LAYOUTS FOR OIL AND GAS INSTALLATIONS

OISD – STD. 118

INDEX

SECTION CONTENTS

1.0 Introduction
2.0 Scope
3.0 Definitions
4.0 Plant Layout Philosophy
5.0 Layout of Blocks/Facilities
5.1 General Considerations
5.2 Inter-distances
6.0 Layout of Process Units
6.1 General Considerations
6.1.1 Process Equipment
6.1.2 Control Room and Sub-Station
6.2 Equipment Spacing within Process Units
7.0 Layout of Storage Tanks
7.1 General Considerations
7.2 Inter-distances between Tanks / Offsite Facilities
8.0 Layout of LPG Facilities
8.1 General Considerations
8.1.1 LPG Storage
8.1.2 LPG Bottling
8.1.3 LPG Bulk Handling
8.2 Inter-distances for LPG Facilities
9.0 Layout of Utility Stations
9.1 General Considerations
9.2 Inter-distances
10.0 References

TABLES
1. Inter-distances between Blocks/Facilities
2. Equipment Spacing within Process Units
3. Inter-distances between Storage Tanks/Offsite Facilities
(for Small Installations)
4. Inter-distances between Storage Tanks/Offsite Facilites
5. Inter-distances between Storage Tanks
6. Distances from Boundary Fencing
7. Inter-distances for LPG Facilities
 8. Inter-distances between LPG Storage Vessels and Boundary/Property Line/
Group of Buildings not associated with LPG plant.

ANNEXURE 1: TYPICAL LAYOUT OF LPG STORAGE VESSELS

LAYOUTS FOR OIL AND GAS INSTALLATIONS

1.0 INTRODUCTION (i) PETROLEUM REFINERY

Petroleum Refinery is a plant where crude oil is

Hydrocarbon processing and handling plants are
inherently hazardous. Today's trend of large and
complex plants presents 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 up-dating 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.
It is not intended that requirement of this
standard should be applied rigidly to existing premises
where for a variety of reasons, it may not be practicable
to comply with. This standard will however create
awareness and help in selective implementation of the
recommen-dations at existing installations.
received and processed into intermediates and
finished products.
(ii) OIL/GAS PRODUCTION PLANT
Oil/Gas production plant is a plant where oil
and/or gas is collected, stabilised and despatched
for further processing. Drilling activities and
facilities upstream of the christmas tree of a well
are not covered under this definition.
(iii) GAS PROCESSING PLANT
Gas processing plant is a facility where natural
gas is received and processed to make gas, LPG,
condensate etc.
(iv) LPG FILLING PLANT
LPG filling plant is a plant where liquefied
petroleum gas (LPG) is received/despatched by
rail, road and pipeline and filled in cylinders.
(v) OTHER PETROLEUM STORAGE INSTALLA-
TIONS

2.0 SCOPE Other petroleum storage installations include:

This document lays down minimum
requirements of layouts within the plant boundary for
petroleum refineries, Oil/Gas production and
processing plants, LPG filling plants and other
petroleum storage installations. The requirement of
green belt/buffer zone beyond the plant boundary is
outside the scope of this standard. Such provision may
be considered based on local environmental/ security
requirements.
- Crude oil gathering stations
- Coastal storage installations for crude oil
and petroleum products
- Marketing depots and terminals
- Aviation storage and fuelling stations
- Pipeline installations/terminals.
(vi) FLASH POINT

