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General Plant Layout
ConsiderationsCopyright ©, 2008,
William G. Beazley, PhD
All Rights Reserved
Other Copyrights Apply as Noted
Course Information• Contact
– William G. Beazley
– Cell: 713-443-9914 – wbeazley@infoassets.com
• If you must miss class – VHS tapes can be borrowed
– Email me in advance if you can
• Certification Test (your choice) – Level I
– Level III
Course Outline03 Oct-06 Basics of Plant
Layout
05 Oct-06 Layout Specs
& Plot Plans
10 Oct 06 Computer
Aided Design
12 Oct 06 Drums
17 Oct 06 Towers
19 Oct 06 Underground
Piping
24-Oct 06 Stress Analysis
26 Oct 06 Pipe Racks
02 Nov 06 Structures
07 Nov 06 Pumps
09 Nov 06 Compressors 14
Nov 06 Furnaces
16 Nov 06 Reactors
28 Nov 06 Exchangers
30 Nov 06 Storage Tanks
05 Dec 06 Instrumentation
07 Dec 06 SPED Ann Meeting
12 Dec 06 PPD Level III
Review
15 Dec 06 PPD Level I & III
Exam
Accidents with Plant Layout as Factor (Source: UK Health & Safety Executive)
• BASF Warehouse Fire (9/10/1995) – Smoke did not
reach detectors
• Flixborough (Nypro UK) Explosion (1/6/1974) – 28
dead, 13 in collapsed control room
• Hickson and Welch Ltd Fire (22/9/1992) – Burning
sludge impinged on office bldg
• Mexico City - Pemex LPG Terminal (19/11/1984) –
500 dead in successive BLEVE’s
• Pasadena - Phillips 66 (23/10/1989) – 23 dead in
close-in control center & blocked escape routes, while
occupied buildings sucked in vapors.
http://www.hse.gov.uk/comah/sragtech/techmeasplantlay.htm
Plant Layout Designer • Principal Activities
– Plot Plan Development,
– Equipment Layout, And
– Piping Design
• Plant Layout: – Significant Driver Of Project Engineering Costs,
– Focal Point For Clients, Project Management,Construction, Engineering, And SupportingDisciplines.
• Success Metrics: – Economy,
– Constructability,
– O&M Efficiency
Principal Functions of Plant Layout
Designer
• Layout of equipment and its associatedinfrastructure. – Conceptual process unit plot plans AKA
equipment arrangements; – Tradeoff of many “macro” considerations
• Routing of major above- and below-gradepiping systems – Major Driver of Cost & Layout
– Best to Analyze & Fix Early
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Confluence of Disciplines and Considerations(Source: Bausbacher and Hunt)
Implicit Requirements On Every Plant:
• Functional
• Safe
• Economical
• Operable
• Maintainable
• Constructible
• Compliant
Layout philosophy• Project conditions may change priorities
– Client specifications
– Schedule constraints, and
– Availability of information
• Good basic rule: avoid designing one line at a time – Routing a line f rom one piece of equipment to another
before thinking about the next one.
– Lack of consistency
• Better approach – Overview first then details
– Group and Position major equipment first
– Sketch major lines
– Consider “ilities”, e.g., constructability, Operability,Maintainability
Typical Plant: Oakville Refinery
Petro-Canada, Oakville, Ontario(Source: Ventech Process Equipment, Inc.)
http://www.ventechequipment.com/oakville.htm
Typical Plant: Oakville Refinery
Petro-Canada, Oakville, Ontario(Source: Ventech Process Equipment, Inc.)
http://www.ventechequipment.com/oakville.htm
Explicit Requirements:
• Process Design
• Site Topography
• Site Environment
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Plot Plan Information
• Pipe Racks
• Layout of the Equipment in the PFD• Layout of Major Equipment
– Tankage
– Other areas shown as blocks
– Access v ia roads, rail, waterway
– Plant perimeter
Sample Equipment List(Source: Bausbacher and
Hunt)
Vendor data
• All purchased equipment and specialty
bulk items require preliminary vendor
drawings
– Pumps, compressors,
– Air coolers, furnaces,
– Control and safety valves,
– Level instruments, strainers, silencers
• Final certified drawings usually not
required until detail phase.
