DEP SPECIFICATION
Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale
LAYOUT OF ONSHORE FACILITIES
DEP 80.00.10.11-Gen.
February 2017
DESIGN AND ENGINEERING PRACTICE
DEM1
© 2016 Shell Group of companies
All rights reserved. No part of this document may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 2
PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1)
Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2)
Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3)
Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person
whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs
or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the
DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned
after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The
copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 3
TABLE OF CONTENTS
1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
INTRODUCTION ........................................................................................................ 5
SCOPE ....................................................................................................................... 5
DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 5
DEFINITIONS ............................................................................................................. 6
CROSS-REFERENCES ........................................................................................... 10
SUMMARY OF MAIN CHANGES ............................................................................. 10
COMMENTS ON THIS DEP ..................................................................................... 11
DUAL UNITS............................................................................................................. 11
NON NORMATIVE TEXT (COMMENTARY) ............................................................ 11
2.
LAYOUT STRATEGY .............................................................................................. 12
3.
3.1
3.2
3.3
3.4
GENERAL LAYOUT REQUIREMENTS .................................................................. 12
INTRODUCTION ...................................................................................................... 12
HSSE ........................................................................................................................ 13
CONSTRUCTABILITY .............................................................................................. 15
OPERABILITY AND MAINTAINABILITY .................................................................. 15
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
SITE MASTER PLAN ............................................................................................... 16
INTRODUCTION ...................................................................................................... 16
MINIMUM SEPARATION DISTANCES AND SITING REQUIREMENTS ................ 17
LNG TRAINS ............................................................................................................ 23
UTILITIES ................................................................................................................. 23
FIXED IGNITION SOURCES ................................................................................... 24
FLARES AND VENT STACKS ................................................................................. 24
COOLING WATER TOWERS .................................................................................. 25
ELECTRICAL/INSTRUMENT CABLING .................................................................. 26
PIPING ...................................................................................................................... 26
Loading facilities ....................................................................................................... 27
NON-REFRIGERATED ATMOSPHERIC/Low Pressure Liquid Storage ................. 30
Pressurised LPG storage .......................................................................................... 32
Refrigerated LNG/LPG Storage ................................................................................ 37
BUILDINGS ............................................................................................................... 38
LOGISTIC AREAS .................................................................................................... 41
SITE SPECIFIC PARAMETERS .............................................................................. 41
5.
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
PLOT PLAN .............................................................................................................. 44
INTRODUCTION ...................................................................................................... 44
SAFETY .................................................................................................................... 44
CONSTRUCTION ..................................................................................................... 45
COST ........................................................................................................................ 46
ENGINEERING ......................................................................................................... 46
OPERATION ............................................................................................................. 47
MAINTENANCE ........................................................................................................ 47
PLANT BUILDINGS .................................................................................................. 48
STRUCTURES ......................................................................................................... 48
PLATFORMS/LADDERS/STAIRS ............................................................................ 48
PIPE RACKS ............................................................................................................ 48
RELIEF/FLARE/BLOW-DOWN LINES ..................................................................... 48
BATTERY LIMITS ..................................................................................................... 49
SPECIAL UNITS ....................................................................................................... 49
PACKAGE UNITS ..................................................................................................... 49
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 4
6.
6.1
6.2
6.3
6.4
6.5
6.6
MECHANICAL GENERAL ARRANGEMENT ......................................................... 50
INTRODUCTION ...................................................................................................... 50
SAFETY .................................................................................................................... 50
OPERATION AND MAINTENANCE ACCESS ......................................................... 50
INSTRUMENTATION/ELECTRICAL ........................................................................ 50
ANALYSERS ............................................................................................................ 51
EQUIPMENT SPECIFIC ........................................................................................... 51
7.
REFERENCES ......................................................................................................... 63
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 5
1.
INTRODUCTION
1.1
SCOPE
This DEP specifies requirements and gives recommendations for layout of onshore facilities
and specifically covers the following deliverables:
a. Site master plans
b. Plot plans
c. Mechanical general arrangement drawings
This DEP is applicable both for new sites (greenfield projects) as well as for revamps or
expansions of existing sites (brownfield projects).This DEP is applicable to commonly
applied facilities and explicitly excludes Movable Modular Liquefaction Systems (MMLSs)
and Modular Liquefaction Units (MLUs) for LNG. This DEP is applicable to artificial islands
where the Principal has defined them to be onshore facilities.This DEP contains mandatory
requirements to mitigate process safety risks in accordance with Design Engineering
Manual (DEM) 1 – Application of Technical Standards.This DEP is a revision of the same
number dated February 2016; see (1.5) regarding the changes.
1.2
DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS
Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorised access to DEPs does not for that reason constitute an
authorisation to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to oil and gas production, gas handling, oil
refining, chemical processing, gasification, distribution and supply/marketing. This DEP
may also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented;
this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases, the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 6
1.3
DEFINITIONS
1.3.1
General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The capitalised term SHALL [PS] indicates a process safety requirement.
The word should indicates a recommendation.
The word may indicates a permitted option.
1.3.2
Specific definitions
Term
Definition
Building Risk
Explosion risk to an individual in the building, based on an occupancy
rate of 40 hours/week.
Facility
Process and utility plants, tanks, buildings, marine structures, pipe racks
and roads located within a site boundary.
Flammable
The term flammable is used to cover both flammable and combustible
fluids which are classified as Class I,II or III(a) in DEP 80.00.10.10-Gen.
(DEP 80.00.10.13-Gen.).
Layout
One or more of the following deliverables: site master plan, plot plans
and mechanical general arrangement drawings.
Mechanical
General
Arrangement
Drawings
Overall spatial arrangement of equipment within the available unit
boundaries.
Minimum
Separation
Distances
Separation distances aim to ensure that the risk of escalation from a fire
and/or explosion event(s) on an adjacent area are tolerable, for most
common processes.
These distances allow for safe SIMOPs during normal operations,
construction and maintenance activities. The required protection
measures for the construction workforce have to be assessed on a
case-by-case basis
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 7
Term
Definition
Occupied
building
Building that personnel occupy while doing a major part of their work,
such as control rooms, laboratories, office buildings, maintenance work
areas, outside operator buildings, etc.; or a building with a primary
purpose that necessitates people to occupy it, such as field labs, lunch
rooms, locker facilities used to change clothes, showers, restrooms or
toilets (lightweight plastic porta-toilets are excluded from this definition),
etc.
Other buildings that have a primary purpose to house or store
equipment or materials are considered an “occupied building” if an
individual spends on average 10 hours or more a week inside the
building, 10 or more people are in the building at any given time, or a
group spends an average of 200 hours or more a week inside the
building.
Observation shelters provided for weather protection for the marine,
road, or rail loading operator may, in consultation with the Principal’s
relevant Technical Authority, be excluded from the definition of an
occupied building. By nature, such buildings are small and require a
large amount of window area to satisfy operational safety requirements
with the loading operations.
For the purpose of this DEP, the requirements for occupied buildings
also apply to those buildings containing safety critical equipment
Plot Plan
Overall spatial arrangement of one or more unit(s) and related general
facilities within a plot boundary, showing the arrangement of equipment
within units.
Portable
building
Portable buildings include office trailers, porta-cabins, shipping
containers, modular buildings, truck trailers or lorry trailers, tool rooms,
mobile homes, personnel shelters, etc.
Process unit
A process unit is a collection of Equipment within a Plant, arranged to
perform a defined function. A process unit enables the execution of a
physical, chemical and/or transport process, or storage of process
material.
Property
boundary
The location of the site fence line or area of control based on risk and
radiation criteria as defined in this DEP.
Restricted
plant road
A road which cannot be accessed without a permit and which has either
physical barriers or signs posted.
Risk Contour
Iso-risk line on the map to indicate Location of the specific risk value.
Safety Critical
Equipment
(SCE)
Any equipment, structure, or system (including software logic) acting as
a barrier to prevent or mitigate the uncontrolled release of a hazardous
substance or release of energy leading to a worst case credible
scenario with RAM red, yellow 5A or yellow 5B Risk.
In the context of this DEP the requirements only apply to the Safety
Critical Equipment that enables controlled process shutdown or
potentially controls further incident escalation in the event of an incident.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 8
Term
Definition
Site Master
Plan
Overall spatial arrangement of all process and utility plants, tankage
areas, buildings and connecting infrastructure (e.g., roads, pipe racks).
The site master plan shows the individual plant boundaries within the
overall site boundary.
Site
Plot of land with defined boundaries.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 9
1.3.3
Abbreviations
Term
Definition
ALARP
As Low As Reasonably Practicable
BC-IR
Building Contribution to the Individual Risk, Annual frequency that an
individual might be killed from an explosion while occupying a specific
building. It is calculated by multiplying the building risk with the fraction
of 40 hrs/week the individual is occupying the specific building.
BLEVE
Boiling Liquid Expanding Vapour Explosion, an explosion caused by the
rupture of a vessel containing a pressurized liquid above its boiling
point.
BRM
Blast resistant module per DEP 34.17.10.33-Gen.
CONOPS
Concurrent Operations, Concurrent Activities, equivalent to SIMOPS,
but done under a single organization and management system.
ERC
Emergency Release Coupling
ESD
Emergency Shutdown
HFE
Human Factors Engineering
HSSE
Health, Safety, Security and Environment
IRPA
Individual Risk per Annum, Annual risk of fatality of a particular
individual taking into account their exposure, throughout their working
year, to all company- induced hazards.
ISBL
In Side Battery Limit
KO
Knock-Out
LEL
Lower Explosive Limit
LFL
Lower Flammability Limit
LSR
Location Specific Risk, Annual risk of fatality to a hypothetical individual
at a location for 24 hours per day, 365 days per year, unprotected and
unable to escape.
MLU
Modular Liquefaction Unit
MMLS
Movable Modular Liquefaction System
MOF
Material Off-Loading
ORP
Opportunity Realisation Process
Ro-Ro
Roll-Off Roll-On
SCE
Safety Critical Equipment
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 10
Term
Definition
SIMOPS
Simultaneous Operations
Two or more sets of activities, carried out concurrently by different
organizations or under different management systems that, because of
their proximity or other factors, could interact with each other.
May include simultaneous operation and maintenance activities as well
as simultaneous operation and constructions activities.
STSC
1.4
Short Term Survivability Criteria at short term exposure (e.g., 5 minutes)
that may be received with a negligible statistical probability of fatality
and without impairment of individual ability to escape.
CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section or
clause number is shown in brackets ( ). Other documents referenced by this DEP are listed
in (7).
1.5
SUMMARY OF MAIN CHANGES
This DEP is a revision of the DEP of the same number February 2016, including corrections
to DEP cross-references that have changed. The following are the main non-editorial
changes to the February 2015 version.
Section/Clause
Change
2
A site master plan also for the construction phase
3.2
Removed SHALL [PS] on Segregation, rewrote sub-sections on
Toxics and on Safety critical equipment
3.3
Moved to Section 4.2 and clarified for Brownfield
4
New Figure 4.1
4.2
Amended tables and notes
4.5
Modified title and wording of SHALL [PS]
4.9
Modified to change to recommendations
4.10.2
Removed section on LPG bulk transfer via road or rail
4.11
Removed radiation criteria
4.12
Modified separation valued C, E and F and removed
requirements for radiation
4.14
Modified Flowchart for building design and various distances in
the sub-sections
4.16
Modified various distances in sub-sections
5.2.
Simplified requirement for drains
5.11
Revised recommendations to requirements
6.3
Deleted requirement to assess critical interventions
6.4
Simplified requirements
6.6
Simplification of various sub-sections and revision of SHALL [PS]
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 11
1.6
COMMENTS ON THIS DEP
Comments on this DEP may be submitted to the Administrator using one of the following
options:
Shell DEPs Online
(Users with access to
Shell DEPs Online)
Enter the Shell DEPs Online system at
https://www.shelldeps.com
Select a DEP and then go to the details screen for
that DEP.
Click on the “Give feedback” link, fill in the online
form and submit.
DEP Feedback System
(Users with access to
Enter comments directly in the DEP Feedback
System which is accessible from the Technical
Standards Portal http://sww.shell.com/standards.
Shell Wide Web)
Select “Submit DEP Feedback”, fill in the online form
and submit.
DEP Standard Form
Use DEP Standard Form 00.00.05.80-Gen. to record
feedback and email the form to the Administrator at
standards@shell.com.
(other users)
Feedback that has been registered in the DEP Feedback System by using one of the above
options will be reviewed by the DEP Custodian for potential improvements to the DEP.
1.7
DUAL UNITS
This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.
1.8
NON NORMATIVE TEXT (COMMENTARY)
Text shown in italic style in this DEP indicates text that is non-normative and is provided as
explanation or background information only.
Non-normative text is normally indented slightly to the right of the relevant DEP clause.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 12
2.
