMS AND DRAWINGS
BMPS-L-144019 Standard Valve Installation Guide
BMPS-SD-A-23194 Spacing between Plants for Fire and Safety Considerations
BMPS-SD-B-23195 Data for Typical 80 Ton Mobile Crane
BMPS-M-83687 Typical Details Vehicles Height Restriction Frame
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BMPS BMPS-A4
BMPS-M-135766 Structural Details, Height Restriction Frame, Refinery External Car

Parks
4. LAYOUT CONSIDERATIONS
4.1 General
4.1.1 Process unit layout shall satisfy law and statute of the prevailing governing authority.
4.1.2 Conflicts between the Owner specifications and the applicable codes, standards, laws and
statures shall be submitted in writing to Owner for resolution.
4.1.3 Any and exceptions to Owner specifications shall be submitted in writing to Owner for review
and acceptance.
4.1.4 Access and clearances for operation and maintenance on proprietary equipment or parts of
proprietary equipment shall be in accordance with the equipment manufacturer’s standards.
4.1.5 Process unit layout shall include the following:
 Equipment location
 Access and egress for personnel safety
 Access for operations and maintenance
 Provisions for operational housekeeping and constructability
4.1.6 Process unit layout shall adhere to the requirements of BMPS-A5 ‘Safety in Design
incorporating Human Factors Engineering’.
4.1.7 Prevailing weather and site conditions shall be considered in the development of general
plant arrangements.
4.1.8 Consideration shall be given to further expansions, and to possible encroachments from the
surrounding community based on future growth.
4.1.9 Plant equipment shall be located to minimize risk to the public and to the environment.
4.1.10 Where the history indicates a probability of extreme conditions, such as monsoons, violent
thunderstorms, airborne saltwater spray, fog, and floods, the Contractor shall make
appropriate provisions for these conditions in laying out the facilities.
4.1.11 Prevailing winds shall be considered, and any equipment handling light hydrocarbons shall
be located downwind of fired heaters to minimize the possibility of vapors being carried
toward open fires.
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4.1.12 Noise control engineering, plant layout, and procurement of noisy equipment are integrated
processes and shall be planned accordingly.
4.1.13 The process unit shall be integrated within a common plant site so that independent
operating and shutdown requirements for maintenance of other process units are not
affected.
4.1.14 Facilities shall be provided for the isolation of a process unit when independent operation
and maintenance are required.
4.1.15 Plant and equipment layout shall provide exit routes in accordance with BMPS-A5 ‘Safety in
Design incorporating Human Factors Engineering’ and BMPS-SD-A-23194 ‘Spacing
between Plants for Fire and Safety Considerations’.
4.1.16 Layout shall permit full utilization of mobile handling equipment for construction, servicing,
and maintenance from roads through or adjacent to the process unit.
 Maintenance requirements during plant shutdowns shall be considered.
4.1.17 Space for access by emergency response personnel shall be provided, including adequate
area for isolation required to effectively contain an incident.
4.1.18 The Designer shall ensure that the clearances required for large equipment, such as fire
trucks, spill response trailers/equipment, tank trucks, etc., are adequate.
4.1.19 Spacing requirements shall be in accordance with the equipment spacing charts located in
BMPS-SD-A-23194 ‘Spacing between Plants for Fire and Safety Considerations’.
4.1.20 Vehicle access through the plant shall allow for safe interaction with personnel, safe egress
during operations, maintenance, delivery and pick-ups and emergency situations.
4.1.21 The plant layout shall consider the following constructability issues:
- Size and location of construction lay-down areas
- Transportation corridors to the laydown areas and from the laydown areas to the
installed position.
- Access for the transportation and placement of bulk construction materials
- Crainage and other equipment to be used for construction.
- Sequence of construction.
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4.2 Efficient Design
4.2.1 Each site will have different conditions influencing design choices. What is common is the
need to establish and verify, or at least anticipate, the key parameters for the chosen site as
early as possible in the study.
Layout designs very quickly become difficult to change, and decisions which may seem trivial
at the start will later necessitate either rework or force unnecessary compromises.
4.2.2 The development of the overall plot plan is an interactive process. It is likely that the initial
plan will be based on similar facilities built elsewhere. Almost inevitably the new facilities will
be different in terms of actual site conditions, equipment and design philosophy. It is essential
therefore that all the issues which may affect plot area and layout be settled as early in the
project as possible.
The Contractor shall therefore produce a checklist, or “what-if” list, of all factors likely to influence the
layout throughout all phases of plot plan development, and continuously review and develop this list, in
conjunction with the Owner, at identified design development milestones.
4.3 Legal Requirements
The more stringent of either local/state governmental requirements or this Specification shall apply.
Where local or governmental requirements mandate that a Quantitative Risk Assessment (QRA) be
conducted, the Contractor shall develop the study eventually appointing a suitable consultant. Refer to
BMPS-A15 ‘HAZOPs of Major Projects’ for correlated information.
5. LAYOUT OBJECTIVES AND BASIC REQUIREMENTS

