Revision - II
FOR RESTRICTED
CIRCULATION
LAYOUTS
FOR
OISD-STD-118
Revision II
September 2004
FOR RESTRICTED
CIRCULATION
LAYOUTS
FOR
Prepared by
Committee on
Layouts for Oil and Gas Installations
NOTE
OISD Publications are prepared for the use in the Oil and Gas Industry
under the Ministry of Petroleum & Natural Gas. 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.
Though every effort has been made to assure the accuracy and reliability of
the data contained in these documents, 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.
(ii)
FOREWORD
Oil Industry in India is over 100 years old. As such variety of practices have been in vogue
because of collaboration / association with different foreign companies and governments.
Standardization in design philosophies and operating & maintenance practices at national
level was hardly in existence. This, coupled with feed back from some serious accidents that
occurred in the recent past in India and abroad, emphasised the need for the industry to
review the existing state-of-the-art in designing, operating and maintaining oil and gas
installations.
With this in view, 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, standardising and upgrading the existing standards to
ensure safer operations. Accordingly, OISD constituted number of functional committees
comprising experts nominated from the industry to draw up standards and guidelines on
various subjects.
The original document on "Layouts for Oil and Gas Installations" was published in
November 1988 and its first revision released in July 1995. In August 2000 it was amended
inline with the recommendations of the High Power Committee. The present document on
Layouts for Oil and Gas Installation is the second revision of this OISD Standard.
Attempts have been made to incorporate the latest technological changes, experience gained
after the implementation of standards and relevant updation in the various national and
international codes and practices.
It is hoped that the provision of this document, if implemented objectively, will go a long
way in improving the safety in oil and gas industry.
This document will be reviewed periodically for improvements based on the experience and
better understanding. Suggestions from industry members may be addressed to:
The Coordinator
Committee on Layouts for Oil and Gas Installation
Oil Industry Safety Directorate
7th Floor, New Delhi House
27, Barakhamba Road
New Delhi-110 001
(iii)
COMMITTEES ON
LAYOUTS FOR OIL AND GAS INSTALLATIONS
Members
Shri K K Arora
Shri S K Mukherjee
Shri V K Raina
Member Coordinator
Shri B K Trehan
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 /
COMMITTEES ON
LAYOUTS FOR OIL AND GAS INSTALLATIONS
Second Revision Month /Year
LEADER
MEMBERS
Shri K.T.Lokhande,
Shri S.G.Palnitkar,
Shri D.K.Banerjee
Shri M.D.Shah
Shri S.S.Maji,
BPCL, NOIDA
Shri A.Buragohain,
MEMBER-CO-ORDINATOR
S K Aggarwal
In addition to the above, several other experts from the industry contributed in the
preparation, review and finalization of this document.
(v)
INDEX
SECTION
CONTENTS
PAGE No.
1.0
Introduction
2.0
Scope
3.0
Definitions
4.0
5.0
Layout of Blocks/Facilities
6.0
7.0
8.0
9.0
References
TABLES
T1.
T2.
T3.
T4.
T5.
T6.
T7.
OISD-STD-118
1
---------------------------------------------------------------------------------------------------------------------------------------
INTRODUCTION
Hydrocarbon processing and handling
plants are inherently hazardous. Today's
trend of large and complex plants
present substantial risk potential. At
times plants are modified to operate at
higher capacities or efficiencies
necessitating larger storage requirements
than contemplated earlier. For these
reasons, initial site analysis for the
proposed new construction or addition
should be done carefully while
considering the space allocation to the
various facilities.
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. The minimum
distances recommended many years ago
need review in the context of today's
environment in the industry.
2.0
b)
c)
SCOPE
e)
DEFINITIONS
d)
Block
Facilities operated / used in integrated
way and surrounded by roads. For
example process unit, boiler house,
group of tanks located in a dyke, group
of pressurized storage tanks, loading
gantries, flare etc.
