PRIMA HFE Orange Book - Rev-2 1

Shell Pernis PRIMA Projects HE 09.
019
Human Factors Engineering - Workplace Design Specification Rev. 2.0
DOCUMENT HISTORY
• The custodian must approve all revisions to this document.

• Original E-copy will be stored in Livelink.
REVISION STATUS APPROVAL

Rev. Date Description Prepared by CAH Pernis
Custodian Owner
Shell Canada Oil Sands original
00 April 08
document (the ‘Green Book’)
First draft –for Pernis and SGSL
0.1 Mar. ’09 Rob Saunders Ron McLeod
review.
Final draft – Pernis ‘Orange
1.0 May ‘09 ” ”
Book’
2.0 July ‘09 Revised re Bouwbesluit " “
Page 2 of 105
Shell Pernis PRIMA Projects HE 09.019
TABLE OF CONTENTS
1.0 INTRODUCTION ...................................................................................................................................11

1.1 PURPOSE..................................................................................................................................... 11
1.2 SCOPE & STRUCTURE OF DOCUMENT................................................................................... 11
1.3 HIERARCHY OF SOURCES ........................................................................................................ 11
1.4 DEFINITIONS ............................................................................................................................... 12
1.5 RESPONSIBILITY......................................................................................................................... 12
1.6 ERRORS & OMISSIONS .............................................................................................................. 13
1.7 COMMENTS ON THIS DOCUMENT............................................................................................ 13
1.8 REFERENCES.............................................................................................................................. 14
1.8.1 V.26 Design Engineering Practices ................................................................................... 14
1.8.2 Standard Drawings............................................................................................................. 15
1.8.3 Other/External Standards................................................................................................... 15
2.0 HUMAN FACTORS OBJECTIVES .......................................................................................................17
2.1 OPERABILITY............................................................................................................................... 17
2.2 MAINTAINABILITY........................................................................................................................ 17
2.3 ACCESS/EGRESS ....................................................................................................................... 17
2.4 MANUAL MATERIALS HANDLING .............................................................................................. 17
2.5 COMMUNICATION & LABELLING............................................................................................... 17
2.6 ENVIRONMENTAL ....................................................................................................................... 17
3.0 STRUCTURAL DESIGN REQUIREMENTS .........................................................................................19
3.1 EMERGENCY EGRESS ............................................................................................................... 19
3.1.1 Safe Egress ........................................................................................................................... 19
3.1.2 Doors in Egress Route........................................................................................................... 19
3.2 WALKWAYS ................................................................................................................................. 19
3.2.1 Headroom .............................................................................................................................. 19
3.2.2 Width...................................................................................................................................... 19
3.2.3 Over Ground-level Pipes ....................................................................................................... 19
3.2.4 Interconnecting Walkways ..................................................................................................... 19
3.2.5 Buildings: Doors & Corridors ................................................................................................. 19
3.3 STAIRS & LADDERS.................................................................................................................... 19
3.3.1 Use......................................................................................................................................... 19
3.3.2 Stairways ............................................................................................................................... 20
3.3.3 Ladders .................................................................................................................................. 20
3.3.4 Ramps/Sloped Walkways ...................................................................................................... 20
3.4 DESIGN OF STAIRS .................................................................................................................... 20
3.4.1 Width...................................................................................................................................... 20
3.4.2 Consistency ........................................................................................................................... 20
3.4.3 Stair Angle ............................................................................................................................. 20
3.4.4 Risers & Treads ..................................................................................................................... 20
3.4.5 Number of Steps .................................................................................................................... 21
3.4.6 Headroom .............................................................................................................................. 21
3.4.7 Landings ................................................................................................................................ 21
3.4.8 Handrails................................................................................................................................ 21
3.5 DESIGN OF FIXED LADDERS..................................................................................................... 22
3.5.1 Dimensions & Clearance ....................................................................................................... 22
3.5.2 Rungs..................................................................................................................................... 22
3.5.3 Side-step................................................................................................................................ 22
3.5.4 Cage ...................................................................................................................................... 22
3.5.5 Landings ................................................................................................................................ 23
3.6 PLATFORMS & DECKS ............................................................................................................... 23
3.6.1 Clearance............................................................................................................................... 23
3.6.2 Connected Decks .................................................................................................................. 24
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3.7 GUARDRAILS............................................................................................................................... 24
3.7.1 Design & Installation .............................................................................................................. 24
3.8 TOE BOARDS............................................................................................................................... 24
3.8.1 Design.................................................................................................................................... 24
3.9 SIGNAGE ...................................................................................................................................... 24
3.10 MAN-WAY DIMENSIONS ......................................................................................................... 25
3.10.1 Universal - Columns, Vessels, Tubulars, etc......................................................................... 25
3.10.2 Columns – Cylindrical & Conical Skirt ................................................................................... 25
3.10.3 Furnaces & Related ............................................................................................................... 25
3.10.4 Storage tanks......................................................................................................................... 25
3.10.5 Columns................................................................................................................................. 25
3.10.6 Column Trays......................................................................................................................... 25
3.10.7 Pressure Vessels ................................................................................................................... 26
3.10.8 Water Tube Boilers ................................................................................................................ 26
3.10.9 Fired Heaters ......................................................................................................................... 26
3.11 ADDITIONAL REQUIREMENTS............................................................................................... 27
3.11.1 Emergency Egress ............................................................................................................. 27
3.11.2 Secondary Means of Escape ............................................................................................. 27
3.11.3 Walking Surface ................................................................................................................. 28
3.11.4 Floor-plate, Grating/ Decking ............................................................................................. 28
3.11.5 Finishing ............................................................................................................................. 28
3.11.6 Walkway Width................................................................................................................... 28
3.11.7 Stairways............................................................................................................................ 29
3.11.8 Ramps ................................................................................................................................ 29
3.11.9 Stair Treads........................................................................................................................ 29
3.11.10 Handrails ............................................................................................................................ 29
3.11.11 Ladder Orientation ............................................................................................................. 30
3.11.12 Ladder Reach..................................................................................................................... 30
3.11.13 Ladder Dimensions & Clearance ....................................................................................... 30
3.11.14 Ladder Rungs..................................................................................................................... 30
3.11.15 Step-through Ladders ........................................................................................................ 30
3.11.16 Gate.................................................................................................................................... 30
3.11.17 Landings............................................................................................................................. 31
3.11.18 Platforms & Decks.............................................................................................................. 31
3.11.19 Platform Clearance ............................................................................................................ 31
3.11.20 Platform Space................................................................................................................... 31
3.11.21 Platform live-loads.............................................................................................................. 32
3.11.22 Guardrails........................................................................................................................... 32
3.11.23 Toe-plate & Pipes............................................................................................................... 32
3.11.24 Manway Clearance ............................................................................................................ 33
3.11.25 Manway Size ...................................................................................................................... 33
3.11.26 Vessel Skirt Manways ........................................................................................................ 34
4.0 EQUIPMENT LAYOUT & ACCESS......................................................................................................35
4.1 GENERAL WORKER ACCESS.................................................................................................... 35
4.1.1 Worker Envelope ................................................................................................................... 35
4.1.2 Access & Clearance .............................................................................................................. 35
4.2 COLUMNS & INTERNALS ........................................................................................................... 36
4.2.1 Access – Installation & Removal ........................................................................................... 36
4.2.2 Fractionating Tray Installation & Removal ............................................................................. 36
4.2.3 Fractionating Trays & Access Within ..................................................................................... 37
4.2.4 Draw-off Trays, Liquid Collectors & Gravity Liquid Distributors............................................. 38
4.2.5 - and provisions for installation and removal ........................................................................ 38
4.2.6 - and provisions for access ................................................................................................... 38
4.2.7 Gravity liquid distributors ....................................................................................................... 38
4.2.8 Packing & Loads .................................................................................................................... 38
4.2.9 Packing & Provisions for Installation & Removal................................................................... 39
4.2.10 Feed Inlet Device - Installation & Removal............................................................................ 39
4.2.11 O & M Tasks & Considerations (Columns, Reactors, Vessels)............................................. 39
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4.3 PRESSURE VESSELS ................................................................................................................. 39

4.3.1 Grouping ................................................................................................................................ 39
4.3.2 Manholes & Inspection Openings .......................................................................................... 40
4.4 GAS & LIQUID SEPARATORS .................................................................................................... 40
4.4.1 Vessel Accessibility ............................................................................................................... 40
4.4.2 Vane Packs - Mounting.......................................................................................................... 40
4.5 RELIEF SYSTEMS ....................................................................................................................... 41
4.5.1 Platforms................................................................................................................................ 41
4.5.2 O & M Tasks & Considerations.............................................................................................. 41
4.6 FLARE DERRICK ......................................................................................................................... 42
4.6.1 Access ................................................................................................................................... 42
4.6.2 Riser Platform ........................................................................................................................ 42
4.6.3 Heat shields ........................................................................................................................... 42
4.7 AIR COOLERS (FIN FANS).......................................................................................................... 43
4.7.1 Structure ................................................................................................................................ 43
4.7.2 Tube Bundle Design .............................................................................................................. 43
4.7.3 Air-Side Design ...................................................................................................................... 43
4.7.4 Heat Shielding........................................................................................................................ 43
4.7.5 Access Facilities .................................................................................................................... 43
4.8 WATER TUBE BOILERS .............................................................................................................. 44
4.8.1 Design & Engineering - General ............................................................................................ 44
4.8.2 Water Level............................................................................................................................ 44
4.8.3 Drums .................................................................................................................................... 44
4.8.4 Observation............................................................................................................................ 44
4.8.5 Access ................................................................................................................................... 44
4.8.6 Dampers ................................................................................................................................ 45
4.8.7 Steel structure........................................................................................................................ 45
4.9 FIRED PROCESS HEATERS....................................................................................................... 46
4.9.1 Inspection Access .................................................................................................................. 46
4.9.2 Access Door – Box Cabin Heater .......................................................................................... 46
4.9.3 Access Door – Box Vertical Cylindrical Heater...................................................................... 46
4.9.4 Access Door – Damper & Convection ................................................................................... 46
4.9.5 Access Door – Vertical Tube Heaters ................................................................................... 47
4.9.6 Observation Ports .................................................................................................................. 47
4.9.7 Removable Wall..................................................................................................................... 47
4.9.8 Platform Locations ................................................................................................................. 48
4.9.9 Circular Platform .................................................................................................................... 48
4.9.10 Platform Clearance ................................................................................................................ 48
4.9.11 Dual Access ........................................................................................................................... 48
4.9.12 Stairways ............................................................................................................................... 48
4.9.13 Landing .................................................................................................................................. 48
4.9.14 Ladders .................................................................................................................................. 48
4.9.15 Railing .................................................................................................................................... 49
4.9.16 Burner Piping ......................................................................................................................... 49
4.9.17 Damper Controls.................................................................................................................... 49
4.9.18 Combustion Ducts & Plenums ............................................................................................... 49
4.10 ROTATING EQUIPMENT GENERALLY................................................................................... 50
4.10.1 Access ................................................................................................................................... 50
4.10.2 Piping ..................................................................................................................................... 50
4.10.3 Valves .................................................................................................................................... 50
4.10.4 Utility Station .......................................................................................................................... 51
4.10.5 Pumps.................................................................................................................................... 51
4.11 CENTRIFUGAL PUMPS ........................................................................................................... 51
4.11.1 Auxiliary Piping Heat Protection ............................................................................................ 51
4.11.2 Mounting of Auxiliaries........................................................................................................... 51
4.11.3 Flange Alignment ................................................................................................................... 51
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4.11.4 O & M Tasks & Considerations for Pumps & Compressors .................................................. 51
4.12 COMPRESSORS ...................................................................................................................... 52
4.12.1 Layout .................................................................................................................................... 52
4.12.2 Air Compressor Intake Filters – Design & Access................................................................. 52
4.13 CENTRIFUGAL FANS .............................................................................................................. 53
4.13.1 Noise Control ......................................................................................................................... 53
4.13.2 Bolting Access ....................................................................................................................... 53
4.14 LUBRICATION .......................................................................................................................... 53
4.14.1 O & M Tasks and Considerations .......................................................................................... 53
4.15 LUBRICATION, SHAFT-SEALING & CONTROL OIL SYSTEMS & AUXILIARIES ................. 53
4.15.1 Outdoor Operation ................................................................................................................. 53
4.15.2 Accessibility ........................................................................................................................... 54
4.15.3 Filter Access .......................................................................................................................... 54
4.15.4 Transfer Valves...................................................................................................................... 54
4.15.5 Instruments ............................................................................................................................ 54
4.15.6 Self-acting Gas Seal .............................................................................................................. 54
4.16 HGV LOADING FACILITIES ..................................................................................................... 55
4.16.1 Manual Product Flow Control Valves .................................................................................... 55
4.16.2 Top Loading Gantry – Working Platform ............................................................................... 55
4.16.3 Top Loading Gantry – Access Ramp..................................................................................... 55
4.16.4 Top Loading Gantry - Guard Rails......................................................................................... 56
4.16.5 Visibility & Access .................................................................................................................. 56
4.16.6 Other Requirements .............................................................................................................. 56
4.17 ADDITIONAL REQUIREMENTS............................................................................................... 56
4.17.1 Worker Envelope................................................................................................................ 56
4.17.2 Reach Limitations............................................................................................................... 56
4.17.3 Hand Openings .................................................................................................................. 56
4.17.4 Platforms ............................................................................................................................ 57
4.17.5 Standing Surface................................................................................................................ 57
4.17.6 Priority of Access ............................................................................................................... 57
4.17.7 General Equipment Layout ................................................................................................ 57
4.17.8 Relief Valve Location ......................................................................................................... 58
4.17.9 Air Coolers (Fin Fans) ........................................................................................................ 58
4.17.10 Air Cooler Platforms ........................................................................................................... 58
4.17.11 Heat Exchangers................................................................................................................ 59
5.0 INSTRUMENTATION ............................................................................................................................61
5.1 INSTRUMENT NAME AND WARNING PLATES ......................................................................... 61
5.1.1 General .................................................................................................................................. 61
5.1.2 Language ............................................................................................................................... 61
5.1.3 Field-mounted Nameplates.................................................................................................... 61
5.1.4 SIL1 IPF Initiators .................................................................................................................. 61
5.1.5 Other Identification Requirements ......................................................................................... 61
5.1.6 Nameplates for Indoor Use.................................................................................................... 61
5.1.7 Labels inside Instrument Cabinets ........................................................................................ 62
5.1.8 Abbreviations ......................................................................................................................... 62
5.2 PLANT INSTRUMENTS ............................................................................................................... 62
5.2.1 Finish ..................................................................................................................................... 62
5.2.2 Lamp Test Facilities ............................................................................................................... 62
5.2.3 Integral and Receiving Indicators .......................................................................................... 62
5.2.4 Diaphragm Seals ................................................................................................................... 62
5.3 LOCATION AND ACCESSIBILITY ............................................................................................... 62
5.3.1 On-line Instruments ............................................................................................................... 62
5.3.2 Limited accessibility ............................................................................................................... 63
5.3.3 Rodding-out ........................................................................................................................... 63
5.3.4 Insulation Enclosures............................................................................................................. 63
5.3.5 Model Reviews....................................................................................................................... 63
5.3.6 Hoisting Requiremements ..................................................................................................... 64
5.3.7 Toxic Service ......................................................................................................................... 64
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5.3.8 Mounting Height..................................................................................................................... 64

5.4 SPECIFIC INSTRUMENTS .......................................................................................................... 64
5.4.1 Relief Valve Location ............................................................................................................. 64
5.4.2 Level Gauges......................................................................................................................... 64
5.4.3 Positive Displacement Meters ............................................................................................... 65
5.4.4 Displacer Level Instruments .................................................................................................. 65
5.4.5 Pressure Gauges ................................................................................................................... 65
5.4.6 Hydrogen Fluoride Service .................................................................................................... 65
5.5 ADDITIONAL REQUIREMENTS .................................................................................................. 65
5.5.1 Grade access ..................................................................................................................... 65
5.5.2 Instrument Location............................................................................................................ 66
5.5.3 Insulation Enclosures ......................................................................................................... 66
6.0 PIPING...................................................................................................................................................67
6.1 CLEARANCE ................................................................................................................................ 67
6.1.1 General .................................................................................................................................. 67
6.1.2 Flange Clearance .................................................................................................................. 68
6.2 LOW POINT DRAINS ................................................................................................................... 69
6.2.1 Clearance............................................................................................................................... 69
6.3 BLINDS AND SPACERS .............................................................................................................. 69
6.3.1 Access ................................................................................................................................... 69
6.3.2 Hoisting .................................................................................................................................. 69
6.3.3 Blinds - Weight....................................................................................................................... 70
6.3.4 Spacers and Spades - Weight ............................................................................................... 70
6.3.5 Removable Spool and Blind Flange ...................................................................................... 70
6.4 PIPING ADJACENT TO EQUIPMENT ......................................................................................... 71
6.4.1 General .................................................................................................................................. 71
6.4.2 Auxillary Piping ...................................................................................................................... 71
6.4.3 Strainers................................................................................................................................. 71
6.4.4 Heat Exchangers ................................................................................................................... 71
6.4.5 Pressure Vessels ................................................................................................................... 71
6.4.6 Steam..................................................................................................................................... 71
6.4.7 Tank Farms............................................................................................................................ 72
6.4.8 Jetty Loading/ Unloading Facilities ........................................................................................ 72
6.4.9 Hydrogen Fluoride Service .................................................................................................... 72
6.5 PIPELINE PIG-TRAP SYSTEMS.................................................................................................. 72
6.5.1 Valves .................................................................................................................................... 72
6.5.2 End-closures .......................................................................................................................... 72
6.5.3 Safety Devices ....................................................................................................................... 72
6.5.4 Pressure Indicators ................................................................................................................ 73
6.5.5 Sphere Launching/Receiving Pins/Flappers.......................................................................... 73
6.5.6 Layout .................................................................................................................................... 73
6.5.7 Horizontal Pig Traps .............................................................................................................. 74
6.5.8 Vertical Pig Traps .................................................................................................................. 74
6.5.9 Access Platforms ................................................................................................................... 74
6.5.10 Recommended Pig Working-area Dimensions...................................................................... 74
6.6 VALVE ANALYSIS ........................................................................................................................ 75
6.6.1 IVA ......................................................................................................................................... 75
6.6.2 Category 1 Valves ................................................................................................................. 75
6.6.3 Category 2 Valves ................................................................................................................. 75
6.6.4 Category 3 Valves ................................................................................................................. 75
6.6.5 Initial Valve Classification Table ............................................................................................ 77
6.6.6 Deviations .............................................................................................................................. 77
6.7 VALVE SPECIFICS....................................................................................................................... 81
6.7.1 Block Valve and Spades........................................................................................................ 81
6.7.2 Wafer and Lug Valves ........................................................................................................... 81
6.7.3 Chain Valves.......................................................................................................................... 81
6.7.4 Location ................................................................................................................................. 81
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6.7.5 Stems in Horizontal Pipes...................................................................................................... 81

6.7.6 Hand-Wheels ......................................................................................................................... 81
6.7.7 Control Valves – Dismantling and Hoisting ........................................................................... 82
6.8 SAMPLE POINTS ON PIPING ..................................................................................................... 82
6.8.1 Location ................................................................................................................................. 82
6.8.2 Connections ........................................................................................................................... 82
6.9.1 Access & Clearances ......................................................................................................... 83
6.9.2 Flange Height ..................................................................................................................... 83
6.9.3 Low-point Drains ................................................................................................................ 84
6.9.4 Sewer Cups........................................................................................................................ 84
6.9.5 Stand-alone Vessels .......................................................................................................... 85
6.9.6 Multiple Valve Sets on Single Deck ................................................................................... 85
6.9.7 Pump Drains....................................................................................................................... 86
6.9.8 Cleaning ............................................................................................................................. 86
6.9.9 Blinds & Spacer Storage .................................................................................................... 86
6.9.10 Orientation.......................................................................................................................... 86
6.9.11 Installation .......................................................................................................................... 86
6.9.12 Differentiation ..................................................................................................................... 86
6.9.13 Emergency Shut-down Valves ........................................................................................... 86
6.9.14 Valve Location.................................................................................................................... 86
6.9.15 Sample Point Location ....................................................................................................... 87
6.9.16 Accessibility Features ........................................................................................................ 87
6.9.17 Sample Point Location ....................................................................................................... 87
6.9.18 Sample Point Clearance .................................................................................................... 87
6.9.19 Safety ................................................................................................................................. 87
6.9.20 Sampling Connections ....................................................................................................... 87
6.9.21 Sample Bottles and Bombs................................................................................................ 87
6.9.22 Cabinet Drains.................................................................................................................... 88
7.0 STORAGE TANKS................................................................................................................................89
7.1 TANKS – GENERAL DESIGN ...................................................................................................... 89
7.1.1 Accessibility ........................................................................................................................... 89
7.1.2 Primary Wind Girders and Platform ....................................................................................... 89
7.1.3 Man-ways............................................................................................................................... 89
7.1.4 Deck height ............................................................................................................................ 89
7.1.5 Stairways/Walkways .............................................................................................................. 89
7.1.6 Vertical ladders ...................................................................................................................... 89
7.1.7 Liquid Level Alarms/Indication System .................................................................................. 90
7.2 FLOATING TANK SPECIFICS ..................................................................................................... 90
7.2.1 Access ladders....................................................................................................................... 90
7.2.2 Staircases - Elevated Gauger's Platform............................................................................... 90
7.3.1 Roof Manway ..................................................................................................................... 90
7.3.2 Rescue hatch ..................................................................................................................... 90
7.3.3 Tank Stairways................................................................................................................... 90
7.3.4 Sample Connections .......................................................................................................... 91
7.3.5 Davitts ................................................................................................................................ 91
7.3.6 Additional Platforms ........................................................................................................... 91
7.3.7 Guard/ handrails................................................................................................................. 91
8.0 PRIMA/PERNIS SPECIFIC EQUIPMENT.............................................................................................93
9.0 MATERIAL HANDLING & HOISTING ..................................................................................................95
9.1 GENERAL REQUIREMENTS ....................................................................................................... 95
9.1.1 National Guideline ................................................................................................................. 95
9.1.2 Lifting limits ............................................................................................................................ 95
9.1.3 Material Handling Study......................................................................................................... 95
9.1.4 Mechanical Lifting Plan.......................................................................................................... 95
9.1.5 Hoisting & Lowering ............................................................................................................... 96
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10.0 AMBIENT ENVIRONMENT...................................................................................................................97

