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CT-EPC/017/SH/EPM/RPC-X/2023

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GENERAL SPECIFICATION - LAYOUT AND PIPING DESIGN CRITERIA

3 2 1 0

17/02/2025 3/12/2024 20/10/2024 20/09/2024

IFF – Issue for Final IFF – Issue for Final IOC – Implementation of Comments IFA - Issued for Approval

A. Antognozzi A. Antognozzi A. Antognozzi A. Antognozzi

S. Milind S. Milind S. Milind S. Milind

G. Acerbi G. Acerbi G. Acerbi G. Acerbi

Issue

Date

Reason for Issue – Revision Description

Prepared

Checked

Approved

This document is Tecnimont’s/Sonatrach’s property and cannot be used by others for any purpose, without prior written consent

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Contents

1

INTRODUCTION … 4

1.1 Reference Documents … 4

1.1.1

1.1.2

CA/COMPANY documents … 4

CONTRACTOR documents… 4

1.2 Order of precedence… 4

2

PROJECT DESCRIPTION … 6

2.1

Abbreviations … 8

2.2 Definitions … 9

3 UNITS SYSTEM … 9

4

REFERENCE DOCUMENTS … 10

ALGERIAN STATUTES & REGULATIONS. … 10

API STANDARDS (AMERICAN PETROLEUM INSTITUTE). … 11

ASME STANDARDS (AMERICAN SOCIETY FOR MECHANICAL ENGINEERS). … 11

ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS). … 12

ANSI STANDARS (AMERICAN NATIONAL STANDARS INSTITUTE) … 12

MANUFACTURES STANDARIZATION SOCIETY OF THE VALVES AND FITTINGS INDUSTRY (MSS) … 13

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) … 13

NORME EUROPEENNE (EN) … 13

5 BASIC DOCUMENTS FOR THE DETAIL DESIGN OF PIPING … 13

5.1

5.2

5.3

5.4

5.5

5.6

Equipment layout … 13

Piping and Instrumentation Diagram (P&IDs) … 13

Line Lists … 14

Piping Classes … 14

Piping Isometrics … 14

Piping Assembly Drawings … 14

5.7 MTOs … 14

5.8

3D Model … 14

6 PIPING DESIGN ARRANGEMENT CRITERIA … 15

6.1 General … 15

6.2 Road and access clearance … 16

6.3

PLATFORMS, WALKWAYS, LADDER AND STAIRS … 16

6.4 MAINTENANCE … 19

6.5

PLANT OPERATION … 23

6.6 MISCELLANEOUS … 25

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6.7 OFFSITE PIPING … 26

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1

INTRODUCTION

This specification constitutes the general requirements, guides, rules, and methods to be used during piping design

and plant layout for the Linear-Alkyl-Benzene (LAB) detail Engineering project. All these criteria defined in this

specification are general but not mandatory; applicable codes and good engineering practice and judgment shall

prevail when related to specific systems.

1.1

Reference Documents

In case of conflicts between two or more reference documents, the priority defined by contract shall apply.

1.1.1 CA/COMPANY documents

1CD1673A-8230-PH-0000-0001

PLOT PLAN PHILOSOPHY

1CD1673A-8230-SP-0000-50A1

PIPING GENERAL SPECIFICATION

1.1.2 CONTRACTOR documents

4439-XH-SL-000000001

PIPING MATERIAL SPECIFICATION

4439-XH-SG-000000008

PIPING FABRICATION AND ERECTION GENERAL SPECIFICATION

4439-SZ-SG-000000001

HSE GENERAL SPECIFICATION

4439-AR-SG-000000001

PROJECT SPECIFICATION FOR ROADS AND PAVING

4439-XH-SG-000000005

STRESS ANALYSIS GENERAL SPECIFICATION

4439-AI-DX-000000003

STEEL STANDARD DWG

4439-AI-DX-000000005

STEEL STANDARD DWG

1.2 Order of precedence

The EPC project shall be carried out based on the contract documents and fulfilling the requirements of any

applicable Local Standards and Regulations.

The order of precedence to adopt for the development of the Detail Design shall strictly follow the below sequence,

in a top-down order, applied to both the relevant contractual documents and the regulatory references:

1. The Contract body (the so-called Terms&Conditions) and all its annexes from Annex I to Annex XXIII,

2. Local Regulations (for sake of clarity: the Algerian Law),

3. Applicable nationals and international norms, codes and standards (last edition).

REMARKS:

a) Annex I prevails over all other Annexes;

b) Within Annex I, the order of precedence is CEOT > DAO > Licensor / FEED documents. Within the CEOT

and DAO, the higher number prevails upon the lower number (chronological order from the latest to the

earliest);

c)

In case of conflict within the documents found at the same level of precedence, the most stringent

requirement prevails.

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d) For subjects not covered by regulations, codes, standards and specifications, the design, material,

fabrication, and installation shall be based on good economical engineering practice.

