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Terminal facilities ‐ applications
Indian Bulk Liquid Storage
Conference 2016
• Petroleum Terminals: Include tank farms, loading
unloading facilities, pipeline manifolds, warehouse,
laboratory etc.
• Pipeline Tankage Facilities: Tanks to receive crude oil
and refined products from pipelines, trucks, railcars or
marine facilities.
• Refinery Facilities: Loading Unloading Crude Oil,
intermediate products and finished products.
• Bulk Plants: Smaller quantities of products, by truck or
packaging, bulk containers etc.
• Lube Blending and Packaging Facility: Blend refined
base stocks with additives and package in drums, pails,
portable tanks etc.
• Asphalt Plants / Aviation Service Facilities
Messe Frankfurt Trade Fairs India
Design of Tank
Terminal Facilities
By Jyoti Swarup
Consultant, Oil & Gas
12 February 2016
At Ramada Powai Hotel,
Mumbai
By: Jyoti Swarup
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Site Selection (1/2)
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• Availability of off‐site emergency services and access for
emergency response.
• Availability of required utilities including: electricity, sewers,
potable water, firewater, etc.
• Requirements for receipt and shipment of products including
over‐the‐road, rail, marine, and pipeline.
• Codes, permits, and regulations applicable to construction,
eg: zoning requirements; building permits; and air, water, and
waste discharge permits.
• Proximity to existing
supply and distribution
facilities.
• Topography of the site
including elevation, slope,
and drainage.
• Environmental conditions:
soil and groundwater
conditions, water table.
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• The provisions for location of aboveground storage tanks
with respect to property lines, public ways, and important
buildings on the same property are listed in OISD‐244 /
NFPA 30.
• Type of floating roof used in an AST affect spacing
requirements.
• Aggregate capacity (Combined safe capacity) of tanks
located in one dyked enclosure shall not exceed following
values (Ref. OISD 6.4.1a):
STORAGE AND HANDLING OF
PETROLEUM PRODUCTS AT
DEPOTS AND TERMINALS
INCLUDING STANDALONE CRUDE
OIL STORAGE FACILITIES
Relevant to design scope
Ch 6, Installation Design Layout
Ch 7: Design Considerations
Ch 8: Safe Operating Practices
Ch 9: Fire Protection facilities
– 60,000 KL for a group of fixed roof tanks.
– 120,000 KL for a group of floating roof tanks
This standard lays down the minimum Safety
requirements in design, layout, automation,
storage, loading / unloading operation, inspection &
maintenance, fire protection, training, emergency
planning & response and safety audit systems of
Petroleum Depots, Terminals and standalone Crude
oil storage Terminals.
By: Jyoti Swarup
By: Jyoti Swarup
Spacing of A/G Storage Tanks (1/2)
OISD STD 244‐2015
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Site Selection (2/2)
Proximity to public ways.
Proximity to waterways, other surface waters.
Proximity and risk (to and from) adjacent facilities.
Types and quantities of products to be stored.
Proximity and risk to populated areas.
Present and predicted development.
By: Jyoti Swarup
By: Jyoti Swarup
OISD: OIL INDUSTRY SAFETY DIRECTORATE
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•While in many projects that I have handled abroad for petroleum
products, tanks are of 25m height; it is limited to 20 m by OISD
specs, which effectively requires larger terminal space in India.
•Volume / capacity limitation of
enclosure was also not there.
By:dyked
Jyoti Swarup
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SEPARATION DISTANCES BETWEEN STORAGE TANKS WITHIN A DYKE
OISD‐STD‐244 Table 2 (Large Installations)
Spacing of A/G Storage Tanks (2/2)
SEPARATION DISTANCES BETWEEN TANKS/OFFSITE FACILITIES
• The requirements for spacing (shell‐to‐shell) between any
two adjacent aboveground storage tanks are listed in OISD‐
244 Table 3 (Below). The type of floating roof used in an AST
affect spacing requirements.