10.1 LIGHTING.................................................................................................................................. 97
10.1.1 National Guidelines................................................................................................................ 97
10.1.2 DEP Requirements ................................................................................................................ 97
10.1.3 Fouling Factor ........................................................................................................................ 97
10.1.4 Illumination Levels ................................................................................................................. 97
10.1.5 Fixture Location ..................................................................................................................... 99
10.1.6 Safety..................................................................................................................................... 99
10.1.7 Stray Light.............................................................................................................................. 99
10.2 NOISE ..................................................................................................................................... 100
10.2.1 Legal Codes......................................................................................................................... 100
10.2.2 Noise Exposure Limits ......................................................................................................... 100
10.2.3 Absolute Noise Limit ............................................................................................................ 100
10.2.4 Work Area Limit ................................................................................................................... 100
10.2.5 Restricted Areas .................................................................................................................. 100
10.2.6 Indoor Limits ........................................................................................................................ 101
11.0 DESIGN REQUIREMENTS FOR BUILDINGS ...................................................................................103
11.1 PLANT BUILDINGS ................................................................................................................ 103
11.1.1 HVAC Systems .................................................................................................................... 103
11.1.2 Control Room....................................................................................................................... 103
11.2 NON-PLANT BUILDINGS ....................................................................................................... 103
11.2.1 HVAC Systems .................................................................................................................... 103
11.2.2 Indoor Environment ............................................................................................................. 103
11.2.3 Dimensions .......................................................................................................................... 103
11.2.4 Office and Computer Workstation Dimensions.................................................................... 103
Page 9 of 105
Page 10 of 105
1.0 INTRODUCTION
1.1 PURPOSE
This document is a collection of minimum acceptable Human Factors Engineering (HFE) requirements for
the design and layout of equipment and work-spaces to be used throughout Pernis PRIMA Projects.
1.2 SCOPE & STRUCTURE OF DOCUMENT
In compliance with Shell Health Management Standards, all new facilities projects must consider human
factors engineering principles during design. The aims are to minimise risk to health as well as to provide
a workplace with easy and safe access for operation and maintenance under all conditions (i.e. normal,
upset/emergency and in all weather conditions).
Requirements and technical specifications for workplace layout are currently spread across a large
number of Shell Design Engineering Practices (V.26 understood), standard drawings and other sources.
This document brings all of these requirements and specifications under a single cover providing a single
point of reference for all workplace design specifications for use by the PRIMA Projects.
The book also provides project managers, engineers, designers and HSE professionals with a convenient
source of HFE-related design detail.
Most of the specifications in this document are directly traceable to existing Shell standards or drawings:
the principle behind this document is not to change or amend existing specifications. The only exceptions
to this are either;
1. where there are specific Dutch regulations that are not consistent with Shell standards.
2. where operational experience requires defining details not currently addressed by a DEP.
Some existing engineering standards require that projects customise dimensions to match the
anthropometrics (human body dimensions) or societal norms of the local workforce, the nature of the work
or the work environment. So far as possible, this document includes these customised details where they
are necessary for the PRIMA projects.
This document does not cover information displays, alarms and controls within the control room and DCS
system. These aspects are covered in DEP 30.00.60.15.GEN Human/Machine Interface and Control
Room Design and DEP 30.00.60.16.GEN Human Machine Interface Design for Situation Awareness.
This document is based on version prepared for the Canadian Oil Sands Project (document OSG-P9.15, Rev
1, Feb 2008). Some of the SCAN material has been retained and is included here in Chapters 3 to 7 as
‘Additional Requirements’ (the final sub-section in each section). This is generally material that is
considered both important and useful (particularly from the experience gained from operations &
maintenance), and/or which addresses an issue existing DEP’s or Drawings do not cover. Where the
original source is a North American Shell standard, this is referenced accordingly.
1.3 HIERARCHY OF SOURCES

There is a Shell Group guideline on the use and application of standards
(http://sww05.europe.shell.com/standards/), addressing principles such as maximising the use of
common, external/international industry standards, minimising the need for additional company
requirements, ensuring any deviations are justified and ensuring a continuous improvement of applied
standards.
Page 11 of 105
Part of this includes a ‘transparent standards structure’, illustrated below as it applies to this document
and it is important to note that there is a hierarchy or priority to the sources of the data it contains.
National law and guidelines
Industry standards
Design & Engineering Practices – DEP’s
Standard drawings
In all cases where it applies, national law or derived guidelines (i.e. Bouwbesluit, AI-bladen) take
precedence. After that, where an external, international/industry standard applies or is relevant, its
specifications form project/design baselines, followed, and supplemented, by Shell Group DEP-GEN’s
(V.26 in this instance) in order to reflect the minimum, additional Group requirements.
Some DEP’s make reference to particular Standard Drawings and these are used to supplement the DEP.
Finally, there are OU and Project Standards which should be referred to in the absence of a standard or
DEP-GEN; (i.e. DEP-SCAN, ESTG’s).
1.4 DEFINITIONS
COMPANY _ Shell Netherlands Refinerie Ltd
CONTRACTOR – Equipment or Module Manufacturer/Vendor and EPC CONTRACTOR
Vendor – Same as CONTRACTOR
Shall/Must – Describes a mandatory requirement. Departure is subject to written approval
Describes a recommendation, which although not explicitly required, should be considered in

Should –
order to optimize workplace usability.
1.5 RESPONSIBILITY
The CONTRACTOR shall be solely responsible for providing complete and operable equipment in full
accordance with the latest edition of applicable Industry Codes/Standards and all Government
Regulations.
This document is intended as a convenient source of HFE content contained in adopted project standards,
but the CONTRACTOR shall be solely responsible for providing equipment and facility structures in
accordance with adopted project standards.
All conflicts between HFE requirements defined herein and other Technical Requirements, applicable
codes and standards including Government Regulations shall be submitted in writing to COMPANY for
resolution.
Page 12 of 105
The CONTRACTOR shall submit in writing to COMPANY any and all exceptions to HFE requirements for
approval. Any applicable impact on cost or schedule must be stated along with the proposed exception.
COMPANY has no obligation to consider or accept any exceptions that have been offered. Any deviations
shall be considered on a case-by-case basis and must receive prior approval from the COMPANY.
Shell Operations and Maintenance personnel shall hold final approval of design details concerning access
to equipment and egress from work-spaces.
1.6 ERRORS & OMISSIONS

This document has been through a number of reviews to ensure accuracy, legislative compliance and
consistency across the four sources: national building regulations; various standards; Shell DEPS and
standard drawings.
If any discrepancies (i.e. a contradiction with a Building Code requirement), errors or omissions are noted
or suspected, please report them to the custodian at the email address in the Comments section below.
1.7 COMMENTS ON THIS DOCUMENT
Comments on this workplace design specification may be sent to rob.saunders@shell.com.
Page 13 of 105
1.8 REFERENCES
1.8.1 V.26 Design Engineering Practices
DEP 30.00.60.10: Human Factors Engineering in Projects, May 2007

DEP 30.00.60.13: Human Factors Engineering - Valve Analysis, May 2004
DEP 30.00.60.14: Human Factors Engineering - Application during Construction, Jan 2005
DEP 30.00.60.15: Human Factors Engineering - Human/Machine Interface & Control Room
Design, March 2005
DEP 30.00.60.16: Human Factors Engineering - Design & Procurement of Skid-Packaged Units,
Nov. 2006
DEP 30.75.10.30 - Water-Tube Boilers, July 1999
DEP 31.06.11.11: Loading Facilities for Bulk Road Vehicles, Aug. 2005
DEP 31.10.00.31: Noise Control – Amendment/Supplement to ISO 15664, May 2004
DEP 31.20.20.31: Internals for Columns, Sep. 2002
DEP 31.21.01.30: Shell & Tube Heat Exchangers (Amends/Supplements ISO 16812), May 2004
DEP 31.21.70.31: Air-Cooled Heat Exchangers (Amends/Supplements to ISO 13706), Mar. 2001
DEP 31.22.05.11: Gas/Liquid Separators – Type, Selection & Design Rules, v26 - Dec. 2007
DEP 31.22.05.12: Liquid/Liquid & Gas/Liquid Separators, v26 - Jan. 2008
DEP 31.22.10.32 - Pressure vessels (Amendments/Supplements to PD 5500), Mar. 2001
DEP 31.24.00.30: Fired Heaters (Amendment/Supplement to ISO 13705), Dec. 2004
DEP 31.29.00.33: Shaft Sealing Systems for Centrifugal & Rotary Pumps (Amends/Supplements
ISO 21049:2004); June 2007
DEP 31.29.02.30: Centrifugal Pumps (Amends/Supplements ISO 13709:2003); June 2007
DEP 31.29.40.10: Compressors - Selection, Testing & Installation; Nov. 2006
DEP 31.29.47.30: Centrifugal Fans (Amends/Supplements API 560 Appendix E); Jan. 1998
DEP 31.29.60.32: Lubrication, Shaft-sealing & Control Oil Systems & Auxiliaries, (Amends/
Supplements API 614); Nov. 2006
DEP 31.38.01.11: Piping Design - General Requirements, Aug. 2005
DEP 31.76.10.10: HVAC for Plant Buildings, July 1998
DEP 31.40.10.13: Design of Pipeline Pig Trap Systems; Nov. 2006
DEP 32.31.00.10: Instrument Engineering Procedures, July 1985
DEP 32.31.00.32: Instruments for Measurement & Control, July 1999
DEP 32.36.01.17: Control Valves – Selection, Sizing & Placement, April 2003
DEP 32.37.10.11: Installation of On-line Instruments, Oct. 2001
DEP 33.64.10.10: Electrical Engineering Design, Jan. 2008
DEP 34.17.00.32: Design and Engineering of Buildings, Sep. 2002
DEP 34.28.00.31: Technical Specification - Steel Structures, July 1996
DEP 34.51.01.31: Vertical Carbon Steel Storage Tanks (based on EN 14015), v26 - Dec. 2007
DEP 80.45.10.10: Design of Pressure Relief, Flare and Vent Systems, July 1996
Page 14 of 105
1.8.2 Standard Drawings
S 10.031-D Hatchway covers

S 10.039-B Pad-type hand holes with cover flange ANS Class 150 & 300 for unfired
carbon steel, low alloy steel and stainless steel pressure vessels
S 20.001-J Skirts, cylindrical and conical
S 24.101-D Observation window for observing burner throats, coils and furnace cell
S 24.102-D Detail of handles and weather protection for observation windows
S 24.108-D Peephole with flapper - 4 inch air-cooled
S 24.109-D Sight glass for 4 inch air-cooled peephole with weather protection
S 24.221-E Access door for furnace bottom
S 24.303-E Sliding plate in flue duct
S 24.304-D Access door for flue duct
S 28.001-B Stairways, general arrangement
S 28.004-B Stairways, intermediate platform
S 28.006/7/8-C Hand-railings; Types A, B & C
S 28.009/10-C Hand-railings, connection of railing to concrete; Types A, B & C
S 28.011–001-H Ladder, general arrangement to columns, stacks and structures
S 28.011–002-O Ladder, general arrangement to columns, stacks and structures
S 51.051-B Handrails for fixed roof tanks
S 51.052-B Handrails for dome roof tanks
S 51.087-B Spiral type staircase provided with stair-treads of galvanised grating
S 51.100-O Single manhole
S 51.127-C Roof manhole 20" or 24" diameter
S 51.130-C Vertical ladder (Tanks up to 6 m height)
S 51.131-C Walkway between tanks
S 51.156-001-O Elevated walkway (galvanized) to centre of a fixed roof tank - cone roof
S 51.156-002-O Elevated walkway (galvanized) to centre of a fixed roof tank - dome roof
S 51.160-O Walkway and wind-girders - slope and welding sequence
S 51.227-A Shell manhole tanks
1.8.3 Other/External Standards
ANSI/IESNA RP-7-01 Recommended Practice for Lighting Industrial Facilities. Annex A2 Figure
A2-3 Recommended Illuminance Values for Specific Industries – Petroleum, chemical and
petrochemical industry.
ASHRAE 62.1-2004 Ventilation for Acceptable Indoor Air Quality
ENG0072SP Human Factors Specifications for Workplaces, Shell Exploration & Production
Company, December 2007
Ergonomics and Health, Chapter 10 Shell Works Toolkit, Shell Real Estate, 2007
ISO 13705: 2006 - Fired Heaters for General Refinery Service
ISO 13706: 2005 - Air-Cooled Heat Exchangers
ISO 15664:2001(E) - Acoustics — Noise Control Design Procedures for Open Plant
ISO 16182: 2007 – Shell and Tube Heat Exchangers
Page 15 of 105
Page 16 of 105
2.0 HUMAN FACTORS OBJECTIVES

2.1 OPERABILITY
Ensure that the layout of equipment allows for easy access during the operation and maintenance of the
units under all normal, upset/emergency and weather conditions by the full range of potential employees
(i.e. 5th percentile female to the 95th percentile male, with personal protective equipment). The operability
of the equipment also ensures the usability of display and control design including local control panels.
This would mean that the placement and orientation of all controls and displays/instruments are
appropriate to ensure safe and effective viewing, reach, and operation by COMPANY personnel.
2.2 MAINTAINABILITY
Ensure the efficient and safe movement of equipment requiring maintenance without removal of other
items such as piping, motors, etc. This includes the provision of adequate space and lay down areas for
all anticipated activities. Consideration should also be given to the provision and configuration of doors
and access hatches.
2.3 ACCESS/EGRESS
Ensure that all areas of the facility and equipment can be accessed and evacuated safely under normal
and emergency conditions.
2.4 MANUAL MATERIALS HANDLING
Ensure requirements for manual lifting, pulling, pushing, and carrying of equipment, with respect for the
biomechanical and physiological capabilities and limitations of the personnel, are included during design.
Associated needs include the availability of mechanical lifting aids for assisted lifting and appropriate
storage or placement of lifting aids for safe reach and effective operation.
2.5 COMMUNICATION & LABELLING
Ensure the clear communication of information and equipment identification, including effective viewing,
reading, and understanding of instructions, signs, labels, operations and maintenance manuals.
2.6 ENVIRONMENTAL
Ensure that environmental requirements regarding noise, lighting, vibration, climatic conditions and indoor
air quality have been addressed to optimize human performance. Environmental requirements to eliminate
or minimize impacts on worker health and safety are included in other standards and not duplicated here.
Page 17 of 105
Page 18 of 105
3.0 STRUCTURAL DESIGN REQUIREMENTS
3.1 EMERGENCY EGRESS

3.1.1 Safe Egress On platforms, the distance to a stair or ladder shall not exceed 25 metres
for accessibility and ease of escape in the event of an emergency.
DEP-34.28.00.31: 2.4.4
3.1.2 Doors in Egress External doors shall always open outwards and in the direction of the
Route escape route.
Revolving doors and sliding doors are not allowed for emergency exits.
DEP 34.17.00.32 6.6.1
3.2 WALKWAYS
3.2.1 Headroom A minimum of 2300 mm of head clearance shall be provided above the
walking surface for the full length and width of all walkways, at the access
point of an area and around equipment, valves, etc. where operators pass.
Bouwbesluit; Article 2.28, 4.11 & 4.12

(supersedes DEP 34.28.00.31: 2.4.4 & DEP 31.38.01.11: 3.3)
3.2.2 Width The minimum unobstructed width of walkways, including walkways on

skids, modules and between equipment and walls or guard-rails shall be
750 mm.
DEP 34.28.00.31: 2.4.4 & DEP 31.38.01.11: 3.3
[NB: Bouwbesluit Articles 2.29 specifies a minimum dimension of 800 x
800 mm for all landings.]
3.2.3 Over Ground-level The minimum width of walkways over ground level pipe racks shall be 800
Pipes mm.
Bouwbesluit; Article 2.28
(supersedes DEP 34.28.00.31: 2.4.4)
3.2.4 Interconnecting Where practical, pressure vessels, which are grouped together shall have
Walkways platforms and interconnecting walkways at the same elevation. The
number of stairways and ladders to the platforms shall be sufficient to
meet safety requirements.
DEP 31.38.01.11: 4.5
3.2.5 Buildings: Doors & The minimum dimensions of access points (i.e. doors) and circulation
Corridors routes (i.e. corridors) for new buildings are a clear unobstructed width of
850 mm, and free passage (headroom/clearance) of 2300 mm.
Bouwbesluit; Articles 4.11 & 4.12
3.3 STAIRS & LADDERS

3.3.1 Use The choice of stairs or fixed vertical ladders should be based on the
purpose and frequency of use: the Valve Criticality Analysis will determine
the access needs for most operating equipment.
Page 19 of 105
3.3.2 Stairways Stairways are required for access to elevated work platforms, walkways,
and other elevated work areas where the frequency of use is once per shift
or less if access is required to Category 1 valves
DEP 31.38.01.11 and DEP 30.00.60.13
3.3.3 Ladders Ladders may be installed instead of staircases if the ladders are only
required for occasional use and escape routes.
DEP 34.28.00.31: 2.4.4
3.3.4 Ramps/Sloped Sloped walkways shall have a maximum 15 degree angle of inclination
Walkways and the walking surface shall be slip-resistant. For inclinations greater
than 5 degrees, cleats shall be added, which run the full width of the
walkway at right angles to the direction of travel.
adapted from ASTM F1166 HFE for Marine Industry
3.4 DESIGN OF STAIRS

3.4.1 Width The minimum width of a staircase for onshore steel structures shall be
800 mm.
(supersedes DEP 34.28.00.31: 2.4.4 & S 28.001/2-B)
For the staircases of new buildings, the minimum width between handrails
shall be 1250 mm.
DEP 34.17.00.32 6.9.2
3.4.2 Consistency The angle of inclination, the width of treads and the height of risers shall
be uniform throughout the length of a stairway. Stairs servicing similar
equipment should be of similar dimensions.
3.4.3 Stair Angle The maximum slope of a stair in a new building shall be 3:4.
DEP 34.17.00.32: 6.9.2
The maximum slope of a stair on a steel structure shall be 5:6.

