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Oil and Chemical Plant Layout and Spacing Property Risk Consulting Guidelines PRC.2.5.2 A Publication of AXA XL Risk Consulting OIL AND CHEMICAL PLANT LAYOUT AND SPACING INTRODUCTION Loss experience clearly shows that fires or explosions in congested areas of oil and chemical plants can result in extensive losses. Wherever explosion or fire hazards exist, proper plant layout and adequate spacing between hazards are essential to loss prevention and control. Layout relates to the relative position of equipment or units within a given site. Spacing pertains to minimum distances between units or equipment. AXA XL Risk Consulting layout and spacing recommendations are for property loss prevention purposes only and are intended for existing and new oil and chemical facilities. These guidelines are intended to limit explosion overpressure and fire exposure damage. They do not address shrapnel damage. If these guidelines cannot be followed, then additional loss control measures, such as fire proofing, waterspray or blast hardening will be necessary. Property Risk Consulting Guidelines only address spacing and layout within a plant and are mostly applicable to open structures. An open-air design favors vapor dissipation, provides adequate ventilation, reduces the size of the electrically classified area, and increases firefighting accessibility. Additional information can be found in several publications, Hazard Survey of the Chemical and Allied Industries, Technical Survey No. 3, 1968, An Engineer’s Guide To Process-Plant Layout by F.F. House, Process Plant Layout by J.C. Mecklenburgh, Loss Prevention In The Process Industries by F. P. Lees, Volumes 1 & 2, Loss Prevention Fundamentals For The Process Industry, Loss Prevention Symposium, March 1988, NFPA 30, and NFPA 58. POSITION Management Programs Management program administrators should report to top management through the minimum number of steps. They should also institute loss prevention inspection and audit programs to communicate program effectiveness to top management. This management feedback is a key feature of PRC.1.0.1 (OVERVIEW). In developing a program, pay particular attention to the following important areas: Hazard Identification and Evaluation Program Determine the plant layout and spacing necessary to limit loss size based on worst-case scenarios for vapor cloud, vessel and building explosions, and for fires. Calculate overpressure circles. See PRC.8.0.1.1 for hazard analysis and evaluation methods applicable to various explosion or fire scenarios. This analysis can be completed in coordination with AXA XL Risk Consulting loss prevention personnel. 100 Constitution Plaza, Hartford, Connecticut 06103 Copyright 2020, AXA XL Risk Consulting Global Asset Protection Services, LLC, AXA Matrix Risk Consultants S.A. and their affiliates (“AXA XL Risk Consulting”) provide loss prevention and risk assessment reports and other risk consulting services, as requested. In this respect, our property loss prevention publications, services, and surveys do not address life safety or third party liability issues. This document shall not be construed as indicating the existence or availability under any policy of coverage for any particular type of loss or damage. The provision of any service does not imply that every possible hazard has been identified at a facility or that no other hazards exist. AXA XL Risk Consulting does not assume, and shall have no liability for the control, correction, continuation or modification of any existing conditions or operations. We specifically disclaim any warranty or representation that compliance with any advice or recommendation in any document or other communication will make a facility or operation safe or healthful, or put it in compliance with any standard, code, law, rule or regulation. Save where expressly agreed in writing, AXA XL Risk Consulting and its related and affiliated companies disclaim all liability for loss or damage suffered by any party arising out of or in connection with our services, including indirect or consequential loss or damage, howsoever arising. Any party who chooses to rely in any way on the contents of this document does so at their own risk. AXA, the AXA and XL logos are trademarks of AXA SA or its affiliates © 2020 AXA SA or its affiliates. PRC.2.5.2 Management of Change Evaluate the impact of all modifications to equipment and procedures to the plant process safety using the Management of Change program Conduct a Hazard Identification and Evaluation program for all new processes or for any modification to an existing process prior to completing final site selection and equipment layout. Determine the need for changes to spacing or layout. Duplication of Facilities For large-scale chemical and petrochemical plants, provide