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2

PROJECT DESCRIPTION

In order to fulfil its domestic needs in Linear-Alkyl-Benzene (LAB) used for the production of detergents and

possibly export the excess to the international market, Sonatrach plans to build a new LAB production complex in

Skikda (Algeria). The new complex will produce 100,000 tons of LAB per year and will be installed in the existing

industrial zone of Skikda. Skikda is a coastal town located 350 km east of Algeri, Algeria.

Field Location and Overall Layout

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The LAB project includes the following installations located on four different sites:

➢ New LAB complex (DEV1 area):

The new LAB complex includes the following three process units for the production of N- Paraffins:

✓ ✓ ✓

(U-100) Prefractionation of Kerosene feedstock, (U-200) Kerosene Hydrotreating to remove sulfur, nitrogen and aromatics contaminants, (U-300) Molex unit to extract N-paraffins through adsorption.

LAB is then produced from N-Paraffins in the following four units:

✓ ✓ ✓ ✓

(U-400) Pacol unit carrying out the dehydrogenation of n-paraffins to n-olefins, (U-500) Define unit carrying out the selective hydrogenation of di-olefins to n-olefins, (U-600) PEP unit removing the aromatics from the Pacol outlet stream, (U-700) Detal-Plus unit making alkylation of benzene with linear olefins to produce linear-alkyl- benzene LAB and separating the HAB by-product.

(U 805) – Power Plant

Utilities units consists of the following: ✓ ✓ U (810)- Natural Gas and Fuel Gas ✓ U (820) – Plant and Instrument Air ✓ U (830) - Nitrogen ✓ U 835 – Hydrogen Production Unit ✓ U 840 – Industrial Water ✓ U 850 – Demineralized Water system ✓ U 860 – BFW, steam and condensate ✓ U 870 – Cooling Water system ✓ U 880 – Potable Water system ✓ U 890 – Hot Oil system

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Offsites units consists of the following:

✓ U 910 – Feedstock Kerosene and Benzene storage ✓ U 920 – Intermediate and recycled products storage ✓ U 930 – Final product storage ✓ U 950 – Flare system ✓ U 960 – Closed Drainage system ✓ U 965 – Sour Water treatment system ✓ U 970 – Waste Water system ✓ U 980 – Fire Water system ✓ Chemicals storage facilities

➢ Skikda refinery RA1K:

The project includes all the necessary facilities:

✓ To export from the RA1K refinery, Kerosene and Benzene to the new LAB complex,

✓ To receive the by-products generated by the LAB complex.

➢ Skikda industrial area (DRIK):

The project covers the interconnecting lines for raw materials, by-products, finished LAB product to the port and

utilities.

➢ Port of Skikda:

The project includes all the facilities necessary to load finished LAB product on ships.

2.1

Abbreviations

ARH

ANSI

API

ASTM

CA

CEOT

CTC

DAO

EDD

EIE

EN

EPC

FEED

IEC

ISO

LAB

Autorité de régulation des hydrocarbures

American National Standards Institute

American Petroleum Institute

American Society for Testing and Materials

Contracting Authority (SONATRACH)

Commission d’Evaluation des Offres Techniques

Contrôle Technique de la Construction (Algerian Authority)

Dossier d’Appel d’Offres

Etude de Dangers

Etude d’Impact sur l’Environnement

European norms

Engineering, Procurement and Construction

Front End Engineering Design Development

International Électrotechnique Committee

International Standards Organization

Linear-Alkyl-Benzene

LP Steam

Low Pressure Steam

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MP Steam

Medium Pressure Steam

NFPA

N.A.

TCM

2.2

Definitions

National Fire Protection Association

Not Available

Tecnimont S.p.A., engineering company located in Milan (Italy) and performing activities

of Engineering Procurement and Construction for the PROJECT;

CA / COMPANY / Maitre de l’Ouvrage

SONATRACH DC-EPM

CONTRACTOR / Entrepreneur

TECNIMONT SPA

TECHNOLOGY LICENSOR

HONEYWELL UOP

PROJECT

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE

LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

3 UNITS SYSTEM

Unless otherwise stated, the International System of Units shall be used, except for nominal diameters of pipe

and fittings, which shall be expressed in inches.

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4

REFERENCE DOCUMENTS

In case of conflicts between two or more reference documents priority defined in paragraph 1.2 shall apply.

ALGERIAN STATUTES & REGULATIONS.

•

•

•

•

•

•

•

•

•

•

•

•

•

Executive Decree No. 21-261 of 13 June 2021 Regulation of pressure equipment (ESP) and

electrical equipment intended to be integrated into installations in the hydrocarbon sector.

Executive Decree No. 21-315 of 14 August 2021 Requirements for the design, manufacture,

construction and operation of pipelines and storage facilities for hydrocarbons and petroleum

products.

Executive Decree No. 21-256 of 13 June 2021 Operating procedures of the system of equalization

of transport tariffs for petroleum products and the rules for the use of storage infrastructure petroleum

products.

Executive Decree No. 21-319 of 14 August 2021 Operating authorization scheme specific to

hydrocarbon activities facilities and works as well as the terms of approval of risk studies relating to

research activities and their content.