Preliminary Information Sketches(Source: Bausbacher and Hunt)
Floor
Space
Sizes(Source:
Bausbacher and Hunt)
Site Information Required• On-Site Features
– Geographic location of the plant;
• Water table and water courses
• Climatic conditions and air movements
• Environmental sensitivity
– Other on-site plants (Greenfield or Brownfield)
• Off-site features, e.g.
– Local codes and regulations; topography;
– Vulnerable Populations:
• Housing and apartment blocks
• Hospitals, schools, leisure centers, shopping malls
– Transportation
• Proximity to roads, railways, and waterways,
• Airports
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Facility Site Plan With Surroundings(EPA)
http://www.epa.gov/oilspill/guidance.htm
Unified OilCompany
Direction of drainage
STON EFI ELD
A Street
Mars Ice Island, Beaufort Sea Alaska
http://www.mms.gov/alaska/kids/shorts/iceislnd/iceislnd.htm
Access by SeaFCC Regenerator
Access by RoadFCC Re enerator
Storage and Tanker Access(US Coast Guard, PA2 James Dillard)
http://cgvi.uscg.mil/media/main.php?g2_itemId=116706
Types of Guidance(Source: James Madden)
Equipment AccessSpacing and orientation Removal/lift ing/laydownLining-up and grouping similar items Maintenance/operating space
Equipment Features Structures
Fo un da tio ns a nd s up po rt s F lo or h eig ht sDynamic loads Stairs/laddersVibration Gangways
Enclosures Platforms/handrails
Transport Standards and Good PracticeRoad widths and clearances Equipment sizing procedures, catalogues,
Vehicle size and turning circles plant records(similar data for railtraffic) Space allowances for operation,
maintenanceSite Facilities Gangway, stair, ladder standardsOffices, laboratories, carparks Plant and equipment spacing standardsAmenities - canteens, washrooms, Allowances and reserved space for piping,Messrooms ducting, cablingUtilities and effluent plants Road, rail, pipetrack standards
Fire and medicalcentres Controlroom, switch roomareas andWorkshops, stores spacing
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Example Layouts
http://www.airproducts.com/PhotoLibrary/restricted/photo-plant.asp
Open Single-Level Plant(Source: Air Products)
http://www.airproducts.com/PhotoLibrary/restricted/photo-plant.asp
Open Single-Level Plant with Multiple Pipe Racks(Source: Air Products)
http://www.airproducts.com/PhotoLibrary/restricted/photo-plant.asp
Multilevel Plant(Source: Air Products)
Multilevel Plant
with <hopefully>
Normally
Unoccupied Bldg.(Source: Air Products)
h tt p: // ww w. ai rp ro du ct s. co m/ Ph ot oL ib ra ry /r es tr ic te d/ ph ot o- pl an t. as p h tt p: // ww w. ai rp ro du ct s. co m/ Ph ot oL ib ra ry /r es tr ic te d/ ph ot o- pl an t. as p
Multilevel Plant with Multilevel Rack(Source: Air Products)
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http://www.airproducts.com/PhotoLibrary/restricted/photo-plant.asp
Open Multilevel Plant with Multiple Racks & Underground Piping(Source: Air Products)
http://www.airproducts.com/PhotoLibrary/restricted/photo-plant.asp
Open Plant with
Central Rackand Room for
Expansion(Source: Air Products)
Layout Techniques and Methods
2-D Cut-Outs (Paper Dolls)• Scaled shape item footprint on cards, including
its access and other spaces
• Shapes shuffled on scaled plot of plant space
• Advantages:
– Cheap
– Simple
• Disadvantages:
– Requires skilled use to achieve good results in a
reasonable time
– Lack of 3-D element for multi-level plants – Need to copy agreed layout into another form
Physical Block Models• Rough scaled equipment models from cheap and
easily worked plastics
• Arranged in space until acceptable layout is produced – Spatial support by transparent sheets, rods or wires
– Sheets ≠ Floor levels
– Floor requirements marked on sheets or modeled separately
• Advantages: – Cheap and simple
– Preferred for complex or new plants with better representation for reviews by non-engineering staff
• Disadvantages: – Requires skilled designers
– Modification and Manipulation are difficult
– Need to copy the layout into another form for development
Physical Plant Model
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2-D and 3-D CAD Systems• 2D simulates cut-out and model techniques: Pure
drafting tool under skilled designers control
• 3D is Fully Rendered or Hidden Line View
• Advantages:
– 3-D shading and ‘walkthrough’ help communicate with
clients
– Manipulation i s easier
– Agreed layout ready captured in CAD database for later
development
• Disadvantages
– Model set-up more expensive.
