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THE GAZETTE OF INDIA: EXTRAORDINARY Part II – Sec. 3(I) - importance to planning and implementation of such activities as regards health. OISD-STD-118 Revision – II September 2004 FOR RESTRICTED CIRCULATION LAYOUTS FOR OIL AND GAS INSTALLATIONS Prepared by Committee on Layouts for Oil and Gas Installations OIL INDUSTRY SAFETY DIRECTORATE 7 TH FLOOR, NEW DELHI HOUSE 27, BARAKHAMBA ROAD NEW DELHI – 110 001.OISD-STD-118 Revision - IIFOR RESTRICTED CIRCULATION LAYOUTS FOR OIL AND GAS INSTALLATIONS OISD – STANDARD – 118 Revision – II, September 2004 Oil Industry Safety Directorate Government of India Ministry of Petroleum & Natural Gas OISD-STD-118 Revision – II September 2004 FOR RESTRICTED CIRCULATION LAYOUTS FOR OIL AND GAS INSTALLATIONS Prepared by Committee on Layouts for Oil and Gas Installations OIL INDUSTRY SAFETY DIRECTORATE 7TH FLOOR, NEW DELHI HOUSE 27, BARAKHAMBA ROAD NEW DELHI – 110 001 NOTE OISD Publications are prepared for the use in the Oil and Gas Industry under the Ministry of Petroleum & Natural Gas. (ii) . Though every effort has been made to assure the accuracy and reliability of the data contained in these documents. These are the property of Ministry of Petroleum & Natural Gas and shall not be reproduced or copied or loaned or exhibited to others without written consent from OISD. OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use. These documents are intended to supplement rather than replace the prevailing statutory requirements. Barakhamba Road New Delhi-110 001 (iii) . It is hoped that the provision of this document. coupled with feed back from some serious accidents that occurred in the recent past in India and abroad. operating and maintaining oil and gas installations. will go a long way in improving the safety in oil and gas industry. Oil Industry Safety Directorate (OISD) was established in 1986 staffed from within the industry in formulating and implementing a series of self regulatory measures aimed at removing obsolescence. This document will be reviewed periodically for improvements based on the experience and better understanding. With this in view. experience gained after the implementation of standards and relevant updation in the various national and international codes and practices. if implemented objectively.FOREWORD Oil Industry in India is over 100 years old. The original document on ’Layouts for Oil and Gas Installations’ was published in November 1988 and its first revision released in July 1995. emphasised the need for the industry to review the existing state-of-the-art in designing. As such variety of practices have been in vogue because of collaboration / association with different foreign companies and governments. In August 2000 it was amended inline with the recommendations of the High Power Committee. This. The present document on “Layouts for Oil and Gas Installation” is the second revision of this OISD Standard. Suggestions from industry members may be addressed to: The Coordinator Committee on Layouts for Oil and Gas Installation Oil Industry Safety Directorate 7th Floor. Standardization in design philosophies and operating & maintenance practices at national level was hardly in existence. Accordingly. standardising and upgrading the existing standards to ensure safer operations. Attempts have been made to incorporate the latest technological changes. New Delhi House 27. OISD constituted number of functional committees comprising experts nominated from the industry to draw up standards and guidelines on various subjects. COMMITTEES ON LAYOUTS FOR OIL AND GAS INSTALLATIONS First Edition – November 1988 Leader Shri R P Bhatia Members Shri K K Arora Shri S K Mukherjee Shri V K Raina Shri K Ravi Kumar Member Coordinator Shri B K Trehan Oil Industry Safety Directorate. New Delhi First Revision – July 1995 Leader Shri R P Bhatia / Shri M M Kapur (Feb 95 – July 95) Members Shri S K Mukherjee Shri K K Arora Shri V K Raina Shri S Pandarinathan Member Coordinator Shri B Sadhukhan / Oil Industry Safety Directorate. Shri S N Mathur (April 95 – July95) Hindustan Petroleum Corporation Ltd. Madras Refineries Limited. Bombay. Bombay. Madras. New Delhi Amended Edition – August 2000 Amendments were carried out to this standard based on the recommendation of High Power Committee set up in 1997 by the Ministry of Petroleum and Natural gas to review the standard with respect to land requirement inline with national and international standards. Oil and Natural Gas Corporation Ltd. (M).. Bombay. Bharat Petroleum Corporation Ltd. Bombay. Engineers India Limited.