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Plant Layout, Spacing and Clearances

This document is issued by PE&S, SABIC E&PM, Jubail Industrial City, Kingdom of Saudi Arabia. The information contained
in this document is the confidential property of SABIC. It cannot be disclosed, copied or used for any purpose without approval
from SABIC. If you are not authorized to posses this document, please destroy it immediately.
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CONTENTS
1 SCOPE ........................................................................................................................................3
2 REFERENCES ............................................................................................................................3
3 DEFINITIONS ..............................................................................................................................3
4 PROCESS SAFETY REQUIREMENTS ......................................................................................4
5 SPACING REQUIREMENTS.......................................................................................................5
6 ADDITIONAL CONSIDERATIONS IN LAYOUT..........................................................................5
6.1 Maintenance ............................................................................................................................5
6.2 Road ways in plants and other facilities ..................................................................................6
6.3 Clearances and accessibility ...................................................................................................6
6.4 Exchangers and Reboilers ......................................................................................................7
6.5 Air Cooled Exchangers ............................................................................................................7
6.6 Towers and Vessels ................................................................................................................7
6.7 Reactor and Dryers .................................................................................................................7
6.8 Compressors, Turbines, Expanders ........................................................................................7
6.9 Pipe racks ................................................................................................................................7
6.10 Pipeways and equipment clearance from road .......................................................................8
6.11 Access and Egress ..................................................................................................................8
7 PLANT BUILDINGS .....................................................................................................................8
8 PROPERTY FENCES .................................................................................................................9
9 REVISION SUMMARY ................................................................................................................9

Table I Equipment position with respect to prevailing wind direction ..................................................4

Table II Minimum Clearance Dimensions ..........................................................................................10
Table III Clearance Around Equipment ..............................................................................................11
Table IV Minimum Access Provisions for Valves and Instruments ....................................................12

Figure -1 Typical Cross Section Through Unit Pripe Rack.................................................................13

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1 Scope
1.1 This standard provides the minimum requirements for plant layout, spacing, access and
clearances for Petrochemicals, Fertilizers, and specialty chemicals plants.
1.2 This standard is applicable to all facilities, including new projects, expansion of existing
facilities and upgrades.

2 References
Reference is made in this standard to the following documents. The latest issues, amendments, and
supplements to these documents shall apply unless otherwise indicated.
SABIC Engineering Standard (SES)
B01-E03 Design of Buildings for Petrochemical Plants
C04-E01 Design Criteria for Surfacing, Paving and Roadways
E02-G01 (NEC or IEC) Electrical System Design Criteria
E14-E01 (NEC or IEC) Main Substation: Design
E14-S02 (NEC or IEC) Design Requirement for Unit Substation
R08-E01 Process Analyzer System Design Criteria
S04-E01 Flare and Blowdown system
X07-E01 Control Building Design Criteria
High Commission of Industrial Security (HCIS), KSA.
SAF-03 Buildings for Industrial Facilities
SAF-04 Fire Protection Systems and Equipment
SAF-06 Plant Layout, Spacing, and Access
SAF-08 Storage Tanks and Storage Vessels
SAF-10 Pressure Piping, Transportation Pipelines and Pressure Vessels
SAF-15 Private Industrial Fleet Vehicle Filling Stations
SEC-01 General Requirements for Security Directives
SEC-02 Security Fencing Systems
Royal Commission Environmental Regulation (RCER)
Royal Commission Environmental Regulation Volume- 1
Royal Commission Environmental Regulation Volume- 2
American Petroleum Institute
API 521 Pressure-relieving and Depressuring Systems
IBC International Building Code

3 Definitions
Dimensions: Measurements that apply to spacing between equipment, or from equipment to
defined lines, and which are “edge-to-edge” dimensions (not “centerline” dimensions).
Main Pipeway: Pipeways, at grade or elevated on pipe supports, that contain utility lines and product
lines for a number of process units and that are connected to process unit pipeways.
PDP: Process Design Package
Process Unit Pipeway: Pipeways that are at grade or elevated on pipe supports and contain feed,
recycle, and rundown lines, as well as utility lines within process unit battery limit.
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Process Equipment: Any components of an operating facility such as vessels, tanks, fired heaters;
heat exchangers, rotating equipment, and piping that are part of a process train used in the
processing material into a given product or products.
Main substation / Major Electrical Distribution Centre: A substation that provides the interface
between the source of power (power grid, utility, or generating plant) and the plant electrical
distribution system.
Unit Substation / Onsite Plant Electrical Load Centre: A substation which provides the interface
between the plant distribution feeders (13.8 or 34.5 kV) and the plant utilization equipment.