3.0
a)
Facility
This refers to any building, structure,
installation, equipment, pipeline, or
other physical feature used in petroleum
refining, storage, transportation and
distribution.
Fire station
A building housing facilities of parking
fire tenders and keeping other ready to
use fire-fighting equipment for meeting
plant emergencies, fire control room
with
required
communication
facilities/mimic panel.
f)
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
flash on application of a small pilot
flame under specified conditions of test
as per IS: 1448 (Part-I).
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from
use of the OISD Standards/ Guidelines/ Recommended Practices."
OISD-STD-118
2
---------------------------------------------------------------------------------------------------------------------------------------
h)
i)
l)
m)
May
n)
o)
p)
Hazardous Area
q)
k)
Process Unit
A unit having integrated sequence of
operation, physical and chemical, and
may involve preparation, separation,
purification, or change in state, energy
content or composition.
Petroleum Refinery
Petroleum Refinery is a plant where
crude oil is received and processed into
intermediates and finished products.
Pipeline Installations
Pipeline Installations are the facilities on
cross-country pipelines and include
sectionalizing valve station, pig
launching
/
receiving
station,
intermediate
pumping
station
/
compressor station, tap-off station,
dispatch and receiving facilities with or
without storage.
r)
s)
Service building
A building housing facilities for
inspection / maintenance / other
supporting services which are directly
required for operation of the plant e.g.
warehouse, workshop etc.
LPG Facilities
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from
use of the OISD Standards/ Guidelines/ Recommended Practices."
OISD-STD-118
3
---------------------------------------------------------------------------------------------------------------------------------------
t)
Shall
Should
Indicates
provisions
that
are
recommended but not mandatory.
Implementation of these provisions shall
be made based upon consideration of the
followings, as appropriate: (a) risk /
benefit analysis, (b) company standards,
(c) company experience, and (d)
company philosophy.
v)
Stabling Line
It is an additional railway line / spur
reserved for additional rake / stabling.
w)
f)
g)
h)
i)
j)
k)
l)
x)
Tank height
Tank height is the height from tank
bottom to top kerb angle for cone roof
tanks. For floating roof tanks, it is the
height from tank bottom to top of tank
shell.
y)
4.0
a)
b)
c)
d)
e)
o)
5.0. LAYOUT
OF
BLOCKS
FACILITIES
To prepare a layout, information should
be collected on the following aspects, as
applicable;
- Process units, utility requirements,
storage tanks, LPG storage vessels
and other pressurized storage vessels
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from
use of the OISD Standards/ Guidelines/ Recommended Practices."
OISD-STD-118
4
---------------------------------------------------------------------------------------------------------------------------------------
(j)
- Aviation considerations
- Risk to and from adjacent facilities
- Environmental considerations
- Statutory obligations
5.1
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from
use of the OISD Standards/ Guidelines/ Recommended Practices."
OISD-STD-118
5
---------------------------------------------------------------------------------------------------------------------------------------
(o)
(p)
(q)
(r)
(s)
(t)
(u)
5.2
Separation distances;
Minimum separation distances between
various blocks / facilities described
above shall be as per Table-1. The table
shall be read in conjunction with the
notes specified with the table.
6.0
6.1
(a)
(b)
(c)
(d)
(e)
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from
use of the OISD Standards/ Guidelines/ Recommended Practices."
OISD-STD-118
6
---------------------------------------------------------------------------------------------------------------------------------------
(o)
(g)
Thermo-siphon
reboilers
should
preferably be placed close to their
associated towers.
(p)
(h)
(q)
(i)
(r)
(s)
(t)
(u)
6.2
(f)
(j)
(k)
(l)
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from
use of the OISD Standards/ Guidelines/ Recommended Practices."