(R) Bombay Bharat Petroleum Corporation Ltd. Hindustan Petroleum Corporation Ltd. (iv) . Engineers India Limited. Madras Refineries Limited. Madras. (M).(R) Bombay Oil and Natural Gas Corporation Ltd. T. Shri Thomas Chacko. Shri S. Shri K.Banerjee Shri M. Shri D.Palnitkar. Rao. New Delhi BPCL. Shri A.Maji.Lokhande.D. (v) . NOIDA IOCL. Visakhapatnam. IOCL Pipelines Division. review and finalization of this document. New Delhi In addition to the above. several other experts from the industry contributed in the preparation.S. Panipat IOCL Refineries HQ. Panipat Refinery. Duliajan MEMBER-CO-ORDINATOR S K Aggarwal Oil Industry Safety Directorate.Shah Shri S. Shri Sunil Dewan. Mumbai Refinery.S. Shri H.COMMITTEES ON LAYOUTS FOR OIL AND GAS INSTALLATIONS Second Revision – Month /Year LEADER Shri Vinay Kumar MEMBERS GAIL (India) Limited. Kochi HPCL Visakh Refinery. Engineers India Limited. New Delhi Department of Explosives.P.G. Mumbai Kochi Refineries Limited. Nagpur BPCL.Buragohain. New Delhi Shri Arvind Kumar.K. NOIDA Oil India Limited. 0 6. Separation distances between Blocks / Facilities Separation distances between equipment within Process unit Inter-distances between Storage Tanks and Offsite facilities (Large installation) Separation distances between Storage Tanks and Offsite facilities (Small Installations) Separation distances between Storage Tanks within a Dyke Separation distances for LPG Facilities Separation distances between LPG Storage Vessels and Boundary / Property line / Group of Buildings not associated with LPG facilities (vi) . T4.0 4. T2. T7.0 5.0 8. T3.INDEX SECTION CONTENTS PAGE No.0 9. 1. T5.0 3.0 Introduction Scope Definitions Plant Layout Philosophy Layout of Blocks/Facilities Layout of Process Units Layout of Storage Tanks Layout of LPG Facilities References TABLES T1. T6.0 7.0 2. flare etc. The minimum distances recommended many years ago need review in the context of today’s environment in the industry. For these reasons. communication and alarm system. group of pressurized storage tanks. loading gantries. Tank farm for storage of crude / products. LPG. Propane.’ . transportation and distribution. treating or storing crude oil and includes central tank farm. c) Crude Oil Gathering Station: Crude oil gathering station / Group gathering station is a production installation used for gathering. Lube oil installations and other Petroleum storage installations such as Crude oil gathering stations. Today’s trend of large and complex plants present substantial risk potential. e) d) 3. group of tanks located in a dyke. Fire station A building housing facilities of parking fire tenders and keeping other ready to use fire-fighting equipment for meeting plant emergencies. structure. it may not be practicable to comply with. Examples are Butane. boiler house. At times plants are modified to operate at higher capacities or efficiencies necessitating larger storage requirements than contemplated earlier. a mixture of propane and butane also fall under the same category. LPG facilities. oil collecting station. jockey pumps. The requirement of green belt / buffer zone beyond the plant boundary is outside the scope of this standard. It is not intended that requirement of this standard should be applied rigidly to existing premises where. For example process unit. or other physical feature used in petroleum refining. gas compressor station and well head installation.0 SCOPE This document lays down minimum requirements of layouts within the plant boundary for petroleum refineries. instrumentation and the required operating & supporting personnel.0 INTRODUCTION Hydrocarbon processing and handling plants are inherently hazardous.0 a) DEFINITIONS Block Facilities operated / used in integrated way and surrounded by roads.OISD-STD-118 1 -------------------------------------------------------------------------------------------------------------------------------------- LAYOUTS FOR OIL AND GAS INSTALLATIONS 1. equipment. The hydrocarbon industry over the years learnt lessons from fires and explosions throughout the world and has been updating plant safety norms including inter-distances between facilities and their relative locations. Oil / Gas production and processing plants. 