Piping Design Tank Farm

Tank Farm
Page 2 of 36
Doc. No : DG-PP-72002
Rev. 00
CONTENTS
Page No.
1.0
Purpose
2.0
Scope
3.0
Reference Code / Standard
4.0
Terms and Definitions
5.0
Abbreviations
6.0
General requirements
7.0
Test / Inspection
14
8.0
Documentation
14
9.0
Annexure
15
Date: 31-12-2007
File Name: DG-PP-72002-00

Copyright BecRel-All rights reserved
BecRel Engineering Private Limited
Tank Farm
Page 3 of 36
1.0
Rev. 00
Purpose
To provide general guidelines and requirement for development of Tank farm layout and
its associated facilities.
2.0
Scope
This work instruction describes the procedure and methods to be used for the preparation
of Tank Farm layout and processing of the statutory drawings for the approval of the chief
controller of explosives in India.
3.0
Reference Code / Standard

CCOE Regulations
TAC Rules
OISD 118 / 116
OSHA
SMPV Rules (unfired )
The Petroleum Act
API 12F
4.0
Terms and Definitions

Flame arrester: In the event of lighting or another source of vapor ignition a flame
arrester in the vent line o a storage tank prevents flames from flashing to the vapor inside
the tank.
Floating roof tank: A floating-roof lank is designed to conserve vapor loss and minimize
fire hazard.
Foam: This is a solution with a density lower than that of oil and water It is used to form a
blanket over dangerous vapors and thereby reduce the risk of explosion.
Heaters: These are heat exchangers used inside large storage tanks. They heat viscous
materials using steam, hot water, or gases at high pressure.
Sphere: This spherical vessel is used to store liquids and gases at high pressure.
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Tank Farm
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Intermediate holding tank: This tank is used for temporarily storing a liquid until it
reaches a specified state, at which time it is pumped downstream in a process.
Sediment: This sludge accumulates in tank and piping. It consists of dirt, wax, and mill
scale and must he disposed of periodically.
Sleeper: sleepers are steel or concrete supports , located at grade for piping systems
commonly found in off sites.
Sump: This is the low point wit hin an area used to collect liquids for removal.
Tank farm: A location with many storage tanks is often called a tank farm.
5.0
Abbreviations
OISD
CCOE
TAC
OSHA
NFPA
API
Oil Industry Safety Directorate

Chief Controller of Explosives, Nagpur
Tariff Advisory Committee
Occupational Safety and Health Act
National Fire Protection Agency
American Petroleum Institute
6.0
General requirements
6.1
Piping Arrangement For Storage Tanks

Steel containers are used for storin g liquids in a process plant. Although many such vessels
are found within the confines of a process unit, most vessels and tanks are located in area
commonly referred to as off sites or tank farms. The two most important factors governing
these layouts are safety and economics. Any comprehensive design must consider local
codes and regulations, client specifications, topography, adjacent process units, and
neighbouring commercial or residential property as well as maintenance, operation, and
constructabilit y. This document discusses the most common types of storage vessels plot
plan arrangements, safety considerations, spill containment, pumping and general piping
layout
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Tank Farm
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6.2
Rev. 00
Codes And Regulations

The plant layout designer should review codes and regulations of the National Fire
Protection Association, the Occupational Safety and Health Act, and regulations of local
jurisdictions, such as Oil Industry Safety Directorate, Chief Controller of Explosives etc.
All NFPA codes are recommended as a basis for legal regulations. They are intended to
reduce % potential hazards to public safety, but compliance does not eliminate-' such
hazards as those that occur When .flammable and comb ustible liquids are stored in process
facilities.
Factory Act
The main considerations in the layout of storage facilities that fall under Occupational
Safety-and Health; Act (OSHA) regulations are personnel access ladders, and stairways
and catwalks
Local Codes and Regulations
Any documents concerning local codes and regulations should be reviewed before any off
site layout is begun
6.3
Types of Tanks
Storage tank come in many shapes and sizes, according to the type of product to be stored,
its potential for fire, and the amount to be held. This section discusses the most common
types of vessels found in most process facilities.
Cone Roof Tank
This low-pressure tank is used for countless products, including petroleum, chemicals,
petrochemicals, food products and water Another low-pressure storage vessel is the fiatroof tank
Floating Roof Tank
The roof of this tank rises and lowers with the stored contents, thereby reducing vapor loss
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Tank Farm
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Rev. 00
and minimizing fire hazard It is commonly found in oil refineries.

