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TRAINING MANUAL- PIPING
Uhde India Limited
PIPING STUDY TANKFARM PIPING
DOC No. : 29040-PI-UPS-1007 Rev.
: R0
Page
: 1
CONTENTS Page 0.0
Cover Sheet
1
List of illustrations
2
1.0
General
3-4
2.0
Key Words
4
3.0
Bund Area to Contain Spillage
4-5
4.0
Tank Details
5
5.0
Pump Location in Tankfarm
5
6.0
Piping Arrangement
6
Applicable Revision: Prepared:
Checked:
Approved:
Date: First Edition: R0 Prepared: AKB
Date:
Date:
Checked: TNG
Approved: RUD
Date: File Name:
Date: Server:
Date: VKO: KUMUS 209
PUNE: KUMUS 207
TRAINING MANUAL- PIPING PIPING STUDY TANKFARM PIPING
Uhde India Limited
DOC No. : 29040-PI-UPS-1007 Rev.
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LIST OF ILLUSTRATIONS
SR.NO. DWG.NO.
DESCRIPTION
1
TFP1
TYPICAL TYPE OF DYKES
2
TFP2
DRAINAGE FROM DYKE
3
TFP3
TYPICAL HORIZONTAL PRESSURE TANK (BULLET)
4
TFP4
TYPICAL VERTICAL TANK DETAILS
5
TFP5
VALVE ACCESS CATWALKS
6
TFP6
TYPICAL TANK HEATERS
7
TFP7
TYPICAL FLOATING ROOF TANK ACCESS
8
TFP8
9
TFP9
LOW TEMPERATURE TANK FOUNDATION WITH ELEVATED CONCRETE BASE COMPACTED FILL TANK PAD
10
TFP10
TYPICAL RING WALL FOUNDATION
11
TFP11
PUMPS INSIDE DYKED AREA
12
TFP12
PUMPS OUTSIDE DYKED AREA
13
TFP13
PUMPS INSIDE CONCRETE DYKED AREA
14
TFP14
DYKE-PENETRATION SEAL
15
TFP15
FLEXIBLE DYKE SEAL
16
TFP16
ALTERNATE PIPING LAYOUTS
17
TFP17
TANK PIPING LAYOUT
18
TFP18
CROSS SECTION OF PIPE WAY AND PUMPING
19
TFP19
BULLET-TANK PIPING LAYOUT
20
TFP20
LIQUEFIED NATURAL GAS TANK LAYOUT
21
TFP21
LIQUEFIED NATURAL GAS TANK LAYOUT
22
TFP22
TYPICAL FIRE WATER SYSTEM IN TANKAGE AREA
23
TFP23
PROTECTION BERM
TRAINING MANUAL- PIPING PIPING STUDY TANKFARM PIPING
Uhde India Limited
DOC No. : 29040-PI-UPS-1007 Rev.
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1.0
GENERAL
1.1
The study of the tankfarm consisting of a group of tanks shall be carried out keeping the following basic points in consideration.
1.2
Grouping of tanks, Specification of the content. Capacity of tanks Nature of hazard - fire -
toxic explosive corrosive bulk handling
loading unloading
Statutory distance Requirement of Dykewall or curbing Dykewall height or curb height calculation Location of Pumps - inside dyke area -
outside dyke area
Approach to tank nozzles with valve Approach to tank roof Drainage of dyke area - Sump and pump Road around tankfarm Fire hydrant / monitor requirement Underground system connected to specific system of treatment / disposal 1.3
Storage tanks located in a safe area and grouped according to the contents are called tankfarm. Normally, in chemical plants, the storage shall be either input raw material or output products or intermediate chemicals storage. Storage tanks may contain acids, alkalis, oil viz. petrol, diesel, naptha, fuel oil or benzene etc. Oil, acid, alkali are usually stored in vertical storage tanks designed as per API 650.
1.4
Tanks should be grouped or segregated according to the contents. Tanks containing hydrocarbons should be separated according to the flash point, CCE classification for space planning, dykewall and its height requirement. Layout of the storage facility shall be based on the following considerations and systematic approach. -
Statutory Regulations viz. CCE
-
TAC/NFPA recommendations
-
Safety requirements as per OISD, OSHA, HAZOP study
-
Valve access platform / ladders at the piping outlet nozzles of tank.
-
Access to top of tanks and interconnecting walkway
-
Piping on sleepers or piperack inside dyke area.
-
Pumps location outside dyke area
TRAINING MANUAL- PIPING
Uhde India Limited 1.5
PIPING STUDY TANKFARM PIPING
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The practical objective to prepare a most economical plot plan and piping arrangement for a tankfarm should be to keep provisions of operational ease, maintenance facility, safety arrangements and overall aesthetics. The tankfarm shall also have provisions for efficient drainage and disposal facility as required for various kinds of fluid storage. The tankfarm should be secured against unauthorised entry by fencing, security gates depending on the tank storage capacity or the type of hazards posed by the nature of contents.
