Petroleum Development Oman L.L.C.

UNRESTRICTED Document ID: SP-1127

June, 2004 Filing Key:

Plant Equipment Layout Specification

Keywords: Layout, Site Selection, Prevailing Wind, Fire Fighting, Flare, Risk, Access,
Operability, Waste Disposal, Control Building, Spacing

This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of this
document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by
any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the
owner.
Plant Equipment Layout Specification Version 2.0

Authorised for Issue:

Signed: ……………………………

A. C. Sluijterman
CFDH – Process Engineering

Date:……………………………….

The following is a brief summary of the most recent revisions to this document.

Version No. Date Author Scope/Remarks

1.0 June 1999 A.C. Sluijterman Specification developed from ERD-09-03
UEP/1 “Layout and Spacing of Plant Equipment and
Facilities”
2.0 June 2004 A.C. Sluijterman Revalidation and update references.
UEP

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Content

1.0 INTRODUCTION...................................................................................................................................... 5
1.1 BACKGROUND........................................................................................................................................ 5
1.2 PURPOSE AND SCOPE .............................................................................................................................. 5
1.3 COMPLIANCE WITH THIS SPECIFICATION ................................................................................................ 5
2.0 LAYOUT SPECIFICATION .................................................................................................................... 6
2.1 SITE SELECTION CONSIDERATIONS ........................................................................................................ 6
2.1.1 Future Extensions......................................................................................................................... 6
2.1.2 Contour of the Ground ................................................................................................................. 6
2.1.3 Prevailing Wind ........................................................................................................................... 6
2.1.4 External Factors ........................................................................................................................... 6
2.2 FACILITY LAYOUT CONSIDERATIONS .................................................................................................... 6
2.2.1 Access Arrangements................................................................................................................... 6
2.2.2 Hazardous Area Classification ..................................................................................................... 6
2.2.3 Operability ................................................................................................................................... 7
2.2.4 Layout Review ............................................................................................................................. 7
3.0 EQUIPMENT MODULE SPACING ....................................................................................................... 8
3.1 OVERVIEW ............................................................................................................................................. 8
3.2 WELLHEADS .......................................................................................................................................... 8
3.3 LOW PRESSURE PROCESS MODULES ...................................................................................................... 8
3.4 HIGH PRESSURE PROCESS MODULES ..................................................................................................... 8
3.5 TRANSFER OPERATIONS ......................................................................................................................... 8
3.6 STORAGE ............................................................................................................................................... 8
3.7 PIPE RACKS AND TRACKS ...................................................................................................................... 8
3.8 PLANT INLET/OUTLET ESD VALVES ..................................................................................................... 8
3.9 FURNACES AND HEATERS ....................................................................................................................... 9
3.10 FLARES.................................................................................................................................................. 9
3.11 OVERHEAD POWER LINES ...................................................................................................................... 9
3.12 FENCES .................................................................................................................................................. 9
3.13 CONTROL ROOMS .................................................................................................................................. 9
3.14 ROADS ................................................................................................................................................... 9
4.0 EQUIPMENT SPACING WITHIN MODULES................................................................................... 11
4.1 COMPRESSORS ..................................................................................................................................... 11
4.2 PUMPS.................................................................................................................................................. 11
4.3 TANKS WITHIN A BUNDED AREA .......................................................................................................... 11
4.4 MULTIPLE FURNACES/HEATERS ........................................................................................................... 12
5.0 RELATED BUSINESS CONTROL DOCUMENTS ............................................................................ 13

APPENDIX A GLOSSARY OF TERMS, DEFINITION & ABBREVIATION ....................................... 14

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1.0 Introduction

1.1 Background

This specification is developed from and replaces the “Layout and Spacing of Plant Equipment and
Facilities” Engineering Reference Document (ERD-09-03), issued in March 1991.

