2015 Piping Design Manual

PIPING
DESIGN
MANUAL
Piping
Department
2015-10-20
Rev. 2
Jacobs Canada Inc.

205 Quarry Park Blvd S.E.
Calgary, Alberta, Canada T2C 3E7
Phone: 1.403.258.6411
Fax: 1.403.255.1421
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Section: Page:
PIPING DESIGN MANUAL 1 of 1
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Foreword 2
Issuing Department: Approval: Revision Date:
Piping Design Guy Jubinville 2015-10-20
Foreword
This manual provides an outline of the Piping Design Department's design base.
These guidelines should be adhered to, so that a consistent approach is maintained for each
project. Reference to the various sections will help prevent omissions and provide quality
assurance.
Note: For each project, Clients specifications shall be examined and any conflict with these
guidelines shall be resolved.
Purpose
These guidelines are provided for the following purposes:
1. To clarify design, layout and equipment arrangements.
2. To assist new staff in becoming familiar with Jacobs’ design base.
3. To provide quality assurance by qualifying Jacobs’ preferred design practices.
CAUTIONARY NOTE:
This manual, and the information contained herein, is the property of Jacobs Canada Inc.,
information contained is not to be reproduced for any purpose other than for use by Jacobs
Canada Inc. without the written consent of Jacobs Canada Inc.
Note: It is the responsibility of each member of the Piping Design Department to familiarize
themselves with the contents of this manual, and to follow the guidelines contained
herein.
Update and addition to these guidelines will be our aim. Your suggestions will be welcomed
and considered.
Reference Documents:
Canadian Work Instructions- CWI-230
This information is proprietary to Jacobs Canada Inc.

Hard copy is uncontrolled, refer to the network to ensure you have the latest revision
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Table of Contents 2
INDEX
Section Name
1.0 Process Plant Plot Layout
2.0 Design/Layout Guidelines
3.0 Equipment Design Considerations
4.0 Useful Charts & Tables

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Process Plant Plot Layout - Table of Contents 2
1.0 PROCESS PLANT PLOT LAYOUT
1.1 INTRODUCTION
1.2 UNIT SPACING
1.3 PLANT ROADS
1.4 EQUIPMENT WITHIN PROCESS UNITS
1.4.1 Fired Process Heaters

1.4.2 Gas Compressors
1.4.3 Reactors
1.4.4 Pumps
1.4.5 Exchangers
1.4.6 Process Vessels
1.4.7 Air Coolers
1.5 UTILITIES
1.6 COOLING TOWERS
1.7 EVAPORATION PONDS, SULPHUR STORAGE BLOCKS
1.8 FLARES, INCINERATOR STACKS
1.9 TANK FARMS
1.9.1 Atmospheric Storage Tanks

1.9.2 Pressure Tank Storage
1.9.3 Refrigerated Storage
1.10 FIRE PROTECTION
1.10.1 Fire Pumps

1.10.2 Water spray Deluge Valves
1.10.3 Hose Stations/Hydrants
1.11 CONTROL BUILDINGS
1.12 NON PROCESS BUILDINGS
1.13 INDUSTRIAL RISK INSURER'S SPACING GUIDELINES

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Process Plant Plot Layout - Table of Contents Date: 2015-10-20
1.14 UNDERGROUND PIPING
1.15 ACCESS FOR CONSTRUCTION & MAINTENANCE
1.16 HOUSED EQUIPMENT
1.17 PIPERACK LAYOUTS
(To Section 2.0)

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1.0 PROCESS PLANT PLOT LAYOUT
1.1 INTRODUCTION
This guideline provides the information necessary to develop a Plot plan acceptable to all
stakeholders, based on current insurance underwriting guidelines for Equipment and Building
spacing, providing for safe operation and adequate maintenance space requirements and
Jacobs’ extensive experience in Process Plant Design. Reference should also be made to
Section 2.0 Design/Layout Guidelines, Section 3.0 Equipment Design Considerations and
Section 4.0 Useful Tables and Charts.
The information presented here outlines recommended practices.

Economics, client requirements or other situations may dictate preferential equipment spacing.
1.2 UNIT SPACING
Clear space should be maintained between adjacent units, on a battery limit-to-battery limit
basis, and also maintained between major process vessels or equipment.
This clear space between units should not be considered as a potential area for future
expansion of the units.
1.3 PLANT ROADS
Generally road allowances are determined by the Civil Department during grading plan layout.
All roads should be continuous with no dead ends. Generally all items requiring maintenance
should be accessible from 2 directions to provide access during a major plant shutdown. Verify
that truck turning areas at loading facilities are of sufficient radii for the specific vehicles that the
client will be using.
1.4 EQUIPMENT WITHIN PROCESS UNITS
Spacing of equipment within units shall be sufficient to reduce fire exposure to other equipment
and adjacent process units as well as provide reasonable operating and vehicular maintenance
access.
1.4.1 Fired Process Heaters
Fired Process Heaters should be located in the corner of a unit, on the up wind side and
should be clear of all other process equipment. Individual fired heaters should be separated
by clear space. In high pressure service clearance may be required between individual
heaters. Locate heaters to prevent flue gases from drifting into tall structures. Refer to
Section 3.13.

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1.4.2 Gas Compressors
Gas Compressors shall be located downwind from fired heaters. Large compressors of high
value and critical to a unit operation or the operation of several units should be given special
consideration. It may be advisable to locate these compressors in a separate building away
from operating units and depending on their value and replacement time, it may be advisable
to provide a separate building for each compressor. Refer to Section 3.12.
1.4.3 Reactors
Reactors should be situated at the periphery of a unit, away from adjacent units, cooling
towers and control rooms.
1.4.4 Pumps
Pumps handling flammable or combustible products should not be located under piperacks
or process structures. The pump end should be located out from the edge of a piperack.
The motor end may be oriented either into the rack or away from it, depending on client
preferences. Pumps operating at high pressures should be separated from major process
equipment and other pumps. Refer to Section 3.18.
1.4.5 Exchangers
Exchangers shall be located next to their related equipment or vessel in the sequence of
process flow, keeping large diameter and alloy piping to a minimum. Where possible, line up
all shell covers on the operating aisle way to maintain clearances. Channel ends should be
directed toward a road or maintenance way. Refer to Section 3.16.
1.4.6 Process Vessels
Process Vessels should be located next to their related equipment. Heads of horizontal
vessels should be lined up with the heads of exchanger shells to form a clear operating aisle
way. Attention should be given to elevation requirements for process considerations. Refer
to Section 3.17.
1.4.7 Air Coolers
Air Coolers shall be located as close as practical to their related equipment, either elevated
above pipeways or grade mounted. Where practical, they should be grouped to share a
common support structure. Care should be taken when locating air coolers to prevent
starvation of air flow, recycling of air flow and ingesting hot exhaust air from lower air coolers
or equipment. Refer to Section 3.15.

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1.5 UTILITIES
The Utilities area should be located away from the battery limits of process areas and from the
shell wall of hydrocarbon storage tanks. Generally, in cold climates all utilities will be housed
within a heated building.
1.6 COOLING TOWERS
Clearance should be maintained between Cooling Towers and process equipment. Position
cooling towers so that winter wind will carry fog or drift away from equipment, structures and
roadways. Refer to Section 3.14.
1.7 EVAPORATION PONDS, SULPHUR STORAGE BLOCKS
Generally these should be located in low lying areas of the plant site, preferably downwind from
the major process units.
1.8 FLARES, INCINERATOR STACKS
Flare Stacks and Incinerator Stacks should be located at 90° to the prevailing wind or downwind
of process areas. Refer to Section 3.25.
1.9 TANK FARMS
There should be clearance from the shell wall of the storage tanks to the battery limits of any
process unit, from all other buildings.
There should be no intermingling of classes of hydrocarbons, i.e. pressure tank storage,

refrigerated storage, refined products, boil over products and crude oil located within the same
area of risk.
No tank should be more than 91.5 m from an access roadway.
1.9.1 Atmospheric Storage Tanks
Distance from tank shell to top of dike wall should not be less than one half the height of the
tank.
All pumps, manifolds, meters and fire hydrants should be located outside of the dike walls.
Tanks of large capacity should be individually diked. The area within the dike should contain
the volume of the tank. Smaller tanks may be commonly diked.
A diked enclosure for one or more tanks should have a maximum capacity of the largest tank
plus 10% of the capacity of all other tanks enclosed. In calculating the available space, the

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volume of all tanks except the largest to the height of the dike plus the volume occupied by
any spill dike should be deducted.
Confer with civil lead for size, shape, height and slope of dike or containment wall.
1.9.2 Pressure Tank Storage
Horizontal pressure tanks should be arranged in a single row with their longitudinal axes
parallel.
If more than one group is required, each group should be separated.
Diversionary diking should be provided for all pressure storage. If this is not possible, then
individual dikes for spheres and group diking for horizontal tank groups should be provided.
Pressure tank areas should be located on the outside perimeter of the plant site and the
ends of the cylindrical pressure tanks should not be facing process units or other areas of
risk.
1.9.3 Refrigerated Storage
Each refrigerated storage tank should be installed in a separate dike.
Refrigerated storage areas should be located on the outside perimeter of the plant site well
removed from process units or plant utilities.
1.10 FIRE PROTECTION
1.10.1 Fire Pumps
The fire pumphouse should be located away from any process unit, product storage tanks or
flare facilities. The pumphouse may be incorporated within a water treatment building or
other non-hazardous area. It may require a concrete block enclosure.
1.10.2 Water spray Deluge Valves
The water spray deluge valves for fixed water spray systems should be located in a shielded
location.
They should be operable from grade and be readily accessible.
1.10.3 Hose Stations/Hydrants
Refer to client spacing guidelines.

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1.11 CONTROL BUILDINGS
The control building or room should be centrally located, and away from the hydrocarbon
process unit. It may be adjacent to or can form a part of the MCC building or utilities building.
1.12 NON-PROCESS BUILDINGS
Non-process buildings such as warehouses, shops and laboratories in all probability will have
open flame devices or other sources of ignition. Therefore, these types of buildings should be
spaced away from process units and, if possible, upwind.
1.13 GE COMMERCIAL INSURANCE STANDARDS AND GUIDELINES
Many clients are now using distances specified in these guidelines as mandatory requirements.
Verify with client before plot layout has begun to determine if distances specified should be
regarded as mandatory, or as a guideline only.
Specifications available from the Library are as follows:
1.13.1 GAP.2.5.2 Oil and chemical plant layout and spacing (9/3/01)
1.13.2 GAP.2.5.2A Hazardous classification of process operations for spacing
requirements (9/3/01)
1.13.3 GAP.2.5.3 Drainage for outdoor oil and chemical plants (6.1/00)
1.13.4 ERCB Directive 55 Storage requirements for the upstream Petroleum industry
1.14 UNDERGROUND PIPING
Prior to laying out underground piping all equipment, pilings, foundations and existing
underground, if any, should be located.
Consult with civil lead for minimum bury depths and location of roads, right of way (ROW), etc.
Determine the location of any battery limits or tie-ins.
Refer also to Section 2.13
1.15 ACCESS FOR CONSTRUCTION & MAINTENANCE
A plant that has good construction access most probably will have good maintenance access.
Therefore, it is essential to maintain specified spacing and headroom clearances during all
phases of plant layout and piping design.
Client guidelines should be adhered to whenever possible.

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1.16 HOUSED EQUIPMENT
Harsh climatic conditions often dictate certain types of equipment be contained in a more
hospitable environment. Generally, these items are of a complex or more "delicate" nature (e.g.
compressors, water treatment packages, etc.).
1.17 PIPERACK LAYOUTS
The piperack is the main artery of any plant piping system. Early in plant layout, the main
piperacks must be sized to a close approximation. Height and number of decks should be
established, along with the location and approximate size of instrument and electrical raceways.
Client's requirements for future expansion should also be considered at this stage of
development.
As piping layouts are developed and information becomes available, more detailed rack layouts
will be made. These will include firm rack sizes, spacing of supports, expansion loop
requirements and location and routing of piping. Refer to Section 2.4.
(To Section 2.0)

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END OF
SECTION
ONE
Section: Page:
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Design/Layout Guidelines – Table of Contents 2
2.0 DESIGN/LAYOUT GUIDELINES (Also refer to Jacobs Canada General Specification for
Piping Design and Layout in BPS: CAL-PESP-35-01-3
NOTE! These guidelines may be enhanced by any Client specifications if available.
2.1 CLEARANCE AROUND EQUIPMENT FOR MAINTENANCE
2.2 ACCESS REQUIREMENTS TO MANWAYS
2.3 EMERGENCY ESCAPE ROUTES
2.4 PIPERACK LAYOUT
2.4.1 General
2.4.2 Preliminary Piperack Sizing
2.4.3 Piping Arrangement and Spacing on Piperack
2.4.4 Supports - General
2.5 INSTRUMENT REQUIREMENTS - NOT ISSUED
2.6 RELIEF VALVES - PIPING & INSTALLATION
2.7 UTILITY STATION REQUIREMENTS
2.8 CONTROL VALVES
2.9 INSULATION REQUIREMENTS - GENERAL
2.10 WINTERIZATION REQUIREMENTS
2.11 SHIPPING LIMITATIONS - PIPE SPOOLS & MODULES
2.11.1 Pipe Spools

2.11.2 Modules
2.11.3 Modules in Excess of Maximum Overall Dimension
2.12 BUILDING REQUIREMENTS
2.12.1 General
2.12.2 Overhead Cranes - General
2.13 UNDERGROUND SERVICES
2.13.1 Sewer Systems

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2.0 Design/Layout Guidelines – Table of Contents Date: 2015-10-20
2.13.2 Systems Layout - General

2.13.3 Surface Drainage
2.13.4 Sewer Design
2.13.5 Catch Basin
2.13.6 Seals
2.13.7 Floor Drains
2.13.8 Cleanouts
2.13.9 Sewer Sizing
2.13.10 Firewater
(To Section 3.0)

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2.1 Clearance Around Equipment For Maintenance Date: 2015-10-20
2.1 CLEARANCE AROUND EQUIPMENT FOR MAINTENANCE
It is important that adequate clearance for maintenance and safety be allowed for at the
preliminary layout stage. Refer to Section 3.0 for individual equipment design guides.
2.2 ACCESS REQUIREMENTS TO MANWAYS
If bottom of manway is located more than 3 m above grade, then a platform shall be provided.
Minimum and maximum dimensions from centre line of manway to platform will be 500 mm and
1000 mm respectively.
2.3 EMERGENCY ESCAPE ROUTES
A layout designer can help safety by providing short and simple escape routes from all points.
All of the following contribute to safe operation:-
a. access at appropriate ends of structures

b. grouping of hazardous equipment
c. proper safety distances and clearances
d. remote hazardous - equipment locations
e. application of sprinkler systems at places of fire hazard
f. eye-wash fountains or showers in dangerous chemical areas
(To Section 2.4)

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2.4 Piperack Layout Date: 2015-10-20
2.4 PIPERACK LAYOUT
2.4.1 General
The piperack is the main artery of any plant piping system. Early in plant layout the main
piperacks must be routed and sized to a close approximation. Elevation and number of levels
should be established including electrical and instrument raceways. This should be done during
the Plot Plan phase of the project using the "Flow Diagram Transposition" method explained
later. If flow diagrams are not available the designer should discuss process and utility
requirements with the Process Engineer and develop a list of lines and their sizes to be included
on the piperack.
2.4.2 Preliminary Piperack Sizing
Flow diagram Transposition involves the schematic drafting of Process and Utility piping on the
Plot Plan. The commodity and size together with the branches to equipment, buildings, etc.
should be shown. Since it is a schematic drawing much less detail is required than will appear
on the final drawing and the lines are not drawn, positioned to scale or sequence. Orifice
Flanges should be shown and some preliminary thought given to the location of meter runs for
6" and larger pipes and off rack supports.
2.4.3 Piping Arrangement and Spacing on Piperack
When the first transposition has been completed then the following should be considered to
finalize the rack design:
a. Total piperack width required, allowing spare capacity for future expansion, generally
20% or as required by client.
b. Hot lines positioned to one side of rack, this permits any expansion loops to be
incorporated within the piperack steelwork.
c. Grouping Utility lines together in centre of rack, on the top rack if two levels are required.
d. Locate heavy lines regardless of service near piperack columns (centrally loaded
columns and reduced bending moment on beams will result in light structural members).
Avoid placing lines directly over main column as future extension to plant may require
adding further levels to rack.
e. Position Process lines interconnecting equipment on same side of rack near edge of
rack, on that side.
f. Position lines with Orifice runs near edge of rack with Orifice flanges near a column for
access by ladder.
g. Relief headers should be self-draining to KO Drum and from Flare stack to KO Drum.
To eliminate pockets the headers may be placed at a higher elevation than the main
piperack usually on a tee support or an extended piperack column.