LAYOUT STRATEGY
This DEP defines the requirements at the different stages of layout development in a
project from the site master plan (4), into more defined plot plans (5) and finally the
detailed mechanical general arrangements drawings (6).
General requirements are explained in (3) and further expanded in later sections as
greater design definition is achieved.
1.
A layout strategy shall be developed, documented in the Layout Dossier and
implemented.
The layout strategy aims to achieve the following:
2.

Safety and environmental risk levels for surrounding facilities and
communities are tolerable and as low as reasonably practicable (ALARP)

Safety risk levels for “on site” workforce are tolerable and ALARP

Minimum cost by utilizing compact layouts with minimum hydrocarbon
inventory and minimum required separation distances

Minimum lost production resulting from damage to facilities in the event of
fire and/or explosion.
Depending on the relevant stage of the Opportunity Realisation Process (ORP) one or
more of the following deliverables shall be included:
a.
Site master plan for the operational phase and for the construction phase
b.
Plot plans
c.
Mechanical general arrangement drawings
3.
The layout strategy, the site master plan, the plot plans and mechanical general
equipment arrangement drawings shall incorporate and address the requirements of
the Project Health, Safety, Security and Environment (HSSE) plan.
4.
Allowance for the defined future phases by the project, taking unhindered access
during construction and sufficient separation distances considering Simultaneous
Operations (SIMOPS), shall be taken into account.
3.
GENERAL LAYOUT REQUIREMENTS
3.1
INTRODUCTION
The layout requirements, defined in this DEP, are applicable to all project phases and
deliverables.
Additional requirements or exceptions for site master plans, plot plans or mechanical
general arrangement drawings are specified in the relevant chapters.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 13
3.2
HSSE
3.2.1
General
This DEP is based on the assumption that the measures described in
DEP 80.47.10.30-Gen. are implemented.
3.2.2
Segregation inside the property boundary
1.
The required segregation between all new, or between new and existing process and
utility plants, tankage areas, buildings and supporting/connecting infrastructure shall
be obtained either by providing:
a.
adequate separation distance
b.
a physical barrier (being a mitigation measure which reduces the likelihood of
escalation between two units).
2.
The barrier shall not increase the escalation risk associated with any increased
confinement or obstruction of access.
3.
The effectiveness of a barrier shall be demonstrated.
4.
Adequate separation shall be provided by applying the minimum separation distances
as defined within this DEP, including Table 4.1 and (4.3) to (4.16).
Defined minimum separation distances aim to ensure that the risk of escalation
from a fire and/or explosion event(s) on an adjacent area are tolerable, for most
common processes. The project hazard and effects management processes
confirm this later in the project.
The separation distances have in general been arrived at through consequence
modelling of relevant failure scenarios (e.g., tank top fire, or loss of containment via
a 25 mm (1 inch) hole in a pressurized system), giving distances to blast
overpressures and radiation levels.
These distances include allowance for safe SIMOPS during normal operations,
construction and maintenance.
5.
Increased separation, above the minimum distances specified, shall be provided to the
extent required to allow for sufficient access and working space to support
construction and maintenance activities.
6.
Reduced minimum separation distances or physical barriers shall only be used when
sufficient segregation is demonstrated to be ALARP by using appropriate
consequence modelling or risk assessment.
a.
7.
The methodology and criteria to be used for the modelling or assessment, and
the results, shall be subject to the approval of Principal’s designated Technical
Authority.
For plant, equipment, units, tankage, buildings and connecting/supporting
infrastructure not included in Table 4.1 and (4.3) to (4.16), it SHALL [PS] be
demonstrated that the risk of escalation from a fire and/or explosion event(s) on an
adjacent area is ALARP.
The above approach typically applies for scenarios such as:
 Products with particular reactive hazards, low ignition energy, high
flammable range or high heat of combustion (e.g., Ethylene Oxide, Ethylene),
 Non-typical storage pressures or leakage scenarios.
8.
ALARP demonstration shall be executed in accordance with Principal’s ALARP guide.
9.
If a risk assessment is applied, it shall be used in conjunction with the project risk
tolerability criteria.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 14
3.2.3
3.2.4
3.2.5
Segregation outside the facility property boundary
1.
Separation distances to facilities, people and buildings outside the property boundary
SHALL [PS] be demonstrated to be ALARP in accordance with Principal’s ALARP
guide and include appropriate consequence modelling or risk assessment.
2.
The ALARP methodology and results shall be subject to the approval of the Principal’s
designated Technical Authority.
3.
If a risk assessment is applied, the assessment shall prove that the risks conform to
the project risk tolerability criteria requirements and that the location specific risk (LSR)
is ALARP.
4.
Where local regulations specify risk contour limits and other risk criteria (e.g. societal
risk), they shall be followed.
Toxics
1.
For definitions of toxicity refer to DEP 01.00.01.30-Gen., Part III.
2.
For “very toxic” services, the separation between plants, units, equipment and
buildings SHALL [PS] be agreed with the Principal’s designated Technical Authority.
Safety critical equipment
1.
3.2.6
Safety Critical Equipment SHALL [PS] retains its safety critical functionality when
subject to the hazard it is preventing or mitigating by means of one of the following:
a.
Location in an area where emergency and/or unplanned events do not impact the
safe operation
b.
Protection from the hazard
c.
Designed to function through the exposure (e.g. fail safe)
2.
Access to Safety Critical Equipment which needs to be accessed during an unwanted
event/hazard shall be unobstructed and permanent.
3.
Refer to (4.14) for requirements for buildings housing Safety Critical Equipment.
4.
The location of outdoor Safety Critical Equipment shall be demonstrated to be ALARP
in accordance with (3.2.2)
Hazardous area classification
1.
Hazardous area classification standards provide industry-accepted separation
distances between ignition sources and likely sources of flammable release. The
distances provided by the codes do not address the effects of larger (but less likely)
failures. These shall be reviewed as part of an overall layout study.
2.
Reference is made to DEP 80.00.10.10-Gen. and DEP 80.00.10.13-Gen., as
applicable.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 15
3.3
CONSTRUCTABILITY
1.
Requirements as defined in the project or facility construction strategy (including precommissioning and initial start-up) shall be included in all layout activities to include
optimal provisions for:
a.
Human factors engineering to address accessibility (3.4.3),
b.
Suitable (in terms of obstructions, slope, and bearing capacity) access for
construction equipment (including cranes, heavy equipment and transporters),
c.
Minimum workspace envelope (including turning radii) for construction equipment
(including cranes, heavy equipment and transporters),
d.
Areas for laydown, storage and temporary facilities (e.g., office, camps, welfare),
e.
Material (off) loading facilities,
f.
Safe SIMOPs,
g.
Traffic and pedestrian management,
h.
Security and exclusion requirements,
i.
Desired construction strategy (stick built/modular), sequence and schedule.
2.
During expansions of an existing site, the construction area should have a separate
entrance, gatehouse and fence to keep free access for construction personnel and
delivery of construction materials clear of the existing operating facilities.
3.
A clear distinction shall be established by physical barriers between operating areas
and construction areas for both security of operating facilities and to ensure control of
hazards, e.g., vehicle traffic through the operating facility.
3.4
OPERABILITY AND MAINTAINABILITY
3.4.1
General
1.
3.4.2
Requirements as defined in the project or facility operating and maintenance
philosophy (including start-up and shutdown) shall be included in all layout activities to
include optimal provisions for:
a.
Human factors engineering to address accessibility (3.4.3)
b.
Suitable (in terms of obstructions, slope, and bearing capacity) access for
maintenance equipment (including cranes, heavy equipment and transporters)
c.
Minimum workspace envelope (including turning radii) for maintenance
equipment (including cranes, heavy equipment and transporters)
d.
Areas for laydown, storage and temporary facilities (e.g., office, welfare)
e.
Safe SIMOPs and Concurrent Operations (CONOPS)
f.
Traffic and pedestrian management
g.
Security and exclusion requirements
Expansion
1.
Expansion (planned or future) requirements shall be taken into consideration in all
layout activities to include optimal provisions for:
a.
Construction (3.3)
b.
General Operability and Maintainability requirements (3.4.1)
c.
Tie-in to existing and new infrastructure (piperacks, piping, utilities, drainage, etc.)
d.
On-going operation and maintenance activities of the existing facility
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 16
3.4.3
Human factors engineering
1.
3.4.4
Emergencies, escape and evacuation
1.
3.4.5
Refer to DEP 30.00.60.20-Gen. for the human factors engineering (HFE)
requirements.
Safe means of escape and evacuation shall be provided for all credible emergency
conditions, taking the following into account:
a.
Escape and evacuation of all areas at all times throughout the year, whether or
not they are regularly manned;
b.
The effect on the ability of personnel to escape to safe areas of toxic releases or
the heat flux and smoke from a fire;
c.
The effect of flare radiation on escape and evacuation.
2.
The road system shall be designed such that access to all areas is possible in case of
an emergency, taking the different wind directions into account.
3.
All access to plant areas shall be by paved walkways or hard standing with
appropriate grade and width as outlined in DEP 30.00.60.20- Gen., avoiding the need
to walk over rough or unmade ground
4.
The location of helipad(s) and the facilities relative to water access shall be designed
such that access to those is possible in case of an emergency taking the different wind
directions into account.
Natural ventilation
1.
Where practicable, natural ventilation shall be used, to reduce the likelihood of
potential accumulations of explosive hydrocarbon/air mixtures or toxic acute
substances.
2.
Equipment should be oriented to minimise disruption of natural ventilation.
3.
Designs shall avoid dead pockets where explosive mixtures or toxic acute substances
can remain for extended periods of time.
a.
In cases that this cannot be avoided (e.g., sumps), the location shall be treated
as a confined space.
4.
SITE MASTER PLAN
4.1
INTRODUCTION
The site master plan of a facility gives the overall spatial arrangement of all process and
utility plants, tankage areas, buildings and connecting infrastructure (e.g., roads, pipe
racks).
The site master plan shows the individual plot boundaries within the overall site
boundary.
The site master plan indicates relevant surrounding local geographic features (e.g.,
rivers, coastline, slopes).
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 17
4.2
MINIMUM SEPARATION DISTANCES AND SITING REQUIREMENTS
This section is to be read in conjunction with (3.2.2).
Figure 4.1 clarifies the interpretation of separation distances for process plants/utility
areas handling flammable material as provided in Table 4.1. The figures are provided in
SI and in USC versions and are different for greenfield or brownfield applications.
The distances in Table 4.1 and more generally in this DEP are horizontally projected
distances.
The brownfield approach can normally not be used for greenfield applications since the
required data is not available at the early stages of the project.
For greenfield applications, the separation distance “X” is defined as the distance
between ISBLs of adjacent hydrocarbon containing units or plants.
For brownfield expansions, the separation distance “X” is defined as the distance
between the outmost sides of equipment or drainage channels of adjacent hydrocarbon
containing units or plants.
1.
If the data is available for greenfield applications, the brownfield approach may be
applied.
2.
Minimum separation distances and siting requirements specified in Table 4.1 with a
[BOLD] annotation SHALL [PS] be met.
3.
Minimum separation distances and siting requirements specified in Table 4.1 with a
normal annotation shall be met.