S 28.001-B
3.4.4 Risers & Treads For risers and goings in new buildings, the following shall apply:
- Risers (R): - Min. 160 mm, maximum 190 mm;

- Goings (G): - Min. 250 mm, maximum 310 mm.
Furthermore, the following rise-to-going/tread ratio shall apply:
- (R x G) min. 48,000 mm2, otherwise too dangerous to descend;

- (R x G) max. 55,000 mm2, otherwise too tiring to ascend.
DEP 34.17.00.32: 6.9.2
For stairs in onshore steel structures, the maximum riser height shall be
200 mm.
S 28.002-B; Note 4.
Page 20 of 105
3.4.5 Number of Steps The maximum height of any staircase shall be 4 metres.
In a new building, no stairway shall exceed 16 rises (steps) in any one

flight; if more are necessary a landing shall be provided.
DEP 34.17.00.32: 6.9.2
On onshore steel structures, any flight of stairs shall not have more than
20 steps. For a single stair, the number of steps shall be 25 maximum.
Maximum height without a change of direction shall be 8 metres (40

steps).
S 28.002-B: Notes 1 - 3.
3.4.6 Headroom Minimum clearance between the top of any stair tread and any obstruction
directly overhead of that tread shall be at least 2300 mm measured from
the leading edge of the tread.
(supersedes DEP 31.38.01.11: 3.3 & DEP 34.17.00.32: 6.9.2)
3.4.7 Landings Stairway platforms, intermediate or straight-run landings shall have a

minimum floor area of 800 x 800 mm.
On tanks, one (1) landing shall be provided every 6 m of vertical rise. For
tanks that do not exceed 20 m in height, no more than 2 intermediate
landings are necessary.
Straight-run landings on tank stairs shall have a minimum length of 1100
mm.
3.4.8 Handrails Hand- or guard-rails shall be provided on stair landings and at any edge or
floor where there is drop of 1 or more metres to grade or the level below or
adjacent.
Hand- or guardrails shall be provided on both sides of the stairs where any
tread is greater than 1 metre over grade or the adjacent level.
Where a hand-railing is installed, floors, platforms and walkways shall be

provided with 100 x 6 mm toe plates.
S 28.007-C
On onshore steel structures, the height of handrail above the leading edge
of the tread shall be 1000 mm and the height of the handrail above the
landing shall be 1100 mm.
Bouwbesluit; Article 2.16 & 2.31;
DEP 34.28.00.31 (S.28.006) & DEP 34.17.00.32: 6.9.2
Page 21 of 105
For platforms with an elevation higher than 13 metres (relative to grade,

water-level or adjacent platform), the height of the hand-rail shall have an
elevation of 1200 mm (to top of grade/decking). An additional mid-rail is
also required in addition to the knee-rail for these elevations.
Lighting fixtures, junction boxes, etc. shall not be supported by the hand-
railing.
GSI Best Practice requirement
3.5 DESIGN OF FIXED LADDERS
3.5.1 Dimensions & Single-stage ladders shall be no longer than 9 metres. Multiple-stage
Clearance ladders shall be staggered every 6 metres.
Ladders shall be 500 mm in width, with ladder rungs spaced on 300 mm
centres. The rungs shall be 20 mm diameter.
A minimum clearance of 200 mm shall be provided between the ladder
rungs and the structure to which it is affixed, including all piping,
electrical conduit, fireproofing, and other protrusions that may be
present.
S 28.011-001-H; Notes 2, 3, 6 & Section A-A
The ladder shall extend at least 1200 mm above the level of the platform
or landing.
S 28.011-001-H; Note 8.
3.5.2 Rungs The surface of the rungs shall have a slip resistant walking surface and
be designed to minimise build up of ice or compacted mud, etc.
ISO 14122:4-2004
3.5.3 Side-step Wherever possible, ladders should be made with a side-step in

preference to step-through ladders.
DEP 34.28.00.31: 2.4.4
Step-through ladders should only be used when a side-step ladder is not

practical, and shall require the approval of the COMPANY.
3.5.4 Cage Ladders serving platforms or landings more than 3 m above grade or
platform shall be fitted with cages.
S 28.011-001-H; Note 4
Ladder cages shall begin at a height not less than 2300 mm or more
than 2700 mm above grade or the landing platform.
Bouwbesluit; Article 4.11 & S 28.011-001-H
Cage dimensions shall be 600 x 760 mm hoops of flat steel, section 40 x

6 mm, centre-to-centre approx. 850 mm with five (5) verticals of flat steel
4 x 6 mm.
S 28.011-001-H; Note 5
Page 22 of 105
For ladders starting at elevated platforms, either the platform handrails

shall be extended, or the safety cage shall be extended (for details, see
the drawings contained in the ISO and Shell Standard Drawing.
ISO 14122:4-2004 and S 28.011-002-O
If a ladder protrudes through a platform, the hole shall be protected by a

cage, open in the direction of the next ladder, and the platform shall be
extended with a walk-around at the back of the cage.
The cage opening shall be protected by a GRP self-closing double-swing
bar.
S 28.011-001-H; Note 14
3.5.5 Landings Single-stage ladders shall be no more than 9 metres in length. Multiple-
stage ladders shall be staggered at least every 6 metres, with a landing
provided.
S 28.011-001-H; Note 2
3.6 PLATFORMS & DECKS
Access to work platforms shall be by either fixed ladder or stairway.

All main platforms shall be provided with an emergency means of escape
leading to ground level
DEP 30.75.10.30: 2.6.3
3.6.1 Clearance Walkways on elevated work platforms for vessels/columns/towers (except
storage spheres – see Item 3.6.3) shall provide a minimum of 750 mm
clear access between any object (including insulation and cladding) and
the guardrail.
DEP 34.28.00.31: 2.4.4 & DEP 31.38.01.11
750 1220 min
750 750
750
Page 23 of 105
3.6.2 Connected Decks Where practical, pressure vessels which are grouped together shall have
platforms and interconnecting walkways at the same elevation. The
number of stairways and ladders to the platforms shall be sufficient to meet
safety requirements.
DEP 31.38.01.11: 4.5
3.7 GUARDRAILS
3.7.1 Design & Installation The top rails of guardrails shall not be less than 1100 mm in height above
the top of the platform and an intermediate knee-rail shall be located
approximately midway between the top rail and the walkway level at 600
mm.
The maximum spacing of railing posts shall be 1500 mm centre to centre.
S28.006
For platforms with an elevation that is higher than 13 m (relative to grade,

water-level or adjacent platform), the hand railing shall have an elevation of
1200 mm (from top of platform grating). An additional mid-rail is also
required in addition to the knee-rail for these elevations.
Higher railings shall be used at certain locations to provide additional

protection for persons climbing short lengths of non-caged ladders located
near the edge of a platform.
ISO 14122:4-2004 and S 28.011-002-O
3.8 TOE BOARDS
3.8.1 Design Where hand-railing is installed, floors, platforms and walkways shall be
provided with toe plates of a minimum of 100 x 6 mm.
S 28.006-C
3.9 SIGNAGE All signage shall comply with the requirements of EU Directive 92/58/EEC
and site code BBS 05.00.1081 - Veiligheids en Gezondheidssignalering.
Page 24 of 105
3.10 MAN-WAY The following table of man-way dimensions is compiled from the Standard
DIMENSIONS Drawings and DEP’s.
Vessel Type: Requirement/Specification Source:
3.10.1 Universal - Columns,

Hatch-way covers, rectangular opening:
Vessels, Tubulars, S 10.031
etc. - 460 x 460 mm (ID) - [18 x 18 in.]
Obround skirt entry (mm): - [20 x 12 in.]
305 150
3.10.2 Columns –
Cylindrical & Conical S 20.001
Skirt 500
Access door - furnace bottom, rectangular:

S 24.221
- 450 x 650 mm (ID) - [18 x 26 in.]
3.10.3 Furnaces & Related
Access door for flue duct, rectangular:

S 24.304
- 800 x 1200 mm (ID) - [32 x 48 in.]
Single manhole, circular opening:

S 51.100
- 750 mm Ø (ID) - [30 in.]
Roof manhole, circular opening:

3.10.4 Storage tanks S 51.127
- 500 or 600 mm Ø (ID) - [20 or 24 in.]
Shell manhole, circular opening:

S 51.227
- 610 mm Ø (ID) - [24.5 in.]
Minimum, circular opening with ID:

3.10.5 Columns - should be at least 610 mm [24 in.], but DEP 31.20.20.31: 2.4
- shall not be less than 460 mm [18 in.].
Minimum opening (obround/elliptical):

3.10.6 Column Trays DEP 31.20.20.31: 3.5
- 320 x 500 mm - [13 x 20 in.]
Page 25 of 105
Vessel Type: Requirement/Specification Source:
Where the above is impossible for

construction reasons, the use of smaller
Column trays cont’d man-ways shall be subject to the approval DEP 31.20.20.31: 3.5
of the Principal. The man-way shall not be
smaller than 270 mm x 450 mm.
Manholes shall have a minimum clear inside

diameter of 460 mm (18 in.)
3.10.7 Pressure Vessels DEP 31.22.10.32: 3.11
However, nominal pipe sizes DN 500 (20
in.), DN 600 (24 in.) and DN 750 (30 in.) are
preferred.
Access/inspection doors in each section or

tube bank, a minimum free opening of:
3.10.8 Water Tube Boilers DEP 30.75.10.30: 2.2.10
- rectangular: 400 x 400 mm (16 x 16 in).
As a minimum one unobstructed access

door shall be provided in the wall of a
vertical box-type heater for access from the
burner platform.
3.10.9 Fired Heaters DEP 31.24.00.30: 12.3.2.1
Minimum, rectangular opening:
- 600 x 900 mm - [20 x 36 in.].
[See Section 4.11 in this document for

further fired heater access requirements].
Page 26 of 105
3.11 ADDITIONAL REQUIREMENTS
3.11.1 Emergency Egress

The length of a dead-end platform shall not exceed 7 metres.
(DEP 80.00.10.11 SCAN 8.8)
Routing of escape ways shall be clear and straightforward and not be

hampered by obstructions from equipment or present tripping hazards.
(DEP 80.00.10.11 SCAN 7.3.3)
Equipment parts, instrumentation, instrument stands, pipe supports,

valve hand-wheels, piping etc. shall not protrude into access and escape
ways.
(DEP 80.00.10.11 SCAN 4.2.3.5)
3.11.2 Secondary Means of Escape at grade towards safe areas shall be provided from all areas by
Escape a minimum of two (2) routes (at opposite directions).
(DEP-80.00.10.11-SCAN 4.2.3.5 & 7.3.3)
A secondary means of egress shall be provided for:

• all platforms serving fired equipment;
• platforms serving two or more pieces of equipment that are
concurrently maintained or operated; and
• elevated platforms serving three or more vessels.
(ESTG 13-1.02 3.6.1)
A secondary means of egress shall also be provided for permanent:

• elevated work platforms 3 m or more above grade, and
• work areas 760 mm or more below grade,
2
• that have an area of 20 m or more.
SCAN - Reason: Additional quantifiable requirements: in the event of a
dangerous occurrence at height or in a hole where the work area is large
enough the worker may still be physically able to evacuate but the route
may be blocked, a second way out needs to be provided. A person could
jump from a platform lower than 3m high or climb out of a hole up to 760
mm in depth so a means of secondary egress would not be necessary.
(Extract from California OH&S requirements 3228(h) which is US
industry standard).
Secondary means of egress may be either a fixed ladder or a second

stairway.
(ESTG 13-1.02 3.6.1)
Page 27 of 105
3.11.3 Walking Surface Walking surfaces shall:

• be even at all joints to eliminate tripping hazards, and
• have sufficient traction (i.e. slip-resistance) to allow workers to
move on it safely.
(Alberta OH&S Code 121)
3.11.4 Floor-plate, Grating/ Unless otherwise noted, solid flooring shall be used only for interior or
Decking other applications free of precipitation or frequent wetting. Grating may
be used for both interior and exterior applications.
(ESTG 13-1.02 3.4)
3.11.5 Finishing All ragged edges, welds, protruding bolts, or other fasteners that might
cause injury to personnel shall be avoided, or if required, ground smooth.
(ESTG 13-2.01 6.1.3)
3.11.6 Walkway Width The minimum unobstructed width of walkways, including walkways on
skids, modules and between equipment and building wall shall be 1000
mm, and for operating aisles the minimum distance shall be 1500 mm.
Larger horizontal clearance shall be provided where necessary to
perform all maintenance work including, but not limited to, the complete
removal of rotating equipment and heat exchanger tube bundles and
channels.
(SCAN DEP 31.38.01.11 3.3.1)
Operating aisles are considered areas where operating or maintenance

personnel will be performing work (e.g. other than walking or observing).
The minimum unobstructed width shall be 1500 mm for walkways:

• intended for two-way traffic,
• which lead to or from an entrance or exit, or
• which provide a primary means of egress at grade.
SCAN - Reason: This width is needed for these types of walkways to

provide sufficient space for PPE, RPE & winter clothing
Page 28 of 105
3.11.7 Stairways Stairs or fixed vertical ladders shall be provided whenever operators or
maintainers must change elevation abruptly by more than 300 mm.
(ESTG 13-01.02 3)
Stairways shall be used for primary access to:
• all battery limit valves, blinds, vents and drains.
DEP 31.38.01.11
• main operating levels and main service levels, and
• elevated work platforms, walkways, and other elevated work areas
where the frequency of use is more than once per shift.
Stairways are required for access to elevated work platforms, walkways,
and other elevated work areas where the frequency of use is once per
shift or less if:
• access is required to Category 1 valves, or
• material, tools or other equipment must be carried for operations
and/or maintenance, or
• there is a potential for exposure to hazardous chemicals or
materials (e.g. H2S) at the elevated location
Reason: operator safety & efficiency of rounds, outcome of valve
criticality analysis
3.11.8 Ramps Ramps shall not be used unless otherwise approved by the COMPANY.
Sloped walkways adjacent to operating equipment or conditioning and
transport piping are not considered ramps.
Reason: Lessons learned re safety incidents
3.11.9 Stair Treads The top tread of stairs shall be flush with the walking surface. The height
of the bottom tread above the walking surface shall be the same as the
riser height used throughout the length of the stairs.
The leading edge of each tread shall have a non-slip skid-resistant
material to prevent slips and falls and the leading edges shall be visually
distinctive (e.g. yellow) from the colour of the rest of the tread to create a
contrast between the stair treads and/or the walking surface below.
(SCAN)
3.11.10 Handrails A clearance of 75 mm shall be provided for the user's hand between the
outside edge of the handrail and the surface on the closed side.
Reason: usual practice is 50 mm, but additional space is required for
hands in winter gloves.
A single-tier stair rail for maintaining balance while going up or down the
stairs shall be installed on the enclosed side(s) of stairs.
Reason: provide a grip along the wall side of the stairs.
The use of wood for handrails shall not be allowed.

Upper handrails on stairways shall be minimum 38 mm O.D. pipe.
Reason: minimum grip diameter – from population anthropometric data
Page 29 of 105
3.11.11 Ladder Orientation Ladders shall be installed in the vertical. In no case shall a ladder be
installed with a forward pitch.
Vertical fixed ladders should be orientated so that a person faces the

structure or vessel while climbing.
No vertical ladder shall interfere with the movement or removal of any

item.
Vertical ladders used to access tank openings or pressure vessel man-

ways, or any other opening equipped with a hinged cover, shall be
located so the cover swings away from the ladder.
(SCAN)
3.11.12 Ladder Reach A vertical ladder used by workers to reach an object while standing on
the ladder shall be located so the object is no more than 800 mm from
the centreline of the ladder and is at least 900 mm below the top rung.
(ISO 13705; 15.5)
Tasks performed at this maximum distance shall only involve simple
adjustments or such tasks as can be performed with light tools and one
(1) hand while the other maintains a grip on the ladder.
Ladders, used by workers to access a work area to perform tasks that
require the use of two (2) hands, shall be provided with a work platform
(to allow the use of both hands and provide a stable standing surface).
(SCAN)
3.11.13 Ladder Dimensions & Ladders shall be 500 mm in width, with ladder rungs spaced on 300 mm
Clearance centres.
A minimum horizontal clearance of 200 mm shall be provided from the
outside edge of each stringer to the nearest obstruction on both sides of
the ladder.
SCAN - Reason: room to either side to prevent banging against objects
& snagging of clothing or tools
3.11.14 Ladder Rungs The top rung on all vertical ladders shall be top flush with the walking
surface or platform.
Ladder rungs shall be square bar and rotated 45 degrees to provide a
sharp edge at the top and alleviate ice build up.
SCAN - Reason: lessons learned - safety, reduces ice accumulation;
provides better grip for mud/snow/caked boot-insteps; provides boot
scrape
3.11.15 Step-through Ladders Step-through ladders, where approved, shall have the side rails carried
to a support point at the top landing. Grab rails, with a diameter of 22
mm, shall be attached to the handrail post on either side of the access,
and shall project 300 mm from the handrail post as a continuation of the
ladder side rail. A 600-mm clearance shall be provided between the
grab bars.
(ESTG 13-1.02 3.6.3k)
3.11.16 Gate Safety gates shall be installed at the top entrance to all ladders.
(ESTG 13-1.02 3.6.3)
Page 30 of 105
Safety gates shall be self-closing double bar type and cover the full width
of the opening between the ladder stringers. The safety gate shall be
installed at a height 920 mm above the landing/walking surface.
(Alberta OH&S Code 130-4)
Where ladders provide access to small platforms that do not provide

sufficient space for the self-closing gate to swing horizontally, manually
operated gates that open and close via a vertical swing may be used.
The gate shall open away from the person climbing up the ladder.
(SCAN)
3.11.17 Landings Where it is not practical to install landing platforms or install ladder
cages, a certified fall arresting device shall be provided.
(ESTG 13-1.02 3.6.3)
3.11.18 Platforms & Decks Platforms shall typically be provided where items are not accessible from
the surrounding facilities. Examples of locations requiring platforms shall
include, but not be limited to, the following:
• Access to equipment inspection or service opening, such as
manholes;
• Access to equipment which requires inspection, adjustment or
servicing during operations, such as control valves and level
controls; and
• Access to valves on towers or equipment elevated above grade.
(ESTG 13-1.02 3.5.2)
Any elevated work area where tasks require the use of both hands shall
be provided with a work platform to give workers a stable standing
surface without requiring them to stand on stair treads or ladder rungs
while performing work.
Note: Valve hand wheels greater than 125 mm are considered to be a
two-handed operation; DEP 30.00.60.13-SCAN 1.2.1
(SCAN)
Platforms shall also be provided at locations where access deteriorates

due to weather conditions or maintenance activities, such as a tank pad
slope that becomes slippery during winter.
(ESTG 13-1.02 3.5.3)
3.11.19 Platform Clearance For clearance on walkways on elevated work platforms between guard-
rail and any object (including insulation), Shell in North America has
adopted 1000 mm to allow for winter clothing, PPE and breathing
apparatus.
(SCAN DEP 31.38.01.11 3.3.1)
3.11.20 Platform Space Platforms shall be designed to provide space for:

• storage of blinds where blinding is expected to occur and there
is no spectacle blind installed,
• the lay down of heavy and/or large vessel internals and machine
parts during maintenance activities,
• the placement of tools, spare parts, and/or equipment
preparatory to, and during the task, and
Page 31 of 105
• temporary storage of catalyst, desiccants etc. prior to loading

vessels as needed.
(SCAN)
3.11.21 Platform live-loads The calculation of live loads for platforms should consider:
• the placement of tools, spare parts, and/or equipment on the
platform preparatory to, and during the work,
• the lay down of heavy and/or large vessel internals and machine
parts during maintenance activities, and
• temporary storage of catalyst, desiccants etc. prior to loading
vessels as needed.
(ESTG 13-1.01 3.2)
3.11.22 Guardrails Guardrails shall be installed along all the edges of open sided decks,
floors, walkways, platforms, runways, and balconies at all locations 910
mm or greater above grade.
(ESTG 13-1.02 3.7.2)
Guardrails shall be installed along rooftop service platforms edges that

are less than 1500 mm from the roof edge.
(ESTG 13-1.02 3.7)
Walkways and platforms not provided with guardrails (less than 910 mm)
shall have a guard at least as wide as the walkway at any sharp change
of direction (L or T-shaped).
(SCAN)
Floor or deck openings 300 x 300 mm or greater which are left exposed
and unattended require guard railings or barriers.
(SCAN)
Regardless of height, open-sided floors, walkways, platforms, or

runways above or adjacent to dangerous equipment, valves, piping or
other hazards shall be guarded with a standard guardrail.
(SCAN)
3.11.23 Toe-plate & Pipes As an alternative to steel toe-plates around piping that penetrates a
platform, flush-fitting flexible toe plates can be used to minimize the
opportunity for dropping objects to a lower level.
Reason: Lessons learned dropped objects
Page 32 of 105
3.11.24 Manway Clearance Around manways, a minimum of 760 mm on each side of the manway
and a minimum of 1220 mm out in front of the manway shall be provided
clear of obstruction to allow for entry and exit.
Vessel Minimum clearance in

X: = 1220 mm
man-way X front of man-way
Minimum clearance
Y: = 760 mm
either side of manway
SCAN - Reason: presence of manway cover, safety watch, rescue

equipment, gas detection, radios, sign-in board etc now mandatory for all
entries but traditional deck space does not consider it adequately in
original design dimensions.
3.11.25 Manway Size Manways shall be sized and located to accommodate the safe and
efficient removal of vessel internals where the removal of those internals
is a regular part of inspection.
(SCAN)
Manways for vessels up to 1220 mm in diameter shall be a minimum
diameter of 510 mm.
Manways for vessels larger than 1220 mm in diameter shall be a
minimum diameter of 610 mm, with 760 mm being preferred.
SCAN - Reason: larger diameter is required for entry with winter
clothing, PPE and RPE requirements. Under new OH&S Code
requirements being adopted in North American sites and operations,
entries require a documented rescue plan and fully equipped rescue
personnel must be able to quickly respond, enter and extract a worker.
For top manways in horizontal vessels, in sour or toxic services (where a
portable ladder is inserted through a manway is necessary for entry), the
access manway shall have 710 mm minimum inside diameter.
(ESTG 8-1.04 3.10.1)
For vessels 915 mm or less in diameter that require manways,
consideration should be given to providing a top- or end-break flange
instead of a nozzle-type manway. A dished head or blind flange shall be
used on top of break flange, and marked with the symbol "M" for
manway.
(ESTG 8-1.04 3.10.3)
Page 33 of 105
3.11.26 Vessel Skirt Manways Manways for vessel skirts up to 1220 mm in diameter shall be a
minimum diameter of 510 mm.
Manways for vessel skirts larger than 1220 mm in diameter shall be a
minimum diameter of 610 mm, with 760 mm being preferred.
SCAN - Reason: larger diameter is required for entry with winter
clothing, PPE and RPE requirements. Under new OH&S Code
requirements being adopted in North American sites and operations,
entries require a documented rescue plan and fully equipped rescue
personnel must be able to quickly respond, enter and extract a worker.
Page 34 of 105
4.0 EQUIPMENT LAYOUT & ACCESS
4.1 GENERAL WORKER ACCESS
4.1.1 Worker Envelope Working space shall be provided wherever an operator or maintainer is
required to work. Using anthropometric data for a Dutch workforce, our
climatic conditions and required personal protective equipment (e.g. hard-
hat, Self-contained Breathing Apparatus) this space shall be:
• a minimum of 1000 mm x 1000 mm with a minimum head clearance
of 2300 mm for a walking or standing working position, and
• at least 1300 mm deep with a minimum head clearance of 1700 mm
for kneeling or squatting positions.
Standing & Walking Worker Envelope: Kneeling or Squatting Worker Envelope:
1700
2300
1300
1300
1000
1000
The location of valves hand-wheels and/or stems shall not obstruct

platforms or walkways.
DEP 31.38.01.11 3.12.2
4.1.2 Access & Clearance Operators shall have access to equipment and skid-mounted equipment
(vendor packages) from all sides.
DEP 30.00.60.18.GEN
Horizontal clearance greater than the minimum required or stipulated for

standard walkways shall be provided where necessary to perform all
maintenance tasks including, but not limited to, the complete removal of
rotating equipment and heat exchanger tube bundles and channels.
Page 35 of 105
4.2 COLUMNS & INTERNALS
4.2.1 Access – Installation