The Shell HSE manual on Design (EP 95-0230) provides a good overview of the facility layout
considerations for the design of new facilities. This specification highlights the key requirements and is
more specific on the allowable equipment spacing.

1.2 Purpose and scope

The purpose of this specification is to ensure that the PDO layout and spacing of plant equipment are
designed in a safe, cost effective and consistent manner. The equipment spacing specifications have
been developed in order to:
• minimise the likelihood of ignition resulting from a hydrocarbon release;
• contain the effects of a jet or pool fire and prevent escalation to adjacent modules;
• allow access for operations and maintenance;
• minimise any overpressure from an explosion;
• provide suitable means for escape and evacuation.
This specification shall be applied to extension of existing plants and to all new plants. This
specification is not intended to be applied retroactively to existing plants.

1.3 Compliance with this specification

The user shall obtain written approval from the Corporate Functional Discipline Head (CFDH) Process
Engineering for any deviations from this specification.

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2.0 Layout Specification

2.1 Site Selection Considerations

2.1.1 Future Extensions

Consideration shall be given to any future expansion of the plant and/or expansion of the surrounding
communities and facilities.

2.1.2 Contour of the Ground

The contour of the ground including hollows, ditches and changes in levels, shall be considered in
relation to the consequences of accidental release of flammable or toxic liquids and vapours.

2.1.3 Prevailing Wind

The effect of the prevailing wind on accidental and operational release of vapours and gases, such as
from vent and flare stacks, shall be considered in locating the site in relation to neighbouring facilities,
and in the layout of the plant itself.

2.1.4 External Factors

The potential danger, to life and property of adjoining communities and the environment, shall be fully
considered. Further, the risks to and from adjacent facilities and plants shall be taken into account in
locating the site.

2.2 Facility Layout Considerations

2.2.1 Access Arrangements

Means of emergency escape in the event of a fire, gas leak or other dangerous occurrence, shall be
provided from all buildings, structures and plant areas. Escape routes and exits shall be incorporated
into the overall facility layout. Where practical there should be at least two escape routes from every
location within the facility, and these routes should be in different directions so that personnel can
always retreat from the danger. The length of escape routes should be kept to a minimum, and
emergency exits from the facility should lead to safer assembly areas. Dead ends, areas with only one
exit, should be avoided.

2.2.2 Hazardous Area Classification

To ensure that ignition sources, such as fire heaters, combustion engines and flares are located at an
adequate distance away from potential sources of flammable substances, Hazardous Areas shall be
defined and classified in accordance with DEP 80.00.10.10-Gen.

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2.2.3 Operability

Access ways for operations and maintenance shall be a minimum of 3 m wide and unrestricted.
Consideration shall be given to access to cranage, if required, for major maintenance activities.
Maintenance access shall be provided to allow for dismantling of equipment. For example access is
required to pulled out reciprocating compressor rods and heat exchanger tube bundles.

2.2.4 Layout Review

Upon completion of the draft facility Plot Plans and Hazardous Area Classification drawings, a layout
review shall be carried-out with representatives from Operations, the Engineering Design team and the
Project Engineer.

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3.0 Equipment Modules Spacing

3.1 Overview

The recommended minimum spacing requirements for onsite plant equipment are listed in Table 1. All
spacing is measured from edge of the skid. The tables shall be used in conjunction with the explanations
detailed below.

3.2 Wellheads

A minimum distance of 80 m is required between wellhead and plant fence or flowline/pipetrack to

allow for access of both drilling and work over rigs. This distance may be further reduced in
consultation with the Well Engineering department.

3.3 Low Pressure Process Modules

Low Pressure (LP) module spacing applies to facilities which have a maximum operating pressure of
1900 kPa(g) and are hence considered “low risk”, i.e. manifolds, bulk separation and crude stabilisation.

3.4 High Pressure Process Modules

High Pressure (HP) module spacing applies to facilities whose operating pressures exceed 1900 kPa(g)
and are hence considered “high risk”, i.e. gaslift/export compressors and gas treatment facilities.

