training manual- piping doc no. : 29040-pi-ups-1007 · training manual- piping piping study...

TRAINING MANUAL- PIPING

PIPING STUDYTANKFARM PIPING

Uhde India Limited

DOC No. : 29040-PI-UPS-1007

Rev. : R0

Page : 1

CONTENTS

Page

0.0 Cover Sheet 1

List of illustrations 2

1.0 General 3 - 4

2.0 Key Words 4

3.0 Bund Area to Contain Spillage 4 - 5

4.0 Tank Details 5

5.0 Pump Location in Tankfarm 5

6.0 Piping Arrangement 6

Applicable Revision:Prepared:

Date:

Checked:

Date:

Approved:

Date:First Edition: R0Prepared: AKB

Date:

Checked: TNG

Date:

Approved: RUD

Date:File Name: Server: PUNE: KUMUS 207 VKO: KUMUS 209



Uhde India Limited

DOC No. : 29040-PI-UPS-1007

Rev. : R0

Page : 2

LIST OF ILLUSTRATIONS

SR.NO. DWG.NO. DESCRIPTION

1 TFP1 TYPICAL TYPE OF DYKES

2 TFP2 DRAINAGE FROM DYKE

3 TFP3 TYPICAL HORIZONTAL PRESSURE TANK (BULLET)

4 TFP4 TYPICAL VERTICAL TANK DETAILS

5 TFP5 VALVE ACCESS CATWALKS

6 TFP6 TYPICAL TANK HEATERS

7 TFP7 TYPICAL FLOATING ROOF TANK ACCESS

8 TFP8 LOW TEMPERATURE TANK FOUNDATION WITH ELEVATEDCONCRETE BASE

9 TFP9 COMPACTED FILL TANK PAD

10 TFP10 TYPICAL RING WALL FOUNDATION

11 TFP11 PUMPS INSIDE DYKED AREA

12 TFP12 PUMPS OUTSIDE DYKED AREA

13 TFP13 PUMPS INSIDE CONCRETE DYKED AREA

14 TFP14 DYKE-PENETRATION SEAL

15 TFP15 FLEXIBLE DYKE SEAL

16 TFP16 ALTERNATE PIPING LAYOUTS

17 TFP17 TANK PIPING LAYOUT

18 TFP18 CROSS SECTION OF PIPE WAY AND PUMPING

19 TFP19 BULLET-TANK PIPING LAYOUT

20 TFP20 LIQUEFIED NATURAL GAS TANK LAYOUT

21 TFP21 LIQUEFIED NATURAL GAS TANK LAYOUT

22 TFP22 TYPICAL FIRE WATER SYSTEM IN TANKAGE AREA

23 TFP23 PROTECTION BERM



Uhde India Limited

DOC No. : 29040-PI-UPS-1007

Rev. : R0

Page : 3

1.0 GENERAL1.1 The study of the tankfarm consisting of a group of tanks shall be carried out keeping the following

basic points in consideration.

1.2 Grouping of tanks,

Specification of the content.

Capacity of tanks

Nature of hazard - fire

- toxic- explosive- corrosive- bulk handling loading

unloadingStatutory distance

Requirement of Dykewall or curbing

Dykewall height or curb height calculation

Location of Pumps - inside dyke area

- outside dyke area

Approach to tank nozzles with valve

Approach to tank roof

Drainage of dyke area - Sump and pump

Road around tankfarm

Fire hydrant / monitor requirement

Underground system connected to specific system of treatment / disposal

1.3 Storage tanks located in a safe area and grouped according to the contents are called tankfarm.Normally, in chemical plants, the storage shall be either input raw material or output products orintermediate chemicals storage.

Storage tanks may contain acids, alkalis, oil viz. petrol, diesel, naptha, fuel oil or benzene etc. Oil,acid, alkali are usually stored in vertical storage tanks designed as per API 650.

