Section v - Field Issues

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Section V - Field Issues

Section V - Field Issues

A. Field trip guidelines - By: James O. Pennock

This discussion is about what to expect when you are asked to go to the field?

B. Defining Offsite Facilities for Process Plants - Contributed by Jadeep Choudary, Anita R. Legvold and

James O. Pennock.

Some have asked questions such as: What is Balance of Plant?; What is Offsites? What is OSBL? and

What needs to be considered when a project includes Offsites. The purpose of this document is to aid

in answering this type of question.

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Section - V

A: Field Trip Guidlines

By: James O. Pennock

What is involved when you are asked to go to the field? If you are truly a knowledgeable and

experienced designer or engineer you are supposed to know the answer to that question. If you are a

novice, new to the business or if you have never been to a job site you will not know. However, you

should be smart enough to ask. Yet, we see many cases where people show up at a job site, uninformed

of what they are supposed to do, and unprepared to do it.

I remember a case that is a classic. A team of four were selected and sent to a job site. All the members

had ten plus years of experience so the supervisor made the assumption that they all knew what was

expected. The individuals involved happened to live in a widely scattered area and were to travel from

different airports and at different times. This point eventually contributed in part to the problem

because there was no face to face meeting in the office or at the airport before getting on the plane.

Friday they were all given (or sent) plane tickets and directions for finding the plant and were to meet at

the job site on arrival on Monday.

Three of the four seemed to know what was expected. The forth, a contract employee, new to the

company, but with more than thirty years of total experience proved to be the exception. This person


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showed up in dress casual and with nothing in hand. The supervisor, thinking the person had left his

work clothes in the car or some place close by, told him to change into his field gear and be ready to go

to work. Change, into what? What field gear? To make a long story short, this person had only

brought casual clothes and had brought nothing in the way of field gear or tools. He had no work shoes,

no work clothes, no hard hat, no safety glasses, and no hearing protection. He also had no pencil,

eraser, sketch paper, no clipboard, and no tape measure. Nothing! When asked why not, the answer

was that he expected the company or the client to supply everything. As quietly as possible the person

was told that he was fired and to leave the job site, go get on the plane and go home.

The situation proved to be an embarrassment to not only the supervisor but also the company. You see

job sites such as the type we had in this case are tight little communities and you cannot keep secrets

from people who are in charge. It was not long before the company construction manager and the

client both knew about the fiasco. Although they agreed with sending the employee away, they were

not happy with the cost and the effect on the schedule. They expected everyone to show up ready,

willing and able to work.

Ready, willing, and able to work means everybody. It means all the members of the team. It includes

the team leader and each individual engineer or designer. The balance of this article is intended to be a

guide to any individual who is required to go to a job site to perform work. It is offered to held define

the major procedural and technical issues related to making the field trip both cost effective and safe.

When it is recognized that a trip is required, the first thing that is normally done is to define the purpose

of the trip and obtain all required approvals. This is normally done at the project senior supervisory and

management levels. We will not dwell on why a field trip is required. What we need to do is insure that

it is done right.

The next thing to do is activate the team. Engineers or designers assigned to a field team for routinefieldwork or specific problem solving need to be selected carefully. They should be selected on the basis

of knowledge and prior experience. They may also need specific skills, or the familiarity with operations,

maintenance, or construction.

In order to activate the team the following may be required:

Names & phone numbers of client site primary & secondary "Key" contacts

Names of the engineering company primary & secondary contacts

Name of the person responsible for decision making, time sheet and expense report approval

Team member names

Assign someone as the team leader, someone in charge

Team member release from present assignment (if applicable)

Travel arrangements (Airline, lodging, ground transportation, meals, etc.)


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Maps to site location, site logistics, site safety criteria, badges, camera pass and site access

Charge number for this (Problem/Solution) assignment

Next, before leaving for the site, there should be a pre-trip meeting of all the team members. The direct

supervisor who is responsible for the team and the results should conduct this pre-trip meeting. The

agenda for this meeting should include a review of the purpose of the trip and the expected results.

Have a plan for everyone and for all the work objectives. Other items that should be covered would

include the chain of command, the schedule, the cost and expense issues, and an exchange of phone

numbers for emergency contacts. Review what to do if someone misses the plane, etc.