3.5 Transfer Operations

Transfer operations typically represent road tanker loading/unloading of liquid hydrocarbons, i.e.
diesel, crude and process drains vessel contents.

For loading/unloading of LPG a minimum distance of 60m is recommended between the transfer
operation and process facilities and storage.

3.6 Storage

Spacings are specified on the basis of limiting damage to other facilities as a result of a tank fire
(contained within the bund wall) and vice-versa.

For pressurised LPG storage DEP 30.06.10.12-Gen. “Liquefied Petroleum Gases Bulk Storage
Installation” shall be applied.

3.7 Pipe Racks and Tracks

Spacings apply provided the pipes in the tracks are related to the plant concerned. These distances are
not relevant to pipe racks/tracks to and from the modules/equipment concerned.

3.8 Plant Inlet/Outlet ESD Valves

Distances apply to main plant inlet/outlet Emergency ShutDown (ESD) valves.

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3.9 Furnaces and heaters

Furnaces and heaters present a constant source of ignition to any hydrocarbon releases; therefore, their
location must be carefully selected. The preferred location is on the upwind side of a plant near the
battery limit.

3.10 Flares

The layout and spacing of flares shall be designed in accordance with DEP 80.45.10.10-Gen. “Pressure
Relief, Emergency Depressurings, Flare and Vent Systems”.

3.11 Overhead Power Lines

Overhead power lines shall be located a minimum of 15 m outside the plant fence to protect the plant
from collapsing pylons. These are normally high voltage lines and are also considered sparking sources.

3.12 Fences

All PDO plants shall be surrounded by a fence. Non hazardous area shall extend beyond the fence.

PDO wellhead locations are normally not fenced, with the following exceptions:
• Wellheads visible from main public roads or Government “black top” roads.
• H2S wells located in normally sweet fields.
• Free flowing wells with a Flowing Tubing Head Pressure > 15,000 kPa(g).

3.13 Control Rooms

The control building shall be designed with a certain resistance against explosions, depending on the
level of risk. The risk level in turn depends on the manning level and the distance from the process
equipment.

For unmanned control rooms (visited less than 1 hour per day) that satisfy the minimum spacing
requirements in Table 1, no special explosion resistance measures are required.

For manned control rooms (visited more than 1 hour per day), the room shall be able to withstand the
overpressure loads predicted by the Shell software SCOPE or equivalent PDO approved software.

3.14 Roads

Roads, not for maintenance access, within a fenced site shall be at least 15 m from process plant
equipment (30 m from LPG facilities).

Public roads (not access roads) shall be at least 15 m from the facility fence, 80 m from wellheads and
15 m from overhead power lines.

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Table 1 - Recommended Minimum Safety Distances for onsite Plant Equipment (in metres from skid edge)

Pipe Rack /Track

Over-head power
Furnace /Fired

Control Room
L.P. Process

/Outlet ESD
HP Process

Operations
Well-heads

Plant Inlet
Transfer

Heaters
Module

Module

Storage

Fences
Flares
Valve

Lines
Wellheads 95 -- -- -- -- -- -- -- -- -- -- --

L.P. Process Module 95 15 -- -- -- -- -- -- -- -- -- --

H.P. Process Module 95 25 25 -- -- -- -- -- -- -- -- --

Transfer Operations 95 20 30 -- -- -- -- -- -- -- -- --

Storage 95 15 25 20 -- -- -- -- -- -- -- --

Pipe Rack/Track 80 5 5 5 5 -- -- -- -- -- -- --

Plant Inlet/Outlet ESD 80 15 25 30 25 5 -- -- -- -- -- --

Valve

Furnaces/Fired Heaters 95 20 30 30 30 5 30 20 -- -- -- --

Flares 95 60 60 60 60 60 60 60 -- -- -- --

Overhead Power Lines 60 30 30 30 30 15 30 30 60 15 -- --

Fences 80 15 15 15 15 15 3 15 60 15 -- --

Control Room 80 20 30 30 30 15 30 20 60 15 3 --

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4.0 Equipment Spacing within Modules

4.1 Compressors

Equipment associated with a compressor such as fin fan coolers, knock-out drums, etc., may be
located in the compressor area and need not comply with spacing requirements provided they do
not restrict access for fire fighting and maintenance.