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2.4 Piperack Layout Date: 2015-10-20
h. On a double level piperack Process lines are positioned on the lower level and utility
lines on top. An exception to this general rule is the case of larger diameter piping
entering the rack from a higher elevation.
i. 2" and smaller lines may be positioned between larger lines where they can be
supported by pick-ups from the larger lines.
j. See Jacobs Metric Piping Standards for allowable pipe spans A-SD-35961M and A-SD-
35960M for line spacing chart.
The spacing may have to be adjusted to accommodate the lateral movement of a line
due to thermal expansion at a change in direction of the piperack.
Whenever heavy duty clamps are required on lines, e.g.: vibrating service, compressor
suction and discharge, the line spacing may have to be adjusted to accommodate the
clamps.
k. If the piperack changes direction or where sub-racks are connected to the main
piperack, it is usual to change elevation. The elevation change will usually be 750 mm
but on larger plants 1000 mm should be considered.
See Jacobs Metric Piping Guidelines B-SD-35917M for typical stick built piperack
arrangement, including module to module interface.
2.4.4 Supports - General
Pipe supports shall normally be designed to transmit all piping loads directly to foundations.
Where the piping loads are transmitted through other structures, these structures and their
foundations shall be checked for the additional load.
Piping to equipment requiring removal for maintenance, including control valve assemblies,
shall be supported so that temporary supports are not required during removal.
(To Section 2.5)

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2.5 Instrument Requirements Date: 2015-10-20
2.5 INSTRUMENT REQUIREMENTS
Refer to Instrumentation Department General Specification for Design Requirements CAL-

ICSP-J0001
(To Section 2.6)

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2.6 Pressure Relief Systems Date: 2015-10-20
2.6 PRESSURE RELIEF SYSTEMS
a. The size of the inlet line shall not be less than the size of the relief valve inlet.
b. The length of the inlet piping shall be kept to a minimum.
c. For steam to atmosphere, the discharge shall be at a safe location. A weep hole shall
be drilled to the discharge piping at the valve if the piping is vertical, or drain pan
installed per Jacobs Metric Piping Standards A-SD-35967M.
d. A pressure relief valve in steam service and discharging to atmosphere shall do so at a

safe place and the discharge location shall be visible.
e. Any pressure relief valve discharging to a closed system shall be installed so that the
discharge piping drains to the header. If this is not possible, a 3/4” valved drain line shall
be installed from the lowest point in the discharge piping to a safe area permitting
periodic draining of the line to a safe location e.g. Closed Hydrocarbon Drain (CHD). In
all cases, the discharge piping shall enter the header in the top or side.
f. An overall preliminary layout shall be drafted and submitted to the Process Engineer for
confirmation of header and subheader sizing if configuration differs from the P & ID.
Refer to Jacobs Metric Piping Guidelines B-SD-35918M for general layout guidelines.
(To Section 2.7)

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2.7 Utility Station Requirements Date: 2015-10-20
2.7 UTILITY STATION REQUIREMENTS
A typical utility station hook-up is shown on Jacobs Metric Piping Guidelines B-SD-35953M.
The layout designer shall determine the position and location of all utility stations; they must not
obstruct access ways or hinder maintenance around equipment, etc.
Utility stations shall be located so that areas to be served can be reached with a 16 m hose.
(Refer to Project Specifications).
Type of hose connections are to be specified by client.
Insulation and tracing requirements to be determined by designer (in conjunction with Piping
Specifications) when location of utility stations have been finalized i.e. inside or outside
buildings.
(To Section 2.8)

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2.8 Control Valves Date: 2015-10-20
2.8 CONTROL VALVES
a. The accompanying charts contain "Roughing-In" dimensions only and are intended for
guideline usage. For actual dimensions control valve data sheets (supplied by
Instrumentation Department) must be consulted. See Jacobs Metric Piping Standards
A-SD-35962M, A-SD-35963M and A-SD-35964M.
b. All vents used for high pressure air and steam blow off service shall be installed at a
minimum distance of 30 m from operating equipment and buildings.
c. Refer also to Piping design Handbook Module No.12 Piping Control Stations
(To Section 2.9)

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2.9 Insulation Requirements Date: 2015-10-20
2.9 INSULATION REQUIREMENTS - GENERAL
a. Hot insulation shall be applied to piping, instrumentation, and equipment for the following
requirements:
i. Conserve heat.
ii. To stabilize process temperature to prevent interruption or failure of plant

operations due to extreme ambient temperature.
iii. Avoid overheating of enclosed spaces such as buildings.
iv. Prevent personnel burns (personnel protection).
v. Prevent freezing.
b. Cold Insulation shall be applied to piping, instrumentation, and equipment operating at

temperatures 0°C or less, and/or water lines inside buildings to prevent condensation on
outside of pipe.
c. Acoustic Insulation shall be applied to piping instrumentation and equipment to reduce

the noise inside buildings due to moving parts (e.g. compressors, expanders, etc.) or
excessive pressure drop through control valves to a recommended acceptable level.
Refer to Jacobs Canada General Specifications for Hot and Cold Insulation CAL-PESP-
33-03 and Installation of Hot and Cold Insulation CAL-PESP-33-04
(To Section 2.10)

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2.10 Winterization Requirements Date: 2015-10-20
2.10 WINTERIZATION REQUIREMENTS
a. Winterization shall be provided in any location that a material could possibly be

subjected to temperatures below its freezing or hydrate point, for lines and equipment
carrying viscous fluids which cooling would make unmanageable and for vapor lines
where condensation of vapor would cause problems (e.g. compressor suction lines).
Particular emphasis must be placed on protection during periods of shutdown.
b. Fuel gas lines and other gas lines where pressure reduction may cause hydrates shall
be traced and insulated.
c. Flare line laterals which are not self draining to the header or those on gas service
where hydrates may form shall be traced and insulated.
d. All connections that are dead and may contain water, e.g. pressure connections and
orifice leads, are to be adequately heat traced.
e. Winterization will include the following methods or combination of them:
i. Heat tracing with, glycol, oil, steam or electricity

ii. Drains on equipment
iii. Bypasses around equipment to provide continuous flow
iv. Hot air recirculation in aerial exchangers
v. Instrument and equipment housing
vi. Diluent connections to displace viscous material
vii. Steam purging
Refer to Jacobs Canada General Specifications for Glycol Tracing CAL-PESP-35-09 and
for Steam Tracing CAL-PESP-SP-35-11
(To Section 2.11)

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2.11 Shipping Limitations – Pipe Spools and Modules Date: 2015-10-20
2.11 SHIPPING LIMITATIONS - PIPE SPOOLS AND MODULES

Note: The following shipping limitations apply to the Province of Alberta only. For other
provincial or international requirements consult the expediting group.
2.11.1 Pipe Spools
Maximum legal load limit for trucks is:
· 2438 wide
· 2438 high
· 13716 long
Total weight not to exceed 20.412 kg. Piping designers are urged to design piping spools on a
"2 dimensional configuration" basis if possible. This will allow a more compact stacking
arrangement on truck beds.
2.11.2 Modules
Maximum legal load limit for trucks is:
· 2438 wide
· 2438 high
· 13716 long
Total weight not to exceed 20,412 kg.
Maximum over-dimensional load limit for trucks is:
· 4420 wide
· 3658 high
· 15240 long
Total weight not to exceed 40824 kg. This load requires a special permit and usually two pilot
cars.
2.11.3 Modules in Excess of Maximum Overall Dimensions.
The piping designer must confer with the expediting group as early as possible when
considering module designs in excess of maximum overall dimensions. This is essential to
determine the feasibility of his proposed module design for shipping purposes. Parameters to
bear in mind are:
· 7000 wide
· 24000 long
· 5500 high (from top of truck deck)

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2.11 Shipping Limitations – Pipe Spools and Modules Date: 2015-10-20
Height is usually restricted by wire lifts.
Maximum load limit for rail transportation is usually restricted by maximum truck loads to/from
the rail head.
Refer to the Project Traffic Co-ordinator for the specifics for your project.
(To Section 2.12)

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2.12 Building Requirements Date: 2015-10-20
2.12 BUILDING REQUIREMENTS
2.12.1 General
Buildings used in the oil and gas industry generally fall into two categories, self-framing or rigid
frame.
a. Self Framing buildings are used to house equipment when no structural members are
required to support a traveling crane or equipment. Engineered design allows easy
assembly of self framing buildings and components with a minimum of steel supports or
bracing. Limits of this type of building vary somewhat depending upon the manufacturer,
however, a span of 11.5 m and eave height of 6.0 m should be used as a maximum.
Care should be taken when designing piping and equipment in a self framing building to
avoid the steel bracing which spans the building at eave height.
b. Rigid Frame Buildings are used when the building size is outside the limits of a self
framing building or when maintenance of equipment inside the building requires an
overhead traveling crane, monorail, etc. or if equipment has to be suspended from the
building structure.
The positioning of Purlins and Girts relative to the main structural framework differs with
the building manufacturer, therefore it is essential that the piping designer discuss with
civil department which method of construction will likely be used to ensure enough
clearance around equipment and piping.
c. Heating and Ventilating
The heating of buildings is usually accomplished by using horizontal throw unit heaters
placed strategically around the perimeter of the building. Note that the unit heaters are
arranged to produce an overall stirring motion with one heater carrying on where the last
left off. This arrangement does much to reduce stratification or dead spots throughout
the building as there is a gradual movement throughout. The heaters can generally be
spaced from 10 m to 15 m apart, depending upon the size of heaters and their outlet
throw characteristics. Most manufacturers catalogues have tables which will show the
throws of each unit. Typical unit heater hook-ups are also shown in Jacobs Metric
Piping Guidelines B-SD-35904M.
In addition to unit heaters which only compensate for the building heat losses, if a
building is equipped with exhaust fans to operate on gas detection or the building is
required to be ventilated as per client’s specifications, make-up air units are installed.
The make-up air units should be located inside the building if possible with an air intake
ducted to outside. Care should be taken to locate the outside air intake as far as
possible away from any hydrocarbon or toxic gas source.
Air make-up units are also installed in Boiler Buildings where the air inside the building is
used for combustion.

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2.12 Building Requirements Date: 2015-10-20
Please note when designing the piping to a make-up air unit, clearance should be left in
front of all the access doors, heating coil and filter sections for maintenance. Particular
care should be taken to the gas hook-up for a gas fired unit as it is usually located
adjacent to the blower motor access door.
Refer also to Summary Natural Gas Code.
2.12.2 Overhead Cranes - General
Overhead cranes are installed in buildings where heavy rotating or reciprocating equipment is
installed, parts of which may have to be removed for either repair or replacement. The crane
must have the capacity to move the heaviest item and the total travel should be determined by
the location of the item and the laydown area.
The crane hook height, its capacity, the type of traveling beam and trolley should be discussed
with the Civil Department when determining the building eave height. The piping designer
should carefully consider the pipe routing since the removal by crane of such items as motors,
pumps, etc. could be impacted.
Removal of equipment either in between or over other live equipment could have a bearing on
the equipment spacing requirements.
The location and size of instrument and electrical panels, particularly in pump houses where
space is very limited, should be considered in the early layout stages to ensure clearance to
remove large motors, pumps, etc.
Make-up air units and unit heaters sometimes determine crane travel, make-up air units often
protrude into the building from the gable end thus restricting the total travel of the crane beam.
Do not locate equipment too close to the building walls where they cannot be reached by the
crane hook.
Space for a laydown area should be allocated somewhere within the crane travel, preferably
adjacent to the main access doors to permit off-loading and loading of equipment.
(To Section 2.13)

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2.13 Underground Services Date: 2015-10-20
2.13 UNDERGROUND SERVICES
This section is highly important at the beginning of the design phase on all jobs. Since the
underground must be installed first, before any above ground piping systems, it is imperative to
design the underground piping system early.
Refer also to Jacobs Metric Piping Guidelines- Underground Piping Details B-SD-35915M and
for Hydrant and monitor details B-SD-35916M
2.13.1 Sewer Systems
The waste streams in most plants can be classified under five basic sewer systems: a) open
drains, b) closed drains, c) acid or chemical sewer, d) storm water sewer and, e) sanitary sewer.
a. Open Drains
Designed to collect all non-corrosive process wastes which are drained from tanks,
towers, exchangers, pumps and other process equipment. It uses open-end drain hubs
located adjacent to the equipment it serves. During maintenance shutdowns and at
turnarounds, these drain hubs will be used for draining water from equipment that may
be required for hydrostatic testing or washing out towers or tanks. Pumps and
compressors should also be provided with open-end drain hubs located at the ends of
the foundation blocks, these open-end drain hubs collect drainage from pump bedplates
and drainage from gland and seal piping.
Drainage should be diverted to the oily water sewer in paved and unpaved areas
adjacent to equipment where waste spillage is apt to be considerable. This would be the
case when wash water would be heavily contaminated during turnaround for
maintenance operations.
This system is also designed to collect water from floor washing and water used in a
"housekeeping" capacity. Often, equipment of a non-hazardous service will also drain
into this system. Floor drains are mounted flush with floor surface while equipment
drains utilize drain hubs. Clean outs are also installed as required. This system
gravitates to an underground sump where the water is pumped to a disposal pit or
recycled. This sump is vented to atmosphere.
b. Closed Drains
Closed drains are used for volatile liquids or for liquids containing chemicals which
present hazards to personnel when exposed to the atmosphere, such as liquids
containing hydrogen sulphide. Closed drains are also used to avoid contamination of a
system when collecting drained chemicals for recycling and reuse.
Closed drains for recyclable liquids run to an underground collection tank where gases
are vented to the flare. The liquids are then pumped to other facilities for reclamation.
Double block valves should be provided at all connections to the closed drain system. In
non-hazardous service, a bleed valve should be provided between the two block valves.
c. Acid or Chemical Sewer

