GP 04 02 01

GP 04-02-01 Auxiliary Structures for Operation and Maintenance February 2010
Auxiliary Structures for Operation

and Maintenance
GP 04-02-01
Scope
[I] This Global Practice (GP) covers the use, design, and layout of auxiliary structures and facilities
provided for access and maintenance of plant equipment. The requirements for stacks, chimneys, and
flares are not covered by this Practice.
Refining/Chemicals For Company Use Only Version 4.3.0
Page 1 of 18 ExxonMobil Development Company
Copyright Waiver
ExxonMobil Development Company and ExxonMobil Pipeline Company hereby license the use of ExxonMobil Engineering Practices System (EMEPS) Global Practices (GPs) for
use by any ExxonMobil division, subsidiary, or more-than-50%-owned affiliate. The GPs may be downloaded and modified as necessary for project and affiliate use. Written
permission from ExxonMobil Development Company or ExxonMobil Pipeline Company is not required. However, any modified GPs must be renumbered to a project-specific or
affiliate-specific number to distinguish them from the GPs on the EMEPS web site. ExxonMobil operated joint ventures may utilize GPs to create project-specific or location-specific
specifications. It is the responsibility of individual affiliate or joint venture to ensure that the use of GPs and their derivatives is limited to joint venture related business and not
disclosed or used outside the JV without appropriate EM management approval.
Table of Contents
Table of Figures...............................................................................................................3
1. Required References...............................................................................................4
1.1. Global Practices–ExxonMobil Engineering Practices.....................................4
1.2. ALI–American Ladder Institute.......................................................................4
1.3. ASSE–American Society of Safety Engineers...............................................4
1.4. NAAMM–National Association of Architectural Metal Manufacturers............4
2. General......................................................................................................................4
3. Platforms..................................................................................................................5
4. Stairways and Ladders...........................................................................................7
5. Permanent Handling Facilities.............................................................................13
Record of Change..........................................................................................................15
Attachment: Purpose Code Definitions......................................................................18
RFCH For Company Use Only Version 4.3.0

Table of Figures
Figure 1: Typical Ladder Detail (Side-Step Access)...................................................9
Figure 2: Ladder Cage Bar Extensions at Elevated Platform..................................10
Figure 3: Minimum Clearance to Obstructions.........................................................11
Figure 4: Handrail and Safety Gate Details....................................................................12

1. Required References
This Section lists the Practices, codes, standards, specifications, and publications that shall be used with
this document. Unless otherwise specified herein, use the latest edition.
1.1. Global Practices–ExxonMobil Engineering Practices

GP 04-01-02 Structural Steel Design
GP 14-03-01 Fireproofing
GP 19-01-01 Paint and Protective Coatings
1.2. ALI–American Ladder Institute

ALI A14.3 American National Standard for Ladders - Fixed - Safety Requirements
1.3. ASSE–American Society of Safety Engineers

ASSE/SAFE A1264.1 Safety Requirements for Workplace Floor and Wall Openings, Stairs,
and Railings Systems
1.4. NAAMM–National Association of Architectural Metal

Manufacturers
NAAMM MBG 531 Metal Bar Grating Manual
(http://www.naamm.org/landing_pages/MBG_531-09.pdf)
[I] Local codes and standards may be substituted for the ones referenced herein, provided the following
provisions are met:
1) The resultant design meets the safety and serviceability criteria attained through this GP.
2) [A] Substitution is accepted by the authorities where the facility is to be located and by the Owner's
Engineer.
2. General
1) [I] The design and layout of platforms, and stairway or ladder access, serving equipment or facilities,
not specifically covered by other practices shall meet the requirements given herein.
2) [M] [R] All structural steel members referenced in this Practice shall be coated or hot dipped
galvanized per GP 19-01-01. Hot dip galvanizing is preferred.

3. Platforms
1) [*] [M] [O] Platforms shall be provided to the extent indicated in Table 1, unless the equipment or
facilities described are accessible from grade or from other permanent platforms. Access to these
platforms shall be by permanently installed ladders or stairs, unless otherwise specified.
Table 1: Requirements for Platforms
Equipment or Facility Specific Requirements
Service and inspection openings All which are located with the bottom of the opening
more than 10 ft (3 m) above grade.
Instrumentation and controls, 1. All which require operator attention, or which are
including associated manifolds and otherwise observed, adjusted, or serviced, during plant
take-off connections operation.
2. Access to instrument take-off valves by permanent