4 Process Safety Requirements

The basic objective of providing Process Safety requirements for the development of plant layout
are as follows:
a) To provide inherent safety in the plant design
b) Minimization of Environmental impact
c) Safety of personnel and community
Following requirements shall be considered during development of Plant layout:
4.1 Process blocks shall be located in the sequential order of process flow.
4.2 Process, Utilities and offsites blocks shall be arranged considering prevailing wind direction
so that flammable gases are not carried towards sources of ignition (flares and furnace). Also
the unwanted fumes, spray of water shall not affect the adjacent facilities.
Table I
Equipment position with respect to prevailing wind direction
Facility Equipment position
 Heater/Boiler/Incinerator
 Flare Upwind or cross wind
 Cooling Tower
 Effluent Treatment Plant Downwind
 Dusty/fume releasing equipment
 Operator Cabin Preferably Upwind
 Storage tank area Downwind

4.3 Gas compressors shall be located downwind from heaters/furnaces so that leaked gases will
not drift towards them.
4.4 Process areas shall be constructed at higher elevations than storage areas to avoid runoff of
major spills and minimize the potential for ignition of hydrocarbon vapor releases from storage
areas.
4.5 Utility block shall be kept at safe area close to process plants.
4.6 Electrical sub-stations shall be placed at the load centre to minimise cabling.
4.7 Electrical receiving station shall be placed near the supply point.
4.8 Ware houses/truck loading facilities shall be located close to the product movement gate to
avoid truck traffic within the process area.
4.9 Effluent treatment plant (WWTP) shall be located at a safe distance from the process and
utility area.
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4.10 Separate access gates should be provided for material and employees entry/exit. Material
gate shall be equipped with appropriate weigh bridge, if required. Employee gate shall be
provided with access control facilities, if required..
4.11 Equipment such as drums, heat exchangers shall not be located under the pipe racks.
4.12 Vessels and/or pumps containing flammable or combustible liquids shall not be located
beneath air coolers.
4.13 Pumps handling hydrocarbon shall not be located under pipe racks, cable runs, or air-cooled
heat exchangers. In offsite areas, pumps shall be located outside tank dikes.
4.14 Pumps and compressors shall be located to allow open ventilation to dissipate leaks or spilled
vapors.
4.15 Cooling towers
a. Cooling towers shall be located away from fired heaters, boilers, Control room and
Substation with consideration given to the prevailing wind direction so that drift
from the tower does not cause corrosion, obstruct vision and short circuiting.
b. Cooling tower shall be located so that spray/mist from the tower is kept away from
buildings and process areas.
4.16 For other process safety requirements refer to HCIS SAF-03, SAF-04, SAF-06, SAF-08, SAF-
10 and SAF-15.
4.17 The requirement of hazardous material classification for storage tanks and its dyke
containment shall be as per RCER.

5 Spacing Requirements
5.1 Preliminary Plot Plan for ISBL and OSBL shall be developed based on spacing requirements
given in PDP, HCIS, International Standards such as NFPA and API as applicable. Risk
Analysis study shall be performed with preliminary Plot Plan and a site specific Spacing Table
shall be developed. Preliminary plot plan shall be updated to incorporate the spacing table
developed as part of Risk Analysis study.
5.2 The minimum spacing requirement for similar services such as pump and its spare, or
compressors and their drivers shall be based on operation and maintenance.
5.3 For cooling tower especially for sea water cooling tower mists dispersion study shall be carried
out to decide separation distance with adjacent equipment/facilities. If equipment are placed
within the mist dispersion zone, suitable protective painting or other suitable mitigation
measures shall be provided.
5.4 For layout consideration related to flare refer SES S04-E01.
5.5 For non-process equipment, spacing shall be provided to meet operation and maintenance
requirements.