Low-Temperature Storage Tank
This tank stores liquefied gases at there boiling point. Products found in such tanks
include ammonia (-28 F), propane (-43 7 F).
Horizontal Pressure Tank (Bullet)
Bullet tanks are usually shop-fabricated vessels used to store products under high pressure
The heads of these vessels are either elliptical or hemispherical the latter being used when
higher pressures are required
Sphere Pressure Vessel
This sphere is used to store large quantities of liquids and gases under pressure Limited
road access to a plant site may make it more advantageous to erect a sphere in the field to
store products under pressure
6.4
Spill Containment
Because of the real risk of failure of storage tanks and primary piping systems, means must
be provided to contain the resulting spills Containment may be a second tank wall around
the vessel holding the liquid or a continuous dyke designed to hold all of the liquid stored
in the largest tank Dykes may be constructed of earth, steel, concrete or solid masonry
They may be square, rectangular, circular or irregular in shapes confirming to the natural
terrain around them. Dykes may hold one or many tanks. OISD-118 / Petroleum Act
should be consulted for matters that concern the dyking of flammable and combustible
liquids
Another dyke design commonly found in restricted or tight areas is the concrete wall The
location of storage tanks often must be within the battery limits of a process unit, and
earthen dykes are not practical for this application
Tanks are often located in sloped or hilly areas where square or rectangular dykes would be
impractical The designer should consider using the natural terrain for a group of tanks In
addition. roadways and pumping facilities must be located to suit the terrain
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When the overall plot plan for a process facility is developed off site storage should be set
at a lower eleva tion than the process unit whenever possible This approach provides an
additional margin of safety in the event of a major rupture.
Developing a layout for buried storage tanks in an existing chemical plant often poses
special problems It may not be possible or practical to move existing underground
obstructions in the area in which the tank must be located One solution to this problem is
to bury the tank above grade in a concrete containment. Pumps, maintenance access, and
all appurtenances must be installed in the roof of the tank.
Spills that pose a high risk to adjacent facilities must be diverted to a remote holding area.
One method would be to erect a concrete diversion canal. Drain valves that are located
outside the dyked area usually would be closed but would be opened in the event of a
critical spill Sump drain lines discharge into the concrete diversion canal and flow
downward to a holding basin. Refer Annexure-8 for General arrangement fo r Catch pit,
Annexure-18 for typical underground arrangement.
6.5
Dyke Access
Consideration must be given to providing vehicular and personnel access into dyked areas
Personnel access should be by stairways designed according to Factory Act standards A
single stairway located at the pump area provides access to a catwalk located on top of the
dyke. Two other sta irways provide service access to the dykes
When initially trying to establish a tank farm 1ayout the designer should consult local
codes and regulations Rules for spacing between tanks and all adjacent facilities usually
can be found in the latest issue of the industrial risk Insurers GE Insurance Solutions or in
Oil Industry Safety Directorate Rules and Petroleum Act.
OISD-118 / Petroleum act will indicate what the designer should consider when grouping
several tanks within a single dyke or whether the tanks should be individually dyked
because of large capacities There is no simple answer to this layout problem Each plant
site is unique, with different products, tank capacities fire prevention requirements terrain
and adjacent commercial or residential property. .
After the dyking arrangement has been established, there are a few additional factors to
plan for The grade sloping away from the tanks to a sump must be determined minor spills
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Tank Farm
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and rainwater may have to be pumped from the sump to a treating pond Dyke heights must
also be established on the basis of inventories and available real estate
6.7
Sizing Tanks And Dykes