ladder is acceptable.
Control valves, pressure relief All which are not located at grade elevation.
Devices, motor actuated valves
(electric, pneumatic, or hydraulic
operated), lubricated valves
Emergency isolation valves (EBV) 1. All which are not located at grade elevation.
2. Permanent ladders shall be provided, as required, for

direct access from grade.
Other operating valves, sample outlet Individual or grouped (for convenience of operation) and
valves which are not provided with chain operators or
extensions.
Machinery 1. All machinery mounted on elevated foundations or not
otherwise accessible for operation and maintenance from
grade or floor level.
2. Floor grating shall be provided between adjacent

cylinders of multi-cylinder compressors.
Vertical shell and tube exchangers For maintenance access to covers, channels, or bonnets,
where the flanges of such components are more than 12 ft
(3.7 m) above grade.
Separators, basins (or tanks) For operation of sluice gates, plugs, or similar control
components.

2) [M] Platform size shall be governed by the following:

a) Minimum clear platform width shall be 2 ft, 6 in. (750 mm) except for the services listed in
Table 2.
b) [*] Clear length and width of platforms dedicated to special operation and maintenance tasks
shall be specified. (Such facilities include: instrument maintenance, blanking of tower nozzle
connections, removal and testing of pressure relief devices, servicing corrosion probes or
retractable water sprays.)
c) [*] The space on platforms used for permanent or temporary storage of containers of catalyst,
chemicals, and similar materials shall be specified.
d) Platforms around compressors and other large machinery shall provide space for placement of
rotors and similar components.
e) When welding terminal boxes are located on platforms in process unit structures, space shall be
available on the platform (served by the welding box) sufficient to accommodate one welding
machine.
f) [*] [O] Handrails shall have removable sections where specified for equipment maintenance.
Table 2: Minimum Clear Platform Widths
Minimum Clear Width

Service
ft, in. mm
In front of equipment for servicing trays 3 ft 900

At each end of the shell and tube units for
servicing bonnet, channel, and tube bundle 3 ft 900
Connecting walkways between platforms 2 ft 600
(except around elevated machinery) 2 ft, 6 in. 750
Around safety valves for maintenance 3 ft, 6 in. 1050
3) [O] Platforms servicing equipment manholes shall be not more than 3 ft, 6 in. (1050 mm) below the
manhole centerline.
4) [S] [O] The minimum headroom over platforms and walkways shall be 6 ft, 9 in. (2050 mm).
Headroom shall be measured to the lowest point of overhead structural framing (including
fireproofing), piping (including insulation), or equivalent.
5) [S] [A] Unless otherwise approved by the Owner's Engineer, platforms for structures located within a
40 ft (12 m) horizontal radius of high fire potential equipment, as defined in GP 14-03-01, or located
above equipment handling flammable gases above their autoignition temperature or above 600F
(316C), whichever is lower, shall be as follows:
a) Steel structures and equipment platforms: floorplate
b) Concrete structures: concrete or floorplate
c) All compressor platforms: grating

6) [R] Drainage shall be provided by one hole 1/2 in. (13 mm) diameter, for approximately every 15 ft 2
(1.5 m2) of steel floor plate. Holes shall be located at low spots, and shall be drilled after erection.
Where practicable, drainage holes shall not be located directly above ladders and plate stair treads,
nor shall they be located over water-sensitive equipment.
7) [R] Platform floor plate shall have a raised pattern and a 1/4 in. (6 mm) nominal thickness.
8) [A] The use of a rolling stair/platform (in lieu of permanent structures) for access to equipment near
grade shall be approved by the Owner's Engineer.
9) [A] [R] The use of operating and service platforms interconnecting two or more equipment items
(such as elevated towers) or facilities shall be approved by the Owner's Engineer. Such platforms
shall be designed for differential movement of the two or more equipment items.
10) [A] The final number and arrangement of platforms, including access and exit locations, shall be
reviewed by the Owner's Engineer.
11) [R] Platforms attached to vessels or similar equipment shall be designed to accommodate thermal
expansion.
12) [S] Grating and floorplate shall be mechanically fastened to supports with a minimum of two
fasteners per support and four fasteners per panel. Clamp type fasteners relying on friction are not
permitted. Grating installation shall comply with the guidelines presented in NAAMM MBG 531.
Note that anchoring details 1 and 3 of MBG 531 are not applicable as GP 04-01-02 requires bolted
connections for coated steel.
4. Stairways and Ladders