Due to the excessive heat transfer surface of fin fan coolers and the types of metals used in those
surfaces, cooler bundles are highly vulnerable to damage within a few minutes under fire
exposure. Fin fans should preferably be located on the opposite side of the module, away from
fire sources, to avoid ignition in the event of fin fan tube leakage.

Access to compressors for fire fighting purposes must be maintained on at least two sides of the
installation.

Gas Turbine or Gas Engine driven compressors shall be located not closer than 20 m from
parallel units, as the drivers constitute a source of ignition. A minimum of 10 m is recommended
for electrically driven units.

4.2 Pumps

Gas Turbine or Gas Engine driven pumps shall be located not closer than 20 m from parallel
units, as the drivers constitute a source of ignition. The recommended distance for electrically
driven units is 10 m.

Pumps shall be isolated from the gas turbine drivers by a fire wall, which is normally an integral
part of the Turbine enclosure.

Firewater pumps shall be located at least 20 m away from oil storage tanks and 25 m from
hydrocarbon containing equipment.

4.3 Tanks within a bunded area

For spacing of tanks within a bunded area DEP 34.18.51.10-Gen. shall be applied.

Pumps may be located at a minimum distance of 3 m from the bund wall for maintenance access
reason, provided the pump is electric motor driven and is considered an integral part of the tank
module.

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4.4 Multiple furnaces/heaters

For multiple furnaces/heaters that are shutdown together for maintenance, only nominal spacing
for access is required (5 m). Furnaces/heaters shutdown individually require a spacing of 15 m if
the coil inlet design pressure is less than 1900 kPa(g), and a spacing of 25 m if the coil design
pressure exceeds 1900 kPa(g).

Pipe racks located 5 m from furnaces/heaters shall not contain any valves except those related
specifically to the furnace/heater concerned.

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5.0 Related Business Control Documents
The following Business Control Documents are referred to in this specification:
PDO Specifications
PDO SP-1190
PDO SP-1075
Shell Standards
EP 95-0230
DEP 30.06.10.12-Gen.
DEP 34.18.51.10-Gen
DEP 80.00.10.10-Gen
DEP 80.45.10.10-Gen.
June 2004
Version 2.0
Design for Sour Service Specification
HSE Specification – Fire and Explosion Risk Management
HSE Manual – Design
Liquefied Petroleum Gases Bulk Storage Installation.
Minimum Requirements for the Construction and
Maintenance of Tanks Foundations, Bund Walls and
Drainage Systems for Small storage Installations
Area Classification (Amendments/Supplements to IP-15)
Pressure Relief, Emergency Depressurising, Flare and Vent
Systems.
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Appendix A Glossary of Terms, Definition & Abbreviation

CFDH Corporate Functional Discipline Head

DEP Design Engineering Practice
ESD Emergency ShutDown
Hazardous Area An area in which explosive gas/air mixtures may be expected to
be present in quantities such as to require special precaution
with respect to potential sources of ignition.
HP High Pressure (> 1900 kPa(g))
LP Low Pressure (< 1900 kPa(g))
LPG Liquid Petroleum Gas
NGL Natural Gas Liquids
PDO Petroleum Development Oman
Process Module A single process facility fulfilling a distinct process function,
i.e., gas dehydration; mechanical refrigeration; NGL or crude
stabilisation.
Or
Parallel equipment performing the same process function, i.e.,
bulk separators; gaslift or export compressor trains; export,
booster or injection pumps.

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