6 Additional Considerations in Layout

6.1 Maintenance
The layout of the equipment shall be designed taking into considerations the following
maintenance requirements.
6.1.1 Equipment, structures and piping shall be arranged to permit maintenance and service
by means of mobile equipment. Permanent facilities shall be provided only where
maintenance with mobile equipment is impractical.
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6.1.2 A clear drop out area shall be provided at grade for Reactors, vessels / towers with
removable internals, mechanical agitators, large PSV’s etc. or which require loading
and unloading.
6.1.3 Heat exchangers shall be located perpendicular to the pipe rack or such that tube
bundles are accessible from unit road.
6.1.4 Crane approach for air coolers removal / re-installation shall be provided.
6.1.5 Provision of monorail for pumps and exchangers shall be provided wherever such
equipment can not be accessed/maintained using plant mobile equipment.
6.1.6 Sufficient access and clearance shall be provided at fired equipment(Heater/
reformers / Boiler / Incinerator etc.) for removal and cleaning of tubes, soot blowers,
air preheater baskets, burners, fans and other related serviceable equipment. Fired
heater is preferably lined up along the plant road for easy maintenance and safety.
Sufficient space shall be provided around the fired heaters for mobile equipment
handling/crane approach. The top of vertical tube heaters must have clear areas for
removing tubes. Bottom fired heaters shall have 2.5 m clearance for burner removal.
6.1.7 Wherever possible, large compressor trains shall be located such that the working
platform can be interconnected.
6.1.8 All Major / Process Turbo-Compressor Trains shall have a permanent Overhead
crane. The crane shall be designed for the heaviest maintenance lift required on the
compressor deck. The overhead crane shall be designed to provide sufficient
overhead clearance to allow lifting any major component over other installed machine
bodies. It shall have sufficient overhead lifting clearance to allow lifting the assembled
upper casing half of any machine.
6.1.9 Trolley beams or other means shall be provided for removal and installation of large
vertical pumps, if the pumps are not accessible to a crane. Clear space shall be
provided above these pumps for removal. Care must be taken to locate the trolley
beams directly over the center of the pumps.
6.1.10 Towers and column shall be located such that all working platforms and manholes
face the access road.
6.1.11 Dosing units, truck loading/unloading and chemical storage buildings shall be located
near roads for easy access.
6.1.12 Sufficient clear access should be provided around the extruder for entry of mobile
maintenance equipment and for dismantling extruder components such as pelletizer
and barrels. Monorails may be required to remove components. A laydown area for
monorail should have access for removing components from building. Monorail may
extend outside of building to permit loading and unloading of equipment parts onto
mobile equipment. An adequate unobstructed laydown/dropout area shall be provided
for carrying out any emergency repairs at site.
6.1.13 Removable sections of Floors, Platforms, Walls and Roofs
Removable section in floors, platforms, walls, and roofs shall be provided as
appropriate for removing and lowering machinery components to grade level for
further handling by mobile equipment. However, built-in equipment handling facilities
shall be provided where practical.
6.2 Road ways in plants and other facilities
Roadways in plants and other facilities shall be in accordance with directive HCIS SAF-06 and
SES C04-E01.
6.3 Clearances and accessibility
6.3.1 Minimum requirement for head room clearance, overhead clearance and access
walkway clearance shall be as per Table-II
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6.3.2 Clearances around equipment shall be as per Table III.

6.3.3 Minimum access requirements for Valves, Instruments and equipment shall be as per
Table IV
6.4 Exchangers and Reboilers
6.4.1 Exchangers shall be grouped together wherever possible. Shell and tube exchangers
shall be stacked (similar service) as follows:
1.2 m in diameter Stacked three high
1.2 to 1.8 m in diameter Stacked two high
Over 1.8 m in diameter Shall not be stacked
Over 19 tons (wt) Shall not be stacked
6.4.2 Reboilers shall be located as close as possible to the equipment they serve.
6.5 Air Cooled Exchangers
6.5.1 Air fin coolers shall preferably be installed above the pipe racks. If the space above
the pipe rack is not sufficient for installing aircoolers, the space above steel structures
or independent structure may be considered.
6.5.2 Platforms are required below the air cooled exchangers for maintenance access to
exchanger motors and fan drives. These platforms must allow access without
scaffolding.
6.5.3 When the air cooler is located over a process unit pipe rack, the clearance between
the lowest portion of an air cooler and the uppermost pipe or cable tray should be
2.4m minimum. To the maximum extent possible, critical cable trays should be routed
underground or, at a minimum, away from high fire potential process equipment, such
as air coolers.
6.6 Towers and Vessels
6.6.1 Towers and vessels are to be arranged in single rows, parallel to unit pipeways
(preferable), and conform to the process flow sequence.
6.6.2 Vertical vessels shall generally be placed on a common centerline parallel to the main
pipeway.
6.7 Reactor and Dryers
Adequate access and area at ground level and on platforms shall be provided for handling
drums and/or tote bags at equipment (e.g., dryers, reactors, etc.) that require frequent catalyst
changes or raw material charging.
6.8 Compressors, Turbines, Expanders
6.8.1 Pumps and compressors handling flammable products shall not be grouped in one
single area
6.8.2 For Major / Process Turbo-Compressor Trains:
The compressor bodies and drivers along with all auxiliaries/ancillaries shall be
installed under a shelter with provisions for protecting the machines from ambient
conditions. Protection from atmospheric dust/sand intrusion shall be provided to
protect the disassembled compressors/turbines components at the compressor deck
during major overhaul. Adequate maintenance drop zones shall be provided on each
compressor deck
6.9 Pipe racks
6.9.1 The unit pipe rack should be kept in the centre, thereby splitting the unit into two or
more areas of equipment.
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6.9.2 The total width of pipe rack shall include a minimum of 10 percent extra space (at the
time of plant “as built”) for modifications in unit at later stage. However, this minimum
extra space shall be increased based on type of projects and, expected future
expansion/modification with approval of SABIC.
6.9.3 A clear maintenance aisle, 3.0 m wide and 3.7 m high is required under the unit pipe
rack to facilitate the maneuvering of cherry picker or other type of maintenance
equipment.
6.9.4 A typical cross section of pipe rack design is shown in Figure-1.
6.10 Pipeways and equipment clearance from road
The pipeways and equipment clearance from road shall be as per HCIS SAF-06.
6.11 Access and Egress
6.11.1 All facilities shall be provided with the required access and egress for personnel,
materials and equipment by using access, ladder roads stairways, etc., shall be as
per directive HCIS SAF-06.
6.11.2 Requirements for primary and secondary access/egress to elevated work areas:
If the frequency of use is daily, a fixed stairway shall be provided as primary access
to and egress from each elevated working area. If the frequency of use is less than
daily, a stairway shall be provided if materials, tools or other equipment normally
needs to be carried for operating or maintenance, or if there is a potential for exposure
to injurious chemicals or material at the elevated working surface.
6.11.3 A secondary means of egress (which may be either a fixed ladder or a fixed stairway)
shall be provided for each elevated working surface if:
a. The location is 3m or more above grade, floor, and has 19m2 or more area, or if:
b. There is a potential spill or fire hazard or injurious chemical exposure that could
block access to an exit. This secondary means of egress shall not be more than
25m horizontally from an area where operating or maintenance personnel may be
working, and shall be located such that an alternative route of escape to a place
of safety is provided.