1) [S] In addition to the primary means of access and egress, additional means of egress (escape) shall
be provided from platforms to limit travel to an egress point to a maximum of 50 ft (15 m).
2) [S] Stairways shall have a maximum vertical continuous flight of 12 ft (3.7 m).
3) [S] Ladders, railings, toe plates, safety cages, and similar items shall be constructed of steel per
ASSE/SAFE A1264.1 and ALI A14.3, except as modified.
a) Ladders shall provide for side-step access to platforms. Step-thru ladders are not permitted.
b) Ladders shall be maximum 30 ft (9.1 m) unbroken length landing-to-landing.
c) [A] Ladders shall be vertical unless approved by the Owner's Engineer. Any inclined ladder shall
have constant pitch from landing to landing.
d) [*] The paint specification for ladders shall be specified.
e) Safety cages shall be provided for ladders having a length of climb greater than 20 ft (6.1 m) or
where the top platform is greater than 20 ft (6.1 m) above grade.
f) The vertical cage bars shall be extended and attached to the handrail where ladders are on
elevated platforms greater than 20 ft (6.1 m) above grade and the ladder centerline is within 3 ft
(0.9 m) from the platform side handrail or 4 ft (1.2 m) from the handrail on the climbing side of
the ladder.
g) Ladder safety devices shall not be used in lieu of cage protection.

h) Railings shall be constructed of open structural steel shapes.

i) Safety gates shall be self-closing, double-bar swing gates. The double bars of the safety gate
shall generally align with the top and mid rails. They shall be provided across ladder openings at
each platform landing and designed for the same load as the railings.
j) Toe plates shall not be provided at stairway or ladder access points.
4) [I] Figures 1 through 4 provide typical ladder and platform details. Dimensions are in feet and inches
due to space limitations (1 in. = 25.4 mm).
5) [S] [A] Unless otherwise approved by the Owner's Engineer, ladders or stairways that provide egress
from platforms or structures over a fire hazardous area, as defined in GP 14-03-01, with containment
toe walls shall be designed with the ladders/stairways exiting to a location outside the toe wall.

Figure 1: Typical Ladder Detail (Side-Step Access)

Figure 2: Ladder Cage Bar Extensions at Elevated Platform

Figure 3: Minimum Clearance to Obstructions

Figure 4: Handrail and Safety Gate Details

5. Permanent Handling Facilities

1) [M] Built-in handling facilities shall be provided for the following equipment if it is not accessible to
mobile handling facilities:
a) Davits shall be provided for handling pressure relief valves, inlet flange size NPS 4 (100 mm) and
larger, if no other overhead handling facility is available.
b) Facilities shall be provided for servicing channel and tube bundle of tubular units located on the
ground under a structure, and for tubular units located at an elevated level in a structure.
c) As determined by the final layout, lifting facilities such as trolley beams or cranes shall be
provided to service large pumps, motors, turbines, compressors, and similar equipment which are
housed in an enclosure or otherwise inaccessible. These lifting facilities shall be extended
beyond equipment foundations or into drop areas, to permit lowering machinery components to a
grade level accessible to mobile handling equipment. Removable wall or roof sections enclosing
such equipment shall not be provided to allow access by mobile lifting equipment. These are not
an acceptable substitute for built-in handling facilities.
d) A permanently installed overhead bridge crane shall be provided for all mezzanine mounted turbo
compressor trains. It shall be sized to lift the maximum weight (typically top half of casing or
motor driver) and shall be installed high enough so that the lift height is adequate for maximum
maintenance lift requirements.
e) [S] Overhead crane facilities shall incorporate fail-safe features to insure that the load will not fall
to grade in the event of a mechanical drive train failure or control circuit problem.
2) [M] Removable sections shall be provided in the flooring of platforms where required for
maintenance of auxiliary equipment mounted below the flooring.
3) [M] Trolley beams shall be provided for handling the following, if inaccessible to mobile equipment:
a) Heavy slide valves.
b) Heavy piping, rotation and expansion joints requiring maintenance or repair if sufficient platform
framing or working area is not available for temporary rigging.
c) Tubes and similar materials for retubing of equipment (i.e., waste heat boilers of fluid catalytic
cracking units) that cannot be lowered to the ground for servicing.
d) Tubes and fittings of fired heaters.
4) [M] A trolley beam or a davit shall be located at the top of a tower for handling tower internals (and
pressure relief valves, as required). Orientation of davit and manholes shall be such that:
a) Internals removed through manholes are accessible for lifting by davit.
b) Drop-out areas provided at the tower are accessible to mobile equipment.
5) [S] The working capacity shall be clearly marked on trolley beams and davits (other than those
servicing manholes).
6) [I] Design, fabrication, and testing of permanent handling facilities shall be according to the
Manufacturer's specifications and applicable codes.