3.0 DEFINITIONS
 "Flash point" of any petroleum liquid is the
minimum temperature at which the liquid yields
vapour in sufficient concentration to form an
ignit-able mixture with air and gives a
momentary flash on application of a small pilot
flame under speci-fied conditions of test as per
IS:1448 (Part-I).
(vii) GENERAL CLASSIFICATION OF
PETROLEUM PRODUCTS
Petroleum products are classified according to
their closed cup FLASH POINTS as follows:
— Class "A" Petroleum:
Liquids which have flash point below 23
o
C.
— Class "B" Petroleum:
Liquids which have flash point of 23 oC
and above but below 65 oC.
— Class "C" Petroleum:
Liquids which have flash point of 65 oC
and above but below 93 oC.
— Excluded Petroleum:
Liquids which have flash point of 93 oC
and above.
Liquefied gases including LPG, do not fall under
this classification but form separate category.
In the following cases, above classification does
not apply and special precautions should be
taken as required:
(a) Where ambient temperatures or the
handling temperatures are higher than the
flash point of the product.
(b) Where product handled is artificially
heated to a temperature above its flash
point.
(viii) TANK HEIGHT
Tank height is the:
- Height from tank bottom to top kerb angle
for cone roof tanks
- Height from tank bottom to top of tank
shell for floating roof tanks
(ix) STABLING LINE
It is an additional railway line/spur reserved for
additional rake/stabling.
4.0 PLANT LAYOUT PHILOSOPHY
A petroleum installation may be broadly
considered as a group of one or more of the following
units/facilities:
- Crude oil storage
- Intermediate and finished product storage
- LPG storage and handling facilities
- Process units and control room
- Product loading/unloading facilities (Rail,
Road and Pipelines)
- Utilities generation and distribution centres
- Blowdown and flare system
- Waste water treatment facilities
- Administrative and service buildings
(ware-house, workshop, canteen, fire
station, laboratory, first aid, parking lot
etc.)
Following points shall be kept in mind while
developing overall plant layout of any
installation.
(i) BASIC INFORMATION
(a) Information on following items should be
collected before proceeding with the
development of overall plot plan:
- Process units and their capacities
- Process flow diagram indicating flow
sequence
- Utility requirements
- Storage tanks list
- LPG storage vessels and their sizes
- Product despatch and mode of transport
(rail, road and pipeline)
- Warehouses, open storage areas
- Number of flares
 - Operating and maintenance philosophy for
grouping of utilities
- Plant and non-plant buildings
- Environmental considerations
- Scrap yards and dumping ground
- Fire station and fire training ground
- Chemical/Toxic Chemical storage
- Storage areas for solid products such as
petroleum coke, petroleum wax, coal,
bitumen and asphalt
(b) Data on following infrastructural facilities
should be collected before detailed layout
activity is taken up and due consideration
should be given for the same while deciding
plant layout:
- Site location map
- Prevailing wind direction
- Area topography contour map
- High flood level in the area
- Source of water supply and likely entry
point
- Electric supply source and direction of entry
point
- Crude oil entry point
- Storm water disposal point and effluent
disposal point
- Railway entry point and marshalling yard
location
- Approach roads to main plant areas
- Inward/outward product movement by
rail/ road and pipelines.
- Surrounding risks
(ii) BLOCKS
(a) In any process installation, it is recommen-
ded that plant layout arrangement should
follow the general route of raw material to
process unit (s) with tankages interposed as
required followed by despatch facilities.
(b) Block layout should be adopted as much as
possible. The entire area should be sub-
divided into blocks. Maximum size of a
block should be established based on tank
farm layouts.
(iii) ROADS
(a) All process units and dyked enclosures of
storage tanks shall be planned in separate
blocks with roads all around for access and
safety. Primary traffic roads in the
installation should be clear of hazardous
classified areas. Roads separating the blocks
shall provide fire breaks and have facilities
for fire fighting activities.
(b) Alternative access should be provided for
each facility so that it can be approached for
fire fighting/maintenance/construction in
the event of blockage on one route.
(c) Road widths and turning radii at road
junctions shall be designed to facilitate
movement of the largest fire fighting vehicle
in the event of emergency.
(d) Rail spur shall be located close to the
periphery of the plant to minimise road
crossings and blockage of roads during
shunting.
(e) Layout of the facilities shall be made to
minimise truck traffic ingress in the plant.
(f) Two road approaches from the highway
should be provided, one for employees and
other for product movement. Both these
approaches should be available for receipt
of assistance in emergency. However, for
smaller installations, this requirement may
be relaxed if not feasible.
(iv) LOCATION
(a) Process unit(s) should be located on high
ground to avoid flooding.
(b) Presence of ignition source shall always be
contemplated beyond the boundary wall of
the installation.
(c) Orientation of flares,furnaces/heaters, dusty
operations (e.g. sulphur handling) and
cooling towers should be decided based on
prevailing wind direction.
(V) ERECTION AND MAINTENANCE
(a) Erection methods shall be anticipated for all
types of equipments. Towers, reactors and
fired equipments should be located away
from congested areas to facilitate erection at
any stage.
(b) Maintenance methods for each type of
equipment shall be identified in advance
since these affect the requirements for
layout. Equipment requiring frequent atten-
tion shall have easy accessibility. For equip-
ments having removable parts, wherever
possible, arrangements shall be made to
facilitate their removal without dismantling
long lengths of piping. Free access shall be
provided for hoisting the equipment.
(vi) FUTURE EXPANSION
Future expansion shall be assessed and space
provision for known and unforeseen needs shall
be made. Orderly future expansion shall be
affected by providing space adjacent to similar
type of facilities for expansion. Extension of pipe
sleepers and pipe way, road crossings for yard
piping shall be given due consideration. Care
shall be taken to facilitate future expansion
without any interferene to plant on-stream.
5.0. LAYOUT OF BLOCKS/FACILITIES
An installation may consist of one or more of the
following basic blocks/facilities:
- Storage tanks/offsites
- LPG storage and filling facilities
- Process units
- Utilities and effluent disposal facilities
5.1 GENERAL CONSIDERATIONS
While locating the above blocks/facilities and
further sub blocks/facilities within them, following
items should be considered :
(i) Layout planning should be in sequential order of
process flow.
(ii) Orientation should be to suit wind direction to
avoid travel of hydrocarbon vapour over sources
of ignition.
(iii) Process units should be centrally located with
straight approach from main gate. Orientation of
process units should follow process flow in
sequential order so that piping runs are also
minimum.
Location of tall columns and furnaces should be
close to road side for ease of construction and
maintenance.
(iv) Storage tanks should be grouped according to
product classification. In undulating areas,
storage tanks should be located at lower
elevations.
(v) Utility blocks should be located adjacent to unit
blocks.
(vi) Main power receiving station should be close to
the fence line with minimum overhead power
transmission lines passing through the installa-
tion.
Overhead power transmission lines shall not pass
over process units, storage tanks, offsite and
utility areas. Wherever these lines are passing
through plant premises adequate safety distances
shall be kept.
(vii) H T sub-station should be located close to major
load centres. One or more sub-stations could be
provided to limit distances.
(viii) L T sub-station should generally be located at
load centres in such a way that the distance
between distribution transformer and farthest
motor is minimum.
(ix) Gas/Oil based power plants should be located
close to process units/utility blocks and closer to
Main Receiving Station, as far as possible. Coal
based power plants should be located away from
criticalfacilities like air separation plants, electri-
cal installations etc. to avoid problems due to coal
dust and ash.
(x) Flare should be located upwind of process units.
Height of flare and its distance from operating
facilities shall be decided based on heat radiation
considerations and other considerations like
ground level concentration, cold venting etc.
 5.2 INTERDISTANCES
Area around flare should be paved to avoid
growth of grass/vegetation which can otherwise Interdistances between various blocks/facilities
provide combustible material for fires. (Ref. described above shall be as per Table-1.
section 8.0 of OISD-STD-106 on "Process Design
and Operating Philosophies on Relief and
Disposal systems").

(xi) Truck loading facilities should be located close to

product movement gate. Rail loading facilities
should suit rail siding layout and preferably be
located along periphery of the installation.

(xii) Effluent Treatment Plants should be located

minimum one block away from unit area, down
wind of process units and important areas to
avoid odour problems. They should be closer to
disposal point and at lower grade to facilitate
gravity flow of effluent.