Figure 4.1A Minimum separation distances (SI) for process plants (brownfield)
ISBL = InSide Battery Limit
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 18
Figure 4.1B Minimum separation distances (USC) for process plants (brownfield)
Figure 4.1C Minimum separation distances (SI) for process plants (greenfield)
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 19
Figure 4.1D Minimum separation distances (USC) for process plants (greenfield)
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 20
Table 4.1.A
Minimum separation distances (SI units)
NA
Fire Station, Fire Pumps (e)
B
NA
NA
Main Electrical Station
C
NA
30
NA
Utilities Area not handling
flammable products
D
30
30
30
NA
Cooling Towers
E
[15]
[15]
[60]
[30]
Process Plants/Utility Areas
handling flammable products
F
[(h)]
[(h)]
[60]
[50/25
(c)]
Control Room (e)
G
NA
NA
30
30
[30]
[30]
NA
Non-refrigerated
atmospheric/low pressure
flammable or combustible
liquid storage tanks (j)
H
[(i)]
[(i)]
[60]
[(i)]
[75]
[(i)]
[(i)]
[(i)]
Oily Water Interceptors
(CPI/API)
I
[15]
[15]
[15]
[15]
[15]
[15]
[15]
[15]
NA
Road/Railcar loading station
for LPG
J
[60]
[60]
[60]
[(f)]
[(f)]
[(f)]
[(f)]
[(f)]
[(f)]
NA
Road/Railcar loading station
except LPG
K
[30]
[30]
[30]
[(f)]
[(f)]
[(f)]
[(f)]
[(f)]
[(f)]
[(f)]
Elevated Flare
L
[100] [100] [100]
[60/100 [60/100 [60/100 [60/100 [60/100 [60/100 [60/100 [60/100
(a)]
(a)]
(a)]
(a)]
(a)]
(a)]
(a)]
(a)]
Transfer Pumps in tank farms
M
[60]
[60]
[60]
[30]
[30]
[50/25
(c)]
[30]
[15]
[15]
[(f)]
[(f)]
[60/100
(a)]
NA
Main Pipeway
N
[15]
[15]
[15]
[15]
[7.5]
[15]
[7.5]
[15]
[15]
[(f)]
[(f)]
[60/100
(a)]
NA
NA
Unrestricted plant road
O
3
3
3
3
[(k)]
[(k)]
3
[(k)]
[(k)]
[(k)]
[(k)]
[60/100
(a)]
[(k)]
Note p
NA
Restricted plant road
P
3
3
3
3
(l)
(l)
3
(l)
(l)
(l)
(l)
[60/100
(a)]
(l)
(l)
NA
NA
Property Boundary
Q
10
10
10
30
[(m)]
[(m)]
30
[(m)]
[(m)]
[(f)]
[(f)]
[150/250
(b)]
[(m)]
[15]
3
3
NA
Pressurized LPG Storage
R
[(60)] [(60)] [(60)]
[(n)] [(n)] [(n)]
[(g)]
[50]
[(g)]
[(g)]
[(g)]
[(o)]
[(g)]
[(g)]
[60/100
(a)]
[60]
[(g)]
[(g)]
[(g)]
[(m)]
[(g)]
Refrigerated Storage (d)
S [100] [100] [100]
[80]
[45]
[80]
[45]
[45]
[60]
[(f)]
[(f)]
[60/100
(a)]
[30]
[30]
[30]
[15]
[(m)]
[(g)]
[45]
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
Main Electrical Station
Utilities Area not handling flammable
products
Cooling Towers
Process Plants/Utility Areas handling
flammable products
Control Room (e)
Non-refrigerated atmospheric/low
pressure flammable or combustible liquid
storage tanks (j)
Oily Water Interceptors (CPI/API)
Road/ Railcar loading station for LPG
Road/Railcar loading station except LPG
Elevated Flare
Transfer Pumps in tank farms
Main Pipeway
Unrestricted plant road
Restricted plant road
Property Boundary
Pressurized LPG Storage
Refrigerated Storage (d)
A
B
Fire Station, Fire Pumps (e)
A
Non –blast resistant
Occupied Buildings (e)
Non –blast resistant
Occupied Building (e)
Figures in Meters
NA = Not Applicable
15
[50/25 [50/25
(c)]
(c)]
NA
NA
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 21
NOTE: a.
100 m for LNG facilities, 60 m for other facilities.
b.
250 m for LNG facilities, 150 m for other facilities.
c.
25 m between process facilities (either plants or units depending on the acceptable lost production
level) for gases.
50 m between process facilities (either plants or units depending on the acceptable lost production level) for
pressurised liquids.
100 m between process facilities (either plants or units depending on the acceptable lost production level) having
a total ISBL area (see Figure 4.1) in excess of 25,000 m2.
d.
Distances are for full containment concrete tanks.
e.
See (4.14.1) and (4.14.2) for additional building requirements.
f.
See (4.10.1, Item 1).
g.
See (4.12, item 1).
h.
150 m from process units and 400 m from LNG trains.
i.
See (4.11, item 1).
j.
Distances are measured from the external wall of the tank.
k.
See (4.5, item 1)
l.
See (4.16.6.1)
m.
See (3.2.3, item 1)
n.
See (4.12, item 1) for mounded storage
o.
See Figure 4.6.
p.
See (4.5, item 1) when any of the hydrocarbon containing pipes include flanges; 3 m can be used if
none of the hydrocarbon containing pipes include flanges (i.e. all pipes are fully welded).
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 22
Table 4.1.B
Minimum separation distance (USC units)
Non –blast resistant
Occupied Building (e)
A
NA
Fire Station, Fire Pumps (e)
B
NA
NA
Main Electrical Station
C
NA
100
NA
Utilities Area not handling
flammable products
D
100
100
100
NA
Cooling Towers
E
[50]
[50]
[200]
[100]
Process Plants/Utility Areas
handling flammable products
F
[(h)]
[(h)]
[200]
[165/82 [165/82 [165/82
(c)]
(c)]
(c)]
Control Room (e)
G
NA
NA
100
100
[100]
[100]
NA
H
[(i)]
[(i)]
[200]
[(i)]
[250]
[(i)]
[(i)]
[(i)]
I
[50]
[50]
[50]
[50]
[50]
[50]
[50]
[50]
NA
Road/Railcar loading station
for LPG
J
[200] [200] [200]
[(f)]
[(f)]
[(f)]
[(f)]
[(f)]
[(f)]
NA
Road/Railcar loading station
except LPG
K [100] [100] [100]
[(f)]
[(f)]
[(f)]
[(f)]
[(f)]
[(f)]
[(f)]
Elevated Flare
L
Transfer Pumps in tank farms
M [200] [200] [200] [100] [100]
[165/82
[100]
(c)]
[50]
[50]
[(f)]
[(f)]
[200/330
(a)]
NA
Main Pipeway
N
[50]
[50]
[50]
[50]
[25]
[50]
[25]
[50]
[50]
[(f)]
[(f)]
[200/330
(a)]
NA
NA
Unrestricted plant road
O
10
10
10
10
[(k)]
[(k)]
10
[(k)]
[(k)]
[(k)]
[(k)]
[200/330
[(k)]
(a)]
Note p
NA
Restricted plant road
P
10
10
10
10
(l)
(l)
10
(l)
(l)
(l)
(l)
[200/330
(a)]
(l)
(l)
NA
NA
Property Boundary
Q
33
33
33
100
[(m)]
[(m)]
100
[(m)]
[(m)]
[(f)]
[(f)]
[500/820
[(m)]
(b)]
[50]
10
10
NA
Pressurized LPG Storage
R
[(200)] [(200)] [(200)]
[(g)]
[(n)] [(n)] [(n)]
[165]
[(g)]
[(g)]
[(g)]
[(0)]
[(g)]
[(g)]
[200/330
[200]
(a)]
[(g)]
[(g)]
[(g)]
[(m)]
[(g)]
Refrigerated Storage (d)
S
[330] [330] [330]
[250]
[150]
[250]
[150]
[150]
[200]
[(f)]
[(f)]
[200/330
[100]
(a)]
[100]
[100]
[50]
[(m)]
[(g)]
[150]
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
Non –blast resistant
Occupied Buildings (e)
Fire Station, Fire Pumps (e)
Main Electrical Station
Utilities Area not handling flammable
products
Cooling Towers
Process Plants/Utility Areas handling
flammable products
Control Room (e)
Non-refrigerated atmospheric/low
pressure flammable or combustible liquid
storage tanks (j)
Oily Water Interceptors (CPI/API)
Road/ Railcar loading station for LPG
Road/Railcar loading station exceptLPG
Elevated Flare
Transfer Pumps in tank farms
Main Pipeway
Unrestricted plant road
Restricted plant road
Property Boundary
Pressurized LPG Storage
Refrigerated Storage (d)
Non-refrigerated
atmospheric/low pressure
flammable or combustible
liquid storage tanks (j)
Oily Water Interceptors
(CPI/API)
[330] [330] [330]
Figures in Feet
NA = Not Applicable
50
NA
[200/ [200/ [200/ [200/ [200/ [200/ [200 /330 [200/
330 (a)] 330 (a)] 330 (a)] 330 (a)] 330 (a)] 330 (a)] (a)] 330 (a)]
NA
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 23
NOTE: a.
330 ft for LNG facilities, 200 ft for other facilities.
b.
820 ft for LNG facilities, 500 ft for other facilities.
c.
82 ft between process facilities (either plants or units depending on the acceptable lost production
level) for gases
165 ft between process facilities (either plants or units depending on the acceptable lost production level) for
pressurised liquids
330 ft between process facilities (either plants or units depending on the acceptable lost production level) having a
total ISBL area (see Figure 4.1) in excess of 270,000 ft2
4.3
d.
Distances are for full containment concrete tanks.
e.
See (4.14.1) and (4.14.2). for additional building requirements
f.
See (4.10.1, Item 1).
g.
See (4.12, item 1).
h.
500 ft from process units and 1300 ft from LNG trains.
i.
See (4.11, item 1).
j.
Distances are measured from the external wall of the tank.
k.
See (4.5, item 1)
l.
See (4.16.6.1)
m.
See (3.2.3, item 1)
n.
See (4.12, item 1) for mounded storage
o.
See Figure 4.6
p.
See (4.5, item 1) when any of the hydrocarbon containing pipes include flanges; 10 ft can be used if
none of the hydrocarbon containing pipes include flanges (i.e. all pipes are fully welded).
LNG TRAINS
1.
Additional siting and/or separation requirements for multiple air-cooled liquefied
natural gas (LNG) trains in respect to air recirculation shall be considered in
consultation with the Principal’s relevant Technical Authority.
4.4
UTILITIES
4.4.1
General
1.
For layout purposes, utility units handling flammable materials shall be treated as a
hydrocarbon processing plant.
2.
Site shared utilities (such as central cooling towers and units producing steam, water
and power) shall be located in positions where they will not be put out of action by an
explosion, fire (from outside the utility area) or flood.
3.
In locating the steam and water producing plant, the effects of the prevailing wind on
the stack emission should be taken into account.
4.
The steam, water and electricity supply mains to the major consumers should not be
uneconomically lengthy.
a.
These services may be on the periphery, but close to the largest users.
b.
Consideration should be given to a ring main system.
c.
Allowance should be made for future expansion.
5.
Large water producing plants should be located in a separate building (if climatologic
conditions require) or a separate area, to permit access for chemicals required for
regeneration, locating water storage and effluent drainage systems.
6.
The location of the power generation facility shall take into account the area
classification requirements.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 24
7.
4.4.2
4.4.3
Primary water treatment facilities
1.
Oily Water Interceptors (CPI/API) that are part of primary water treatment facilities are
considered to be hydrocarbon containing equipment and the distance to a fixed source
of ignition SHALL [PS] be as per (4.5, Item 1).
2.
See DEP 34.14.20.31-Gen. for the design and layout of drainage and primary
treatment facilities.
Air separation units
1.
4.4.4
For further guidance on design issues for and location of air separation units, refer to
DEP 30.05.10.30-Gen.
Distribution of utility services
1.
4.5
For noise reasons, power generators should be located at an acceptable distance
from the office buildings and/or include noise attenuating buildings or enclosures as
defined in DEP 31.10.00.31-Gen.
Steam and water mains, electricity and telephone cables etc., shall not run through
plant areas.
FIXED IGNITION SOURCES
Fixed ignition sources include furnaces, incinerators, electrical substations, field auxiliary
rooms, uncertified electrical equipment, unrestricted roads, burn pits, flares, gas turbines
and electric power generators, and all other fired equipment.
1.
The minimum distance between a potential hydrocarbon leak source and a fixed
ignition source SHALL [PS] be one of the following:
a.
For greenfield projects: 15 m (50 ft)
b.
For greenfield projects where data is available for area classification: as per
DEP 80.00.10.10-Gen. or DEP 80.00.10.13-Gen., as applicable.
c.
For brownfield expansions: as per DEP 80.00.10.10-Gen. or
DEP 80.00.10.13-Gen., as applicable.
The minimum distance may need to be greater for certain cases (as detailed
elsewhere in this DEP) such as LNG or LPG units.
2.
4.6
Individual fixed ignition sources may be located closer to each other than the
distances specified in (4.5, Item 1).
FLARES AND VENT STACKS
1.
A sterile area shall be provided around elevated and/or ground flares.
2.
Non-flare specific equipment shall not be located within the sterile zone. See
DEP 80.45.10.10-Gen, Part IV, Section 5.7.
3.
Flares and vents shall be built in an open area, preferably crosswind from process
units, to minimise discharge across the plant and preferably downwind from buildings
to minimize odours.
4.
Locations of flares and vents shall be made with due consideration to neighbouring
facilities outside of the site boundary.
5.
Vent stacks shall be designed so that thermal radiation arising from accidental ignition
will not exceed the values given in DEP 80.45.10.10-Gen., Section 4.7.
6.
A reduced separation distance (from Table 4.1) between elevated flares/vent stacks
and both non-flare-specific equipment and the property boundary shall only be used
when sufficient segregation is demonstrated in accordance with (3.2.2).
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 25
7.
A consequence analysis to justify reduced separation shall take the following into
account:
a.
Thermal radiation. See DEP 80.45.10.10-Gen. Section 4.7 for calculation of
thermal radiation and the acceptance criteria for items such as process units,
property boundary, areas where large numbers of people may be exposed and
activities that cannot be stopped in a timely manner (e.g., turnaround activities);
b.
The potential for liquid overfill out of the flare and associated consequence;
c.
i.