• The impact on spacing requirements by the use of dikes,
berms, shall be considered
• Dikes and intermediate dikes shall be constructed in
accordance with OISD‐244
Item
1
2
All tanks with
Diameter ≤ 50 m
Tanks with
Diameter >50 m
Between
floating Roof
Tanks
Class A & B
Between fixed
Roof Tanks
Class A & B
(D+d) / 4
Min 10 m
(D+d) / 4
(D+d) / 4
Min 10 m
(D+d) / 3
1
2
3
4
Between Fixed Between Class C
Petroleum
and Floating
Storage tanks
Roof tanks
(D+d) / 4
Min 10 m
(D+d) / 3
Spacing of Tank Truck Loading Racks
T3
x
30
x
x
30
30
X
8
8
20
Tank Vehicle loading /
unloading for Class C
Flame proof Electric Motor
Boundary wall
30
x
X
x
x
10
8
0.5 D
x
0.5 D
8
20
x
10
x
x
x
x
2
T3
3
30
4
30
5
8
6
0.5 D
Min 20 m
0.5 D
Min 20 m
Min 20 m Min 20 m
By: Jyoti Swarup
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Design of transfer facilities
• Need to conform to local codes, as OISD‐244‐2015 and/or
NFPA‐30
• Design for hazards associated with tank trucks, rail tank cars
or marine vessels.
• Fire prevention and environmental protection.
• Spacing of facilities shall be in accordance with codes.
• Normal operation and escape route plan to be developed.
• Piping, Valves and
fittings of
materials
compatible with
products
• Loading arms /
hoses suitable for
application
By: Jyoti Swarup
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DYKE Capacity
Spacing of Pumps and other Equipment
• The requirements for the spacing of pumps for the handling
of flammable and combustible liquids are found in OISD.
• Pumps inside secondary containment are considered ignition
sources due to the possibility of mechanical seal failures and
should be located outside the secondary containment area.
• Risk reduction measures
include heat sensors to
provide early warning of a
seal fire and automated
isolation valves among
other measures.
• API RP 500 may also be
consulted when locating
new pumps for the electric
motor portion of the pump.
By: Jyoti Swarup
Storage Tank for Petroleum
Class C
Tank vehicle loading /
Unloading for petroleum
class A or class B
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• Tank truck loading racks for
flammable and combustible liquids
should be located near the terminal
access way
• Oriented to provide a one‐way
traffic pattern for entrance and exit
with clear and direct access to the
terminal exit.
• Spacing or location of truck loading
racks from aboveground tanks, and
other buildings or adjoining
property lines are listed in OISD‐
STD‐244
• In table 2, for large tanks > 5000 m3,
spacing of Truck Loading rack to
tank is 30m.
By: Jyoti Swarup
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T3
•“x” indicates suitable distance as per good engineering practices.
•In Table – 2 all distances shall be measured between the nearest points on the perimeter of facility
•For different combination of storage tanks, the stringent of the applicable distance to be used.
•The distance of storage tanks from boundary wall is applicable for;
• Floating roof tanks having protection for exposure
• Tanks with weak roof-to-shell joint having foam or inert gas system and the diam. < 50m
(D+d) / 6
Min 6 m
(D+d) / 4
By:smaller
Jyoti Swarup
D & d stands for diameter of larger and
tanks.
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Tanks / Facility
Storage Tank for Petroleum
Class A / Class B.
• Dykes shall be sized so as to contain the greatest amount of
liquid that may be released from the largest tank within the
dyked area, (see also OISD/NFPA 30).
• Height of tank dyke (OISD) shall be 1.0m min. to 2.0m max.
• If height > 2m due to space constraint, additional OISD
requirements to be complied.
• The requirement for
freeboard is 200mm
or 10% of dyked
capacity whichever is
higher.
Refer my publication in Hydrocarbon
Processing - Dec 2006 on Dike capacity.
NFPA-30 limits Bund height to 6 ft (1.8m)
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By: Jyoti Swarup
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Distance and height of bund wall (Dyke)
NFPA 30: FLAMMABLE AND COMBUSTIBLE LIQUIDS
CODE: Few clauses (§22.11.2) are as below:
The tank spacing provisions are intended to minimize fire
hazard and exposure risk to adjacent tanks, buildings,
equipment or facilities
•A slope of not less than 1 percent away from the tank shall be
provided for at least 50 ft (15 m) or to the dike base,
whichever is less.