2. C4 and Lighter ends Hydrocarbons or a mixture of Hydrocarbons containing four or less than four carbon atoms. Such provisions should be considered based on local environmental / security requirements. f) Fire Water pump house A building housing fire water pumps. fire control room with required communication facilities/mimic panel. g) Flash Point ’Flash point’ of any petroleum liquid is the lowest temperature at which the liquid yields vapour in sufficient concentration to form an ignitable mixture with air and gives a momentary ’OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended Practices. Facility This refers to any building. pipeline. storage. installation. initial site analysis for the proposed new construction or addition should be done carefully while considering the space allocation to the various facilities. for a variety of reasons. Propylene etc. Aviation storage & fuelling stations. Pipeline installations / terminals. Marketing depots and terminals. May Indicates provisions that are optional.C is likely to be refined. blended or stored at above its flash point. stabilized and despatched for further processing. Lube Oil Installations The facilities for receipt.C or any flammable gas or vapor in a concentration capable of ignition is likely to be present. p) Petroleum Refinery Petroleum Refinery is a plant where crude oil is received and processed into intermediates and finished products. and may involve preparation. q) Process Unit A unit having integrated sequence of operation. Liquefied gases including LPG do not fall under this classification but form separate category. j) Hazardous Area An area will be deemed to be hazardous where. r) Protection for exposure This refers to fire protection for structures on property adjacent to liquid storage. For classification and extent of hazardous area. received / despatched by rail / road / pipeline and / or filled in cylinders. grease manufacturing plants.OISD-STD-118 2 -------------------------------------------------------------------------------------------------------------------------------------- flash on application of a small pilot flame under specified conditions of test as per IS: 1448 (Part-I). storage and blending of base oils & additives into finished Lube products. (i) Petroleum having flash point below 65 deg. intermediate pumping station / compressor station. s) Service building A building housing facilities for inspection / maintenance / other ’OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended Practices. or change in state. Note: In the following cases. above classification does not apply and special precautions should be taken as required: o) Pipeline Installations Pipeline Installations are the facilities on cross-country pipelines and include sectionalizing valve station. i) General Classification Of Petroleum Products Petroleum products are classified according to their closed cup FLASH POINTS as given below: l) — Class-A Petroleum: Liquids which have flash point below 23oC. (ii) Where product handled is artificially heated to a temperature above its flash point. refer ’The Petroleum Rules . (i) Where ambient temperatures or the handling temperatures are higher than the flash point of the product. tap-off station. It includes lubeblending plants. Drilling activities and facilities upstream of the Christmas Tree of a well are not covered under this definition. LPG. — — Class-C Petroleum: Liquids which have flash point of 65 oC and above but below 93 oC.2002’. Excluded Petroleum: Liquids which have flash point of 93 oC and above. condensate etc. Oil / Gas Production Plant Oil / Gas production plant is a plant where oil and/or gas is collected. h) k) LPG Facilities LPG facility is one where liquefied petroleum gas (LPG) is stored. m) n) — Class-B Petroleum: Liquids which have flash point of 23 oC and above but below 65 oC.’ . separation. physical and chemical. Gas Processing Plant Gas processing plant is a facility where natural gas is received and processed to separate gas. energy content or composition. (ii) Petroleum or any flammable liquid having flash point above 65 deg. pig launching / receiving station. dispatch and receiving facilities with or without storage. purification. g. gradient and turning radii at road junctions shall be designed to facilitate movement of the largest firefighting vehicle in the event of emergency. ’OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended Practices. Shall Indicates provisions that are mandatory. f) Road widths. For floating roof tanks. h) Layout of the facilities shall be made to minimise truck traffic ingress in the plant. workshop etc. and (d) company philosophy. it is the height from tank bottom to top of tank shell. Plant layout arrangement should follow the general route of raw material to process unit(s) with tankages interposed as required followed by storage & despatch facilities. (c) company experience. (b) company standards. fired equipment etc should be located in such an area so to facilitate erection. g) Rail spur shall be located close to the periphery of the plant to minimise road/pipe crossings and blockage of roads during shunting. x) Tank height Tank height is the height from tank bottom to top kerb angle for cone roof tanks. d) e) Pedestrian pathways should be provided / marked alongside the primary traffic roads. n) For construction activities. The entire area should be sub-divided into blocks. reactors. 