This shall be through a multi-discipline review, such as a HAZOP,
considering the scenarios of liquid to the flare knock-out (KO) facilities and
associated barriers to reduce the probability of this event.
ii.
Refer to DEM 2 Process Safety Basic Requirements (PSBR) no 6: Avoid
liquid release relief to atmosphere.
Dispersion modelling for lower flammability limit (LFL) and toxics shall be carried
out to show that the LFL and toxic concentration contours do not overlap with
ignition sources or expected personnel locations, including grade level, elevated
platforms and elevated areas.
i.
8.
For ground flares (Enclosed Refractory Lined and Open Field) the separation distance
shall be based on a consequence analysis taking the following into account:
a.
Dispersion modelling for LFL and toxics shall be carried out to show that the LFL
and toxic concentration contours do not overlap with ignition sources or expected
personnel locations, including grade level, elevated platforms and elevated areas.
i.
b.
9.
This modelling shall consider the scenario of an unignited flare.
Minimum distance for vendor recommended air flow to the ground flare.
The location of flare and vent stacks shall address noise levels during flaring.
a.
4.7
This modelling shall consider the scenario of an unignited flare.
Refer to DEP 31.10.00.31-Gen., Part II and Annex D.5.
COOLING WATER TOWERS
1.
Flammable fluid being cooled by a cooling water tower shall be considered as a
source of flammable vapours.
2.
Cooling water towers should be sited taking the prevailing wind into account such that
water drift will not restrict visibility and the effects of moisture (e.g., exterior corrosion,
ice formation) on other parts of the facility, roads, rail or public amenities is minimised.
3.
Equipment such as air compressors, fired heaters, or other air intake stacks that
operate at a negative pressure should be located away from areas where water laden
vapours from cooling towers may be discharged.
4.
The towers should be oriented cross-wise to the prevailing wind to minimize recycling
of air from the discharge of one tower to the inlet of an adjacent tower.
5.
The arrangement of multiple natural draught cooling tower installations shall take
account of resonant frequencies generated by through-wind velocities.
6.
The possible entrainment of corrosive vapour from adjacent facilities should be
avoided.
When terraces are applied, it may be possible to reduce the required pump head by
locating the cooling water towers on a higher terrace.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 26
4.8
ELECTRICAL/INSTRUMENT CABLING
1.
Adequate and appropriate space shall be allocated to meet cable installation
requirements.
2.
The routing of the main electrical and instrument cabling should be established to
ensure that the number and location of electrical substations and field auxiliary rooms
are optimised.
3.
Electrical and instrument cabling should be routed to minimise the effects of blast, fire,
and other hazards.
4.9
PIPING
4.9.1
General
4.9.2
1.
Consult with piping engineers to define the dimensions and locations of piping in
accordance with DEP 31.38.01.11-Gen.
2.
The length of piping shall be kept to a minimum to minimise cost and to minimise
process inventory.
Piping at ground level
1.
2.
4.9.3
Piping should be at ground/grade level unless one of the following apply:
a.
it is not possible for process/operational reasons;
b.
it obstructs emergency access
c.
it obstructs access for operations and maintenance.
Open pipe trenches should not be used in places where there is a risk of:
a.
flammable vapours or liquids (e.g., naphtha) collecting;
b.
flooding.
Overhead piping
1.
Pipe-racks/bridges and supports should be of the simplest form with minimum cross
bracing or in-filling of steel-work to give the maximum freedom of pipe routings, while
meeting (5.2.3) and (5.2.5).
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 27
4.10
Loading facilities
4.10.1
Bulk road vehicle transfer
1.
The siting of bulk loading facilities for road vehicles SHALL [PS] comply with the
minimum distances specified in Figure 4.2.
The value for plant boundary also applies to Utilities areas not handling flammable
products, cooling towers, process plants/utility areas handling flammable products
and oily water interceptors (CPI/API).
Figure 4.2.A Minimum separation distances (SI) for bulk vehicle loading facilities
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 28
Figure 4.2.B Minimum separation distances (USC) for bulk vehicle loading
2.
4.10.2
Refer to DEP 31.06.11.11-Gen. and DEP 30.06.10.13-Gen. for the requirements for
the layout and design of loading facilities for bulk road vehicles.
Marine transfer
4.10.2.1 General
1.
Minimum exclusion zones (radii) (measured from the loading arm/hose) for marine
transfer facilities in which no sources of ignition may be present SHALL [PS] be as
follows:
a.
Berths for LNG carriers: 200 m (660 ft)
b.
Berths for refrigerated LPG carriers: 300 m (1000 ft)
c.
Berths for pressurised LPG carriers: See 4.10.2.2
d.
Berths for Very Large Crude Carriers (VLCCs): 40 m (130 ft)
e.
Product carriers (non LPG): 40 m (130 ft)
2.
For multipurpose jetties, the exclusion zone shall be equal to the largest individual
exclusion requirement.
3.
These distances are based on the presence of Emergency Shutdown (ESD) systems
and Emergency Release Couplings (ERCs) for LNG and refrigerated liquefied
petroleum gas (LPG) services. In case ESD systems and ERCs are not being applied,
the Principal shall be consulted on how to determine these distances.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 29
4.10.2.2 Pressurised LPG specific
1.
The minimum separation distances for bulk pressurised LPG marine transfer facilities,
in addition to those specified in (4.10.2.1) SHALL [PS] be as shown in Figure 4.3.
Figure 4.3
Code
Minimum separation distances for LPG bulk transfer via marine
facilities
Description
Separation
distances
(m)
Separation
distances
(ft)
A
Between LPG carrier and the edge of
unrestricted plant/depot roads
30
100
B
Between LPG carrier and the site boundary
60
200
C
Clearance between moored vessels
40
130
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 30
4.11
NON-REFRIGERATED ATMOSPHERIC/Low Pressure Liquid Storage
1.
The minimum separation distances for the siting of non-refrigerated atmospheric/low
pressure flammable or combustible liquid storage tanks SHALL [PS] be based on all of
the following:
2.
a.
Based on a full surface tank fire.
b.
Based on tank diameter as follows:
i.
For tanks with a larger diameter than 10 m, as specified in Table 4.2.
ii.
For tanks with a smaller diameter than 10 m, as Energy Institute Model
Code of Safe Practice EI 19 Annex C Table C1 and EI 2 Table B.1 and
Table B.2.
Atmospheric tanks/low pressure storage tanks of flammable fluids within the battery
limits of a process unit are not permitted. With the Principal's approval, small quantities
of flammable liquids with flash points above 38 °C (100 °F) may be stored on the
process plot.
Table 4.2
Minimum separation distances for tanks with a diameter larger than
10 m (33 ft)
Description
Required distance
Distances between tank walls for Class I,
Class II (2) and Class III (2) fluids
0.5 D (of the largest tank) unless local
requirements (e.g., NFPA 30) are more stringent
Distance between tank walls for Class II (1),
Class III (1) and unclassified fluids
Construction and operation convenience
Distance between tank wall and the top of the
bund wall
0.5 x the tank height
Distance between tank walls and a utility
plant/unit
1 D (of the largest tank) with a minimum of 15 m
(50 ft)
Distance between tank walls and a process
plant/unit
Demonstrate to be ALARP in accordance with
(3.2.2)
Distance between tank bunds and property
boundary
(3.2.3)
Separation distances for tanks with products
where boil-over is a credible scenario
Demonstrate to be ALARP in accordance with
(3.2.2)
Where D is the diameter of the largest tank.
3.
The layout shall allow for the possibility of storing more than one class of material in
certain tanks or of changing the tank service at some future date.
a.
When future changes of service of the storage tanks are anticipated, the layout
and spacing shall be suited for the most stringent case.
Distances might need to be increased for odorous products.
4.
For bitumen storage refer to Energy Institute Model Code of Safe Practice EI 11.
5.
Bunded areas may be used to prevent spillage of liquid flowing into process units or
source of ignition. See DEP 34.11.00.11-Gen. for requirements for bunds.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 31
6.
The maximum storage volume for non-refrigerated atmospheric/low pressure
flammable or combustible liquid storage tanks in a bunded area SHALL [PS] be as
listed in Table 4.3.
Table 4.3
Maximum storage volume within a bunded area for atmospheric tanks
Service
Maximum storage within a single bunded area
Class I, II and III:
- Single tanks
No restriction
- Groups of floating roof tanks
120,000 m (4,240,000 ft )
- Groups of fixed roof tanks
60,000 m (2,120,000 ft )
- Crude tanks
Not more than 2 tanks of individual capacity greater than
3
3
60,000 m (2,120,000 ft )
Service
Minimum bund capacity
Class I, II and III
100 % of the volume of the largest tank standing in the
bund + 0.3 m (1 ft) freeboard.
See DEP 34.11.00.11-Gen. for further details.
Unclassified
NO maximum volume
3
3
3
3
7.
Determination of Class I, II or III shall be based on closed cup flash points, as per
DEP 80.00.10.10-Gen. or DEP 80.00.10.13- Gen., as applicable.
8.
Storage arrangements within bunded areas may be provided with intermediate kerbs
(normally not higher than 0.6 m (2 ft)) to improve containment in case of fire and to
divide the tankage into groups of a convenient size.
a.
9.
Layout and supporting design considerations shall be submitted to the Principal’s
relevant Technical Authority for approval.
Tank farms SHALL [PS] be designed such that in case of spillage the liquid cannot
flow into process units or to any source of ignition.
10. For firefighting reasons, there shall be no more than two rows of tanks between
access roads.
a.
The use of more than two rows of tanks between access roads (e.g., for other
tank sizes, product properties, tank types, fire safety measures and available
fixed and mobile firefighting capabilities) shall be validated by a fire safety
assessment and is subject to acceptance by the Principal’s designated Technical
Authority.
11. Access to the tank farm area SHALL [PS] be provided from two opposite sides with
the access roads linked in such a way that access is always possible should any road
be cut off.
12. Pipe racks and tracks containing process, utility, flare piping that are not connected to
the tanks shall not be routed through the bund.
13. When stored liquids are incompatible such that they can produce a hazardous
substance when they react, the tanks shall be segregated and not located in the same
bund.
14. Tank farms shall be placed on one side or not more than two sides of the process
plant area.
This arrangement allows that adequate safety precautions can be taken and it gives
the possibility to expand either the tank farm area or process plant area at any time
in the future.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 32
15. Tanks shall be grouped and bunded so that the contents of the tanks in one bund will
require one type of firefighting method only.
16. Tanks for the storage of the same materials shall be located in one group within a
bund area, subject to the prescribed limitations of the bunded area.
17. The distance from a process area to the tank farm may need to be limited because of
process reasons (e.g., polymerisation of chemicals in the line connecting the process
area and tank farm). Intermediate tanks should be located in an area close to the
unit(s) providing the materials to those tanks.
18. For tanks grouped together, consideration should be given to a common walkway with
not less than two means of escape landing outside of any containment or berms,
dependent upon the number of tanks served.
19. Pumps, valve manifolds and transfer piping shall be installed outside of bund walls or
impounding basins to minimise the amount of piping, valves and flanges in the bund
area.
4.12
Pressurised LPG storage
1.
The minimum separation distances for the siting of pressurised LPG storage tanks
SHALL [PS] be as specified in Figure 4.4.A and Figure 4.4.B, as applicable.
2.
A boiling liquid expanding vapour explosion (BLEVE) is not a credible design scenario
provided the pressurized vessels/spheres are designed as per the requirements of this
DEP and the requirements in DEP 30.06.10.12-Gen., Section 3.
3.
Pressurised LPG storage shall not be installed within the battery limits of a process
unit.
4.
Horizontal (non-mounded) vessels SHALL [PS] be placed parallel to each other (i.e.,
not in line with or at right angles to one another).
This is to avoid the possibility that, if involved in a fire, vessels are propelled along
their longitudinal axis into another vessel.
5.
Horizontal (non-mounded) vessels shall not be directed towards nearby plants,
storage or buildings. For a typical layout, see Figure 4.5.
6.
The maximum number of vessels in any above-ground (non-mounded) group shall be
six.
7.
Groups of pressurised LPG storage vessels SHALL [PS] be separated by at least
15 m (50 ft).
8.
All LPG storage and associated facilities, e.g., piping, pumps, compressors,
vaporisers, control systems and facilities for loading/unloading bulk road vehicles and
rail tankers, shall be located on the same area of the site.
9.
The routes to road/rail/water LPG handling facilities shall be segregated from other
material movements.
10. Mounded vessels shall be located so that:
a.
They do not affect, and are not affected by, other nearby underground structures
(e.g., foundations, pipelines, sewers);
b.
