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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
TRAINING MANUAL- PIPING
PIPING STUDYTANKFARM PIPING
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
TRAINING MANUAL- PIPING
PIPING STUDYTANKFARM PIPING
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
TRAINING MANUAL- PIPING
PIPING STUDYTANKFARM PIPING
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.
TRAINING MANUAL- PIPING
PIPING STUDYTANKFARM PIPING
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.
TRAINING MANUAL- PIPING
PIPING STUDYTANKFARM PIPING
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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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
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PIPING STUDY
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TANK FARM PIPING
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L
TYPICAL HORIZONTAL PRESSURE TANK (BULLET)
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TANK FARM PIPING
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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
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ROOF ACCESS AREAPROVIDE HANDRAIL ON BOTH SIDE OF
PLAN
TANK
ELEVATION
VALVE EXTENSION STEM
VALVE ACCESS CATWALKS
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CATWALK
CATWALK
FINNED TUBES
STEAM IN
CONDENSATEOUT
OUTCONDENSATE
FINNED TUBES
STEAM IN
TYPICAL TANK HEATERS
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PIPING STUDY
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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
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PRIMARY CONTAINER
12"/300MINIMUM
COLUMNS
CONCRETE SLAB
LOW TEMPERATURE TANK FOUNDATION WITH ELEVATED CONCRETE BASE
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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
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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
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PUMPS INSIDE CONCRETE DYKED AREA
CONCRETE DYKE
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18"/450 18"/450
DYKE- PENETRATION SEAL
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PIPE SLEEVE
SEAL
PRODUCT LINE
DYKE WALL
FLEXIBLE DYKE SEAL
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PIPE SLEEVE
INSULATION
PRODUCT LINE
INSIDE DYKE WALL
STEEL STRAP
FLEXIBLE SEAL
ALTERNATE PIPING LAYOUTS
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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)
TANK FARM PIPING
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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
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C PUMPSL
PRODUCT OUTLET
CATWALK
RELIFE VALVE
PLAN
ELEVATION
RELIFE VALVETO ATMOSPHERE
CATWALK
LIQUID OUTLET
LIQUEFIED NATURAL GAS TANK LAYOUT
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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
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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
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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
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BULLET TANK
BERM
PLAN
BERM
BULLETS
SLOPE
ELEVATION