1.4 Tanks should be grouped or segregated according to the contents. Tanks containinghydrocarbons should be separated according to the flash point, CCE classification for spaceplanning, dykewall and its height requirement.

Layout of the storage facility shall be based on the following considerations and systematicapproach.

- Statutory Regulations viz. CCE

- TAC/NFPA recommendations

- Safety requirements as per OISD, OSHA, HAZOP study

- Valve access platform / ladders at the piping outlet nozzles of tank.

- Access to top of tanks and interconnecting walkway

- Piping on sleepers or piperack inside dyke area.

- Pumps location outside dyke area



Uhde India Limited

DOC No. : 29040-PI-UPS-1007

Rev. : R0

Page : 4

1.5 The practical objective to prepare a most economical plot plan and piping arrangement for atankfarm should be to keep provisions of operational ease, maintenance facility, safetyarrangements and overall aesthetics.

The tankfarm shall also have provisions for efficient drainage and disposal facility as required forvarious kinds of fluid storage.

The tankfarm should be secured against unauthorised entry by fencing, security gates dependingon the tank storage capacity or the type of hazards posed by the nature of contents.

2.0 Key WordsAtmospheric tank - The tank that operates at pressure levels ranging from atmospheric pressure to0.5 psig.

Bullet - This is a high pressure horizontal storage vessel shaped like a bullet (Refer Fig.TFP3)

Cone-roof tank - This is a low-pressure vertical storage tank with a cone-shaped fixed roof.

Fixed roof tank - This is a low pressure vertical storage tank with a roof welded to the shellirrespective of roof design or method of support.

Floating roof tank - A floating roof tank design is adopted to conserve vapour loss and minimisefire hazard. (Refer Fig.TFP7)

Double-wall storage tank - A double wall storage tank has an inner wall to contain a liquid, anannulus space usually filled with insulation and outerwall for containment of spillage.

Horton sphere - It is a spherical vessel used for storage of high pressure liquid and gases.

Dyke - A dyke is a barrier designed to contain liquid in the tank in case of emergency within thearea for safety reasons. (Refer Fig.TFP1)

Diversion dyke - This is a barrier designed to divert spillage from other storage tanks. It usesnatural terrain to direct liquids to the sump area.

Flame arrester - In the event of lightning or another source of vapour ignition, a flame arrester inthe vent line of a storage tank prevents flames from flashing to the vapour inside the tank.

Breather valve - This is provided as a measure to protect the tank against collapse due to suddencreation of vacuum inside the tank during suction by pumps.

Foot valve - This valve is provided at the bottom of a riser in a tank where a submersible pump canbe installed. During regular operation, foot valve remains open.

Sleeper - Sleepers are steel or concrete supports usually located within 450mm of grade of pipingsystems commonly found in offsites.

Sump - This is the low point basin within an area used for collection of liquid waste for disposal.

Foam - This is a solution with a density lower than that of oil and water. It is used to form a blanketover dangerous vapours and reduce the risk of explosion.

3.0 BUND AREA TO CONTAIN SPILLAGE3.1 The risk of failure of storage tanks and the primary piping systems is reduced to certain extent, if

the fluid is contained within the bund wall and is not allowed to spread throughout the arearesulting in various hazards like fire, toxic spread, pollution problem etc.

3.2 The dyke may be constructed of earth, concrete, solid masonary or steel. It may be square,rectangular, circular or irregular in shape, conforming to the natural terrain around the tank.



Uhde India Limited

DOC No. : 29040-PI-UPS-1007

Rev. : R0

Page : 5

3.3 The containment dyke for tankfarm under the purview of chief controller of explosives (CCE) shallbe planned according to the CCE rules and regulations. CCE rules are applicable to the fluids ofpetroleum and petroleum products classified as class A, B or C according to its flash pointcharacteristics.

The rules of CCE can be followed for other hazardous / inflammable products as good guidelinesof safety, even though the product is not classified as petroleum product.