Development of optimum sizes for tanks and dykes comes through trial and error.
Considerations include the availability of real estate, the possible use of standard-sized
tanks for smaller capacities, and the nature of potential foundation design problems caused
by early tank-size selections. The designer should refer to API 12F for standardized shopfabricated tank sizes. Larger field-fabricated storage tanks must be sized to suit each sizes.
Dykes containing multiple tanks are sized to hold the capacity of the largest tank for the
dimensions of dykes containing more than one tank, it is necessary not only to subtract the
volume of each tank from the dykes capacity but to subtract the volume of the soil in each
berm (foundation).
6.8
Tank Details
After primary liquid-transfer line connections have been located, roof access ladders (or
stairways) and side shell and roof maintenance access connections should be located
addresses these issues. Refer Annexure-7 for Nozzle Orientation
Tank maintenance includes such activities as internal inspection, cleaning, and repairs roof
supports, and level instruments, Setting entrances to stairway or ladder areas at grade is the
most convenient choice for operations personnel. It should be noted that stairways are not
recommended for tanks whose diameter is less than 4.5m & height less than 6m.
For safety, handrails should be added also on the tank roof edge on both sides of the ladder
or stairway. Level instruments with internal floats are usually located in this area, as are
roof maintenance access openings, which are convenient for inspections, repairs, and
cleaning of instruments. The standard, round opening is a minimum of 0.460m in diameter.
The larger, oval-shaped, flat-bottom opening is more commonly used on. large tanks or
those that use internal heaters The layout designer must keep the area immediately around
access openings free of such obstructions as large pipe supports, piping, and light poles
Valve access catwalks shall be provided It is of utmost Importance to give operations
personnel adequate access to primary tank valves Consideration must be given to the
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Tank Farm
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elevation of all valve hand wheels in relation to the catwalk Adding extension stems to
smaller valves will facilitate opening or closing such valves
Tank mixers: A tank mixer is another auxiliary piece of equipment found in tanks with
highly viscous fluids Adequate area must be provided for removal of tank mixers
Tank heater: The heaters co me in various sizes and shapes sufficient unobstructed space
must be provided outside access openings to permit removal of heaters
Interconnecting Walkways :
For storage areas with many small or medium sized tanks, consideration should be given to
designing interconnecting catwalks for operator convenience The limiting factor is catwalk
length Travel distance to exists in high-hazard industrial occupancies shall not exceed 23m
Additional length can be accommodated by adding ladders or stairways. Refer Annexure
9.
Tank Supports
Three common tank support designs are Concrete ring wall, Compact soil, Concrete table
The civil engineer is responsible for determining the most cost-effective design, on the
basis of available data about soil conditions. Layout designers should understand the
fundamental nature of each design to optimize piping, stairway and ladder locations
without creating problems for cons truction or plant personnel. Refer Annexure 11 for
concrete ring wall.
For a low-temperature tank foundation design concrete table design is used This particular
design employs a concrete slab supported by columns, providing an air space under the
slab This air space helps raise the temperature of the slab during a failure in the primary
tank
Pumps shall be located outside the dyke Tank outlet piping can either penetrate the dyke or
pass over. The latter approach would usually be considered if the maximum dyke height
were 1.8m and if the minimum liquid level in the tank would not cause damaging
cavitation in the pump The designer must carefully examine each layout before employing
this design The location of an elevated pipe rack or sleeper relative to the pumps should
account for plant maintenance philosophy Sleepers permit unobstructed pump access when
located between the pump and the dyke wall Pumps pipe racks support discharge piping
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Tank Farm
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but limit access to pumps during maintenance. Prime consideration should be given to
providing an ample maintenance area around and above pumps.
Locating pumps inside a concrete dyked wall is common in many process plants. In this
design the pump block set at the same elevation as the dyke. With this configuration, the
pump would not be submersed during a spill inside the dyke This configuration enables a
close-coupled piping arrangement Providing for differential settlement allows the
discharge line to be run to the pipe rack over the dyke wall This approach should be
approved by the client.
Lines penetrating concrete dyke walls against leakage by using commonly available seals.
The seal is used when an insulated line runs through a larger pipe sleeve that must be
sealed on the inside of the dyke This design permits minor line movement A stress or
support engineer should be consulted when the designer is planning its application.
6.9
Differential Settlement
This concern must be addressed early in the layout of any process unit or tank farm The
foundation of any process facility will eventually settle or sink to some extent depending