4. as appropriate: (a) risk / benefit analysis. Towers. furnaces & Block layout should be adopted as far as possible. heaters. warehouse. y) Tank vehicle loading / unloading Facility for loading / unloading of petroleum product to / from tank wagon or tank truck. Presence of ignition source shall always be contemplated beyond the boundary wall of the installation. Roads separating the blocks shall act as firebreaks. Both these approaches should be available for receipt of assistance in emergency. j) k) Orientation of flares. Implementation of these provisions shall be made based upon consideration of the followings.0 PLANT LAYOUT PHILOSOPHY Following philosophy should be adopted in layout of an installation. Alternative access shall be provided for each facility so that it can be approached for fire fighting in the event of blockage on one route. All process units and dyked enclosures of storage tanks shall be planned in separate blocks with roads all around for access and safety.OISD-STD-118 3 -------------------------------------------------------------------------------------------------------------------------------------- supporting services which are directly required for operation of the plant e. Erection methods shall be studied for all types of equipment / structures. dusty operations (e. i) t) u) Should Indicates provisions that are recommended but not mandatory. Primary traffic roads in the installation should be outside hazardous areas.g. area should be earmarked. l) b) c) m) Maintenance requirements for each type of equipment shall be identified and considered. v) Stabling Line It is an additional railway line / spur reserved for additional rake / stabling.’ . sulphur handling etc) and cooling towers should be decided based on prevailing wind direction to avoid travel of hydrocarbon vapour over sources of ignition. a) Two road approaches from the highway / major road should be provided. w) Storage / filling shed Facility for storage and filling of packed (non-bulk) petroleum product. one for employees and other for product / material movement. Chemical / Toxic chemicals storage. fire station and fire training ground . the following should be considered: (a) Layout of Blocks / facilities should be in sequential order of process flow. as applicable. information should be collected on the following aspects. refer OISD-STD-163. (i) Low Tension (LT) sub-station should be located at load centers in such a way that the distance between distribution transformer and farthest motor is minimum.Risk to and from adjacent facilities .Statutory obligations 5. hazardous waste storage / disposal. For details. (f) Power generation facilities which also supply steam for process requirement should be located near the process unit block. . storage tanks. Horizontal clearance shall be in line with the Indian Electricity Rules. then it may be considered as a single block. tank farm. loading space provision be made accordingly. It shall not be located on a lower level than surrounding plants and tank farms. petroleum wax. storage areas for solid products such as petroleum coke. (h) High Tension (HT) sub-station(s) should be located close to major load centers. . (d) Control room should be located in a non-hazardous area upwind of process plants / hydrocarbon storage and handling facilities. (e) Utility block(s) should preferably be located adjacent to unit blocks.) for installations in coastal areas. utilities. To prepare a layout. natural streams/ canals . water table.Service buildings.Site topography including elevation. bitumen / asphalt etc and other open storage areas like scrap yards and dumping ground . 5. road and pipeline) . LPG storage vessels and other pressurized storage vessels . Effluent Treatment Plant (ETP) and approach roads should be located on high ground to avoid flooding. utility requirements. sulfur. solid storage. In undulating areas.OISD-STD-118 4 -------------------------------------------------------------------------------------------------------------------------------------o) Future expansion should be assessed and (b) Process unit(s). and drainage . surge wave height etc. (g) Overhead power transmission lines shall not pass over the installation including the parking areas. Cooling Towers should be located downwind of process equipment and substation so that fog developed will not cause corrosion or obstr