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Designed to collect heavily contaminated, corrosive process chemical wastes, which

occur as spillage, leakage and valved drains at process equipment and pumps.
Acid areas, which collect corrosive wastes, are usually curbed to collect and confine
spillage within these areas.
The acid or chemical sewers will flow to some form of neutralizing sumps or acid treating
facility. These acid and alkaline sewer wastes are collected separately at sumps for the
purpose of neutralization or treatment.
d. Storm Water Sewer
Designed to collect the maximum surface drainage. Usually based on maximum rainfall
in one hour. Storm water run-off is calculated on the basis of 100 percent run-off for all
paved areas and 50 percent run-off for unpaved areas. The remaining 50 percent in the
unpaved areas is assumed to be absorbed into the ground.
The storm water sewer should be provided with facilities for oil skimmers and a trash
screen before final discharge to point of disposal.
e. Sanitary Sewer
Designed to carry sanitary wastes to a sewer system. When a sewer system is

unavailable, a sewage treatment plant may be installed within the plant facility. Another
alternative is installation of a septic tank discharging to an underground leaching field.
Provincial and local regulations must be followed in design of leaching fields and in the
disposal of effluent from sewage treatment plants.
2.13.2 Systems Layout - General
The plot plan will be a major aid in the design and layout of various underground systems. It will
indicate the locations of all the various pumps, exchangers, tanks and towers. It will also
indicate the extent of paved areas, roads, underground utilities, (water and electric) and the
locations and Bottom of Pipe of the various pipeline tie-ins at the battery limits.
a. The layout of the various underground systems should begin with a careful indication of
all the major equipment foundations, the locations of which are taken from the plot plan
and/or foundation location plan and pile layout. Whenever possible use the same scale
as the civil drawings. Care should be exercised here to indicate all pipe rack columns,
lighting poles and all minor footings which, if not shown, may result in interferences with
the sewers. Underground cooling water systems and underground electrical should be
integrated into the sewer system layout in order to avoid interferences.
b. The layout will now be used to design the sewer systems. It will be necessary to provide
gravity flow in each of the systems, maintain the given Bottom of Pipe of the various
systems and be free of interferences at the cross-over of the sewer systems,
underground water, and underground electrical systems. All line should be sloped at

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1:100. Keep in mind that there may be existing underground piping, electrical or other
existing obstructions. Piping below plant roads shall run in sleeves.
Road crossings shall normally be made at a 90° angle to the road axis if possible and
shall not be less than 45°.
c. Final Bottom of Pipe elevation of header terminus shall be calculated from furthest points
of system origin.
d. Vent lines for open systems shall not be located near furnaces or other sources of
ignition. Vent lines shall be self-draining. All sealed sections of drain lines to be vented
to prevent blowing of seals by pressure build-up.
e. "P" traps to be installed at all open drains.
f. Building drain systems shall be designed in accordance with all applicable requirements
of the National Building Code and Provincial Plumbing and Drainage Act regulations.
g. All branches to enter main at 45°.
h. Horizontal reducers to be Eccentric, Flat on Bottom (ECC FOB)
i. Underground lines should be designed to have minimum cover within a building (this
reduces excavation costs).
j. Indicate Bottom of Pipe elevation of headers at start point, change of direction and
termination points only. All other elevations are to be determined by field.
k. Do not indicate elevations of branch lines or intersection points at headers.
l. Minimize the use of fittings whenever possible.
m. All connections to Headers are to be stub-ins. (Unless client requirements state

otherwise.)
n. Give coordinates in two directions of all above ground connections, floor, drains,
clean-outs, equipment, piperack columns and building columns.
2.13.3 Surface Drainage
The plot plan, and/or foundation location plan having given the locations of equipment, will also
show the extent of paved or curbed areas. The paved or curbed areas adjacent to equipment
should be segregated into proper sewer system classifications, (open drains, closed drains, acid
or chemical sewer, storm water sewer).

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Paved or unpaved areas in outlying locations, not adjacent to process equipment or buildings,
should be divided into surface drainage areas. These areas are most likely free from
contamination and may be channelled into the storm water sewer.
Diked or curbed areas at tank farm and storage locations will also require provisions for surface
drainage and should be divided into suitable drainage areas.
Surface drainage areas should be designed and sized, keeping in mind, the limitations of the
permissible slopes of paving or grades. The slopes of all drainage areas should be governed by
the following limits so as not to present a hazardous or tripping condition.
The paving inside of buildings should have a minimum slope of 25 mm in 3000 mm and a
maximum drop of 75 mm in elevation, for each drainage area.
Paved areas and unpaved areas outside of buildings should have a sewer box or catch basin
provided for each surface drainage area. The maximum difference in elevation between high
point of grade and the grade at the catch basin should not be more than 150 mm, using a slope
of 25 mm in 3000 mm.
The total number of divided surface area divisions will depend upon the drop in elevation of
surface drainage areas.
2.13.4 Sewer Design
The surface drainage area having been divided into specific smaller areas, based on slope and
drop in elevation, must now be segregated and run into the proper classification of sewer.
The divided areas should be provided with a sewer box or catch basin. The outlet connections
at the sewer box or catch basin may be located at the bottom or side depending upon the limits
of sewer Bottom of Pipe.
Drain hubs collecting drainage from equipment above grade or paving should also be run to the
proper classified sewer. Flow diagrams should be consulted to make sure that no drain
connection has been omitted, especially those located at upper or elevated equipment levels.
Drain hubs should project minimum 50 mm above grade or paving to prevent the undesired
surface drainage from entering the sewer systems.
2.13.5 Catch Basin
Catch Basins should be used at junctions or changes in direction of sewer branch lines. The
location of junctions of sewer branches may so coincide that a catch basin may be substituted
for a sewer box. A sewer box is normally used as a junction for a change in diameter or size of
all sewer mains.
Catch basins with open tops, covered with grating, should be used to collect surface drainage in
unit areas where drainage may wash down appreciable amounts of debris or foreign matter.
The bottom of the catch basin should be designed deep enough to provide a minimum of 150
mm for sediment settlement or separation.

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Catch basins in paved areas should be flush with the paving. In unpaved areas the top of the
catch basin should be 50 mm above grade.
2.13.6 Seals
Seals should be provided on all inlets or sewer branches and sewer mains connecting to a
catch basin or manhole. Seals consist of an elbow rotated downward or the inlet located below
the outlet to provide for a minimum of a 150 mm seal. Fittings when used, should be removable
from inside the catch basin or manhole to permit cleaning and rodding.
Areas that are considered hazardous, from the standpoint of having accumulations of flammable
gases in the sewer mains, should have catch basin or manhole covers sealed or gasketed to
prevent escaping or leakage of gases from sewer lines. Catch basins and manholes should be
provided with a 4" minimum size vent. In areas having furnaces or other fired equipment or
sources of possible ignition, vents should be run underground for at least 30 m from the ignition
source, then up 3000 mm above grade or adjacent platforms, if necessary.
2.13.7 Floor Drains
Inside of buildings, floor drains should be used in floors only where they will handle water. They
are to be mounted flush or just below (25 mm maximum) at the low point of finished concrete.
Floor drains should not be permitted in control rooms, switch room or lavatories. There is
always the possibility of sewer gas accumulation backing up.
2.13.8 Cleanouts
a. A sufficient number of cleanouts must be provided to ensure that any obstruction can be
removed from the lines. Do not locate cleanouts in front of doorways, in walkways, or in
areas where they create tripping hazards.
b. Both inside and outside buildings Cleanouts in hazardous service should be flanged.
c. Cleanouts should be every 15 m or 135° change in direction.
d. Cleanouts should be the same size as the pipe up to 4" and not less than 4" on larger
sizes.
2.13.9 Sewer Sizing
The minimum size underground sewer branch connection shall be 2" diameter. The minimum
size sewer main shall be 4" diameter. The minimum size sewer main collecting two or more 4"
branches shall be 6" diameter. The minimum size sewer pipe in any curbed or diked area shall
be 8". The minimum slope for sewer system shall be 10 mm in 1000 mm or 1%.
2.13.10 Firewater

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Refer to section 3.21 Fire protection equipment
(To Section 3.0)

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END OF
SECTION
TWO
Section: Page:
Rev:
Equipment Design Considerations 2
3.0 EQUIPMENT DESIGN CONSIDERATIONS
3.10 BOILERS
3.10.1 Description
3.10.2 Power Boiler Types
3.10.3 Design Data
3.10.4 Location and Arrangement
3.10.5 Piping
3.10.6 Access, Maintenance and Safety
3.10.7 Boiler Layout Check List
3.10.8 Boiler Glossary
Figure 3.10.9 Typical Components of a Boiler Plant
Figure 3.10.10 Typical Boiler Plant Plot Layout
Figure 3.10.11 Typical Boiler Locations
Figure 3.10.12 Typical Boiler Components
Figure 3.10.13 Typical Boiler Piping- Details 1 through 5
Figure 3.10.14 Typical Burner Piping- Detail 6 and 7
3.12 COMPRESSORS
3.12.1 Description
3.12.2 Types
3.12.3 Compressor Accessories
3.12.4 Drives and Drive Accessories
3.12.5 Location and Arrangement - General
3.12.6 Location and Arrangement - Compressors in Buildings
3.12.7 Piping
3.12.8 Piping Information Required to Perform Analog
Figure 3.12.9 Centrifugal Compressor- Typical Turbine/Motor Drive
Arrangements
Figure 3.12.10 Cross Section of Reciprocating Compressor and General Notes
Figure 3.12.11 Reciprocating Compressors– Typical Arrangements
Figure 3.12.12 Top Nozzle Orientation for Horizontal and Vertical Split Casing
Figure 3.12.13 Typical Steam Piping
Figure 3.12.14 Typical Steam Piping
Figure 3.12.15 Typical Air Removal and Lube Oil piping
Figure 3.12.16 Dampeners

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3.0 Equipment Design Considerations Date: 2015-10-20
3.13 FIRED HEATERS
3.13.1 Description
3.13.2 Types
3.13.3 Parts of a Heater
3.13.5 Piping
Figure 3.13.6 Typical Vertical and Horizontal Box Type Heaters
Figure 3.13.7 Fired Heaters- Typical Locations
Figure 3.13.8 Heaters and Reactors– Typical Locations
3.14 COOLING TOWERS
3.14.1 Description
3.14.3 Piping
3.15 AERIAL COOLERS
3.15.1 Description
3.15.2 Types
3.15.4 Piping
Figure 3.15.6 Aerial Cooler Piping
Figure 3.15.7 Aerial Cooler Piping- Alternate Arrangements
3.16 SHELL AND TUBE EXCHANGERS
3.16.1 Description
3.16.2 Types
3.16.4 Piping
Figure 3.16.6 TEMA Nomenclature- Shell and Tube Exchangers
Figure 3.16.7 TEMA Nomenclature of Shell and Tube Exchanger Components
3.17 PROCESS VESSELS
3.17.1 Description
3.17.2 Types
3.17.4 Piping
3.17.6 Instrument Connections

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Figure 3.17.7 Tower Platform Access Configurations and Miscellaneous Piping

Access
3.18 PUMPS & TURBINES
3.18.1 Description
3.18.2 Types
3.18.4 Piping
3.18.5 Access, Maintenance & Safety
3.18.6 Turbine Piping
Figure 3.18.6 Pump Piping Reducer Applications
Figure 3.18.7 Pump Piping Arrangements
Figure 3.18.8 Automatic/Manual Startup Turbines
3.19 STORAGE VESSELS
3.19.1 Description
3.19.2 Types
3.19.4 Piping
3.19.5 Access, Maintenance & Safety
Figure 3.19.6 Tank Dike Requirements and Sizing
Figure 3.19.7 Storage Tank Piping Configurations
3.20 PROCESS FILTERS & SEPARATORS
3.20.1 General
3.20.2 Types
3.20.3 Multiple Filters
3.21 FIRE PROTECTION EQUIPMENT
3.21.1 Description
3.21.2 Types
3.21.3 Location & Arrangement
3.21.4 Piping
Figure 3.21.5 Typical Hose Installation
B-SD-35916M Installation Details for Hydrant with Monitor, Indicator Post,
Underground Supports and Insulation/Tracing of Underground
Lines
3.22 DEHYDRATION EQUIPMENT
3.22.1 General
3.22.2 Types
3.22.3 Liquid Desiccant Dehydrators

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3.22.4 Solid Desiccant Dehydrators
3.23 LOADING STATIONS
3.23.1 Description
3.23.2 Types
3.23.3 Location
3.23.4 Piping
3.23.5 Access
3.24 WATER SUPPLY AND TREATING EQUIPMENT - (NOT ISSUED)
3.25 INCINERATORS AND FLARE STACKS
3.25.1 Description
3.25.2 Types
3.25.3 Location
3.25.4 Piping
3.26 HEATING VENTILATION & AIR CONDITIONING
3.27 PROCESS TREATERS
3.27.1 Description
3.27.2 Vertical Downflow Treater
3.27.3 Horizontal Electrostatic Treaters
3.27.4 Alternate Heating Methods
3.27.5 The Electrical System
3.27.6 Optional Features
(To Section 4.0)

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3.10 Boilers Date: 2015-10-20
3.10 BOILERS
3.10.1 Description
A steam boiler is a device in which water is boiled to generate steam.
Available water is usually not suited to be injected into a boiler. It contains a number of
impurities, which have to be removed. Additives are often used to prevent corrosion and
formation of scale.
An example of one type of boiler feedwater preparation is shown in Figure 3.10.9. In this
example, raw water is fed to water softeners, where it is filtered and chemically softened. The
softened water is then stored. From storage, it is pumped to the deaerator where carbon
dioxide (CO ) and oxygen are removed. The deaerator usually sits on top of a boiler feedwater
²
drum. Deaerated water drops into the boiler feed water drum, where sulfite is added. From the
deaerator, boiler feedwater (BFW) is pumped to the boiler as required. Before the BFW enters
the boiler, phosphate is injected.
Removal of CO and oxygen prevents forming of acids. Sulfite and phosphate injection
²
prevents corrosion and formation of scale.
Various essential parts common to most boilers are listed below with a description of their
function.
a. Firebox
That part of the boiler designed for burning of fuel.
b. Safety Valve
A device designed to relieve the pressure in the boiler at a set pressure to prevent
damage to the boiler.
c. Steam Gauge
An instrument for indicating the steam pressure in the boiler. The gauge may be
connected to the steam space, water column, or to the steam connection to the water
column in a boiler. Each gauge must be connected to a siphon or equivalent device, this
is to prevent the high temperature of the steam from contacting the material and
mechanism of the gauge.
d. Test Valve
A test connection used to check the accuracy of the boiler steam gauge with a calibrated
test gauge.
e. Water Gauge Fixtures - Petcock and Gauge Glass

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3.10 Boilers Date: 2015-10-20
Water gauge valves control the steam and water passages between the boiler and
gauge glass. In the event the glass breaks, the valves can be closed and glass replaced
while boiler is in operation. The gauge glass indicates the water level in the boiler.
Opening the petcock or drain cock on the bottom of the lower gauge fixture allows a flow
of steam to sweep through the glass tube and blow out sediment accumulation.
f. Tri-Cocks
Supplementary or substitute water gauges. Each high pressure boiler should have at
least three. The middle one is set at the normal liquid level, the top and bottom ones are
set at the highest and lowest allowable water level.
g. Blow-Off Valve
Feedwater always carries dissolved solids with it into the boiler. These are left in the
boiler after the water has been evaporated into steam. The amount of solids is therefore
continuously increasing and unless the concentration is reduced, trouble will result from
foaming, carry-over and possibly burned tubes. The solids may be reduced by blowing
off some of the boiler water and replacing it with fresh feedwater.
3.10.2 Power Boiler Types
ASME Boiler and Pressure Vessel Code Section 1, latest edition.
Boilers are generally classified into three types:
a. Water Tube Boilers
In this type boiler, the water is inside the tubes and the hot combustion gases pass
around the outside of the tubes. There is less volume of water contained in water tube
boilers than in fire tube boilers of the same rating. Water tube boilers are fast steamers
because of the small amount of water contained in comparison to the amount of heating
surface.