on the weight it carries and the condition of the soil. To determine where pipes may be
supported safely without imposing excessive stress on equipment nozzles, a civil engineer
and soil exports must work together to determine how much the foundation is likely to
settle. subtracting sleeper settlement from tank settlement yields the differential settlement
between the two By figuring line size wall thickness, and allo wable stresses distance
between tank and first line support can be established Differential settlement can also be
caused by tilting of the tank by out-of-plane settlement or by dishing of the tank bottom
(which is a result of greater settlement at the center of the tank than at the edge)
The optimum piping arrangement in a tank farm, as elsewhere in a process facility, is the
most direct route between two points allowing for normal line expansion and stresses
Annexure-3.1 & 3.2 illustrates piping between tanks and pumps , or places where piping
movement is restricted, must be established Tank nozzles are one such anchor point The
second anchor point may be the pump nozzle if line growth is permitted through the dyke
or it may be anywhere along the pip ing within the dyke or at the point dyke penetration To
minimize the potential for tank spills, expansion joints should not be used.
Annexure-3.1 & 3.2 shows how to accommodate line expansion between tank nozzles and
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Tank Farm
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a manifold header. Expansion loops may be added at the sleeper level, as shown
In a cross section of piping, pumps, dykes, and a primary pipe way that is typical of what
might be fo und with in a tank farm Because the primary pipe way is located to the left of
the roadway, pump-discharge lines across the road must be routed to the headers in one of
two ways by burying them under the road, making allowances for vehicular loads imposed
on the pipe, or by placing them over the road on a pipe bridge Client preference should be
considered in this design Adequate access to pumps on the side of the pipe way opposite
the road must also be provided. Annexure-4
In a bullet-tank piping layout tanks are set at the lowest possible elevation to satisfy pump
head requirements A catwalk is located across all tanks to provide sufficient access to
operating valves and instruments Liquid outlet piping to the pumps should allow for
differential settlement and line flexibility.
A typical piping arrangement for a high-pressure sp here is shown in Annexure-5 & 6
Layout factors for spheres include
Sphere elevation should be kept low but not less than 1.525 m above grade.
Ideally, each sphere should have it own stairway Figure shows an acceptable
arrangement of stairway
Valves should be installed as close as possible to all nozzles
If an above-grade conventional layout is preferred for liquefied natural gas tanks. NPSH
requirements usually necessitate locating the pumps in a pit when the tank is above grade.
For underground tanks a submersible pump and its motor are Located within a containment
vessel and supported on lugs An adequate clear area directly over the pumps must be
maintained to allow pump removal for maintenance Motor-operated header valves are
located at grade and made accessible by platforms. Individual suction and discharge valves
are located near the nozzle connections in the pt Safety requires that a water-deluge firefighting system be included in this layout as well as a sump and sump pump to remove
unwanted water
When high-pressure bullet tanks are located close to a process unit, a protection berm (or
explosion proof wall) is often used. Berm length is slightly longer than the width of the
tank area, and the berm height is roughly equal to the height of the tanks. These berms
offer some protection in the event of an explosion.
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Although foam fire-fighting systems are often supplied by companies specializing in fire
protection, a basic understanding of such system is beneficial to a layout specialist The
piping usually has quick-connect coupling located outside the dyke The line is routed to
the tank wall A foam maker- which essentially consists of a pressure gauge, an air strainer
and a check valve- is located in the vertical riser The foam solution enters a foam chamber
located at the edge of the tank roof and then discharges across the top of the liquid in the
tank.
In another way foam concentrate from a truck or tank is supplied to a foam maker located
outside the dyke wall. The foam may be injected into the regular product transfer piping or
routed directly to storage tank through a permanent line especially for that purpose.
An alternative to mobile fire-fighting equipment permanent hydrants and monitors may be
used for fighting fires in storage tank areas Local codes and regulations as well as the TAC
rules must be consulted to establish the appropriate coverage of water for a given layout
The fire water piping around this area must come from two supply sources should any part
of the system fail. Refer Annexure 17.
In an effective overall layout of a process and off-site plot plan, the administration area is
immediately inside the plant main entrance as are maintenance and fire- fighting equipment
Process units and the utility plant are located in the central and side word section of the
plot. Truck and allowances for future-expansion are made. Storage tanks are located in the
other side sections of the plot. Truck and rail loading and unloading areas are located
together with storage tanks in co rners of the plot. A flare stack, a cooling tower, and
treating ponds are in the far most corner.
6.10
Guidelines For Preparation Of Drawings For CCOE Approval