multiple process trains. In large scale plants, duplicate, with installed spares, equipment that is highly susceptible to loss or important for continued operations. For smaller scale or batch type plants, install processes important to production in the form of multiple small-scale units rather than a single large unit. Physically separate duplicated units, process trains or equipment with adequate spacing in accordance with this section or compartmentalize with blast resistant construction. General Consider the following when determining the layout and the separation required: • High hazard operations (see Appendix A) • Grouped operations • Critical operations • Number of personnel at risk • Potential environmental damage • Concentration of property and business interruption values • Importance of facility for continuing operations • Equipment replacement and installation time • Interdependency of facilities • Critical customer or supplier relationships • Market share concerns • Fire and explosion exposures • Corrosive or incompatible materials exposures • Vapor cloud explosions • Potential to damage of building components and outdoor equipment • Sources of ignition • Maintenance and emergency accessibility • Drainage and grade sloping of surrounding land • Prevailing wind conditions • Natural hazards and climate • Future expansions • External exposures including other plants, pipelines and transportation (rail, motor vehicle, aircraft, ship) Review the various hazards and loss potentials to establish the degree of separation required between units and equipment. Consult Tables 1, 2 and 3 in this guide for minimum spacing guidelines based on fire and vessel explosion hazards. Increase spacing where appropriate. Property Risk Consulting Guidelines 2 A Publication of AXA XL Risk Consulting PRC.2.5.2 1 ft = 0.305 m / = no spacing requirements * = spacing given in Table 3 Examples: 1 50 ft separation between two cooling towers 2 300 ft separation between service building and flare TABLE 1. Inter-Unit Spacing Recommendations For Oil And Chemical Plants. Property Risk Consulting Guidelines 3 A Publication of AXA XL Risk Consulting PRC.2.5.2 1 ft = 0.305 m / = no spacing requirements TABLE 2. Intra-Unit Spacing Recommendations For Oil And Chemical Plants. Property Risk Consulting Guidelines 4 A Publication of AXA XL Risk Consulting PRC.2.5.2 D = Largest Tank Diameter 1 barrel = 42 gallons = 159 L °C = (°F-32) x 0.555 1 ft = 0.305 m *For Class II, III products, 5 ft spacing is acceptable. **Or Class II or III operating at temperatures > 200°F. TABLE 3. Storage Tank Spacing Recommendations For Oil And Chemical Plants. Where large amounts of flammable vapors could be released and a vapor cloud explosion could occur, perform a more detailed hazard analysis and evaluation per PRC.8.0.1.1. Calculate the vapor cloud explosion overpressure circles. Where applicable, base the minimum spacing required between units upon the following criteria: • Do not locate critical equipment of adjacent units within the 3-psi (0.21 bars) overpressure circle. • Design equipment or structures of adjacent units within the 1-psi (0.07 bars) overpressure circle to withstand the calculated vapor cloud overpressure. If the minimum spacing requirements based on a vapor cloud explosion differ from the minimum spacing required by the spacing tables, use the greater of the two. Property Risk Consulting Guidelines 5 A Publication of AXA XL Risk Consulting PRC.2.5.2 Overall Plant Layout Initially, base site selection on exposure from uncontrollable factors, such as floods, earthquakes, tidal waves, subsidence, hurricanes, and adjacent oil and chemical plants. Once a site has been selected, arrange layout and spacing to reduce the effect of some of the following controllable and uncontrollable factors that contribute to losses: • Uncontrollable factors include site slope, climate, exposure to natural hazards, wind direction and force. However, locating ignition sources upwind of potential vapor leaks or locating the tank farm downhill of essential units may reduce the loss potential from an explosion or fire. Figure 1 illustrates a good layout based on the prevailing wind. • Controllable factors include process design parameters, process equipment design, unloading facilities, maintenance, spare parts supply, control logic and automation, ignition sources, fire protection design, spare production capacity, flammable liquid holdups, spill control and the type of process. Use proper drainage and separation to control spills and fire spread. Refer to PRC.2.5.3 and PRC.8.0.1.2. Figure 1. Good Layout Example. Reprinted by permission of NOVACOR Chemical Ltd. Use a hazard assessment of each plant operation to help establish the layout or orientation of blocks or unit battery
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