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3.10 Boilers Date: 2015-10-20
b. Fire Tube Boilers
In this type boiler the hot gases of combustion pass through the tubes. The tubes are
partially submerged in the water. Heat from the hot combustion gas is transferred to the
water through that portion of the tubes in contact with the water. Fire tube boilers have
straight tubes. Of the fire tube boilers, the three most popular types are:
i. HRT (Horizontal Return Tubular Boilers)
This type has a firebox or combustion chamber in which the fuel is burned. The
pressure vessel is horizontal and sits above the firebox. The firebox is built
separately from the pressure vessel and is either steel with refractory lining or
built of regular brick refractory lined. The heat from the hot combustion gas
contacts the lower outside shell (Belly) of the boiler - then passes upward at the
rear and returns through the fire tubes.
ii. Firebox Water Leg Fire Tube Boilers
This type has water walls extending down the sides and front of the combustion
chamber and forms the combustion chamber which is an integral part of the
horizontal pressure vessel. Water is contained in the horizontal pressure vessel
as well as in the walls of the combustion chamber. The fire tubes run horizontally
in the pressure drum. Thus, the heat from the fuel burned contacts the walls of
the combustion chamber, then strikes the lower outside shell (Belly) of the
horizontal shell passing to the rear, then upward and returns through the fire
tubes.
iii. Scotch Marine Fire Tube Boilers
Scotch Marine boilers are built horizontal and have a circular furnace which runs
through the pressure drum. Fire tubes are above and/or around the circular
furnace. Firing is done at the front of the circular furnace and combustion gases
move through the furnace to the rear and return through the fire tubes. There
can be two or more passes of heat through the boiler. The furnace as well as the
fire tubes are surrounded by the water.
c. Tubeless Boilers
The name tubeless comes from the fact that these boilers do not have either water tubes
or fire tubes. Their design is usually a round vertical shell, containing water to a certain
level and with the top part forming the steam chamber. The heat from combustion is
directed under and around the outside shell. Refinements, depending on design, consist
of fins or other extended surfaces welded to the outside of the shell which helps the
transfer of heat from the fuel burned to the water for steam generation.

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3.10 Boilers Date: 2015-10-20
3.10.3 Design Data
Additional information is listed for the designer's use as follows: a) Draft, b) Ventilation, c) Boiler
Feedwater Equipment, d) Reclaimed Condensate, e) Return System, f) Non-return System.
a. Draft
Boilers must have draft. It is absolutely necessary to mix air, which carries oxygen, with
whatever fuel is burned in the boiler to assure proper combustion.
b. Ventilation
Regardless of what type of fuel firing equipment is used, or whether or not the boiler
requires a stack, it is important that the boiler room be properly ventilated. There should
be a fixed opening in the boiler room, other than a door or window, because often in cold
weather such openings are closed for comfort, thus starving the boiler of air. There
should, therefore, be a louvered, screened opening to the outside in the boiler room.
Many types of equipment in plants add to boiler room ventilation problems and take vast
amounts of air. Add to this the effect of exhaust fans, which further rob the boiler room
of vital air, and it spells trouble. Unless sufficient outside air is brought into the boiler
room, rumbling, combustion noises, minor explosions at start, sooty burning of fuel, and
generally unsatisfactory and inefficient boiler operation will result. Minimum air opening
into the boiler room depends on local code requirements, or on method used to furnish
air to boiler burner.
Three methods are used to bring the necessary air to the fuel burned in a boiler. These
are:
i. Stacks or Chimneys
The function of a chimney is to produce a draft. The draft carries the oxygen
necessary for proper combustion. The chimney also carries the products of
combustion to such a height before discharging them that they will not be
objectionable or injurious to nearby residents.
If a chimney is required, follow carefully the recommendations of the

manufacturer on the diameter and height of the chimney. In any event the
chimney itself should be higher than any adjacent buildings and should extend at
least 1.2 m above a roof, parapet or bulkhead. If a cap is placed on top of the
chimney to prevent entry of rain, it should be mounted at a height above the
stack or chimney equal to the diameter. No other equipment should be attached
to the same stack or chimney, because the efficiency of both units will be
affected.
If ducting is used from the boiler to a chimney, it should be as short as possible,

with as few bends as possible. The ducting should slant upward toward the
chimney. If it is necessary to run the ducting more than 2 m, add 300 mm of

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3.10 Boilers Date: 2015-10-20
chimney height for every 600 mm of ducting. If more than two 90° ells are used,
add 300 mm of height for every extra ell. Vendor to confirm arrangement.
It is far better to have more rather than less stack height than required, as excess
draft can be controlled by the use of a Barometric Draft Regulator. This can be
set to give the right draft for proper combustion of the fuel being burned.
ii. Induced Draft
It is possible to eliminate the high stack by the installation of an induced draft

blower unit. The blower is positioned so it will draw air through the boiler
combustion chamber. With this type unit it is only necessary to run ducting from
the boiler to the draft unit and a vent stack from the draft unit to the outside to
vent the product of combustion to the atmosphere.
Induced draft units save the cost of large diameter and high stacks plus erection
and maintenance costs. They maintain a proper draft uniformly, regardless of
weather, wind velocity or barometric conditions. They provide instant and
constant draft to the fuel at the required rate.
Induced draft units are installed at or near the stack connection on the boiler.
iii. Forced Draft
It is also possible to eliminate the high stack using a blower unit positioned to
force air through the boiler fire box. On this type boiler all that is required is a
vent stack to the outside of the building to remove the products of combustion.
On boilers using either forced draft or induced draft, remember that the products
of combustion leaving the boiler must be directed so that they are not
objectionable to nearby residents. This must be done in accordance with local
regulations.
c. Boiler Feed Water Equipment
All steam boilers require some type of automatic water feed equipment in order to
maintain a uniform water level and steam space in the boiler. The specific type of water
feed equipment will depend on the type of operation required.
d. Reclaimed Condensate
If steam from the boiler is supplied to steam-using process equipment from which it is
possible to return the condensation (condensed steam), the boiler feed equipment
should be of a type that will return this hot condensation to the boiler.
Condensation is distilled water, and makes excellent boiler feed water. Also, it is hot
water, and for every 10 degree rise in the temperature of boiler feed water, a fuel
savings of approximately 1 percent can be realized.

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Equipment from which condensation can be reclaimed should be equipped with steam
traps. The purpose of a steam trap is to hold the steam in the process equipment until
the heat units (latent heat) have been extracted and it returns to condensate form
(water).
The steam trap discharges the condensate from the process unit automatically.
The condensate from the steam traps can be discharged into a return line, which is
piped to a condensate receiver. From this condensate receiver it can be pumped back
into the boiler.
In some plants only a portion of the steam from the boiler is used in process equipment
from which condensation can be reclaimed. Other steam from the boiler may be used in
a process where the steam discharges to atmosphere, which represents lost steam,
which must be replaced in the form of more water.
e. Return System
The ideal type of automatic boiler feed unit in the mentioned case is one that will take
care of all the water requirements of the boiler, in addition to returning the condensate,
such as a return-to-boiler system. This type system comprises a condensate receiver, to
which condensate is returned. The receiver is equipped with an automatic make-up
valve assembly mounted so that a halfway level of water is always available in the
receiver. The make-up valve assembly is connected to the water supply line. When
water level in the condensate receiver falls below the halfway level, the float controlled
make-up valve opens and allows treated water to enter the receiver and return the water
level to the halfway level.
The return-to-boiler system includes a Motor Driven Pump.
The operation of the return-to-boiler system is controlled by a water level switch control,
which is mounted on the boiler at the boiler water level.
f. Non-Return Systems
In some plants, steam from the boiler is used in such a manner that after it is supplied to
the process, none of the condensed steam (condensate) can be reclaimed and returned
to the boiler.
In such cases it is necessary to have some type of automatic boiler feed equipment
which will feed the necessary make-up water to the boiler to replace all of the water lost
in the generation of the steam.
g. Automatic Water Feed Pumping Unit
This is required if the maximum steam pressure carried on the boiler exceeds the
available feed water pressure. It consists of a turbine type boiler feed pump. A water

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3.10 Boilers Date: 2015-10-20
level control, mounted on the boiler at the boiler water level, starts and stops the pump
according to the water level in the boiler.
A water pressure relief valve is recommended for installation in the pump discharge line
to prevent the water from flooding the boiler, should the steam pressure in the boiler go
below the feed water pressure at any time.
It is always recommended that the return-to-boiler system or automatic water feed

pumping unit be sized to pump against the maximum safety valve setting on the boiler.
In this way, if the setting of the pressure control, which controls the firing unit, is raised at
any time, the boiler feed pump unit will be of sufficient capacity to feed the boiler.
Modern day boilers are automatically fired, and should have automatic boiler feed
equipment.
Boiler plants, like all fired equipment, should be located up wind of process units to prevent
gases from being blown into burner flames. Actual arrangement of the boiler plant and
associated equipment varies from plant to plant depending on space required. Typical
arrangements are shown in Figures 3.10.10 and 3.10.11.
3.10.5 Piping
See Figures 3.10.12, 3.10.13 and 3.10.14 for some piping pointers. Certain portions of external
piping connections to boilers fall under the jurisdiction of the ASME Boiler Code. Refer to the
ASME Boiler and Pressure Vessel Code, Section I, latest edition.
Boilers are generally large and heavy, and the designer must allow sufficient access space for
erection and assembly: Tube removal or repair, maintenance of drive units for
Combustion air blowers, unobstructed maintenance and operation space at burners, soot
blowers, etc.

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3.10 Boilers Date: 2015-10-20
3.10.7 Boiler Layout Check List
a. Piping
· Verify size, rating, and type of connection for:

· Boiler feed water
· Chemical feed
· Fuel gas or fuel oil
· Intermittent blowdown
· Continuous blowdown
· Steam sample connections (superheater inlet coils and/or steam drum)
· Steam connections for sootblower piping
· Steam outlet
· Superheater and economizer drains
· Drip Pan for Steam PSV see Jacobs Metric Piping Standard A-SD-35967M
b. Instrument Connections
Verify size, rating and orientation:
· Level controller
· Water column
· Instrument blowdown connections (water column level controller, level switch)
· Relief valve
· Pressure and temperature gauges
c. Stack
Check Stack height relative to adjacent platforms- minimum height 4.5 m above any
platforms within a 12 m radius
Locate and orient stack access opening.
d. Observation Ports/Boiler Firebox Manholes
Verify accessibility from grade or platform.
e. Oil or Gas Fired Burners
Verify accessibility from grade or platform. Verify oil gun removal clearances.

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3.10 Boilers Date: 2015-10-20
f. Platforms
Determine platform requirements. Platforms are generally required at:
· Burners
· Steam drum (for safety valves, vent valves, steam non-return valve and drum
instruments)
· Sootblowers
g. Stress Requirements
Boiler vendor must indicate boiler thermal movements at external piping connections.
Allowable forces and moments at terminal connections should be confirmed (using

piping layouts) with stress group.
h. Air Preheater
Verify clearance for drain piping.
Verify accessibility to valves for cleaning device, valve for air motor and oil cooler, and
basket removal door.
i. Fan
Verify accessibility for connections to damper control linkage and operation and
maintenance around driver.
3.10.8 Boiler Glossary
a. Air Preheater
Mechanical device that preheats combustion air by absorbing heat from flue gas.
b. Blowdown-Continuous
Line from steam drum which flows continuously to remove solids and insoluble
suspended matter in boiler water.
c. Blowdown Drum
Drum (normally vertical) that collects flow from continuous and intermittent blowdown
lines.

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d. Blowdown-Intermittent
Line from bottom of mud drum which is used to blow sludge out of drum.
e. Blowdown Pit
Underground concrete pit that collects flow from continuous and intermittent blowdown
lines.
f. Boiler
A closed pressure vessel in which a liquid, usually water, is vaporized by the application
of heat.
g. Casing
Sheet metal that encloses the boiler.
h. Deaeration
Removal of air and gases from boiler feed water.
i. Desuperheater
Header containing superheated steam into which water is injected to produce saturated
steam.
j. Ducts
Sheet steel ducts which connect fan to air preheater and air preheater to boiler and
stack.
k. Economizer
A heat recovery device (usually a series of coils) designed to transfer heat from the
products of combustion to a fluid, usually boiler feedwater.
l. Fan
Motor or turbine driven fan that supplies combustion air to boiler.
m. Firebox
Refractory lined steel box that houses tubes, steam and mud drums, sootblowers, and
burners; the section that produces steam.

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3.10 Boilers Date: 2015-10-20
n. Mud Drum
Lower drum in firebox. Water to mud drum is fed from steam drum through downcomer
tubes. Sediment in water collects in bottom of drum.
o. Power Boilers
Boiler used primarily to develop steam for power applications such as generating
electrical energy and feeding power turbines.
p. Pressurized Boiler
Firebox which is sealed by mechanical means and with air pressure to be air tight.
q. Retractable Oil Gun
Oil gun whose horizontal position can be adjusted during firing.
r. Sealing Air
Air which seals observation ports, sootblower connections, burners, etc. and prevents
escape of heat and gases. Also used to cool sootblowers steam lances.
s. Sootblowers
Retractable or non-retractable permanently installed lances that rotate and spray steam
or air to clean tube exteriors.
t. Stack
Cylindrical structure that exhausts flue gases to atmosphere.
u. Steam Drum
Upper drum which is connected to the mud drum with downcomer tubes. Steam is
discharged from top of drum.
v. Superheater
Separate set of coils in boiler firebox, which recirculates saturated steam in order to
raise the temperature of the vapor above the temperature corresponding to its pressure.
w. Tri-Cocks (Gauge Cock)
Valves attached to a water column or drum for checking water level.