Common Guidelines
Following are the requirements, which should be followed in layouts falling under CCOEs
purview. Suitable notes should be added on the CCOE drawings to take care of these
requirements.
Layouts should meet the requirements of applicable statutory / OISD and TAC rules, they
should be incorporated to reduce insurance premium on the tank farms. This should be
done in consultation with the client.
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Tank Farm
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Layouts must be submitted to and approved by CCOE before starting construction work.
All the equipment shall be supported on concrete columns. Steel supports, if provided,
shall have concrete encasing. Encasing to extend upto the joint of support and the
equipment.
Tanker loading & unloading area shall have concrete paving. However, concrete paving
may not be required if this area is located on proper road.
Finished floor inside tankfarm shall be RCC paved / unpaved / compacted earth. Type of
floor to be finalized in consultation with the client.
Design and construction of tanks and bullets shall be in accordance with relevant Indian /
International Standards & Codes and shall also meet the requirements laid down by
applicable stat utory regulations.
All fittings such as pressure relief valves, level gauges, emergency shut-off valves on the
tanks and bullets shall be in accordance with Indian / International Standards & Codes and
shall also meet the requirements of applicable statutory regulation.
All valves shall be cast & forged steel construction and tested as per relevant Standards &
Codes. Cast iron valves are not acceptable.
The design of electrical apparatus such as earthing, lighting, motors, switches etc. shall be
in accordance with Indian Standard & Codes and shall also meet the requirements of
applicable stat utory regulations.
All electrical equipment shall be suitable for the hazardous area classification as shown in
hazardous area classification drawing for the project. All electrical equipment shall be
earthed with two separate earth conductors.
An earth bus shall be provided near tanker loading / unloading area to enable earthing of
the tanker with flexible earth connections.
Fire fighting scheme proposed for this tankfarm shall be shown in the layout drawings.
This shall consist of water hydrants and monitors as required by TAC regulations.
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Tank Farm
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Medium velocity spray systems 1 fixed foam systems shall be provided for the tankfarm as
required by Insurance requirements and as agreed with the client.
Any building / shed inside the fence shall be of fireproof construction. Minimum two gates
shall be provided for the fenced area.
The layouts shall be reviewed with respect to the attached check list Annexure-1 before
they are issued for approval to CCOE.
The equipment layouts shall be processed as per Annexure-12
Records
Drawings & documents for CCOE approva l shall be treated as Quality document.
Drawings / documents with check prints shall be maintained.
7.0
Test / Inspection
Not Applicable
8.0
Documentation
Not Applicable
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Tank Farm
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9.0
Rev. 00
Annexure
Annexure 1
Annexure 2
Annexure 3
Annexure 4
Annexure 5
Annexure 6
Annexure 7
Annexure 8
Annexure 9
Annexure 10
Annexure 11
Check points for CCOE layout