– Higher cost
Conceptual Layout Studies
(Source: Bausbacher and Hunt)
Planning Study: Key Data for Other Disciplines
(Source: Bausbacher and Hunt)
Layout Considerations
Piping Layout
Source: Design Power, Inc.
Pipe Routing To Save Fittings, Steelwork
• Lines to close nozzles:
– On outside of the pipe rack
– Peel off first with flat piping turns.
• Lines to Far nozzles
– To the center of the rack
– Peel off later in most cases.
• Note: Flat turns not recommended with
likelihood of future expansion. Alternative –Multiple elevations for flat turn piping
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Routing Lines by System not Singly
(Source: Bausbacher and Hunt)
Minimized Elevations in Plant
(Source: Bausbacher and Hunt)
Change Diagonal Elevation to Cross
Multiple Lines
(Source: Bausbacher and Hunt)
Piping Crossovers(Source: Midwest Maintenance & Industrial, Inc.)
http://www.midwestmaintenance.net/pictures.htm
Minimizing Fittings Using Reducing Tees(Source: Bausbacher and Hunt)
Bypass Valve Arrangement
(Source: RAKI)
http://www.raking.com/articles/Constructability.htm
• Usual vs DFC
bypass valve
arrangements
– Bypass and block
valves unnecessarily
sized at same line ID. – Valve twice as large
often costs four times
as much)
• Design for
Construction:
– eliminates half the
number of welds
– reduces the size of
several valves
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Use Manifolds and
Standard Configurations
Steam
TracingUses
Manifoldsto
Distribute
and Collect
Steam
Heat Lines
(Source:
Bausbacher
and Hunt)
Steam Tracing
Manifolds
(Source: Spirax
Marshall)
http://www.forbesmarshall.com/spirax/paref1.htm
Vertical
Stacking to
Minimize
“Footprint”
Standardization(Source: RAKI)
http://www.raking.com/articles/Constructability.htm
Inline vs Non-Inline Items
(Source: Bausbacher and Hunt)
Their length
becomes part
of the pipelength
calculation
Generally attachto the pipe run
with a branchfitting, tap or
similar branchingarrangement.
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Elevate &
Slope for
Gravity
Flow(Source:
Bausbacher
and Hunt)
Open vs Closed Systems
(Source: Bausbacher and Hunt)
Allow for Thermal Expansion
through Built in Flexibility
(Source: Bausbacher and Hunt)
http://www.airproducts.com/PhotoLibrary/restricted/photo-plant.asp
Open Plant with
Expansion Loops at
Kettle Reboiler (Source: Air Products)
Support Pipe thatExpands
Thermally
(Source:
Bausbacher and
Hunt)
Allow for Installation Variations
(Source: Bausbacher and Hunt)
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Engineering Design Specifications
• Basis from which final plant design is produced
• Includes: – Start-up procedures,
– Initial site selection information,
– General pre-commissioning guidelines,
– Equipment testing procedures and acceptance
methods
– Final process topology,
– Material and energy balance information
Functional Equipment Characteristics
• Describe or specify the functional
requirements for the equipment• Service provided to process by
equipment
• What the equipment is supposed to do
Vendor-Proprietary Equipment
• Equipment whose performance is
guaranteed by the vendor.