3.4 One common method of dyke construction is by earth upto a height of 1.8m and with width of dykeon top to be about 600mm. The slope on the surface of dyke is usually 1:1.5 consistent with theangle of repose of earth.

In congested area or where space is limited, usually concrete dyke is made with varying height fordifferent containment capacity.

3.5 The free volume of the bund area is sized to contain the contents of one largest tank plus a marginof 10 percent.

3.6 All drains from the dyke area should be equipped with a valve outside the dyke regardless ofwhether the drainage goes to disposal pit or sewer system. This prevents liquid spillage fromentering the sewer or released from the dyke area.

These valves should be kept closed and blanked off except when withdrawing water.

The contamination of spillage with the natural rain water or wash water needs this drainage to betreated before disposal. Depending on the contamination, the valve can be used for divertingeither to storm water system or to the Effluent Treatment Plant.

3.7 Access to the dyke area is usually provided by making vehicular ramp at one end and a steppedentry at the other end (Refer Fig. TFP2)

4.0 TANK DETAILS

4.1 A typical illustration on the top of a vertical storage tank is given in Fig.TFP4

4.2 Valve access catwalk (Fig.TFP 5), Tank heater installation (Fig.TFP6), Floating Roof Tank access(Fig.TFP7) are illustrated as typical examples.

4.3 A low temperature tank foundation with elevated concrete base is illustrated in Fig.TFP8

4.4 A tank located on compacted granular fill is illustrated in Fig.TFP9 and a tank on the ring wallfoundation is illustrated in Fig.TFP10.

5.0 PUMP LOCATION IN TANKFARM5.1 To determiine the optimum location of pumps, the potential hazards and client preferrence shall be

considered.

Fig.TFP11 and TFP13 illustrates the location of pump within the dyke area with the curb wall heightof approx. 400-500mm.

This design protects the pump from minor spillage within the dyke and enable the discharge pipingto exit the dyke over the wall and there is no need to have dyke penetration seals.

The piping outside the dyke may run on a piperack or sleepers.

5.2 The pumps located outside the dyke area are illustrated in Fig.TFP12.

Tank outlet piping can either penetrate the dyke or pass over the dyke in case the minimum liquidlevel in the tank do cause cavitation in the pump.

5.3 Adequate maintenance area around the pump shall be the prime consideration for planning thepiping arrangement at suction as well as discharge.



Uhde India Limited

DOC No. : 29040-PI-UPS-1007

Rev. : R0

Page : 6

6.0 PIPING ARRANGEMENT6.1 The Optimum piping arrangement in a tankfarm is the most direct route between two points

allowing for normal line expansion and stresses.

Fig.TFP16 illustrates between tanks and pumps.

Fig.TFP17 shows how to accommodate line expansion between tank nozzles and a manifoldheader. Expansion loops may be added at the sleeper level.

6.2 Fig.TFP18 illustrates a cross-section of piping, pumps, dykes and a primary pipeway in a typicaltankfarm.

6.3 A bullet tank piping arrangement is shown in Fig.TFP19.

Tanks are installed at the lowest possible elevation to satisfy the pump head requirements.

A catwalk is usually located across all the tanks in a row to provide access to the operating valvesand instruments.

Liquid outlet piping to the suction of Pump shall allow for differential settlement and the flexibility ofthe piping.

6.4 A typical layout of liquefied natural gas (LNG) tanks is shown in Fig.TFP20 and TFP21.

The secondary containment is a steel lined concrete structure.

There is heavy cryogenic insulation between primary and secondary containers.

Submersible pumps are located at the bottom of the pump shaft.

The roof is steel and domed.

The operation platform, piping and jib crane structure are supported on the concrete containmentwall.

6.5 In addition to the provisions for mobile fire-fighting equipment, permanent hydrants, monitors areused for protection against fire in the tankfarm areas.