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THE GAZETTE OF INDIA: EXTRAORDINARY Part II – Sec. 3(I) - importance to planning and implementation of such activities as regards health. OISD-STD-118 Revision – II September 2004 FOR RESTRICTED CIRCULATION LAYOUTS FOR OIL AND GAS INSTALLATIONS Prepared by Committee on Layouts for Oil and Gas Installations OIL INDUSTRY SAFETY DIRECTORATE 7 TH FLOOR, NEW DELHI HOUSE 27, BARAKHAMBA ROAD NEW DELHI – 110 001.OISD-STD-118 Revision - IIFOR RESTRICTED CIRCULATION LAYOUTS FOR OIL AND GAS INSTALLATIONS OISD – STANDARD – 118 Revision – II, September 2004 Oil Industry Safety Directorate Government of India Ministry of Petroleum & Natural Gas OISD-STD-118 Revision – II September 2004 FOR RESTRICTED CIRCULATION LAYOUTS FOR OIL AND GAS INSTALLATIONS Prepared by Committee on Layouts for Oil and Gas Installations OIL INDUSTRY SAFETY DIRECTORATE 7TH FLOOR, NEW DELHI HOUSE 27, BARAKHAMBA ROAD NEW DELHI – 110 001 NOTE OISD Publications are prepared for the use in the Oil and Gas Industry under the Ministry of Petroleum & Natural Gas. (ii) . Though every effort has been made to assure the accuracy and reliability of the data contained in these documents. These are the property of Ministry of Petroleum & Natural Gas and shall not be reproduced or copied or loaned or exhibited to others without written consent from OISD. OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use. These documents are intended to supplement rather than replace the prevailing statutory requirements. Barakhamba Road New Delhi-110 001 (iii) . It is hoped that the provision of this document. coupled with feed back from some serious accidents that occurred in the recent past in India and abroad. operating and maintaining oil and gas installations. will go a long way in improving the safety in oil and gas industry. Oil Industry Safety Directorate (OISD) was established in 1986 staffed from within the industry in formulating and implementing a series of self regulatory measures aimed at removing obsolescence. This document will be reviewed periodically for improvements based on the experience and better understanding. With this in view. experience gained after the implementation of standards and relevant updation in the various national and international codes and practices. if implemented objectively.FOREWORD Oil Industry in India is over 100 years old. The original document on ’Layouts for Oil and Gas Installations’ was published in November 1988 and its first revision released in July 1995. emphasised the need for the industry to review the existing state-of-the-art in designing. As such variety of practices have been in vogue because of collaboration / association with different foreign companies and governments. In August 2000 it was amended inline with the recommendations of the High Power Committee. This. The present document on “Layouts for Oil and Gas Installation” is the second revision of this OISD Standard. Suggestions from industry members may be addressed to: The Coordinator Committee on Layouts for Oil and Gas Installation Oil Industry Safety Directorate 7th Floor. Standardization in design philosophies and operating & maintenance practices at national level was hardly in existence. Accordingly. standardising and upgrading the existing standards to ensure safer operations. Attempts have been made to incorporate the latest technological changes. New Delhi House 27. OISD constituted number of functional committees comprising experts nominated from the industry to draw up standards and guidelines on various subjects. COMMITTEES ON LAYOUTS FOR OIL AND GAS INSTALLATIONS First Edition – November 1988 Leader Shri R P Bhatia Members Shri K K Arora Shri S K Mukherjee Shri V K Raina Shri K Ravi Kumar Member Coordinator Shri B K Trehan Oil Industry Safety Directorate. New Delhi First Revision – July 1995 Leader Shri R P Bhatia / Shri M M Kapur (Feb 95 – July 95) Members Shri S K Mukherjee Shri K K Arora Shri V K Raina Shri S Pandarinathan Member Coordinator Shri B Sadhukhan / Oil Industry Safety Directorate. Shri S N Mathur (April 95 – July95) Hindustan Petroleum Corporation Ltd. Madras Refineries Limited. Bombay. Bombay. Madras. New Delhi Amended Edition – August 2000 Amendments were carried out to this standard based on the recommendation of High Power Committee set up in 1997 by the Ministry of Petroleum and Natural gas to review the standard with respect to land requirement inline with national and international standards. Oil and Natural Gas Corporation Ltd. (M).. Bombay. Bharat Petroleum Corporation Ltd. Bombay. Engineers India Limited.(R) Bombay Bharat Petroleum Corporation Ltd. Hindustan Petroleum Corporation Ltd. (iv) . Engineers India Limited. Madras Refineries Limited. Madras. (M).