Flow Diagram for CCOE Drawing
3.1 & 3.2 General Arrangement of Tanks
Sectional Detail of Tank Layout
General arrangement of Sphere Layout
Sectional Detail of Sphere Layout
Nozzle Orientation of Storage Tank
Typical arrangement plan of channel interceptor in Tank bund &
connection to Manhole
General arrangement of Platforms
General arrangement of Tank - Section
Tank Foundation Drawing
Annexure 12
Annexure 13
Annexure 14
Annexure 15
Layout Drawing for CCOE Approval

Typical Pump Piping
Typical Manifold Piping
Level Transmitter
Annexure 16
Annexure 17
Annexure 18
Culvert Drawings
U21 Drawing for Fire Protection System
Typical Underground arrangement for Tank Farm
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Annexure -1
Check points for CCOE Layouts
1. Drawings are prepared as per applicable statutory rules. (Petroleum rules, SMPV rules
O.I.S .D. rules) (O.I.S .D. rules only f specifically required by the Client).
2. All dyke walls are minimum I m height.
3. All CCOE tanks Containing class A or/& class B fluids & having diameters larger
than 4 mts. are located In such a way that the spray water requirement is minimized,
particularly In cases where spray water requirements govern the pump capacities.
4. The requirement in clause 3 above is met even though foam protection is specified
initially.
5. The spheres & bullets containing flammable liquids shall be located at 15 m clear
distance from each other as far as possible to reduce aggregate spray water
requirements. This is essential for large spheres & bullets, where the spray water
requirements govern the pump capacities.
6. Volume of dyke is 110% of the largest tank as required by TAC.
7. Interceptor if required is shown in the drawings. Interceptor capacity / size are as per
process data sheet.
8. Standard notes are attached to the drawing, with a project document number added on
the drawing.
9. Reference drawings indicated on the drawing include the following:
a) Plot, plan
b) P & I Diagram
c) Mechanical drawings for. equipment
d) Hazardous area classification drawing (if made for the concerned project).
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Tank Farm
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Annexure -2
Flow Diagram For CCOE Drawing
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Tank Farm
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Rev. 00
Annexure-3.1
General Arrangement Of Tanks
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Tank Farm
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Rev. 00
Annexure-3.2
General Arrangement Of Tanks
General Tank Layout For Utility Services.
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Tank Farm
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Rev. 00
Annexure -4
Sectional Detail Of Tank Layout
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Tank Farm
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Annexure -5
General Arrangement of Sphere Layout
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Tank Farm
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Rev. 00
Annexure -6
Sectional Detail Of Sphere Layout
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Tank Farm
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Rev. 00
Annexure -7
Nozzle Orientation For Storage Tank
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Tank Farm
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Rev. 00
Annexure -8
Typical Arrangement Plan Of Channel Interceptor In Tank Bund
And Connection To Manhole
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Tank Farm
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Rev. 00
Annexure -9
General Arra ngement of Platforms
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Tank Farm
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Annexure-10
General Arrangement of Tank Section
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Tank Farm
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Rev. 00
Annexure-11
Tank Foundation Drawing
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Tank Farm
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Annexure-12
Layout Drawing For CCOE Approval
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Tank Farm
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Annexure-13
Typical Pump Piping
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Tank Farm
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Rev. 00

Tank Farm
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Annexure-14
Typical Manifold Piping
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Tank Farm
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Annexure-15
Level Transmitter
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Annexure-16
Culvert Drawing
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Tank Farm
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Date: 31-12-2007
Rev. 00

Annexure -17
U21 Drawing for Fire Protection System
Annexure -18
Typical Underground Arrangement

Piping Design Tank Farm

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Tank Farm

Reference Code / Standard

Terms and Definitions

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

Reference Code / Standard

Terms and Definitions

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

Oil Industry Safety Directorate

Piping Arrangement For Storage Tanks

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

Codes And Regulations

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

and minimizing fire hazard It is commonly found in oil refineries.

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

Sizing Tanks And Dykes

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

Guidelines For Preparation Of Drawings For CCOE Approval

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

Check points for CCOE layout

Layout Drawing for CCOE Approval

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

General Tank Layout For Utility Services.

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00

BecRel Engineering Private Limited

File Name: DG-PP-72002-00