OISD-STD-118
7
---------------------------------------------------------------------------------------------------------------------------------------
7.1
General considerations
7.1.1
Dyked Enclosures;
(a)
(e)
(f)
(g)
7.1.2
(a)
(b)
(c)
(c)
(d)
Grouping;
(b)
(c)
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from
use of the OISD Standards/ Guidelines/ Recommended Practices."
OISD-STD-118
8
---------------------------------------------------------------------------------------------------------------------------------------
(b)
(c)
(d)
7.2
General;
The tank height shall not exceed one and
half times the diameter of the tank or 20
m whichever is less. For the installations
covered under Oil Mines Regulation, the
maximum height of the tank, dyke
requirements etc. shall be as per Oil
Mines Regulations
Piping from / to any tank located in a
dyked enclosure should not pass through
any other dyked enclosure. Piping
connected to tanks should run directly to
outside of dyke to the extent possible to
minimise piping within the enclosures.
8.1
General Considerations:
8.1.1
LPG Storage;
The requirements given below are
applicable to above ground LPG storage
facilities. For mounded LPG storage,
refer OISD-STD-150.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
8.0
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from
use of the OISD Standards/ Guidelines/ Recommended Practices."
OISD-STD-118
9
---------------------------------------------------------------------------------------------------------------------------------------
(b)
(c)
(d)
(e)
8.1.3
(a)
(c)
8.2
Separation
facilities;
distances
REFERENCES:
9.0
for
11. NFPA
30,
flammable
Combustible Liquid Code.
LPG
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from
use of the OISD Standards/ Guidelines/ Recommended Practices."
and
OISD-STD-118
---------------------------------------------------------------------------------------------------------------------------------------
10
From / To
2
Note-3
Process Units
Note-1
Note-3
10
30
30
30
60
90
45
45
60
30
60
90
45
45
30
11
45
12
13
14
15
16
30
60
60
30
90
Note-3
30
15
30
30
Note-4
Note-5
30
Note-4 Note-6
Note-6
Note-6
30
90
30
30
60
(90)
30
T3
60
30
50
30
Note -5 Note-6
Note-6
Note-6
30
90
30
30
60
(90)
30
T3
30
30
50
30
30
Note-6
Note-6
30
90
30
30
60
(90)
30
T3
30
30
50
Pressurised Storage:
LPG/ C4 & Lighter / H2
60
60
30
30
30
T7
90
30
T6
90
(90)
30
T7
45
30
60
Flare
(Note-7)
Bulk Loading POL
(Rail /Road)
90
90
90
90
90
90
90
90
90
90
90
90
90
90
90
90
45
45
30
30
30
30
90
Note-8
T3
60
30
50
45
45
30
30
30
T6
90
Note-9
60
30
60
60
60
90
90
60
(90)
(90)
(90)
(90)
90
30
Note-10
8
9
10
Fire Station /
First Aid Center
Boiler house / Process
Unit Heaters (Note-11)
11
45
TABLE 1
Note-3
Note-6
Note-9
60
30
90
(90)
T6
T6
60
30
50
90
30
30
12
12
30
90
(90)
30
15
50
30
30
Note12
T6
30
15
30
15
50
T6
Note-10
12
Rail Spur
30
30
30
30
30
90
13
60
30
T3
T3
T3
T7
90
T3
T6
12
50
30
30
50
14
Service buildings
60
15
60
30
30
45
90
60
60
12
30
30
50
15
Cooling tower,
30
30
30
30
30
30
90
30
30
30
30
15
30
30
15
16
90
30
50
50
50
60
90
50
50
90
50
50
50
15
Note-12
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended
Practices."
OISD-STD-118
---------------------------------------------------------------------------------------------------------------------------------------
11
All distances shall be measured between the nearest points on the perimeter of each facility except (i) In case of tank vehicle loading /
unloading area where the distance shall be from the center of nearest bay. (ii) The distances given in the brackets ( ) are from the shell of
the Heater / Boiler / Furnace / Still.