•To allow for volume occupied by tanks, the capacity of the
diked area enclosing more than one tank shall be calculated
after deducting the volume of the tanks, other than the largest
tank, below the height of the dike.
•Where the average interior height of the walls of the diked
area exceeds 6 ft (1.8 m), provisions shall be made for normal
access; necessary emergency access to tanks, valves, and
other equipment; and egress from the diked enclosure.
– The distance and height of bund relative to the tanks shall ensure
any oil loss due to tank puncture does not result in oil spouting
beyond the confines of the bund.
– The distance to bund wall should be minimized to make it
convenient for portable fire monitors to access the tank top.
An optimum balance between the
above two opposing requirements
is selected, by various codes.
Low wall heights (1 m - 1.5 m) are often
used to facilitate fire fighting but are
poor defense against spigot flow (a leak
in the wall of a tank passes over the
bund wall.)
By: Jyoti Swarup
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By: Jyoti Swarup
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Piping
Drainage of Rainwater
• The floor of the diked area shall be graded to at least 1% for
50 ft (15 m) away from the tank(s) or to the dike base,
whichever is less.
• The sloped area shall be directed toward drain openings or
retention areas. Piping should be protected where it crosses
over drainage routes.
• Drainage that would bypass
the in‐plant treatment
system shall be
accomplished through block
valves that may be safely
operated from outside the
diked area.
• Drainage system designs
should consider the fire
water loading.
By: Jyoti Swarup
Dike Height (NFPA‐30: 2015)
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• Piping passing through dike walls shall be
designed to prevent build‐up of excessive
stresses on pipe as a result of settlement.
• Penetration of dikes (except drains) shall
be kept to a minimum.
• The area surrounding the penetration shall
be sealed with a high‐temperature fire
resistant material.
• Piping that penetrates the
dike shall be protected from
corrosion by use of coatings,
pipe wraps, etc.
• Conduit passing through the
dike shall be sealed liquid
tight.
By: Jyoti Swarup
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Piping System
• A piping system consists of the pipe, fittings, valves, pumps,
and other types of equipment that are connected together.
• Care must be taken to consider the interaction of the
components in the overall piping system design.
• The design of the piping
system should be as
uncomplicated as
possible.
• Operating errors,
maintenance costs, and
risks of an
environmental release
will increase as a piping
system becomes more
complex.
A transfer pump is NOT permitted by PESO inside a dike area
as shown here. (Petroleum Rules 2002, Ch. 5 #132)
By: Jyoti Swarup
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By: Jyoti Swarup
PESO: Petroleum and Explosives Safety Organization
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Fire Prevention and Protection
GASOLENE TANK FIRE- South East Asia 2000
• In a “hierarchy of importance,” protection of personnel and the
public, environment, and equipment should dictate time and
resources dedicated to identify, control, and mitigate potential
incidents.
• The practices and procedures addressed in this presentation
are considered to be an effective means of preventing,
controlling, and extinguishing fires.
• Some of these provisions apply to
the design and construction of
new facilities while others apply
to operation, and maintenance
for all facilities. Refer to the OISD
or NFPA 30.
By: Jyoti Swarup
Control of Ignition sources (1/2)
Ignition from hot work is controlled
by following established hot work
permit procedures. Preventing
ignition from electrical equip. is
accomplished by:
• Following appropriate electrical
standards;
• Assuring that electrical equipment is
in good operating condition, is
properly installed, and is suitable for
the area electrical hazards
classification;
• Ensuring that specific procedures are
in place when tank receipts are
taking place.
By: Jyoti Swarup
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Tank Overfill Protection
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Overfill Protection for Storage Tanks
• Tank overfills that allow flammable liquids to spill
from tanks into the dike or surrounding area,
may create a potential for fire hazards.
• API Std 2350 and NFPA 30 recommend specific
overfill protection for terminals receiving
flammable liquids from pipelines or marine
vessels.
• Additionally, NFPA 30
address these and other
issues related to the
handling of flammable and
combustible liquids.