They cannot be damaged by the impact from vehicles.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 33
Figure 4.4.A Minimum separation distances (meters) for pressurised LPG vessels
Individual
vessel
capacity
A (1)
B
C
D (2)
E
F
G (3)
H
I
J
K (3)
L
N (2)
O
P
S
≤2.5 m3
(D1+D2)/4
10
50
1.5Dr
15
15
7.5
15
5
5
15
10
Dr
(8)
1
3
Dr
(8)
1
3
Dr
(8)
1
3
Dr
(8)
1
3
Dr
(8)
1
3
Dr
(8)
1
3
Dr
(8)
1
3
Dr
(8)
1
3
Dr
(8)
1
3
3
2.5<m ≤5
3
5<m ≤10
3
10<m ≤50
3
50<m ≤95
3
95<m ≤135
3
135<m ≤265
3
265<m ≤500
>500 m
3
(D1+D2)/4
(D1+D2)/4
(D1+D2)/4
(D1+D2)/4
(D1+D2)/4
(D1+D2)/4
(D1+D2)/4
(D1+D2)/4
10
10
10
10
10
15
15
15
50
50
50
50
50
50
50
50
1.5Dr
1.5Dr
1.5Dr
1.5Dr
1.5Dr
1.5Dr
1.5Dr
1.5Dr
15
15
15
15
15
25
25
25
15
15
15
15
15
22.5
30
30
7.5
7.5
7.5
7.5
7.5
7.5
7.5
7.5
15
15
15
15
15
22.5
30
30
5
5
5
5
5
15
15
15
5
5
5
5
5
5
5
5
15
15
15
15
15
15
15
15
10
10
10
10
10
22.5
30
30
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 34
NOTES: 1. D1 and D2 are the diameters of two adjacent vessels.
2.
Dr is the diameter of the outer tank of the refrigerated storage tank.
3.
Definition of product class is in accordance with DEP 80.00.10.10-Gen.
4.
Separation distances are measured from exposed nozzles, tank fittings of the vessel nearest to the
hazard.
5.
Relative orientation of mounded and above ground storage is for representative purposes only.
6.
The distance from a sphere to an unrestricted plant road is the same as from an aboveground
horizontal vessel to an unrestricted plant road (F).
7.
The distance from an aboveground horizontal vessel to a restricted plant road is the same as from a
sphere to a restricted plant road (B).
8.
See (3.2.3)
Figure 4.4.B Minimum separation distances (feet) for pressurised LPG vessels
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 35
Individual
vessel
capacity
A (12)
B
C
D (2)
E
F
G (3)
H
I
J
≤90 ft3
(D1+D2)/4
33
165
1.5Dr
50
50
25
50
16
16
3
90<ft ≤180
(D1+D2)/4
3
180<ft ≤350
3
350<ft ≤1750
3
1750<ft ≤3350
3
3350<ft ≤4770
3
4770<ft ≤9350
3
9350<ft ≤17,650
>17,6500 ft3
(D1+D2)/4
(D1+D2)/4
(D1+D2)/4
(D1+D2)/4
(D1+D2)/4
(D1+D2)/4
(D1+D2)/4
33
33
33
33
33
50
50
50
165
165
165
165
165
165
165
165
1.5Dr
1.5Dr
1.5Dr
1.5Dr
1.5Dr
1.5Dr
1.5Dr
1.5Dr
50
50
50
50
50
82
82
82
50
50
50
50
50
75
100
100
25
25
25
25
25
25
25
25
50
50
50
50
50
75
100
100
16
16
16
16
16
50
50
50
16
16
16
16
16
16
16
16
K
(3)
L
50
33
50
50
50
50
50
50
50
50
33
33
33
33
33
75
100
100
N
O
P
S
Dr
(8)
3.25
10
Dr
(8)
3.25
10
Dr
(8)
3.25
10
Dr
(8)
3.25
10
Dr
(8)
3.25
10
Dr
(8)
3.25
10
Dr
(8)
3.25
10
Dr
(8)
3.25
10
Dr
(8)
3.25
10
(2)
NOTES: 1. D1 and D2 are the diameters of two adjacent vessels.
2.
Dr is the diameter of the outer tank of the refrigerated storage tank.
3.
Definition of product class is in accordance with DEP 80.00.10.10-Gen.
4.
Separation distances are measured from exposed nozzles, tank fittings of the vessel nearest to the
hazard.
5.
Relative orientation of mounded and above ground storage is for representative purposes only.
6.
The distance from a sphere to an unrestricted plant road is the same as from an aboveground
horizontal vessel to an unrestricted plant road (F).
7.
The distance from an aboveground horizontal vessel to a restricted plant road is the same as from a
sphere to a restricted plant road (B).
8.
See (3.2.3)
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 36
Figure 4.5A Typical layout (SI) of pressurised LPG storage vessels
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 37
Figure 4.5B Typical layout (USC) of pressurised LPG storage vessels
4.13
Refrigerated LNG/LPG Storage
1.
Minimum separation distances for full containment tanks are specified in Table 4.1.
2.
Tanks and manifolds shall be accessible from two roads on opposite sides of the tank.
3.
Roads shall be provided to and around the tank in order to enable access by mobile
crane to equipment on the tank roof and on the pumping platform.
4.
Lay-down areas shall be provided such that hoists can be used to lower equipment
from the tank roof to grade level.
5.
A parking area shall be provided near each pumping platform.
6.
Refrigerated LNG/LPG shall not be stored in a process unit and but stored remotely
from other products.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 38
4.14
BUILDINGS
4.14.1
General
1.
The location of buildings for a new or existing facility may be determined either by
following the prescriptive distance within this DEP or using calculated Building Risk
values.
a.
2.
Where used, the Building Risk values should be calculated by completing a
Facility Siting study.
Where a Facility Siting study is completed, the following shall be met:
a.
The assessment shall be completed using the Shell Shepherd software or a
model approved by the Principals’ designated Technical Authority.
b.
The generic building construction type used to generate the building risk contour
shall be chosen to best represent the proposed building construction type.
3.
Figure 4.6 SHALL [PS] be used to determine the design requirements of all new
buildings except for occupied portable buildings including Blast Resistant Modules, for
which refer to (4.14.3).
4.
In calculations, construction villages shall be considered to have a 24 hr per day
occupation.
5.
Buildings should be located upwind or cross wind of the prevailing wind direction of
any plant capable of venting fumes to the atmosphere.
6.
On-site buildings shall have no more than two stories if they meet one of the following:
a.
within 500 m (1640 ft) of process units;
b.
within 200 m (660 ft) of storage tanks.
7.
Temporary and permanent buildings shall be located outside bund walls used for
product containment.
8.
The potential risks arising from neighbouring facilities (outside of the site boundary)
shall be considered when siting all buildings.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 39
Figure 4.6
Flowchart for building design requirements
Will the new building be
occupied or contain safety
critical equipment?
[Refer to definitions (1.3.2)]
YES
NO
Will the location of the new
building be such that the
explosion risk level* is >10-5
using the appropriate generic
building type** ?
Conventional design and
construction using
DEP 34.17.00.32-Gen.
For a B5 blast resistant building
use DEP 34.17.10.30-Gen.
NO
YES
Blast resistant building
design using
DEP 34.17.10.30-Gen
to reduce the
explosion risk level*
below 10-5 .
NO
Will the location of the building
be such that the explosion risk
level* is >10-6 using the
appropriate generic building
type**?
YES
NO
Verify the structural configuration of
the building against the generic
building type** used to generate the
explosion risk level*.
(By civil/structural engineer)
From the verification, has the correct
building type been used?
YES
* Based on the BC-IR or Building Risk, whichever is higher
** Generic building types B1 to B10 are used in the Shell Shepherd software –
Refer to Principal for further details
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 40
4.14.2
Occupied non portable buildings
The requirements in this section are also applicable for buildings containing safety
critical equipment.
1.
The BC-IR levels for any occupied building SHALL [PS] not exceed the following:
a.
10-5/yr for new buildings
b.
10-4/yr for existing buildings
2.
Administration and service buildings that are occupied, should be located in close
proximity to the main facility entrance.
3.
Minimum separation distances for the siting of non-blast resistant occupied buildings
in relation to process facilities are defined in (4.2) and summarised in Table 4.1.A and
Table 4.1.B. For instances for non-portable non-blast resistant occupied buildings that
are not defined by Table 4.1.A and Table 4.1.B, the minimum separation SHALL [PS]
be as follows:
a.
60 m (200 ft) from process equipment in isolated areas that present a significant
risk such as production wells, pumps, pressure vessels, relief valves to
atmosphere, flares, process vents, and low pressure storage (including their
associated loading and unloading racks) that could, during an unexpected
operational upset, release flammable or toxic products.
In this context, isolated areas means it is not part of a congested process area.
4.14.3
30 m (100 ft) from furnaces and boilers
c.
15 m (50 ft) from all above ground piping containing flammable or toxic materials.
Fuel gas lines and utility service lines routed to buildings are excluded from this
requirement.
d.
100 m (330 ft) from slugcatchers.
e.
30 m (100 ft) from the edge of the drill/work-over floor on drilling/work-over rigs.
f.
1.5 Diameter of the largest tank, with a minimum of 60 m (200 ft) separation, from
atmospheric storage tanks having a tank sidewall greater than 5 m (15 ft) in
height and containing non-refrigerated atmospheric/low pressure flammable or
combustible liquids.
Occupied portable buildings including blast resistant modules
1.
4.14.4
b.
For the siting of onshore occupied portable buildings, including blast resistant modules
(BRM), refer to DEP 34.17.10.35-Gen.
Service buildings
1.
All service buildings should be close to the main site entrance.
2.
Buildings needed for emergency situations shall be located such that they will not be
affected by a major incident and have good access to all parts of the facility to enable
emergency action without hazard to plant traffic.
3.
Car parking requirements should be assessed and adequate facilities provided.
4.
The main entrance gate for vehicles shall be adjacent to the guardhouse nearby the
administration office building.
5.
The guard house shall be located such that a guard sitting inside has an unrestricted
view of the approach road on both sides of the gate.
6.
Canteen and medical centre should be located within a short distance of the main
concentration of people.
7.
Off-loading of food and other necessary supplies should not interfere with other traffic.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 41
4.14.5
8.
Workshop/warehouse, etc., should be located together and within easy access of the
process units.
9.
Off-loading to the workshop/warehouse buildings should not interfere with other traffic.
The workshop may need adjacent external space for activities such as outside
fabrication, scrap yard, storage and lay down area.
Plant buildings
4.14.5.1 General
1.
The requirements in (4.14.1) and (4.14.2) shall apply for plant buildings containing
safety critical equipment (e.g., unit electrical substations/field auxiliary rooms/analyser
houses) and for plant buildings considered to be occupied.
2.
See (4.5) for the siting of unit electrical substations and field auxiliary rooms relative to
potential hydrocarbon leak sources
3.
Unit electrical substations should be located near the centre of the load they are
required to supply. Reference is made to DEP 33.64.10.10-Gen. and
DEP 33.64.20.10-Gen., as applicable.
4.14.5.2 Analyser houses
1.
4.15
An analyser house may not be considered a potential hydrocarbon leak source where
sufficient measures are in place, in accordance with DEP 32.31.50.10-Gen. and
DEP 32.31.50.13-Gen., to:
a.
bring the hydrocarbon content in the analyser house to below the lower explosive
limit (LEL) level, and
b.
allow emergency shutdown in case of hydrocarbon content reaching LEL level.
2.
Where analyser houses are a potential hydrocarbon leak source, see (4.5) regarding
the minimum distance to fixed ignition sources.
3.
There shall be enough space between the analyser building and surrounding
equipment to allow maintenance access for both the analyser building as well as for
the surrounding equipment.
LOGISTIC AREAS
1.
The siting of logistics areas (e.g., unloading areas, transit storage) should take the
following into consideration:
a.
Proximity to facility entrance and exit points,
b.
Traffic movements and controls through process plants and tank farms,
c.
Nuisances (e.g., odour) or hazards associated with material/goods.
4.16
SITE SPECIFIC PARAMETERS
4.16.1
Topography
1.
All process facilities should be on the same elevation.
2.
In setting spatial arrangements (especially for facilities which are built on terraces) the
relative densities of flammables shall be taken into account in the design scenarios,
considering the rising of lighter-than-air-flammables, drifting of neutral-density
flammables and falling of heavier-than-air flammables.
3.
The effect of re-circulation of hot air from air coolers and cooling water towers, shall be
studied for “terraced” sites.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 42
4.16.2
4.16.3
4.16.4
Bathymetry
1.
The location of the jetty, material off-loading (MOF) and/or Roll-Off Roll-On (Ro-Ro)
facility should be decided such that the length of the required causeway is minimised.
2.
The bathymetry of the water-body, the required exclusion zones, the draught of ships,
the possible area to be dredged and the tide and currents shall be considered.
Meteorology
1.
The prevailing wind directions shall be considered when establishing spatial
arrangements and orientation of the facilities.
2.
Analysis shall include circumstances where the wind does not always blow in the
prevailing wind direction or is strongly affected by seasonal or other factors.
3.
The site master plan shall be designed such that flooding of sensitive areas is
avoided.