On arrival, check in with the key Client contact person and the jobsite construction manager. Safety is

the first and most important step of the actual site visit. Make sure that every member of the team has

received the site-specific safety training. Know and understand the emergency warning system and the

evacuation routes. Identify and agree on a place to meet, if there is a possibility of getting separated.

Engineers and Designers who visit a Client facility or site are expected to know the type of work they willbe doing when they arrive and should be prepared to take prompt action to address that work. They are

also expected to have with them the tools and supplies required for their jobs.

Standard safety clothing and personal protective equipment (PPE) Requirements:

- Hard hat

- Goggles or safety glasses w/ permanent side shields (no contact lenses and no removable side shields)

- Work shoes (check, some job sites require steel toed work boots)

- Gloves

- Ear protection

- Respirator with Cartridges (When required)

- NOMEX or Equivalent flame retarding outer wear (This is sometimes optional depending on the client

or type of plant)

Basic tools:

- Pencils and markers, a clip board, straightedge

- Sketch paper and Isometric forms

- 25 ft. Tape measure

Alternate tools that may be helpful


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- String line, Plumb Bob, and String Level (Used for measurements)

- Stopwatch (Used for checking frequency of events)

- Medical type Stethoscope (Used for listening for unusual noises inside of pipes)

- Camera (Requires Client approval and pass)

The team should not expect to borrow any tools or supplies from the Client. If a new requirement for

tools or supplies is identified, after arrival at the site, the team should arrange to rent or purchase the

item and turn in the cost on an expense report. An exception may be made if the required item is

unusual and or very costly and the client has the item available.

Once in the field and trained in the site safety criteria, the team is ready to go to work. Everyone should

go about the work in a prompt and professional manner. Where possible, fieldwork should be done by

two person teams. The people on each team should check each others work as the work progresses.

They should review their list of activities and tasks as they proceed. Review the trip plan. Its better to

get too much information thus insuring you do not miss something. Remember that this job site may be

thousands of miles from your home office. A return trip for one missed item could be very costly.

Check in with the home office daily or per previous instructions. Let the home office supervisor know

the progress of the planned work and ask if there are any new requirements. Proceed through the list

of all planned trip requirements. Perform all activities and tasks. Do no return from the job site until all

planned items are complete (unless directed otherwise). It is also recommended that you check in with

the site construction manager on a daily basis. There may be additional project needs that have come

up. There may also be a change in some critical site condition that could effect the team safety. When

leaving the job site you should check out with the construction manager and your client host.

Upon return to the office, there should be a debriefing meeting. The responsible supervisor, the project

engineer (or manager) and all team members should attend. Review the purpose of the trip, the results.

Review the trip plan. Did you accomplish everything that was required? If not, why not? Were there

any problems? Were they solved and what were the solutions? Are there any lessons to be learned

from this trip? Is another trip required? If so why? And when will the next trip be required?

Every field trip should be planned and executed in a proper and cost effective manner. If so, then the

project will benefit. The individuals on the team also benefit. They gain value and a reputation for

being an experienced and effective candidate for future fieldwork. Good luck and have a safe and

successful trip.

Back to top


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Section - V

B: Defining Offsite Facilities for Process Plants

Contributors (In alphabetical order):

Jadeep Coudhary, Anita R. Legvold, James O. Pennock

Introduction

Some have asked questions such as: "What is Balance of Plant?"; "What is Offsites?" What is OSBL?" and

"What needs to be considered when a project includes Offsites."

The term Offsites is a general term and does not mean the same for every project or every plant. A

project may include extensive tankage for feed storage along with tankage for in-process product,

intermediate product, run-down tankage, slops and finished product tankage. Another project may

include none of this because they already exist. The point here is just because you are told that the

project includes "Offsites" you need to ask a lot of questions to determine exactly what they mean and

what will be required.

The purpose of this document is to aid in answering this type of question. This document will not tell

you how to design the Offsites or design any of the individual sub-items or equipment found on this list.

That design guidance should properly be left up to you, your supervisors and your management. I do

however intend to start a listing of major elements along with some minor key issues that should be

considered.

I invite others to submit their own thoughts and comments to add to and improve this list.

