DESIGN MANUALSEM - 3118EPiping Design

Tankyard Piping

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Table of Contents

1. General Page1.1 Purpose -------------------------------------------------------------------------------------------------- 11.2 Scope ----------------------------------------------------------------------------------------------------- 11.3 Reference ----------------------------------------------------------------------------------------------- 1

2. Type of Tank2.1 Classification by Shape of Tank ---------------------------------------------------------------- 12.2 Classification by Installing Method of Tank -------------------------------------------------- 2

3. Arrangement Plan3.1 Tank ------------------------------------------------------------------------------------------------------ 53.2 Dike ------------------------------------------------------------------------------------------------------- 63.3 Pipe Rack and Sleeper ---------------------------------------------------------------------------- 83.4 Pump Station ------------------------------------------------------------------------------------------ 83.5 Stair Way ----------------------------------------------------------------------------------------------- 93.6 Drainage ------------------------------------------------------------------------------------------------- 11

4. Tankyard Piping4.1 Process and Utility Piping ------------------------------------------------------------------------- 114.2 Fire Extinguishing Piping --------------------------------------------------------------------------- 13

5. Tank Nozzle Orientation5.1 Cylindrical Tank --------------------------------------------------------------------------------------- 155.2 Spherical Tank ---------------------------------------------------------------------------------------- 165.3 Horizontal Tank --------------------------------------------------------------------------------------- 17

6. Revision History ----------------------------------------------------------------------------------------------- 17

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1. General

1.1 Purpose

This Manual has its purpose on increasing efficiency for piping design of tankyard in a plantdesigned by SECL and providing uniformity.

1.2 Scope

This Manual is applicable to the piping design around storage tank which is included in the offsitefacilities of plant designed by SECL. But, if the Job specification (client's request or contractcontents) and contents of this manual disagrees, primarily apply the Job specification.

1.3 Reference

1.3.1 H-101E "Piping Design"1.3.2 SEM-2002E "Plant Layout Standard"1.3.3 SEM-2006E "Design Standard of Tankyard by NFPA 30"1.3.4 SEM-3015E "Underground Piping"1.3.5 SEM-3036E "Rack Piping"1.3.6 SEM-3039E "Piping Design Standard"1.3.7 SEM-3074E "Pump Piping"1.3.8 6310-500-001 "Arrangement Standard by Domestic Law"1.3.9 6310-500-002 "Arrangement Standard by Foreign Law"1.3.10 6310-500-024 "Design Standard of Fire Extinguishing for Each Fire Extinguishing Facility"

2. Type of Tank

2.1 Classification by Shape of Tank

2.1.1 Cylindrical Type(1) Cone Roof Tank

Low pressure container which is generally used type of tank, used for storing utilitiessuch as oil, chemicals, refined oil, food, and water.

(2) Floating Roof TankA tank applied for storage of hazardous substances with high volatility and large-capacity because it can minimize the vapor loss by moving the roof of container upand down.

(3) Dome Roof TankLow pressure tank mainly storing gas liquefied at the boiling point (Ammonia,Propane, Methane, etc.)

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2.1.2 Spherical Type TankTank mainly storing gas, used for high pressure.

2.1.3 Horizontal or Bullet TypeUsed for high pressure, and shall be installed with a Berm on the head side as it isshown below [Fig. 2-1] in order to minimize damage to near by facilities and human livesin case of explosion.

[Fig. 2-1] Horizontal Tank

2.2 Classification by Installing Method of Tank

2.2.1 Ground-installed Type

(1) Earth Foundation (Compacted Fill Foundation)Applied to large capacity tank, minimizing origination of settlement by doingcompacted fill like [Fig. 2-2].

[Fig. 2-2] Compacted Fill Tank Pad

(2) Concrete FoundationMost general type, mainly applied to small capacity tanks.

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(3) Concrete Ring Wall FoundationMake concrete ring outside foundation and inside, it is totally filled with soil bycompacted fill and filling soil on the concrete ring. Generally applicable when thebase elevation of tank is high.

(4) Concrete Slab FoundationApply to low pressure tank which should block the earth heat transmitted from theground, and maintain some gap (Min.300mm ~ Max.1800mm) under the slab as [Fig.2-3].

[Fig. 2-3] Concrete Slab Foundation

2.2.2 Underground-installed Type

(1) Underground LayingMethod to completely lay a tank under the ground in order to protect fromtemperature change, explosion, fire from outside, etc. Details are as follows.