• Specified by equipment
datasheet in process design
specifications package.
• Usually designed by selected
vendor who sizes and tests item
Required Access
• Assembly Access – Space required to construct,
assemble or rework plant
• Operator Access – Space required between
components to permit walking, operating valves,
viewing instruments, climbing ladders or stairs and
safely exiting the unit in an emergency
• Maintenance Access – Space required to service
equipment in place or remove part or all of the unit for
off-site repair
• Emergency Access – Space required for personnel
wearing fire or chemical protected Clothing needed toaccess abnormal or malfunctioning equipment.
http://www.warfab.net/
Millwright
Equipment
Setting(Source: Warfab)
Block Valves not Provided Regular Access
(Source: Bausbacher and Hunt)
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Walkway Access to
Valve Manifolds
(Source: ship-
technology.com)
http://www.ship-technology.com/projects/amoretti/index.html#amoretti7
Hard to Access Valves(Source: Midwest Maintenance & Industrial, Inc.)
http://www.midwestmaintenance.net/pictures.htm
Pulling Equipment(Source: Midwest Maintenance & Industrial, Inc.)
http://www.midwestmaintenance.net/pictures.htm
In-Place Repair (Source: Warfab)http://www.warfab.net/
Extreme Access(Source: Fire & Rescue)
http://www.nfrmag.com/backissues/MayJun2003/default.asp
Firefighting Training Demonstration(US CDC/NIOSH)
• Demonstration included: – a flammable liquid containment spill of 2,000
square feet of diesel and 8-10 inches of gasolinefuel,
– elevated pressurized flammable liquid fire, – flammablel iquid run down (spill) from a vertical
vessel, and
– liquefied petroleum gas.
• Platform or walkway similar to those in a refinery,chemical process unit, or a loading rack/terminal.
• Suppression tasks included – cooling the structure and
– controlling, approaching, and extinguishing themulti-fueled pipe rack fire.
http://www.cdc.gov/niosh/fire/reports/face200615.html
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BusinessOpportunity
SelectProcess Route
ProcessDesign
Evaluate:-Safety
Environment
Operabil i ty
Evaluate Costs:-C apital
Operating
PlantLayout
Layout Interactions with Business
Case and Design Baseline
Large Space - Safer
Less Space - Cheaper
Goodheat conservation,
Awkwardboiler plant
(b) Boiler to Evaporator Steam Constraint
(a) Furnace and Flammable Storage
Evaporator Boi l er
Anci l l ari es
Goodboiler plant,
Big heat loss
Evaporator Boi l er
Anci l l ari es
Conflicting Layout Constraints
(Source: Jame Madden)
Stacked Equipment Layout
(Source: RAKI)
http://www.raking.com/articles/Constructability.htm
Example:
Madden Methodology
Steps to Creating Layout
Review available process data:
• Flowsheet
• Equipment specifications
• Process description• Mass/energy flows
• Plant site information
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H123
T101 T102 T103
R104
H105H109 H113
R108 R112
T114
P115P111
T110T106
P107P116
P128
T126
H125
C124
H127
T117
T120
D129
F119
V130
X132
P133
X131
P122
P118
Acetone in