Contents:

Section Subject

1 Definitions -- Offsite vs. Onsite

2 Codes, Standards, and Practices

3 Site Issues

4 Terrain, Grading, Roads, & Drainage

5 Tankage

6 Flares

7 Piperacks & Sleepers


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8 Pipelines

9 Loading / Unloading Racks (Truck, Rail, Barge, and Ship)

10 Cooling Water Supply Systems

11 Hazardous Chemicals

12 Waste Treatment Facilities

13 Electrical

14 Buildings & Auxiliaries

15 Fire Protection & Safety

16 LPG Bottling Facilities

17 Solids Storage & Disposal

1, Definitions

Offsite -- In a process plant (Refinery, Chemical, Petrochemical, Power, etc.), any supporting facility that

is not a direct part of the primary or secondary process reaction train or utility block. Offsites are also

called OSBL.

Onsite - Any single or collection of inter-related and inter-connected process equipment that performs

an integrated process function. Typically any Onsite Unit could be made to function independently of

another Onsite Unit. Onsite Units are also called ISBL.

Utility Block - A single or multiple grouping of facilities that generate the support services required by

the Onsite Process units to function. This normally includes: Steam Generation, Plant Air, Instrument Air,

Decimalized Water, Plant Water, etc.

Balance of Plant - This is another term for Offsites and/or anything else other than the Onsite Units or

the Utility Block.

Battery Limit -- Line used on a plot plan to determine the outside limit of a unit. The Battery Limit line is

usually established early in the project and documented on all discipline documents such as Plot Plans,

Site Plans, Drawing Indexes, etc... (1)

Property Line -- A Property Line is the recorded boundary of a plot of land. (2) Defines the separation

between what is recognized legally as Owner's land and non-Owner's or other land.

On Property -- All land and or water inside the Property line shown on the property map or deed.

Off Property - Off property is any land (or water) outside of the Property line shown on the property

map or deed.


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Right of Way (ROW) -- Any land (On Property or Off Property) set aside and designated for a specific use

or purpose. A Right-of-Way within a piece of property may also be designated for use by someone other

than the property owner.

Setback or Setback Line -- A line established by law, deed restriction, or custom, fixing the minimum

distance from the property line of the exterior face of buildings, walls and any other construction form; sstreet, road, or highway right-of-way line (3). Setback is a clear area normally at the boundary of a piece

of property with conditions and restrictions for building or use.

Easements -- A vested or acquired right to use land other than as a tenant, for a specific purpose; such

right being held by someone other than the owner who holds the title to the land (2). An easement is

typically a strip of land within which overhead power lines or underground pipes are run.

(1) -- Lamit, Louis Gary, 1981 Prentice-Hall

(2) -- Construction Dictionary

2, Codes, Standards, & Practices

ANSI (American National Standards Institute)

API (American Petroleum Institute)

ASME (American Society of Mechanical Engineers)

ASTM - American Society of Testing Materials

AWS (American Welding Society)--

AWWA (American Water Works Association)

CFR (Code of Federal Regulations)

Division of Weights & Measures --

DOT (Department of Transportation)

FAR (Federal Accounting Regulations)

IRI (Insurance Regulators Institute)

Local Permits (Country, State, City, etc.)

MSS (Manufacturing Standards Society) --


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NACE (National Association of Corrosion Engineers)--

NFPA (National Fire Protection Association)

OIA (Oil Insurers Association)

PFI (Pipe Fabrication Institute)

USCG (United States Coast Guard) Regulations

3, Site Issues

Brownfield (Revamp Existing)

Climate (Wind Rose)

Demolition

Feed stock type, source and method of delivery

Future growth

Grass Roots or Greenfield (New construction)

Impact across the fence

Power requirements and source

Products, Primary, Secondary and by-products

Seismic zone

SHE (Safety, Health and Environmental)

Utilities requirements

4, Terrain, Grading, Roads, Ditches & Drainage

Terrain

- Level vs. Sloping

Geotechnical influences

- Type of soil

- Angle of repose


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- Grading

- Contours

- Grubbing (Tree and shrub removal)

- Rough Grading

- Finished Grading

Roads

- Primary

- Secondary

- Type and purpose of traffic

- Right hand or left hand drive

- Traffic pattern, potential for congestion

- Pipeway or Sleeper Crossings (Overhead Vs Ramp & Culvert)

Rail Spurs (see Loading and Unloading for additional criteria)

- Number

- Location

- Capacity (number of rail cars)