5.1 Plant Datum
All co-ordinates, dimensions and elevations shall be in rational terms and tied to one fixed and
established datum marker. Refer to Vol 2 Section 4.3.
Site elevations shall be in accordance with project design drawings
For area boundaries refer to BMPS-A1 Section 5.2
5.2 General
The overall objective is to protect all plant personnel and the general public. Good design practices
contributing to the protection of the facility must also be given emphasis, in order to avoid the prospect of
long and costly shutdowns.
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Understanding the safety and operability requirements for refinery layout is therefore important both in
planning new installations and in making alterations and extensions to existing facilities.
5.3 Consequence Analysis and Probabilistic Risk Assessment
5.3.1 A quantitative consequence analysis will normally be required for all grass roots refinery
projects and most projects involving the addition of new plant, or normally occupied buildings
which are come under new risk. Various scenarios, based on real foreseeable events, would
provide the basis for such an analysis.
The resulting predicted effects that a fire, explosion or toxic/flammable materials release
would have on the facilities and adjacent property shall be determined.
5.3.2 Factors to be considered, in estimating the potential blast overpressures, radiant heat flux
and/or the extent of toxic vapour clouds that could result, will include:
 the explosive energy of the process materials
 rate of flow, volume and pressure
 volatility and temperature
 toxicity
 local atmospheric conditions, etc.
5.3.3 The analysis will be conducted by the Contractor using Owner-approved software. The
results of this analysis will form an integral part of developing the plant layout with respect to
spacing criteria.
5.3.4 Where deemed necessary by the Owner or local authorities, a probabilistic risk assessment
will be performed to verify acceptability.
5.4 Default Spacing
When the Owner has determined that a study as described above is not necessary, the Contractor shall
use the spacing data and referenced notes given in BMPS-SD-A-23194 ‘Spacing between Plants for
Fire and Safety Considerations’ to locate facilities.
5.5 Separation from Adjacent Property
5.5.1 General
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An important objective is the protection of others from exposure to spills, fires, explosions,
heat radiation, smoke and toxic releases, odours and damaging or nuisance-level noise.
Consideration shall be given to present and possible future activities on land adjacent to the
refinery, and to maintenance and operations on any rights-of-way for highways, railroads and
pipelines that may traverse or be adjacent to the property.
5.5.2 Use of Perimeter Buffer Zones
The use of greenbelts and undeveloped areas as buffer zones shall be considered to lessen
public impact. Some of the benefits will be:
 Aesthetic and public image improvements
 Hazard and risk reduction
 Environmental impact reduction (particularly odour and noise)
The Contractor’s proposals for perimeter buffer zones shall encompass the full range of
benefits, in order for the Owner to make a balanced decision.
5.6 Separation of Facilities
5.6.1 Effect on Adjacent Areas
Process units, storage tanks, control buildings and other facilities shall be separated to
minimise the effect of fires, explosions, radiant heat, spills, etc, in one area up on adjacent
areas.
5.6.2 Blast Resistant Buildings
Facilities shall be laid out to avoid, where practicable, the necessity for blast resistant
buildings, refer also to §7.2 (Plant-to-building Spacing) of this specification.
5.6.3 Maintenance and Inspection Considerations
General plant arrangement shall permit full utilisation of mobile maintenance equipment and
handling facilities for servicing and maintenance from roads adjacent to each plant.
When a group of process units has a common maintenance and inspection shutdown time,
they may be considered as one unit with no spacing requirements between the separate
processing sections. When making such groupings, due consideration shall be given to the
potential for increased risk (refer to §5.7, for instance), and such proposed grouping of
discrete process units into process complexes shall require the Owner’s approval.
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Process units having separate maintenance and inspection time periods shall be spaced in
accordance with BMPS-SD-A-23194 ‘Spacing between Plants for Fire and Safety
Considerations’. The layout of units shown on this drawing is indicative only and is not
intended to preclude the use of other arrangements, such as a “U” shaped plan.
5.6.4 Access to confined spaces
Requirement to enter confined spaces shall be eliminated. Where this is not possible,
confined spaces shall be subject to hazard reviews in order to assess solutions to render the
space non-hazardous and to define work and access requirements for operating and
maintenance personnel. These procedures will be developed by the customer.
A confined space is defined as a space:
- Large enough and so configured to permit entrance of personnel to perform assigned

work
- Which has limited or restricted means of entry or exit
- Which is not equipped or designed for continuous occupancy
If one or more of these do not apply, then the space is not classified as a confined space.
Signs shall be posted to alert personnel of areas that have been classified as confined
spaces
Electrical pull pits are considered to be a confined space.
In confined space design, headroom must be (as much as possible) 2100mm minimum;
where passages are lower than 1900mm they must be shorter than 6m in length.
5.7 Noise Control
5.7.1 The Contractor shall take early cognisance of the Owner’s requirements stated in BMPS-A20
‘Noise Limitations’. The Owner’s approval of overall plant noise performance is required
before the plot plan, and in particular major equipment grouping, is finalised.
5.7.2 The Contractor must appreciate that noise control engineering, plant layout and procurement
of noisy equipment is an integrated process, and shall plan his activities accordingly. BMPS-
A20 ‘Noise Limitations’ provides procedural guidance on how to achieve this.
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5.8 Separation of Hazardous Plants
High hazard plants shall be separated from each other and from low hazard plants. Minimum spacing
requirements are detailed in BMPS-SD-A-23194 ‘Spacing between Plants for Fire and Safety
Considerations’.
High hazard units typically involve a combination of high pressure, ie greater than 3450kPa (500psig),
and a high temperature, ie greater than 315°C (600°F), or volatile processes with flammable materials
and fast chemical reaction rates.
These units have a greater chance for a “significant consequence” release than would a low hazard unit,
or areas such as offsites facilities, utility plants, etc. However, while low hazard units may have a lower
probability of release, the consequences could be just as great.
5.9 Protection of Critical Equipment
Critically important equipment or systems shall be located in areas which afford maximum possible
protection. For the purposes of this section, critical equipment is defined as that equipment necessary
for safe normal operation and control, as well as operation and control or safe shutdown during plant
upsets, fires and other emergencies. The Contractor and the Owner shall mutually agree on which items
and systems are to be classified as critical.
5.10 Protection for Utilities
Firefighting facilities, power generating plants, boiler plants and main substations serve multiple areas
and should be able to continue operation under the worst-case plant failure scenario. They are the last
line of defence in disaster control units and shall be protected against incidents which may occur on
process areas.
Therefore greater spacing of these facilities from facilities that may be sources of vapour clouds or toxic
release, than that required by BMPS-SD-A-23194 ‘Spacing between Plants for Fire and Safety
Considerations’ may be justified.
Electrical substations in particular shall be located in non-classified areas. Substations serving more
than one process plant shall be located at least 15m (50ft) from the edge of any Zone 2 (as per API RP
505) area. For Electrical Substation Architectural and Structural criteria and details, refer to BMPS-R3.
5.11 Piping Arrangements
While ‘’BMPS-L1 ‘Refinery Piping‘ provides detailed guidance on piping design and layout, the following
areas shall be addressed during layout development.
5.11.1 Risk Reduction
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BMPS BMPS-A4
Hazard analyses will highlight those pipelines carrying significant inventories of flammable or
toxic materials, and the Contractor shall give priority to minimising long large-bore piping
runs for these services and, in particular, routing them away from other hazardous plant.
Lines carrying volatile material, such as LPG, and those containing such hazardous streams
as H2S, amine and sour gas/water shall receive particular attention.
5.11.2 Cost Reduction
Runs of high cost piping (alloy, large-bore or jacketed piping) should be short and
economical. Once equipment and pipeways are tentatively located, the most expensive
piping should be routed first to optimise short run-lengths, followed by the routing of the
lower cost piping.
5.11.3 Main Relief Header
Establishing a continuous slope for what is often the largest line in the refinery, at the
highest elevation on the pipeways, shall also be a subject for early piping studies.
5.11.4 Free Space Considerations
Free piperack space for future additional pipelines shall be allowed. Once actual
requirements have been established, within specified requirements for accessibility and safe
clearances, 20% extra width is usually allowed.
Subject to the Owner’s approval, this allowance may be adjusted upwards or downwards on
the expectation of future plans. However, the allowance shall not be less than 10% (refer
also to §9.3).
5.11.5 Battery Limit Isolation
Each process unit or process complex, or utility unit shall have a clearly designated area at
the battery limit area where all pipelines (process and utilities) enter and leave the unit with
process and utility lines physically separated. Suitable isolation facilities shall be provided at
these limits.
5.12 Utilisation of Topography
For purposes of energy conservation, elevation differences on the site should be exploited to maximise
gravity feed to the process units and to allow gravity flow to and from the Effluent Treatment Plant (see
§5.12 below).
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5.13 Drainage
5.13.1 Drainage is an important part of both fire protection and pollution control, and the Contractor
shall ensure that plant layout complements the objectives of the drainage system in
according to P&ID’s.
In general, a good drainage design will:
 Route chemicals and flammable liquids away from ignition sources and into enclosed
sealed drains and sewer systems. It also isolates flammable vapours and hydrocarbons
in drainage piping from possible ignition sources.
 Route spilled or drained burning liquids away from equipment. It also minimises
exposure to adjacent property.
 Reduce the potential for heat input to, and minimise the surface area of, LPG liquid in
the event of a leak, rupture or spill.
 Remove rain water and fire water quickly and prevent flooding from internal or external
sources.
 Avoid erosion.
 Avoid relying on mechanical equipment to remove storm water, potentially contaminated