(R) Bombay Oil and Natural Gas Corporation Ltd. T. Shri Thomas Chacko. Shri S. Shri K.Banerjee Shri M. Shri D.Palnitkar. Rao. New Delhi BPCL. Shri A.Maji.Lokhande.D. (v) . NOIDA IOCL. Visakhapatnam. IOCL Pipelines Division. review and finalization of this document. New Delhi In addition to the above. several other experts from the industry contributed in the preparation.S. Panipat IOCL Refineries HQ. Panipat Refinery. Duliajan MEMBER-CO-ORDINATOR S K Aggarwal Oil Industry Safety Directorate.Shah Shri S. Shri Sunil Dewan. Mumbai Refinery.S. Shri H.COMMITTEES ON LAYOUTS FOR OIL AND GAS INSTALLATIONS Second Revision – Month /Year LEADER Shri Vinay Kumar MEMBERS GAIL (India) Limited. Kochi HPCL Visakh Refinery. Engineers India Limited. New Delhi Department of Explosives.P.G. Mumbai Kochi Refineries Limited. Nagpur BPCL.Buragohain. New Delhi Shri Arvind Kumar.K. NOIDA Oil India Limited. 0 6. Separation distances between Blocks / Facilities Separation distances between equipment within Process unit Inter-distances between Storage Tanks and Offsite facilities (Large installation) Separation distances between Storage Tanks and Offsite facilities (Small Installations) Separation distances between Storage Tanks within a Dyke Separation distances for LPG Facilities Separation distances between LPG Storage Vessels and Boundary / Property line / Group of Buildings not associated with LPG facilities (vi) . T4.0 4. T2. T7.0 5.0 8. T3.INDEX SECTION CONTENTS PAGE No.0 9. 1. T5.0 3.0 Introduction Scope Definitions Plant Layout Philosophy Layout of Blocks/Facilities Layout of Process Units Layout of Storage Tanks Layout of LPG Facilities References TABLES T1. T6.0 7.0 2. flare etc. The minimum distances recommended many years ago need review in the context of today’s environment in the industry. For these reasons. communication and alarm system. group of pressurized storage tanks. loading gantries. Tank farm for storage of crude / products. LPG. Propane.’ . transportation and distribution. treating or storing crude oil and includes central tank farm. c) Crude Oil Gathering Station: Crude oil gathering station / Group gathering station is a production installation used for gathering. Lube oil installations and other Petroleum storage installations such as Crude oil gathering stations. Today’s trend of large and complex plants present substantial risk potential. e) d) 3. group of tanks located in a dyke. Fire station A building housing facilities of parking fire tenders and keeping other ready to use fire-fighting equipment for meeting plant emergencies. structure. it may not be practicable to comply with. Examples are Butane. boiler house. At times plants are modified to operate at higher capacities or efficiencies necessitating larger storage requirements than contemplated earlier. a mixture of propane and butane also fall under the same category. LPG facilities. oil collecting station. jockey pumps. The requirement of green belt / buffer zone beyond the plant boundary is outside the scope of this standard. It is not intended that requirement of this standard should be applied rigidly to existing premises where. For example process unit. or other physical feature used in petroleum refining. gas compressor station and well head installation.0 SCOPE This document lays down minimum requirements of layouts within the plant boundary for petroleum refineries. instrumentation and the required operating & supporting personnel.0 INTRODUCTION Hydrocarbon processing and handling plants are inherently hazardous.0 a) DEFINITIONS Block Facilities operated / used in integrated way and surrounded by roads.OISD-STD-118 1 -------------------------------------------------------------------------------------------------------------------------------------- LAYOUTS FOR OIL AND GAS INSTALLATIONS 1. equipment. The hydrocarbon industry over the years learnt lessons from fires and explosions throughout the world and has been updating plant safety norms including inter-distances between facilities and their relative locations. Oil / Gas production and processing plants. 