- Elevation

- Roadbed & Ballast Details

- Vertical and Horizontal Clearance requirements

- Standards and jurisdiction of Rail company (Right of Way)

Drainage systems

- Storm

- Oily Water

- Chemical

- Sanitary Sewage


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- Contaminated

- Other

Ditches

- Depth

- Width

- Slope

Culverts

- Location, Size, Type

- Invert Elevation

Basins & Ponds

- In ground or On ground

- Lined vs. Unlined (or Rip Rap)

- Skimmers & Aerators

- Overflows & Runoff

- Fenced or Unfenced

- Access

Stiles, Stairs, Catwalks, and Platforms

- Existing or new

- Material if existing

- Material if new

- Location & Elevation

- Access

- Valve extension stem requirements

5, Tankage


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Types & Purpose

- Atmospheric vs. Pressurized

- Cone Roof

- Floating Roof

- Bullets

- Spheres

- Spheroids

- Other (Used tank cars as storage)

Tank Construction

- Single Wall vs. Double Wall

- Metallic vs. nonmetallic

- Unlined vs. Lined

- Insulated, Jacketed, Heated, Cooled,

Commodity Grouping & Spacing Criteria

- Commodity (Compatible vs. non compatible)

- Single Tank

- Multiple Tank Group -- Same Size

- Multiple Tank Group -- Different Sizes

Spill Containment

- Containment Criteria

- Earthen Berm (Dike)

- Wall (Concrete)

- Topography

- Combination

Tank Supports and Foundations


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- Foundation Types

- Foundation Details

- Sloping Bottoms

- Settlement

Tank Auxiliary Equipment

- Heaters & Coolers

- Internal Coil Type

- Internal Bayonet Type

- External Type

- Mixers

- Motor Driven Mechanical Types

- Jet Types

- Support requirements

- Removal methods and clearance

Fire or ignition suppression

- Snuffing steam to V/PRV (Vacuum & Pressure Relief Valve) Tail Pipes

- Water Spray Systems (Deluge Systems)

Tank Nozzles & Appurtenance

- Primary Inlet & Outlet Connections (Single vs. Multiple)

- Vent Connections (Closed, Open, Flame Arresters)

- Drain Connections (Closed, Winterized, Non-winterized)

- Instrument Connections (Flow, Level, Pressure, and Temperature)

- -- Level Controller & Gage

- -- Float & Target Board

- -- Automatic (Tape Type) Tank Gage


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- -- Gage Hatch

- -- Pressure Taps

- -- Thermowells

- -- Radar type Level Instruments

- -- Sonar

- Heating Coil Connections (Inlet/Outlet)

- Mixer Mounting Nozzles

- Manholes

- Internal Nozzles

- -- Internal Piping

- -- Swing Lines (Winch, Clearance, Accessibility)

- -- Internal Pipe Supports

- -- Internal Floating Roof Supports

- Orientation & Elevation

- Size & Rating

- Projection

- Recommendations

- -- Avoid weld seams

Ladders, Stairs, and Platforms

- Orientation

- Primary access - entrance and exit

- Roof traffic Vs Formal Platform

- Safety - Tank Edge Handrail

Pumps

- Types


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- Location

- Sumps

- Piping Elements

Product Piping

- Differential Settlement

- Location of First Support

- Natural Anchors (Dike Sleeves)

- Slops Collection System

Hot Oil Systems

- Asphalt Tankage & Distribution

Utilities Piping

- Condensate

- Instrument Air

- Nitrogen

- Plant Water

- Plant Air

- Potable Water

- Steam

- Glycol

- Ammonia

- Cooling Water

- Chilled Water

- Tracing Fluids (Low Temp. or High Temp.)

Dike Penetrations (Piping)

- Sleeves (U/G Protection & Grounding)


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- Double Containment

- Casings

Operations Issues

- "Roll Over"

- "Boil Over"

Maintenance Issues

- Access (Mobile Equipment)

- Cleaning and Repair

- Housekeeping Pads (Spillage control)

- Utility Station Location & Access

- CIP (Clean in place)

- Wash Stations & Spray Wands

6, Flare, Incinerator, and Thermal Oxidizer

Flare

- Location Criteria

- Prevailing Wind (Wind Rose)