(xiii) Sulphur recovery unit and sulphur loading area

should be located close to product movement
gate and away from hazardous and populated
areas. A minimum distance of 50m is recommen-
ded between sulphur storage/handling and any
building or boundary wall.

(xiv) Petroleum coke/coal storage and handling

facilities should be located as far as possible away
from process units, air separation plants,
populated and hazardous areas.

(xv) Sufficient open areas should be left where

construction activities can be undertaken.
Requirements for erecting tall structures should
be studied before finalising the layout.

(xvi) Fire station should be located close to main entry

gate with straight approach to process
units/other critical areas. Fire station and fire
water pump house shall be located at a safe place
away from hazardous areas. Fire station includes
fire tenders, foam equipments and fire fighting
accessories.

(xvii) Fire water storage and pumps shall be located at

a minimum distance of 60 m from hydrocarbon
storage and process units. However for
petroleum depots and terminals, it shall be as per
clause 4.3.5(V) of OISD-STD-117.
OISD-STD-118 Revision - II 9

TABLE - 1 (NOTE1)
MINIMUM INTERDISTANCES BETWEEN BLOCKS/FACILITIES

S.No. From \ To 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1. Process Units 36 *** 30 45 30 60 90 150 45 60 45 30 60 60 30 90

2. Process Control *** - ** 45 30 60 90 150 45 30 30 - 30 15 30 30

Room

3. Storage Tank 30 ** T3 & T3 & T3 & 30 90 150 30 60 90 30 T6 60 30 50

Class A T5 T5 T5

4. Storage Tank 45 45 T3 & T3 & T3 & 30 90 150 30 60 90 30 T6 30 30 50

Class B T5 T5 T5

5. Storage Tank 30 30 T3 & T3 & T3 & 30 90 150 30 60 90 30 T6 30 30 50

Class C T5 T5 T5

6. Storage Vessels 60 60 30 30 30 T7 90 150 30 90 90 30 T8 45 30 60

(Pressure) LPG/Other

7. Flares-elevated 90 90 90 90 90 90 90 150 90 90 90 90 90 90 90 90

8. Flares-ground 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150

9. Bulk loading racks 45 45 30 30 30 30 90 150 T7 90/60 30 T7 T6/T760 30 50

(rail/road) LPG/POL

10. Fire stations/ 60 30 60 60 60 90 90 150 90/60 - 30 30 12 12 30 90

First aid centre

Contd...
10

TABLE - 1 (Contd..)

S.No. From \ To 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

11. Boiler House/ 45 30 90 90 90 90 90 150 30 30 - 15 50 30 30 90

heaters

12. Rail spur 30 - 30 30 30 30 90 150 T7 30 15 - 30 6 15 50

13. Boundary fence 60 30 T6 T6 T6 T8 90 150 T6/T7 12 50 30 - 6 30 50

around installation

14. Service buildings 60 15 60 30 30 45 90 150 60 12 30 6 6 - 30 50

15. Cooling towers, 30 30 30 30 30 30 90 150 30 30 30 15 30 30 - 15

water storage,
nitrogen plant

16. API Separators/ 90 30 50 50 50 60 90 150 50 90 90 50 50 50 15 -

oil sludge pit

** Distance will be 30 meters in case Control Room is blast proof and 60 meters in case it is not blast proof.

*** Refer OISD-STD-163 on Process Control Room Safety

Notes :
1. All distances are in metres.
2. 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 measured from the centre of each bay.
3. "T" indicates the table to be referred.
4. Where distances have not been specified, it shall be decided based on construction,operation & maintenance requirements.
5. API/CPI, open oil separators/oil collection sumps shall be categorised under the same risk and shall be located at 90m distance from
heaters/boilers. However, if these are covered from top and provided with adequate venting to safe location, the minimum safe distance can be
reduced from 90m to 30m.
OISD-STD-118 Revision - II 11

6. Distance between bulk loading racks and fire station shall be :

(i) For LPG Gantry - 90 m &
ii) For POL Gantry - 60 m.

7. Definitions :

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.

Service building – a building housing facilities for inspection/maintenance/other supporting services which are directly required for operation of the
plant.

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.