The codes, regulations viz.CCE, TAC, NFPA shall be consulted to finalise the safety requirementof the tankfarm.

Fig.TFP22 shows a typical arrangement of firewater hydrants and monitors in a tankfarm. The firewater piping around the tankfarm area shall be provided with supply from two different sources.This is normally done by installation of an firewater pump with diesel engine drive in addition to theelectric motor driven pumps.

6.6 When high pressure bullet tanks are located close to the process unit, a protection berm (ReferFig.TFP23) is normally used. The berm length shall be slightly longer than the width of the tankarea and the berm height will be equal to the height of tanks. These berms are provisions forprotection against explosion.

6.7 The sump and sump pump shall be provided for disposal of water accumulation due to rain or fire-fighting.

6.8 The foam piping shall be arranged with the quick-coupling to the line supply to the foam chamberat the edge of the roof of the tank. The coupling shall be located outside the dyke wall.

VA

RIE

S

2'/600MIN.

TOE OF DYKEW

H

3'-6'/900-1800ABOVE INTERIOR GRADE

EARTHEN DYKE

W : H = 1 1/2 : 1

AS REQUIRED

CONCRETE DYKE

DOUBLE CONTAINMENT DYKING METHOD

CONCRETE CONTAINMENT

EARTHEN CONTAINMENT

EARTHEN AND CONCRETE COMBINATION DYKE

25'/7

.6

EARTHEN DYKE

CONCRETE DYKE

TYPICAL TYPE OF DYKES

DOC NO.

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PageUhde India Limited

TRAINING MANUAL - PIPING

PIPING STUDY

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TANK FARM PIPING

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: TFP1

DIVERSION CANAL TO REMOTE AREA

SUMP(TYP)

DIVERSION CANAL

VALVES USUALLY CLOSED

CONCRETE DIVERSION CANAL

PUMP AREA

C PLANT ROAD

VEHICULAR RAMP

STAIRWAY

VEHICULAR AND PERSONNEL ACCESS

DRAINAGE FROM DYKE

DOC NO.

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PIPING STUDY

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L

TYPICAL HORIZONTAL PRESSURE TANK (BULLET)

DOC NO.

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PIPING STUDY

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SLOPEOUTLET

PRIMARY TRANSFER PIPING

C LEVEL GAUGEL

C LADDER

L

TANK ROOF MAINTENANCEACCESS

ALTERNATE ACCESS

MAINTENANCE ACCESS FOR CLEAN-OUT DOOR

STAIRWAY ENTRANCE AT GRADE

PROVIDE HANDRAIL ON BOTH SIDE OF ROOF ACCESS AREA

TYPICAL VERTICAL TANK DETAILS

DOC NO.

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ROOF ACCESS AREAPROVIDE HANDRAIL ON BOTH SIDE OF

PLAN

TANK

ELEVATION

VALVE EXTENSION STEM

VALVE ACCESS CATWALKS

DOC NO.

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CATWALK

CATWALK

FINNED TUBES

STEAM IN

CONDENSATEOUT

OUTCONDENSATE

FINNED TUBES

STEAM IN

TYPICAL TANK HEATERS

DOC NO.

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STRAIGHT STAIRWAY

ROOF ACCESS STAIRWAY

CIRCULAR STAIRWAY

15'-6" IN DIAMETERFOR TANKS LESS THAN NOT RECOMMENDED

TYPICAL FLOATING ROOF TANK ACCESS

DOC NO.

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PRIMARY CONTAINER

12"/300MINIMUM

COLUMNS

CONCRETE SLAB

LOW TEMPERATURE TANK FOUNDATION WITH ELEVATED CONCRETE BASE

DOC NO.