Geotechnical conditions and seismicity
1.
4.16.5
The siting of plant, tankage areas, buildings and connecting infrastructure shall
consider the local geotechnical conditions to arrive at the most optimal foundation
solution and to reduce the potential risks from geo-hazards and earthquake events in
seismically active regions.
Environment
1.
Visual impact, impact to wildlife and impact to local communities shall be addressed.
High elevation equipment and stacks may cause an aerial hazard and might be
limited to a maximum height.
4.16.6
2.
Plants producing gaseous effluents, dust and other pollutants, or noise, should not be
located upwind of residential or similar property.
3.
Liquid effluent shall not be able to flow to plants on adjacent property and vice versa.
4.
Solid effluents storage should be remote from adjacent property.
5.
Storm water shall be directed to the appropriate drain.
6.
Outside stores of drums or unwanted or scrap equipment should not be visible from
any location outside the fence.
7.
Rail spurs should be placed so that noise of shunting to persons onsite as well as the
public is minimized.
Site boundary and access
4.16.6.1 Roads and parking areas
1.
The edge of restricted and unrestricted plant roads shall be located at least 3.0 m
(10 ft) from equipment handling hydrocarbons.
2.
For unrestricted plant roads, additional requirements are given in (4.5).
3.
The site shall:
a.
have a peripheral road connected at a minimum of two points with the public road
system.
b.
be arranged such that a major fire can be approached from two directions.
4.
In laying out the road system, the expected handling and traffic requirements during
construction, operation, (shutdown) maintenance, emergency and decommissioning of
the facilities shall be analysed. Future traffic requirements shall be taken into account.
5.
Access roads shall be designed to be kept open during facility maintenance
campaigns to allow passage of fire trucks or other equipment in case of an
emergency.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 43
6.
See DEP 34.13.20.31-Gen., Section 2 for the extent, type, width, radii, and gradients
of roads.
7.
Corner radii should suit the turning circle of the largest vehicle and any special loads.
8.
Railway crossings, crossroads, road junctions, dead ends, right angle bends and
ramps should be avoided.
9.
A traffic circulation plan shall be made to arrange the roads such that vehicles do not
pass through process areas or violate area classifications.
a.
The total number of road car kilometres on site should be minimized.
10. Clearances for passage of mobile equipment shall be based on the largest piece of
equipment anticipated.
11. The minimum elevation of the bottom of overhead obstructions outside units shall be:
a.
6.0 m (20 ft) over railways
b.
6.0 m (20 ft) over unrestricted plant roads
In some situations the lower side of the pipe supports or the supporting steel
dictates the minimum elevation of overhead piping.
12. There should always be at least one route to each unit and to the expansion areas
without pipe rack crossings.
13. A plant area shall be accessible on all four sides by a road.
14. Turning areas for tankers and vehicles shall not be allowed.
15. Pedestrian pathways adjacent to roads should be included in areas of high personnel
concentration and traffic movement.
16. In the sizing of roads, room shall be allowed for adjacent drainage channels,
especially if the site is low or near surface water.
17. Adequate parking space shall be available for vehicles waiting:
a.
to load and unload;
b.
for the weighbridge;
c.
to receive clearance to enter or leave the facility.
18. Vehicles should not have to queue on the public road to gain entrance to the facility.
19. Car and bus parks for personnel and visitors and their access roads should be in a
safe area and outside security points.
20. The parking area for night-shift employees should be under observation of the
gatekeeper.
4.16.6.2 Rail tracks
1.
The rail layout should be considered early in the development of the site master plan
in conjunction with the road plan.
2.
Rail tracks and rail links with a local or national system shall be laid-out in consultation
with the responsible railway authorities.
3.
Rail-tracks shall be situated outside hazardous areas as defined in
DEP 80.00.10.10-Gen. or DEP 80.00.10.13-Gen., as applicable.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 44
4.16.6.3 Gates/security fencing
1.
Refer to DEP 34.13.20.31-Gen.
2.
The site shall be provided with a security fence.
3.
Entrances should be provided with a gatehouse.
4.
For security reasons, the number of entrances should be kept to a minimum.
5.
The gateway between the process area and the building areas should have its own
security control point.
6.
Site gates should be sited so that the effect of personnel coming off duty on the
outside traffic is limited.
5.
PLOT PLAN
5.1
INTRODUCTION
A plot plan gives the overall spatial arrangement of the individual units and general
facilities within the available plant boundaries.
1.
Due to process configuration and to minimise space requirements, air-cooled heat
exchangers should be located on top of the pipe-racks.
2.
The area under a pipe rack may be used for access by forklifts/smaller vehicles.
3.
Free area under a pipe rack may be utilised for underground electrical and instrument
cables if it is permitted by local regulations and practices.
5.2
SAFETY
5.2.1
General
5.2.2
1.
The requirements in this Section apply in conjunction with (3.2.2).
2.
The general philosophy should be to apply open structures, unless this is constrained
by other factors such as the nature and frequency of operators' work, climate, type of
equipment, nature of process, proximity of hazards, noise.
3.
The temperature on working areas (e.g., platforms, staircases, column cage ladders)
shall not exceed the limit defined in the project HSSE Plan, taking into account heat
emission sources (e.g., hot air outlets of air-cooled heat exchangers, heater stacks).
4.
Mirror image equipment/unit arrangements should be avoided. For example, refer to
the requirements in DEP 30.05.10.30-Gen.
Utility units
1.
2.
5.2.3
Utility units handling flammable products (e.g., hot oils, fuel oils, fuel gas) shall be
treated as units processing hydrocarbons and located as follows:
a.
in close proximity to the serviced process units
b.
away from office buildings, workshops.
c.
See (4.5) regarding the minimum distance to fixed ignition sources.
Utility handling non-flammable products (e.g., instrument air, boiler feed water,
nitrogen) should not have process safety related requirements.
Escape and personnel access
1.
The layout shall provide an escape route during an emergency and shall provide
personnel access during operation and maintenance. Reference is made to
DEP 34.28.00.33-Gen.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 45
5.2.4
5.2.5
Equipment grouping
1.
Equipment having similar hazard potential should be grouped together to reduce risk.
2.
Furnaces and fired heaters are fixed sources of ignition and should be grouped
together and be located at the edge of the plant plot and upwind (considering the most
prevailing wind direction) of potential flammable vapour sources.
Piping/cabling
1.
The minimum elevation of the bottom of overhead piping inside a unit shall be:
a.
4.0 m (13 ft) for crane access
b.
4.0 m (13 ft) for truck access
c.
2.7 m (9 ft) for fork-lift truck access
In some situations, the lower side of the pipe supports or the supporting steel
dictates the minimum elevation of overhead piping.
2.
Pipe-work and cabling being part of a safety critical equipment (e.g., blow-down
headers, fire mains, control cabling) shall be routed around areas which may not be
operating when this pipe-work and/or cabling is in operation.
For example, avoid a situation where a unit is in a maintenance turnaround while
transit pipe-work and/or cabling continues in live operation to support other units
that are not shutdown.
3.
Routing of pipe-work containing hazardous fluids through non-hydrocarbon containing
areas should be avoided.
4.
If the situations in (5.2.5, Item 2) or (5.2.5, Item 3) above are unavoidable, the
following apply:
5.
5.2.6
5.2.7
pipe-work shall have minimum flanges;
b.
pipe-work and cabling shall not be located in a vulnerable position where they
can be mechanically damaged.
Cables may be run underground or aboveground if allowed by local regulations and
practices. If both options are acceptable from a safety point of view, the most cost
effective option should be determined on a case-by-case basis.
Drainage
1.
Sumps, trenches, channels and unsealed manholes that can contain hydrocarbon (or
other flammable liquids) are a potential hydrocarbon leak source, see (4.5) regarding
the minimum distance to fixed ignition sources.
2.
Spillage/flow of hazardous liquids or gases from one unit to another shall be prevented
by proper separation.
Solid decks
1.
5.3
a.
Elevated solid decks shall not be applied unless required to support large bottomnozzle compressors.
CONSTRUCTION
1.
The plot plan shall be designed such that adequate access is available to transport
and lift all equipment into place.
2.
Reference is made to the ORP with respect to the constructability reviews to be
carried out early in the design phases.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 46
5.4
COST
1.
All equipment should be at the same elevation unless there is a safety, process, space
limitation, or accessibility requirement that requires equipment to be located at varying
elevations (e.g., gravity flow from one vessel to another).
2.
Positioning equipment on elevation should only be considered when dictated by
ground space limitations and/or process requirements.
3.
Equipment should be located such that long pipe runs are minimised.
5.5
ENGINEERING
5.5.1
Equipment grouping
5.5.2
5.5.3
1.
Equipment sharing a common need or serving a common purpose should be grouped
together.
2.
Equipment grouping should be done for:
a.
Equipment involving high pressure piping
b.
Equipment involving similar maintenance requirements (compressors, pumps)
c.
Equipment with high electrical power requirement or under the same area
classifications
d.
Locating of heavy equipment on stronger surface
Pipe routing
1.
Space for piping shall be reserved during the development of the layout.
2.
Pipe routing shall be established to ensure that:
a.
All special process requirements (e.g., gravity flow, self-draining, mixed phase,
critical NPSH, etc.) have been addressed
b.
The cost of piping runs (e.g., large diameter, alloy, high temperature, high
pressure, etc.) has been optimised
c.
Adequate space has been provided for considerations as expansion loops,
manifolding, orifice runs, utility service stations, etc.
d.
Piping does not hamper inspection or servicing of equipment
e.
Valves and instruments can be effectively and efficiently accessed
3.
Within plant limits, piping should run aboveground.
4.
Firewater lines may be buried if considered necessary for safety (mechanical
protection).
Instrument and electrical cable routing
1.
Space for instrument and electrical cables shall be reserved during the development of
the layout.
2.
When cable trays are located on pipe racks, the following shall be met:
a.
Cables trays shall be on the top level to create segregation between piping and
cable trays.
b.
Electrical cables shall be at one side of the pipe rack and instrument cables at the
other side to create segregation between the two
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 47
5.6
OPERATION
5.6.1
Operation/monitoring considerations
1.
Equipment requiring frequent attendance by operation personnel shall be identified
and the layout optimised to enable the shortest and most direct routes for operators
when on routine operator rounds.
In this context, frequent access is equipment that is expected to be checked daily
as part of the operator surveillance round.
5.6.2
Operating areas
1.
The arrangement of equipment, instruments and controls (in terms of location,
orientation, spacing and clearances) shall support safe, effective and efficient human
performance on operational tasks.
2.
The dimensions of the areas required for operation shall be assessed for normal and
emergency activities taking human factors constraints and local requirements into
account (3.4.3).
5.7
MAINTENANCE
5.7.1
General
1.
Clearances for passage of mobile equipment shall be based on the largest piece of
equipment anticipated and local practices. Reference is made to
DEP 34.13.20.31-Gen., Section 2.3.
2.
The layout should prevent the need to lift or slew over live operating (on-stream)
equipment when conducting maintenance.
a.
Where deemed necessary, a risk assessment shall be conducted during the
design to confirm the residual risk is ALARP.
5.7.2
Maintenance space
5.7.2.1
General
1.
The arrangement of equipment, instruments and controls (in terms of location,
orientation, spacing and clearances) shall support safe, effective and efficient human
performance of maintenance tasks (3.4.3).
2.
Adequate access shall be provided to areas where maintenance has to be carried out
and to areas where equipment or material is brought in for maintenance/cleaning
purposes.
3.
The dimensions of the areas required for maintenance shall be:
a.
based on the largest piece of equipment that will service the area;
b.
assessed for normal and emergency activities, taking human factors constraints
into account.
4.
Adequate free space shall be provided for the access to equipment and to remove, lift,
and transport equipment (parts) during maintenance or replacement.
5.
Use of restricted access roads into the process area should be considered depending
on the nature of the equipment to be serviced.
6.
To allow maintenance access and safe escape, the area under plant pipe racks shall
not be obstructed.
a.
An open space of at least 4 m (13 ft) wide over the entire length of the pipe rack,
not obstructed by manifolds, ladders, equipment, etc., and accessible from the
roads, shall be left available.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 48
5.7.2.2
Lay-down areas
1.
5.7.2.3
5.7.3
5.8
Tall equipment
1.
Tall process equipment having removable parts (such as trays or packing, relief
valves, etc.) should be located near an access road for removal and reinstallation of
these parts.
2.
A drop zone shall be determined and indicated on the layout drawings to ensure that
sufficient space is reserved at grade to handle such items.
Maintenance equipment
1.
If required, access for mobile lifting/transporting equipment shall be provided.
2.
The width and road class of the roads shall be based on the largest piece of
equipment that will service the area. Reference is made to DEP 34.13.20.31-Gen.,
Section 2.3.
PLANT BUILDINGS
1.