1) Method to lay directly under the ground2) Method to install a tank inside the Concrete Wall3) Method to fill soil or sand between the wall and tank4) Method to install a tank inside tunnel (for special case )5) Method to store using water layer after excavating rock(for special case )

(2) Half-underground LayingA type considering merits of underground storage and economic efficiency, which isto be installed in following ways to minimize excavation.1) Method to lay directly on earth

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2) Method to install a tank inside concrete wall3) Method to fill earth or sand between the concrete wall and tank4) Method to do steel lining inside concrete wall

For Underground Laying

For Half-Underground Laying

For Ground Laying

[Fig. 2-4] Tank Laying

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3. Arrangement Plan

The locations and distance of Tank, Dike, Pipe Rack, Sleeper, Pump Station,etc are organized earlyduring general layout planning based on the manual (SEM-2002E, SEM-2006E) and related laws.Therefore, this manual only mentions other matters.

3.1 Tank3.1.1 Consider economic efficiency, safety and process characteristics during arrangement, putting

on lower area for the whole site.3.1.2 Do grouping by tanks with the same characteristics of storing contents as [Fig. 3-1], and

specially put aside tanks with other characteristics.3.1.3 Arrangement of tanks shall be single or double so that it becomes easy for approaching

and fire extinguishing in case of disaster.

[Fig. 3-1] Tank Grouping

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3.1.4 A tank that needs to load or unload contents should be arranged near road.3.1.5 A foam Tank for fire extinguishing should be arranged as far as possible from a tank

containing dangerous contents or corresponding dike.3.1.6 Decide the height of tank foundation by considering the height of pump suction, which

should be 300mm at least.

3.2 Dike

3.2.1 Installation of Dike

(1) Install dikes around tank required by the law or code, preventing spread of spilledstored fluid .

(2) The height of dike, distance between a tank and dike, maximum number of tanks inone dike, necessity of a middle dike, etc. should be designed under related laws andcodes since it differs by the type of stored fluid .

[Fig. 3-2] Dike & Intermediate Dike

(3) If the upper part of dike is to be used as inspection passage also, make the width ofdike 800mm at least.

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3.2.2 Type of Dike

(1) Concrete Dike(2) Earth Dike(3) Mix of Earth and Concrete, etc.

3.2.3 Calculation of Capacity(Height) of Dike

(1) Calculation of capacity is generally done based on the maximum storage tank in dike,but details should follow related laws and codes and be checked by the fireextinguishing design manager.

(2) Domestic law regulates the height of dike as 0.5 ~ 3.0m from the inside ground ofdike, but generally apply 1.0~1.5m. (NFPA recommends 1.8m)

(3) For the exact calculation of the capacity(height) of dike, refer to the following formula.

Dike Capacity= Capacity of the Largest Tank + Foundation Volume of Each Tank

+ Area of Tank excluding the Largest Tank × ( Height of Dike - FoundationHeight of Each Tank)

(4) Make it little bigger than the calculated capacity (5~10%) considering pipe, sleeper,stairway, etc. that are to be installed in dike.

3.2.4 Dike Penetration Method

Penetration of a dike should be limited as much as possible, but if it is inevitable such asPump Suction piping, select as it fits to the design(fluid) conditions with following methodsby referring to [Picture 3-3] in order to prevent fluid leakage through the penetration part.

(1) Penetrate dike with sleeve and seal the gap between sleeve and pipe with asphaltpitch, urethane foaming, mortar, and other caulking materials. (But, the used materialmust be proper to the fluid, and the sleeve should be in one level larger size thanthe pipe)

(2) Install the Penetration Plate, welding with pipe to prevent leakage.(3) Make the penetration part in box form, and seal inside with clay or sand or materials

of item (1).(4) Method to lay/execute pipe directly on dike(5) Method to lay pipe under the dike footing (But, Low Point Pocket originates)

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[Fig. 3-3] Dike Penetration Seal3.3 Pipe Rack and Sleeper

3.3.1 Design as it becomes the shortest distance for the Pipe Racks or Sleepers3.3.2 Consider pipe rack for the following areas in tankyard.

(1) Section necessary for vehicle approach(2) Road crossing(3) Section with slope or no pocket pipe such as flare line

3.3.3 Install sleeper inside a dike as much as possible, and decide the height of sleeper byconsidering tank nozzle, height of pump suction and dike, and especially design so that it islower than the height of dike.

3.3.4 The first layer of sleeper should be concrete, and the upper side that contacts with pipeshould be steel(insert plate).