7 Plant Buildings
Plant Building entry and exit requirements for life safety shall be in accordance with SES B01-E03
and IBC.
7.1 Control building
7.1.1 Control Building should not normally be combined with administration buildings,
laboratories, or any other non-related structure. In the event that a laboratory is
located within a control building, both the HVAC and drainage systems shall be
segregated.
7.1.2 Control building should be located adjacent to a plant roadway to ensure access
during an emergency.
7.1.3 Requirement of blast resistance wall for control room shall be decided based on
project requirement / building risk assessment.
7.2 Remote Instrument Building (RIB)
Remote instrument buildings shall be located at the perimeter of the unit battery limits so that
access to the Remote Instrument Building can be gained without traversing a process unit.
For details and descriptions, refer to SES X07-E01.
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7.3 Analyzer Shelters

Analyzer shelters shall be located as centrally and conveniently to sample take off points
located in a non-hazardous location as possible. Shelters shall be located close to roadways
for easy accessibility. For further details, refer to SES R08-E01.
7.4 Main and Unit substations
Main and unit substations shall not be part of administration buildings, shops, control buildings,
laboratories, or any other nonrelated structure. In locations where it is deemed absolutely
necessary, approval must be obtained from SABIC to combine a main or a unit substation with
another structure. In such cases the substation shall be separated by a 3-hour rated fire wall
with no direct access or any other penetration through the wall. For further details, refer to
SES E02-G01, E14-E01, and E14-S02 (NEC or IEC).

8 Property Fences
The minimum required distance between plant facilities and property fencing shall meet directive
HCIS SEC-01 and SEC-02.

9 Revision Summary
Revision No.1, June 2013:
Restructured : Overall restructuring by combining S01-G01 requirement.
Added : HCIS Requirements, Minimum access provisions for valves and Instruments
Updated : References
Deleted : Generally known definition and theories.

Revision No.2, December 2017:

Updated : References, Definitions & Table II, Table IV
Added : Para.7.2, 7.3
Modified : Para. 4.10, 5.2, 6.1.3, 7.1
Deleted : Para. 5.1, 5.7, 6.9
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Table II
Minimum Clearance Dimensions
Minimum headroom clearance, overhead clearance and access walkway clearance shall be as follows:

Sr. # Item Description Dimension

(mm)
1 Headroom at grade and over elevated platforms, walkways, working areas and 2200
stairways
2 Overhead clearance over roads (from crown) or Overhead clearance for pipe rack
above road crown to bottom of pipe rack beams:
a. For primary roads 7000
b. For secondary roads 5500