Fire pump house – a building housing main fire water pumps, jockey pumps, communication and alarm system, instrumentation and the required
operating & supporting personnel.
12
6.0 LAYOUT OF PROCESS UNITS
6.1 GENERAL CONSIDERATIONS
6.1.1 PROCESS EQUIPMENT
(i) Process flow sequence and operating
procedures shall be thoroughly understood
so that equipment arrangement in the plot
plan is functional. Equipment shall be
arranged in logistic process sequence for
short piping runs and operational ease.
(ii) It is recommended that the unit pipe rack
be kept in the centre, thereby splitting the
unit into two or more areas of
equipments.Pumps may be arranged in
two rows close to and on either side of the
central pipe rack. Heat Exchangers and
vessels should be grouped together
forming outer rows on both sides of the
rack. Fired heaters should be kept at open
end of the unit upwind from the remaining
plant equipments.
(iii) Spacing between battery limits of
individual pieces of equipment shall be
adequate for undertaking maintenance
jobs.
(iv) Spacing between two process units in a
complex should be decided based on shut
down philosophy for maintenance of the
units. If the shut down of the units are
expected at different occasions, then inter
distances may be increased.This will
facilitate ease in maintenance and
minimise risk from/for operating units
due to hot jobs in the units under shut
down.
(v) Heat exchangers should be located
perpendicular to the pipe rack on the outer
row to facilitate pulling of tube bundles
with mobile crane or by other means. Shell
and tube heat exchanger should have a
longitudinal clearance of at least one metre
plus the length of removable bundles.
(vi) Air fin coolers should be installed above
the pipe rack. Pumps handling hydro-
carbons and materials above the
temperature of 230 degree C should not be
installed underneath the air fin coolers.
OISD-STD-118 Revision - II
-118 Revision - I
(vii) Cold boxes should be located on grade or
on separate elevated structures. Adequate
space should be provided around cold
boxes for ease of operation and
maintenance.
(viii) Vessels having large liquid hold-up should
be installed at lower heights and preferably
at grade. Adequate drainage should be
provided around such vessels. Where
process requirement dictates their installa-
tion above grade, these should be located
in open area.
(ix) Towers/columns should be located along
the pipe rack towards open areas for
unobstructed erection as well as
maintenance of internals at grade. Tall
towers require frequent operating attention
at upper levels. Hence they may be located
at one place so that common connecting
platform can be provided.
(x) Thermo-siphon reboilers should
preferably be placed close to their
associated towers. Reboiler should be
mounted on the tower so that vertical
expansion will be uniform, piping system
design is simplified and inlet/outlet piping
is minimised. Clearance shall be provided
for movement between reboiler and tower.
(xi) Gas compressors should be located down
wind from heaters so that leaked gases will
not drift towards the heater. Gas
compressors should have roofing and open
from sides to avoid accumulation of
heavier vapours/gases on the floor of
compressor house. Compressor house
should be located near the battery limits to
facilitate ease in maintenance and
operation.
(xii) Heaters should be located up wind at one
corner of the unit. Space should be
provided for removal and cleaning of
heater tubes besides approach for crane.
Areas around the heaters shall be graded
for guiding spills away from process
equipment. FD fans shall be located away
from process equipment from where they
arelikely to suck hydrocarbon vapours.
The local control panel for soot blower
control and flue gas analyser shall only be
OISD-STD-118 Revision - II
located on and near the process heater. The
rest of controls shall be taken to central
control room.
(xiii) No other tankage except day tanks shall be
provided within battery limits of any
process unit.
(xiv) Flare knock out drum of the closed blow
down system should be located at battery
limit of the unit.
(xv) Blow down facilities/burried drum shall be
located at one corner of the plant farthest
from furnace or any fired equipment and
on the lee-ward side of the unit.
Vent from Blow down facility shall be
minimum 6m clear off the air fin coolers. It
shall be minimum 6m above the highest
platform if horizontal distance of 15m from
process equipment is not possible.
6.1.2 CONTROL ROOM AND SUB-STATION
6.2
(i) Control room should be located distinctly
in the process block or in the adjoining
block. It should be at a safe distance where
13
protection to instruments and personnel is
ensured and non-hazardous electrical area
classification is permitted. It should have
alternate means of exit with doors opening
towards outside. Doors should be made of
fire proof material.
(ii) Control room should be designed to cater
for minimum occupancy.
(iii) Transformers should be located in open
area on the rear side of sub-station.Each
transformer shall be isolated from the other
by a brick masonary wall. Approach road
to sub-station and transformer bays should
be provided to facilitate crane movement
for erection and maintenance.
(iv) Electrical sub-station should be located
adjacent to the control room building and
should meet the requirements of electrical
area classification.
EQUIPMENT SPACING WITHIN PROCESS
UNITS
Interdistances betweenvarious equipments in
process units shall be as per Table-2.
14 OISD-STD-118 Revision - II

TABLE-2
MINIMUM INTERDISTANCES BETWEEN EQUIPMENTS WITHIN PROCESS UNIT
“This table could be used by the oil companies as a guideline for their projects. These could be suitably modified as required to suit space constraints and
relevant engineering practices.” NOTE 1

S.No. From \ To 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

1. Fired heaters/ - 15 15 15 22.5 15 15 20 15 15 15 16/30 15 - 18 15 6 30 15 15

any fired equip.
2. Reactors 15 2 2 6 8 7 15 7 7 4 3 16 - 15 5 15 3 15 15 3
3. Distillation 15 2 3 4 7.5 5 15 5 5 2 3 20 - 15 3 15 3 15 15 3
columns
4. Accumulators 15 6 4 2 8 5 15 4 4 2 3 20 - 15 3 15 3 15 15 3
(Hydrocarbon)
5. Gas compressors 22.5 8 7.5 8 3 7.5 15 7.5 7.5 7.5 7.5 16 - 15 4 15 3 20 15 7.5
(Hydrocarbon)
6. Hot oil transfer 15 7 5 5 7.5 1 7.5 1 1 1 2 2 16 - 15 3 15 - 15 15-
pumps
7. Fuel Oil Day tank 15 15 15 15 15 7.5 2 15 15 15 15 16 - 15 15 15 - 15 15 15
8. Pump for Class A & 20 7 5 4 7.5 1 15 1 1 2 2 16 - 15 3 15 - 15 15 -
all products above
auto-ignition temp.
9. Pumps - other 15 7 5 4 7.5 1 15 1 1 2 2 16 - 15 3 15 - 15 15 -
Hydrocarbon
10. Heat Exchanger- 15 4 2 2 7.5 2 15 2 2 2 2 16 - 15 2 15 2 15 15 -
Hydrocarbon
11. Air Fin Coolers- 15 3 3 3 7.5 2 15 2 2 2 - 16 - 15 2 15 - 15 15 2
Hydrocarbon
12. Control room 16/30 16 20 20 16 16 16 16 16 16 16 - 16 20 16 - 16 16 5 16
13. Snuffing/purging 15 - - - - - - - - - - 16 - - 2 - - 15 5 -
steam isolation
valve
OISD-STD-118 Revision - II 15
14. Fired heaters - 15 15 15 15 15 15 15 15 15 15 20 - - 10 15 - 15 15 5
control panel (local)

Contd....