storm water, fire water during emergencies and any other water from drainage systems.
Gravity flow systems are to be used, unless the economics of site preparation dictate
otherwise. The use of systems involving mechanical equipment will require the Owner’s
approval.
 Reduce air pollution from evaporation of volatile liquids by capturing them in closed
systems.
 Prevent solid and liquid wastes from reaching groundwater and surface water.
 Minimise contaminated water (e.g. provide a roof over areas where product and waste
materials are stored).
 Segregate clean and contaminated water to minimise the amount of water to be treated.
 Assure there is no contaminated or uncontrolled drainage from the refinery to any

adjacent land.
 Minimise maintenance.
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5.13.2 The Contractor must consider safety and environmental issues involved in the handling,
processing and storing of hydrocarbons and other chemicals in the design of drainage
systems.
5.13.3 Refer to BMPS-S1 ‘Drainage Sewer Systems and Effluent Treating’ for specific drainage
requirements.
5.13 Corridors and Maintenance Lifting
Piping and electrical/instrumentation cable corridor requirements and plant maintenance

access requirements shall be established via piping and lifting studies at the beginning of the
project with the following criteria being applied:
- All rotating equipment shall be accessible preferably by mobile crainage. Where not
accessible, removal must be achieved with an overhead crane, monorail or davit with
sufficient area for laydown and/or transfer to a truck tray.
- Heavy maintenance areas such as grinding and materials handling shall be readily
accessible by mobile crane and transfer equipment to enable convenient transfer of
heavy wear consumables and plant maintenance. Allowances must be made for a
graded surface to allow stability for such heavy maintenance equipment.
- Adequate access both at ground level and on platforms shall be provided for removal of
items such as filter cloths, large scale baskets, mechanical agitators and large valves
and actuators. The use of overhead hoists, mobile equipment and if justified, overhead
bridge crane shall be considered.
- Routine maintenance, access and travel envelopes must be allowed for when looking at
the routine maintenance of all equipment such as filter cloths, pumps, de-scale
equipment and heat exchangers. All equipment is to be located such that complete
removal for maintenance is possible.
- Space should be allowed for crane stabilisers and full boom swing envelopes. Hardstand
areas for cranes shall be provided where required.
- Roadways shall have sufficient radius corners to accommodate all mobile equipment
turning circles.
- Integration of plant access ways between adjacent plant areas to minimise undefined
pedestrian and equipment routing between areas.
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5.14 Clearances and accessibility
All mechanical plant, piping and equipment that require periodic or frequent access shall be
readily accessible to operational and maintenance personnel through the provision of
walkways, stairways, ladders and platforms.
All equipment and piping to be operated, maintained or inspected must be safely accessible
without the need to climb or reach over other equipment, piping or handrails.
Specific equipment enclosure requirements (such as weather, noise or dust protection) shall
be clearly identified.
Where occasional maintenance access cannot be provided from fixed platforms

economically, the requirement for temporary scaffold or mobile platform access shall be
clearly identified and approved by owner.
For equipment located in structures, hoisting and rigging criteria shall be established to meet
projected maintenance methods. Maximum lifts (weight and bulk) shall be determined and
requirement for removable building panels etc allowed for. Where a mobile trolley or similar
is required, the floor surface shall be designed to accommodate.
All mechanical equipment shall be arranged such that drive motors can be removed without
disturbing other items.
Access provisions shall also consider emergency evacuation for injured personnel from
within the vessel or tank area platforms.
Maintenance requirements for specific equipment shall be included in the model design as
recommended by the equipment supplier.
5.15 Safety Showers/Eyewash Stations
Refer to BMPS-S5 for a typical Safety Shower type, arrangement and the model number.
The Safety Shower shall inclusive of associated valving, chillers, water storage tanks and
pumps. Owner to approve make and vendor of safety shower to be used throughout the
BMP project.
Safety shower/eyewash units are to be installed to all locations where caustic liquor, acid,
lime or other harmful chemicals or substances that can cause temporary blinding or
immediate and irreversible damage on contact. They are to be installed no closer than 3m
and no further than 30m from a hazard on the same level as the hazard with a clear
unobstructed path.
In no case shall a station be placed so far from a hazard that it requires more than 10
seconds to move to. Nor shall the distance be more than 30m.
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Stations should be placed between hazardous areas and main passages or egress routes
such that the victim or helpers do not have to pass through the danger zone to get to or
leave the station.
Stations at grade should be located away from areas subject to flooding with process fluids,
especially adjacent to sumps (or similar low points). Wherever possible, stations are to be
located near high point of floors within the curbed area or at the perimeter of bund with an
unobstructed path, free of level changes or steps.
6. BLOCK LAYOUT AND ROADS
6.1 General
6.1.1 The refinery should be laid out in a rectangular or block pattern with adequate roadways
giving access to all major elements. Roads that separate blocks should also function as fire
breaks, and should facilitate movement and use of fire fighting equipment.
6.1.2 Fire protection, the economy of operations and maintenance require adequate main
roadways for access. The Contractor shall ensure that, within operating areas, all units and
facilities have roadways, so that fire fighting equipment may be used effectively.
6.1.3 During an emergency, it may be necessary to close off certain roadways. Therefore, each
unit or operating area shall have two or more approaches. Block layout will generally provide
two- direction access.
6.1.4 Maintenance considerations shall include access by large lifting equipment as appropriate.
Roadways and pipeway crossings shall be designed to handle expected weight loads and
provide adequate space for maneuverability
6.1.5 There should be a minimum of two main access roads to and from the refinery wherever
possible.
6.1.6 Roadways shall follow the requirements BMPS-S3 ‘Roads and Paved Areas’. Roads shall
generally be laid out in straight, long runs.
6.2 Roads
6.2.1 Roads inside the refinery shall be classified as follows:
 Primary Roads (Full Road Width 7.2m (24ft) with Shoulder Width 2.4m (8ft) each side)
Roads connecting or serving the main gate, administrative buildings, storehouse,
workshop, cafeteria, firehouse, principal car parks, entrance/exit roads and TTLR areas.
 Secondary Roads (Full Road Width 6m (20ft) with Shoulder Width 1.5m (5ft) each side)
Roads to offsite pump areas, flares, rail loading area and the central control building.
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Roads encircling the process block.