& Removal A manhole in the top column shell ring, a blind flange or a flanged head
should be provided to allow column internals to be installed and removed.
Access to the column via a manhole in the top column shell ring is
preferred.
Manholes should be provided for other column internals. The internal

diameter of manholes should be at least 610 mm, but in any case shall not
be less than 460 mm.
To facilitate access to the column internals, column manholes should be

located as follows:
 every 15 to 20 fractionating or contacting trays;
 next to a Schoepentoeter;
 below a spray distributor;
 above a gravity liquid distributor;
 below draw-off trays;
 in the bottom compartment/sump of the column;
 in the flash zone;
 at the top of the column if there is no top flange or top dome.
If a manhole is installed between two column internals, the clearance

between the manhole and the internal above or below should be at least
150 mm.
DEP 31.20.20.31: 2.4
The internals Supplier shall verify that the manholes and top flange or top
dome necessary for the installation of the column internals will be provided
on the column.
DEP 31.20.20.31: 2.4

4.2.2 Fractionating Tray
Installation & To facilitate installation and maintenance, fractionating trays shall be made
Removal in sections which shall pass through manholes or the top dome of the
column.
Stacked trays shall be designed to permit installation and removal through

the column top
Unless otherwise specified, all fractionating trays shall be designed to

permit installation and removal from the top.
All parts should have durable markings, in paint or ink, relating to the
erection plan from which the internals can be unmistakably identified
DEP 31.20.20.31: 3.4.1
Page 36 of 105
4.2.3 Fractionating Trays &

Access Within Fractionating trays and fittings shall be designed so that the tray is easily
accessible for cleaning, gas freeing, inspection and maintenance.
Access to fractionating trays not served by column man-ways shall be

provided by means of bolted man-ways in the fractionating trays.
The column manufacturer shall ensure that a man can pass through the
man-ways of the fractionating trays as installed.
Whenever possible, tray man-ways shall have a minimum opening of 320

mm x 500 mm.
Where this is impossible for construction reasons, the use of smaller man-
ways shall be subject to the approval of the Principal. The man-way shall
not be smaller than 270 mm x 450 mm.
If no man-way is possible, the cover plate of the tray shall be split.
If the clearance between the tray deck and the bottom of the main
supporting beams of the tray above is less than 400 mm, tray man-ways
shall be installed on each side of the beams.
For HiFi trays, the Manufacturer shall ensure suitable access to the tray
below on both sides of the beam.
On Calming Section trays, man-ways are preferably not located directly

underneath Calming Sections of the tray above. Where this is unavoidable,
the column Manufacturer shall check whether it is necessary for part or all
of a Calming Section or baffle to be made removable.
DEP 31.20.20.31: 3.5
For the sake of flexibility, bolting and unbolting of tray man-ways should be
possible from both sides of the tray. If access from one side is impossible,
e.g., in case of small-diameter Hifi trays, this requirement may be relaxed if
approved by the Principal.
Exposed edges of trays at locations where people may have access shall
be bevelled or rounded off, e.g., at man-ways and top edges of weirs.
DEP 31.20.20.31: 3.5
Page 37 of 105
4.2.4 Draw-off Trays, Liquid Collectors & Gravity Liquid Distributors
4.2.5 - and provisions

for installation and To facilitate installation and maintenance, each draw-off tray, liquid
removal collector or gravity distributor shall be made in sections that shall pass
through the manholes or the top dome/flange of the column.
Unless otherwise specified, all draw-off trays, liquid collectors or gravity

distributors shall be designed to permit installation and removal from the
top.
All parts should have durable markings, by means of paint or ink, and by
means of stamping relating to the erection plan from which the internals
can be unmistakably identified.
DEP 31.20.20.31: 4.4.1

4.2.6 - and provisions for
access Man-ways in draw-off trays, liquid collectors or gravity distributors are
normally not required, because access to this type of tray shall be
provided by means of man-ways in the column and man-ways in the tray
above.
The support beams of the tray above shall be located so as to allow ready
access via the man-ways to all parts of the draw-off tray, liquid collector or
gravity distributor. If appropriate, e.g., in the case of a draw-off tray close
below a packed bed, the tray should be removable from below.
Only in the case of single-deck draw-off trays may access be provided
through a removable section of the riser cap. Minimum width of such a
removable section shall be 270 mm.
If the minimum width of 270 mm cannot be achieved on a riser-cap,

provisions shall be made to enable the removal of a complete gutter.
Double-deck draw-off trays, chimney tray draw-off trays, gutter

arrangements, vane collectors and gravity liquid distributors should have
no man-ways.
DEP 31.20.20.31: 4.5

4.2.7 Gravity liquid Attachments welded to the column wall (support rings, lugs and brackets)
distributors should not hamper the installation or removal of the packing elements.
This is especially important for column diameters smaller than 800 mm.
DEP 31.20.20.31: 4.6.6

4.2.8 Packing & Loads Apart from the required operating load, the packing and support grid shall
be capable of absorbing the loads resulting from installation and
maintenance activity. These loads shall be taken as 1000 N downward,
equivalent to the weight of one man working on the assembly.
During installation and maintenance, standing directly on the packed bed

should be avoided. Where standing on the packing is necessary for
installation purposes, any protection requirements shall be indicated in the
installation procedure.
DEP 31.20.20.31: 5.3.1
Page 38 of 105
4.2.9 Packing & Provisions

for Installation & To facilitate installation and maintenance, the packed bed and support
Removal grid shall be made in sections that can pass through manholes or the top
dome/flange of the column.
All parts should have durable markings, by means of paint or ink and by
means of stamping, relating to the erection plan from which the internals
can be unmistakably identified.
DEP 31.20.20.31: 5.5.1

4.2.10 Feed Inlet Device -
Installation & To facilitate installation and maintenance, the feed inlet device shall be
Removal made in sections that can pass through manholes of the column.
All parts should have durable markings, by means of paint or ink, and by
stamping relating to the erection plan from which the internals can be
unmistakably identified.
Generally, parts shall be made as large as possible in order to reduce the

number of joints.
During shutdowns, there should be direct access to feed inlets via a

column manhole.
DEP 31.20.20.31: 6.5.1; 6.5.2; 6.6
4.2.11 O & M Tasks & “Tie-Downs”/ Fastening devices easy to install/remove.

Considerations
Internal insulation should be easily maintainable
(Columns, Reactors,
Vessels) Ability to ensure that stripping steam is dry before commissioning.
Access to top of reactors should be via stairs/elevators.
Flawless Operability & Maintainability
4.3 PRESSURE VESSELS

4.3.1 Grouping Where practical, pressure vessels which are grouped together shall have
platforms and interconnecting walkways at the same elevation.
The number of stairways and ladders to the platforms shall be sufficient to
meet safety requirements.
Where practical, pressure vessels grouped together shall have their level
gauges at a common level.
DEP 31.38.01.11 4.5
Page 39 of 105
4.3.2 Manholes & Manholes shall have a minimum clear inside diameter of 460 mm;
Inspection Openings however, nominal pipe sizes DN 500 (20"), DN 600 (24") and DN 750
(30") are preferred.
The nominal minimum diameter for inspection openings (hand holes) is

DN 150 (6").
For the required sizes of access openings in columns with removable

trays, see DEP 31.20.20.31-Gen.
Davits shall be provided for all openings DN 300 (12") nominal up to and
including DN 750 (30"). Typical details are shown in Standard Drawing S
10.070, except for vessels in low temperature
service, for which the covers shall be hinged.
Hand hole covers shall be provided with a grip, see Standard Drawings S
10.039, S 10.053 and S 10.054.
DEP 31.22.10.32: 3.11
4.4 GAS & LIQUID

SEPARATORS
4.4.1 Vessel Accessibility Because of the risk of cyclone erosion, regular inspection of the internals
is required. The design of the separator should therefore enable the
removal of the complete cyclone bundle and the vessel should be
equipped with a top flange or a full-diameter top cover.
DEP 31.22.05.11: 3.9.5
The manholes shall be located so that the plate pack internals can easily
be installed, and are accessible from both sides.
DEP 31.22.05.12: 3.2.2
4.4.2 Vane Packs - The vessel shall provide sufficient access for inspection, cleaning,
Mounting maintenance and the removal and installation of the vane pack and other
internals.
In the case of a vertical vessel, the vessel can be provided with a full top
flange or with manholes. A full top flange allows for the installation of
internals as a prefabricated box; this is preferred for vessel diameters
below 1.2 m.
Alternatively two manholes should be provided; one upstream and one

downstream of the vane pack. The least preferable option is to provide
only one manhole; in such a case it shall be located upstream of the vane
pack.
DEP 31.22.05.11: App. IX
Page 40 of 105
4.5 RELIEF SYSTEMS
4.5.1 Platforms Where practical, all safety valves shall be accessible from platforms for
servicing and inspection.
DEP 31.38.01.11 4.6
Relief devices require periodic inspection and maintenance and hence
they should be easily accessible.
DEP 80.45.10.10: 2.8.1
4.5.2 O & M Tasks & Flare sumps must be serviceable without a total shutdown.
Considerations
Critical Equipment to have sufficient relief valves to prevent shutdown if
one fails (ability to repair on the run)
Design / lay out to ensure that no liquid backpressure or stagnant liquid on
the downstream can occur.
Page 41 of 105
4.6 FLARE DERRICK
4.6.1 Access A derrick structure shall be supplied with the following access equipment:
a) a stairway from grade to the riser removal/replacement platform;
b) a ladder from the riser removal/replacement platform to the top
platform;
c) step-off platforms at intervals of 9 m (30 ft) to the top platform at
the flare tip;
d) platforms with ladder access for all manways and handholes;
e) ladders from the riser removal/replacement platform to all eyes
attached to the derrick structure that are used to raise, lower and
tilt the riser sections.
DEP 80.45.10.10: 6.2
4.6.2 Riser Platform Riser removal/replacement platforms may comprise more than one level
and shall be of a retractable type.
The exact elevation of the riser removal/replacement platform will depend

upon the number of riser sections and the elevation of the hoisting blocks
and associated eyes that are attached to the support structure to raise,
lower and tilt the riser sections.
DEP 80.45.10.10: 6.2
4.6.3 Heat shields A proper heat shield at the first platform and temporary shelters at grade
shall be provided within the sterile area to protect personnel.
DEP 80.45.10.10: 6.3.2
Page 42 of 105
4.7 AIR COOLERS (FIN FANS)
4.7.1 Structure Design of support structures providing access to air coolers shall follow
Section 3 Structural Design Requirements of this document.
4.7.2 Tube Bundle Design The width of the tube bundle shall be chosen with due regard to
transport and handling aspects, and unless otherwise specified shall not
exceed 3 metres.
DEP 31.21.70.31: 7.1.1.1
4.7.3 Air-Side Design For two fans per bay, the height of the underside of the fan inlet bell (on
forced draft units) or of the underside of the bundle (on induced draft
units) shall be at least 2 m or one fan diameter (whichever is the
greater) above the ground level, elevated floor or pipe bridge.
For three or more fans per bay, the height of the underside of the bundle
shall be agreed with the Principal.
DEP 31.21.70.31: 7.2.1.2.1
4.7.4 Heat Shielding If the air outlet temperature at design conditions exceeds 90 °C,
personnel heat protection shielding shall be installed along the side
platforms of forced-draught heat exchangers.
DEP 31.21.70.31: 7.3.5.3

4.7.5 Access Facilities Ladders or stairs shall be provided at both ends of each bank.
DEP 31.21.70.31: 7.3.5.1
If specified, maintenance platforms shall be provided beneath each

drive assembly to provide access for removal and replacement of all
drive components.
ISO 13706: 7.3.5.2
Platforms shall have a clear width of at least 0.75 m (30 in).

ISO 13706: 7.3.5.3
The floor of the walkways, platforms, etc. shall be grating, expanded

metal or a raised-pattern solid plate with drain holes. If raised-
pattern steel is used, the thickness shall be at least 6 mm (1/4 in).
ISO 13706: 7.3.5.4
The following shall apply:

a) Safety cages shall be provided for ladders over 3 m (10 ft) high. .
b) A GRP self-closing double-swing bar shall be provided across ladder
openings at platforms.
c) Ladders over 2 m (6 ft) high shall provide for side-step access to
platforms unless otherwise specified.
ISO 13706: 7.3.5.5
Header platforms shall be provided with a toe-board on the side next to

the exchanger. If the gap between the platform and the
exchanger is greater than 150 mm (6 in), a knee rail shall be fitted.
ISO 13706: 7.3.5.6
Page 43 of 105
4.7.6 O & M Tasks & Access should be designed for:

Considerations
Lubrication of bearings, changing adjusting belts, side “make-up air”
screens easy to clean.
Clear line of sight to the blades for starting/stopping purposes.
Ability to have individual control of outlet and plenum temperatures
when freezing is a concern.
4.8 WATER TUBE BOILERS

4.8.1 Design & Engineering - Safety, ease of operation, inspection, maintenance, repair and cleaning
General are of major importance.
There shall be sufficient space and access for inspection, cleaning,

removal and maintenance of such parts as drums, tube bundles,
headers, retractable burner parts, fixed and retractable soot-blowers,
valves, pumps, fans, turbines and electric motors.
DEP 30.75.10.30: 2.1
4.8.2 Water Level Water level shall be easily visible from the operating platform by means
of either a drum gauge image transmission system or a remote level
indicator.
DEP 30.75.10.30: 2.5.2
4.8.3 Drums Drum internals shall be accessible and cleanable and they shall be
removable through manholes. Elliptical or circular manholes may be
used.
DEP 30.75.10.30: 2.2.7
4.8.4 Observation Air-cooled observation windows shall be provided and shall afford an
unrestricted view of all burners, tips, throats and flames. The windows
shall be at least 250 mm by 100 mm (10 x 4 in) and shall also allow
observation of all surfaces on the back and side walls and the screen or
super-heater gas inlet on which flames can impinge: the line of sight
shall be parallel to these surfaces.
Observation windows shall be installed at each side of the boiler front to
allow viewing along the side walls.
Air purging shall be provided to keep observation windows sealed, clean
and cool. The glasses shall have external covers to prevent cracking by
rain ingress and shall be protected on the hot side by a pivoting metal
plate (protection flapper).
It shall be possible to renew the glasses during operation.
DEP 30.75.10.30: 2.2.10 & S 24.101; S 24.102
4.8.5 Access There shall be a sufficient number of access and inspection doors and
access space for each section or tube bank of the boiler.
Access doors shall have a free opening of at least 400 mm x 400 mm

(16 x 16 in.).
DEP 30.75.10.30: 2.2.10
Page 44 of 105
4.8.6 Dampers Dampers shall be easily accessible for manual operation and shall have
a position indicator, clearly visible from ground level.
It shall be possible to lock the damper in the open position during

normal operation, and it shall tend to open by gravity.
In addition, there shall be a sliding plate, located as close as possible to

the stack. In between the damper and sliding plate there shall be a
purge and in accordance with Standard Drawing S 24.303.
DEP 30.75.10.30: 2.3.3 & S 24.303
4.8.7 Steel structure Further to the requirements of the specifications contained in DEPs
34.00.01.30, 34.28.00.31 and Standard Drawing S 28.006, stairs and
platforms shall provide easy access to all valves, gauges, instrument
fittings, observation points and access doors, and for all other
operational purposes.
Ladders may be used only for providing extra means of escape.
All stairs, platforms and walkways shall be adequately safeguarded with

hand railing and toe plates. [See Section 3.0]
All main platforms shall be provided with an emergency means of

escape leading to ground level.
DEP 30.75.10.30: 2.6.3
Page 45 of 105
4.9 FIRED PROCESS HEATERS
4.9.1 Inspection Access

The convection section tube layout shall provide open access lanes to
permit inspection, water or steam lancing and installation of soot-
blowers or water wash systems. Minimum vertical clear space in these
lanes shall be 600 mm. Soot blower or water wash systems shall be
provided if specified.
Inspection spaces shall be installed at the following locations:

- between bare shock tubes and finned tubes
- preferentially at locations where there is a change in process
th
- for clean gas firing between each 15 tube row
for oil firing further inspection lanes correspond with soot-blower lanes
(see ISO 13705 Clause 14.2.4).
DEP 31.24.00.30: 6.3.4
4.9.2 Access Door – Box Two access doors having a minimum clear opening of 600 x 600 mm
Cabin Heater (24 x 24 in.) shall be provided for each radiant chamber of a box or
cabin heater.
ISO 13705:2006: 12.3.2.1
As a minimum one unobstructed access door shall be provided in the

wall of a vertical box-type heater for access from the burner platform.
The panel dimensions shall not be smaller than 600 x 900 mm. Access
doors shall be provided with hinges.
DEP 31.24.00.30: 12.3.2.1
4.9.3 Access Door – Box One access door having a minimum clear opening of 450 x 450 mm (18
Vertical Cylindrical x 18 in.) shall be provided in the floor for vertical cylindrical heaters. A
Heater bolted and gasketed access door shall also be provided in any air
plenum below the floor accessway. Where space is not available,
access via a burner port is acceptable.
ISO 13705:2006: 12.3.2.2

Access via a burner port shall only be considered if there is no space (in
the floor or side wall) to install an access door.
Opening of and access to access doors shall be unobstructed by piping,

ducts, cable trays, etc.
DEP 31.24.00.30: 12.3.2.2
4.9.4 Access Door – Damper One access door having a minimum clear opening of 600 x 600 mm (24
& Convection x 24 in.), or 600 mm (24 in.) in diameter, shall be provided in the stack
or breeching for access to the damper and
convection sections.
ISO 13705:2006: 12.3.2.3
Page 46 of 105
4.9.5 Access Door – Vertical One tube-removal door having a minimum clear opening of 450 x 600
Tube Heaters mm (18 x 24 in.) shall be provided in the arch of each radiant chamber
of vertical tube heaters.
ISO 13705:2006: 12.3.2.4
4.9.6 Observation Ports Observation doors shall be installed in the heater walls to provide a
clear view of the burner(s), flame(s) and flame-exposed tube surfaces in
the radiant sections.
Particular attention shall be given to the arrangement and positioning of
peepholes for burner viewing to ensure that there is an unobstructed
view of each burner throat and flame zone up to 1 m outside the burner
throat.
Due account shall be taken of the radiant coil layout to prevent tubes
from obstructing the view of the burners.
All observation windows in forced draught heaters shall be provided with
a glass cover, protection flapper and purge air connection. Horizontal
observation windows shall be provided with rain protection.
Observation windows and ports in forced draught heaters shall be in line
with Standard Drawings S 24.101, S 24.102, S 24.108 or S 24.109.
Each forced draught vertical radiant cell shall have at least one circular
200-mm peephole in the roof, providing a clear view to all burner
throats.
DEP 31.24.00.30: 12.3.2.5
For automatically started systems, the ignition flame shall be visible via
either the burner peep hole or the main burner observation window.
DEP 31.24.00.30: 14.1.16
Draught gauges shall be visible from damper operating position.