3 Overhead clearance over working areas at grade for mobile lifting equipment 3700
access / Overhead clearance for tertiary roads and pump access ways
4 Overhead clearance for main process pipe rack from paving surface to bottom of 3700
pipe or rack beams

5 Minimum Access Walkways Clearance

c. Width of stairways (unobstructed width) 750

d. Width of landings (in direction of stairways) 915
e. Width of walkways 915
f. Maximum vertical rise of one flight of stairway 3600
g. Maximum length of dead-end platforms 6100

6 Ladders:
a. Maximum vertical rise of ladders in a single run 9000
b. Maximum allowable slope of ladders from vertical 15 degrees
c. Minimum toe clearance from centerline of rung to obstruction 180

7 Platform:
a. Maximum variance in platform elevations without an intermediate step 300
b. Minimum unobstructed width of platforms 760
c. Occasional obstructions (level glass, transmitter, etc.) 460
d. Minimum width of manhole platforms on vertical vessels 1070
e. Minimum distance from platform level to centerline of manhole flange on 760
vertical vessels
f. Minimum width of platform from three sides of manhole on vessel top head 760
platforms
g. Minimum width of platforms at ends of horizontal tube furnaces 1070
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Table III
Clearance Around Equipment
Minimum requirement for open space around equipment or clearance between equipment upon final
installation shall be as follows:
Sr. # Item Description Dimension
1 HEAT EXCHANGERS
Between horizontal exchanger’s shell flanges (including
a 450 mm
insulation)
b For shell cover end 1,800 mm
For channel end (removable and fixed tube bundle type, Tube bundle length plus 1,500 mm (not
c and for in situ hydroblast cleaning) more than 1/3 width of the adjacent road
can be used for this purpose)
2 PUMPS
Between pumps of less than 3.7 kW (pumps on a
a 300 mm (between pump base frames)
common foundation)
Between pumps of less than 3.7 kW (pumps on
b 750 mm(between pump foundations)
individual foundations)
Between pumps of more than 3.7 kW (between
c 900 mm
foundations)
d Between pump foundation and obstruction 750 mm
3 COMPRESSORS
2,400 mm between compressor
Between compressors
foundations
4 COLUMNS 1,500 mm between foundations
5 DRUMS 750 mm between foundations
6 SMALL EQUIPMENT ON A COMMON FOUNDATION 500 mm between equipment
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Table IV
Minimum Access Provisions for Valves and Instruments
Minimum Access
Platform (Items Located Over Platform)
Platform (Items Located at Edge of Platform)
Note: For equipment regularly operated or
maintained or operated in an emergency,
such as valve hand wheels, instrumentation,
controls, and their associated manifolds, the
distance, if located outside the handrails, from
a fixed walking/working surface to the
operating point shall be between 500mm and
1500mm vertically and a maximum of 300mm
horizontally. It shall be located away from top
rail, midrails and supports to allow access.
Permanent Ladder
Portable Stair/Platform/ladder
No Permanent Access
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Type of Item to be Accessed
 Elevated heat exchangers
 Elevated control valves (all sizes)
 Manholes (higher than 4500 mm above grade)
 Relief valves -NPS 4 inlet and larger on vertical
vessel or other location
 Process blinds (higher than 4500 mm above grade)
 Furnace soot blowers
 Furnace burners (when not accessible from grade)
 Furnace observation doors and sample ports (higher
than 4500 mm above grade)
 Elevated cleanouts
 NPS 4 and larger gate and globe valves at vessels
 Battery limit valves in elevated pipe racks
 Elevated motor operated valves
 Relief valves - NPS 3 inlet and smaller on vertical
vessels
 Relief valves - All sizes on horizontal vessels
 Level controllers (higher than 4500 mm above grade)
 Sampling devices on vessels (higher than 4500 mm
above grade)
 All sizes of check valves at vessels
 NPS 3 and smaller gate and globe valves at vessels
 Level controllers between 2100-4500 mm above
grade
 Level gauges and valves
 Furnace observation ports between 2100-4500 mm
above grade
 Instruments requiring routine access (temperature
gage, pressure gage etc.)
 Hand holes
 Elevated electrical substations and equipment
All servicing between 2100-4500 mm above grade
except as noted in this Table
 Block valves in pipe racks (except at battery limit)
 Elevated orifices or meter runs
 Nozzles on vessels (without process blinds or valves)
 Check valves not at vessels
 Temperature connections in piping
 Pressure connections in piping
 Silencers or exhaust heads
 Metal temperature measuring points on vessels
 Instrument connections on furnaces
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Figure -1
Typical Cross Section Through Unit Pipe Rack