Record of Change
Version 1.0.0 Date: 07/01
Location Action Description
Initial Publish.

Section 4, Item Deletion, Original Item 3 was deleted: Item 4 renumbered to Item 3 and changed
3 Modification to read: "[S] Ladders, railings, toe plates, safety cages, and similar items
shall be constructed of steel per ASSE/SAFE A1264.1 and ASSE/SAFE
A14.3, except as modified."
Section 4, Modifications, The following changes were made:
Items 3, Deletions,
1. The entire list renumbered. Old Subitem a became Subitem d.
Subitems a Additions
Subitems c, d, and e became Subitems f, b, and c, respectively.
through i
2. New Subitem a was added: "Ladders shall provide for side-step
access to platforms."
3. Subitem d was changed to read as follows: "Safety cages shall be
provided for ladders having a length of climb greater than 20 ft (6.1 m)
or where the top platform is greater than 20 ft (6.1 m) above grade."
4. Subitem e was added: "The vertical cage bars shall be extended and
attached to the handrail where ladders are on elevated platforms greater
than 20 ft (6.1 m) above grade and the ladder centerline is within 2 ft (0.6
m) from the platform side handrail or 4 ft (1.2 m) from the handrail on
the climbing side of the ladder."
5. Subitem f became g and g became i.
6. Subitem b became h and was changed to read: "Safety gates shall be
self-closing, double bar swing gates. They shall be provided across
ladder openings at each platform landing and designed for the same load
as the railings."
Section 4, Item Addition Item 4 was added: "[I] Figures 1 through 4 provide typical ladder and
4 platform details. Dimensions are in feet and inches due to space
limitations (1 in. = 25.4 mm).
Section 4, Addition Figures 1 through 4 were added to end of Section 4.
Figures 1
through 4


Section 4, Item Modification Changed 2 ft (0.6 m) to 3 ft (0.9 m).
3, Subitem e
Figure 2 Addition/ Added horizontal bars and changed 2 ft dimension in plan to 3 ft.
Modification
Figure 4 Modification Changed ½ Clear dimension to ¼.

Global Practice version number and format updated to comply with new
process; however, original publish date remains, and no content was
modified.

All Revision Partial Update to safety related paragraphs only.
Section 1 Addition Substitution of local codes section.
Section 3, Item Addition Revision to Rationale.
5 (to Rationale)
Section 3, item Addition Fastening requirements.
12
Section 4, Item Modifications Changed "escape" to "access and egress"
1
Section 4, Item Deletion Deleted "unless otherwise approved".
2
Section 4, Item Addition Prohibited step-thru ladders
3a
Section 4 Item Additions Ladder Pitch requirements.
3c
Section 4 Item Addition Rationale for paint color scheme.
3d
Section 4, Item Addition Safety gate bar spacing
3, Subitem i
Section 4, Item Modification Deleted use of pipe shapes for handrails. Added reason to rationale.
3, Subitem h
Figure 2 Addition Added plans, modified plan
Figure 4 Addition Hinge location note

Section 1, Addition Metal Bar Grating Manual reference
Item (3)
Section 3, Addition Grating installation requirements

Item (12)
All Global Modifications To standardize the format of the Global Practices and to meet other
Practices requirements, the following changes have been implemented:
"For ExxonMobil Use Only" has been replaced with "For Company Use
Only."
A copyright waiver has been added in the first page Footer.
The definition of asterisks in the Scope has been deleted. The asterisk is
now defined in the Purpose Code attachment and is used within brackets
as other Purpose Codes.
Multiple paragraphs within a Section have been numbered.
The standard text for Required References has been modified.
The standard text for Additional Requirements has been modified.
The [S] Purpose Code has been modified.
The following Purpose Codes have been added:
[*] for additional information or decision required of Owner's
Engineer.
[A] for approval requirements before beginning work or finalizing
design.

General Modification Corrected reference issue.

General Modification Provided hyperlink to NAAMM MBG 531 and deleted "-00" from the
reference.