Roads to parking areas for motorised maintenance equipment, areas for storing and/or
injecting hydrogen/nitrogen from cylinders and to the trailer truck and the fire school.
Roads to other areas used by trucks or automobiles on routine shifts or on a daily basis.
 Tertiary Roads (Full Road Width 3m (10ft), no Shoulder )

Perimeter roads and roads serving areas where access is infrequently required; and
where travel by emergency response equipment vehicles is unlikely. Note that a single
traffic lane will usually be adequate for tertiary roads, unless the Owner specifies
otherwise.
Refer to BMPS-S3 ‘Roads and Paved Areas’ for details.
6.3 Restricted and Unrestricted Roads
6.3.1 For personnel safety and to minimise the risk of a vehicle igniting flammable material in a
facility, any road within 7.5m (25ft) of a normally operating source of flammable (or toxic)
material such as vents, drains, sample points or sumps shall be designated as a restricted
road. These roads shall not be used for routine traffic. Barriers and signs must be provided at
the entrance to restricted roads.
6.3.2 Unrestricted roads are roads that are located more than 7.5m (25ft) from any release source
or any equipment item and do not require traffic control.
6.4 Paved Process Areas
All areas within unit equipment lines shall be concrete paved in accordance with BMPS-S1 ‘Drainage
Sewer Systems and Effluent Treating’. Working areas outside the equipment line, such as bundle
withdrawal areas, shall also be paved. Paving for other areas, both inside the battery limit and in
workways, shall be agreed with the Owner.
7. PLANT SPACING
7.1 Plant-to-plant Spacing
7.1.1 In general, the spacing between major process units shall be not less than 23m (75ft) (refer
to §5.7). Close spacing of operating units permits shorter runs of transfer pipe, facilitates
centralisation of refinery control and results in more compact electrical supply systems.
However, close spacing increases the likelihood of the spread of fire between units,
increases the problems of major maintenance work and may hamper fire fighting activities.
7.1.2 Spacing greater than 61m (200ft) rarely decreases risk, except for specialised operations
such as flare systems and certain petrochemical facilities.
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BMPS BMPS-A4
7.1.3 It is acceptable for an overhead or grade-level piperack to transversely cross a separation

space.
The Contractor may, with the Owner’s approval, also route piperacks longitudinally along a
separation space, provided that it does not occupy the full width. At least 7.5m (25ft) of the
separation space shall be left clear of the piperack as a firebreak and to permit access for
fire fighting and lifting operations.
7.1.4 The Owner will advise the Contractor of the likelihood of, and requirement for, future
expansion of any major process unit and the provision of additional spare equipment. The
minimum spacing between units shall not be considered to be available for possible unit
expansion. Such expansion shall be planned for as a separate requirement.
7.2 Plant-to-building Spacing
7.2.1 The siting of normally occupied buildings will in most cases be determined during the studies
referenced in §5.2. Significantly increased separations over those given in BMPS-SD-A-
23194 ‘Spacing between Plants for Fire and Safety Considerations’- may be dictated by
these studies.
For example, it may be desirable to increase the spacing of the control building from the
process facilities to at least 69m (225ft) to eliminate the need for blast resistant design.
Another factor which could increase building separation distances would be radiant heat
from possible fire scenarios.
7.2.2 The building spacing in BMPS-SD-A-23194 ‘Spacing between Plants for Fire and Safety
Considerations may be used in the absence of the referenced study, with the Owner’s
approval.
7.2.3 The separation distances given therein are valid for hydrocarbon mixtures only, and
represent an acceptable level of risk for typical refining processes and the functions normally
expected in refinery buildings.
7.3 Plant-to-offsites Facilities Spacing
7.3.1 Refer to BMPS-SD-A-23194 ‘Spacing between Plants for Fire and Safety Considerations’ for
offsite facilities spacing.
7.3.2 Block layout of plants and roads is a convenient means of separating process units from
equipment in non-process operating areas. See §6. for more considerations on the layout of
roads.
Page 21 of 35
BMPS BMPS-A4
7.3.3 The firefighting facilities and utility plants shall be able to operate in the worst-case plant
failure. They are the last line of defense in fire and accident control. Therefore, greater
spacing of these facilities from facilities that may be sources of vapour clouds or toxic
releases than that required by BMPS-SD-A-23194 ‘Spacing between Plants for Fire and
Safety Considerations’ may be desirable.
7.4 Spacing of Miscellaneous Facilities
Non-processing facilities involved in shipping, pipeline and marketing facilities may often be located
near process units. Examples are pipeline pump stations, marketing terminals, loading racks,
warehouses and marine terminals.
These facilities should be treated as offsite facilities and spaced accordingly. Siting of tank truck loading
racks (refer also §14.) and gas bottling plants shall consider prevailing winds, with the view of
minimising vapour release travel into other plants or to ignition sources, should a spill occur.
7.5 Construction and Maintenance Considerations
During the development of the plot plans and refinery models, the Contractor shall consider and
address potential constructability problems, such as the delivery of heavy equipment to site and its
subsequent erection. Opportunities for substantial construction cost savings shall be studied and
highlighted at this early stage. Similarly, maintenance requirements during plant shutdowns shall be
considered.
7.6 Odour and Hazardous Waste Considerations
7.6.1 The Contractor shall locate potential odour producing facilities such as effluent treating
plants and landfarms so as to minimise their effect on plant personnel and the surrounding
area. Generally, this requires siting away from the main office and the entrance to the
refinery, and providing a buffer zone.
7.6.2 A hazardous waste storage facility shall be provided in a secure area for the storage of
spent catalyst or potentially hazardous materials. This facility should be in a separate area
from the maintenance or warehouse areas.
7.6.3 Storage facilities, particularly hazardous materials/waste storage facilities, shall be located in
areas where, in the event of accidental discharge or leaks, the hazardous material/waste will
not contaminate environmentally sensitive locations in and around the facility.
7.7 LPG Facilities
Refer to BMPS-S6 ‘Facilities for Pressurized Mounded Storage and Loading of LPG’ for specific
requirements for the layout of LPG facilities.
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BMPS BMPS-A4
7.8 Tankage
Refer to BMPS-D5 ‘Tankfarm Layout and Spill Control’ for specific requirements for tank layout and
spacing.
7.9 Pump Stations
Offsite pumps should be centralised to the maximum extent practicable.
8. PROCESS EQUIPMENT LAYOUT AND SPACING