This shall be 36 meters considering the 6-meter wide road passing through the center. The edge of the road shall not be less than 15 meters away from the edge of
the unit.
Note-2:
Note-3:
Process control room to Process units / boiler house / heaters the minimum separation distance shall be 30 m. For a control room attached to single process unit
or a boiler or a heater, the minimum separation distance shall be 16 m. For Gas processing plants, it shall be minimum 30 meters irrespective of whether it is for
one or more units.
Note-4:
Note-5:
Note-6:
Separation distances between the nearest tanks located in two dykes shall be equivalent to the diameter of the larger tank or 30 m, whichever is more. For
distances within a dyke, it shall be as per Table-3 and Table-4
Note-7
The distances specified are for the elevated flare. For ground flare, these distances shall be 150 m. For Exploration & Production installations, this shall be in
line with Oil Mines Regulations
Note-8
Separation distance between Tank truck gantry and wagon gantry shall be 50m.
Note-9
The separation distance shall be 50 m. However for LPG tank truck bulk loading to POL tank truck bulk loading it shall be 30 m.
Note-10
Separation distance between tank truck gantry and rail spur shall be 50 m.
Note-11:
Boiler house or heater of a process unit is to be treated as a separate identity only for the consideration of surrounding blocks / facilities. However, heater of a
process unit remains an integral part of the process unit to which it is attached and in that case the inter equipment distances should be inline with Table 2.
Note-12:
Centralized / common API separators, Corrugated Plate Interceptor (CPI), open oil separators shall be categorized under the same risk and shall be located at a
distance of 90 meters from heaters / boilers. However, if these are covered from the top and provided with adequate venting to safe location, the minimum
separation distance shall be 30 meter.
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended
Practices."
OISD-STD-118
---------------------------------------------------------------------------------------------------------------------------------------
12
From / To
TABLE-2
10
11
12
13
14
15
16
15
15
15
22
15
15
20
15
15
15
18
30
15
15
15
15
15
Distillation column
15
15
15
15
15
15
15
15
22
15
15
20
Accumulators
Hydrocarbons
Compressors Hydrocarbons
Hot oil pump
15
15
15
15
15
15
15
15
T-5
15
15
15
15
15
15
15
15
20
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
10
15
18
15
10
15
14
15
15
30
15
15
15
20
15
15
15
15
15
15
15
15
15
15
15
15
15
9
10
11
12
13
16
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended
Practices."
OISD-STD-118
---------------------------------------------------------------------------------------------------------------------------------------
13
b)
x indicates suitable distance as per good engineering practices to meet construction, operational and maintenance requirements.
c)
Distances specified in Table-2 are the minimum recommended distances that the industry should adhere. These could be suitably
modified as required to suit space constraints and relevant engineering practices except the followings.
(i)
Blow down facility (open pit type) / oil catcher shall be located at a distance not less than 30 m from fired heater / any fired
equipment. If the blow down drum is located underground / oil catcher is cover with vent to safe location, the minimum
separation distance shall be 15m.
(ii)
Fuel Oil day tank shall be located at a distance of not less than 15m from equipment except those facilities such as heat
exchanger, pump connected directly with the Fuel Oil system.
d)
Firewater hydrant / monitors shall be minimum 15 m away from the equipment that is to be protected.
e)
Water spray deluge valve shall be minimum 15 m from equipment handling hydrocarbon.
f)
Fuel gas knock out drum shall be located at a minimum separation distance of 15 m from the heater.
g)
Separation distances specified in other OISD standards or elsewhere in this standard (other than Table 2) shall be followed as
recommended.
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended
Practices."
OISD-STD-118
---------------------------------------------------------------------------------------------------------------------------------------
14
TABLE - 3
T4
T4
15
15
15
15
15
T4
15
15
15
15
15
15
15
10
15
15
15
15
20
15
15
10
15
15
15
Boundary wall
0.5 D
0.5 D
15
10
20
10
Min 20 m
Min 20 m
9
0.5 D
Min 20 m
15
0.5 D
Min 20 m
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended
Practices."