Attachment: Purpose Code Definitions

Code Description
* Assigned to paragraphs that require the Owner's Engineer to provide additional information or
make a decision.
A Assigned to paragraphs that require approval from the Owner's Engineer before the work may
proceed or the design is finalized.
C Assigned to paragraphs whose primary purpose is reduced costs. Reduced cost in this context
refers to initial investment cost and does not include life cycle cost considerations. Life cycle
cost considerations are captured under reliability, maintainability, or operability purpose codes.
E Assigned to paragraphs whose primary purpose is driven by environmental considerations.
Environmental considerations typically include specifications intended to protect against
emissions/leakage to the air, water, and/or soil. Deviations from the specifications contained
in such paragraphs require formal review and approval according to local environmental
policy.
I Assigned to paragraphs that provide only clarifying information, such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs whose primary purpose is to provide for maintainability of equipment
or systems. Maintainability provisions are those that facilitate the performance of maintenance
on equipment/systems either during downtimes or during onstream operations.
O Assigned to paragraphs whose primary purpose is to assure operability of equipment or
systems. Operability is the ability of the equipment/system to perform satisfactorily even
though conditions are off-design, such as during start-ups, process swings, subcomponent
malfunction, etc.
R Assigned to paragraphs whose primary purpose is to improve or assure the reliability of
equipment or systems. Reliability is a measure of the ability of equipment/systems to operate
without malfunction or failure between planned maintenance interventions.
S Assigned to paragraphs containing specifications/guidance where the primary purpose is the
avoidance of incidents impacting personnel safety, operational safety, and the public in general
and/or involving responses to emergency situations. Any deviation from the specifications
contained in such designated paragraphs requires formal review and approval according to
local safety policy.
Personnel Safety: Refers to incident-related personnel injuries or illness, e.g., burns, cuts,
abrasions, inhalation of or exposure to dangerous substances, etc., that
could result in medical treatment, restricted work, lost-time incidents, or
fatalities.
Operational Refers to the prevention and control of process releases, fires, and/or
Safety: explosions that could result in damage to equipment, process disruption,
or personnel injury or illness.


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GP 04-02-01 Auxiliary Structures for Operation and Maintenance February 2010

Auxiliary Structures for Operation

Refining/Chemicals For Company Use Only Version 4.3.0

Page 1 of 18 ExxonMobil Development Company

4. Stairways and Ladders...........................................................................................7

5. Permanent Handling Facilities.............................................................................13

Attachment: Purpose Code Definitions......................................................................18

RFCH For Company Use Only Version 4.3.0

Page 2 of 18 ExxonMobil Development Company

Figure 1: Typical Ladder Detail (Side-Step Access)...................................................9

Figure 2: Ladder Cage Bar Extensions at Elevated Platform..................................10

Figure 3: Minimum Clearance to Obstructions.........................................................11

Figure 4: Handrail and Safety Gate Details....................................................................12

RFCH For Company Use Only Version 4.3.0

Page 3 of 18 ExxonMobil Development Company

1.1. Global Practices–ExxonMobil Engineering Practices

1.2. ALI–American Ladder Institute

1.3. ASSE–American Society of Safety Engineers

1.4. NAAMM–National Association of Architectural Metal

Page 4 of 18 ExxonMobil Development Company

Table 1: Requirements for Platforms

Equipment or Facility Specific Requirements

2. Access to instrument take-off valves by permanent

2. Permanent ladders shall be provided, as required, for

2. Floor grating shall be provided between adjacent

RFCH For Company Use Only Version 4.3.0

Page 5 of 18 ExxonMobil Development Company

2) [M] Platform size shall be governed by the following:

Table 2: Minimum Clear Platform Widths

Minimum Clear Width

In front of equipment for servicing trays 3 ft 900

RFCH For Company Use Only Version 4.3.0

Page 6 of 18 ExxonMobil Development Company

4. Stairways and Ladders

RFCH For Company Use Only Version 4.3.0

Page 7 of 18 ExxonMobil Development Company

h) Railings shall be constructed of open structural steel shapes.

RFCH For Company Use Only Version 4.3.0

Page 8 of 18 ExxonMobil Development Company

Figure 1: Typical Ladder Detail (Side-Step Access)

RFCH For Company Use Only Version 4.3.0

Page 9 of 18 ExxonMobil Development Company

Figure 2: Ladder Cage Bar Extensions at Elevated Platform

RFCH For Company Use Only Version 4.3.0

Page 10 of 18 ExxonMobil Development Company

Figure 3: Minimum Clearance to Obstructions

RFCH For Company Use Only Version 4.3.0

Page 11 of 18 ExxonMobil Development Company

Figure 4: Handrail and Safety Gate Details

RFCH For Company Use Only Version 4.3.0

Page 12 of 18 ExxonMobil Development Company

5. Permanent Handling Facilities

RFCH For Company Use Only Version 4.3.0

Page 13 of 18 ExxonMobil Development Company

Version 2.0.0 Date: 08/03

RFCH For Company Use Only Version 4.3.0

Page 14 of 18 ExxonMobil Development Company

Version 3.0.0 Date: 08/03

Version 3.0.0 Date: 11/03