General spacing recommendations are shown on BMPS-SD-A-23194 ‘Spacing between Plants for Fire
and Safety Considerations’, and are supplemented by the following requirements.
8.1 Basic Configuration
The process flow basically dictates the configuration of equipment within an operating unit. The spacing
between individual pieces of equipment is determined by such requirements as piping thermal
expansion, access for operation and maintenance and fire protection. Equipment spacing for fire
protection is intended to provide:
 Protection against flammable vapour reaching sources of ignition
 Access for control of fires
 Protection of important equipment from fire
8.2 Main Piperacks and Adjacent Equipment Configuration
8.2.1 Generally, equipment shall be located on either side of the main overhead piperack and not
under the piperack. Perpendicular spur piperacks may be used to serve reactors and
furnaces and other equipment.
8.2.2 The area immediately adjacent to the piperack is preferentially allocated to pumps. When
space permits, other equipment may be located in this area, but it is usually necessary to
place at least some equipment outboard of the pumps.
8.2.3 Usually, equipment is arranged with its centreline perpendicular to the overhead pipeway. A
common convention is to locate pumps such that their top discharge nozzles have a common
centreline. In the same manner, shell and tube heat exchangers are often arranged with
channel nozzles on a common centreline.
Page 23 of 35
BMPS BMPS-A4
8.2.4 Design detail requirements are provided in §9.
8.3 Onplot Piping
8.3.1 Onplot piping shall be run in elevated pipeways where possible. Such overhead piperacks
shall function as separation between equipment, and should generally run through the
centre of an operating unit.
8.3.2 Equipment shall not be located under overhead piperacks, as stated in §8.1. Equipment is
thus located on the perimeter of the operating unit, facilitating maintenance and fire control
operations.
8.3.3 Short runs of lines may be located at ground level, provided they do not obstruct drainage or
any maintenance or operational access. These at-grade runs will require the Owner’s
approval. Where the crossing of lines is required, steel stiles shall be provided.
8.3.4 Below grade pipe trenches shall be installed only with the Owner’s approval.
8.3.5 All main operating valves and control valves shall be located in easily accessible locations,
preferably near-grade, and should not obstruct access in any operating or maintenance
position. Refer to BMPS-L-144019 ‘Standard Valve Installation Guide’ for additional
information.
8.3.6 When located belowgrade, heat traced piping and piping in services requiring inspection and
servicing shall be in open concrete culverts. Other piping may be buried underground, with
the Owner’s approval. Buried piping will be protected using a method agreed with the
Owner. .
8.4 Power and Instrument Cabling
In conjunction with the Owner and guided by the requirements of BMPS-M6 ‘Fireproofing’, BMPS-P1
‘General Design Rules for Electrical System’ and BMPS-J1 ‘Control System Design Basis’, the
Contractor shall establish whether power and instrument cabling in process and utility areas are to be
buried, or carried in cable trays in overhead piperacks, fireproofed where necessary. In the latter event,
it is preferable not to mount the cable trays on the same level as the piping, but to provide some
separation from piping.
8.5 Vessels
When a horizontal vessel has a head-mounted manway, this head end shall face outwards from the
pipeway. Columns shall be oriented so that internal parts may be lowered to grade on the most
accessible side.
Page 24 of 35
BMPS BMPS-A4
8.6 Shell and Tube Heat Exchangers
8.6.1 Shell and tube exchangers shall be located at grade when possible and stacked not more
than three shells high and, with shells 610mm (24in) and over in diameter, not more than
two high. The bottom shell of stacked exchangers shall be at such an elevation that any
connecting piping is a minimum of 250mm (10in) above the paving and the exchanger’s
shell is a minimum of 690mm (27in) above the paving.
8.6.2 Heat exchangers mounted either horizontally or vertically shall be positioned to allow a 1.2m
(4ft) wide accessway on at least one side. The accessway on the other side shall be 0.8m
(2ft 6in). These clearances shall be considered as minimums and shall be increased where
the size of the equipment which has to be handled in the accessways during maintenance
so warrants. Clearances around exchangers shall also be adequate to permit safe
installation and removal of blinds and bolting.
8.6.3 In addition to the space provided for pulling bundles, space shall be provided for the removal
and temporary storage of shell covers, floating heads and test rings at the floating head end.
The channel end shall face away from the pipeway.
8.6.4 Elevated exchangers mounted on common steel work adjacent to columns shall be spaced
to allow sufficient clearance around columns to permit access for work on the exchanger or
its associated piping. Structures shall be designed so that selected mobile facilities can be
used to the fullest possible extent. Where mobile equipment cannot be used, permanent
handling facilities shall be provided.
8.6.5 For exchangers under drums or unit structures, the channel end shall, if possible, be clear of
overhead obstructions that would prevent handling of the channel ends by cranes. Failing
this, permanent handling structures shall be provided.
8.6.6 If water-cooled condensers and coolers are used, they shall be located near grade level
(instead of overhead), unless operating pressures or other conditions do not permit.
8.7 Air-cooled Heat Exchangers
8.7.1 Air-coolers are generally located above overhead piperacks. They may also be located over
equipment areas where the risk of fire is minimal. They shall not be located over potential
sources of fire, such as flammable liquid pumps and pumps handling materials above their
autoignition temperature or above 316°C (600°F).
8.7.2 Care shall be taken to keep bare hot lines or other hot equipment out from under the air
intake to coolers. Layouts shall also prevent recirculation of heated air to the coolers.
Page 25 of 35
BMPS BMPS-A4
8.7.3 Sufficient access shall be provided to permit removal or replacement of air-cooler bundles,
fans and drivers. Air-cooler bundle weights shall be within the handling capacity of the crane
described in the Owner Specifications, or as advised by the Owner.
8.8 Fired Equipment and Heater Stacks
8.8.1 Fired equipment shall be segregated from equipment and portions of the plant where a
flammable vapour release might occur. Where possible, fired equipment shall be located
upwind of other equipment to minimise the possibility of vapours being carried towards open
fires.
8.8.2 Individual stacks for each fired heater are preferred. Common stacks are permitted only with
the Owner’s approval.
8.8.3 Suitable isolation must be provided in individual ducting to common stacks such that it would
be possible to take a heater offline without interrupting the operation of the other heaters.
8.8.4 All heater tubes will generally be removed by mobile crane, therefore adequate dropout and
swinging space shall be provided. External piping shall be minimised at the tube pulling end
of horizontal fired heaters.
8.8.5 The location of heaters should not result in increased ambient air temperatures in areas
where air-cooler performance might be affected. In this respect, due regard shall be taken of
the prevailing wind direction and the relative position of heaters and air-coolers.
8.9 Pumps and Compressors
8.9.1 General
Pumps and compressors handling flammable liquids and gases are the most likely source of
accidental leakage to the atmosphere. This equipment shall therefore be located a minimum
of 15m (50ft) from sources of ignition, such as fired heaters. Further, this equipment shall
normally be spaced far enough from other equipment to ensure that seal fires do not
overheat adjoining or overhead equipment.
In general, pumps shall be located alongside in-plant overhead pipeways, with any part of a
flammable liquid pumps at least 1.5m (5ft) outside the extremities of the overhead pipeway.
Refer also to §8.1.
Pumps shall not be located under overhead piperacks, but may be located close to
equipment served where suction conditions are critical. In the case of large heavy pumps,
the location may be influenced by the need for crane access. Top suction and discharge
pumps are preferred when the piping is all overhead.
Page 26 of 35
BMPS BMPS-A4
Reciprocating compressors shall be spaced with sufficient clearance for rod-pulling without
necessitating removal of cylinders.
8.9.2 Hot Oil Pumps
Pumps handling hydrocarbon above either its auto-ignition temperature, or above 260°C
(500°F) shall be subject to the following:
Any pump part shall be at least 3m (10ft) from equipment handling other flammables to
reduce the likelihood that a mechanical seal fire will affect adjacent equipment, and
associated electrical or instrument cables and other facilities.
Pumps shall be located along the outer edge of the equipment line, outboard of columns and
vessels, and with no equipment installed overhead. Where it is necessary to locate such
pumps alongside in-plant overhead pipeways, any pump part shall be at least 3m (10ft)
outside the extremities of the overhead pipeway. To further reduce risk or fire loss, a pump
may be separated from its spare by another pump or by increased spacing.
8.10 Cooling Towers
Cooling towers shall be located downwind or crosswind (based on prevailing wind direction) of
buildings, process units, and electrical substations and equipment.
8.11 Packaged and Skid-mounted Equipment
This Specification is also applicable to equipment furnished as a part of a Supplier’s package, and to
special equipment (e.g. packaged units, skid mounted units, CCR Reactor/Regenerator Structure, etc).
Therefore the Contractor shall exercise due control over Subcontractor and Suppliers, to ensure
compliance with the overall plant requirements.
8.12 Catalyst and Chemicals Handling
Adequate space shall also be provided for handling, loading, unloading and temporary storage of
catalysts (both fresh and spent), chemicals, hydrogen, nitrogen, etc, including truck access where
appropriate. In general, maximum use of mobile equipment shall be made for transporting and handling
these commodities.
Page 27 of 35
BMPS BMPS-A4
8.13 Equipment Servicing and Protection
8.13.1 The Contractor shall ensure that equipment location allows in-place servicing, wherever
practicable. Equipment shall be arranged to accommodate maximum possible servicing and
maintenance by mobile facilities. Permanent handling facilities shall be limited to specific
items which cannot be handled manually, or by plant mobile equipment. Detailed
requirements are stated in BMPS-M1 ‘Basic Civil and Structural Design Data’.
8.13.2 Unless otherwise stated in the Owner Specifications, it should be assumed that a crane
having the capabilities and dimensions shown on drawing BMPS-SD-B-23195 ’ Data for
Typical 80 Ton Mobile Crane’ with a boom length of 30m (100ft) will be available for
maintenance work, and access ways shall be provided for its operation. Use of such a crane
is intended to permit:
 Servicing of air-coolers and elevated exchangers.
 Handling of valves, fittings, piping and lighter weight equipment up to 24m (80ft)
elevation.
8.13.3 Smaller mobile lifting equipment will be available for handling equipment located at grade,
such as pumps and motors. The Owner will advise characteristics.
8.13.4 For columns inaccessible by crane, davits shall be provided at column tops to handle items
such as safety relief valves and trays.
8.13.5 In general, only equipment which is suitable for outdoor installation shall be purchased. Any
exceptions will require the Owner’s approval. In the event that an enclosure is required, it
preferably shall be a simple roofed structure open at the sides or sheeted down to a
maximum height of 2.5m (8ft) above the shelter floor. Ventilation shall also be provided by
natural draught at the roof apex. Fully enclosed structures are to be avoided wherever
possible.
8.12.6 Maintenance lifts over live equipment and piperacks are not acceptable. If this cannot be
avoided, it shall be reviewed by owner during the model reviews and approved.
8.14 Other Equipment Spacing Concerns
8.14.1 Adequate spacing for access by operating and maintenance personnel must be provided.
Where regular access is necessary, a minimum clear aisle width of 1000mm (39.4in) is
required.
8.14.2 Space for access by emergency response personnel shall be provided, including adequate
area for isolation required to effectively contain an incident. The Contractor shall ensure that
the clearances required for large equipment, such as fire trucks, spill response
trailers/equipment, tank trucks, etc, are adequate.
Page 28 of 35
BMPS BMPS-A4
8.15 Location of Fire Fighting Equipment Inside Process Units
See BMPS-S5 ‘Loss Prevention Basis of Design, Fire Protection and Safety System’ for location and
spacing of firefighting equipment.
9. OVERHEAD PIPERACKS
9.1 Basic Requirements
9.1.1 The piperacks shall be designed to route all process and utilities lines inside Process Units
and among Units.
9.1.2 Additional requirements relating to overhead piperacks are to be found in BMPS-M1 ‘Basic
Civil and Structural Design Data’.
9.2 Electrical and Instrument Cable Support
The Contractor shall ensure that each piperack known to have a requirement for support of electrical or
instrument cable (see §8.3), for conduit and cable tray on the top level below Air Coolers.
9.3 Allowances for Future Additions
9.3.1 Structural design of single level piperacks shall provide for the future addition of an
additional level at the top of the existing piperack. The columns shall extend 300mm (12in)
beyond the top level to provide easy extension and pipe should not be routed this area. The
new level shall be capable of being added to each level at a later date without any
modification to the columns or foundations.
9.3.2 Free space allowance shall be as stated in §5.10.4.
9.4 Clearances
9.4.1 The minimum clearances shall be:
 Over Roads - 6.5m (21ft)
 In Process Units - 4.6m (15ft)
Page 29 of 35
BMPS BMPS-A4
 Between Levels - Design as per biggest pipe diameter, minimum clearances shall be
agreed with Owner taking into considerations access for operation and maintenance and
as approved by the Owner unless otherwise shown on relevant drawing.
9.4.2 Minimum height between TOS levels in pipe racks shall be 2,000 mm with side steel to be
half tier height TOS.There shall be no cross-bracing below 2m (6.5ft) in the process units
and utility areas.
9.4.3 Sufficient clearance shall be provided under piperacks in the process units and utility area to
permit access by mobile lifting equipment, as described in §8.12.3.
10. EQUIPMENT AND UNIT ACCESS