3.3.5 If the sleeper is to be organized more than two tier, make it mix structure of concrete andsteel.

3.3.6 Design the sleeper as low as possible.

3.4 Pump Station3.4.1 Do not distribute pumps in various locations, and install on one location in a group.3.4.2 Install pumps in group so that the number of pump station can be minimized.3.4.3 The pump station is to be installed as near as possible from tank.3.4.4 If there are a lot of tanks, also consider the design with more than two pump stations to

make the distance of pump suction pipe shortest.3.4.5 Arrange pump station near road considering pump operation and repair.

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3.4.6 Decide the height of Pump Foundation by considering the location of related tank nozzle,which is to be at least 300mm.

3.4.7 Install the spill wall with the height of 150~300mm for pump station so that in case ofprocess fluid leakage it does not spread out.

3.4.8 Design to install trench and drain pit inside the pump station to converge drainage, andconverged fluid is to be connected to the corresponding U/G sewer system.

3.4.9 Paving and spill wall do not have to be installed around the pump that transports the fluidevaporated with liquefied gas during leakage or the non-contaminate fluid.

3.5 Stair Way

3.5.1 Installing Location(1) Location where dike entrance and exit are needed(2) Location where a person should go through sleeper for inspection(3) Location where valves and equipments installed on sleeper are needed to be operated

and inspected(4) Location where valves and equipments installed on tank are needed to be operated

and inspected(5) Location where operation of valve around pump and passage are needed

3.5.2 Points to be considered during Designing Stair Way for Dike(1) Stairs installed around dike must follow the width and distance required by related laws or

codes.

[Fig. 3-4] Access Route

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(2) The width of stair must be more than 1.5m based on the domestic law, and thedistance between stairs must be in 50m along the circumference of dike, andgenerally apply concrete structure.

(3) For the installing location of stair way, consider the inspection of tankyard andapproach of passage as [Picture 3-4], and make sure there are in the same form.

(4) When a slope is to be installed instead of stair way, the slope must be in 30 degrees.

3.5.3 Matters to be considered during Designing Stair Way for Tank(1) Generally, for the tank diameter of over 10m or the height of over 6m or special case

it is planned for stair way, and if not a casing ladder is installed.(2) Select between the following shapes by tank size, height, machinery, geological design

condition, etc.1) Install circular stair way directly on tank2) Install pipe column next to tank and install spiral type stair way3) Organize structure next to tank and install stair way4) Install straight stair way

[Fig. 3-4] Circular Stair Way

(3) Generally the installing degree of stair way is to be about 35( MAX. 42), and thewidth is 900 ~ 1200mm, the middle platform is appropriate to be installed in 4m atmost.

(4) If more than 2 Tanks are to be installed with one stair way, it should be planned tobe easy for emergency exit and approach in case of disaster.

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(5) Do not connect the platform and stairway installed on top of the tank and maintaincertain gap so that in case of disaster the tank explodes only to the top whichminimizes damage.

(6) Design stair way or the entrance of ladder in the same direction or symmetrically byconsidering main passage of tankyard.

(7) Install stair way or ladder on the sunny side for cold site.

3.6 Drainage

3.6.1 Should collect drainage by installing trench and drain pit inside dike and pump station. But,it is good not to consider for the fluid that evaporates during leakage such as liquefied gas.

3.6.2 Design it for the converged fluid to be discharged separately between oily and non-oily.

4. Tankyard Piping

4.1 Process and Utility Piping

4.1.1 Design piping around tank inside dike basically as sleeper piping.4.1.2 For piping on a sleeper, arrange utility piping in the middle as [Fig. 4-1], and on both

sides, arrange process piping connected on tank to the side with corresponding tank.

[Fig. 4-1] Sleeper Piping

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4.1.3 Piping inside dike that is not related to tank should not go through inside dike.4.1.4 Design that piping so that it does not penetrate dike as possible except pump suction pipe.4.1.5 Make sure there is no air pocket part in pump suction pipe.4.1.6 Pump suction pipe that penetrates dike should be flexible so that heavy load by thermal

expansion does not influence pump nozzle.4.1.7 Install the first valve between blind flange and pipe directly on tank nozzle.4.1.8 If a large(heavy) valve is attached directly to tank nozzle, check if the nozzle should be

reinforced. Examine following reinforcing method by discussing with the machinery manager.