5.9
5.12
The number of structures should be minimised by combining structures (e.g., for shell
and tube heat exchangers and for vessels).
PLATFORMS/LADDERS/STAIRS
1.
5.11
If partially clad structures or fully enclosed buildings are used, attention shall be given
to access, mechanical handling and lay-down requirements.
STRUCTURES
1.
5.10
Space shall be provided for the lay-down of equipment during maintenance or
replacement, particularly for replacing large items such as turbine rotors or rotor
bundles, shell and tube heat exchanger bundles and compressor shafts.
Refer to DEP 34.28.00.31-Gen. and DEP 34.28.00.33-Gen. for the design of
platforms/ladders/stairs.
PIPE RACKS
1.
The on-plot flare header shall freely drain towards the off-plot flare header and related
equipment, taking account of the minimum required height crossings over the roads.
2.
Heavy lines (large diameter lines or large lines full of liquid) shall be located on the
edge of the piperack.
3.
Flanges in the pipe shall be staggered with flanges in adjacent piping.
4.
Flange connections and valves in hydrocarbon lines shall not be located below aircooled heat exchangers.
5.
Relief valve platforms shall not be placed underneath air-cooled heat exchangers.
6.
Allowance should be kept for future piping based on the project specific design class
specifications.
7.
See DEP 31.38.01.11-Gen., Section 3.8 for minimum distances between lines and
spans of a pipe rack.
RELIEF/FLARE/BLOW-DOWN LINES
1.
See DEP 80.45.10.10-Gen. for layout of relief/flare/blow-down lines.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 49
5.13
BATTERY LIMITS
1.
5.14
The battery limit pipe rack bay area shall be kept clear of equipment to facilitate ease
of access and operation and maintenance at the battery limit (this reduces equipment
layout space).
SPECIAL UNITS
1.
For non-standard units (e.g., sulphur pelletisers, effluent treating systems) and
standardized equipment packages (e.g., gas turbines, air compressors and engine
driven generator sets) the Manufacturer/Supplier should be consulted on layout and
operation/maintenance aspects.
5.15
PACKAGE UNITS
5.15.1
Introduction
This section applies to equipment designed and supplied as a largely self-contained
physical unit, and potentially mounted on a portable skid (skid-package) or as standalone module.
Packaged units are generally designed, built and tested at the Manufacturer/Supplier’s
premises and delivered for integration into the overall plant or facility
5.15.2
5.15.3
Objective
1.
Layout design of package units shall be primarily based on the functional requirements
and logical process flow of the required system.
2.
The design shall allow for the minimum required plot space and access to and around
equipment parts, to carry out operational and/or maintenance tasks in an effective,
efficient, safe and healthy manner.
3.
The design shall incorporate the requirements in this DEP and the latest minimum
legal or professional human factors engineering standards and practices. Refer to
DEP 30.00.60.18-Gen.
Location
1.
5.15.4
When developing the layout of the package unit, the relative position of the package
unit to the total facility and the facilities adjacent to the package unit, shall take the
following factors into account:
a.
Access and clearance for loading/unloading using mechanical equipment
b.
Access/egress once interconnected with non-skid equipment
c.
Access for emergency response and fire fighting
d.
Requirements of line-of-sight communications
e.
Potential sources of lighting and glare
f.
Noise exposure
g.
Surfaces at extreme temperatures
Access
1.
Structural members of the package unit, platforms or supports of individual equipment
shall not prevent access to equipment to be operated or maintained.
2.
Equipment that needs to be accessed frequently for inspection, monitoring or servicing
purposes should be located at the outside of the skid and placed at sufficient
elevation.
3.
Operational interfaces (both controls and displays) should be specified and mounted
outside the skid in such a way that they are easy accessible.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 50
5.15.5
Piping
1.
All piping shall be installed within the base frame plan of the package unit.
2.
All piping should be routed at one side of the package to leave the other side
completely free for maintenance access.
6.
MECHANICAL GENERAL ARRANGEMENT
6.1
INTRODUCTION
The mechanical general arrangement drawings give the overall spatial arrangement of
equipment within the available unit boundaries.
6.2
6.3
SAFETY
1.
The requirements in this Section apply in conjunction with (3.2.2).
2.
Equipment shall be protected against major mechanical impact (e.g., fork lift truck,
crane/hoist impacts and car collision),
3.
Valves that isolate the unit inventory should be located in areas where they will not be
affected by mechanical damage.
OPERATION AND MAINTENANCE ACCESS
1.
Reference is made to (3.4.3).
2.
The location and arrangement of equipment, instruments and controls shall:
a.
allow for space required for personnel to perform their tasks;
b.
be based upon input of anthropometric data relevant to the anticipated population
operating/maintaining the package.
3.
Adequate elevation access, walkways and platforms shall be provided for operating
and maintenance access to all equipment.
4.
Locations where frequent maintenance needs to be carried out shall be specified and
provided with access for both the people and the relevant equipment such as a crane
or lifting device.
5.
The unobstructed area or space around and above equipment shall be based on the
requirements for maintenance, replacement and mechanical handling.
6.
Equipment parts requiring alignment shall be provided with sufficient working and
inspection space for safe removal and installation.
7.
Equipment such as filters and lubrication systems shall be easily accessible for
maintenance, fluid draining, replacement of internals, refilling.
6.4
INSTRUMENTATION/ELECTRICAL
6.4.1
General
1.
Instrument tubing and cable routing shall not interfere with unit accessibility for
emergencies, operation and maintenance.
2.
The optimum location of instrumentation and electrical hardware (including supports)
shall be determined taking instrumentation, electrical, mechanical, engineering, and
maintenance aspects into account.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 51
6.4.2
6.4.3
Instrumentation
1.
Instruments displays or indicators that need to be read by personnel shall be visible for
operators/maintenance personnel from grade or from platforms.
2.
Instruments shall either be mounted at a height that allows access for routine
maintenance and calibration, or provided with platform access.
3.
Refer to (3.4.3) and DEP 32.31.00.32-Gen., Section 2.5 for minimum accessibility
requirements for plant instruments.
Local control panels
1.
6.4.4
6.5
All local control panels, instruments and valves required for controlled start-up or
emergency shutdown of the unit shall be mounted at one side of the unit and be easily
accessible/visible.
Electrical
1.
High and/or low voltage cables shall be laid in trenches or on trays separated from
those used for instrumentation, telecom and computer/data cables.
2.
Refer to DEP 33.64.10.10-Gen., Section 5 for additional requirements.
ANALYSERS
1.
Space is required for the instruments, storage compartments, washbasin, portable
equipment and containers.
6.6
EQUIPMENT SPECIFIC
6.6.1
Fired equipment
6.6.1.1
General
1.
Fuel knock-out vessels for furnaces are considered piping items and should be located
as close as possible to the burners.
This is both for improved process control and to minimise separation of liquids in
the line between the knock-out vessel and the furnace.
6.6.1.2
2.
If multiple stacks are used, unhindered access shall be available for tube removal by
crane.
3.
For top fired furnaces, adequate exit routes shall be provided from each end of the
furnace, with at least one being a stairway.
4.
The distance between furnaces shall be determined by operational and maintenance
considerations.
5.
Access shall be provided to peepholes/observation doors and other operational areas.
6.
Access shall be provided for relining, tube removal/cleaning and other repairs.
7.
Platforms shall be provided for maintenance of soot blowers.
Transfer lines
1.
Furnace transfer lines should be kept short and simple.
Straight inlet line requirements might set the minimum distance between the
furnace and the downstream equipment.
2.
If coking is expected, the line should have flanged fittings and elbows, and be provided
with crane access.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 52
6.6.1.3
6.6.2
Fuel supply lines
1.
The distribution header shall slope in the direction of the gas flow without a pocket in
the line.
2.
A drip leg shall be fitted at the low point.
Reactors
1.
6.6.3
An area shall be made available to remove internal heat exchangers, coils/mixers, and
to change-out catalysts.
Columns
1.
For non-pumped refluxes, the condenser and reflux drum shall be on a higher
elevation than the reflux inlet nozzle to provide gravity flow.
2.
Sufficient space around the column base for major maintenance work requiring
scaffolding (replacement of internals, painting, insulating) shall be included in the
design.
3.
Provisions for internal access shall be made to allow cleaning, exchanging internals,
inspection, etc. (3.4.3)
a.
4.
6.6.4
Lay-down area/space for required tools and equipment should be taken into
account.
A 3 m (10 ft) minimum should be allowed between columns.
Shell-and-tube heat exchangers
1.
Shell-and-tube heat exchangers should normally be located at grade.
2.
If shell-and-tube heat exchangers are stacked on common supports, they shall be no
more than two shells high.
3.
Sufficient space shall be available in between heat exchanger (trains) for (bypass)
valves. (3.4.3)
4.
Wrench clearance should be provided at the exchanger flanges.
a.
5.
If necessary, spool pieces should be provided between channel nozzles and
valves, with the valves clearing the removal space. (3.4.3)
The following layout issues shall be considered:
a.
Location and accessibility of spading points
b.
Required facilities/tools/space required for bundle pulling
c.
Cleaning philosophy (in-situ or off-site)
i.
For in-situ cleaning, access for bundle removal and/or bundle cleaning
devices shall be provided.
iii.
The channel, shell cover and tube bundle withdrawal space shall be clear of
any obstruction (e.g., piping) which could hamper removal of these items by
either mobile or in-place maintenance facilities.
d.
Need to locate temporary supports
e.
Need to provide break flanges
6.
Consideration should be given to the use of side or tangential connections to reduce
the heights of exchangers.
7.
Reboiler lines should be as simple and direct as possible.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 53
6.6.5
6.6.6
Air-cooled heat exchangers
1.
Space shall be provided for crane access to allow maintenance/inspection/cleaning of
the tubes and to change out an entire bundle if required.
2.
Air-cooled heat exchangers shall not be located directly over any of the following:
a.
potential leak sources of flammable fluids (e.g., pump seals, compressors);
b.
control buildings;
c.
electrical rooms.
3.
Convenient access shall be available to the tube-ends for inspection, in-tube cleaning,
etc. and to the finned tubes for inspection, out-tube cleaning, etc.
4.
A fully grated maintenance floor shall be provided to give access to the motors,
V-belts, plenum chambers, gearboxes, fan blades.
5.
To prevent human error, the manual control points associated with air-cooled heat
exchangers shall be arranged to match the physical location of the equipment.
Vessels
1.
Access and space for operations shall be provided around each vessel.
2.
Access and space shall be provided at the top of a vessel to allow replacement of
pressure relief valves.
3.
Level controls shall be accessible by a stair or access platform.
6.6.7
Rotating equipment
6.6.7.1
General
6.6.7.2
1.
There shall be a clear space between rotating equipment, rows of rotating equipment
and the end of each row, subject to any special maintenance considerations.
2.
Refer to DEP 31.25.00.10-Gen., Section 2 for the requirements of housing for rotating
equipment, weather and/or noise protection and hoisting facilities.
3.
When no permanent facilities are provided, maintenance shall be possible by mobile
cranes.
4.
Lay-down space shall be provided.
Pumps
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 54
6.6.7.2.1
General
1.
Pumps in C4 and lighter services SHALL [PS] be located to meet all of the following
a.
a minimum of 3 m (10 ft) from pipe racks and major process structures;
b.
accessible for fire fighting
c.
in the open (on the outside of the unit);
d.
in a non-congested area;
In this context, non-congested means that the area the pump is located in is
sufficiently open so that, in case of release of process material, the resulting
vapour is able to disperse.
2.
Pumps in flammable services (C5 or heavier) above their minimum auto-ignition
temperature SHALL [PS] be located as follows:
a.
a minimum of 3 m (10 ft) from pipe racks and major process structures;
This is to avoid escalation of a possible fire due to chimney effects.
b.
3.
accessible for firefighting.
Pumps in flammable services (C5 or heavier) below their minimum auto-ignition
temperature shall be located as follows unless otherwise agreed with the Principal’s
Technical Authority:
a.
a minimum of 3 m (10 ft) from pipe racks and major process structures;
This is to avoid escalation of a possible fire due to chimney effects.
b.
accessible for firefighting.
If there are major constraints and cost implications, it can sometimes be acceptable
to locate the pumps between pipe rack and equipment such as distillation columns
provided ALARP is achieved.
4.
Only pumps handling non-flammable liquids may be located under pipe racks or
structures.
5.
Pumps shall be located on ground level and above the known flood level. If there is no
NPSH reason, pumps should not be installed in a sump or pit in order to avoid gas
traps and to avoid costly civil work and drainage problems.
6.
Whenever practical, pumps shall be located in a row with the concrete blocks in one
line and with the motors all facing the same direction to be able to make a straight
underground drain line.
7.
All pumps shall be accessible for operation, maintenance and emergencies. (3.4.3)
8.
Pumps should be located close to the equipment from which they take suction.
9.