2.0
Key Words Atmospheric tank - The tank that operates at pressure levels ranging from atmospheric pressure to 0.5 psig. Bullet - This is a high pressure horizontal storage vessel shaped like a bullet (Refer Fig.TFP3) Cone-roof tank - This is a low-pressure vertical storage tank with a cone-shaped fixed roof. Fixed roof tank - This is a low pressure vertical storage tank with a roof welded to the shell irrespective of roof design or method of support. Floating roof tank - A floating roof tank design is adopted to conserve vapour loss and minimise fire hazard. (Refer Fig.TFP7) Double-wall storage tank - A double wall storage tank has an inner wall to contain a liquid, an annulus space usually filled with insulation and outerwall for containment of spillage. Horton sphere - It is a spherical vessel used for storage of high pressure liquid and gases. Dyke - A dyke is a barrier designed to contain liquid in the tank in case of emergency within the area for safety reasons. (Refer Fig.TFP1) Diversion dyke - This is a barrier designed to divert spillage from other storage tanks. It uses natural terrain to direct liquids to the sump area. Flame arrester - In the event of lightning or another source of vapour ignition, a flame arrester in the vent line of a storage tank prevents flames from flashing to the vapour inside the tank. Breather valve - This is provided as a measure to protect the tank against collapse due to sudden creation of vacuum inside the tank during suction by pumps. Foot valve - This valve is provided at the bottom of a riser in a tank where a submersible pump can be installed. During regular operation, foot valve remains open. Sleeper - Sleepers are steel or concrete supports usually located within 450mm of grade of piping systems commonly found in offsites. Sump - This is the low point basin within an area used for collection of liquid waste for disposal. Foam - This is a solution with a density lower than that of oil and water. It is used to form a blanket over dangerous vapours and reduce the risk of explosion.
3.0
BUND AREA TO CONTAIN SPILLAGE
3.1
The risk of failure of storage tanks and the primary piping systems is reduced to certain extent, if the fluid is contained within the bund wall and is not allowed to spread throughout the area resulting in various hazards like fire, toxic spread, pollution problem etc.
3.2
The dyke may be constructed of earth, concrete, solid masonary or steel. It may be square, rectangular, circular or irregular in shape, conforming to the natural terrain around the tank.
TRAINING MANUAL- PIPING
Uhde India Limited 3.3
PIPING STUDY TANKFARM PIPING
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The containment dyke for tankfarm under the purview of chief controller of explosives (CCE) shall be planned according to the CCE rules and regulations. CCE rules are applicable to the fluids of petroleum and petroleum products classified as class A, B or C according to its flash point characteristics. The rules of CCE can be followed for other hazardous / inflammable products as good guidelines of safety, even though the product is not classified as petroleum product.
3.4
One common method of dyke construction is by earth upto a height of 1.8m and with width of dyke on top to be about 600mm. The slope on the surface of dyke is usually 1:1.5 consistent with the angle of repose of earth. In congested area or where space is limited, usually concrete dyke is made with varying height for different containment capacity.
3.5
The free volume of the bund area is sized to contain the contents of one largest tank plus a margin of 10 percent.
3.6
All drains from the dyke area should be equipped with a valve outside the dyke regardless of whether the drainage goes to disposal pit or sewer system. This prevents liquid spillage from entering the sewer or released from the dyke area. These valves should be kept closed and blanked off except when withdrawing water. The contamination of spillage with the natural rain water or wash water needs this drainage to be treated before disposal. Depending on the contamination, the valve can be used for diverting either to storm water system or to the Effluent Treatment Plant.
3.7
Access to the dyke area is usually provided by making vehicular ramp at one end and a stepped entry at the other end (Refer Fig. TFP2)
4.0
TANK DETAILS
4.1
A typical illustration on the top of a vertical storage tank is given in Fig.TFP4
4.2
Valve access catwalk (Fig.TFP 5), Tank heater installation (Fig.TFP6), Floating Roof Tank access (Fig.TFP7) are illustrated as typical examples.
4.3
A low temperature tank foundation with elevated concrete base is illustrated in Fig.TFP8
4.4
A tank located on compacted granular fill is illustrated in Fig.TFP9 and a tank on the ring wall foundation is illustrated in Fig.TFP10.