Executive Decree No. 21-257 of 13 June 2021 Terms and procedure for authorizing the production

and energization of installations and structures relating to hydrocarbon activities.

Executive Decree No. 21-331 of 25 August 2021 Conditions for bringing into compliance installations

and equipment relating to hydrocarbon activities carried out previously.

RNV-2013 Snow and Wind Regulations.

”Décret exécutif n° 21-261 du 13 juin 2021 Réglementation des équipements sous pression (ESP)

et des équipements électriques destinés à être intégrés aux installations relevant du secteur des

hydrocarbures.

Décret exécutif n° 21-315 du 14 août 2021 Exigences auxquelles doivent répondre la conception,

la fabrication, la construction et l’exploitation des canalisations et des installations de stockage des

hydrocarbures et des produits pétroliers.

Décret exécutif n° 21-256 du 13 juin 2021 Modalités de fonctionnement du système de péréquation

des tarifs de transport des produits pétroliers et les règles d’utilisation des infrastructures de

stockage des produits pétroliers.

Décret exécutif n° 21-257 du 13 juin 2021 Modalités et la procédure d’autorisation de mise en produit

et de mise sous tension des installations et ouvrages relevant des activités d’hydrocarbures.

Décret exécutif n° 21-319 du 14 août 2021 Régime d’autorisation d’exploitation spécifique aux

installations et ouvrages des activités d’hydrocarbures ainsi que les modalités d’approbation des

études de risques relatives aux activités de recherche et leur contenu.

Décret exécutif n° 21-331 du 25 août 2021 Conditions de mise en conformité des installations et équipements relevant des activités hydrocarbures réalisées antérieurement.

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API STANDARDS (AMERICAN PETROLEUM INSTITUTE).

API RP 520

Sizing, Selection, and Installation of Pressure Relieving Devices in Refineries.

API RP 521

Guide for Pressure Relieving and Depressurizing System.

API 6D

API 594

API 598

API 600

API 601

API 602

API 604

API 607

API 609

API 6FA

API 610

Specification for tube line valves (gate, plug, ball and check valves).

Check valves, wafer, wafer-lug and double flanged type.

Valve inspection test.

Steel gate valves, flanged and B.W. ends, bolted and pressure seal bonnets.

Metallic gasket for refinery piping.

Compact Carbon steel gate valves.

Ductile iron gate valves.

Fire test for soft seated quarter – turn valves.

Butterfly valves, lug - type and wafer - type.

Fire test for valves.

Centrifugal Pumps for Petroleum, Petrochemical industries.

ASME STANDARDS (AMERICAN SOCIETY FOR MECHANICAL ENGINEERS).

ASME Boiler and Pressure Vessel Code, Section II Part C, Section V and IX Latest edition and all Mandatory

addenda.

ASME B31.3

Process Piping.

ASME B1.1

Unified Screw Threads

ASME B1.20.1 Pipe Threads, General Purpose (NPT).

ASME B2.1

Pipe Threads.

ASME B16.9

Factory Made wrought Steel Butt – Welding Fittings.

ASME B16.10

Face to Face and End Dimensions of Valves.

ASME B16.11

Forged Steel Fittings, Socket-Welding and Threaded.

ASME B16.20 Ring – joint Gaskets and Grooves for Steel Pipe Flanges.

ASME B16.21 Nonmetallic gaskets for pipe flanges.

ASME B16.5

Steel Pipe Flanges and Flanged Fittings.

ASME B16.25 But Welding Ends

ASME B16.36 Orifice Flanges

ASME B16.47

Large Diameter Steel Flanges.

ASME B36.19 Stainless Steel Pipe

ASME B31.8

Gas Transmission and Distribution Piping Systems

ASME B36.10M Welded and Seamless Wrought Steel Pipe.

ASME B31.1

Power Piping.

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ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS).

ASTM A193

Alloy Steel and Stainless-Steel Bolting Material for High Temperature Service.

ASTM A194

Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High -Temperature Service.

ASTM A370

Standard test Methods and Definitions for Mechanical Testing of Steel Products.

ASTM C1029

Specification for spray-applied rigid cellular polyurethane thermal insulation.

ASTM C165

Test method for measuring compressive properties of thermal insulation.

ASTM C795

Specification for wicking-type thermal insulation of use over austenitic stainless steel.

ASTM C585

Practice for inner and outer diameters of rigid thermal insulation for nominal sizes of pipe and tubing.

ANSI STANDARS (AMERICAN NATIONAL STANDARS INSTITUTE)

ANSI B 1.1

Unified Inch Screw Treads (UN &UNR Tread Form).

ANSI B1.20.1

Pipe Threads, General Purpose.

ANSI B2.1

Pipe Threads (for pipe, fittings, flanges and valves.

ANSI B16.5

Steel pipe flanges and flanged fittings, including rating for class 150, 300, 400, 600, 900, 1500, and 2500.

ANSI B16.1

Cast Iron pipe Flanges and Flanged Fittings.

ANSI B16.9

Steel butt welding fitting.

ANSI B16.10

Face to face and end to end dimensions of valves.