TABLE - 2 (Contd...)
S.No. From \ To 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

15. Pressure Vessel/ 18 5 3 3 4 3 15 3 3 2 2 16 2 10 2 15 3 15 15 2

Drums
(Hydrocarbon)
16. Fire water 15 15 15 15 15 15 15 15 15 15 15 - - 15 15 - 15 15 - -
hydrants/monitors
17. Pipe rack (main) 6 3 3 3 3 - - - - 2 - 16 - - 3 15 - 15 15 -
18. Blow down facility 30 15 15 15 20 15 15 15 15 15 15 16 15 15 15 15 15 - 15 15
(pumps, drums,
stacks)
19. Water spray 15 15 15 15 15 15 15 15 15 15 15 5 5 15 15 - 15 15 - -
Deluge valve
20. Structural main 15 3 3 3 7.5 - 15 - - - 2 16 - 5 2 - - 15 - -
(Technological
platforms)

Notes:
1. All distances are face to face clear minimum distances in meters.
2. Distance between equipments not covered herein & equipments handling non-hydrocarbons shall be as per good engineering practices.
3. From control room to heater, safe distance shall be 16m if the control room is for one unit and shall be 30m, if it is for two units. For gas
processing plants, it shall be 30m irrespective of whether the control room is for one or more units.
4. Distances between the reactor and furnace when directly connected process-wise, can be relaxed to 5m.
5. Only distances indicated from fired heaters (1) Fuel oil day tank (7), Control room (12), Fired heater local control panel (14), Fire water
hydrant/monitor (16), Blow down facility (18) and water spray deluge valve (19) are by safety considerations. Other distances indicated are
recommended from erection, operation and maintenance safe guards.
6. The local control panel meant for soot blower control & fuel gas analyser shall only be located on and near the process firedheater. The rest of
controls shall be taken to central control room.
7. Safety distances as per preceeding Table-2 for blow down facilities are for open pit location. If the blow down drum is located underground, the
distance from fired heater shall be reduced from 30m to 15m.
8. Steam snuffing/purging valve shall be located minimum 15m from only those equipments which are served bythe steam valve.
16 OISD-STD-118 Revision - II

9. Fuel Oil day tanks shall be located at a safe distance of 15m from equipment except those facilities such as heat exchanger, pump connected directly
with the Fuel Oil system. (Refer Table-5 for interdistance between tanks).
10. Distance between fired heater and distillation column shall be increased to 22.5m in case of light ends such as Naphtha stabiliser.
11. Minimum distances between equipment shall not be applicable for package items and their related appertenances.
OISD-STD-118 Revision - II
7.0 LAYOUT OF STORAGE TANKS
7.1 GENERAL CONSIDERATIONS
(i) DYKED ENCLOSURES
(a) Petroleum storage tanks shall be located in
dyked enclosures with roads all around the
enclosure. Aggregate capacity of tanks
located in one dyked enclosure shall not
exceed following values :
For a group of
floating roof tanks : 120,000 cu.m.
For a group of
fixed roof tanks : 60,000 cu.m.
If a group of tanks contains both fixed and
floating roof tanks, thenit shall be treated
as a group of fixed roof tanks for the
purpose of above limits.
(b) Dyked enclosure should be able to contain
the complete contents of the largest tank in
the tank farm in case of any emergency.
Enclosure capacity shall be calculated after
deducting the volume of tanks (other than
the largest tank) upto the height of the
enclosure. A free board of 200 mm above
the calculated liquid level shall be
considered for fixing the height of the
dyke.
However, for excluded petroleum, the
capacity of the dyked enclosure should be
based on spill containment but not for
containment on tank rupture.
(c) The height of tank enclosure dyke shall be
at least one metre and shall not be more
than 2.0 m above average grade level
inside. However, for excluded Petroleum,
the minimum height of dyke wall shall be
600 mm.
(d) Interdistance between the nearest tanks
located in two dykes shall be equivalent to
the largest tank diameter or 30m, which-
ever is more.
(e) The tank or tanks shall be supported on
well designed foundations and shall be
17
either buried underground or installed in
the open and surrounded by wall or
embankment not more than two meter
high and made of earth, concrete or solid
masonry capable of withstanding fully
hydrostatic load. Earth wall of over 1 meter
high shall have not less than 0.6 meter wide
flat section on top. Note 2
(f) Pump stations should be located outside
dyke areas by the side of roads.
(g) Tanks located overhead for process
considerations shall meet safety distance
and shall also have dyked enclosure of
RCC construction and provided with drain
valves at suitable height for easy operation.
(ii) GROUPING
(a) Grouping of petoleum products for storage
shall be based on the product classifi-
cation. Class "A" and/or class "B" petro-
leum can be stored in the same dyked
enclosure. Class "C" petroleum should
preferably be stored in separate enclosure.
However, where class "C" petroleum is
stored in a common dyke along with class
"A" and/or class "B" petroleum, all safety
stipulations applicable for class "A" and/
or class "B" respectively shall apply.
(b) Excluded petroleum shall be stored in a
separate dyked enclosure and shall not be
stored along with class A, B or C
petroleum.
(c) Tanks shall be arranged in maximum two
rows so that each tank is approachable
from the road surrounding the enclosure.
However, tanks having 50,000 cu.m
capacity and above shall be laid in single
row.
(iii) FIRE WALLS
In a dyked enclosure where more than one tank is
located, fire walls of 600mm should be provided
as explained below:
(a) Any tank having a diameter more than
30m should be separated with fire walls
from other tank.
18
(b) Fire walls should be provided by limiting
the aggregate capacity of each group of
tanks within, to 20,000 cu.m.
(iv) GENERAL
(a) The tank height shall not exceed one and
half times the diameter of the tank or 20m
whichever is less.
(b) Piping from/to any tank located in a single
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.
(c) No fire water/foam ring main shall pass
through dyked enclosure.
(d) The minimum distance between a tank
shell and the inside toe of the dyke wall
shall not be less than one half the height of
the tank.
7.2 INTERDISTANCES BETWEEN TANKS / OFF-
SITE FACILITIES
OISD-STD-118 Revision - II
The following stipulations shall apply for the
inter distances for above ground tanks storing
petroleum:
(i) Inter distances shall be as given in Table-3
for tanks storing class "C" petroleum; or
class "A" and "B" petroleum products with
total storage capacity not exceeding 5000
cu.m at one installation.
(ii) Inter distances shall be as given in Table-4
for tanks storing class "A" and class "B"
petroleum products with total storage
capacity exceeding 5000 cu.m
(iii) Interdistances between tanks and fencing
shall be as given in Table-6 for tanks
storing Class "A", Class "B" and Class "C"
petroleum products with total storage
capacity of class "A" and class "B"
petroleum stored exceeding 5000 cu.m
(iv) Interdistances between tanks storing
excluded petroleum will not be governed
by Table-3 and 4 and should be decided on
construction, operation and maintenance
requirements.
OISD-STD-118 Revision - II 19