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SPREAD FOOTING

SECONDARY CONTAINER

3'-0"900 TANK BOTTOM

HIGH POINT

VARIES12"/300

POINT OF SUPPORT

1"- THICK ASPHALTIC CONCRETE

COMPACTED GRANULAR FILL

TANK FARM PIPING

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COMPACTED FILL TANK PAD

C O

F T

AN

KL

12"/

300

POINT OF SUPPORT

RING WALL

12"/300

TANK BOTTOM

6"/150±

GRANULAR CLASS I COMPACTED STRUCTURAL FILL

TYPICAL RING WALL FOUNDATION

DOC NO.

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15"-18"/380-460 CURB

PUMPS INSIDE DYKED AREA

PIPE RACK OR SLEEPERS

CURBED AREA

DYKE

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ALTERNATE ROUTING

PUMPS OUTSIDE DYKED AREA

PIPE RACK

DYKE

PIPE RACK ALTERNATE LOCATION

SLEEPERS

DOC NO.

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PUMPS INSIDE CONCRETE DYKED AREA

CONCRETE DYKE

DOC NO.

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18"/450 18"/450

DYKE- PENETRATION SEAL

DOC NO.

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PIPE SLEEVE

SEAL

PRODUCT LINE

DYKE WALL

FLEXIBLE DYKE SEAL

DOC NO.

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PIPE SLEEVE

INSULATION

PRODUCT LINE

INSIDE DYKE WALL

STEEL STRAP

FLEXIBLE SEAL

ALTERNATE PIPING LAYOUTS

DOC NO.

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PUMPING

ALTERNATIVELAYOUT FOR FLEXIBILITY (TYPICAL ALTERNATIVES)

TANK NOZZLE(TYPICAL)

LAYOUTPREFERRED

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TANK PIPING LAYOUT

ELEVATION

SLEEPER

PLAN

TANK

OPTIONAL

EXPANSION LOOPS

HEADERS

SLEEPERS(TYP)

BA C

(SEE VALVE ACCESS CATWALKTFP5)

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CROSS SECTION OF PIPE WAY AND PUMPING

TANKS

PUMPING DEPRESSEDSLEEPER

ROADWAY PUMPING

TANKS

DYKEDYKE

PIPE BRIDGEALTERNATIVE

PRIMARY TANK PIPE WAY

BURIED PUMP DISCHARGE

ACCESS

BULLET-TANK PIPING LAYOUT

DOC NO.

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C PUMPSL

PRODUCT OUTLET

CATWALK

RELIFE VALVE

PLAN

ELEVATION

RELIFE VALVETO ATMOSPHERE

CATWALK

LIQUID OUTLET

LIQUEFIED NATURAL GAS TANK LAYOUT

DOC NO.

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VENTMAINTENANCEACCESS CATWALK

RELIEF

VALVE

VACUUM

BREAKERS CATWALK

C PUMPS (4 NOS.)L

TANK ROOF

JIB CRANE

OPERATIONS PLATFORM

PIPE TRESTLE

STAIRWAY

EARTHEN EMBANKMENT

ACCESS ROAD

PRESSURE TEMPERATURE INSTRUMENTS

(TYP)

LIQUEFIED NATURAL GAS TANK

DOC NO.

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JIB CRANE

OPERATIONS PLATFORM

TRESTLE

PROCESS

PIPE BRIDGE SUPPORT

PIPING

UTILITYPIPING

STEEL INNER

TANK

STEEL LINER

PUMP

FOOT VALVE

INSULATION

CONCRETE CONTAINMENT

PUMP SHAFT

STEEL ROOF

EARTHENEMBANKMENT

DOC NO.

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TYPICAL FIRE WATER SYSTEM IN TANKAGE AREA

ROAD

ROAD

RO

AD

RO

AD

FIRE WATER SUPPLY

FIRE MONITOR

FIRE HYDRANT

PROTECTION BERM

DOC NO.

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BULLET TANK

BERM

PLAN

BERM

BULLETS

SLOPE

ELEVATION

training manual- piping doc no. : 29040-pi-ups-1007 · training manual- piping piping study...

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