By: Jyoti Swarup
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Control of Ignition sources (2/2)
• Sources of ignition must be controlled in
areas where the potential exists for the
presence of flammable vapor‐air
mixtures.
• Common ignition sources include:
lightning, static electricity, stray
currents, hot work, internal combustion
engines, smoking, and unprotected
electrical equipment.
• Refer to API RP 500 for classifications of
locations for electrical installations at
petroleum facilities. Control of vapor
ignition from lightning and static
electricity are covered in API RP 2003.
By: Jyoti Swarup
By: Jyoti Swarup
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Key Elements of API Std 2350 (4th ed.) Safety Management
System (Overfill Prevention Process or OPP)
– Risk Assessment system
– Operating Parameters
• Levels of Concern
(LOCs) and Alarms
• Categories
• Response time
• Attendance
– Procedures
– Equipment Systems
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Increasing Efficiency
Operational Improvements
• To comply with modern best practices in Ovefill protection,
API Std 2350 4th ed is used.
• By applying this standard, increased operational efficiency
and higher tank utilization can be achieved.
• Using Safety Instrumented Systems (SIS) designed in
accordance with IEC61511 is one example of how to fulfill
some of the requirements in API 2350
• There are radical changes compared to previous versions
including the requirement for a safety management system.
• API Std 2350
ed uses the latest principles
of management systems, operational
improvements may result from:
4th
– Simplified and clarified response to alarms
– More usable tank capacity
– Generalized understanding and use of the
Management of Change (MOC) process
– Operator training and qualification
– Inspection, maintenance and testing
– Procedures for normal/ abnormal conditions
– Lessons learned used to evolve better
operational, maintenance and facility practices
IEC 61511 "Functional safety - Safety instrumented systems for the process
industry sector". is a technical standard which sets out practices in the
engineering of systems that ensure the safety of an industrial process through
the use of instrumentation. Such systems are referred to as Safety
Instrumented Systems.
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Reduced cost of risk with Modern
Overfill prevention systems
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Fire Fighting Equipment (1/2)
The use of specific fire protection
equipment may be required by
local regulatory agencies. The
emphasis should, however, be on
fire prevention.
Portable Fire Extinguishers
• All facilities shall have portable fire
extinguishers available at or near
areas where fires may occur.
• Extinguishers shall be of suitable
class and of an appropriate size for
the nature of the fire that might
occur. Refer to NFPA 10 for
portable extinguisher
• By implementing modern overfill prevention the insurance
premium may be reduced.
• It results in fewer tank
overfills, thereby
lowering the need for
costly emergency
responses.
• By having a better
understanding of
what’s in the tank,
fewer manual
measurements are
required.
• Require less
maintenance.
By: Jyoti Swarup
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Fire Extinguishment and Control
Fire Fighting Equipment (2/2)
Mobile and Portable Fire Fighting Equipment
• Larger facilities with trained fire brigades will have specialized
pieces of mobile and portable fire fighting equipment
• Such equipment may include, foam towers, large flow pumps
and monitors, equipment trailers and foam trailers, and
specialized fire fighting trucks.
• The need to provide fire
fighting brigades and
equipment, either on‐site or
through mutual aid, should be
evaluated for facilities where
local public fire fighting
services are inadequate.
By: Jyoti Swarup
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Controlled Burn
• Rapid extinguishment in fires with flammable and
combustible liquids, may not always be possible.
• It may be safer to allow the fire to burn itself out under
controlled conditions.
– Heat impingement on other vessels or facilities may be controlled
– Controlling the flow or limiting the materials involved in the fire
(e.g., pumping out the tank),
– Providing cooling water on surrounding equipment.
• Decision to select this
should be made with the
advice of authority having
jurisdiction.
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By: Jyoti Swarup
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Manual Control & Extinguishment
• Manually fighting flammable and combustible liquid fires
involves the use of portable fire extinguishers on fires in their
initial stages.
• Larger fires usually require the application of water for
control and cooling or application of foam for fire
extinguishment.
• Manual attack of large fires
should be by properly
trained personnel, or
municipal fire departments.
• The minimum requirements
for industrial fire brigades
are identified NFPA 600.