2. C4 and Lighter ends Hydrocarbons or a mixture of Hydrocarbons containing four or less than four carbon atoms. Such provisions should be considered based on local environmental / security requirements. f) Fire Water pump house A building housing fire water pumps. fire control room with required communication facilities/mimic panel. g) Flash Point ’Flash point’ of any petroleum liquid is the lowest temperature at which the liquid yields vapour in sufficient concentration to form an ignitable mixture with air and gives a momentary ’OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended Practices. Facility This refers to any building. pipeline. storage. installation. initial site analysis for the proposed new construction or addition should be done carefully while considering the space allocation to the various facilities. for a variety of reasons. Propylene etc. Aviation storage & fuelling stations. Pipeline installations / terminals. Marketing depots and terminals. May Indicates provisions that are optional.C is likely to be refined. blended or stored at above its flash point. stabilized and despatched for further processing. Lube Oil Installations The facilities for receipt.C or any flammable gas or vapor in a concentration capable of ignition is likely to be present. p) Petroleum Refinery Petroleum Refinery is a plant where crude oil is received and processed into intermediates and finished products. and may involve preparation. q) Process Unit A unit having integrated sequence of operation. Liquefied gases including LPG do not fall under this classification but form separate category. j) Hazardous Area An area will be deemed to be hazardous where. r) Protection for exposure This refers to fire protection for structures on property adjacent to liquid storage. For classification and extent of hazardous area. received / despatched by rail / road / pipeline and / or filled in cylinders. grease manufacturing plants.OISD-STD-118 2 -------------------------------------------------------------------------------------------------------------------------------------- flash on application of a small pilot flame under specified conditions of test as per IS: 1448 (Part-I). storage and blending of base oils & additives into finished Lube products. (i) Petroleum having flash point below 65 deg. intermediate pumping station / compressor station. s) Service building A building housing facilities for inspection / maintenance / other ’OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended Practices. or change in state. Note: In the following cases. above classification does not apply and special precautions should be taken as required: o) Pipeline Installations Pipeline Installations are the facilities on cross-country pipelines and include sectionalizing valve station. i) General Classification Of Petroleum Products Petroleum products are classified according to their closed cup FLASH POINTS as given below: l) — Class-A Petroleum: Liquids which have flash point below 23oC. (ii) Where product handled is artificially heated to a temperature above its flash point. refer ’The Petroleum Rules . (i) Where ambient temperatures or the handling temperatures are higher than the flash point of the product. tap-off station. It includes lubeblending plants. Drilling activities and facilities upstream of the Christmas Tree of a well are not covered under this definition. LPG. — — Class-C Petroleum: Liquids which have flash point of 65 oC and above but below 93 oC.2002’. Excluded Petroleum: Liquids which have flash point of 93 oC and above. condensate etc. Oil / Gas Production Plant Oil / Gas production plant is a plant where oil and/or gas is collected. h) k) LPG Facilities LPG facility is one where liquefied petroleum gas (LPG) is stored. m) n) — Class-B Petroleum: Liquids which have flash point of 23 oC and above but below 65 oC.’ . separation. physical and chemical. Gas Processing Plant Gas processing plant is a facility where natural gas is received and processed to separate gas. energy content or composition. (ii) Petroleum or any flammable liquid having flash point above 65 deg. pig launching / receiving station. dispatch and receiving facilities with or without storage. purification. g. gradient and turning radii at road junctions shall be designed to facilitate movement of the largest firefighting vehicle in the event of emergency. ’OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended Practices. Shall Indicates provisions that are mandatory. f) Road widths. For floating roof tanks. h) Layout of the facilities shall be made to minimise truck traffic ingress in the plant. workshop etc. and (d) company philosophy. it is the height from tank bottom to top of tank shell. Plant layout arrangement should follow the general route of raw material to process unit(s) with tankages interposed as required followed by storage & despatch facilities. (c) company experience. (b) company standards. fired equipment etc should be located in such an area so to facilitate erection. g) Rail spur shall be located close to the periphery of the plant to minimise road/pipe crossings and blockage of roads during shunting. x) Tank height Tank height is the height from tank bottom to top kerb angle for cone roof tanks. d) e) Pedestrian pathways should be provided / marked alongside the primary traffic roads. n) For construction activities. The entire area should be sub-divided into blocks. reactors. 