10.1 Access to Structures
Refer to BMPS-M3 ‘Steel Structures’ for requirements for stairs, ladders, walkways and platforms
necessary for access to equipment for maintenance and operations.
Refer to BMPS-A5 for details for stairs, ladders, walkways and platforms.
10.2 Mobile Equipment Movement and Access
10.2.1 The routes to be used by the crane referred to in §8.12.2 shall be established in conjunction
with the Owner, and these routes shall be designed with a width, turning path and allowable
loading to suit the specified crane. Clear headroom on the route shall be 6.5m (21.3ft)
minimum.
10.2.2 The design of access-ways for the crane shall take into consideration the characteristics of
the crane, the expected operating area and the anticipated loadings. The locations of these
accessways are to be developed in conjunction with the Owner.
10.2.3 Other main access-ways into units shall be a minimum of 6m (20ft) wide. These access-
ways, plus areas between units where vehicular traffic is expected, shall be designed for the
loadings given in BMPS-S3 ‘Roads and Paved Areas’.
10.2.4 Sufficient accessways shall be provided to permit mobile equipment access.
Page 30 of 35
BMPS BMPS-A4
10.3 Satellite Operator Shelters
Any requirements for satellite operator shelters will be described in the Owner Specifications. These
may be required depending on distance from the control building, percentage of time operating
personnel must remain in area and the importance of function and weather.
11. CLEARANCES FROM ATMOSPHERIC DISCHARGES