(1) Method to attach reinforcement pad(2) Method to attach support to the tank shell(3) Method to attach support to the tank foundation

4.1.9 Install emergency shutdown valve as near as possible to tank.4.1.10 If the block valve for safety valve is a gate valve, install it to straight pipe so that if any

disc problem occurs because of corrosion it can be maintained in open form.4.1.11 Piping installed in dike should be supported by U bolt or in a shape that is able to hold so

that the piping does not float up by buoyancy in case of rain or contents leakage.4.1.12 For locations predicted for possible tank settlement, select between following plans and

reflect it to design.(1) Installation of L type or type horizontal loop(2) Install Flexible Tube (apply only to less than 6", pressure less than 15㎠/㎏)(3) Install Expansion Joint (apply if design pressure is high or piping size is big)(4) Install Adjustable Type Support (first support from tank nozzle)

[Fig. 4-2] Pump Suction Piping

4.1.13 Support for the piping installed on top of tank is to be Resting Type.4.1.14 Drainage discharged from tank is to be connected by trench or sump box through laid pipe

by receiving with Drip Funnel.

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4.1.15 If the Tank Foundation is Earth, make sure that sleeper, piping, support, etc. are notinstalled on the side or top of Earth Foundation.

4.1.16 Lateral displacement Volume by the Length of Flexible Tube should be designed byreferring to [Table 4-1] below.

[Table 4-1] Maximum Displacement and Bending Range by the Length of Flexible Tube

(Unit:mm)

Size(Inch)

lateral displacement Volume (d) by Tube Length (L)BendingRange500 800 1000 1300 1500 2000

2 35 100 150 225 300 750

3 25 85 140 200 275 850

4 20 65 100 185 250 1200

6 - 35 70 110 175 250 1400

4.2 Fire Extinguishing Piping

For detail design standard about fire extinguishing piping, refer to the piping registration technicaldata 6310-500-024 "Fire Extinguishing Facility Design Standard for Each Fire Extinguishing Facility”and related regulations.

4.2.1 Water Spraying Fire Extinguishing Facility(1) General

1) Fire extinguishing water cannot be used for other purposes.2) Fire extinguishing piping of tankyard is generally to be laid except inside dike.3) Fire extinguishing piping inside dike is to be installed on the ground around tank.

(2) Hydrant System Piping1) Main piping should be planned to make loop shape around each area as [Picture

4-3].2) Install block valves on the main piping so that it can block the zone.3) Install blind flange if additional execution is predictable.

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[Fig. 4-3] Loop of Fire Extinguishing Piping

(3) Water-Spray and Deluge Systems1) For an old fashioned tank, protect the top surface with Top-Nozzle-Deluge

System, and protect the bottom surface with Bottom-Spray System.2) For a cone roof tank that is storing liquefied oil gas, protect roof by Top-Nozzle-

Deluge System or Drencher System, and protect sides with Drencher System.3) Install Distribution Valve and Main Valve at a safe area outside dike more than

15m distant from the outer surface of tank.4) Must install strainer between Main Valve and Distribution Header, and use

Galvanized Pipe for downstream side of strainer.5) Make the piping inside dike on the ground, and install Drain Valve.6) Make sure fire extinguishing piping does not penetrates dike.

(4) Steam Curtain1) If the length of Steam Curtain Header exceeds 15m, steam should be supplied

on both sides, and the material of Header should be Stainless Steel Pipe.2) Use manual controlling valve, and set it more than 15m distant from the object

and Steam Curtain Header so that it becomes easy to approach in case of gasleakage.

3) Install Steam Curtain Header inside Trench as [Fig. 4-4].

[Fig. 4-4] Steam Curtain Detail

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(5) Sprinkler System1) Install strainer at the entrance part of piping, and use galvanized pipe for the

posterior part of strainer.2) Generally install in Warehouse, Bagging Warehouse, etc.

4.2.2 Foam Fire Extinguishing Facility

(1) Foam fire extinguishing facility should be designed that foam solution in foam hydrantor foam chamber can be supplied from both the pressure balance tank and air-foamfire truck.

(2) If more than two foam chambers are to be installed in one tank, install foamchambers on the outer surface of tank in a fixed distance, and organize piping so thatsame amount of foam is distributed from each chamber.

(3) Foam solution pipe does not have to form a loop.(4) Foam solution piping inside tank dike is to be on the ground and should not penetrate

dike.(5) Foam solution pipe should maintain al least the slope of 1/250, and install drain valve

at the lowest location so that the foam solution in pipe can be totally discharged. Fora laid pipe, install pit for Drain Valve.

(6) Must install strainer on the water piping supplying to foam solution tank.(7) Install foam solution tank and manually operated control valve outside dike, and make

the distance at least 15m from the outer surface of tank.(8) Install the block valve for hydrant piping for foam extinguishing outside dike. Install in

group as possible, and make the distance at least 15m from the outer surface oftank.