ANSI B16.11

Forged Fittings.

ANSI B16.20

Ring Type Joint Gaskets and grooves for steel pipe flanges.

ANSI B16.21

Non-metallic gaskets and grooves for steel pipe flanges.

ANSI B16.25

Butt welding ends for pipe, valves, flanged &fittings.

ANSI B16.34

Valves, flanged, threaded & welding ends.

ANSI B16.42

Ductile iron flanges & flanged fittings.

ANSI B18.2

Hexagonal bolts and nuts.

ANSI B31.1

Power Piping.

ANSI B31.3

Chemical Plant and petroleum refinery piping.

ANSI B31.4

Code of Liquid petroleum transportation piping systems.

ANSI B31.8

Code of gas transportation piping Systems.

ANSI B36.10M Welded and seamless wrought steel pipe.

ANSI B36.19M Stainless steel pipe.

ANSI B46.1

Surface texture (surface roughness, waviness and lay).

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MANUFACTURES STANDARIZATION SOCIETY OF THE VALVES AND FITTINGS INDUSTRY (MSS)

MSSSP- 6

Standard Finishes for Contact Faces of Tube Flanges &Connecting – End Flanges of Valves & Fittings.

MSSSP- 25

Standard Marking System for Valves, Fittings, Flanges & Unions.

MSSSP- 42

Class 150 Corrosion Resistant Gate, Globe, Angle and Check Valves with Flanged and Butt Weld Ends.

MSSSP- 43

Stainless steel butt weld fittings.

MSSSP- 44

Steel Tube Line Flanges.

MSSSP- 45

By – Pass and Drain Connection.

MSSSP- 61

Pressure Testing of Steel Valves.

MSSSP- 80

Bronze gate, globe, angle and check valves.

MSSSP- 83

Class 3000 steel pipe unions socket welding and threaded.

MSSSP-97

Integrally reinforced forged branch outlet fittings socket welding threaded and but welding ends.

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 30

NFPA 58

NFPA 59

Flammable and Combustible Liquids Code.

Liquefied Petroleum Gas Code.

Standard for the Production, Storage and Handling of Liquefied Natural Gas (LNG).

NORME EUROPEENNE (EN)

EN10 204

Produits Métalliques – Type de documents d’inspection.

5 BASIC DOCUMENTS FOR THE DETAIL DESIGN OF PIPING

Here below the list of the basic documents which shall be considered during the detail design of the plant.

5.1 Equipment layout

The Equipment layout is the drawing which represents the complete configuration of one or more plants, except the piping systems. The purpose of the document is to supply information for the equipment erection and the basic data for the detailed engineering of the foundations, structures, buildings, underground installations, electric and instrumental ducts and trays.

5.2 Piping and Instrumentation Diagram (P&IDs)

P&IDs are the diagrams which represent all the connection lines, the equipments and the instruments of the plant to allow the development of the detailed engineering and to define the modalities of the start-up, operating and shut down during the commissioning and the operation phases. All the components shown in the P&I Diagrams are represented using their appropriate symbols and are directly or indirectly marked with the items assumed as reference for the later documentation.

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5.3 Line Lists

It is a list which describes all the detailed data necessary for the detailed design of all lines of the plant, (such as physical properties of the fluids, painting and insulation classes, P&IDs references).

5.4 Piping Classes

Piping classes are the main piping documents which defines, the mechanical properties of the lines which constitute the plant. The basic parameters used for every class definition are as follows.

• The basic material: defined according to the technological, economical and market availability

considerations and other special design requirements.

• Pressure rating: defined over the design conditions. The rating calculated for flanges and valves shall be

assumed as the nominal class rating.

• Thickness of pipes and fittings: calculated on the basis of the design conditions and formulae as stated

in the CODES used for the design of the plant.

• Main inline components: such as gaskets, flanges, valves

The following special in line components are not included in the piping class datasheets:

• Elements which convey fluids like piping does, including cut-off, manual regulation, expansion bellows

which has not process or mechanical functions.

• Elements with shape, size and material not standard type or which requires special tests

5.5 Piping Isometrics

The piping isometrics are the main document which allows the pre-fabrication and the installation of the piping systems how defined during the design phase. They are issued officially for construction and their tagging follows the official numbering procedure of the plants 4439-YZ-PC-00000111.

5.6 Piping Assembly Drawings

The piping assembly drawings represents (in plan and in section) all the mechanical connections between the equipment and the machines of a plant which const of piping, ducts and similar.

5.7 MTOs

The MTOs (Material Take Off) are files extracted by the 3D model of the plant in which are indicated in terms of lists all the piping materials. They are typically split in zones in accordance with the WBS of the plant.

5.8 3D Model

It is the main design tool of the EPC projects in which are defined all the necessary information for the procurement and construction.

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6 PIPING DESIGN ARRANGEMENT CRITERIA

6.1 General

The relation of units, location of equipment and routing of pipe shall be based on economics, safety and ease of maintenance and operation. The alignment of equipment and routing of pipe shall offer an organized appearance. Piping shall not be run diagonally except where diagonal runs offer substantial savings or are required for layout reasons. Break-out spools shall be provided at exchanger heads to facilitate the removal of heads. Piping shall not be routed directly above (longitudinally) the centerline of heat exchangers.