11.1 General
11.1.1 Refer to BMPS-A18 ‘Overpressure Protection’ and BMPS-A19 ‘Design of Flare Equipment’
for requirements regarding the location of platforms and ladders relative to the tail pipes of
pressure-relieving devices discharging to atmosphere. These requirements also apply to
discharges from operating vents.
11.1.2 In general, stacks from fired heaters and boilers discharge at a sufficiently high elevation
relative to platforms and ladders that they usually present no personnel safety hazard.
11.1.3 The above are generalisations and, if there is concern for safety due to the toxicity of the
effluent or from radiant heat flux from the stack, a dispersion or radiant heat analysis shall be
conducted by the Owner, or an appointed consultant, to determine the acceptable
separation distances.
11.1.4 In some circumstances, platforms and ladders may be required in locations that otherwise
would be prohibited. In general, these will be required for maintenance rather than
operations, and in any case access shall be restricted.
12. PITS AND PIPE TRENCHES

12.1 General
12.1.1 Below grade pits and pipe trenches shall be avoided where possible, and their use is subject
to the Owner’s approval.
12.1.2 Where justified and approved by the Owner, pits may be provided for below grade
equipment, including instruments, valves or piping auxiliaries that require operational or
normal maintenance access.
Page 31 of 35
BMPS BMPS-A4
12.1.3 In general, pipe trenches and pits shall have concrete walls and floors and open tops
covered with removal grating or plate. Floors shall be sloped for drainage. Removable
covers shall be provided which are suitable for the loadings in the area. Firebreaks
requirements for pipe trenches shall be provided.
 If the Owner approves, open pits and pipe trenches may be provided with handrailing
and150mm (6in) high curbs above grade level.
 Sealed covers shall be provided with a vent piped to a safe location.
For Pits and Trenches details refer to BMPS-M2 ‘Concrete Structures’.
13. STORAGE TANKS

13.1 General
13.1.1 Tank spacing and location shall comply with NFPA 30 as well asBMPS-D5 ‘Tankfarm Layout
and Spill Control’.
13.1.2 Equipment such as pumps and exchangers shall be located outside of diked storage areas.
14. TANK TRUCK LOADING RACKS

14.1 General
14.1.1 Tank Truck Loading Racks (TTLRs) shall be spaced from other plant facilities in accordance
with BMPS-SD-A-23194 ‘Spacing between Plants for Fire and Safety Considerations’ and
shall preferably have a separate entrance.
14.1.2 The access route and tank truck loading area shall allow the following:
 Clear, unrestricted truck access during peak hours.
 Access should not conflict with or congest access to adjacent facilities.
 Routes shall not require trucks to reverse or require curves to be ‘banked’.
 Routes shall not pass by process areas, office areas or other high pedestrian traffic
areas.
 A waiting area for trucks standing by to be loaded that allows orderly evacuation in case
of emergency, without cross-traffic or confusion.
Page 32 of 35
BMPS BMPS-A4
 A parking location for trucks making load and seal checks and completing final paper
work.
 An access route that does not require tank truck paths to cross on entry and exit.
 Spill containment shall be provided at all loading/unloading areas.
Page 33 of 35
BMPS BMPS-A4
TABLE : ACCESS WALKWAYS, PLATFORMS, LADDERS AND MAINTENANCE