TABLE - 3 (NOTE1)
INTERDISTANCES BETWEEN TANKS/OFFSITE FACILITIES
(For small installations)

S.No. From \ To 1 2 3 4 5 6 7 8 9 10 11 12 13

1. Storage tank for 0.5 D 0.5 D 0.5 D 9 9 9 15 15 15 3 15 15 15

petroleum class A or 6 or 6
2. Storage tank for 0.5 D 0.5 D 0.5 D 9 0.5 D 0.5 D 9 4.5 4.5 3 4.5 D D
petroleum class B or 6 or 6 min.4.5 min.4.5
3. Storage tank for 0.5 D 0.5 D - 9 0.5 D - 9 4.5 - - - 0.5 D 0.5 D
petroleum class C or 6 or 6 min.3 min.3
4. Storage / filling shed 9 9 9 - 4.5 6 9 9 9 3 9 9 9
for petroleum class A
5. Storage / filling shed 9 0.5 D 0.5 D 4.5 - 1.5 9 4.5 4.5 1.5 4.5 4.5 4.5
for petroleum class B
6. Storage / filling shed 9 0.5 D - 6 1.5 - 9 4.5 - - - 3 3
for petroleum class C
7. Tank vehicle loading / 15 9 9 9 9 9 - 9 9 3 9 9 9
unloading area for
petroleum class A
8. Tank vehicle loading/ 15 4.5 4.5 9 4.5 4.5 9 - 4.5 1.5 4.5 4.5 4.5
unloading area for
petroleum class B
9. Tank vehicle loading/ 15 4.5 - 9 4.5 - 9 4.5 - - - 3 3
unloading area for
petroleum class C
10. Flame-proof electric 3 3 - 3 1.5 - 3 1.5 - - 3 - -
motors

Contd...
20 OISD-STD-118 Revision - II

TABLE - 3 (Contd...)

S.No. From \ To 1 2 3 4 5 6 7 8 9 10 11 12 13

11. Non-flameproof 15 4.5 - 9 4.5 - 9 4.5 - 3 - - -

electric motors

12. Office building, stores, 15 D 0.5 D 9 4.5 3 9 4.5 3 - - - -

amenities etc. within min. 4.5 min. 3
installation

13. Boundary fencing 15 D 0.5 D 9 4.5 3 9 4.5 3 - - - -

around installation min. 4.5 min. 3

Notes:

1. All distances are in metres.

2. Above table is applicable for installations where
i) Only petroleum class C is stored.
ii) The total quantity of petroleum class A and class B stored above ground in bulk does not exceed 5000 cu.m.
iii) The diameter of any tank storing petroleum class A or petroleum class B does not exceed 9m.
3. Interdistances given for tanks are shell to shell in the same dyke.
4. All distances shall be measured between the nearest point on the perimeter of each facility except in the case of tank vehicle
loading/unloading area where the distance shall be measured from the centre of each bay.
5. Where alternate distances are stipulated, maximum thereof shall be observed.
6. Notation :
"D" – diameter of the tank
(-) – a distance suitable for constructional and operational convenience.
OISD-STD-118 Revision - II 21

TABLE - 4

INTERDISTANCES BETWEEN STORAGE TANKS/OFFSITE FACILITIES

S.No. From \ To 1 2 3 4 5 6 7 8 9

1. Storage tank for petroleum T5 T5 T5 15 15 15 15 8 15

class A
2. Storage tank for petroleum T5 T5 T5 15 15 15 15 8 15
class B
3. Storage tank for petroleum T5 T5 T5 15 - 8 - - -
class C
4. Storage / filling shed for 15 15 15 - 8 15 15 8 15
petroleum class A or
class B
5. Storage/filling shed for 15 15 - 8 - 8 - - -
petroleum class C
6. Tank vehicle loading/ 15 15 8 15 8 - - 8 15
unloading area for
petroleum class A or B
7. Tank vehicle loading/ 15 15 - 15 - - - - -
unloading area for
petroleum class C
8. Flame proof electric pump 8 8 - 8 - 8 - - 8
motor
9. Non-flame proof electric 15 15 - 15 - 15 - 8 -
pump motor

Notes :

1. All distances are in metres.

2. Above table is applicable for installations where total quantity of petroleum class A and class B stored above
ground in bulk exceeds 5000 cu.m or where the diameter of any such tank for the storage of petroleum exceeds 9
m.
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 centre of each bay.
4. Notation:
(-) – any distance suitable for constructional or operational convenience.
T5 – Table-5 shall be referred.
5. This table is applicable for class C petroleum storage also alongwith class A & B petroleum as per limits specified
under note-2 above.
OISD-STD-118 Revision - II 23

TABLE - 5

INTERDISTANCES BETWEEN STORAGE TANKS

Sl. Item Floating Roof Fixed Roof Class C

No. Tanks Tanks (Class Petroleum
A & B Petroleum

1. All tanks with diameters (D + D) / 4 (D + d) / 4 (D + d) / 6

upto 50 metres

2. All tanks with diameters (D + d) / 4 (D + d) / 3 (D + d) / 4

exceeding 50 metres

Notes :

1. This table is applicable for installations where aggregate storage capacity of class A and class B
petroleum stored above grade exceeds 5000 cu.m. or where the diameter of any such tank for the storage
of petroleum exceeds 9 m.

2. Distances given are shell to shell in the same dyke.

3. Notation:

D – diameter of larger tank in metres

d – diameter of smaller tank in metres

4. If the interdistance (for class A & B) calculated as above are less than 15m,then minimum of 15m or 0.5 D
or d shall be followed.