4. as appropriate: (a) risk / benefit analysis. Towers. furnaces & Block layout should be adopted as far as possible. heaters. warehouse. y) Tank vehicle loading / unloading Facility for loading / unloading of petroleum product to / from tank wagon or tank truck. Presence of ignition source shall always be contemplated beyond the boundary wall of the installation. Roads separating the blocks shall act as firebreaks. Both these approaches should be available for receipt of assistance in emergency. j) k) Orientation of flares. Implementation of these provisions shall be made based upon consideration of the followings.0 PLANT LAYOUT PHILOSOPHY Following philosophy should be adopted in layout of an installation. Alternative access shall be provided for each facility so that it can be approached for fire fighting in the event of blockage on one route. All process units and dyked enclosures of storage tanks shall be planned in separate blocks with roads all around for access and safety.OISD-STD-118 3 -------------------------------------------------------------------------------------------------------------------------------------- supporting services which are directly required for operation of the plant e. Erection methods shall be studied for all types of equipment / structures. dusty operations (e. i) t) u) Should Indicates provisions that are recommended but not mandatory. Primary traffic roads in the installation should be outside hazardous areas.g. area should be earmarked. l) b) c) m) Maintenance requirements for each type of equipment shall be identified and considered. v) Stabling Line It is an additional railway line / spur reserved for additional rake / stabling.’ . sulphur handling etc) and cooling towers should be decided based on prevailing wind direction to avoid travel of hydrocarbon vapour over sources of ignition. a) Two road approaches from the highway / major road should be provided. w) Storage / filling shed Facility for storage and filling of packed (non-bulk) petroleum product. one for employees and other for product / material movement. Chemical / Toxic chemicals storage. fire station and fire training ground . the following should be considered: (a) Layout of Blocks / facilities should be in sequential order of process flow. as applicable. information should be collected on the following aspects. refer OISD-STD-163. (i) Low Tension (LT) sub-station should be located at load centers in such a way that the distance between distribution transformer and farthest motor is minimum.Risk to and from adjacent facilities .Statutory obligations 5. hazardous waste storage / disposal. For details. (f) Power generation facilities which also supply steam for process requirement should be located near the process unit block. . storage tanks. Horizontal clearance shall be in line with the Indian Electricity Rules. then it may be considered as a single block. tank farm. loading space provision be made accordingly. It shall not be located on a lower level than surrounding plants and tank farms. petroleum wax. storage areas for solid products such as petroleum coke. (h) High Tension (HT) sub-station(s) should be located close to major load centers. . (d) Control room should be located in a non-hazardous area upwind of process plants / hydrocarbon storage and handling facilities. (e) Utility block(s) should preferably be located adjacent to unit blocks.) for installations in coastal areas. utilities. To prepare a layout. natural streams/ canals . water table.Service buildings.Site topography including elevation. bitumen / asphalt etc and other open storage areas like scrap yards and dumping ground . 5. road and pipeline) . LPG storage vessels and other pressurized storage vessels . Effluent Treatment Plant (ETP) and approach roads should be located on high ground to avoid flooding. utility requirements. sulfur. solid storage. In undulating areas.OISD-STD-118 4 -------------------------------------------------------------------------------------------------------------------------------------o) Future expansion should be assessed and (b) Process unit(s). and drainage . surge wave height etc. (g) Overhead power transmission lines shall not pass over the installation including the parking areas. Cooling Towers should be located downwind of process equipment and substation so that fog developed will not cause corrosion or obstr
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