DEP 31.24.00.30: 14.4.8
Access doors shall have a minimum clear opening of 600 x 600 mm.
DEP 31.24.00.30: 12.3.2.6
4.9.7 Removable Wall If the return bends of convection section tubes are located in the flue
gas path, one end wall shall be removable to enable removal of the tube
bundle for maintenance purposes. The opposite end wall may also
contain removable panels to provide access for field welds.
DEP 31.24.00.30: 12.3.2.7
Page 47 of 105
4.9.8 Platform Locations Platforms shall be provided as follows:
a) at burner and burner controls that are not accessible from grade;
b) at both ends of the convection section for maintenance purposes;
c) at damper and soot-blower locations for maintenance and operation

purposes;
d) at all observation ports and firebox-access doors not accessible from
grade;
e) at auxiliary equipment, such as steam drums, fans, drivers and air

pre-heaters as required for operating and maintenance purposes;
f) at all areas necessary to meet the requirements of 15.5.
ISO 13705:2006: 12.4.1
4.9.9 Circular Platform All vertical cylindrical heaters shall have a full circular platform at the
floor level.
DEP 31.24.00.30 12.4.2
4.9.10 Platform Clearance Platforms shall have a minimum clear width as follows:
Operating platform at the burner control side 1.5 m
If burner guns have to be manipulated from

1.8 m
this platform
All other platforms 0.9 m
Walkways 0.8 m
DEP 31.24.00.30 12.4.3
4.9.11 Dual Access Dual access shall be provided to each operating platform, except if the
individual platform length is less than 6 m (20 ft).
ISO 13705:2006: 12.4.5
4.9.12 Stairways Stairways shall be provided for platforms where operators require
access at least once per shift or under emergency conditions. Burner
platforms and soot blower platforms shall always be accessible by
stairways. Stairways giving access to various levels shall be combined
in a flight of stairs.
DEP 31.24.00.30 12.4.5
4.9.13 Landing An intermediate landing shall be provided if the vertical rise exceeds 9
m (30 ft) for ladders and 4,5 m (15 ft) for stairways.
ISO 13705:2006: 12.4.6
4.9.14 Ladders Ladders should conform to the requirements of ISO 13705:2006: 12.4.7
and Sections 3.3 & 3.5 of this document.
Page 48 of 105
Ladders shall be made so as to provide a side step at the top. The hand
railing shall extend at least one metre above the top platform.
DEP 31.24.00.30 12.4.7
4.9.15 Railing Railings shall be mounted on the top of the radiant section and the top
of a side mounted convection section where access is necessary and
platforms are not required.
DEP 31.24.00.30: 12.4.10
4.9.16 Burner Piping Burner piping shall be arranged to minimize obstruction to access.
Below the heater, the piping shall be arranged so that the operator has
a clear unobstructed route of emergency escape from below the heater
over 270°.
Piping to burners shall be arranged so that burner assemblies and man

holes can be removed without cutting/welding (e.g. flanged connections
to be provided).
DEP 31.24.00.30: 14.1.24
4.9.17 Damper Controls A manually operated flue gas damper shall be operated from grade or
the firing platform.
DEP 31.24.00.30: 14.4.8
Unless the damper is open to view and close to grade a direct shaft
connected position indicator visible from grade shall be provided.
DEP 31.24.00.30: 14.4.11(b)
The actuating mechanism and the linkage and damper bearings shall be
accessible for servicing. The actuator should normally be located close
to the damper shaft and be accessible from grade or a platform.
DEP 31.24.00.30: 14.4.13
4.9.18 Combustion Ducts & The air ducts shall be provided with inspection panels near the dampers
Plenums to allow for damper blade inspection and maintenance.
DEP 31.24.00.30: 14.5.1
Page 49 of 105
4.9.19 O & M Tasks & View ports correctly orientated, easy/safe to clean/replace and provide
Considerations adequate view of fires and furnace internals.
Ability to air blow/clean fuel gas systems/lines when flow is restricted
due to fouling.
Ensure design has considered sufficient turn down for refractory dry-out.
Flame-eyes preferably in a 2 out of 2 set-up.
Ensure that flame eyes are functional at maximum turndown
Permanently installed pilot and initiator design should be verified by
plant technologists and operations on operability: (easy to ignite, easy to
visually confirm functioning and reliability).
Air/fuel ratio control system must be reliable and a proven technology.
Correct position and reliability of skin temperature thermocouples should
be verified by operations.
Automated starting is preferred to ensure proper purging and ignition.
Flawless Operability & Maintenance
4.10 ROTATING EQUIPMENT GENERALLY
4.10.1 Access Adequate space based on the minimum worker envelope for standing,
kneeling or squatting positions shall be provided around pump and
compressor seals, couplings, bearings and stuffing boxes for removal and
replacement activities as appropriate.
Maintenance decks shall be considered for all large pumps.
Pumps, compressors and turbines shall, when practical, be located on the
outside periphery of a module or skid for ease of access for maintenance
purposes.
DEP 30.00.60.18
4.10.2 Piping Auxiliary piping shall be neatly routed along the base-plate and shall not
extend across the operating floor. This piping shall not obstruct inspection
covers, bearing caps, upper halves of casings or any other items which
require access for operations or maintenance.
DEP 31.38.01.11: 4.2.1
Arrange the piping around compressors to allow free clearance completely
around each machine and to permit removal and access of critical machine
parts.
DEP 31.38.01.11
4.10.3 Valves Valves in the piping shall be arranged in a logical sequence for
convenience in start-up, shutdown and operating modes.
DEP 31.38.01.11
Compressor block valves and depressurizing connections shall be located

where they are operable.
DEP 31.38.01.11 4.2.3-13
Page 50 of 105
4.10.4 Utility Station Utility stations shall be located in close proximity to compressors. Ensure
platform access and access to bottom suction and discharge lines where
applicable.
4.10.5 Pumps Piping shall be arranged around pumps to allow sufficient clearance
completely around each pump and to permit the removal of the entire
pump.
DEP 31.38.01.11
Start/stop switch shall be located at the motor end of pump such that
discharge pressure gauge is visible to the operator when starting up the
pump.
Reason: efficiency of operation
4.11 CENTRIFUGAL
PUMPS
4.11.1 Auxiliary Piping Heat Insulation or guarding shall be provided as an integral part of the auxiliary
Protection piping system to provide personnel protection if the non-insulated metal
temperature exceeds 70 °C (160 °F) and the auxiliary piping system is in
an area where it can be touched during normal operation and maintenance
activities.
DEP 31.29.00.33; 8.1.20 & DEP 31.29.02.30; 6.5.1.2
4.11.2 Mounting of All auxiliary equipment such as instrumentation, seal support components,
Auxiliaries lube-sets, etc. shall be mounted in a manner that does not interfere with
normal maintenance or operator surveillance activities.
DEP 31.29.02.30; 6.7.1
4.11.3 Flange Alignment Threaded connections shall be limited to the final connections at the gland
plate. The last flanged connection before the gland plate shall be made
with a lap joint or clamped joint (e.g. Graylock) flange at the gland plate
side in order to facilitate proper flange alignment after maintenance.
Beyond these limits, a clamped joint shall be used.
DEP 31.29.00.33; 8.1.8
4.11.4 O & M Tasks & Correct size for temporary suction filters if they are required.
Considerations for
Rotational lock-outs clearly visible and securely lockable in the Open and
Pumps &
Closed positions.
Compressors
Protect trip and shutdown transmitters from weather conditions; (i.e. hot,
cold, wet, sand).
Design must include the ability to check with 100% certainty that “hot”
service pumps and vacuum pumps are water-free.
Priming and venting requirements should be confirmed with operations.
Flawless Operability & Maintenance
Page 51 of 105
4.12 COMPRESSORS
4.12.1 Layout In deciding upon the location of a compressor, consideration shall be given
to maintenance and process operations.
The overall layout of a compressor installation shall allow safe access to all
operating positions and to overhead lifting equipment if provided. There
shall be no unguarded floor openings around machines.
Sufficient space shall be provided at the compressor floor level for

dismantling the compressor (for reciprocating compressors including the
removal of piston rods), its driver and auxiliary equipment.
If two or more compressors are located on the same floor, provision shall
be made for a clear floor area that is adequate for the simultaneous
overhaul of all compressors, their drivers and associated auxiliary
equipment. The permissible floor loading shall be able to withstand the
maximum cumulative weight that arises during maintenance.
Special attention shall be given to the ventilation of compressor houses

and enclosures, particularly for units in hydrogen services, flammable
services and very toxic services. Electrical equipment located in
compressor houses/enclosures shall comply with the related area
classification.
For ease of maintenance access, horizontally split compressors shall

normally be installed with down-down nozzle orientation, however in
special cases, subject to the approval of the Principal, installation at grade
level may be considered for compressors operating in clean services with
top-top connections provided that driver installation is not a problem. Grade
level installation shall be balanced against installation of the compressor
train on a table top with either top-top or bottom connections.
The layout of auxiliary equipment and the provision of permanent steps and
platforms and of adequate clear floor space shall permit easy and safe
access to all components for operation and maintenance.
DEP 31.29.40.10; 5.1
4.12.2 Air Compressor Satisfactory access shall be provided by means of doors in the filter
Intake Filters – housing and ducting and no undue hazard shall be created.
Design & Access
DEP 31.29.40.10; 5.3.1
Specific attention shall be paid to maintenance during the specification and

selection of air filters. Due consideration shall be given to on-line changing
of filter elements and access to the filter housing.
DEP 31.29.40.10; 5.3.2
Page 52 of 105
4.13 CENTRIFUGAL FANS
4.13.1 Noise Control The Contractor shall comply with DEP 31.10.00.31-Gen., Noise Control,
and thereby communicate to the Vendor the specified equipment noise
limitations by using data sheet DEP 31.10.00.94-Gen., which forms part of
the requisition.
The Vendor is responsible for assuring that these equipment noise

limitations have been specified.
DEP 31.29.47.30; E.2.1.16.1
The Vendor shall submit guaranteed sound power levels and sound
pressure levels (including octave band spectrum) of the equipment,
together with any other relevant information as requested on the data
sheet, DEP 31.10.00.94-Gen.
The Vendor shall indicate what special silencing measures, if any, are
proposed in order to meet the specified levels.
DEP 31.29.47.30; E.2.1.16.2
4.13.2 Bolting Access Clearance shall be provided at bolting locations to permit the use of socket
or box wrenches.
DEP 31.29.47.30; E.2.3.3
4.14 LUBRICATION
All lubricant fittings shall be easily accessible.

Configuration of equipment containing mechanical items requiring
lubrication shall permit both lubrication and checking of lubricant levels
without disassembly.
4.14.1 O & M Tasks and Consider use of head tanks to allow for bulk loading of lube-oil.
Considerations
4.15 LUBRICATION, SHAFT-SEALING & CONTROL OIL SYSTEMS & AUXILIARIES
4.15.1 Outdoor Operation As a minimum the systems shall be suitable for unsheltered outdoor
operation. The anticipated weather and environmental conditions shall be
indicated by the Principal on the data/requisition sheets, and so shall the
need for any special precautions (e.g. "winterizing").
DEP 31.29.60.32; Ch 2: 1.1.13

& Ch 3: 1.2.10
Page 53 of 105
4.15.2 Accessibility Oil systems shall conform to the data sheet and shall include the following
features:
a. All instruments shall be installed so that they can be read from an

operator-accessible location no more than 600 mm (2 ft) away.
b. Filters shall be located so there is free overhead space to replace

the elements. Personnel shall be able to switch and to replace
filtering elements from an operator-accessible location.
c. Piping, instrumentation, and other components shall not obstruct

either side of the oil pumps and drivers. Both sides of the pumps
and drivers shall be clear for a minimum distance of 750 mm (30
in). Piping shall not be run through this space above the pumps
and drivers.
d. Valves, control valves, and instrumentation shall be accessible for

operation and maintenance.
DEP 31.29.60.32; Ch 2: 1.1.14
4.15.3 Filter Access The access area for filter maintenance shall be a minimum of 600 mm x
600 mm (2 ft x 2 ft).
DEP 31.29.60.32; Ch 2: 1.6.7
4.15.4 Transfer Valves In systems with a pressure rating of ASME rating class 900 and higher,
spectacle blinds shall be used for tight shut-off purposes to facilitate
maintenance.
DEP 31.29.60.32; Ch 2: 1.7.5
4.15.5 Instruments Pump discharge pressure indicator shall be visible to the operator while
starting pumps.
DEP 31.29.60.32; Ch 2: 3.1.6
4.15.6 Self-acting Gas Seal As far as possible, the layout should be such that the functions of control
valves and changeover valves for spared items are clearly evident and the
valves themselves are easily accessible.
The location and arrangement of the DGS module or modules shall not
cause obstruction to normal operation and maintenance of the
compressor. Maintenance, particularly of the compressor bearings and
seals, shall be possible with a minimum of disconnections.
DEP 31.29.60.32; Ch 4: 2.1.4
Page 54 of 105
4.16 HGV LOADING

FACILITIES
4.16.1 Manual Product Flow In traditional top loading a 'deadman control' in the form of a 'hold-open'
Control Valves valve should be provided. This enables the operator, when filling through
an open manhole, to watch the level of the product and to stop the flow
immediately in an emergency. The valve-operating lever (or control rod)
shall be located so that the operator can see the product in the
compartments at high level, while avoiding the vapour plume emitted from
the manhole.
Alternative arrangements featuring electronic deadman systems for use in

top loading should be applied to enable operators to operate from the
loading platform, rather than the top of the truck, and so avoid vapour
emissions.DEP 31.06.11.11: 4.4.1
4.16.2 Top Loading Gantry Gantry platforms should allow a free passage at least 0.75 m wide over
– Working Platform their entire length to enable operators to move freely, regardless of
whether the loading arms are in use or stowed. Equipment should be
positioned to cause minimum interference; it should not expose the
operator to the risk of physical contact with equipment, nor prevent him
from crossing the platform at each loading arm position.
The platform should be provided with stairs at each end. If space is

restricted then stairs should be provided at one end and at the other end
either access to a passway connecting all gantry islands or a ladder.
Working platforms may be of either concrete or steel construction and

should be provided with a non-slip material or finish. With open grating a
metal flame shield should be fitted under the grating as a means of
protecting both personnel and electric cables in the event of fire.
DEP 31.06.11.11: 8.3.2.1
4.16.3 Top Loading Gantry Each working platform should be provided with two balanced and hinged
– Access Ramp access ramps on either side, to enable personnel to walk easily and safely
to and from the tops of road vehicles (see Figure 8.17 of the DEP for an
example of a hinged access ramp).
The ramp should be easily adjustable by one man to cater for vehicles of
various heights, and any treads fitted should be of the self-levelling type.
A long (6 m) hinged grid side panel, (see Figure 8.18 of the DEP), offers
operational convenience, but as it is narrower its use should be restricted
to gantries where vehicle sizes/heights are fairly uniform.
DEP 31.06.11.11: 8.3.2.2
Page 55 of 105
4.16.4 Top Loading Gantry - The working platform, all stairways, hinged ramps etc., should be fitted
Guard Rails with guard rails on all open sides; handrails (see Figure 8.19 of DEP)
should be constructed opposite the ramp at each bay to provide protection
for personnel standing on top of the vehicle tanks. Unless conditions
dictate otherwise, the height of the guardrails should be 1 m.
DEP 31.06.11.11: 8.3.2.3
4.16.5 Visibility & Access Meter heads or meter pre-set readings should be clearly visible and
readable from the product loading control points.
Control valve equipment should be within easy reach of the operator in

normal loading positions. All handles of valves should be operated in the
same direction.
DEP 31.06.11.11: 8.3.6
4.16.6 Other Requirements Bays and loading islands should be clearly numbered to enable vehicles to
be directed to filling points.
Product grade plates should be provided at the entry side of the gantry to
clearly indicate product availability at the bay concerned.
Loading arms, meters and connections should be clearly marked for

product identification.
Sufficient illumination should be provided for night operations (see 9.5 of

DEP).
The construction of barriers at the exit of loading bays (when used) should
be such that they can be driven through in an emergency (e.g. barrier
bends or snaps off).
DEP 31.06.11.11: 8.3.6
4.17 ADDITIONAL
REQUIREMENTS
4.17.1 Worker Envelope Equipment parts, instrumentation, instrument stands, pipe supports, valve
hand-wheels, piping etc. shall not protrude into worker envelopes.
(DEP 80.00.10.11-SCAN 4.2.3.5)
4.17.2 Reach Limitations Maximum effective forward reach (i.e. allowing the ability to grasp, turn,
push/pull) shall be 610 mm directly in front of the operator's body.
Jobs requiring the operator to lift more than 3 kg or produce torque (e.g.
turning a wrench) shall be kept within 300 mm of the operator's body.
For light tasks (e.g. turning a small valve or applying minimal torque to a
nut), maximum extended reach of the worker shall be no more than 1800
mm above the standing surface.
(SCAN)
4.17.3 Hand Openings The nominal minimum diameter for inspection openings (hand holes) is
255 mm.
(ESTG 8-1.04 3.10.1)
Page 56 of 105
4.17.4 Platforms Work platforms shall be located and sized to allow the workers to perform
tasks:
• in whatever posture is necessary to accomplish the tasks,
• without having to assume an awkward or unsafe body posture,
• without having to extend tools beyond the platform railings, and
• without having to manipulate equipment, tools and internals beyond
the guard/handrail.
SCAN - Reason: lessons learned and incidents with falling objects
4.17.5 Standing Surface At no time, shall an operator or maintainer be required to stand on any
surface not specifically designed to be used as a standing surface. Work
platforms may be used to meet this requirement.
SCAN - Reason: safety, experience, lessons learned.
4.17.6 Priority of Access Items most critical to system operation and which require rapid
maintenance shall be most accessible.
When relative criticality is not a factor, items requiring most frequent
access shall be most accessible.
High-failure rate items shall be accessible for replacement without moving
non-failed items.
Access to items maintained by one trade or craft should not require
removal of critical equipment maintained by another trade or craft,
particularly where highly specialized skills are involved.
SCAN - Reason: safety, experience, lessons learned
4.17.7 General Equipment Equipment shall be laid out such that:

Layout • it causes a minimum of interference with movement of people or
equipment around the site or tasks;
• it does not expose the operator to the risk of physical contact with
equipment,
• it does not prevent reaching an egress point.
Sufficient space shall be provided around equipment (e.g., compressors,

pumps, motors, heat exchanger bundles, filters) for the lay down of heavy
components during maintenance activities.
(DEP 80.00.10.11-SCAN)
Adequate space shall be provided around vessels filled with solid

catalysts, desiccants, molecular sieve etc. for ease of loading/unloading
activities.
Adequate space shall be provided for heat exchanger tube bundle pulling
activities and for walkway/lay down area accessibility.
(SCAN)
Page 57 of 105
4.17.8 Relief Valve Location Where safety valves have an associated isolation valve in close proximity,
these isolation and relief valves shall be grouped together on a common
platform accessible by stairs for inspection and servicing.
SCAN - Reason: RV isolation valves are Category 1 and therefore need
access by stairs. Safety and ease of access during emergency situations
(stairs to common deck versus several ladders to top of columns).
Minimizes crane needs for RV removal
4.17.9 Air Coolers (Fin Header box level walkways shall be provided for all air-cooled heat
Fans) exchangers.
(ESTG 7-1.21 3.10.1)
Elevated units shall have platforms for access to the mechanical

equipment.
(ESTG 7-1.21 3.10.1)
Where work is performed (e.g. tube header boxes) the width of the header
walkway shall be at least 1500 mm. Where work is not performed and the
walkway is used only as an access route, the width shall be at least 1000
mm. (See Walkway Width).
(SCAN)
4.17.10 Air Cooler Platforms Pipe-rack-mounted exchangers shall have drive assembly access
platforms. Multiple bay exchanger banks mounted on a pipe rack shall
have walkways that connect the drive assembly access platforms in each
bay. Platforms and walkways shall be at the same elevation.
(GS Addendum 7.3.5.3 & 7.3.5.12)
The drive assembly access platform on exchanger banks mounted on a

pipe rack shall have an extension platform that permits lifting the motor
with a crane. Maximum travel distance of the motor to the lift point shall be
33 metres. Platform extension shall be level.
(GS Addendum 7.3.5.10)
A walkway and ladders shall be provided at both ends of an exchange

bank to connect the drive assembly access platform with the header
access platforms.
Grating shall be provided for header access and mechanical access

walkways. Where over the side warm air recirculation is provided, floor
plate shall be used in the side recirculation chamber, and grating shall be
used under the bundle.
Step-through ladders shall be used for exhaust actuator/louver access on

Type 3 units.
Page 58 of 105
Stairways shall be used for primary access to main operating levels and
main services levels.
For forced draft coolers, the minimum clearance between the fan inlet bell
and access platform shall be 2250 mm. For induced draft coolers, the
minimum clearance between the tube bundle frame and access platform
shall be 2700 mm.
Fan guards for forced draft units shall have one hinged section to provide
maintenance access.
4.17.11 Heat Exchangers Adequate space shall be provided for heat exchanger tube bundle pulling
activities and for walkway/lay down area accessibility.
Pull spaces provided for maintenance or repair (e.g. areas needed for the
pulling of tube bundles from heat exchangers or condensers) shall be kept
clear of all piping, cable trays, panels, and any other obstructions.
Guardrails restricting pull spaces shall be removable.
In addition, the pull space shall provide room for the personnel performing
the tasks, tools required, lifting or support equipment, and transport
devices (if used) to move the item from the area.
A minimum of 150 mm space shall be provided for wrench room/access

between pipe flanges and an exchanger shell or its insulation, and
between a pipe or its insulation and the exchanger flanges.
Arrange the channel piping with a removable section between the
exchanger and block valves so that full access is available for bundle
pulling and tube cleaning.
(SCAN)
Page 59 of 105
Page 60 of 105
5.0 INSTRUMENTATION
5.1 INSTRUMENT NAME AND

WARNING PLATES
5.1.1 General All instruments, junction boxes, cabinets, panels and ancillary
equipment shall be provided with nameplates indicating the tag
number only or the tag number and the service. For details, see
standard drawing S 37.601.
In addition to the above, the text on nameplates for manual selector

switches shall repeat the switch position markings and shall
unambiguously describe what each switch position represents.
Similarly, the text on nameplates for push buttons shall describe
what action is taken when the push button is activated.
For nameplate requirements associated with impulse lines, see DEP

32.37.10.11-Gen.
DEP 32.31.00.32: 2.7.1 and S 37.601
5.1.2 Language The language or languages to be used on nameplates at the

Principal’s site shall be in Dutch. Particular additional requirements
(in English) shall be advised by the Principal.
DEP 32.31.00.32: 2.7.1
5.1.3 Field-mounted Nameplates All plant-mounted instruments, e.g. inline instruments, transmitters,
local indicators, converters, control valves, limit switches, solenoid
valves etc., and junction boxes shall be provided with nameplates.
The nameplate shall be properly secured, for instance to the
instrument support and the colour shall be as specified by the
Principal.
DEP 32.31.00.32: 2.7.2
5.1.4 SIL1 IPF Initiators IPF initiators of SIL 1 and higher shall have a red nameplate with
white lettering.
DEP 32.31.00.32: 2.7.2
5.1.5 Other Identification Other additional identification requirements may apply:

Requirements
- for control valves, see DEP 32.36.01.17;
- for valves and instruments in gaseous oxygen service see DEP
31.10.11.31;
- for thermocouples used for furnace coil balancing services see 7.3
of DEP 32.31.00.32.
DEP 32.31.00.32: 2.7.2
5.1.6 Nameplates for Indoor Use All panel-mounted instruments shall be provided with nameplates in
accordance with the Manufacturer's standard.
Cabinets and distribution frames shall be provided with nameplates,

carrying at least the tag number. The material of the nameplates
should be laminated plastic and the colour should be as specified by
the Principal.
DEP 32.31.00.32: 2.7.3
Page 61 of 105
5.1.7 Labels inside Instrument Labels and marking methods used inside instrumentation cabinets
Cabinets shall be to Manufacturers' standards provided they are secure and
permanent.
DEP 32.31.00.32: 2.7.3
5.1.8 Abbreviations Where abbreviations are necessary, these shall be standardised

and consistent for all titles as specified in the Project Specification or
the Principal's site standards.
DEP 32.31.00.32: 2.7.4
5.2 PLANT INSTRUMENTS
5.2.1 Finish IPF trip initiators of SIL 1 and higher should have a red colour and
the finish of plant-mounted instruments in oxygen service should be
yellow. The finish of all other plant-mounted instruments may be in
the Manufacturer's standard colour (but not red or yellow).DEP
32.31.00.32: 3.1
5.2.2 Lamp Test Facilities All indication lamps shall be provided with test facilities in the vicinity
of the lamp, so that one man can execute the test. The test logic
should be located in the DCS or IPS.
DEP 32.31.00.32: 2.10
5.2.3 Integral and Receiving Where a local indicator is required to support operating personnel,
Indicators the physical location of the indicator should be selected so that it
can be read from the intended operator position. If this requirement
cannot be met by an integral indicator, a receiving indicator shall be
applied.
Integral and receiving indicators required for operational reasons

shall be shown on PEFS.
DEP 32.31.00.32: 3.2
5.2.4 Diaphragm Seals Particular care shall be taken while handling diaphragm seals.
Diaphragm seal transmitters are heavy and shall be properly
supported.
DEP 32.31.00.32: 3.5
5.3 LOCATION AND

ACCESSIBILITY
5.3.1 On-line Instruments On-line instruments are to be mounted on or in the direct vicinity of
the instrument process connection(s).
DEP 32.31.00.32: 3.7
Page 62 of 105
5.3.2 Limited accessibility Limited accessibility is acceptable for indicating instruments,

providing that they can be properly read from a permanently
accessible location.
Appendix 3 in the DEP provides minimum accessibility

requirements. However, irrespective of the minimum accessibility
level given in Appendix 3, one should aim for an optimum
accessibility if this can be achieved at acceptable cost. It may, for
instance, be feasible to relocate the piping take-off point during the
engineering stage so as to change the accessibility level of a
pressure transmitter from ‘limited’ to ‘permanent’ at no additional
cost.
DEP 32.31.00.32: 3.7
5.3.3 Rodding-out Instruments and their impulse lines shall be surrounded by sufficient
free space to allow rodding-out of process connections and the
removal of:
- bolts, nuts and gaskets etc;

- covers and enclosures;
- orifice plates from the orifice flanges;
- removable parts from in-line flow meters;
- internals from the control valve;
- displacers from the displacer chambers;
- thermometer elements from the thermo-wells.
DEP 32.31.00.32: 3.7
Direct mounting is less suitable for applications that require rodding

out of process connections.
DEP 32.37.10.11: 2.2.3.7
5.3.4 Insulation Enclosures
The body enclosure shall be constructed so that it can easily be

removed in the event that the instrument needs maintenance, taking
account of restrictions posed by winter clothing and PPE.
DEP 32.37.10.11: 7.4
5.3.5 Model Reviews In the event of a model check, special attention shall be given to:
- correct location of control rooms/analyser houses

- location and access of main cable routes/junction boxes
- accessibility of instruments
- free clearance for insertion or withdrawal of certain instruments
e.g. displacers, capacitive level probes, temperature elements,
etc.
DEP 32.31.00.10: 9
Page 63 of 105
5.3.6 Hoisting Requiremements Heavy equipment such as control valves and inline flow meters of
DN 100 and larger and all positive displacement meters and turbine
meters should be accessible by mobile hoisting equipment. Where
this is not possible, permanent hoisting facilities shall be considered.
DEP 32.31.00.32: 3.7
5.3.7 Toxic Service Consideration shall be given to any special requirements for the safe
handling of toxic substances, as dictated by the relevant piping
class.
DEP 32.31.00.32: 3.7
5.3.8 Mounting Height Whenever possible, instruments shall be mounted at eye level (circa
1600 mm), but in any case not lower than 750 mm from the base.
unacceptable DEP 32.31.00.32: 3.9
Max. 1600 mm
Min. 750 mm
unacceptable
5.4 SPECIFIC INSTRUMENTS
5.4.1 Relief Valve Location Relief valve systems require periodic inspection and maintenance
and hence they should be easily accessible.
DEP 80.45.10.10: 2.2.1
5.4.2 Level Gauges If the visible level range in a gauge is continued in a second
(staggered) level gauge, or the level is used to check another level
instrument, both levels shall be readable from the same location.
To ensure clear visual access for the operator, level gauges shall
not be placed behind pipes or other obstacles. The level gauge
shall be positioned so that it can be read from ground level, platform
or ladder.
If a light is needed to read the level gauge, the level gauge shall be
less than 1000 mm away from where the operator is standing. If this
is not possible, an illuminator shall be installed behind the level
gauge.
DEP 31.38.01.11 4.7.3.1
Page 64 of 105
5.4.3 Positive Displacement Positive displacement meters and their ancillary equipment such as
Meters filters and vapour eliminators shall be installed so that they can
easily be reached by hoisting equipment.
DEP 32.31.00.32: 4.10
5.4.4 Displacer Level All displacer instruments shall be specified with left-hand or right-
Instruments hand mounting of the instrument with respect to the mechanism
chamber, depending on the relative position of process equipment
and displacer chamber and operator access from platforms, etc.
DEP 32.31.00.32: 5.4
5.4.5 Pressure Gauges If local pressure indication is regularly needed to support field
operator actions, a pressure gauge or receiving pressure indicator is
needed.
If pressure transmission is also required for control room indication,

a local (integral or remote) receiving indicator has preference over a
pressure gauge.
A pressure point shall be considered if a pressure measurement is

only occasionally required for non-operational activities.
DEP 32.31.00.32: 6.1
Where practical, pressure vessels grouped together shall have their

level gauges at a common level.
DEP 31.38.01.11: 4.5
5.4.6 Hydrogen Fluoride Service All instruments shall be located at an elevation of maximum 1 metre
above the working floor for safe and easy handling during operation
and maintenance.
DEP 31.38.01.11: 10.4.1
5.4.7 O & M Tasks & For vacuum towers, sufficient rods for rodding-out plugged level
Considerations instrumentation shall be available.
Purge gas on level instrumentation to be maintainable at required
flow levels.
5.5.1 Grade access All monitored instruments required on elevated piping or non-
accessible vessel components shall be tubed to grade level or
alternatively located on access platforms.
All instruments and transmitters that require regular (nominally
monthly) testing or calibration or other access shall be located either
at grade level or have permanent access platforms.
(SCAN)
Page 65 of 105
5.5.2 Instrument Location All instruments shall be located and oriented in such a way that:
• operators and maintainers have safe and convenient access,
• they do not obstruct access to equipment for maintenance or
ongoing operating requirements, and
• it is possible to conduct in-place calibration and in-place
withdrawal of parts for maintenance.
Magnetic level gauges, gauge glasses and level transmitters shall
be readable from grade, platforms, or permanent ladders.
(SCAN ESTG 16-3.11)
Indicators and meters shall be visible from grade, permanent ladder

or platform. Those located less than 4 metres above high point of
finished surface shall be accessible from grade or a portable ladder.
Those over 4 meters above high point of finished surface shall be
accessible from a platform or permanent ladder. This applies to:
• local pressure indicators
• temperature test wells
• flow meters
• temperature indicators and thermocouples.
(SCAN ESTG 16-3.11)
5.5.3 Insulation Enclosures Gauges and displays associated with frequently monitored systems
shall be located outside acoustic enclosures wherever possible.
Wherever feasible, instrumentation enclosures shall be mounted
outside the guardrail of a platform as close as possible to the edge
of the platform to keep the walkway clear of obstructions but keep
the instrumentation within easy reach.
SCAN - Reason: lessons learned, when mounted inside the rail
enclosures obstruct walkway, access & egress
Page 66 of 105
6.0 PIPING
6.1 CLEARANCE
6.1.1 General Piping shall be routed so that the optimum piping layout is achieved in
terms of process requirements, ergonomics, operation, inspection and
maintenance.
DEP 31.38.01.11: 3.1
Piping with instrument connections shall be routed so that safe access to
these connections is ensured; if necessary, platforms or walkways shall be
provided (see DEP 32.31.00.32-Gen).
A forked pipe shall be designed and supported so that no excessive loads

on equipment may occur when one branch of the pipe is disconnected.
The minimum elevation of the bottom of overhead piping (or supports or

steel, whichever is the lower) shall be 2.1 m over walkways and platforms.
(Refer to DEP for clearances for road, rail, HGV and crane).
There shall be a minimum horizontal clearance of 0.75 m for access ways

and walkways, and 0.9 m for thoroughfares – see Section 3.
DEP 31.38.01.11: 3.3
The elevation of support sleepers in pipe tracks or trenches shall be such

that there is access for maintenance and for operation of valves, drains,
etc.
DEP 31.38.01.11: 3.4.2
The use of spring supports, snubbers and sway braces should be avoided.
If they are unavoidable, good access for maintenance via a permanent
platform shall be provided. If this may lead to unacceptable costs the
Principal shall be consulted.
DEP 31.38.01.11: 3.5
The distance between piping shall allow for the turning of any spectacle
blind, if present.
DEP 31.38.01.11 3.8
Page 67 of 105
The minimum distance between pipes in racks, from insulation to insulation

where applicable, shall be 75 mm.
Where required, the distance between pipes shall be increased to allow for
movements caused by thermal expansion.
DEP 31.38.01.11: 3.8
75 mm
- pipe-to-pipe in rack or trench
- from outside of insulation if present
6.1.2 Flange Clearance The minimum distance in a pipe-rack between a flange and a pipe, or its
insulation where applicable, and between a flange and another flange shall
be 75 mm to allow access for tools.
Reason: Learning from incidents: 30 mm is inadequate clearance for tools
to work flanges at battery limits
Derogation from DEP 31.38.01.11: 3.8
75 mm flange to pipe in pipe-rack or

trench, including insulation
75 mm flange to flange in pipe-rack or

trench, including insulation
The flanges shall be lined up so that the bolts can be inserted without
force.
DEP 31.38.01.11: Appendix 12(2)
Page 68 of 105
6.2 LOW POINT DRAINS

6.2.1 Clearance If required for operation/maintenance, valved drain connections shall be
installed at low points, and valved vent connections at high points in piping
systems. These connections shall be shown on the PEFS.
Drains shall be located so that there is sufficient free space underneath to
install temporary facilities to discharge the drained liquid.
DEP 31.38.01.11: 3.13
Drain entry into drain openings should be visible and at a safe distance
from the valve used to control the drain, taking into account the medium.
6.3 BLINDS AND SPACERS

6.3.1 Access If personnel are to enter the equipment, the points of positive isolation
should be as close as possible to the equipment.
Quick-acting blinds or line blind valves (e.g. "Hamer") may be used for
frequent pipe blinding if approved by the Principal if the seat material is
suitable for the fluid and operating temperature.
Piping shall be designed, supported and installed so that the flanges do not
move when the bolting is removed for spading purposes. The piping shall
be sufficiently flexible to be able to install the required isolation fittings
(spades, blind plates etc.) and there shall be sufficient space to turn
spectacle blinds, where provided.
DEP 31.38.01.11; 8.7.1
Spectacle blinds and spades shall be located so that they are accessible
from ground level or from platforms or walkways. The need for scaffolding
shall be minimized.
DEP 31.38.01.11 8.7.2
6.3.2 Hoisting A relatively large force is required to turn a large spectacle blind. A
spectacle blind cannot easily be turned using a crane or a hoisting device,
and therefore the need for cranes and hoisting facilities shall be avoided.
DEP 31.38.01.11: 8.7.2
For easier handling, spading points should not be installed in vertical

piping; if this is unavoidable, special precautions shall be taken to improve
access and handling.
DEP 31.38.01.11: 8.7.2
Page 69 of 105
6.3.3 Blinds - Weight Personnel should not pull or lift loads exceeding 250 N. If the required
force to turn spectacle blinds exceeds 250 N, spades with spacers should
be used instead. Spectacle blinds requiring a force of more than 250 N are
tabulated below.
DEP 31.38.01.11: 8.7.2
ASME rating class Size (DN)

150 450 and larger
300 400 and larger
600 350 and larger
900 300 and larger
1500 300 and larger
2500 300 and larger
6.3.4 Spacers and Spades Spacers and spades exceeding a weight of 250 N should be provided with
- Weight a lifting lug. A mobile crane or, if this is not possible, special hoisting
facilities should be used for handling such items. Spades having a weight
of more than 250 N are tabulated below.
DEP 31.38.01.11: 8.7.2
ASME rating class Size DN

150 350 and larger
300 300 and larger
600 250 and larger
900 200 and larger
1500 200 and larger
2500 150 and larger
6.3.5 Removable Spool A removable spool and blind flanges shall be used in the following
and Blind Flange situations:
• where the nozzle is used for entry into the equipment;
• where the nozzle is used for hoisting purposes (e.g. top nozzles on
columns);
• where the nozzle (e.g. the head of a heat exchanger) is used to
remove internals (e.g. the tube bundle);
• where the nozzle is used for loading/unloading of solids (e.g.
catalyst).
DEP 31.38.01.11: 8.7.2
Page 70 of 105
6.4 PIPING ADJACENT TO

EQUIPMENT
6.4.1 General Piping and pipe supporting structures shall be designed so that access is
provided for maintenance or removal of valves, in-line instruments, tube
bundles and shell/channel covers (e.g. cranes and trucks) and for
operational reasons (e.g. filter cleaning).
Removal or replacement of equipment shall be possible with a minimum

dismantling of piping. Removable pipe spools may be required.
Small pieces of equipment and ancillaries which need regular supervision

or maintenance should be installed on elevated plinths in order to improve
access.
DEP 31.38.01.11: 4.1
6.4.2 Auxillary Piping Auxiliary piping shall be neatly routed along the base-plate and shall not
extend across the operating floor. This piping shall not obstruct inspection
covers, bearing caps, upper halves of casings or any other items which
require access for operation or maintenance.
DEP 31.38.01.11: 4.2.1
6.4.3 Strainers In a horizontal suction pipe the Y-type strainer shall be installed pointing
downwards or at an angle of maximum 45° from vertical, in order to
improve access for cleaning.
Collecting and processing facilities shall be used in order to avoid spillage

during withdrawal or replacement of strainers and maintenance of pumps.
DEP 31.38.01.11: 4.2.2.3
6.4.4 Heat Exchangers Where stacked heat exchangers are welded nozzle-to-nozzle, this option
eliminates flange leakage but puts restrictions on the maintenance of the
exchangers.
DEP 31.38.01.11: 4.3
6.4.5 Pressure Vessels Where practical, pressure vessels which are grouped together shall have
platforms and interconnecting walkways at the same elevation. The
number of stairways and ladders to the platforms shall be sufficient to meet
safety requirements.
Where practical, pressure vessels grouped together shall have their level
gauges at a common level.
DEP 31.38.01.11: 4.5
6.4.6 Steam Steam traps up to and including DN 40 should be welded and should have
removable internals to allow repair without performing hot work.
Steam traps shall be positioned so that they are easy to maintain and
replace.
DEP 31.38.01.11: 5.4
Page 71 of 105
6.4.7 Tank Farms There shall be access to manholes, mixing nozzles, drains and other
facilities on the tanks.
DEP 31.38.01.11: 6
6.4.8 Jetty Loading/ Positive displacement flow meters, and their filters and de-aerators, shall
Unloading Facilities be accessible for operation and maintenance.
DEP 31.38.01.11: 7.1
6.4.9 Hydrogen Fluoride All valves and instruments shall be located at an elevation of maximum 1
Service metre above the working floor for safe and easy handling during operation
and maintenance.
DEP 31.38.01.11: 10.4.1
6.5 PIPELINE PIG-TRAP SYSTEMS
6.5.1 Valves When weld-end valves are used (i.e. very toxic service), the maintenance
requirements shall be addressed i.e. top-entry type valves shall permit the
change out of internals such as valve seats, seals, ball etc.
Actuated valves shall have provision for a hand wheel or hand pump on
the actuator. The maximum force required at the hand-wheel or wrench
shall not exceed 360 N.
DEP 31.40.10.13; 2.5.1
6.5.2 End-closures If the opening of the end closure is not in the vertical plane, i.e. on vertical
or sloped pig traps, the end closure shall be equipped with a counterweight
or hydraulic opening system or similar system to facilitate safe and easy
opening of the door. There should be a locking device to hold open the
door while personnel are loading or unloading pigs.
DEP 31.40.10.13; 2.6.1
6.5.3 Safety Devices The end closure shall have the following safety devices:
• A safety locking device to prevent opening of the door when the pig
trap is pressurised.
• A pressure safety device that when partially released will alert the
operator to a possible hazard unless pressure in the pig trap is
relieved completely. Removal of the safety locking device shall not be
possible unless the pressure safety device is fully released. Engaging
the pressure safety device shall only be possible when the end
closure is fully closed and the safety locking device is correctly
engaged. The pressure safety device shall be designed so that there
is no risk of blockage. In very toxic service, the pressure safety
device shall be non-venting.
The devices shall be constructed and located so that they cannot readily
be rendered inoperative or replaced. The devices shall be easily
accessible for inspection.
An interlocking system between various valves and the end closure door
operating mechanism may be considered to protect personnel and
equipment, depending on the service, trap location and planned pigging
frequency. The necessity for interlocking shall be decided by the Principal.
DEP 31.40.10.13; 2.6.3
Page 72 of 105
6.5.4 Pressure Indicators At least one pressure indicator should be clearly visible to the operator
from the end closure activation point. A second pressure indicator should
be installed on the minor barrel close to the pig trap valve. If pig
launching/receiving operations are anticipated during the hours of
darkness, night-time visibility shall also be addressed.
DEP 31.40.10.13; 2.12
6.5.5 Sphere Common practice is to unload the receiver after several spheres have
Launching/Receiving been received. For spheres with a nominal diameter larger than 450 mm
Pins/Flappers this can be hazardous due to the combined weight of the spheres. In such
cases, consideration should be given to providing a restraint (e.g. flappers
or pins/fingers) to allow the spheres to be unloaded one at a time.
Alternatively, a horizontal receiving tray, long enough for the whole
consignment, should be provided and fixed into position before the end
closure is opened.
DEP 31.40.10.13; 2.13
6.5.6 Layout Pig traps shall be located so that they are orientated with their end
closures pointing away from personnel areas and critical items of
equipment, i.e. those containing hydrocarbons and/or very toxic
substances or in safety service.
The requirements for pig handling depend on the type and mass of pig and
the pipeline size: normal pigs with a mass less than 30 kg may be
manually loaded into or out of the pig traps; typically, this will be the case
in pipelines of nominal diameter 300 mm and smaller.
Pig loading trolleys, cassettes or baskets enable heavier pigs to be

properly loaded, aligned and retrieved from pig traps.
Space shall be provided beyond the end closure door of the pig trap for pig
handling. Typical requirements are given in Figure 6 of the DEP and Item
6.5.10 below.
For pig trap systems where a reduced length barrel is installed, sufficient
working space should be provided to allow the extension spool-piece to be
installed and the intelligent pig to be loaded or retrieved.
Pig traps should be located at least 15 m from any type of equipment,

other than adjacent pig traps. Pig trap systems should generally be located
adjacent to each other for ease of pigging operations.
DEP 31.40.10.13; 4.1
Page 73 of 105
6.5.7 Horizontal Pig Traps The elevation of the bottom of the end closure on horizontal pig traps
should be approximately 700 mm above grade to provide sufficient room to
slope the drain lines and allow easy handling of the end closure and pigs.
Horizontal pig traps with a nominal diameter of 300 mm and larger should
normally be provided with pig lifting facilities, such as a runway beam,
unless they can be readily accessed by cranes. Provision of a trolley with a
push rod and pulling line should be considered to assist loading or removal
of pigs from the trap. In designing the pulling line, a practical and safe
means shall be provided of attaching the hook onto the front of the pig to
retrieve it. The use of these facilities, including the possible use of internal
trays, shall be agreed with the Principal.
DEP 31.40.10.13; 4.4
6.5.8 Vertical Pig Traps If a vertical pig launcher is inaccessible to the platform crane, a dedicated
lifting facility shall be installed capable of lowering an (intelligent) pig into
the barrel, unless it can be shown that the pig can be manually loaded in a
safe manner.
The elevation of the barrel end closure above deck level should provide
convenient access to the door locking mechanism.
A vertical ladder or local stairway shall be provided to allow access

between deck levels local to the pig trap.
DEP 31.40.10.13; 4.5
6.5.9 Access Platforms A platform shall be provided adjacent to any valve where the centre of the
hand-wheel is more than 1500 mm above grade.
Similarly, a platform shall be provided adjacent to any equipment (e.g. pig

signallers) which is more than 1500 mm above grade and which is used
during pigging operations.
DEP 31.40.10.13; 4.6
6.5.10 Recommended Pig

Working-area
AL X
Dimensions
BL/R
work
Y
area
• A/B = See table 3 in the DEP
• X = Maximum pig length plus 1 metre
• Y = 1.8 metres for 100 mm to 800 mm pipeline