5. Interdistance between class A/B storage tanks and classC storage tanks shall not be less than 6 metres.
 TABLE - 6 (NOTE1)

DISTANCES FROM BOUNDARY FENCING

Minimum Distance
from Boundary
S.No. Installation fencing around
Installation

1. Storage tank for Petroleum Class A **

2. Storage tank for Petroleum Class B **

3. Storage tank for Petroleum Class C **

4. Storage/filling shed for Petroleum 15

Class A or Class B

5. Storage/filling shed for Petroleum 10

Class C

6. Tank vehicle loading/unloading area 20

for class A & B petroleum

7. Tank vehicle loading/unloading area 10

for class C petroleum

Notes :

1. All distances are in metres.

2. This table is applicable for facilities in an installation where total quantity of petroleum class A & B stored
above ground in bulk exceeds 5000 cu.m. or where the diameter of any such tank for the storage of
petroleum exceeds 9 m.

3. Notation:

"D" – diameter of larger tank in metres.

4. Above table is based on the assumption that property beyond the boundary line is either protected or
adequate green belt is provided as a safety buffer where no structure exists. Property beyond property
line is deemed protected if it is within the jurisdiction of public Fire Brigade or plant's own Fire Brigade.

** (I) Distance from Floating roof tank to boundary fencing for stable and boil-over liquids, having
protection for exposure shall be D/2 (minimum 20m).

(ii) For tanks with weak roof-to-shell joint :

OISD-STD-118 Revision - II 25

The above distance shall be D/2 (minimum 20m) for tanks having approved foam or inerting
system and the tank diameter not exceeding 50m.
8.0 LAYOUT OF LPG FACILITIES
8.1 GENERAL CONSIDERATIONS
8.1.1 LPG STORAGE
(i) GROUPING
Vessels shall be arranged into groups each having
a maximum of six vessels. Capacity of each group
shall be limited to 15000 cu.m. Each group shall
be provided with a curb wall.
Any vessel in one group shall be separated from a
vessel in another group by a minimum distance
of 30m.
Spheres and bullets shall be treated as separate
groups with 30m safety distance between two
groups. Separate dedicated manifold shall be
provided for each group.
ii) LOCATION
(a) Longitudinal axes of horizontal vessels
(Bullets) should not point towards other
vessels, vital process equipments and
control room.
(b) Storage vessels should be located down
wind of process units, important buildings
and facilities.
(c) LPG storage vessels shall not be located
within the same dykes where other
flammable liquid hydrocarbons are stored.
(d) Storage vessels shall be laid out in single
row both in case of the spheres and bullets.
Storage vessels shall not be stacked one
above the other.
(iii) SPILLS AND LEAKS
(a) Spillage collection shallow sump shall be
located at a distance where the flames from
sump fire will not impinge on the vessel.
This distance shall not be less than the
diameter of the nearest vessel or 15m
whichever is higher. The capacity of the
collection sump shall be as per drawing
enclosed at Annexure-1. However in case
of one sphere, the sump size shall be equal
to layout of two spheres.
(b) Curb wall around the storage tank shall
have a minimum height of 30cm. However
it shall not exceed 60cm at shallow sump
position, as otherwise evaporation of
spilled LPG may get affected.
(c) There shall not be any depressions, large
ditches and low lying areas around LPG
storage as the leaked gas can accumulate,
being heavier than air. Top surface of the
vessels installed in a group should be on
the same plane so that safety blowout from
one vessel does not affect the other vessel.
This will also minimise the chances of
overfilling of adjoining vessels due to
gravitation.
(d) A typical layout plan of LPG sphere area
with major safety requirements of distan-
ces, drainage sump, pump station location
etc. is enclosed at Annexure-1 for general
guidance.
8.1.2 LPG BOTTLING
(i) LOCATION
LPG bottling facilities should be located at a safe
distance from other facilities with minimum
ingress to trucking traffic and downwind to
storage as far as possible.
There shall not be any deep ditches in the
surrounding area to avoid LPG settling.
(ii) CONSTRUCTION
Bottling section shall be of single storey having
roofing and open from sides for adequate
ventilation so that leaked gas can drift away.
RCC roofing should not be used to the extent
possible.
(iii) OPERATION
(a) Stacking areas for empty and filled
cylinders should be located separately.
Cylinders shall be stacked vertically.
Filling machines and testing facilities shall
be organised in sequential manner
distinctly in a separate area.
OISD-STD-118 Revision - II
(b) Filled LPG cylinders shall not be stored in
the vicinity of cylinders containing other
gases or hazardous substances.
(c) Storage shall be kept on or above grade
and never below grade in cellar or
basement.
(d) Trucking traffic shall be smooth to avoid
blocking/ obstruction for loading and
unloading of cylinders.
8.1.3 LPG BULK HANDLING
(i) LOCATION
(a) LPG truck loading/unloading station shall
be located in a separate block and shall not
be grouped with other products.
Maximum number of LPG tank lorry bays
shall be restricted to 8 in one group. The
bay should be designed in such a way that
the driver's cabin will be facing the exit
direction and shall have no obstruction.
27
(b) LPG rail loading/unloading station shall
be located on a separate rail spur and shall
not be grouped with other products.
(c) LPG loading/unloading rail gantries shall
be separated from other rail shunting
facilities by a minimum distance of 50m,
except relating to service for the same
gantry.
(ii) Rail loading/unloading of LPG should be
restricted to a maximum of half rake, presently
capacity of which is 500 MT. If full rake
loading/unloading is envisaged, this shall be
done on two separate rail gantries having a
minimum distance of 50m. In case of 8 wheeler
wagons half rake unloading/ loading capacity
shall be 600 MT.
8.2 INTERDISTANCES FOR LPG FACILITIES
Interdistances for LPG facilities shall be as given
in Table-7.
 TABLE - 7
INTERDISTANCES FOR LPG FACILITIES