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x. Utility Boiler
Boiler used primarily to provide steam to service process plant requirements.
y. Water Column (Instrument Bridle)
Vertical tubular member connected at its top and bottom to the steam and water space
of the steam drum respectively, and to which the water gauge, gauge cocks, and high
and low level alarms may be connected.
(To Section 3.12)

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3.12 Compressors Date: 2015-10-20
3.12 COMPRESSORS
3.12.1 Description
A compressor is a device by which vapor is compressed.
Compressor installations quite often become a "plant within a plant" because of the great
number of essential accessories which accompany the different types of compressors. Outlined
below are basic types of compressors and some of the accessories which the layout designer
must be aware of when arranging compressor equipment.
3.12.2 Types
There are two categories of compressors. Each have different arrangements and/or variations
as follows:
a. Centrifugal Compressors
A centrifugal compressor utilizes centrifugal force to compress gas. An impeller forces

the gas to spin around in a casing. The gas is thereby forced against the casing and
collected, to be either discharged or transferred to a second stage. The higher the
pressure required, the more stages are used.
The two basic types of centrifugals are, the vertically split case types (used for high
pressure applications., and horizontally split case types (used for low to moderately high
pressure applications..
Vertically split case rotors are taken out the front of the machine, while horizontally split
case rotors are removed from the top. There must be no obstructions to rotor removal.
The designer must locate piping, instruments, building columns, panels, etc., out of the
way. Overhead piping on horizontally split case machines must be easily removable.
See Figure 3.12.12.
Centrifugal compressors may have up to ten stages of compression within one casing. If
more than ten stages are required, two or more compressors may be used, coupled
together and powered by a common driver. This is called tandem drive.
b. Reciprocating Compressors
A reciprocating compressor utilizes a piston or plunger operating within a cylinder.

Pressure operated inlet and outlet valves direct the flow of gas through the cylinders.

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At the inlet stroke, the piston enlarges the volume within the cylinder, thereby decreasing
the pressure inside the cylinder. Gas forces the inlet valve to open and flows inside the
cylinder at the same time the outlet valve closes due to back pressure against valve.
Now, the compression stroke of the piston starts, thereby decreasing the volume of the
gas within the cylinder and increasing the pressure. The outlet valve opens and the inlet
closes.
The three basic types of reciprocating compressors are:
i. Balanced Opposed
These compressors have cylinders on both sides of the crankshaft.
ii. Angle Type
These compressors have cylinders on one side of the crankshaft. This type has
an integral gas or diesel engine drive.
iii. Horizontal or Straight Line
These compressors are commonly called "one-lungers", having only one

cylinder.
iv.. Axial Compressors
The flow of gas in these compressors is in an axial direction. This motion is

created by vanes attached to a rotating drum.
3.12.3 Compressor Accessories
The equipment/systems associated with various types of compressors are as follows:
i. Auxiliary lubricating system consisting of oil pump; oil coolers and filters.
ii. Seal oil pump.
iii. Intercooler and interstage separator (used between two compressors operating
in series).
i. Auxiliary lubricating and cooling oil system consisting of lube oil gear pump, lube
oil cooler, oil strainers and oil filters.
ii. Intercoolers, aftercoolers and separators.

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iii.. Cylinder cooling water system consisting of jacket water cooler, jacket water
pump.
iv. Suction knockout drum.
v.. Suction and discharge dampeners.
vi. Loading/unloading suction valve.
c. Axial Compressors
Auxiliary lube and seal oil systems.
3.12.4 Drives and Drive Accessories
i. Motors (refer to Paragraph 3.12.5a).
ii. Steam turbines (if condensing type; surface condenser, jet ejector, condensate
pumps.. Refer to Paragraph 3.12.5b.
iii. Gas turbines.
i. Motors (may have air cooling blowers). Refer to Paragraph 3.12.5a.
ii. Gas or diesel engines. Possible accessories include the following:
· Starting air system;

· Diesel oil tanks, pump, and filter;
· Engine oil gear pump, cooler, filter and strainer;
· Fuel gas surge tank;
· Scavenging air compressor;
· Engine air filter;
· Cooling medium pumps.
3.12.5 Location and Arrangement - General
The location of centrifugal compressors should include consideration for the following:
· Access by mobile equipment for maintenance;

· Keeping suction line as short and direct as possible.

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Space requirements vary depending on compressor size and type of driver. Centrifugals also
have lube and seal oil consoles which can be quite large. These consoles must be lower than
the compressor to allow gravity drain of oil to the console's oil storage tank. When laying out
equipment, allowance must be made for the considerable space which may be required for lube
and seal oil consoles.
All centrifugal compressors have seal oil piped to them, with an overhead seal oil tank that rides
on seal pressure and maintains a reserve supply of critical seal oil should the system lose its
source of power. The reserve will function a short time until the operator can solve the power
loss problem or shut down the compressor. The seal oil tank is elevated 6 m to 9 m above the
compressor centerline so that head in the line will be enough to force seal oil flow to the
machine.
Manufacturers normally specify required minimum height of seal oil tanks for their machines.
Although small, (300 mm to 450 mm diameter x 1 m to 5 m long) seal oil tanks must be carefully
considered, layout wise. Their required elevation and instrumentation (level gauges, etc.) make
platform access mandatory. Piping to them comes from the seal oil console and goes to the
compressor seals, so they should be located somewhere between them. With building type
installations, they are often located on the roof. Outdoor installations require a small separate
structure.
Arrangement of compressor and auxiliary equipment depends largely on driver type. A

discussion of two basic types of driver, electric motor and steam turbines, follows:
a. Electric Motor Drives - These can either be induction or synchronous type, size and
shape varying accordingly. An electric motor is normally larger than the compressor it
drives and may be the determining factor in sizing a building or shelter if required.
Captive transformers, if necessary, should be located near the motors, but outside the
building or shelter.
b. Steam Turbines - These are classified as either non-condensing, or condensing.

Non-condensing turbines use high pressure steam and exhaust lower pressure steam to
a steam system. Condensing turbines exhaust to a surface condenser (shell and tube
exchanger) to recover condensate, and inject back into the condensate system.
Surface condensers are often grade mounted directly below the compressor turbine.
This arrangement uses a turbine with a bottom outlet nozzle directly connected, with an
expansion joint, to the surface condenser inlet nozzle. Since compressor, gear and
turbine are elevated above the surface condenser, this is called mezzanine installation.
Surface condensers can also be grade mounted alongside a grade mounted
compressor.
Some typical arrangements for centrifugal compressors and drives are shown in Figure
3.12.9.

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3.12.6 Location and Arrangement - Compressors in Buildings
Reciprocating compressors are usually installed in buildings. The arrangement of the machines
inside the buildings depends on type. A good layout of reciprocating machines will result in cost
savings on process and utility piping, good maintenance and accessibility and reduced pulsation
in suction and discharge piping.
Balanced opposed machines are placed so the crankshaft runs perpendicular to the suction and
discharge headers. Angle type compressors are located with crankshafts running parallel to the
headers. See Figure 3.12.11 for both configurations.
When sizing buildings for reciprocating compressors, the designer should consider the
following:
a. Eave height - This should be based on height of largest piece (usually the motor for
balanced opposed machines. plus 1.2 m plus size of traveling crane required to handle
heaviest removable piece. (Cylinders gear box, or sometimes the entire motor.)
b. Width and length - This depends on number and size of machines required, but a good
rule of thumb is to allow 2 m clear all around the compressors.
Other space considerations to remember are piston withdraw requirements, local panel
boards, possible large duct work to air cooled motors, control valve manifolds, lube oil
consoles in basements, etc.
One end of the building should be left open as crane drop area with nothing occupying
the floor space.
A typical cross-section through a compressor building may look like that shown in
Figure 3.12.10 complete with associated notes.
3.12.7 Piping
Centrifugal compressors operate at relatively low temperatures and little if any temperature rise
occurs during compression. Piping temperatures are usually 38°C to 54°C. Compressors, in a
unit employing a reactor with a catalyst that can be regenerated by the flow of hot gas are a
special problem of concern to the designer. Regeneration may occur only once every year or
two; however, during this period compressor piping temperatures may reach 150°C. While
150°C is not a high temperature, when combined with large line sizes (20" to 36") large forces
are generated. Regeneration temperatures must be considered in designing suction and
discharge piping at centrifugal compressors.
Typical piping arrangements are shown in Figure 3.12.12, Figure 3.12.13, Figure 3.12.14 and
Figure 3.12.15.

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Reciprocating compressors constitute a major concern to the designer because of pulsation.

Location and arrangement of pulsation dampener, (suction and discharge volume bottles.
supports, clamps, etc.), all affect the performance of the compressor piping.
Figure 3.12.16 shows suggested arrangements for pulsation dampeners.
3.12.8 Piping Information Required To Perform Analog
a. Data Sheets - Giving description of operating conditions.
b. Flow Diagram - Defining extent of suction and discharge piping to be studied.
c. Isometrics - Defining suction and discharge piping, showing the following information:
i. Dimensioned to ± 150 mm.
ii. Locate all hold downs and supports.
iii. Locate block valves, and other heavy in-line items note type, manufacturer, and
model number. Indicate whether valve is normally closed or open.
iv. Locate control valves, note size
v. Locate all orifice flanges and note size.
vi. Locate and dimension all branches from piping to the first closed valve such as
purge lines, relief valves or start-up by-passes.
vii. Note all pipe sizes or reductions, give ID and flange ratings.
viii. Give design and operating pressure of system.
ix. Locate, dimension and give elevation of all overhead supports.
d. Include with "analog package" drawings of all equipment involved including bottles,
showing internal details.
Piping to and from compressors should be extended to a large volume vessel or at least 60 m
for heavy gases such as propane or 150 m for light gases such as hydrogen.
(To Section 3.13)

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3.13 Fired Heaters Date: 2015-10-20
3.13 FIRED HEATERS
3.13.1 Description
A fired heater is a device in which a commodity flowing inside a tube is raised in temperature by
means of an open fire outside the tube. Petrochemical plants utilize oil or gas to fuel the fire.
Sometimes both fuels can be used in turn as alternate fuels in case one or the other is not
available at the time.
A fired heater usually has a radiant section and a convection section.
3.13.2 Types
There are two basic types of fired heaters. These are:
a. Horizontal or Box Heaters
As the name suggests, horizontal heaters have the tubes running horizontally. The
header boxes are at each end of the heaters. See Figure 3.13.6. Horizontal heaters are
the type used when large capacities are needed.
b. Vertical Heaters
Vertical heaters have a round cross-section. The tubes usually run vertically. The
header boxes are at top and bottom of the heater. See Figure 3.13.6. Vertical heaters
do not take a lot of plot space and are used where small capacities are needed and plot
space is limited.
3.13.3 Parts of a Heater
a. Tubes
The commodity may, and frequently does, enter the heater in a split stream (multi-pass).
In this case, it is important that the parallel sections are symmetrical, with equal travel
paths, to ensure identical heating.
Knowing the number of passes, we are able to determine easily the possible location of
inlet and outlet, and can, therefore, plan our layout before we receive the manufacturer's
drawings. In a horizontal heater, flow may progress downward from the upper tubes or
upward from the lower tubes. Normally, down flow is preferred, since it is also the direct
route from the convection section, which the fluid has to pass first. The tubes are
arranged along the walls. One obvious advantage of the horizontal position of the tubes
lies in the fact that it allows substantial drainage on shutdown. This represents an
important safety factor in case of fire.

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b. Headers and Header Boxes
The connection of one tube end to the next tube end can be made by means of
U-bends. This solution is not always satisfactory. It does not permit inspection and
mechanical cleaning of the tubes. Special return headers are often used. These
headers allow inspection and mechanical cleaning by means of a removable plug.
Because of the possible leakage and the resulting danger, headers must be completely
enclosed in header boxes. The header boxes must be provided with independent
permanent snuffing steam connections.
c. Burners and Firebox
Burners are devices designed to burn the oil or gas as efficiently as possible. Oil is
atomized with steam or some other inert medium.
In updraft heaters, the burners can be located at the side, at the end, or at the bottom of
the heater.
Combustion occurs in the combustion chamber which, depending on the intended

reference, is also called "radiant section" or "firebox". This box must also be provided
with permanent snuffing steam connections. The snuffing steam can also be used to
purge the fire box before lighting the burners.
d. Sight Doors
To observe the flame pattern and to discover possible "hot spots" (overheated tubes),
observation openings, referred to as sight doors or peep holes, are provided.
Their location somewhat above the tip of the flame requires access by means of the
firing platform, which we consider an operating platform. Access to this platform should
therefore be by stairway. A ladder should be provided at the other end as an alternate
escape route.
e. Stack and Stack Damper
For the discharge of the combustion gases at a safe height above ground and for the
induction of air into the heater (draft), a stack is required. It should be higher, by at least
6m, than any operating platform located within a 30 m radius.
To regulate the draft, a single disc (butterfly) or a split disc stack damper is used, which,
by means of cables, is operated either from the firing platform or from grade.
In locating heaters consideration must be given to the following:
a. Prevailing Winds

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Flammable gases should not be allowed to drift to the heater and be ignited. Stack
gases should not be allowed to blow into high structures or operating platforms.
b. Local Codes and Insurances
Local codes have to be consulted as well as insurance requirements as to the distance a

heater must be located from process equipment and from another heater.
c. Heater Transfer Lines
Transfer lines should be kept as short as possible, but consideration should be given to
thermal expansion and support problems.
d. Maintenance
The tubes in a heater usually require cleaning and inspection at regular intervals.
Sometimes tubes have to be removed (pulled). Removal of tubes requires a certain
amount of space, which has to be provided in accordance with the heater manufacturer's
specifications; for typical arrangements see Figure 3.13.7 and Figure 3.13.8.
3.13.5 Piping
a. Transfer Lines
The outlet or hot pipe, which originates at the heater outlet, is often called the heater
transfer line. Generally for economic reasons, the lines to and from fired heaters are
located on low level sleepers up to close proximity to process area.
Flexibility is the first thing that the designer has to investigate. Expansion joints are not
desirable. Flexibility should be accomplished by the piping configuration. Another
consideration are the forces and movements on the nozzles of the heaters and vessels.
Even if the pipe is flexible, the forces and movements may still be too great. The
designer should work together with the stress engineer and the mechanical engineer to
satisfy all the requirements.
A good approach to transfer line routing in the plot plan stage is:
i. Confirm the soundness of our judgment in locating heaters relative to the

equipment it serves.
ii. Consider the maintenance problems, the location of the operating platforms, and
the location of control stations.
iii. Supply the stress engineer with enough information to analyze the lines. See
CWI-230-022 Stress Isometrics.
b. Important Details of Transfer Lines

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i. Ask the process engineer about the symmetry of multiple-pass outlets. Is

symmetry desired or not? Are pockets allowed?
ii. Temperature points have to be located very carefully and they must be
accessible.
iii. Removable spools are sometimes required in order to inspect or remove tubes.
c. Fuel Control Valves
Manually operated valves controlling the flow of fuel and steam to the individual burners
are called firing valves. The location of these valves is dictated by the position of the
sight doors. This means that these valves are at an elevation of 3.5 m to 4.5 m above
ground. A platform (firing platform) is therefore required.
The arrangement of these valves should be such, that the operator finds the same
arrangement no matter which sight door he is standing in front of. This will eliminate
mistakes on his part.
The width of the firing platform should be approximately 1.2 m, allowing 450 mm for
valves and 750 mm for passageway.
d. Fuel Headers
The headers, from which the individual lines to the firing valves branch off, follow the
cross-sectional shape of the heater. For the vertical heaters, they are therefore mostly
circular. For horizontal heaters, they are straight, with controls one side only, or
U-shaped, with controls on both sides. Neither the fuel oil nor the fuel gas lines should
be designed as a closed circle or completed rectangle.
It is preferable to stack the headers vertically alongside the heaters versus the alternate
of a side-by-side arrangement. Sometimes horizontally arranged lines form an
obstruction for the ladders serving higher platforms. The designer should look into this
matter before deciding one way or the other. The lowest line is usually the fuel oil line at
±2.2 m above the firing platform. These headers should drain back to the manifolds at
grade.
(To Section 3.14)