- Flare Header

- System Study

Flare KO Drums

- Horizontal

- Vertical/Stack base integrated

- Support

- Pump out

Flare Number and Types


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- Number of Flare Stacks

- Ground Flare

- Elevated -- Free Standing

- Elevated -- Derrick Supported

- Elevated -- Cable Guided

Flare Accessories

- Flame Arrester

Flare Stack Utilities

- Fuel Gas

- Pilot Gas

- Igniter Line

- Atomizing Steam

- Flame Arrester Drain

Incinerators

- Location Criteria


- Collection System

Incinerator Utilities

- Fuel Gas

- Pilot Gas

- Igniter Line

- Atomizing Steam

Thermal Oxidizers

- Location Criteria



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- Collection System

Thermal Oxidizer Utilities

- Fuel Gas

- Pilot Gas

- Igniter Line

- Atomizing Steam

7, Piperacks and Sleepers

Support Types

- Elevated (Overhead) Racks

- Sleeper Racks

- Bridges

Materials of construction

- Steel

- Concrete

- Combination

Overhead Racks

- Height

- Number of levels

- Current Space Requirements

- Future Space Requirements

- Operating Temperature induced expansion

- Solar induced expansion

- Maximum Spans

- Minimum Line Sizes


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- Piping Loops

- Shoes, Anchors, & Guides

Pipe Sleepers

- Height

- Changes in Direction (Flat Turn vs. Elevated)

- Current Space Requirements

- Future Space Requirements

- Operating Temperature induced expansion

- Solar induced expansion

- Maximum Spans

- Minimum Line Sizes

- Piping Loops

- Shoes, Anchors, & Guides

Pipe Bridges

- Number

- Location

- Height

- Span

Auxiliary Piping Services & Systems

- Utility Systems

- Steam Tracing

- Jacketed Piping

- Internal Cleaning requirements for piping systems

- Future (space allowance)

Miscellaneous Piping Details


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- Process Vents & Drains

- Hydrotest Vents & Drains

- Size, location, and access

- Cleaning connections (Maintenance)

- Slip Lining

8, Pipelines

Types and Purpose

- Cross Country

- Inter Plant

- Intra Plant

Accounting Meters

- Meter Provers

- "Bonded Zone"

- Fencing and Security

Pig Launchers & Pig Catchers (Receivers)

- Package System

- Vendor or Third Party Sub contracted

- Stick build

Pipe Line Pigging Criteria

- Minimum bend radius

Slug Catchers

- Types

Special Valving Considerations

- Types


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- Support

Special Instrumentation

- SCADA

- Pig Signals (Pig Sig)

9, Loading / Unloading Racks (Truck, Rail, Barge, and Ship)

Product Data

- Liquid Products

- Gas Products

- Dry Products

- Non-flammable Liquid Chemical Products

- Flammable Liquid Hydrocarbon Products

- Liquefied Petroleum Gas (LPG) Products

Shipping method

- Truck

- Rail

- Barge

- Ship

Loading & Unloading Method

- Loading Arms or Loading Hoses

- Top Loading

- Bottom Loading (Truck & Rail only)

- Vapor recovery criteria

Shipping Plan

- Number of shipments


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- Frequency of shipments

- Loading time

- Unloading time

Loading Rack Size & Location Criteria

- NFPA Criteria

- Size of Carrier (Truck, Rail Car, Barge/Ship)

- Minimum distance between loading "Spots"

- Outline of structure

- Loading Arm Type

- Loading Arm reach

- Loading Arm rest position

- Height and reach of swing-down platforms

- Access & clearance for Operators

- Stair and Ladder access and egress

Barge & Ship only

- Fixed or Floating Dock

- Tide & Current Data

- Maximum "Swing" envelope (Vessel empty at high tide vs. vessel full at low tide)

Auxiliaries

- Meters

- Grounding Lugs

- Spill containment

- Shelters

- Piping

Utility Requirements


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- Utility Steam

- Plant Water

- Plant Air

- Breathing Air

- Nitrogen (for blanketing)

Safety & Fire Protection

- Monitors

- Hydrants

- Deluge Systems

- Fire Blankets

- Fire Extinguishers

- ESD (Emergency Shut Down) System

- Foam Systems

10, Cooling Water Supply Systems

Types

- Once through system

- Closed loop Cooling Tower system

- Atmospheric (Flooded) System

Water Source

- Municipal Water Supply (City, County, etc.)