S.No. From \ To 1 2 3 4 5 6 7

1. LPG Storage vessels * T8 30 30 30 15 60

2. Boundary/property line/ T8 - 30 30 30 30 **
group of buildings, not
associated with LPG plant

3. Shed-LPG/Cold repair shed/ 30 30 15 30 30 15 60

cylinder evacuation facilities

4. Tank Wagon Gantry 30 30 30 50 50 30 60

Tank Truck Gantry

5. Rail spurs 30 30 30 50 50 30 60

6. Pump house/Comp. 15 30 15 30 30 - 60
house(LPG)

7. Fire Pump house 60 ** 60 60 60 60 -

Notes :

1. All distances are in metres.

2. Notation:

T8 – Refer Table - 8

* 1/4 of sum of diameters of adjacent vessels or half the diameter of the larger of the two adjacent
vessels whichever is greater.

** Any distance for operational convenience.

3. Distance of stabling line shall be as per minimum Railway Standards.

OISD-STD-118 Revision - II 29

TABLE - 8 (NOTE1)

INTERDISTANCES BETWEEN LPG STORAGE VESSELS AND

BOUNDARY / PROPERTY LINE / GROUP OF BUILDINGS
NOT ASSOCIATED WITH LPG FACILITIES

Capacity of
S.No. Each Vessel Distance
(Cum.M. of water)

1. 10 - 20 15

2. 21 - 40 20

3. 41. 350 30

4. 351 - 450 40

5. 451 - 750 60

6. 751 - 3800 90

Note :

All distances are in metres.

9.0 LAYOUT OF UTILITY STATIONS
9.1 GENERAL CONSIDERATIONS
Boiler House, Air compressors, fuel oil facilities
(for generation of steam) shall be located in separate
block adjoining the process unit blocks. The steam
generation facilities block should preferably include
boiler feed water pump, chemical block for boiler house
etc., which form the integral part of the steam
generation facilities.
The plant air compressors and drying units
should preferably be located in the boiler house unit
block. Fuel oil heating and pumping facilities may also
be located within the boiler house unit block. These may
be located in the boiler house unit block to minimise the
spreading ofvarious utility blocks around the process
unit, to facilitate ease of operation.
( i) ELECTRICAL
Electrical generation facilities should be located
near the process unit block because such electrical
generation units normally supply steam to the
process units e.g. Cogeneration. When external
power grid is interconnected with plant power
generation facilities, either the power plant shall
be located at the side of boundary wall or the
external power transmission lines shall be taken
underground upto the interconnection grid
inorder to minimise the length of overhead
transmission lines within the plant.
(ii) COOLING TOWERS
Cooling towers should be located away from
process unit area, preferably downstream
direction of wind to avoid corrosion of the
equipments in process areas.
(iii) WASTE DISPOSAL FACILITIES
Separate collection system should be provided for
different types of waste generated in the process
plant such as oily water, cooling tower
blowdown, caustic and acidic effluents, sludge,
fecal etc.
The waste disposal facilities like effluent
channels, land fill areas for disposing off solid
waste etc. should preferably be located by the
side of boundary wall, but down stream of wind
direction so that the foul odour that may be
present at times does not affect the plant
personnel and neighbourhood areas. Locating the
waste disposal facility near the boundary wall
also eliminates the vehicular movement in
process areas in case solid wastes are to be taken
out of installation for disposal.
iv) SMOKING BOOTHS
Smoking booths should not be provided in
hydrocarbon industry. However if it is necessary
to provide smoking booths, these should be
located at a safe distance of :
(i) 30m from hydrocarbon source in case of oil
refinery/storage installation.
(ii) 60m from hydrocabon source in case of
LPG/Gas Processing Plants.
9.2 INTERDISTANCES
Interdistances between various utility stations
and other facilities shall be as given in Table-1.
10.0 REFERENCES
1. OISD-STD-106 on Process Design and
Operating Philosophies on Relief and
Disposal Systems.
2. OISD-STD-144 on LPG Bottling and
Distribution.
3. NFPA Standard No.30 "Flammable and
Combus-tible Liquids Code".
4. Petroleum Rules - 1976.
5. OISD-STD-117on Fire Protection facilities
for Petroleum depots and terminals.
6. OISD-STD-116 on Fire Protection facilities
for Petroleum Refineries/process plants.
7. SMPV Rules - 1981.
OISD-STD-118 Revision - II 31

ANNEXURE - 1

TYPICAL LAYOUT OF LPG STORAGE VESSELS

Section - XX
NOTES :
1. ALL DIMENSIONS ARE IN METRES
2. TOP SURFACE OF ALL VESSELS INSTALLED SHALL BE IN THE SAME PLANE.
3. SIZING CRITERIA FOR SUMP—FULL CONTAINMENT OF LPG SPHERE WITHIN KERB AREA IS NOT ENVISAGED HOWEVER
THERE IS CHANCE OF SMALL SPILL OFLPG IN THE STORAGE AREA IT IS ASSUMED THAT THE LEAK WILL BE ARRESTED
WITHIN ABOUT AN HOUR THE CONTAINMENT VOLUME FOR ONE HOUR LEAK CORRESPONDING TO LARGEST NOZZLE
SIZE AND LIGHTEST MATERIAL IS 18 MT OR ABOUT 35 M3 WITH A MAXIMUM LIQUID COLLECTION RATE OF APPROX. 5
KG./SEC.
4. ALL LEVELS ARE WITH RESPECT TO HIGH POINT OF PAVEMENT LEVEL I.E. 100.00
5. PROTECTIVE WALLS TO BE PROVIDED IF THE VALVE IS WITHIN 30 M FROM SPHERE SHELL.
6. WATER SEAL SHALL BE PROVIDED AT OUTLET FROM SHALLOW SUMP.

LEGEND :

DVA Deluge Valve Assembly

........ Fire Water Piping
(Not to Scale)