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3.14 Cooling Towers Date: 2015-10-20
3.14 COOLING TOWERS
3.14.1 Description
A cooling tower is a heat exchanger transferring heat from water to the atmosphere. It is an
enclosed structure where intimate contact of water and air takes place. It results in accelerated
cooling of the water by evaporation of some of the water.
Towers should be located to allow unrestricted airflow to the unit and a minimum of interference
from outside influences. Allow as much space as possible between the cooling tower and
surrounding structures. If the louvered face of a tower must be placed near a solid wall, it is
advisable to raise the supporting structures of the tower by means of steel columns or concrete
piers to allow good air access. The louvered sides of a tower should be parallel to the direction
of the prevailing summer wind. Locate tower so that winter wind will carry fog or drift away from
equipment or structures. Towers should not be located upwind of electrical equipment or
unprotected substations.
3.14.3 Piping
The tower manufacturer furnishes water distribution systems within the cooling tower. All piping
to and from the tower, including circulation water, make-up, blowdown and basin drain lines are
the designer’s responsibility. In many cases lines must be buried, in others, they may be
supported at ground level or elevated to clear existing equipment. In any case, unnecessary
turns and fittings should be eliminated to lower friction loss. The hot water or return line risers to
the tower should be supported independent of the tower structure, unless agreed by Project
Engineer.
In wooden structured towers a fire deluge system is usually provided. Provision should be
made to run a fire loop leg to the cooling tower area. In a deluge system an uninterrupted air
supply and/or volume bottle may be required.
Water treatment to a certain degree may be required. This can be accomplished in the cooling
tower pump house or directly in the cooling tower basin.
A governing body for cooling tower standards and design is the Cooling Tower Institute (CTI).
Easy access and adequate working space should be provided on all sides of the cooling tower
to perform maintenance work. Cooling towers should always be provided with fan guards, drive
shaft and V-belt guards, handrails, caged ladders and/or stairways.
(To Section 3.15)

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3.15 Aerial Coolers Date: 2015-10-20
3.15 AERIAL COOLERS
3.15.1 Description
Aerial coolers are heat exchangers, in which atmospheric air is used as the cooling medium.
This air is blown around finned tubes by fans. The cooled commodity flows inside the finned
tubes.
3.15.2 Types
There are three main categories of aerial coolers. They are described as follows:
a. Standard Aerial Cooler
This is the most commonly used type. There are two types of standard coolers;
forced draft which means the fan is located in a housing below the tube bank and forces
air upward past the tubes, induced draft which means the fan is located above the tube
bank and blows air upward, sucking air past the tubes below.
b. Humidified Aerial Cooler
This type has a separate adjoining circulating water unit, similar to a cooling tower,
through which air passes before making contact with the tubes in the cell. Air enters a
water circulation area, is washed, cooled and humidified, passes through a mist
eliminator and then is drawn up through the tube cells and out at the top. During winter
months, air does not pass through the water section but enters through open louvers.
c. Coil Shed
The coil shed cooler is an atmospheric tube cell which is placed inside a cooling tower.
Circulating water is sprayed directly on the tubes and the combination of water and
flowing air produces cooling.
Location of aerial coolers with respect to surrounding equipment or multiple coolers in different
services, should be scrutinized carefully, because of hot air recirculation problems. The
following causes some of the most prevalent problems:
a. Aerial coolers placed too close to each other in the downwind direction.
b. Aerial coolers placed downwind of obstructions. (buildings, etc.)
c. Aerial coolers placed at different elevations near each other.
d. Indiscriminate plot plan mixing of forced and induced draft aerial coolers.
e. Inadequate analysis of plot plan layout in view of prevailing summer wind direction.

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Small or relatively small coolers such as those used in gas treating or compressor installations
are usually located at grade, adjacent to related equipment. They are kept as low as possible
for structural economics and ease of maintenance. Access area around these coolers should
be ample to permit removal of periodic maintenance of the drive units.
Large aerial cooler banks used in refinery service are often located on top of the main pipe rack.
This is done for several reasons. First, their light weight may be more economically supported,
by utilizing a structure which already exists and secondly, their large size can be located in a
position out of traffic, and leave plot space for other equipment or future expansion. By
arranging aerial coolers above the pipe rack, as closely as possible to the equipment they
service, pipe runs will be shorter and the need for excessive yard area supports, common in
grade level installations, will be eliminated. Also, the added elevation of the coolers should
assure good air flow and lessen the chances of hot air recirculation.
3.15.4 Piping
As in other exchanger piping, the medium being cooled should flow down through the tubes.
Inlet piping should be connected to the top nozzle and outlet piping to the bottom nozzle. Inlet
piping to coolers in condensing service from fractionating tower overhead vapours must be
routed so that there is no liquid pocket between the top of the tower and the cooler inlet. If there
is a pocket in this line, condensed liquid in the line will accumulate and "slug" in the cooler,
resulting in possible damage to the tubes or a cooling malfunction.
Condensed liquid-vapour from the cooler must also flow down to the accumulator.
Two-phase flow to aerial coolers must be piped to ensure equal distribution of liquid and vapour
to each cooler section- see Figure 3.15.6. In the case of a very large cooler with many inlet
nozzles, care must be taken to ensure that the piping does not contribute to unequal pressure
drop through the tube sections. Symmetrical piping may be required on the inlet side, however,
it is rarely needed on the outlet side if condensation is extensive.
When aerial coolers have six or more inlet nozzles, regulating valves may be specified at each
inlet and outlet. The valves are used for throttling and serve as block valves to isolate a tube
section for repairs while the other tube sections remain in service. Because flow regulating
valves balance distribution among the sections, piping can be routed to the inlet nozzle in any
configuration. If two-phases flow is being handled, piping must still be symmetrical. Access to
valves and temperature indicators at inlet and outlet nozzles is imperative.
Inlet piping to coolers is hotter than outlet piping and will expand at a greater rate. Cooler tube
sections are merely resting in the cooler frame and will move somewhat with line expansion.
For very hot systems connecting six or more nozzles, cooler drawings must be checked to
determine how much movement can be absorbed by the tube section, to compensate for line
expansion. Differential expansion between inlet and outlet piping headers must be considered
and if necessary, offsets built into the piping to compensate for this differential expansion.
Some additional piping design suggestions are shown on Figure 3.15.7.

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Mobil crane access for erection of large cooler banks can be easily overlooked when working in
congested areas or with limited plot space, but this work space is essential and later becomes
useful for the maintenance of drive units. Booming over low shell and tube exchangers may be
adequate access, but distance and weight of cooler units may dictate otherwise.
Platform with ladder access should be provided along the headers containing nozzles. For
large aerial cooler banks above pipe racks, it becomes necessary to provide platforming for
servicing fans, motors and drive belts. Generally, these platforms are furnished with the cooler,
but the designer should review cooler drawings to ensure that adequate platforming and
clearances have been provided.
From a safety standpoint, fired heaters, in refinery applications, should not be located any closer
to the cooler than the distance from grade to the support height of the cooler. Also, do not
locate pumps operating at or above their auto-ignition temperatures directly beneath aerial
coolers.
(To Section 3.16)

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3.16 Shell and Tube Exchangers Date: 2015-10-20
3.16 SHELL AND TUBE EXCHANGERS
3.16.1 Description
A heat exchanger is a device in which two commodities flow against the opposite sides of a
solid boundary wall which separates them, while permitting heat to pass from the hot to the cold
commodity.
Some common designations for exchangers include the following:
a. Exchanger - heats one stream and cools the other.
b. Cooler - cools liquids or gases without condensation (other designations include

intercooler, aftercooler).
c. Subcooler - condenses vapor and cools further the condensed liquid.
d. Condenser - condenses vapor or vapor mixtures, with water or other cold process
stream.
e. Chiller - uses refrigerants for cooling process streams. The temperatures of the
cooling fluid required in this case lies below the freezing point or below
the prevailing cooling medium temperatures.
f. Heater - generally heats the process stream up to its boiling point, without
appreciable vaporization.
g. Reboiler - boils the bottom stream in towers (fractionators, columns, stills, etc.).
Where large quantities of vapor are produced, "kettle type" shells are
used.
3.16.2 Types
There are three types of exchangers and three main categories. They are described as follows:
a. Shell and Tube Exchangers
Shell and tube exchangers are constructed in a variety of shapes and forms. Standard
definitions as prescribed by TEMA (Tubular Exchanger Manufacturer's Association) are
shown in Figure 3.16.6 and Figure 3.16.7.
Also refer to Piping design Handbook Module No. 10 part B- Heat Exchangers – Shell
and Tube
b. Double Pipe Exchangers

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As the name implies, the double pipe heat exchanger consists of two concentric pipes.
One fluid flows in the internal pipe and the other in the annulus between the inside and
outside pipes.
c. Plate Exchangers
The plate exchanger consists of a frame in which independent metal plates supported by
rails are clamped between head and follower. The plates are sealed at their outer edges
and around the ports by gaskets which are so arranged that the liquid and the heating
and cooling medium are directed alternately into the passages formed between plates.
A double sealing system forming pockets open to atmosphere prevents mixing of liquids
in the event of leakage past a gasket.
Exchangers, in general, should be located next to their related equipment in sequence with the
process flow, keeping in mind shortening alloy or large lines. Exchangers should be elevated
only for specific process requirements, such as NPSH or gravity flow. Exchangers, which must
be elevated, should where possible, be grouped together in a common structure with other
equipment having similar process requirements. Reboiler circuits will determine the elevation
for certain types of reboilers.
Using the "in-line" arrangement concept, shell and tube exchangers are usually arranged with
channel ends facing away from piperack toward a tube pulling area or service road. Double
pipe exchangers are arranged similarly with piping connections facing the rack with an operating
aisle and tube pulling end in the opposite direction.
3.16.4 Piping
Exchanger piping should be designed to process specifications and routed as short and direct
as possible, keeping in mind flexibility requirements. The exchanger designer sets the flow
pattern, through an exchanger and arrangement of the shell nozzles. This arrangement is
usually critical to efficient operation of the equipment, but the designer should investigate the
possibility of relocating exchanger shell nozzles if obvious piping cost savings would result. The
equipment supplier can, in some cases, alter the flow through the exchanger by interchanging
the flow media or changing the direction of flow, thereby enabling the piping designer to relocate
shell nozzles to a more suitable location.
Piping should be designed and supported to allow removal of channel or tube bundle without
the need for extensive temporary supports.
Exchangers are serviced on a regular basis in most plants. Either the complete unit is removed,
cleaned or repaired, or only the tube bundle is removed and the shell is cleaned in place. The
tubes of fixed tube exchangers are cleaned in place by rodding. All of these maintenance
functions require adequate work space. Exchangers should be spaced to permit easy removal

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16.doc
of closure bolts and provide ease of access with tube cleaning or removal equipment. Adequate
access aisles between exchangers will also be required.
(To Section 3.17)

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16.doc
3.17 Pressure Vessels Date: 2015-10-20
3.17 PROCESS VESSELS
3.17.1 Description
Vessels are containers, designed for various process functions, handling liquids and/or vapors
under pressure.
3.17.2 Types
Some of the common types of vessels are as follows:
a. Reactor (Converters)
A reactor is a vessel containing a reactive catalyst used to rearrange the molecular

structure of the stream being fed to it. A catalyst causes this reaction but does not take
part in the reaction itself.
b. Fractionation Distillation Columns
A vertical vessel containing trays. Used to extract from a process system a certain
required fraction or fractions, such as butane, propane, etc. Larger columns are
commonly referred to as Towers, which often are more complex in nature.
c. Accumulator
Sometimes called overhead receivers. Normally a horizontal vessel, and normally does
not have any internal parts. Reflux accumulators hold a level of liquid used as "Reflux"
liquid, which is pumped back to the fractionating towers top tray. Sometimes used as 3
phase separators, for vapors, hydrocarbons, and water.
d. Separators (Scrubbers)
May be either horizontal or vertical vessels. They are generally used to separate a
vapor from a liquid. They also can be used to separate two liquids, which have different
specific gravities. To separate two liquids, the process engineer specifies long vessels
with low velocity, long retention time, weir, and/or liquid boot. Often fitted with mist
eliminators (demister pads, coalescing pads, etc.) on gas outlet.
e. Sieves
Used to cleanse or remove contaminates from the main process stream. Scrubbers may
have packed beds, a system of trays, or mist extractors. The operational principle is,
that by halting the gas flow momentarily, the foreign matter will drop out.

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f. Compressor Knock-out Drum (Suction Scrubber)
Knock-out drums are used to remove entrained liquid from compressor suction lines
prior to entering compressor. They are usually equipped with a demister pad for this
purpose.
Vertical vessels are usually located on a common centerline. Group where practical to utilize
common platforming, ladders, and foundations. Keep back side of trayed towers clear for
access and drop area. Special consideration needs to be given to reactor location because of
its need for catalyst loading and unloading.
Horizontal vessels located at grade should have heads facing piperack aligned on a common
line except where common supports and foundations can be used. Provide ample aisle space
around vessel for accessibility to boots, controls and manways, etc. Elevate vessels only when
required for NPSH, gravity flow and layout clearances. Vessels, which must be elevated,
should where possible, be grouped in a common structure with other equipment having similar
process requirements.
For information on davits, manholes, insulation supports, fireproofing attachments, ladder and
platform clips, vessel internals, etc., refer to applicable Jacobs Design Guide/Standards.
3.17.4 Piping
Tower overhead lines to condensers should be as short and direct as possible with no liquid
pockets, in keeping with flexibility requirements.
Piping in general (except for reboiler piping, etc.) should be grouped on side of column toward
piperack.
A davit should be provided on towers for handling such items as trays, internals, relief valves,
etc. The swing of the davit must reach all platforms which service a manhole and also must be
able to swing over drop area- see Figure 3.17.7.
Internal piping (distributors) that interferes with access into vessel or interferes with tray removal
should be flanged and removable through a manway. Flanges on internal piping should be
accessible from a manway.
All instrumentation on vessels should be accessible from grade, platform, or ladder.
3.17.6 Instrument Connections
For instrument connections see Jacobs Metric Piping Reference B-SD-35999M-3. Bridles
should be used where practical, orientated in clear area and accessible from grade or platform.