(9) Install foam solution tank as close as possible to the Control Room.(10) If a pipe for Form Chamber or Spray is supplied by Tank Vender, make the height of

Connection Flange about 1.5m from the ground.

5. Tank Nozzle Orientation5.1 Cylindrical Type

5.1.1 For a tank that should have equivalent concentration, temperature, etc. or the contents intank gets corroded if they remain in, make the location of inlet and outlet in oppositedirection as possible.

5.1.2 Design Overflow Nozzle in the same direction with Drain Nozzle in order to make lineconnection easy.

5.1.3 Install Drain Nozzle in direction of Outlet Nozzle connected to Pump Suction to makeconnection with Pump Suction piping easy, and make Valve Operation in near location.

5.1.4 Nozzle for instrument should be installed at the location with little influence of fluid feed,and it is generally installed at 30 degrees apart from left and right of inlet nozzle.

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5.1.5 Install Level Gage and Level Controller on the Outlet Nozzle side, and it should be whereoperator's approach and control are easy.

5.1.6 Nozzle including manhole installed on the roof is to be installed at one place as possibleso that approach and installation of PF are easy.

5.1.7 Floating Type Level Gauge, Gauge Hatch, and Other System Nozzle installed on Roofshould be installed where approach from PF is easy, but avoid the stair way side.

5.1.8 Install Side Manhole near Drain Nozzle, and arrange it in the direction where wind comesin for ventilation.

5.1.9 Roof Manhole is to be arranged at where the degrees with side manhole os from 90 to180 considering ventilation.

5.1.10 PF installed on roof is to be designed to approach from Stair Way, and make the width atleast 1.0m. For necessary part, install by extending PF, but minimize as much as possible.

5.1.11 Handrail installed on the side of Roof should be installed more than 1.0m from the neededpart.

5.1.12 If the height of Tank is over 10m, install Intermediate PF.

5.2 Spherical Type

5.2.1 General installation height of tank is based on the height of lower part Nozzle, and installas low as possible but at least 1.5m.

5.2.2 Make the distance between Nozzles so that it does not interfere with the next Nozzle andthe Component installed on it, and design Nozzle Elevation in the same height as possible.

5.2.3 The projection of upper nozzle should be at least 100mm from PF TOS(Top of Structure)as [Picture 5-1] so that there is no problem in Bolting work. Especially, when large diameteror high pressure flange is used, calculate necessary projection value by detail calculation.

[Fig. 5-1] Nozzle Projection

5.2.4 Same type of Nozzles are to be installed in group.5.2.5 Install PF on the upper part to make approach to related nozzle easy.5.2.6 Design the installation direction of fire extinguishing spray piping as it does not interfere

other piping and nozzle, and the height of Connection Flange is to be about 1.5m from theground.

5.2.7 All upper part nozzles should be planned to be installed in PF, and the width of PF should

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be over 1.0m.

5.3 Horizontal Type

5.3.1 Generally an inlet nozzle is installed on upper side, being arranged in the opposite directionwith Outlet Nozzle.

5.3.2 Outlet and Instrument Nozzle are installed in the opposite side of Feed Nozzle (maximumdistance).

5.3.3 Drain Nozzle is to be arranged in the opposite direction with Inlet Nozzle, and if theequipment is installed as slope, install at low point.

5.3.4 Arrange Vent and Safety Valve Nozzle in the direction of Outlet Nozzle.5.3.5 Locations where Internal Piping is at and damage of equipments are worried during opening

manhole are excluded from installation locations.5.3.6 If the manhole and an item needed to be controlled and inspected are over 2.1m apart

from the ground, install PF on the top or side of tank. But, if there is no valve andequipment, install PF only for where more than 3.6m apart from the ground.

5.3.7 The width of PF is to be at least 1m.

6. Revision History

REV. DATE PAGE DISCRIPTION

0 2000.12.12 - - Newly Established

- Department : Piping TeamPrepared by : Lee, Joo SangReviewed by : Kim, Gi PilApproved by : Lee, Myung Hak

0 2003.10.31 ALL

- RevisionAdjusted/Complemented based on SEM-0002 "EngineeringManual Framing Guide". Also, to be consistent with thepurpose of this manual, general explanation is omitted and it isreorganized by the contents applied in actual jobs andrecommended by related exclusive books.

- Department : Planning & Piping Engineering TeamPrepared by : No, Hui KwonReviewed by : Kim, Gi Pil (Proposal Team)Approved by : Kim, Suk Gi