3 metres for 900 mm and above
DEP 31.40.10.13; Fig. 6
Page 74 of 105
6.6 VALVE ANALYSIS
6.6.1 IVA The location of a valve shall be based on its criticality of function and
frequency of use for both operation and maintenance.
DEP 30.00.60.13 Human Factors Engineering – Valve Analysis defines a
process called Identification of Valves Analysis (IVA), which optimally
locates valves for use while also recognizing design constraints.
The goal is to ensure that those valves most critical to operation and those
accessed most frequently are the ones most readily accessible and easiest
to operate.
For new projects a session should be held with the project team during
front-end design to get concurrence from engineering and operations on
the valve criticality category. This session also provides an opportunity to
adopt heights and weights that may be more applicable to the anticipated
end-user population than those assumed in the development of Table 5.4-
2. Once agreement is reached for a specific project or installation/facility,
the requirements for each valve criticality category will become mandatory.
Deviation from these requirements needs an approved variance.
The following tables are not intended to be all inclusive of all valve types.
Operations and the project HFE coordinator should be consulted on valve
types that are not listed.
6.6.2 Category 1 Valves Critical Valves

For these valves, rapid and effective intervention is essential.
Access requirements:
• permanent access at grade, or,
• if not practical, access by stairs & platform.
Layout should conform to the preferred range, and shall conform to the
acceptable range, for height and reach limits as shown in Figure 5.4-1.
6.6.3 Category 2 Valves Non-Critical Valves
• permanent access at grade or by stairs & platform, or,
• if not practical, permanent ladder plus a small platform.
Layout should conform to the preferred range, and shall conform to the
acceptable range, for height and reach limits as shown in Figure 5.4-1.
6.6.4 Category 3 Valves Non-Operating Valves

• permanent access (at grade, stairs or ladder) preferable,
• temporary or mobile equipment (e.g. manlift, scaffold) acceptable if
indicated and accommodated in design (i.e. space reserved in 3D
model).
Layout should conform to the acceptable range for height and reach limits
as shown in Figure 5.4-1 but shall be within the limits of safe healthy
human performance.
Page 75 of 105
Unacceptable
1295 mm
(51 in.)
Preferred
457 mm
(18 in.)
Acceptable
152 mm
(6 in.)
457 mm Grade/deck
(18 in.)
Max. horizontal distance from
obstruction or operator’s front
Figure 5.4-1(a): Ergonomic dimensions for valve layout – vertical stem.
Min. 610 mm (24 in.) between

any obstruction
and hand wheel/valve stem
Unacceptable
1830 mm
(72 in.)
Preferred
610 mm
(24 in.)
Acceptable
230 mm
(9 in.)
Grade/deck
457 mm
(18 in.) Max. horizontal distance from obstruction,
or operator’s front
Figure 5.4-1(b): Ergonomic dimensions for valve layout – horizontal stem
Page 76 of 105
6.6.5 Initial Valve Table 5.4-2 provides a typical criticality assessment for valve-types
Classification Table commonly found in refineries using the three categories defined above..
The assessment is based on type of service, reliability, frequency of
operation or maintenance, criticality to plant operation and the need for
rapid intervention.
The footnotes at the bottom of the table must be referred to.
6.6.6 Deviations It is expected that there will be specific situations where it is not possible or
it is impractical to provide the required accessibility of the assigned
category for some individual valves. In these situations, operations
personnel shall be consulted on a case-by-case basis to approve alternate
arrangements for that particular valve (e.g. change classification, height,
means of access, etc.). Such decisions shall be documented, but no
technical deviation is required.
Page 77 of 105
Table 5.4-2: Initial Classification of Valves

Valve Type Valves Associated With -(see below for footnote explanations) Category
1. Columns/Vessels
A
1.1 In/out isolation valves C-2
B
1.2 Process/Maintenance High Point vent valve C-3
1.3 Process/Maintenance open drain/utility connection valve C-2
1.4 Process/Maintenance closed drain valves C-2
1.5 Bypass on isolation valve (purge/pressurization) C-2
1.6 HP Letdown Valves C-1
1.7 In/out isolation valves on product, oil and water underground C-1
C
collection systems (sumps in pit)
1.8 Skimming valves C-1
2 Tanks
A
2.2 VRU and Blanket Gas valves C-1
2.3 Filling connection (from truck/container) C-1
2.4 Sample or extraction valves C-1
2.5 Interface sample lines C-1
D
2.6 Bottom open drain valve/water sumps C-1
2.7 DMW connection to filling line C-1
3 Heat Exchanger
E
E
3.2 Bypass block valve C-2
E
3.3 Bypass throttling valve (manual) C-2
E
3.4 Overhead Condenser isolation valves C-2
E
3.5 Reboiler isolation valves C-2
E
3.6 Open vent valve C-2
E
3.7 Open drain/utility connection valve C-2
E
3.8 Closed drain valve C-2
3.9 Temporary Nitrogen connection C-2
E
3.10 Cooling medium inlet/isolation bypass valves C-2
E
3.11 Cooling medium high point vents C-2
E
3.12 Cooling medium low point drains C-2
E
3.13 Cooling medium inlet/isolation valves C-2
4 Pumps
F
4.1 Suction/discharge isolation valves C-1
G
4.2 Discharge check valve C-1
4.3 Suction/discharge open drain valves C-1
4.4 Suction/discharge closed drain valve C-1
4.5 Discharge open vent valve C-1
4.6 Recycle valve (manual) C-1
4.7 Flushing valve C-1
4.8 Equalizing line block valve C-1
5 Compressors
5.1 Suction/discharge isolation valves C-1
G
5.2 Discharge check valve C-1
5.4 Suction low point open drain valve C-1
5.5 Casing drain valve C-1
5.6 Suction/discharge purge valve to flare C-2
5.7 Temporary Nitrogen Connection
C-2
Page 78 of 105

6 Filters/Strainers
6.2 Bypass valve C-2
6.4 Open drain valve C-2
6.5 Closed drain valves C-2
6.6 Temporary Nitrogen connection C-2
7 Control Valves
7.1 Control valve C-1
7.3 Bypass valve C-1
7.4 Check valve C-2
8 Depressuring/ESD valves
8.1 Depress/ESD valves C-1
H
9 Relief Valves
I
9.1 Relief valves C-1
I
I
I
9.4 Bypass valves C-1
10 Instruments
10.1 Level instrument isolation valves C-2
10.2 Level instrument open vent/drain valves C-2
10.3 Level instrument closed vent/drain valves C-2
10.4 Valves on transmitters to Flow Meters C-2
10.5 Instrument Isolation Root Valve C-2
10.6 Pressure instrument isolation valve C-2
10.7 Analyzer isolation valve - general C-2
10.8 Analyzer isolation valves - with retractable probe C-2
11 Sampling
11.1 Isolation valves - general C-1
11.2 Isolation valves - with retractable probe C-1
11.3 Needle valve C-1
11.4 Isolation Root valve C-2
12 Piping/Utilities
J
12.1 Battery Limit (BL) Isolation Valve C-1
12.2 Bypass on B.L. valve C-2
12.3 Valves in pipeline line-up C-2
12.4 Open vent/drain valves around B.L. valve C-3
12.5 Switching valve (manual/MOV) C-1
12.6 Intermittent on-off valve (manual/MOV) C-1
K
12.7 Throttling valve (manual) C-2
L
12.8 Check valve C-2
12.9 Valves in off spec product line-up C-2
12.10 Firewater deluge main root valves at battery limits C-1
12.11 Utility Letdown Stations C-2
12.13 Utility Station Last Downstream Valve (Steam, Air, Nitrogen, & C-2
Page 79 of 105

Utility Water)
12.14 Utility Station Root Valve (Steam, Air, Nitrogen, & Utility Water) C-3
12.15 Valves in temporary Nitrogen connection C-2
12.16 Valves in permanent N2 connection C-2
12.17 Nitrogen/Gas Purging Connections C-2
12.18 Process/maintenance high point open vent valve C-3
M
12.19 Process/maintenance low point open drain valve C-2
12.20 Valve stations with back-up A/B valve sets C-2
N
12.21 Flow Meters C-2
12.22 Non -routine isolation valves for process and equipment isolation C-3
12.23 Equipment flushing manifolds C-2
12.24 Chemical injection root valves C-3
12.25 Truck loading/unloading valves C-1
O
12.26 Valves at pigging station for heaters and pipelines C-1
12.27 Fired Heater In/out isolation bypass valves C-2
12.28 Fired Heater In/out isolation valves C-2
Footnotes: Additional design requirements for valves indicated in table 5.4.2

A. Ensure adequate space provided for inserting blinds and removal of spool pieces
B. For hydro testing can be C-3.
C. Need to be actuated from above ground. Valve extenders is acceptable
D. Should be piped to grade
E. Clean service can be C-3
F. Consider double block and bleed for isolation to alleviate need to isolate at root valve for
chemical injection point
G. For check valves inside pump/compressor isolation envelope shall be in close proximity to
isolation valves for maintenance access.
H. Should be C-1 if automated
I. Ensure access for lifting equipment and scaffolding
J. This also includes intra-plant BL valves
K. Field flow control/throttling valves shall be C-1
L. By exception can be C-3
M. See HFE requirements for these valves. These shall be 300 mm above grade/platform
N. Any exceptions to be discussed with Shell Instrumentation
O. Locate at grade where possible.
Page 80 of 105
Full specifications of HFE requirements for the selection, location and orientation of
6.7 VALVE SPECIFICS valves are contained in DEP30.00.60.13-GEN (March 2009), Appendix B.
The number of different types of valves shall be minimised.

DEP 31.38.01.11: 3.12.1
6.7.1 Block Valve and All pipes entering and leaving the process unit shall have a block valve and
Spades flanges provided to allow for spading (spades or spectacle blinds) at the
boundary of the process unit ("battery limit").
The block valves shall be located near each other unless impractical.
A drain/vent connection shall be installed as close as possible to the block

valves and spades, for draining, venting and testing purposes.
DEP 31.38.01.11: 3.12.1
6.7.2 Wafer and Lug Pipes with wafer and/or lug type valves may require an extra flanged
Valves connection for installing a spade flange or removal of a pipe spool.
DEP 31.38.01.11: 3.12.1

6.7.3 Chain Valves Chain operated valves shall not be used except with prior approval of the
Principal and then only for specific applications.
DEP 31.38.01.11 3.12.2
6.7.4 Location Valves shall not be installed above roads.

Valves should not be located in overhead pipe racks.
DEP 31.38.01.11 3.12.2
6.7.5 Stems in Horizontal Valves in horizontal pipes shall be positioned with their stem on or above
Pipes the horizontal, except in the exceptions (for safety and corrosion reasons)
specified in the DEP, where it shall be horizontal
DEP 31.38.01.11: 3.12.1
6.7.6 Hand-Wheels The location of valves hand-wheels and/or stems shall not obstruct
platforms or walkways.
The minimum distance between valve hand-wheels and any other
obstruction shall be 75 mm.
DEP 31.38.01.11: 3.12.2
object
Hand wheels less than 125 mm diameter should be operable using only
one hand. Hand wheels greater than 125 mm should be operable using
two hands.
Page 81 of 105
6.7.7 Control Valves – Globe control valves shall be installed with their diaphragm actuator stem
Dismantling and in the vertical position, with sufficient clearance above the actuator and
Hoisting under the bottom flange to allow the control valve to be dismantled without
removing the valve body from the pipe.
Control valves shall be installed with sufficient clearance around the

actuator and valve body to allow the control valve to be dismantled without
the valve body being removed from the pipe and to lift and remove the
valve. Control valves shall be located so that they are accessible for
hoisting equipment where needed.
DEP 31.38.01.11: 3.12.4 and DEP 32.36.01.17: 3.1
6.8 SAMPLE POINTS ON [This section does not apply to sample points on tanks. For sample points
PIPING on tanks, see Section 7.0.]
6.8.1 Location The sampling point shall be positioned so that the valves are easy to
operate and taking the sample will not impair the safety of personnel or
plant or cause environmental impact.
Samples should be taken from a vertical pipe where possible; where this is
not possible:
• For gaseous products in horizontal pipes, sample take-off
connections shall be installed at the top of the pipe.
• For liquid products in horizontal pipes, sample take-off connections

shall be installed at the side of the pipe.
DEP 31.38.01.11: 3.14
6.8.2 Connections Dedicated connections shall be provided for sample collection.

Sample take-off connections shall not be located at dead ends of piping.
Sample take-off connections shall be easily accessible, shall have sample

points as short as possible and not longer than 8 m, and should be at
ground level.
As far as practicable, sample connections shall be grouped together and

provided each with a sample cabinet, which can be connected to one
common drain facility. Drain facilities shall be connected to a sample
recovery system wherever possible.
DEP 31.38.01.11: 3.14
6.8.3 O & M Tasks & Characteristics of produced and functionality considered for final selection
Considerations of application
Tightening method should reflect frequency of tightening and loosening
(e.g. Wing-nuts vs nuts & bolts)
Install differential readings where there are considerable HSE risks to
operator.
Access to filters / strainers should provide enough space for positive
isolation, flushing, draining and purging, and the selected method for
removing, cleaning and installing baskets/filters.
Page 82 of 105
6.9.1 Access & Clearances Piping layout shall not inhibit safe and rapid egress from structures in case
of a leak, fire or other situation requiring personnel to rapidly evacuate an
area.
(SCAN)
Piping shall normally be installed at least 450 mm clear of finished grade or

standing surface. Clearance provided shall be sufficient to permit drain
connections.
At least 50 mm space shall be provided between piping and equipment,

columns or building walls. This shall be increased:
• by the thickness of insulation where applicable,
• for the unbolting and bolting of flanges,
• proper instrument connections, and
• to allow field welding where specified.
The distance between the insulation of a low-temperature pipe and any
other object shall be at least 100 mm.
(DEP 31.38.01.11 3.8-SCAN)
50 mm
pipe to
object
Clearance between a flange and a wall, structural steel or guardrail should

not be less than 500 mm to allow access for wrenches and torquing
equipment.
500 mm
flange to object
6.9.2 Flange Height Flanges on a vertical pipe or vessel nozzle that penetrates decking shall
have a minimum of 300 mm between the top of the kick plate and the
bottom flange nut surface to allow sufficient space for a wrench and a
hand. The same space requirement applies to a flange on a pipe that
penetrates the ground.
Reason: Learning from incidents; muscular strain, hand and finger injuries.
Page 83 of 105
300 mm min between bottom of

flange & top of kick-plate
kick-plate
Where permanent platforms are provided to access flanges, spades,

spacers, spectacle blinds, instruments etc., the platform shall be located
such that items to be worked on are in the range between 800mm and
1400mm vertically above the platform (preferred 1200mm).
Operators should not have to reach more than 610 mm in the horizontal
direction to work on the item.
Provide accessibility for mobile hoisting equipment or provide alternative
hoisting equipment. Provide (break-) flanges to remove piping in order to
facilitate hoisting activities.
6.9.3 Low-point Drains Drains shall be piped open to sewer cups unless otherwise indicated.
Sewer cup shall be an open bell or pipe, minimum diameter 150 mm and
located 75 mm above paving and 150 mm above soil or grade.
6.9.4 Sewer Cups Drain lines which run to open sewers shall terminate approximately 50 mm
inside the top of the sewer inlet cup and shall be visible to a standing
operator.
Reason: History of spills in some Shell facilities.
Page 84 of 105
6.9.5 Stand-alone Vessels The hubs for draining stand-alone vessels shall be located at grade in such
a manner that an operator need not step more than 1.5 metre from a drain
valve to the edge of a platform in order to see the drain hub. Drains from
the platform shall be hard piped to an open hub at grade. Multiple drain
connections on a single platform may be piped to a common line.
1.5 m
Figure 5.2-A: Drain hub for stand-alone vessel
6.9.6 Multiple Valve Sets Similar to multiple pieces of equipment on a single deck, however, to avoid
on Single Deck possible tripping hazards and congestions on the deck the valve drains
shall not be hard piped to the drain hubs on the deck. Instead, temporary
pipe shall be installed in the field by the maintenance team when needed.
Again, each level in a structure shall have its own drain header and be
piped to its own open drain hub at grade.
[*] [*] [*] Note 1
[*] [*]
Note 1: Temporary pipe installed by maintenance when needed (not hard-piped in model).
Figure 5.2-C: Drain hub for multiple valve sets on single deck
Page 85 of 105
6.9.7 Pump Drains The drain hubs shall be located near the pump in such a way that the drain
piping to these hubs will not create a tripping hazard.
M M M
P P P
Figure 5.2-D: Drain hub for stand-alone vessel (SCAN)
6.9.8 Cleaning All drain lines past the last welded root valve, shall have flanged
connection on the downstream side of the root valve or unions installed to
facilitate replacement and cleaning of pipe spools.
(SCAN)
6.9.9 Blinds & Spacer Where blinding is expected to occur on a vessel and there is no
Storage permanently installed spectacle blind, permanent blind storage facilities
shall be provided in close proximity to the flange. Such blinds shall be
stored in a way that does not interfere with safe egress, access to
equipment, or create a trip hazard.
Reason: economy of workflow & effort, removes need for crane &
personnel to move blinds up and down from towers..
6.9.10 Orientation Where assisted lifting will be available, spading points should be installed
in horizontal piping; if this not feasible, special precautions shall be taken
to improve access and handling.
(SCAN)
6.9.11 Installation For spectacle blinds where the blind can be rotated on one of the bolts,
installation in a horizontal section of pipe is preferred.
SCAN - Reason: health & safety, orientation for applying force to handle
6.9.12 Differentiation Handles (tie bar) on spades and blinds shall have different shapes in order
to help visually differentiate between an installed blind and spacer.
SCAN - Reason: safety, especially on start up
6.9.13 Emergency Shut- Emergency shutdown valves shall be accessible from grade and without
down Valves exception shall be located in a clear area. Valve handles or wheels shall
be located as per Category 1 valves.
(SCAN)
6.9.14 Valve Location No valves shall be located directly under a platform grating where it is
necessary to remove the grating to operate the valve.
Platforms servicing valves shall be designed with all valve hand wheels
located within the handrails.
(SCAN)
Page 86 of 105
6.9.15 Sample Point Sample points shall be close coupled to the process and if possible from
Location the nature of the process should be located such that they are accessible
from grade level. If impractical, permanent access by stair may be
acceptable.
Sample point cabinets shall be close-coupled to the fast sample loop.
(SCAN)
6.9.16 Accessibility All sample points shall be behind a cover door with a view panel to see
Features samples bottles/bombs being filled. The see-through panel shall be a plexi-
glass type material.
The sampling cabinet shall be labelled and capable of being opened
without requiring any tools or the removal of any securing fasteners or
other devices.
A 25 mm hole at the top of the cabinet door with plug shall be provided to
allow the interior air to be gas tested prior to opening cabinet door. A min.
illuminance of 200 lux shall be provided at sample points and inside
cabinets.
6.9.17 Sample Point Top of sampling cabinet shall be no higher than 1900 mm and the bottom
Location no lower than 760 mm.
Sample points shall be located so the operator does not have to stand on
adjacent pipe work, cable trays, handrails, other equipment, or any object
not specifically designed as a standing surface for the operation and
maintenance of equipment.
6.9.18 Sample Point A minimum worker envelope of 1000 mm x 1000 mm with a head
Clearance clearance of 2300 mm shall be provided around sampling points to allow
operator to perform sampling tasks while using appropriate personal
protective equipment such as gloves and respirators.
6.9.19 Safety Sampling cabinet shall shield the operator from contact with the material
being sampled.
Volatile and/or toxic substances shall be prevented from escaping into the
local atmosphere by Venturi or by purge to flare. If vented to atmosphere,
the vapour must be released in a safe place.
Cooling water for sampling hot media shall be provided whenever practical.
Other cooling media can be considered on a case-by-case basis.
6.9.20 Sampling All connections for gas bombs shall be located inside a cabinet.
Connections Connections for liquid lines may be located outside a cabinet but must be
close coupled.
All piping and tubing associated with sampling shall be in accordance with
Shell piping specifications. The use of flexible hoses shall be subject to
COMPANY review and approval. A 90-degree connector shall be added to
the end of the sample hoses to prevent the hose from being bent
significantly to accommodate the bomb connection.
6.9.21 Sample Bottles and The sample bottles and bombs shall be properly secured in place inside
Bombs the cabinet during sampling. A minimum clearance of 50 mm shall be
provided around the circumference of the sampling bomb when connected
to allow adequate room to grip the bomb while wearing gloves.
Page 87 of 105
6.9.22 Cabinet Drains Sampling points shall be designed to avoid local spillage, but provisions for
spillage and containment shall be provided.
All liquid sampling cabinets shall be provided with a curbed area under the
cabinet unless the drain is routed to a drain opening hub.
Drains to the drain opening hub shall be a minimum of 20 mm diameter,
unless the sample if heavy oil in which case the drain shall be a minimum
of 50 mm.
All gas samples purge shall be routed to the flare or to a safe area.
Page 88 of 105
7.0 STORAGE TANKS
7.1 TANKS – GENERAL

DESIGN
7.1.1 Accessibility There shall be access to manholes, mixing nozzles, drains and other
facilities on the tanks.
DEP 31.38.01.11: 6
7.1.2 Primary Wind Girders and As the primary wind girder may be used as an access platform for fire
Platform fighting, its width shall not be less than 600 mm and the detail design
shall incorporate a full perimeter hand railing at the outside of the
wind girder.
The shape of the wind girder shall be such that a minimum free
passage of 600 mm is maintained all round including around the
supporting structure of the gauger's platform.
DEP 34.51.01.31: 5.2.2 and S 51.160
7.1.3 Man-ways Shell manholes shall be designed in accordance with EN 14015,