For the purpose of this standard, “screwed lines” are defined as lines in which screwed, or socket welded type fittings are used or specified and “flanged lines” as line in which flanges or butt welding type fittings are specified.

Specific elevations shall be selected for lines running North and South and other specific elevations for those running East and West. These elevations shall be used throughout the unit, except where pockets must be avoided.

Piping and valves shall be arranged so as not to present a tripping, striking or safety hazard. Lines through tower platforms and structures where platform opening is 100 mm (refer to 4439-AI-DX-000000005) and larger shall be sleeved. The sleeve height above the platform/floor, etc., shall be 100 m, as per Steel Standard Dwg 4439-AI-DX-000000005.

Unless otherwise requested by Client or project documents, space allowances shall not be made for future equipment and associated piping.

Normally 25% spare shall be provided in pipe racks for future piping expansion and pipe rack shall be designed structurally for the loads resulting from such anticipated expansions.

In overhead pipe racks (yard piping) the small diameter pipe shall be intermixed with the large diameter pipe so that the small diameter pipe can be supported by the large diameter pipe to avoid numerous intermediate pipe supports.

Adequate space shall be provided in the pipe racks for instrument piping and electrical conduits. In general, a space 600 mm wide x 300 mm high shall be provided in the pipe rack for instrument cables. An additional space for electrical conduits, i.e. lighting, etc., shall be provided on each side of the pipe rack. This space will be an envelope 300 mm wide starting at the face of column or fireproofing, with maximum depth equal to the intermediate pipe rack beams. For units also requiring overhead installation of electrical power, the space for electrical conduits shall be 900 mm wide x 300 mm high, on the top level only.

All pipe shall drop out of racks 900 mm from column centerline as a minimum.

Wherever possible, the centerlines of top discharge nozzles of pumps shall be in line. The same applies also to centerline of channel nozzles of exchangers, saddles, tangent line of horizontal drums and other equipment wherever possible.

In sizes through NPS 24, changes in direction shall be made with fittings unless detail design or layout considerations dictate the use of bent pipe.

Bent pipe may be used to change direction where:

(a) space in pipe rack layout will allow.

(b) The bend radius required is not standard for fittings.

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(c) Flow requirements dictate its use.

Butt-welded elbows shall be long radius type 1 1/2 D. Exceptions shall be noted on the piping drawings.

Flanged valves or fittings having bolt holes which do not straddle the centerline shall be noted on the piping drawings.

Spring hangers, wherever possible, shall be located adjacent to access ways, platforms, stairway or ladders for their maintenance and to facilitate pulling of the shipment pins. To conserve space small pumps may be paired and placed on one block; exchangers may be paired to allow room for maintenance only on one side and operation on the other.

6.2 Road and access clearance

Process units are to be serviced by roads and access ways adjacent to process units, utility plants, material handling and loading areas that require access for maintenance and firefighting.

Minimum clearances for roads and railroads shall comply with the values given in Table C.

ITEM

DESCRIPTION

CLEARANCE (mm)

TABLE C

Primary road

Width (including shoulder) Vertical clearance

Secondary road

Width Vertical clearance

Primary Accessway Width

Vertical clearance

9000 7000

6000 5000

Min.3000 no obstruction

Secondary Accessway

Horizontal clearance for forklift and similar equipment Vertical clearance for forklift and similar equipment Min. horizontal clearance between any obstruction Maintenance aisle under piperack (does not have to be in a straight line)

1800 2250 750 3000 wide by 3600 high

Drop of road Slope of road

Maximum (centerline to edge) Longitudinal -

2.0% 6.0% max

Equipment

Clearance from edge of road to UOP process equipment 10000

6.3 PLATFORMS, WALKWAYS, LADDER AND STAIRS

PLATFORM

Platforms are to be provided at all elevated equipment and controls that are beyond reach from grade for manual operation and maintenance (for Plant Operation, see Table F). When horizontal exchangers and condensers are located in groups, the platform shall be continuous.

When two or more towers or other major items are closely grouped, consideration shall be given to the installation of interconnecting service platforms. The design must allow for differential vertical and horizontal thermal expansion caused by different temperatures of the equipment. When such platforms are installed they

GENERAL SPECIFICATION - LAYOUT and PIPING DESIGN CRITERIA

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000001

SHEET 17 / 26

ISSUE 3

shall be provided with at least two means of escape. As a minimum, a single means of escape is acceptable from the top of a single tower.

Platforms shall be provided at the transition piece of multi-sized stacked vessels so that the ladders will be kept in a vertical position. However, where the upper section of the vessel is smaller in diameter than the lower section, a maximum slope of 15 degrees from the vertical will be permitted.

Platforms serving vertical heat exchanger units shall have at least 900 mm clearance from flange edges. This area shall be designed as a working area. Channel and bonnet flanges shall preferably be at 1200 mm, but not more than 1800 mm above platforms.