5.0
PUMP LOCATION IN TANKFARM
5.1
To determiine the optimum location of pumps, the potential hazards and client preferrence shall be considered. Fig.TFP11 and TFP13 illustrates the location of pump within the dyke area with the curb wall height of approx. 400-500mm. This design protects the pump from minor spillage within the dyke and enable the discharge piping to exit the dyke over the wall and there is no need to have dyke penetration seals. The piping outside the dyke may run on a piperack or sleepers.
5.2
The pumps located outside the dyke area are illustrated in Fig.TFP12. Tank outlet piping can either penetrate the dyke or pass over the dyke in case the minimum liquid level in the tank do cause cavitation in the pump.
5.3
Adequate maintenance area around the pump shall be the prime consideration for planning the piping arrangement at suction as well as discharge.
TRAINING MANUAL- PIPING
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PIPING STUDY TANKFARM PIPING
DOC No. : 29040-PI-UPS-1007 Rev.
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6.0
PIPING ARRANGEMENT
6.1
The Optimum piping arrangement in a tankfarm is the most direct route between two points allowing for normal line expansion and stresses. Fig.TFP16 illustrates between tanks and pumps. Fig.TFP17 shows how to accommodate line expansion between tank nozzles and a manifold header. Expansion loops may be added at the sleeper level.
6.2
Fig.TFP18 illustrates a cross-section of piping, pumps, dykes and a primary pipeway in a typical tankfarm.
6.3
A bullet tank piping arrangement is shown in Fig.TFP19. Tanks are installed at the lowest possible elevation to satisfy the pump head requirements. A catwalk is usually located across all the tanks in a row to provide access to the operating valves and instruments. Liquid outlet piping to the suction of Pump shall allow for differential settlement and the flexibility of the piping.
6.4
A typical layout of liquefied natural gas (LNG) tanks is shown in Fig.TFP20 and TFP21. The secondary containment is a steel lined concrete structure. There is heavy cryogenic insulation between primary and secondary containers. Submersible pumps are located at the bottom of the pump shaft. The roof is steel and domed. The operation platform, piping and jib crane structure are supported on the concrete containment wall.
6.5
In addition to the provisions for mobile fire-fighting equipment, permanent hydrants, monitors are used for protection against fire in the tankfarm areas. The codes, regulations viz.CCE, TAC, NFPA shall be consulted to finalise the safety requirement of the tankfarm. Fig.TFP22 shows a typical arrangement of firewater hydrants and monitors in a tankfarm. The fire water piping around the tankfarm area shall be provided with supply from two different sources. This is normally done by installation of an firewater pump with diesel engine drive in addition to the electric motor driven pumps.
6.6
When high pressure bullet tanks are located close to the process unit, a protection berm (Refer Fig.TFP23) is normally used. The berm length shall be slightly longer than the width of the tank area and the berm height will be equal to the height of tanks. These berms are provisions for protection against explosion.
6.7
The sump and sump pump shall be provided for disposal of water accumulation due to rain or firefighting.
6.8
The foam piping shall be arranged with the quick-coupling to the line supply to the foam chamber at the edge of the roof of the tank. The coupling shall be located outside the dyke wall.
TRAINING MANUAL - PIPING
DOC NO. : 29040-PI-UPS-1007
PIPING STUDY TANK FARM PIPING
Uhde India Limited
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TYPICAL TYPE OF DYKES
W : H = 1 1/2 : 1
TOE OF DYKE W
3'-6'/900-1800 ABOVE INTERIOR GRADE H
VARIES
2'/600 MIN.