Clause 13.
DEP 34.51.01.31: 5.5.1 and S 51.127
S 51.227
Manholes for fixed roof tanks shall comply with EN 14015 Clause 13.
Manholes having a diameter ≥ 600 mm shall be equipped with davits.
Except for 760 mm diameter manholes in the floating roof itself and
the roof compartment manholes, floating roof tanks and open top
tanks shall be equipped with bolted covers only.
DEP 34.51.01.31: 9.2.4
7.1.4 Deck height The minimum height of an internal floating roof deck should be at
least 1500 mm to allow enough head clearance for kneeling work.
7.1.5 Stairways/Walkways Stairways and walkways for tanks shall be designed and constructed
in accordance with EN 14015, Clause 13.11.
DEP 34.51.01.31: 9.2.1 and S 51.087,

S 51.131,
S 51.156-001/002
7.1.6 Vertical ladders Fixed vertical ladders shall be constructed of carbon steel and shall
be completely supported by the tank shell, with the ends of the
runners terminating clear of the tank foundation.
Ladders exceeding 4.0 m in length shall be provided with safety

cages.
DEP 34.51.01.31: 9.2.2 and S 51.130
Page 89 of 105
7.1.7 Liquid Level Liquid level gauges shall be positioned so that they can be read from
Alarms/Indication System ground level, platform or ladder:
DEP 34.51.01.31: 9.2.9
7.2 FLOATING TANK

SPECIFICS
7.2.1 Access ladders The access ladder to the roof of floating tanks shall be equipped with
self-levelling stair treads. The construction shall be in accordance
with the applicable Standard Drawing.
The rails shall be placed at such a height above the centre deck that
snow or rainwater on the deck cannot affect movement of the ladder.
The ladder shall be provided with an anti-derailing device to prevent

uplift of the ladder during strong winds. The ladder wheels shall be of
a ball bearings type.
DEP 34.51.01.31: 9.4.4
7.2.2 Staircases - Elevated The staircase along the shell shall end on the top of the windgirder.
Gauger's Platform A clear vertical height between the platform and primary windgirder of
2000 mm shall be provided.
A separate staircase shall give access to the gauger's platform; both

provided with hand-railing arrangements, adjusted to accommodate
the roof access ladder and gauge pole assembly and shall be in
accordance with ISO 14122.
DEP 34.51.01.31: 9.4.9
7.3 ADDITIONAL
REQUIREMENTS
7.3.1 Roof Manway Internal floating roof tanks shall have a main roof manway located at
the top of the internal ladder with minimum 900 mm diameter or 600
mm x 900 mm rectangular. The hatch shall be hinged with no bolting
or fastening mechanism.
(ESTG 4-1.01 4.1.6)
7.3.2 Rescue hatch A rescue hatch 915 mm x 1200 mm shall be installed on the fixed
roof of an internal floating roof tank. This hatch shall be associated
with the manway/access to the internal ladder and located close to an
external ladder or stairway.
The rescue hatch should be provided with a lifting device designed
for a 225 kg load and the roof structure reinforced to accommodate
the load.
(ESTG 4-1.03 3.5)
7.3.3 Tank Stairways Tanks above 9 m shall have a circular stairway and the base of the
stairs shall be convenient to the road or access over dyke.
One circular stairway may be provided for two tanks if the tanks are
close together and an interconnecting walkway is installed.
(ESTG 4-1.01 4.4)
Page 90 of 105
Stairways for non-insulated tanks shall be two-stringer type and

stairway treads shall not be welded to the tank shell.
Insulated tanks shall be provided with an offset stairway with
stringers on both sides. The offset shall be 25 mm greater than the
finished insulated thickness.
(ESTG 4-1.01 4.4.8)
If the gap between the stair stringer and the tank (or its insulation) is
greater than 75 mm, guardrails and a handrail shall be provided on
both the inside and outside of stairs providing access to the top of
storage tanks.
7.3.4 Sample Connections Sample points along the stairs shall be provided with a standing
platform.
(ESTG 4-1.01 4.4.6 & ESTG 4-1.03 3.8)
7.3.5 Davitts Davits shall be provided for each tank at the primary access platform.
The davits shall be designed for 225 kg, arm length 1500 mm.
7.3.6 Additional Platforms Additional platforms shall be provided at all instrumentation stations
nd
on the tank roof. Most tanks will require a 2 platform 180 degrees
opposite the first/primary platform.
An engineered tie-off point shall be provided at each platform.
7.3.7 Guard/ handrails Non-insulated tanks shall be provided with guard/handrails around
their entire upper circumference. An engineered tie-off rail shall be
provided with such a guard rail.
(SCAN)
Where a guardrail is not provided around the entire circumference of
a tank, guard/handrails shall be provided at the top landing of the
access stairs and all other work platforms on the top of the tank.
Such guard/handrails shall extend a minimum of 3 metres in each
direction from the platform.
Alternatively, each work platform can be provided with guard/hand
rails on 3 sides (edge and each end). Where it is expected that a
work platform will be accessed using a manlift, the outer rail should
be removable to allow ease of assess to the platform from the manlift.
(SCAN)
Page 91 of 105
Notes
Page 92 of 105
8.0 PRIMA/PERNIS SPECIFIC EQUIPMENT
[Reserved for Pernis/PRIMA-specific equipment items]
Page 93 of 105
Page 94 of 105
9.0 MATERIAL HANDLING & HOISTING
9.1 GENERAL REQUIREMENTS

9.1.1 National Guideline Arbo Informatie bladen AI-29 Fysieke Belasting bij Het Werk gives specific
requirements for physical stress during work and governs the primary
requirements as imposed by national legislation and the parent EU
Directive.
9.1.2 Lifting limits In line with the legislation, there are no maximum or minimum weight limits
specified: rather, it is a case of what the individual is capable of.
From a risk assessment perspective, it is assumed that a weight of up to
23 kg* can be lifted by the majority of the workforce, using two hands and
maintaining the load close to their body, without undue risk. For a two-
person lift, this level is assumed to be around 30/31 kg: (i.e. 2 x LC/3)
Where a load cannot be carried by two hands close to the body, the
maximum weight needs to be decreased accordingly.
*Note: This level is based on the NIOSH Lifting equation load constant. The recommended
weight limit assumes a single lift per day and optimum hand location, lift height, lift travel
distance, and body position, and would typically accommodate 99% of healthy male and 75%
of female population.
For any repetitive type lifting or non-optimal body positioning, lift height, or distance, and other
relevant handling factors, consult an HFE professional, as these factors will impose additional
constraints and thus reduce the maximum weight to be lifted.
9.1.3 Material Handling For all equipment in excess of the weight limits and travel distances that
Study must be lifted and transported for repair, replacement, or maintenance, the
project shall conduct a material handling study and develop a plan/strategy
for lifting and moving these heavy pieces of equipment.
9.1.4 Mechanical Lifting The plan shall identify permanent (e.g. cranes, monorails) or portable
Plan assisted lifting devices (e.g. chain falls, come-alongs) to aid in the lifting
and/or moving. When such lifting devices are provided, the design shall
allow space for the devices and the personnel who use them, and provide
area for manoeuvring the devices.
Lifting eyes shall be provided on all equipment to be lifted with the

mechanical lifting aids with a minimum of 100 mm of clear space around
the eye. In the case of removable pipe spools or equipment that can be
safely handled with straps/chains, no lifting eyes are required.
Page 95 of 105
9.1.5 Hoisting & Lowering Where equipment is to be removed and lowered from an elevated platform,
direct access by crane is preferred for lifting and lowering. Adequate area
at grade for the appropriately sized crane shall be provided.
Where direct crane access is not feasible, an engineered lifting point shall
be provided for the manual removal of equipment and its relocation, if
necessary, to an area accessible by crane. The distance between the
equipment's operating location and the elevated lift area shall be no more
than 33 metres.
Appropriate means for safely and efficiently relocating equipment to the
elevated lift area must be provided. This may include an overhead trolley or
a smooth and level surface for a wheeled cart.
Page 96 of 105
10.0 AMBIENT ENVIRONMENT
10.1 LIGHTING
10.1.1 National Guidelines The Netherlands’ requirements regarding illumination in the work place are
given in the following two national guidelines:
- NEN 1891: Binnenverlichting – Meetmethoden voor
Verlichtingssterkten en Luminanties.
- NEN 3087: Visuele Ergonomie in relatie tot Verlichting.
10.1.2 DEP Requirements Otherwise, unless specified in the national legislation, guidelines or
industry standards, the required illumination levels, measured at the
working plane or 1 m above the floor level in a horizontal plane, are given
in Appendix 9 of DEP 33.64.10.10, Electrical Engineering Design and the
table below. These values are mean values and the uniformity ratio
(Emin/Emean) is ¼ for normal installations.
These values shall be used as a basis for the design of new installations
unless higher illumination levels are required by national or local
regulations in the country of installation.
10.1.3 Fouling Factor The tabulated illumination levels apply when the luminaires are dirty, i.e.,
after taking account of the following fouling factors:
Location: Fouling Factor:
Plant areas (both indoor and outdoor): 0.80
Non-plant areas (outdoor): 0.80
Non-plant areas (indoor): 0.85
10.1.4 Illumination Levels Location: E mean: (Lux) Notes:

CONTROL ROOMS
General, including front of panel 300/500 1, 7
Rear of panels 150
Auxiliary rooms 150/300 2
Outside, near entrances 150
PLANT AREAS
Operating areas pumps; compressors;
requiring regular generators; drivers;
150 3
operator intervention valves; manifolds;
loading arms; etc.
indicating instruments;
Local control &
gauges; & control 75
monitoring points
devices
Level gauges (see-through) to be lit from behind
by single tube fluorescent luminaries
walkways; platforms;
Access ways stairways; ladders; 25
module roofs (offshore)
Plant & jetty approaches & road intersections 5
Page 97 of 105
Location: E mean: (Lux) Notes:

PLANT AREAS (cont’d)
Non-operational areas with limited attendance; e.g.
tank farms without equipment requiring regular 0.5
operator intervention
Loading gantries top loading; walkways & 150
top of tanker
bottom loading
(coupling handling 150
area)
Road tanker parking area 25
NON-PLANT AREAS
Switch-rooms, including relay & auxiliary rooms 200
Workshops & garages indoor generally 250 3
local on workbenches & 400 4
machine tools
outdoor storage & 50
handling areas
Warehouses & stores indoor between storage 150
racks
bulk storage 50
outdoor storage areas 5
Laboratories & analyser rooms 400
Street & fence lighting lit by twin 40W
fluorescent or single
70W HP sodium (SON) 5, 6
luminaires on standard
8 m poles at typically 50
m spacing
NON-INDUSTRIAL AREAS
Canteens (dining areas) 100
Car parks 1
Catering areas (food preparation & serving) 300
Communications rooms
Computer rooms 400 7
Conference rooms
Corridors & stairways 100
Offices & drawing offices 7
First aid rooms 400
Libraries & reading rooms
Lifts 100
Plant rooms 150
Print rooms 250
Reception areas 150-400
Recreation rooms & lounges 300
Store rooms 150
Toilets & locker rooms 100
Page 98 of 105
NOTES: 1. 300 lux applies at night and 500 lux during the daytime. Control of the
illumination level down to 100 lux should be possible either by switching off
rows/groups of luminaires, or by use of electronic dimmers, or both.
2. 150 lux applies for normal access and 300 lux for maintenance activities. The
illumination level should be controlled by switching each lamp in a twin fitting
from separately controlled circuits or by switching alternative fittings.
3. Where overhead travelling cranes are installed, floodlights should be fitted
under the crane beam to provide an illumination level of 400 lux for better
illumination during maintenance.
4. In areas where very fine work is carried out, local lighting with higher
illumination levels may be required, e.g., 750 - 1000 lux on an instrument
workshop bench.
5. Higher illumination levels apply where security fence lighting is required, e.g.,
for use with video camera surveillance. These shall be specified to be
compatible with the video system utilised.
6. At the security barrier and checkpoint in front of site entrance gatehouses,
higher illumination levels may be required.
7. In rooms where VDUs are permanently installed, the lighting shall be
designed to avoid reflections and glare from the screens.
Supplementary lighting on the immediate task area or an increase in the

general illumination may be required for specific task activities or areas.
10.1.5 Fixture Location Accessibility of the fixtures for maintenance must be incorporated in the
design (e.g. hinged poles, etc.). Lighting fixtures shall be located in a
manner to enable easy relamping, and a means of disconnecting each
fixture shall be provided within 3 metres of the fixture.
The design shall minimize the use of pole-mounted fixtures and maximize
the use of fixtures mounted on existing structures such as pipe racks and
buildings.
Stanchion-mounted lighting fixtures shall be mounted at least 2 metres
above platform level.
10.1.6 Safety Where fall protection will be required for fixture maintenance (such as
ballast replacement), a means of lowing the fixture closer to the platform
shall be provided, such as swivel poles.
Floodlights shall be located such that glare does not cause a hazardous
situation.
Large buildings with rotating equipment shall have lighting designed to

avoid stroboscopic effects.
10.1.7 Stray Light Outdoor lights shall be equipped with shades, refractors or reflectors, as
applicable, to minimize stray light that may be objectionable to
neighbouring properties.
Page 99 of 105
10.2 NOISE
10.2.1 Legal Codes The EU Directive 2003/10/EC on the minimum health and safety
requirements regarding the exposure of workers to the risks arising from
physical agents (noise), Dutch national legislation (Arbowet and Arbo
Beleidsregel) arising, and national guidleines such as AI-bladen and site
BBS codes (BBS 05.05.2001) dictate the primary requirements regarding
control of noise exposure.
10.2.2 Noise Exposure In summary, the Directive fixes the exposure limit value at 87 decibels
Limits (taking into account the attenuation provided by the individual hearing
protectors worn by the workers), and the exposure action values are fixed
at:
- 80 decibels (lower value), and
- 85 decibels (upper value).
2003/10/EC
10.2.3 Absolute Noise Limit The absolute limit is the sound pressure level anywhere in the work area
that shall not be exceeded in any situation, including emergencies; for
example the operation of safety equipment.
ISO 15664:2001: 5.1.2
The absolute work area noise limit shall be 115 dB(A), unless otherwise
specified.
DEP 31.10.00.31: 5.1.2
10.2.4 Work Area Limit The work area noise limit, which may be different for different areas,
defines the noise level that shall not be exceeded in order to comply with
the limits as determined by law and the action levels.
ISO 15664:2001: 5.1.3
The work area noise limit shall be 85 dB(A), unless otherwise specified.
DEP 31.10.00.31: 5.1.3
10.2.5 Restricted Areas Restricted areas are those work areas in the plant where, according to the
state of the art, it is not reasonably practicable to reduce the noise level at
or below the work area limit. The absolute limit remains valid in such areas.
If it is unavoidable that the work area limit will be exceeded around

particular equipment, action should be taken to limit the area involved as
far as is economically and technically feasible. This may include the
erection of an acoustic enclosure. Areas inside acoustic enclosures around
such equipment may be restricted areas.
ISO 15664:2001: 5.1.4
Attempts shall be made to reduce the level below 90 dB(A) in such areas.
DEP 31.10.00.31: 5.1.4
Page 100 of 105

10.2.6 Indoor Limits The following noise limits shall apply in indoor locations in order to keep
any disturbance of conversations and normal working, caused by
equipment, within acceptable proportions:
Maximum Allowable
Area Description: Sound Pressure Level
(SPL) – dB(A):
• Areas in workshops and machinery
buildings where communication is required. 70
• Workshops for light maintenance
• Workshop offices.
• Control rooms, not continuously manned 60
• Computer rooms
• Control rooms, continuously manned.
• Open plan offices.
50
• Social rooms, changing rooms, wash
places and toilets
• Offices and conference rooms.
45
• Personnel accommodation (bedrooms,

private cabins, etc.). 40
NOTE : Noise that does not stem from equipment but is produced by users of the
various areas need not be considered.
DEP 31.10.00.31: 5.1.5
Page 101 of 105

Page 102 of 105

11.0 DESIGN REQUIREMENTS FOR BUILDINGS
11.1 PLANT BUILDINGS

11.1.1 HVAC Systems Details related to HVAC systems for control rooms, pump-houses,
electrical substations, MCC buildings, etc. are in DEP 31.76.10.10-GEN
Heating, Ventilation and Air Conditioning for Plant Buildings and DEP
34.17.00.32 Section 4.2.
11.1.2 Control Room A separate Human Factors assessment shall be conducted for a main
control room taking into account the varied nature of the work and how the
physical environment (location, layout, lighting, noise, furniture) and the
information presentation (screens, cameras, alarms) can be used to
promote economy of motion, optimize human efficiency and reduce the
potential for error.
DEP 30.00.60.15: Human Factors Engineering - Human/Machine Interface
and Control Room Design, March 2005
11.2 NON-PLANT BUILDINGS

11.2.1 HVAC Systems Details related to HVAC systems for administration, office, security,
warehouse, laboratory, and maintenance buildings are in DEP 34.17.00.32
Design and Engineering of Buildings Section 4.3.
11.2.2 Indoor Environment In most Northern hemisphere cities, the following parameters are
appropriate for the indoor office environment:
indoor temperature 19 to 24 C
relative humidity 20 to 35% winter 40 to 50% summer
air motion 0.15 m/s winter, 0.25 m/s summer
2
minimum fresh air intake 2.5 L/s per person 0.3 L/s per m
air changes per hour 4 to 10
carbon dioxide below 800 ppm
ASHRAE 62.1-2004
11.2.3 Dimensions Details on dimension of offices, doors, hallways, stairs is given in DEP
34.17.00.32 Design and Engineering of Buildings Section 5 and 6.
11.2.4 Office and Computer For general ergonomic and computer workstation dimensions refer to
Workstation Chapter 10.0, pages 10.1-10.10 of Shell Works Toolkit provided by Shell
Dimensions Real Estate.
Page 103 of 105

Notes
Page 104 of 105

Notes
Page 105 of 105

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Shell Pernis PRIMA Projects HE 09.

• The custodian must approve all revisions to this document.

REVISION STATUS APPROVAL

1.0 INTRODUCTION ...................................................................................................................................11

4.3 PRESSURE VESSELS ................................................................................................................. 39

5.3.8 Mounting Height..................................................................................................................... 64

6.7.5 Stems in Horizontal Pipes...................................................................................................... 81

10.0 AMBIENT ENVIRONMENT...................................................................................................................97

1.2 SCOPE & STRUCTURE OF DOCUMENT

1.3 HIERARCHY OF SOURCES

National law and guidelines

Design & Engineering Practices – DEP’s

COMPANY _ Shell Netherlands Refinerie Ltd

CONTRACTOR – Equipment or Module Manufacturer/Vendor and EPC CONTRACTOR

Vendor – Same as CONTRACTOR

Shall/Must – Describes a mandatory requirement. Departure is subject to written approval

Describes a recommendation, which although not explicitly required, should be considered in

1.6 ERRORS & OMISSIONS

1.7 COMMENTS ON THIS DOCUMENT

Comments on this workplace design specification may be sent to rob.saunders@shell.com.

1.8.1 V.26 Design Engineering Practices

DEP 30.00.60.10: Human Factors Engineering in Projects, May 2007

1.8.2 Standard Drawings

S 10.031-D Hatchway covers

1.8.3 Other/External Standards

2.0 HUMAN FACTORS OBJECTIVES

2.4 MANUAL MATERIALS HANDLING

2.5 COMMUNICATION & LABELLING

3.0 STRUCTURAL DESIGN REQUIREMENTS

3.1 EMERGENCY EGRESS

Bouwbesluit; Article 2.28, 4.11 & 4.12

3.2.2 Width The minimum unobstructed width of walkways, including walkways on

Bouwbesluit; Articles 4.11 & 4.12

3.3 STAIRS & LADDERS

3.4 DESIGN OF STAIRS

DEP 34.17.00.32: 6.9.2

The maximum slope of a stair on a steel structure shall be 5:6.

- Risers (R): - Min. 160 mm, maximum 190 mm;

Furthermore, the following rise-to-going/tread ratio shall apply:

- (R x G) min. 48,000 mm2, otherwise too dangerous to descend;

Bouwbesluit; Article 2.28

In a new building, no stairway shall exceed 16 rises (steps) in any one

DEP 34.17.00.32: 6.9.2

Maximum height without a change of direction shall be 8 metres (40

3.4.7 Landings Stairway platforms, intermediate or straight-run landings shall have a

Bouwbesluit; Article 2.30

Where a hand-railing is installed, floors, platforms and walkways shall be

For platforms with an elevation higher than 13 metres (relative to grade,

Bouwbesluit; Article 2.16

3.5 DESIGN OF FIXED LADDERS

S 28.011-001-H; Notes 2, 3, 6 & Section A-A

3.5.3 Side-step Wherever possible, ladders should be made with a side-step in

Step-through ladders should only be used when a side-step ladder is not

Bouwbesluit; Article 4.11 & S 28.011-001-H

Cage dimensions shall be 600 x 760 mm hoops of flat steel, section 40 x

For ladders starting at elevated platforms, either the platform handrails

If a ladder protrudes through a platform, the hole shall be protected by a

3.6 PLATFORMS & DECKS

Access to work platforms shall be by either fixed ladder or stairway.

750 1220 min

For platforms with an elevation that is higher than 13 m (relative to grade,

Higher railings shall be used at certain locations to provide additional