Grating shall be used on loading racks, over trenches, at compressors and platforms.

Handrails shall be provided on all open sides of platforms and walkways which are 500 mm or more above adjacent floor or ground level.

Removable sections of handrail shall be provided for exchanger bundle removal or any other equipment requiring space for removal.

LADDERS

Ladders shall be used as primary access to platforms attached to vessels and to auxiliary service platforms.

Ladders shall have a constant slope from platform to platform, or to grade.

On vertical ladders not equipped with cages, the horizontal distance from the centerline of the rungs to the nearest permanent object on the climbing side of ladder shall not be less than 750 mm. A clear width of at least 375 mm shall be provided each way from the centerline of the ladder in the climbing space.

Side step ladders shall be used. Double side step ladders at the same elevation are not permitted; minimum difference in elevation between two platforms serviced by the same ladder shall be 600 mm. Step through ladders without platforms are not permitted.

The step across distance between the ladder and the elevated landing shall not exceed 300 mm.

In general ladders should not be oriented facing open spaces, they should be oriented facing walls or equipment.

STAIRWAYS

Stairways are divided into Classes A and B and shall meet with the following requirements:

Class A stairs are intended for main stairs for places where a large number of people must be accommodated, such as office buildings, laboratories and main buildings for process units. For these type of stairs, local regulations shall govern.

Class B stairs are not intended to accommodate large numbers of people. Areas of application are:

• Where process, inspection and maintenance operations are required daily.

• Where exposure to hazards from acids, gases and the like may be possible.

• For access to structures supporting catalytic crackers, coke drums and field- fabricated heaters and

boilers.

GENERAL SPECIFICATION - LAYOUT and PIPING DESIGN CRITERIA

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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SHEET 18 / 26

ISSUE 3

• For access to platforms around groups of vessels and other equipment located adjacent to each other.

Stairs in this classification shall not be less than 900 mm wide between handrails and shall be clear of any obstructions, except that handrails attached to walls may project not more than 90 mm at each side within the required width. The rise of every step in Class B stairways shall not exceed 190 mm and the run shall not be less than 240 mm as per 4439-AI-DX-000000003 Steel Standard dwg.

Spiral stairs are not permitted, except for storage tanks.

GENERAL SPECIFICATION - LAYOUT and PIPING DESIGN CRITERIA

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000001

SHEET 19 / 26

ISSUE 3

General criteria for platforms, walkways, ladders and stairs shall comply with the values given in Table D.

ITEM

DESCRIPTION

CLEARANCE (mm)

TABLE D

Platforms Max. level variance without intermediate step

300

Avoid platform elevation where the headroom ranges between 1400 and 2000 Diameter of openings on platforms to be flange OD + 50 or insulation OD + 50 (whichever is larger)

50 + OD flg 50 + OD ins.

Walkways Min. vertical clearance

Ladders

Stairs

Min. horizontal clearance Min. width between centerline of handrails Max. horizontal walking distance to primary or auxiliary exit Max. length of dead end platform

Max. vertical rise between landing platforms (single run) Max. allowable slope from vertical Toe clearance from centerline of rung to obstruction at back of ladder

Max. vertical rise - one flight Min. stairway width Min. landing width Min. width between centerline of handrails Min. free space between two adjacent handrails Max. angle

2200 750 900 15000 7500

9000 5° 200

5000 800 800 900 200 42°

6.4 MAINTENANCE

Where compressors and similar large equipment are located in enclosure or shelter, permanent lifting facilities shall be extended outside of shelter or into drop areas, to permit lowering machinery components to mobile handling equipment at grade level.

In case of extraordinary maintenance activities, provisions for removable sections of walls or roofs enclosing such equipment shall be considered according to manufacturer instructions.

Removable sections shall be provided in the flooring of platforms where required for maintenance of auxiliary equipment mounted below the flooring.

Where mobile cranes are required to approach process equipment for regular maintenance, piping and structures shall be arranged so as not to cause obstruction.

GENERAL SPECIFICATION - LAYOUT and PIPING DESIGN CRITERIA

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000001

SHEET 20 / 26

ISSUE 3

Orientation of davits and manways shall be such that:

Internals removed through manways are accessible for lifting by davit. a. b. Drop-out areas provided at the tower are accessible for mobile equipment.

Manway covers shall be hinged or equipped with handling davits. Hinge shall be located so that manway closes in the direction of escape way.

Access shall be provided for portable bundle pullers used for servicing channel and tube bundles of tubular units.

Exchanger piping and pipe supports shall be located so that they do not interfere with the removal of channel covers and tube bundles when mobile lifting equipment is used. Piping shall not extend past the channel cover. A removable spool with break flanges located 250 mm minimum from the back side of the channel flange shall be provided in channel inlet and outlet lines.

Fired heater tube removal areas shall be kept clear of all piping and pipe supports.

Where commercial style bolt tensioners are specified, adequate clearance shall be provided around flanged connections for installation and operation of the bolt tensioners.