WaterinMonomer in Recycle Acetone
CatalystBags
WatertoEffluent
HP
Steam
Polymer Paste
Polymer
Powder
Bagged
Polymer Out
Exhaust Air
Condensate
To Effluent
P121
H134
Air In
Polymer Slurry
Batch PlantProcess
Flowsheet
F D Hold B
S
F
R
HoldR
R
S
Raw
Mat’l
INProduct
OUT
Air In
Air Out
Water toDrain
Blo ck Dia g ra m - Ba tch Po lym e r
Plant
Process Variables
Item Number T101 T102 T103 R104,108,112 H105,10 9,113 T106,110,114
Description Water weightank
Monomer weightank
Acetone weightank
Polymerisationreactors
Reflux condensers Initiator make-uptanks
Number Off 1 1 1 3 3 3
Dimns. rate orcapacity
1700 dia x2000
1700 dia x 1600 1900 dia x 2100 2700 dia x 3000 tube length 5.0 mshell dia. 1.14 m
400 dia x 1200
Analysis of
material
handled Mass%
water 100% Monomer 100% Acetone 84%Monomer 16%
Acetone 50%Monomer 10%Polymer 10%Water 3 0%
Aceto ne 1 00 % Water 90 %Initiator 10%
Material GRP Stainless Stainless Stainless Mild steel Stainless
Working
pressure
Atmos Atmos Atmos Atmos Atmos Atmos
Working temp.degrees C
Ambient Ambient Ambient 30 30 Ambient
Services N one N one None Cooli ng wa ter p ower Cooli ng wa ter Power
Remarks Mounted on
load cells
Mounted on load
cells
Mounted on load
cells
Establish Main Relationships
• Arising from: – Connected items
– Gravity/2phase flow NPSH
– Elevation requirements
– Equipment features
– Safety and Environment
– Electrical classification
– Utilities
– Site features, etc, etc
• Make notes of relationships for each item
H123
T101 T102 T103
R104
H105H109 H113
R108 R112
T114
P115P111
T110T106
P107P116
P128
T126
H125
C124
H127
T117
T120
D129
F119
V130
X132
P133
X131
P122
P118
Acetone in
WaterinMonomer in Recycle Acetone
Catalyst
Bags
Waterto
Effluent
HPSteam
Polymer Paste
Polymer Powder
Bagged
Polymer Out
Exhaust Air
Condensate
To Effluent
P121
H134
Air In
Polymer Slurry
BPFSHT2
Pr ocess
Pr oxi m i t y
G r avi t y
NPSH
Fig. 2 Batch Plant
Main
Relationships
Find Dominant Relationships
• Ruthlessly eliminate all but the one or two most
important relationships
• Mark these on Flowsheet
• Multiple copies marked with differentcombinations may help to clarify alternatives inmore complex cases
• Decide for each item which is its single mostimportant relationship which must be satisfied.
• Mark up on final copy of Flowsheet
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Treat Groups as Super Items - Arrange
into Super Groups of 5-7 Groups,
• According to the strength of inter grouprelationships.
• The network of Groups should bearranged around the Plant Flow line
• If the plant is not covered by 5-7 Groups,arrange the Super Groups into MetaGroups of 5-7 Groups, using similar reasoning in prior steps
FormMethAnsFig08
Fig. 8
DRYER VACUUM AI R
H123
T117
COLUMN CATALYST
REACTORS
FEED
PRODUCT
PLANT AS SET OF GROUPS
• Two logicalstructuresshowing
networks of Plant items inGroups
• Groups withinthe whole plant,on which the 3-D l ayoutoperation canstart.
Build 3-D Models of Equipment Items
• Allow for access, etc using equipment data
and sketches
• Note regions where main pipes should be
connected.