By: Jyoti Swarup
By: Jyoti Swarup
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Hose and Monitors
Product Considerations
Asphalt, Crude Oil, and Residual Fuel
• For facilities that have an
adequate supply of water
available for manual fire fighting
purposes, hose lines and monitors
may be provided, where required,
to supplement portable fire
extinguishers.
• The supply and pumping system
shall be able to provide sufficient
flow and pressure for the
anticipated emergency.
• Hose lines and monitors should be
used only by trained and qualified
personnel.
By: Jyoti Swarup
• Light hydrocarbons may migrate out of crude oils and residual
fuels and form a flammable mixture in the vapor space within
the storage tank.
• Crude oil in storage should be considered to be a flammable
liquid for fire fighting purposes.
• Asphaltic crude, crude oils, and
residual fuels may have
characteristics that promote
“boil‐over” and “frothing.”
• Storage should be considered
to have this potential.
By: Jyoti Swarup
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Codes and Standards ‐ API
Product Considerations
Gasoline and Distillates
• Gasoline and Distillates are considered to
be stable and water insoluble.
• Normal fire fighting
foams are suitable
for extinguishing
fires involving
gasoline.
• Water may be used
to cool and
extinguish distillate
fires.
By: Jyoti Swarup
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API Std 620 Large, Welded, Low Press St. Tanks, 2013
API Std 625 Tank Systems for Refrig. Liq. Gas Storage, First Ed, 2010
API Std 650 Welded Steel Tanks for Oil Storage, 2013, Add 1, 2014
API RP 651 Cathodic Protection of A/G Storage Tanks, 2014
API RP 652 Lining of A/G Petroleum Storage Tank Bottoms, 2014
API Std 653 Tank Inspection, Repair, Alteration, and Recon, 2014
API Std 2000 Venting Atmosph and Low‐pressure St Tanks, 7th, 2014
API RP 2003 Prot .. from of Static, Lightning, Stray Cts, 8th 2015
API Std 2015 Safe Entry and Clean of Pet.Tanks, 7th ed 2014
API RP 2021 (R2015) Mgmnt of Atmos Storage Tank Fires, 2001
API RP 2350 Overfill Prot for Tanks in Petroleum Facs., 4th ed, 2012
API Std 2610 (R2010) Design, Const, Operation, Maint., and Insp. of
Terminal & Tank Facilities, 2nd Ed, 2005
By: Jyoti Swarup
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Codes and Standards ‐ NFPA
Summary
Additional information on related subjects may be found:
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NFPA 11 Low Expansion Foam and Combined Agent Systems, 2014.
NFPA 15 Water Spray Fixed Systems. 2012
NFPA 20 Installation of Centrifugal Fire Pumps. 2016
NFPA 22 Water Tanks for Private Fire Protection. 2013
NFPA 30 Flammable and Combustible
Liquids Code. 2015
NFPA 77 Recommended Practice on Static
Electricity, 2014
NFPA 326 Safeguarding of tanks for entry,
2015
NFPA 600 Standard on Industrial Fire
Brigades, 2015
NFPA 780 Standard for the Installation of
Lightning Protection, 2014
By: Jyoti Swarup
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Contact: jyotiswarup10@gmail.com
Mobile : 91-98868 97021
Thanks
Presentation by Jyoti swarup
News dated 10th Feb 2016:
UAE's national oil company Adnoc has agreed to store crude oil in India's maiden strategic
storage at Mangalore and give two-third of the oil to it for free.
India is building underground storages at Visakhapatnam (1.33 M Ton) in Andhra Pradesh and
Mangalore (1.5 M ton) and Padur (2.5 M Ton) in Karnataka to store about 5.33 million tonnes of
crude oil to guard against global price shocks and supply disruptions.
By: Jyoti Swarup
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• The criteria for design, construction, operation and
maintenance of petroleum terminal and tank facilities were
described.
• The issues of Site selection and spacing, pollution prevention,
safe operation, fire prevention and protection, tanks dikes,
mechanical
systems, product
transfer, overfill
protection was
briefly described.
• List of latest
editions of
referenced codes
and standards
included.
By: Jyoti Swarup
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