Defining Offsite Facilities for Process Plants

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
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.
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; s street, 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) --
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
- 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
- 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
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
- 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
- -- 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
- 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)
- 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
- 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
- Prevailing Wind (Wind Rose)
- Collection System
Incinerator Utilities
- Fuel Gas
- Pilot Gas
- Igniter Line
- Atomizing Steam
Thermal Oxidizers
- Location Criteria
- Prevailing Wind (Wind Rose)
- 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
- 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
- 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
- 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
- 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
- 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
- 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)
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
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
- 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
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 --
- 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
- 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

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