Maintenance requirements shall be in accordance with Table E1

GENERAL SPECIFICATION - LAYOUT and PIPING DESIGN CRITERIA

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000001

SHEET 21 / 26

ISSUE 3

Minimum clearances required for maintenance shall comply with the values given in Table E2.

ITEM

ACTIVITY

HANDLING DEVICE

TABLE E1

Vertical vessels / Reactors

Maintenance access cover removal Relief and control valve removal Vessel internal removal Catalyst loading and unloading

Exchangers

Cover removal (horizontal)

Bundle removal Bottom cover removal Top cover removal (vertical) Bundle removal (vertical) Rodding Air cooler tube removal Plate removal (plate exchanger)

Maintenance access davit Top head davit Top head davit or mobile crane Mobile crane

Hoist trestle with load up to 2.000 lb (900 kg) or mobile crane Mobile crane and extractor

Hitch points

Mobile crane Mobile crane Manual Mobile crane Manual

Pumps

Motor or component removal

Forklift

Vertical pumps

Motor or component removal

Mobile crane

Large pumps, Turbines, Compressors

Large pumps, Turbines, Compressors

Largest component removal (housed)

Motor (housed)

Trolley beam or traveling crane

Mobile crane

Motor or largest component removal (open installation)

Mobile crane or hoist trestle with load up to 2,000 lb (900 kg)

Furnaces

Coil removal

Mobile crane

Miscellaneous

Filter removal Strainer removal

Relief valves 4 to 6 in and larger Blinds blanks, figure 8s and valves, more than 300 lb (135 kg) Small components 300 lb (135 kg) and less

Manual or hoist trestle Manual Davits, hitch points, or mobile crane Hoist trestle mobile crane, Davit or Pad eye

Manual

GENERAL SPECIFICATION - LAYOUT and PIPING DESIGN CRITERIA

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

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ISSUE 3

Maintenance clearances

(mm)

TABLE E2

Manholes Nozzles

/ Horizontal clearance in front of manhole

Manhole centerline elevation from platform Min. lateral clearance for manhole cover swing Min. lateral clearance (1 side) for manholes on top head of vessels Min. distance from bottom of flange of top nozzle and platform Min. distance from platform and bottom nozzle of equipment Min. platform width on vertical vessel and towers

OD,

900 or manhole whichever is larger 750÷1050 Allow for 120° 900

75

300

1000

Exchangers

clearance at shell cover of heat 1200 on structure

Min. horizontal exchanger Min. horiz. clearance at channel end of heat exchanger Min. passageway between paired exchangers or vessel

1500 at grade 1200 on structure 1000+ bundle at grade 750

150

750

Drains

Min. free space under drain valves

Furnaces

Clearance under raised furnace floors (side burners)

Clearance under raised furnace floors (bottom burners) 2100

Control panel

Horizontal clearance back of control panels

1200

Pumps/ Turbines

Min. vertical clearance over pumps and turbines

Min. operating aisle at driver end of pumps

2400

1500

GENERAL SPECIFICATION - LAYOUT and PIPING DESIGN CRITERIA

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

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ISSUE 3

6.5 PLANT OPERATION

Access to elevated platforms shall be by permanent ladders or stairways. The need for stairways shall be determined on the basis of platform elevation, number of points requiring attention, observation on adjustment and the frequency of same.

Operating valves requiring attention, observation or adjustment during normal plant operation shall be located so as to be accessible from grade, step, platform or permanent ladder. When this is not practical, the valves shall be provided with extension stem operators or chain-wheel operators (chain wheel operators shall not be used on valves NPS 2 and smaller; extension stems shall be provided instead).

Chain- wheels shall not be used on globe valves.

Where valves are normally operated during the unit run, gear operators shall be provided on gate valves 14” size and larger for Classes 125, 150, 300, and 400, and on gate valves 10” size and larger for Class 600 and higher. Gear operators for plug, butterfly, and ball valves shall be furnished in accordance with valve manufacturer’s recommendations. Gear operators shall be indicated on Piping & Instrumentation Diagrams during EPC phase with proper style designation.

No platforms or ladders shall be provided for accessibility to headers valves. Header valves will be accessible by temporary scaffolding.

Valves at Battery Limits shall be accessible from platform or grade as applicable. Chain-wheel operators are not allowed on Battery Limit valves; hand wheel extensions are acceptable.

Control valves shall be located at grade or on platforms unless otherwise dictated by process reasons.

Relief valves shall be accessible from grade or platforms. Wherever practical, they shall be located at platforms which are functional for other purposes.

Instrument connections shall be oriented so that the instruments will not obstruct aisles or platforms. Instrument requiring frequent maintenance, observation or adjustment during normal plant operation shall be accessible from grade, step, platform or permanent ladder as per table F.

Local temperature and pressure indicators shall be visible from grade, ladder or platform.

Liquid level controllers and level glasses shall be arranged adjacent to each other wherever possible and shall be located so as to be accessible as per Table F. The level glass shall preferably be visible from the valve which controls the liquid level in the vessel.