OISD-STD-118
---------------------------------------------------------------------------------------------------------------------------------------
15
TABLE 4
(D+d) / 4
Min 10 m
(D+d) / 4
(D+d) / 4
Min 10 m
(D+d) / 3
(D+d) / 6
Min 6 m
(D+d) / 4
b) x indicates suitable distance as per good engineering practices to meet construction, operational and maintenance requirements
c) D & d stands for diameter of larger and smaller tanks.
d) In Table 3 all distances shall be measured between the nearest points on the perimeter of each facility except in the case of tank
vehicle loading/unloading area where the distance shall be measured from the center of each bay.
e) In Table 4, Distances given are shell to shell in the same dyke.
f) For different combination of storage tanks, the stringent of the applicable formulae shall be considered for minimum separation
distance.
g) The distance of storage tanks from boundary wall is applicable for;
(i)
(ii)
Tanks with weak roof-to-shell joint having approved foam or inerting system and the tank diameter not exceeding 50 meters
OISD-STD-118
---------------------------------------------------------------------------------------------------------------------------------------
16
TABLE 5
10
11
12
13
0.5D
0.5D /
6.0
15
15
15
15
15
15
0.5D /
6.0
0.5D
0.5D
4.5
4.5
4.5
D
Min 4.5
D
Min 4.5
0.5D
0.5D
0.5D /
6.0
0.5D /
6.0
0.5D
4.5
0.5D
Min 3.0
0.5D
Min 3.0
4.5
0.5D
0.5D
4.5
1.5
4.5
4.5
1.5
4.5
4.5
4.5
0.5D
1.5
4.5
15
15
4.5
4.5
4.5
4.5
4.5
1.5
4.5
4.5
4.5
15
4.5
4.5
4.5
10
1.5
1.5
11
15
4.5
4.5
4.5
12
15
D
Min 4.5
0.5 D
Min 3.0
4.5
4.5
13
Boundary wall
15
D
Min 4.5
0.5D
Min 3.0
4.5
4.5
0.5D
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended
Practices."
OISD-STD-118
---------------------------------------------------------------------------------------------------------------------------------------
17
a)
All distances are in meter and the table specifies the minimum requirement.
b)
x indicates suitable distance as per good engineering practices to meet construction, operational and maintenance requirements
c)
d)
Distances given for the tanks are shell to shell in the same dyke.
e)
Where alternate distances are specified (like 0.5 D / 6.0), the minimum thereof shall be used.
f)
All distances shall be measured between the nearest points on the perimeter of each facility except in case of tank vehicle loading
/unloading area where the distance shall be from the center of each bay.
g)
Pig launcher/receiver at liquid hydrocarbon handling pipeline installations should be located at least 5 m from boundary.
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended
Practices."
OISD-STD-118
---------------------------------------------------------------------------------------------------------------------------------------
18
TABLE - 6
FROM / TO
Note-1
T7
30
30
50
30
15
60
T7
30
30
50
30
30
30
30
15
30
50
30
15
60
30
30
30
30
50
50
30
60
50
50
50
50
50
50
30
60
Rail spur
30
30
30
50
50
50
30
60
15
30
15
30
30
30
60
60
60
60
60
60
60
"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from use of the OISD Standards/ Guidelines/ Recommended
Practices."
OISD-STD-118
---------------------------------------------------------------------------------------------------------------------------------------
19
TABLE 7
SEPARATION DISTANCES BETWEEN LPG STORAGE VESSELS AND BOUNDARY WALL / GROUP OF BUILDINGS NOT
ASSOCIATED WITH LPG FACILITIES
Capacity of Each vessel in Cum of water
Distance in meters
10 - 20
21 - 40
41 - 350
351 - 450
451-750
751 - 3800
15
20
30
40
60
90