EARTHEN DYKE
AS REQUIRED
CONCRETE DYKE CONCRETE CONTAINMENT EARTHEN CONTAINMENT
DOUBLE CONTAINMENT DYKING METHOD
CONCRETE DYKE
25'/7.6
EARTHEN DYKE
EARTHEN AND CONCRETE COMBINATION DYKE
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PIPING STUDY TANK FARM PIPING
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DRAINAGE FROM DYKE
SUMP (TYP) DIVERSION CANAL TO REMOTE AREA
VALVES USUALLY CLOSED DIVERSION CANAL
CONCRETE DIVERSION CANAL
CL PLANT ROAD
VEHICULAR RAMP
STAIRWAY
PUMP AREA VEHICULAR AND PERSONNEL ACCESS
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TYPICAL HORIZONTAL PRESSURE TANK (BULLET)
SLOPE OUTLET
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TYPICAL VERTICAL TANK DETAILS
MAINTENANCE ACCESS FOR CLEAN-OUT DOOR
R DE AD CLL
ALTERNATE ACCESS PROVIDE HANDRAIL ON BOTH SIDE OF ROOF ACCESS AREA
CL LEVEL GAUGE TANK ROOF MAINTENANCE ACCESS PROVIDE HANDRAIL ON BOTH SIDE OF ROOF ACCESS AREA
STAIRWAY ENTRANCE AT GRADE PRIMARY TRANSFER PIPING
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VALVE ACCESS CATWALKS
TANK
CATWALK VALVE EXTENSION STEM
CATWALK
ELEVATION
PLAN
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TYPICAL TANK HEATERS
STEAM IN
FINNED TUBES
STEAM IN
FINNED TUBES
CONDENSATE OUT
CONDENSATE OUT
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TYPICAL FLOATING ROOF TANK ACCESS
ROOF ACCESS STAIRWAY
STRAIGHT STAIRWAY
CIRCULAR STAIRWAY
NOT RECOMMENDED FOR TANKS LESS THAN 15'-6" IN DIAMETER
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LOW TEMPERATURE TANK FOUNDATION WITH ELEVATED CONCRETE BASE
PRIMARY CONTAINER SECONDARY CONTAINER
CONCRETE SLAB COLUMNS
12"/300 MINIMUM
SPREAD FOOTING
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TANK FARM PIPING
: TFP9
CL OF TANK
COMPACTED FILL TANK PAD
3'-0" 900
TANK BOTTOM HIGH POINT
1"- THICK ASPHALTIC CONCRETE
VARIES
12"/300
COMPACTED GRANULAR FILL POINT OF SUPPORT
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TYPICAL RING WALL FOUNDATION
POINT OF SUPPORT
12"/300
TANK BOTTOM
6"/150±
RING WALL
GRANULAR CLASS I COMPACTED STRUCTURAL FILL
12"/300
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PUMPS INSIDE DYKED AREA
15"-18"/380-460 CURB DYKE
CURBED AREA
PIPE RACK OR SLEEPERS
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PUMPS OUTSIDE DYKED AREA
ALTERNATE ROUTING DYKE
PIPE RACK PIPE RACK ALTERNATE LOCATION
SLEEPERS
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PUMPS INSIDE CONCRETE DYKED AREA
18"/450
18"/450
CONCRETE DYKE
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DYKE- PENETRATION SEAL
DYKE WALL PIPE SLEEVE
SEAL PRODUCT LINE
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FLEXIBLE DYKE SEAL
INSIDE DYKE WALL STEEL STRAP
PRODUCT LINE
FLEXIBLE SEAL
INSULATION PIPE SLEEVE
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ALTERNATE PIPING LAYOUTS
PREFERRED LAYOUT
TANK NOZZLE (TYPICAL)
LAYOUT FOR FLEXIBILITY (TYPICAL ALTERNATIVES)
ALTERNATIVE
PUMPING
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TANK PIPING LAYOUT
SLEEPER
ELEVATION
OPTIONAL
TANK
A
B
C
SLEEPERS (TYP) (SEE VALVE ACCESS CATWALK TFP5) EXPANSION LOOPS HEADERS
PLAN
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TANK FARM PIPING
: TFP18
CROSS SECTION OF PIPE WAY AND PUMPING
PIPE BRIDGE ALTERNATIVE DYKE
PUMPING
DEPRESSED SLEEPER
TANKS
ROADWAY
PUMPING
DYKE
TANKS
ACCESS
BURIED PUMP DISCHARGE
PRIMARY TANK PIPE WAY
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BULLET-TANK PIPING LAYOUT
RELIFE VALVE TO ATMOSPHERE CATWALK
RELIFE VALVE
CATWALK
LIQUID OUTLET
ELEVATION PRODUCT OUTLET
C L PUMPS
PLAN
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LIQUEFIED NATURAL GAS TANK LAYOUT
MAINTENANCE ACCESS
VENT CATWALK RELIEF
PRESSURE TEMPERATURE INSTRUMENTS (TYP)
VALVE VACUUM BREAKERS
CATWALK TANK ROOF CL PUMPS (4 NOS.) ACCESS ROAD EARTHEN EMBANKMENT
JIB CRANE OPERATIONS PLATFORM
PIPE TRESTLE STAIRWAY
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LIQUEFIED NATURAL GAS TANK
JIB CRANE
OPERATIONS PLATFORM
STEEL ROOF
TRESTLE
UTILITY PIPING
PIPE BRIDGE SUPPORT PROCESS PIPING
PUMP SHAFT STEEL INNER TANK STEEL LINER
EARTHEN EMBANKMENT
PUMP
FOOT VALVE INSULATION CONCRETE CONTAINMENT
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TYPICAL FIRE WATER SYSTEM IN TANKAGE AREA
FIRE WATER SUPPLY
ROAD
ROAD
ROAD
ROAD
FIRE MONITOR FIRE HYDRANT
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PROTECTION BERM
BULLETS
BERM
PLAN
BERM
BULLET TANK
SLOPE
ELEVATION