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For other information on Vessel Design, see Jacobs Metric Vessel, Piping Miscellaneous and
Reference Guidelines- Vessel Miscellaneous section (B-SD-17004M through B-SD-17020M)
and the Piping Design Handbook Section- Vessels (under Construction)
(To Section 3.18)

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3.18 Pumps & Turbines Date: 2015-10-20
3.18 PUMPS & TURBINES
3.18.1 Description
a. Pump
A pump is a mechanical device used for adding energy to a liquid passing through it. A
pump may actually raise the liquid, or force it into a pressure vessel or merely give it
enough head to overcome pipe friction.
b. Turbine
A turbine is a device, which utilizes the energy of a current of fluid, acting on a series of
curved vanes, to rotate a central shaft or spindle. This mechanical energy is then
utilized to drive pumps, compressors and generators.
3.18.2 Types
The three major types of pumps are:
a. Centrifugal
These are the most common in our industry and comprise the majority of pumping
applications. The "radial flow" centrifugal is the most common type of centrifugal; one in
which the pressure is developed principally by the action of centrifugal force. The liquid
enters the pump impeller at the hub and flows radially to the periphery.
b. Reciprocating
These pumps consist of a piston or plunger and displace the liquid and force it out the
discharge nozzle. Both suction and discharge piping are subject to pulsation in this type
of pump.
c. Rotary
A positive displacement pump consisting of a chamber containing cams which rotate

relative to the drive shaft and displace liquid strictly by mechanical means.
Pumps, regardless of type, should in general, be located and arranged with consideration for
the following:
a. Locate as close as possible to the suction source, keeping the suction piping as short as
possible, and minimizing fittings insofar as practical from a flexibility standpoint.
b. Arrange multiple pump units to provide ample access space for in-place maintenance
and service.

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c. Arrange pumps so that suction piping can be routed without pockets.
d. Pumps at storage tanks should be located outside of dikes.
e. To avoid potential fire hazards pumps operating at or above their auto-ignition

temperature should not be located below pipe racks.
f. Provide sufficient supports at suction and discharge piping to prevent excessive load
and forces on pump casings.
g. Location and arrangement of sump pumps, and design criteria for sizing sumps, is
covered in detail in the "Hydraulic Institute Standards" current edition under "centrifugal
pump applications".
h. Locate pumps to satisfy the NPSH requirements of the pumps:
The height of the supply vessel above the pump suction and the friction losses of suction
piping are the primary concern of the layout designer with regard to NPSH. Where
arrangements of pumps and vessels to satisfy NPSH requirements appear impractical or
unsatisfactory, consult with the process or mechanical engineer to see if a different type
of pump or other solutions may be found.
3.18.4 Pump Piping
Piping routing is critical to efficient pump operation. Piping to pumps and their turbine drivers
should be carefully designed to ensure trouble-free operation. Refer to Figure 3.18.7 for typical
Pump piping arrangements.
Piping guides are listed as follows:
a. Route suction lines without pockets. Some piping arrangements appear to be

trouble-free but can cause problems when in operation.
b. Any reduction in line sizing must occur as close as possible to the pump nozzle- see
Figure 3.18.6.
c. Temporary suction strainers must be used at all pump suctions. These may be flat plate
or conical type. Provision must be made for removal of strainers.
d. Suction headers with "dead-legs" should be avoided.
e. Suction piping must be routed to allow for thermal expansion. Pumps with spares,
cause problems in high temperature applications because the one running pump is hot
where the spare is cold. Sufficient supports should be provided to prevent excessive
loads from being transmitted to pump casings.

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f. Valve stems on both suction and discharge lines should be carefully oriented to prevent
becoming a hazard to operating personnel. (Locate away from head or eye level).
Piping shall be designed to permit the removal of the pump without removing the block
valves. Where necessary, spool pieces shall be provided.
g. Overhead horizontal lines to and from pumps should be kept out of the area directly over
the pump, if at an elevation where they could obstruct pump removal.
h. Discharge piping should always be provided with a check valve preceding the block
valve. Check the type of check valve for position requirements. Some types of check
valves must be installed in a specific position to operate correctly and may require a
pressure tap between block and check valve. (Refer to P & ID).
i. Ample flexibility in discharge piping is a must. Provide sufficient supports, etc.
j. Double Suction Pump suction piping shall be per vendor requirements i.e. a) minimum 2
diameters between suction flange and elbow. b) suction piping to be perpendicular to
pump shaft, where possible.
Insufficient space around pumps for access and maintenance is a common problem in process
plants. This is caused by the fact that many times the equipment is located using preliminary
information regarding pump sizes, and by the designers not realizing the relative size of piping
and equipment. 900 mm clear space between adjacent piping is an absolute minimum. When
locating pumps using preliminary pump sizes the designer must allow ample space between
pumps. It is better to have too much space than not enough.
Pumps inherently require frequent attention and service. Maintenance aisles should be
carefully planned and piping sufficiently supported to enable dismantling of portions of piping for
removal of unit without the need for extensive shoring or temporary supports.
3.18.6 Turbine Piping
Refer to Figure 3.18.8 for typical Turbine piping schematics.
(To Section 3.19)

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3.19 Storage Vessels Date: 2015-10-20
3.19 STORAGE VESSELS
3.19.1 Description
All hydrocarbons from crude oil to light volatile fractions, must be stored during the intervals
between production, transportation, refining, blending and marketing. Storage for water and
other utilities is also required at many plants. Both atmospheric and pressure type storage
vessels are employed for these purposes. The type of vessel selected will depend upon a
number of factors; material to be stored, and weather factors such as heat, rain or snow.
Evaporation losses due to filling or breathing must be considered.
3.19.2 Types
The major categories of storage vessel that are most common in our industry are:
a. Cone or Fixed Roof Tanks
These tanks are used to store utilities, crude oil and its products that do not boil at
ambient temperature. The cone roof is the most common and is normally supported by
a series of rafters, girders, and columns.
Self-supporting cone, dome, or umbrella roofs are also available for smaller tanks.
"Pancake" tanks are fixed roof tanks of large diameter up to 60 m. with low shell heights
3 m to 5 m. and are designed to store large quantities of product in "marshy" soil areas
without elaborate pile foundations.
b. Floating Roof Tanks
These are tanks that are constructed for storing volatile liquids where evaporation from
breathing or filling must be kept to a minimum. The roof or cover rides up and down on
the stored liquid. They offer the advantages of reduced evaporation and greatly
increased safety from fire. There are two basic types of floating roof tanks; pontoon type
and double deck type.
Pontoon type tanks are constructed with an annular pontoon around the edge and a
deck of single thickness in the center. In addition to buoyancy, the pontoons provide air
space insulation from the sun's heat, and thus inhibit boiling of the stored product in the
annular area. The deck of single thickness is free to balloon upward as needed to
provide space for such vapors as may form. Vapors trapped beneath the center deck
further provide an insulating blanket and are retained until atmospheric temperature
decreases enough to permit the vapors to condense back into the liquid phase. This
enables the pontoon roof tank to store liquids of high volatility.

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3.19 Storage Vessels Date: 2015-10-20
c. Spheres and Spheroids
The sphere is used for storage of volatile liquids and gases under pressure. Either
refrigerated or non-refrigerated products are stored. Spheroids, plain and noded are
well adapted to storage of motor gasolines and natural gasolines.
d. Storage Bullets
Storage bullets are simply horizontal cylindrical vessels, generally used to store liquid
petroleum gases, liquid nitrogen, or liquid oxygen.
The location of storage tanks will generally follow the flow sequence with consideration to
terrain, access roads, traffic flow, railroads, prevailing winds, soil conditions, etc.
The first consideration is to locate tanks adjacent to the unit they serve. Tanks with steam
traced lines or large diameter lines should be the closest; with final product tanks around the
outside perimeter.
LPG bullets must be aimed away from process units and buildings.
Dike requirements and sizing is shown in Figure 3.19.6. Coordinate with the Civil department.
3.19.4 Piping
Refer to Figure 3.19.7 for recommended piping practices.
Access to storage tanks for fire fighting is imperative. No storage tank should be farther than
100 m from a road. Provide access and maintenance space for pumps outside dikes and for
draw-off boxes and valves.
(To Section 3.20)

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3.20 Process Filters & Separators Date: 2015-10-20
3.20 PROCESS FILTERS & SEPARATORS
3.20.1 General
There are many types of Filters and Separators whose shape and size are dependent upon the
volume and media being filtered. This Section however will cover the ones more commonly
used in the Oil and Gas Industry.
3.20.2 Types
- a. Liquid Phase Separators.

- b. Full Flow Filters.
- c. Vane Mist Eliminators.
- d. Carbon Filters.
- e. Filter Separators.
- f. Intake Air Filters.
a. Single Phase Separators
A single-stage separator is an economical workhorse for removing water and coarse

solids from process streams and product pipelines. The horizontal design provides
gravity separation after coalescing. A two-stage vertical separator is designed to
remove water and solids entrained in streams at high flow rates. It is particularly
effective for separating two immiscible liquids with different specific gravities and is
especially suited for process systems where high solid concentrations are not
encountered.
b. Full Flow Filters
Full Flow Filters are designed for the full flow filtration of engine lube oil or liquid process
streams such as amines, glycol, sulfinol, absorption oil, water, etc., and are available in
various sizes to meet virtually any flow rate. These type of filters contain internal
elements and should be installed with bypass and block valves to permit bypassing the
filter during element changes if the system cannot be shut down. Vertical clearance
above the filter is required for element removal.
c. Vane Mist Eliminators
Vane Mist Eliminators were developed to remove free liquid mist from any steam or gas
streams and are available in a wide assortment of inlets, outlets, flow directions and
mountings to meet any piping configuration. Liquid droplets are centrifugal separated
from the vapor stream and are deposited on the walls of the vane element. The
entrapped liquid is then drained down and deposited in the liquid reservoir area located
in the base of the unit for removal from the vessel.

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3.20 Process Filters & Separators Date: 2015-10-20
d. Carbon Filters
Carbon Filters are used primarily for purification of glycol and amine process streams.
They contain a filter media of granular activated carbon designed for adsorption of high
and low molecular weight liquid contaminants. Media elements are available in canned
disposable units which can be easily changed by one man. Filters should be installed
with bypass block valves to permit by-passing filter during element changes without
shutting down the system.
Carbon Filters are very similar in shape to Full Flow Filters and also require vertical
clearance above the filter for element withdrawal.
e. Filter Separators
The Filter Separator is a pressure vessel separated into two stages. The first stage
contains replaceable filter elements mounted on support carriers welded in a tube sheet
separating the inlet compartment from the second stage compartment. A quick opening
closure is provided for removing or installing the elements. The second stage
compartment is a wire mesh or vane type liquid separator.
The liquid sump, mounted below the separator, is divided into two separate
compartments to prevent gas flow between the two stages.
The gas to be filtered enters the vessel in the first stage compartment. Solids and large
free liquid droplets cannot penetrate the element because of their size and remain on the
outside of the elements. These liquid droplets collect, drain to the bottom of the vessel,
and into the liquid sump through the downcomers. The liquid will wash down some solid
particles; others remain on the outside of the element forming a cake. During operation,
this cake will normally build up and break off falling to the bottom of the vessel. The
remaining solids may build up, raising the pressure drop and necessitating the first stage
to be blown down to effect on stream cleaning.
Any liquid that is carried over to the second stage, is stripped out by the wire mesh or
vane and drains into the second compartment of the sump: Filter separators can be
either horizontal or vertical.
3.20.3 Multiple Filters
If multiple filters are installed the piping should be installed symmetrically to ensure an even flow
to each filter. Block and bypass valves should be installed to permit changing of filter elements
without shutting down the system. Accessibility to each filter is essential both around and in the
case of vertical filters above for maintenance and withdrawing the elements.
(To Section 3.21)

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3.21 Fire Protection Equipment Date: 2015-10-20
3.21 FIRE PROTECTION EQUIPMENT
3.21.1 Description
All Gas and Oil Plants have mandatory requirements to provide fire protection to all areas of the
plant for containment of fires. The type of system selected is dependent on areas to be covered
and client preferences and directives.
3.21.2 Types
a. Firewater System
The Firewater System consists of a water supply that is either limited or unlimited. An
unlimited supply would be from a lake, river or well which would have a suitable
capacity. A limited supply of water requires a storage tank that is independent of other
plant process water usage.
Firewater pumps are used to pressurize a piping system which can be above or below
ground supplying hydrants and monitors positioned around the piping system to give
total coverage of plant.
Hydrants in process areas, pump pads and loading areas are generally equipped with
fixed monitors See B-SD-35916M. Other areas shall be supplied with hose reels that
are either portable or fixed- see Figure 3.21.5.
b. Spray Systems
Spray Systems are used for high risk fire areas, such as buildings used for storage of
low flash or volatile products, or congested area with restricted access. The system
consists of a water main with upright open deluge type spray heads. The system is
connected to the firewater system and is actuated by a manually operated valve.
Automated systems using heat actuated devices, ultra violet detector or other systems
can be supplied at client's request.
c. Deluge System
Deluge Systems are specifically used in tank storage areas. The system consists of a
deluge head at the top of tank or vessel, connected to the firewater system and actuated
by a manually operated valve.
d. Air-Foam System
Air-Foam Systems are used for fixed cone roof tanks operating at approximately
atmospheric pressure. The system utilizes high backpressure foam maker at a fire truck
and foam chambers installed at top of tanks. Operation is from outside the diked area of
the storage tanks.

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3.21.3 Location & Arrangement
Hydrant locations are determined by project requirement, General rules are as follows:
a. A minimum of one standard hydrant should be provided within 60 m of any building, and
fixed monitor hydrants provided for all process areas of buildings located so that
complete coverage is obtained using and effective range of 30 m from the monitor
hydrant. No monitor hydrant should be located closer than 8 m from buildings or
equipment. All monitors should be equipped with a continuously variable tip in order to
obtain a wide range of water spray patterns. Each monitor should be capable of
handling 250 US gpm. Hydrants should be installed to reach vessels from both sides.
Hydrants should be located on the roadside of all pipelines or drainage ditches.
b. The building housing the fire pump or pumps shall be of non-combustible construction
and at least 30 m from any fired process heater, hydrocarbon processing building or
area, compressor house or loading area and 60 m from all hydrocarbon storage tanks.
c. Air foam laterals should terminate at the roadside so that the distance from a fire truck to
the terminals and fire hydrant does not exceed 7.5 m. Terminals shall be 0.6 m to 1.2 m
above grade and no more than 5 m from roadway. If more than one lateral is required at
a tank the terminals shall be brought to a single point 1.2 m apart.
3.21.4 Piping
a. The Firewater System shall be looped and shall be provided with isolation valves so that
no more than half the plant hydrants (maximum of three) will be out of service due to
impairment or breakage.
b. Firewater mains shall be installed a minimum of 300 mm below frost line: check project
specifications for plant location frost penetration information.
c. Firewater piping within Process Unit feeding any combination of three or more monitors,
hose reels, hydrants, or sprays shall be connected to two separate sections of fire main
separated with a valve in the main. Branches less than 15 m long to single monitors do
not need isolation valves.
d. Block valves in underground firewater piping shall be operable from grade with the valve
stem and packing permanently protected from contact with earth, rocks, etc.
e. Block valves to be supplied with a position indicator at grade to indicate full open and
closed positions.
f. Valve guards are required to protect valves located within 1m of roads and access-ways
in areas of high vehicular traffic to avoid mechanical damage to valves.
g. The location of the main actuating valves for spray systems, shall be 15 m from the area
under protection.