Double rows of pumps may be arranged with pumps back-to-back piped up to a
common pipe rack.
a.
Piping should be arranged alongside the pump end of the assembly.
10. Groups of pumps should have their discharges and discharge valves and, if possible,
their suction valves and seal pipes lined up.
11. Adequate length shall be available to install flow measurement or control apparatus
associated with the pumps.
a.
Minimum suction line straight length shall comply with DEP 31.38.01.11-Gen.,
Section 4.2.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 55
6.6.7.2.2
Positive displacements pumps
1.
Access to valve covers, case covers and shaft packing shall be provided, as well as
space for cylinder and shaft removal.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 56
6.6.7.2.3
Centrifugal pumps
1.
The piping arrangements for pumps operating in parallel shall be such that equal flow
distribution between the pumps is ensured.
2.
Pumps having horizontal split casings shall have access from both sides for
convenience in maintenance.
3.
Barrel type arrangements (vertically split casings) shall have space in front of the
pump for pulling the shaft and/or impeller bundle (including diffusers/volutes as
appropriate) during in situ maintenance.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 57
6.6.7.3
Compressors
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 58
6.6.7.3.1
General
1.
Compressors should be supported from grade or on a concrete table top.
2.
Access, space and lay-down area shall be provided around the compressor packages
to allow efficient removal of driver, casing, pistons etc. as well as cooler equipment.
3.
When two or more similar compressors are installed adjacent to each other with
connecting maintenance platforms, the decking shall be at the same elevation. Side
steps on the platform are not acceptable.
4.
Compressors decks shall be large enough for safe and efficient equipment operations
and maintenance without overhanging the decked surface.
a.
A minimum 1.8 m (6 ft) wide maintenance walkway shall be provided around the
compressor driver.
b.
A clearance of minimum 1.8 m (6 ft) between the compressor frame side and the
first obstruction shall be provided.
5.
A minimum of one maintenance drop zone near a maintenance access way shall be
provided on each compressor deck.
6.
All accessible areas between the machine and/or foundation and the deck shall be
covered with grating.
7.
The start/stop station shall be located near the compressor.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 59
6.6.7.3.2
Reciprocating type compressors
1.
Spacing of compressors varies with type and duty, but particular attention shall be
paid to ensure that maintenance of the following can be done without obstruction from
piping and supports:
a.
The withdrawal of engine and compressor pistons
b.
Piston rods, distance pieces
c.
Cam and crank shafts
d.
Oil cooler bundles
e.
The maintenance of cylinder valves
2.
The compressor centreline shall be set to provide good maintenance access to the
discharge valves on the largest cylinder.
3.
The location and routing of process, lube oil, cooling water, and other auxiliary piping
and electrical conduit shall not limit maintenance or inspection access to the
compressor frame, crosshead, rod packing, compressor valves or driver base bolts.
4.
Adequate room and access shall be provided to safely bar over the compressor.
5.
Skid mounted lube oil, jacket water cooling and packing cooling systems shall be
located at grade.
6.
Cylinder lubricator system shall be located on the compressor such that it does not
hinder maintenance access to the crankshaft, bearings or other frame components.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 60
6.6.7.3.3
Centrifugal type compressors
1.
The location of auxiliaries shall allow access for:
a.
Operation of valves
b.
Pulling the heat exchanger bundles
c.
Other operating and maintenance tasks
2.
Compressors operating in parallel shall be sited such that the piping arrangement
provides equal flow distribution between the compressors.
3.
Top-top nozzle compressors may be located on grade. If the compressor, however,
has liquid film seals, height is required for the sour seal oil drains and run-down of the
seal and lube oil.
4.
Compressors having horizontal split casings shall have access from both sides for
efficient maintenance.
5.
Barrel type arrangements (vertically split casings) shall be provided with space in front
of the non-drive end of the compressor for pulling the rotor during in situ maintenance.
6.
When two or more barrel casings are installed in a single train, sufficient space shall
be provided for the inner casing to be removed and setdown, so that the internal
components (bundles) can be removed and/or accessed.
7.
The centreline of the compressor train shall be set as low as practical to provide good
maintenance and operating access.
8.
Decking around the compressor train shall be on the same elevation.
a.
9.
Grating under and around coupling guards shall be provided.
Process, lube oil and other auxiliary piping shall be routed to provide easy access to
compressor trains for operation, inspection and maintenance.
Typically this means routing the lines below the maintenance grating.
6.6.8
Fans
Fans inlet and outlet ducting are space consuming items due to their large size and
required space for bends and clearance around valves and filters.
1.
6.6.9
Adequate space and headroom shall be allowed for removal of filters, impellers,
shafts, motors and bearings.
Piping
1.
All piping shall be installed and supported in such a way that equipment can be
maintained or replaced with the minimum dismantling of the pipe-work.
2.
To allow easy access, piping connections which require frequent disconnection shall
be installed as per (3.4.3).
3.
Slurry piping shall be provided with long radius elbows and provided with sufficient
clean-out facilities.
4.
Piping layout shall not result in tripping hazards.
5.
Minimum required straight in- and outlet requirements for flow controlling elements
and to “Schoepentoeters” shall be taken into account.
6.
Liquid LPG/LNG piping and other liquid or gas hydrocarbon piping which can create a
jet flame SHALL [PS] be arranged such that flame impingement on a LPG liquid
inventory (e.g., a kettle type heat exchanger or column bottom) by a liquid or gas jet
from a leaking flange in this piping cannot occur.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 61
6.6.10
Valves
6.6.10.1 General
1.
For categorization and human factors engineering aspects of valves, see
DEP 31.38.01.11-Gen. and DEP 30.00.60.20-Gen.
2.
The location of and access requirements for a valve shall be based on the criticality
and access frequency for operational/maintenance requirements as determined as
part of the Valve Criticality Analysis in DEP 30.00.60.20-Gen.
3.
Valves used for emergency operations shall be accessible as per
DEP 30.00.60.20-Gen
6.6.10.2 Relief valves
1.
Relief valves and block/bypass valves shall be accessible for inspection, and where
applicable local testing during operation as per DEP 30.00.60.20-Gen.
6.6.10.3 Control valves and block/bypass valves
1.
6.6.11
Mixers
1.
6.6.12
6.6.16
6.6.17
Air intakes/exhausts SHALL [PS] be located according to area classification.
Reference is made to DEP 80.00.10.10-Gen. and DEP 80.00.10.13-Gen., as
applicable.
Vacuum installations
1.
6.6.15
Access shall be provided to basket filters and strainers to remove the filter or strainer
elements for cleaning or replacement.
Air intakes/exhausts
1.
6.6.14
Access shall be provided to mixer mounting manholes and to mixer drive mechanisms,
as well as space to remove the whole or parts of the mixer for maintenance purposes.
Filters
1.
6.6.13
Control valves and block/bypass valves shall be accessible for operation and
maintenance as per DEP 30.00.60.20-Gen.
The length of a barometric leg, which depends on the specific density of the liquid and
the depth of the vacuum, shall be taken into account.
Mechanical conveyors
1.
The Manufacturer/Supplier shall be consulted on layout and operation/maintenance
aspects.
2.
For multiple belt conveyors, a maintenance walkway of 600 mm (2 ft) width minimum
shall be provided along each conveyor.
Manholes
1.
For sizes of manholes, see DEP 31.22.00.31-Gen., section 5.13, and
DEP 30.00.60.20-Gen.
2.
An access platform shall be provided if the manhole centre is higher than 4 m (13 ft)
above grade. Up to 4 m (13 ft) scaffolding may be used.
Filling and packaging equipment
1.
Adequate area shall be available close to the packaging line for buffer storage of
components with adequate access from supply routes.
2.
Sufficient area shall be available for pallets and storage/handling of finished product.
3.
Space shall be available for vehicles and fork lift truck access.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 62
6.6.18
Pig launchers and receivers
1.
Pig traps should be located at least 15 m (50 ft) from any type of equipment, other
than adjacent pig traps.
2.
Pig trap systems should be located adjacent to each other for ease of pigging
operations.
3.
Pig trap systems shall be fenced (either separately or as part of adjoining facilities)
a.
4.
6.6.19
Access shall be provided for light trucks and lifting cranes.
A pig trap shall not point towards hydrocarbon containing equipment, safety critical
equipment, buildings, or adjacent or adjoining roads to prevent these items from being
damaged by a pig which might be released in case of a pig trap door failure.
Special equipment
1.
For specialised items, the Manufacturer/Supplier shall be consulted on layout and
operation/maintenance aspects.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 63
7.
REFERENCES
In this DEP, reference is made to the following publications:
NOTES:
1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.
SHELL STANDARDS
DEP feedback form
DEP 00.00.05.80-Gen.
Definition of temperature, pressure and toxicity levels
DEP 01.00.01.30-Gen.
Human factors engineering – design and procurement of skidpackaged units
DEP 30.00.60.18-Gen.
Human factors engineering – workspace design
DEP 30.00.60.20-Gen.
Human factors engineering - valves
DEP 30.00.60.13-Gen.
Nitrogen / oxygen supply and distribution systems
DEP 30.05.10.30-Gen.
Pressurised bulk LPG storage installations at processing facilities
DEP 30.06.10.12-Gen.
LPG bulk road, rail and pipeline transportation
DEP 30.06.10.13-Gen.
Loading facilities for bulk road vehicles
DEP 31.06.11.11-Gen.
Noise control (amendments/supplements to ISO 15664)
DEP 31.10.00.31-Gen.
Unfired pressure vessels
DEP 31.22.00.31-Gen.
Hoisting facilities and weather protection for rotating equipment
DEP 31.25.00.10-Gen.
Piping – General requirements
DEP 31.38.01.11-Gen.
Instruments for measurement and control
DEP 32.31.00.32-Gen.
On-line process analysers
DEP 32.31.50.10-Gen.
Analyser housing
DEP 32.31.50.13-Gen.
Electrical engineering design
DEP 33.64.10.10-Gen.
Electrical engineering design for North American application
DEP 33.64.20.10-Gen.
Site preparation and earthworks including tank foundations and tank
farms
DEP 34.11.00.11-Gen.
Roads, paving, surfacing, cable trenches, slope protection and fencing
DEP 34.13.20.31-Gen.
Drainage systems and primary treatment facilities
DEP 34.14.20.31-Gen.
Design and engineering of buildings
DEP 34.17.00.32-Gen.
Design of blast resistant onshore buildings, control rooms and field
auxiliary rooms
DEP 34.17.10.30-Gen.
Portable blast resistant modules
DEP 34.17.10.33-Gen.
Siting of onshore occupied portable buildings
DEP 34.17.10.35-Gen.
Onshore steel structures
DEP 34.28.00.31-Gen.
Onshore ancillary steel structures
DEP 34.28.00.33-Gen.
Area classification (amendments/supplements to IP 15)
DEP 80.00.10.10-Gen.
Area classification and electrical equipment spacing for North
American application (amendments/supplements to API RP 505/
API RP 500)
DEP 80.00.10.13-Gen.
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40
DEP 80.00.10.11-Gen.
February 2016
Page 64
Design of pressure relief, flare and vent systems
(amendments/supplements to API RP 520 Part II and API STD 521
Chapter 5)
DEP 80.45.10.10-Gen.
Assessment and design of the fire safety of onshore installations
DEP 80.47.10.30-Gen.
Shell HSSE & SP Control Framework, Design Engineering Manual
(DEM) 1 – Application of Technical Standards Design Engineering
Manual (DEM) 1 - Application of Technical Standards
Design Engineering Manual (DEM) 1 - Application of Technical
Standards
DEM1
ALARP Guide, Shell Global Library, Dec 2013
SR.13.14005
Shell HSSE & SP Control Framework, Health Manual Control
Framework - Health Manual
Control Framework - Health Manual
Health Manual
Shell HSSE & SP Control Framework, Design Engineering Manual
(DEM) 2 – Process Safety Basic Requirements Design Engineering
Manual (DEM) 2 – Process Safety Basic Requirements
Design Engineering Manual (DEM) 2 – Process Safety Basic
Requirements
DEM2
AMERICAN STANDARDS
Design and construction of LPG installations
API STD 2510
Flammable and combustible liquids code
NFPA 30
INDUSTRY STANDARDS
Energy Institute Model Code of Safe Practice Part 2: Design,
construction and operation of petroleum distribution installations 4th
edition ISBN 978 0 85293 663 4
(formerly IP 2)
EI 2
Energy Institute Model Code of Safe Practice, Part 11: Bitumen safety
code 4th edition. ISBN: 978 0 85293 402 9
(formerly IP 11)
EI 11
Energy Institute Model Code of Safe Practice Part 19: Fire precautions
at petroleum refineries and bulk storage installation 3rd edition ISBN
978 0 85293 634 4
(formerly IP 19)
EI 19
This document has been supplied under license by Shell to:
UOP Honeywell ted.fuger@honeywell.com 19/01/2018 10:40:40