Orifice which are located on the pipe rack or lower than 6600 mm above grade or platform shall be deemed accessible from portable ladders. Above 6600 mm, or in any location not directly accessible via portable ladders, a permanent platform or ladder shall be provided. Orifice runs in the horizontal are preferred. Vertical runs are permitted in upward flow only for liquids; downward flow for gases.A minimum of 600 mm shall be allowed from OD of orifice flange to any obstruction, for installation of meter leads. Minimum access required for operator shall comply with the values given in Table F.

GENERAL SPECIFICATION - LAYOUT and PIPING DESIGN CRITERIA

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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SHEET 24 / 26

ISSUE 3

MINIMUM REQUIRED

OPERATING

ACCESS

TYPE OF ITEM TO BE ACCESSED

TABLE F

Platform – Item located over platform

above

(higher than 3600

Heat exchangers grade) Elevated control valves (all sizes) Manholes (higher than 3600 above grade) Relief valves (NPS 2”x3” and larger) Process blinds (higher than 3600 above grade) Furnace burners grade) Furnace observation doors and sample ports (higher than 3600 above grade) Elevated cleanouts All valves NPS 3” and larger (except check valves) Meter runs requiring certified calibration.

(when not accessible

from

Platform – Item located at edge of platform Relief valves (NPS 1 1/2”x2” and smaller) Battery limit valves in elevated pipe racks Handwheel and motor of motor operated valves Sampling devices grade)

(Higher than 3600

above

Permanent Ladder (For items located higher than 3600 above grade)

All valves NPS 2” and smaller (except check valves not at vessels) All sizes of check valves at vessels Level controllers Instruments requiring routine access

Portable ladder

All servicing up to 3600 from grade

No permanent access and accessible temporary scaffoldings

Header block valves Check valves not at vessels Elevated orifices or meter runs. Nozzles on vessels without process blinds or valves Temperature connections in piping Silencers or exhaust heads Metal temperature measuring points on vessels

GENERAL SPECIFICATION - LAYOUT and PIPING DESIGN CRITERIA

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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ISSUE 3

6.6 MISCELLANEOUS

Utility Hose Stations

Utility hose stations providing steam, air, water and, where required, nitrogen shall be located at convenient points at grade so that all parts of the unit may be reached with 15 m lengths of hose. Hose, hose connections, and hose reels shall be furnished by Contractor.

Utility hose stations providing steam, water and air only shall be located as follows:

• at alternate levels of elevated structures so that all parts of the structure may be reached with 15 m lengths

of hose.

• at alternate platforms required for servicing of manholes in towers or vessels within 15 m length of hose. • On utilities area where nitrogen is not required.

The supply for utility hose stations shall be taken from the top of the headers.

Supply lines shall be NPS 1 and shall be provided with gate valves at the user end of the appropriate material specification. Steam connections shall have globe valves with NPS 3/4 line. Water and air connections shall have gate valves with NPS 01 line.

Figure 8 Blinds, Paddle Blinds and Ring Spacers

Figure 8 blinds, paddle blinds and ring spacers shall be installed where indicated on the Piping & Instrumentation Diagrams.

Figure 8 blinds shall normally be used for piping up to NPS 12.

Paddle blinds and spacers shall be used for piping NPS 14 and above, since the weight of a Figure 8 blind would make its operation impractical.

Figure 8 blinds, paddle blinds and ring spacers shall be of the same material as the line in which they are installed.

Special handling devices, such as davits, shall not be provided for lifting blinds and spacers.

When Figure 8 blinds, paddle blinds or ring spacers have to be installed on services requiring ring type joint (RTJ) flanges, the piping design and layout shall ensure that the blind/spacer can be easily installed and removed without damaging the connected pipe or equipment. Removable spool pieces may be required in some cases to achieve this and, in this case, they shall be shown also on the P&ID’s.

GENERAL SPECIFICATION - LAYOUT and PIPING DESIGN CRITERIA

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

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ISSUE 3

6.7 OFFSITE PIPING

Wherever possible, offsite piping shall be located in banks at grade and supported by concrete piers or sleepers.

Where double pipe banks are required, steel columns and supports built up from concrete piers or sleepers shall be used. As a minimum, a clearance of 1800 mm between the two banks shall be provided.

Overhead pipe racks shall be kept to a minimum.

Where piping at grade is required to cross a road, it shall pass through a buried pipe sleeve with a minimum cover height of 450 mm.

The minimum height of concrete piers or sleepers shall be 300 mm.

Wherever possible, changes in direction shall be accomplished by flat turning.

Changes in direction shall be made with fittings.

Consideration shall be given to expansion of pipe as a result of process or climatic conditions. The expansion shall preferably be absorbed by the use of loops or bends. Vertical loops are acceptable except in gravity flow. The use of expansion joints shall be avoided if possible.

Consideration shall be given to providing flexibility in the piping to storage tanks to allow for future settlement.

Except at valves and line terminations, the use of flanges shall be avoided.

Project: Q-32976 - Tecnmont SKIKDA Folder: Reference Documents