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21.doc
h. Spray heads shall have a minimum orifice opening of 1/2" diameter or as recommended
by the process engineer or applicable fire protection vendor.
i. Flush out connections shall be installed, to permit flushing of all sections of the system
with fresh water. They shall be capped or flanged.
j. Underground carbon steel piping and above ground portions of carbon steel pipe
passing through dikes shall be protected against external corrosion by wrapping.
k. Each air foam chamber shall be equipped with its own riser and lateral, the pipe rise to
be installed directly below the foam chamber.
l. All laterals shall slope to terminal point on sleeper supports and shall not pass through
the diked area of any other tank, group of tanks, or paired tanks.
m. Laterals shall extend outside the dike to points at least one tank diameter, or 15 m from
tanks, whichever is greater.
(To Section 3.22)

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21.doc
3.22 Dehydration Equipment Date: 2015-10-20
3.22 DEHYDRATION EQUIPMENT
3.22.1 General
Dehydration of the gas follows the sweetening process to reduce the water content to the level
permitted by the transmission line contract. Most of the water vapours absorbed into the gas
during its direct contact with the sweetening agents must be removed here to eliminate a
potential source of trouble in high pressure pipelines.
3.22.2 Types
The two main processes used to dehydrate natural gas are:
i. Adsorption of water by a liquid desiccant.

Ii. Adsorption of water by solid desiccants.
The first two methods are considered as regenerative processes where the drying mediums are
continuously recovered for reuse in the other succeeding cycles.
3.22.3 Liquid Desiccant Dehydrators
Absorption by a liquid desiccant is one of the most prominent physical dehydrating methods. It
may be accomplished with many types of desiccants, e.g. Sulphuric Acid, Calcium and Lithium
Chlorides, Glycerines and others. Another acceptable drying agent commonly used in gas
plants is a glycol/water solution.
The wet gas is passed through an inlet scrubber to knock out the liquid hydrocarbons. The gas
then bubbles up through the contactor where it comes into contact with the glycol, which
absorbs any water in the gas and leaves the top of the contactor as dry gas.
The glycol, which has absorbed the water after leaving the contactor, is then passed through a
3-phase separator where any hydrocarbons and gas picked up in the tower are separated out
and the glycol is then fed into the reboiler where the water is "boiled-off". The 'dry' glycol then
returns to the contactor and the process is repeated.
3.22.4 Solid Desiccant Dehydrators
There are several types of solid desiccants available in the market but the most common ones
belong either in the "activated alumina" or in the activated bauxite group.
The wet inlet gas stream first passes through an efficient inlet separator where free liquids,
entrained mist and solid particles are removed. The filtered gas then passes into the top of one
of the desiccant towers, and flows downward through the tower on the adsorption cycle. All the
absorbable gas components and water vapours are adsorbed and the gas leaves as "Dry Gas".
After being on the adsorption cycle for a period of time, usually eight hours, the tower is
automatically switched to the regeneration cycle and the other tower previously on the
regeneration cycle is now switched to the adsorption cycle.

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3.22 Dehydration Equipment Date: 2015-10-20
For practical purposes dehydration towers are regenerated by passing a stream of very hot gas
through the bed. The hot natural gas not only supplies heat but also acts as a carrier to remove
the water vapour from the bed. After the bed is heated to a predetermined temperature, it is
cooled by the flow of unheated gas and thus made ready for another adsorption cycle.
(To Section 3.23)

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3.23 Loading Stations Date: 2015-10-20
3.23 LOADING STATIONS
3.23.1 Description
Loading station facilities are provided for the transportation of bulk product from the storage
areas within a plant, to either road or rail transport.
3.23.2 Types
a. Flexible hoses from a valved transfer pump discharge connection to a truck are the most
common method utilized for loading liquids. The hoses are fitted with quick-acting
locking type connections for ease of use.
b. Loading arms are generally utilized on loading racks for railcars. The loading arms are
constructed with spring loaded swivel joints, which give the arm great versatility for
various loading positions. The arms can be used for top or bottom loading of vehicles.
A loading valve, which is manually operated, is often an integral part of the construction
but can also be remotely positioned on a loading gantry. Loading arms can be mounted
at grade or at high level racks, and must be securely anchored at these points.
Alternate methods are used to counter-balance the arms. The standard method is to
use balance weights. The second method utilizes an adjustable spring at the base of
the arm.
3.23.3 Location
Location of loading facilities is usually in close proximity to the storage area, unless a rail head
is used, then the loading rack can be positioned to one side of the rail spur.
3.23.4 Piping
The only specific requirement for piping is at the loading terminal where all connection points for
hoses or loading arms are securely anchored.
3.23.5 Access
The area around loading racks or bays is to be such as to provide adequate space for
manoeuvring lengths of flexible hose for tank trucks.
(To Section 3.24)

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3.24 Water Supply and Treating Equipment Date: 2015-10-20
3.24 WATER SUPPLY AND TREATING EQUIPMENT
NOT ISSUED
(To Section 3.25)

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pma003-24.doc
3.25 Incinerators and Flare Stacks Date: 2015-10-20
3.25 INCINERATORS AND FLARE STACKS
3.25.1 Description
Flare Systems are designed to collect emergency relief and waste gases to a point where they
can be ignited and burned cleanly and efficiently.
Incinerators are used for effective burning, through controlled combustion of liquid or gaseous
wastes and to dispose of potentially dangerous pollutants and odors.
3.25.2 Types
Flare stacks are custom engineered for the application and job site. They can be guyed or
self-supporting. The flare stack consists of igniters and pilot gas systems, a flare "TIP" and
vertical steel stack. When smoke control or emergency extinguishing of the flame is required, a
snuffing steam manifold can be installed at the tip. Ladders are usually provided on the stack
for access to the tip.
Incinerators can be either vertical or horizontal and consist of a refractory lined combustion
chamber fitted with a burner and air supply from a blower.
Horizontal incinerators are the most common type used in gas and oil processing plants to burn
tail gases from the process. Combustion air can be mixed with gases prior to processing as in
Sulphur Recovery Plants. The tail gas mixture is fed to the burner where combustion takes
place. Natural gas is used for igniters and pilot systems at the burner. Combustion products
are passed up a stack to the atmosphere.
Vertical incinerators are specifically designed for liquids and utilize air from a separate blower or
fan and a natural gas supply for the burner. The air is blown into the incinerator tangentially
creating a vortex of high combustion with temperatures up to 1,700°C and combustion efficiency
of 99+%.
3.25.3 Location
Flare stacks and incinerators should be located downwind or at right angles to the prevailing
wind. Spacing should be in accordance with client or insurance guidelines. The igniter location
should be a minimum of 15 m horizontally from flare stack.
3.25.4 Piping
All flare header piping to the flare will be sloped from the flare to the Flare Knock Out Drum.
Flare Header and Sub Header sizing should be confirmed by the process engineer.
(To Section 3.26)

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3.26 Heating Ventilation and Air Conditioning Date: 2015-10-20
3.26 HEATING VENTILATION & AIR CONDITIONING
The design of Heating Ventilation and Air Conditioning is the responsibility of the Mechanical
Department. Piping design will need to closely liaise with this group during the design phases.
(To Section 3.27)

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3.27 Process Treaters Date: 2015-10-20
3.27 PROCESS TREATERS
3.27.1 Description
A treater is designed to provide efficient final separation of oil, gas and water.
The two basic types of treaters are:
1. Vertical downflow treaters.

2. Horizontal electrostatic treaters.
3.27.2 Vertical Downflow Treater
The incoming oil, water, emulsion and gas enter the treater through an inlet near the top of the
treater. Gas is drawn off through an outlet at the top of the treater, while liquids flow through a
downcomer to the bottom of the vessel below the firetubes. Free water separates below the
firetubes and the lighter oil/water emulsion flows upward. The emulsion rises past the firetubes,
absorbing heat. Heat and the scrubbing action of the baffle trays break the emulsion as it
passes through the vessel.
Separated water drops collect and coalesce on a fibrous medium, then settle to the bottom
while oil continues rising.
Water is removed from the bottom of the treater and oil is removed at the top through an outlet
connection and control valve. An adjustable water siphon, located on the outside of the treater,
can maintain the desired oil/water level.
3.27.3 Horizontal Electrostatic Treaters
Initial gas removal occurs as the fluid enters at the top of the vessel. Free water is bypassed
around the heating section and is not heated; it is removed from the vessel separately from the
coalesced water.
Efficient, uniform heating is assured by hydraulic distribution of the fluid stream through meter
holes in spreaders under the firetubes. The uniform up-flow heating pattern developed assures
maximum heating efficiency and equilibrium at the fluid-gas interface. Gas evolved during the
heating is then removed from the process at the warmest part of the flow pattern assuring no
gas break-out later in the process.
The gas-free oil then flows through a surge section and into the electrical coalescing section.
Here another system of distribution headers give uniform flow through both the length and width
of the vessel. This uniform flow distribution assures minimum vertical velocity throughout the
coalescing section.

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An overhead, clean-oil, header-collection system provides uniform out-flow of clean oil. This
further complements the distributor system to assure minimum velocities and even flow
distribution throughout the coalescing section. Any tendency for fluids to channel is reduced to
a minimum. Good distribution assures effective coalescing and maximizes vessel capacity.
Coalescing of the small water drops dispersed in the oil is accomplished by the high-voltage
alternating electrical field. As the emulsion rises through the field, the water droplets are given
an electrical charge. When charged, they rapidly move about - repelling, attracting and colliding
with one another. The action is fast and effective since all the water droplets receive a charge,
regardless of size. The droplets collide with sufficient energy to overcome the emulsifying
forces, and combine into larger and larger drops. This growth in mass allows gravity settling of
the larger drops into the vessel's water phase.
The lighter, clean oil continues to rise to the top of the vessel where it is collected and removed.
3.27.4 Alternate Heating Methods
Heating methods other than conventional firetubes are often practical in Electrostatic treaters
because of the lower temperatures required. They are especially useful in helping to satisfy
safety requirements. These methods include:
a. Electrical resistance.
b. Hot exhaust-gases from internal combustion engines.
c. Hot jacket-water from internal combustion engines.
d. Combinations of the above three sources using an electric generator driven by an

internal combustion engine. The generator also furnishes electricity for the coalescing
section.
e. A heat pump. The refrigeration end is used to cool the treated crude for additional
gravity conservation.
f. Regenerated glycol in a heat exchanger - using the heat from the reconcentrated glycol
that is otherwise wasted.
3.27.5 The Electrical System
The electrical system consists of a step-up transformer and two electrodes (dipoles). The two
electrodes are suspended one above the other in the oil phase of the coalescing section. Their
cross-sectional area is perpendicular to the fluid flow.
The upper electrode is adjustable so that the voltage gradient can be varied to meet the
coalescing requirement. As an optional feature, this electrode can be raised or lowered while
the vessel is pressured.

2015-10-20
The lower electrode is not grounded. The secondary output from the transformer is connected
to this electrode.
3.27.6 Optional Features
a. Gas Domes - to scrub large volumes of gas adequately or to minimize evolved-gas liquid
content, economics may justify installing either a gas-scrubber dome or a combination
condenser-scrubber - utilizing the relatively cool well-stream for condensation.
b. Sand Jets - where sand accumulations are an operating problem, various systems of
sand jets and draw-offs can be furnished. The type used will depend on the severity of
the problem. Operation of the jet system can be manual; or an automatic, programmed
jetting cycle will periodically flush the sand from the vessel.
c. Interface Sludge Drains - when some crudes are treated, unresolved emulsions can
accumulate at the oil-water interface. These sludges may disrupt interface controls and
cause electrical system problems. Interfacial drains, installed in both the heating and
coalescing sections, allow these accumulations to be drained periodically.
(To Section 4.0)

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END OF
SECTION
THREE
Section: Page:
PIPING DESIGN GUIDE 4.0 1 of 1
Rev:
Useful Tables and Charts 2
4.0 USEFUL TABLES AND CHARTS
The following charts and tables are available from the Jacobs Metric Piping Standards in
Toolbox (Piping References and Procedures\Pipe Support Standards) for handy reference
purposes:
A-SD-35960M Line Spacing Chart

A-SD-35961M Allowable Pipe Spans
A-SD-35969M Typical Valve Stem Locations (Horizontal Stem)
A-SD-35970M Typical Valve Stem Locations (Vertical Stem)
Also refer to Jacobs Metric Vessel, Piping and Reference Guidelines in Toolbox (Piping
References and Procedures\Pipe Design Guidelines)

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G:\Piping Design Manual\Useful tables and Charts pma004.doc Rev. 2

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These guidelines are provided for the following purposes:

1. To clarify design, layout and equipment arrangements.

2. To assist new staff in becoming familiar with Jacobs’ design base.

3. To provide quality assurance by qualifying Jacobs’ preferred design practices.

Canadian Work Instructions- CWI-230

This information is proprietary to Jacobs Canada Inc.

1.0 Process Plant Plot Layout

2.0 Design/Layout Guidelines

3.0 Equipment Design Considerations

4.0 Useful Charts & Tables

This information is proprietary to Jacobs Canada Inc.

1.0 PROCESS PLANT PLOT LAYOUT

1.2 UNIT SPACING

1.3 PLANT ROADS

1.4 EQUIPMENT WITHIN PROCESS UNITS

1.4.1 Fired Process Heaters

1.6 COOLING TOWERS

1.7 EVAPORATION PONDS, SULPHUR STORAGE BLOCKS

1.8 FLARES, INCINERATOR STACKS

1.9 TANK FARMS

1.9.1 Atmospheric Storage Tanks

1.10 FIRE PROTECTION

1.10.1 Fire Pumps

1.11 CONTROL BUILDINGS

1.12 NON PROCESS BUILDINGS

1.13 INDUSTRIAL RISK INSURER'S SPACING GUIDELINES

This information is proprietary to Jacobs Canada Inc.

1.14 UNDERGROUND PIPING

1.15 ACCESS FOR CONSTRUCTION & MAINTENANCE

1.16 HOUSED EQUIPMENT

1.17 PIPERACK LAYOUTS

(To Section 2.0)

This information is proprietary to Jacobs Canada Inc.

1.0 PROCESS PLANT PLOT LAYOUT

The information presented here outlines recommended practices.

1.2 UNIT SPACING

1.3 PLANT ROADS

1.4 EQUIPMENT WITHIN PROCESS UNITS

1.4.1 Fired Process Heaters

This information is proprietary to Jacobs Canada Inc.

1.4.2 Gas Compressors

1.4.6 Process Vessels

1.4.7 Air Coolers

This information is proprietary to Jacobs Canada Inc.

1.6 COOLING TOWERS

1.7 EVAPORATION PONDS, SULPHUR STORAGE BLOCKS

1.8 FLARES, INCINERATOR STACKS

1.9 TANK FARMS

There should be no intermingling of classes of hydrocarbons, i.e. pressure tank storage,

No tank should be more than 91.5 m from an access roadway.

1.9.1 Atmospheric Storage Tanks

This information is proprietary to Jacobs Canada Inc.

1.9.2 Pressure Tank Storage

If more than one group is required, each group should be separated.

1.9.3 Refrigerated Storage

Each refrigerated storage tank should be installed in a separate dike.

1.10 FIRE PROTECTION

1.10.1 Fire Pumps

1.10.2 Water spray Deluge Valves

They should be operable from grade and be readily accessible.

1.10.3 Hose Stations/Hydrants