550 Dia
1 1 5 0 0
Col umn C124
1 0 0 0
3 0 0 02700 Dia
R-104/-108/-112
Fi l ter F119
7 5 0
2 2 0 0
1 0 0 0
2000
500
MAJOR ITEM SKETCHES
R104 - C124 - F119
Outlet Box 900 X 2600
1500 Dia
1 8 0 0
1 5 0 0
Inlet Box 1100 X 2600
9300 Long
Drive Unit below Drum
Dryer D129
3 5 0 0
1 5 0 0
1000
Dia
Cycl one X132
3 8 0 02000 Dia
Hopper V130
2 8 0 0
4000
2 0 0 0
2 5 0 0
Bagged Polymer Out
Bagger X131
MAJOR ITEM SKETCHES
R104 - C124 - F119Roughly assemble 3-D models on
flow line
• Ensure calculated elevation requirements
are satisfied
• Sketches shown have elevations of plant
items, not of floor levels
• Orient the items so that nozzles will be in
the correct place and access points are
not obstructed
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REACTOR GROUP
ELEVATIONS
H105 (1140 DIA)
T101/2/3
R104
P106
1000
5600 el
2000
3000
600
15006670 el
Ground Level
COLUMN GROUP
ELEVATIONS2500 to dr ive
C ontrol Valve
1000 piping
1400 dia
540 dia
14400 el
19570
el
3900 el
Liquid level
500 Liquid D epth 2400
Tubes
1500
9000 Packed
H eight
500
1000
Ground level
H127
C124
H125
T126
7300 el
V130
X131
D129
X132
F119
2500
500
3800
500
400
1800
10500 el
10100 el
1000 Min
Ground Level
DRYER GROUP
ELEVATIONS
Minimum pipe angle 45.
Note effect of horizontal
offsets from sloped pipes.
VACUUM
GROUP
ELEVATIONS
10600 el
9100 el
P122
Seal Tank
T120
P121
F119
Ground Level
700 Dia
8 0 0 f o r g o o d
p ip e slo p e
8500 Min
Ba r o m e t r ic
Seal 9000 Min
Ba r o m e t r ic
Seal
Pr e su r e
0.27 Bar
Ab s
Ht 1200
10200 el
600
GROUP and
LAYOUT
EXAMPLE
Product
Store
H134
Power
F119
X131
V130
X132D129
Powder
FlowPaste
Flow
Powder
Flow
AtmosP118Power
Dr yer G r oup
Layout of Dr yer G r oup
Ba g g e r
X131 Dryer D129 Filter
F119
Acce ss a n d M a in t e n a n ce
C yclo n e X1 3 2
H o p p e r
V130
Gr o u p Pe r im e t e r
• Apply inter-itemspacings:
– Tomeet safety or similar
needs, – From good practice
guides,
– For access within thegroup,
• Do not attempt to orientthe whole group along N-S or E-W axes at thisstage.
• This step establishes theoverall 3-D shape of theGroup
• Repeatfor each Group toprovide a set of 3-Dkernels of the whole plant
Building Up
the Layout
1. Convert Group into 3-D items
2. Space and arrange along Group flow
3. Assign Elevations
4. Do not orient 3-D Group yet
From C olumn Group (as before):-
To Plant:-
P128 H127
C124 T 126
H125
4. Arrange/Orient Groups around Plant flow
5. Nest groups as far as possible
6. Normalize Elevations to common floor
levels
7. Apply inter-Group spacing
3-D Kernels
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ASSEMBLING GROUP
LAYOUTS INTO PLANT
R104 R112 R108
DRYER C OLU MN
FEED TANKS
VACUUM AIR (U nder)
F119
G RO UP ASSEM BLY - No t to sca le
PR OD U C T OU T
RAW MAT’LS IN
• Check elevations of all itemsand normalize to common set
of levels – Levels will become Flowsor combined platforms.
– Add in any “lone” items,filling in any spare spaces.
• Nest all Groups as possible
– Reasonable rectilinear shape
– Target aspect ratio in planbetween, say, 1 and 2.5
– Check inter Group access
– line up accessways
– Add space for stairwells,ladders, pipetracks, etc.
Generated Layout• First, logical layout
concept
• Layout evaluated,agreed, passed todetailed engineering
CAD Model of Layout
Questions?
http://www.ziptronix.com/equipment/tools/valve_manifold.html
Valve Manifold
Panel
(Source:
Ziptronix )
https://reader009.{domain}/reader009/html5/0420/5ad90741a5fac/5ad90756178bf.jpg
Steam
Tracing Lines(Source: Tyco
Thermal Controls)