All dimensions are in mm
Access Walkways and Platforms
Width for main access ways, escape routes 1200
Width for secondary access ways 1000
Width for short walkways and access around equipment 750
Minimum clearance around obstructions on access platform (not permitted in escape routes) 600
Maximum length of walkway or platform without a secondary exit 15000
Maximum length of dead end corridor in access routes 6000
Width of platform from 3 sides of manhole 900
Vertical exchangers
Distance of platform below top flange of channel or bonnet 1500 Max
Furnaces
Width of access platforms for horizontal and vertical furnaces 900
Stairways and Ladders

Stairway slope
Normal 200 Riser x 250 Run 38°
Maximum 215 Riser x 305 Run (to be approved by owner) 42°
Minimum 150 Riser x 215 Run 30°
Maximum vertical rise of a single flight of stairs 3600
Maximum number of risers without a landing 18
Minimum unobstructed width of main access stairways 1200
Minimum unobstructed width of other stairways 1000
Preferred length of vertical ladder without intermediate platform 6000
Maximum length of vertical ladder (to be approved by client) 9000
Maximum height of ladder without cage 2500
Minimum ladder width 430
All vertical ladders shall be at 0°
Headroom and Overhead Clearances

Overhead clearances over roads for piperacks from high point finished surface (HPFS) 6500
to the bottom of piping or insulation or the bottom of steelworks
Overhead clearances in process units 4600
Headroom over elevated platforms, walkways, stairways, passageways and working 2300
Areas at grade
For confined space design 2300 x 600 or infrequently operated valves (refer 5.5.4) 2100
For passages less than 6000 long 1900
Page 34 of 35
BMPS BMPS-A4
Operating and Maintenance Clearances

Equipment rooms and buildings will be supplied with adequate clear door openings for the supply,
maintenance and removal of all equipment held within. The removal of process equipment or piping for
equipment removal is not acceptable.
Minimum personnel clearances for operations and maintenance personnel shall be in accordance with
the following:
Minimum clear width between adjacent vessels (insulation thickness to be added) 2000
Minimum clear operating and maintenance width around equipment 1000
Minimum maintenance space at back of pump plinths 1800
Minimum maintenance clearance around valves (refer BMPS-L-144019) 750
Minimum clear width beyond the ends of exchangers (add tube or cover removal 1500
length where applicable)
Clearance for exchangers in front of channel or bonnet flange 1200
Clearance from edge of flange 450
Horizontal clearance between paired exchanger flanges 750
Minimum clearance in front of inspection, cleanout and edge of open manway flange 900
Manways and Inspection Openings

Preferred height from operating level to centreline of manway 900
Maximum height from operating level to bottom of manway opening 1100
Minimum height from operating level to bottom of manway opening 230
Vent pipes and Relief Valves open to Atmosphere

Vent pipes and relief valves that are designed to exhaust to a safe location shall at a minimum exhaust 3m
above any platform within a horizontal radius of 15m. The radius may be reduced to 7.5m for steam
depending on expected volumes. Open end of RV vent pipes shall be directed away from any adjacent
platforms or walkways to a safe location.
Prevailing winds shall be taken into account.
Page 35 of 35

(BMPS) : Bapco Modernization Program Specifications

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BAPCO MODERNIZATION PROGRAM SPECIFICATIONS

PROJECT SPECIFICATION No.

I. GENERAL DESCRIPTION OF BMPS-A4

II. CONFLICTS AND DEVIATIONS

II. CONFLICTS AND DEVIATIONS 2

3. REGULATIONS, CODES AND SPECIFICATIONS 6

5. LAYOUT OBJECTIVES AND BASIC REQUIREMENTS 10

6. BLOCK LAYOUT AND ROADS 19

7.3 Spacing of Miscellaneous Facilities 22

8. PROCESS EQUIPMENT LAYOUT AND SPACING 23

10. EQUIPMENT AND UNIT ACCESS 30

11. CLEARANCES FROM ATMOSPHERIC DISCHARGES 31

12. PITS AND PIPE TRENCHES 31

13. STORAGE TANKS 32

14. TANK TRUCK LOADING RACKS 32

TABLE : ACCESS WALKWAYS, PLATFORMS, LADDERS AND MAINTENANCE 34

OWNER The Bahrain Petroleum Company B.S.C. (Closed).

CONTRACTOR Company / Organisation responsible for detail engineering design,

SUPPLIER Company / Organisation supplying equipment, materials or service.

SUBCONTRACTOR Company / Organisation contracted and managed by the Contractor.

3. REGULATIONS, CODES AND SPECIFICATIONS

API RP 505 Recommended Practice for Classification of Locations for Electrical

NFPA 30 Flammable and Combustible Liquids Code

3.2 Owner Documents

BMPS-A1 Basic Engineering Design Data

BMPS-A2 Specification, Codes and Standards

BMPS-A5 Safety in Design incorporating Human Factors Engineering

BMPS-A15 HAZOPs of Major Projects

BMPS-A18 Overpressure Protection

BMPS-A19 Design of Flare Equipment

BMPS-A20 Noise Limitations

BMPS-D5 Tankfarm Layout and Spill Control

BMPS-J1 Control System Design Basis

BMPS-L1 Refinery Piping

BMPS-M1 Basic Civil and Structural Design Data

BMPS-M2 Concrete Structures

BMPS-P1 General Design Rules for Electrical System

BMPS-R3 Electrical Substation Building

BMPS-S1 Drainage Sewer Systems and Effluent Treating

BMPS-S3 Roads and Paved Areas

Loss Prevention Basis of Design, Fire Protection and Safety

BMPS-S6 Facilities for Pressurized Mounded Storage and Loading of LPG

STANDARDS FORMS AND DRAWINGS

BMPS-L-144019 Standard Valve Installation Guide

BMPS-SD-A-23194 Spacing between Plants for Fire and Safety Considerations

BMPS-SD-B-23195 Data for Typical 80 Ton Mobile Crane

BMPS-M-83687 Typical Details Vehicles Height Restriction Frame

BMPS-M-135766 Structural Details, Height Restriction Frame, Refinery External Car

4.1.5 Process unit layout shall include the following:

 Access and egress for personnel safety

 Access for operations and maintenance

 Provisions for operational housekeeping and constructability

 Maintenance requirements during plant shutdowns shall be considered.

- Size and location of construction lay-down areas

- Access for the transportation and placement of bulk construction materials

- Crainage and other equipment to be used for construction.

4.2 Efficient Design

4.3 Legal Requirements

5. LAYOUT OBJECTIVES AND BASIC REQUIREMENTS

Site elevations shall be in accordance with project design drawings

For area boundaries refer to BMPS-A1 Section 5.2

5.3 Consequence Analysis and Probabilistic Risk Assessment

 the explosive energy of the process materials