- River Intake

- Ocean Intake

- Lake


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- Wells

- Surge Pond

Water Intake & Outfall Structures

- River

- Oceans & Bays

Tower Types

- Forced Draft

- Induced Draft

- Natural Draft

Prevailing Wind

- Direction (primary and secondary)

- Timing (Spring, Summer, Fall, and Winter?)

- Force

- Duration

Basin Design

- In-ground

- Under-ground

- Strainers and Filters

- Fixed Screens

- Rotating Screens

Pump Types & Location

- Vertical

- Horizontal (same level next to basin)

- Horizontal (elevated above basin)


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Operations

- Stand alone

- Manned

Maintenance

- Portable crane

- Built-in lifting facilities

Cooling Water Supply and Return Piping

- Material

- Location (Above ground or below ground)

Water Treatment Chemical piping

- PVC

- FRP

- Stainless Steel

- Alloys

Cathotic Protection

- Type

- Pipe Riser Location

- Insulating Flange Sets

11, Hazardous Chemicals Handling and Storage

Commodities List

MSDS (Material Safety Data Sheet)

Unloading Facilities


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Storage

Loading

Handling

Safety

- Safety Shower/Eye Wash

Winterized (Tempered water system)

12, Waste Treatment Facilities

Types

- Storm Water

- Oily Water

- Chemical

- Sanitary

- Contaminated

Collection Locations

Collection and transfer methods

- Gravity (only) to Treatment

- Gravity to Sump & Pump to Treatment

Types of Treatment

13, Electrical & Instrumentation

Equipment Types

- Instrument Rack/Cabinets

- Junction Boxes

- Load Centers


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- Substations

- Switch and Starter Racks

- Transformers

Aboveground Distribution

- Cable Trays

- Conduit Racks

- Light Standards

- Power Poles

- Push Button Stations

- Telephone Poles

- Transmission Towers

Underground Distribution

- Direct Bury Cable

- Duct Banks (Concrete encasement)

- Electrical Manholes

- Electrical Pull Boxes

Clearance criteria Electrical to:

- Process Equipment

- Piping

- Structures

- Pipe Racks

- Roads

- Rail Facilities

14, Buildings & Auxiliaries


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Buildings and purpose

- Administration -

- Cafeteria --

- Change House (Locker Room) --

- Chemical Storage --

- Control (House) Center --

- Fire House --

- First Aid --

- Gate or Guard Houses --

- House of Worship (Mosque) --

- Laboratory (Product QC) --

- Machine Shop --

- Maintenance --

- Safety Center & Training --

- Warehouse --

Auxiliaries

- Parking Lots

- Truck Loading/Unloading Docks

Utility Services

- Chemical Waste --

- Chilled Water --

- Comfort Steam & Condensate --

- Contaminated Waste

- Hot & Cold Water

- Lab Gas --


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- Potable Water --

- Sanitary Waste --

- Storm Water --

Piping Materials

15, Fire Protection & Safety

Fire Protection & Safety Plan

- Basic Safety Plan

- Contingency Plan

Fire Water System

- Fire Water Source

- Fire Water Storage

- Fire Water Pumps

- Fire Water Loop (Mains and Laterals)

- Fire Hydrants and Monitors

- Foam Chambers (Number and Orientation)

- Foam Stations (Number and Orientation)

- Fire Protection Manifolds (Pumper Connections)

- Fire Hose Carts

Materials of Construction

- Carbon Steel w/ external coating

- Carbon Steel w/ Internal Lining & external coating

- Ductile Iron

- FRP Piping


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- Cement Lining

- Nonmetallic Linings

- Thrust Blocks & Anchors

Fire Training Area

- Location

- Facilities

Fire Equipment

16, Product packaging

LPG Bottling Facility

- Type,

- Open, sheltered, enclosed

- Empty bottle receiving

- Filling

- Full bottle storage

- Bottle shipping

- Truck scales (weighbridge)

Lube Oil packaging facility

- Type

- Sheltered

- Enclosed

- Size

Shipping method

- Truck

- Rail


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17, Solids Storage & Disposal

Type

- Sulphur

- Coke

- Treated waste

Consistency

- Dry

- Semi-dry

Storage

- Open

- Sheltered

Disposal

- On property

- Off property

Shipping method

- Truck

- Rail

- Barge

- Other

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Section v - Field Issues

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