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ConsiderationsfordevelopmentofPlantLayout:AbriefpresentationWhatisPiping

AdditionalUnits
Nearfutureexpansion
Farfutureexpansion
PointstoNote
NormallyConstructionispermittedonmaximum50%oftheplotareawithtotalbuiltupareaequaltoareaoftheplot(i.e.F.S.I.=1
(Dependingupontheregulationgoverningtheareaandthetypeofindustry))
Areareservedfortreeplantationshallbe1/3oftheareaoccupied.
Waterstoragecapacity24hr.minimum.
Domesticwater100litresperpersonperday
WaterrequirementforBoilerSteamratingxWorkingfactor
Coolingtower11/4%ofcapacityasdriftandblowdownlosses
Washing1015litresperdaypersq.ft.offloorareaoftheplant
Gardening5litresperdaypersq.ft.ofgardenarea
Parkingspace10%oftheplotarea
Roads&Paving
Roadsintheplantshallbeplannedforeffectivemovementofthetrucks,cranes&emergencyvehiclesetc.Roadwidth(Blacktop)
shallbegenerallyasfollowsunlessspeciallyrequested.
Mainplantroad&roadsconnectingtoPlantboundaries,roadsforfirefightingaccessis6meterswide(Min)
Secondaryroads4meterswide(Min)
Turningradiusoftheroadshallbeadequateforthemobileequipment&shallclearofanyobstruction.Minimumturningradiustobe
sameasthelengthofvehicle.
Thefinishofroadi.e.gradedorblacktopshallbedecidedinthebeginningwhiledevelopingplotlayout.
Pavingshouldbeprovidedaroundtheequipmentswherespillageislikelyoccurring.Forexample:Pumpsormachineries,below
furnaceorfireheaters,compressoretc.
AlsopavingshouldbeprovidedbelowAirfincoolerthosearelocatedatgrade.
Areahandlingacids,alkalisortoxicmaterialshallbepavedandbunded.Propersurfacetreatmentshallbeprovidedtopavingtomeet
servicerequirement.
Thebelowsketch(Fig.1)showsminimumdistancerequiredbetweentheroadandthefacility.Thisdistanceshallbereviewedtocasetocase
basisfortheproject.
Fig.1:Minimumdistancerequiredbetweentheroadandthefacility
Elevations
Belowdatafortheelevationsshouldbegenerallyfollowed.
UndersidethebaseplateofStructuralsteel:Min150mm.aboveHPoffinishedgrade/paving.
Stairorladderpads:Min75mm.aboveHPoffinishedgrade/paving.
TopofPedestalofVessel&Tower:Min300mm.aboveHPoffinishedgrade/paving.
TopofPumppedestal:Min200mm.aboveHPoffinishedgrade/paving.
Insulation&FireProofing
Fireproofingrequirementsforpiperack,vesselsupports,processstructureshouldbeconsideredasthesereducestheclearanceswith
access,pipework,instrument&electricalequipment.
Properinsulationthicknessshouldbeconsideredforpipework&equipmentclearances.
Equipmentlocations
Pumps:LocatepumpsclosetosuctionsourceconsideringNPSHrequirement.Pumps&driveraxisshouldbelocatedperpendicularto
piperackorotherequipmenttominimizefireexposureincaseofpumpsealfailure.
GascompressororExpanders:Gascompressorsshouldbelocateddownwindofthefiredheaters,flareoranyopenflameequipment.
Theymaybegroupedtogetherformaintenance&operations(CommonEOT/dropdownarea,singlesunshadecanbemade)
PlantAir&Instrumentaircompressors:Plantair&instrumentairisvitalservicefortheplant.Theseunitsshouldbelocatednearthe
controlroom&shallbekeptinsafeareasufficientlyawayfromHACofequipment.
HeatExchangers:Heatexchangersaregenerallyplacedongradeunlessotherwiseduetoprocessortechnicalreasons.(Platformfor
verticalheatexchangers,Tubebundleremovalarea,accesstomobilecraneormonorailwithhoistshallbeconsidered)
Aircooler:Aircoolerlocatedsuchawaytoallowtheaccesstomobileliftingequipment.Preferablyaircoolerislocatedinamain
equipmentrowinaccordancewithprocessrequirement.
CoolingTowers:Coolingtowersshallbelocatedawayfromtheprocessequipment&downwindofprocessequipment,substation,main
piperack.
OffsiteTanks:Storagetanks(Groupedandshallbesurroundedbydikewall,Primary/secondaryroadsforadequatefirefighting
accessibility,Lowerelevationsthantheotheroccupanciesanddownwindofflares,furnaceheaters).Emergencyshutdownvalve,
pumps,manifold&transferpipingshallbeoutsidedikearea.
Pipeways/Piperacks
Pipewaysorpiperacksshouldbeoverheadinprocessmainunitandatgradeinoffsite.
Widthisdeterminedbasedonpresentneed+10%atoutsetthejob+15%forfuturerequirementorasspecifiedbyclient.
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ConsiderationsfordevelopmentofPlantLayout:AbriefpresentationWhatisPiping

Requirementofexpansionbays,anchorbays&bracingshallbecheckedwithstress/structuralengineeratthebeginningoftherack
layout.
ReliefvalveandFlaresystems
Closedreliefvalvesystem
Selfdraining
Nopockettoavoidcondensation&backpressure.
Flareshallbelocatedupwindprocessunit&storage.
ClearanceatPigReceiver
AreaattheendclosureofReceivershallbekeptfreetoavoidanyincident.
Provideconcretewallminimum20meteraway(Fig.2)fromtheendclosureifareaneedstobeutilizedforanyequipment.
Fig.2:ClearanceatPigLauncher
Personalprotection
Eyewashandemergencyshowersshallbeprovidedinareawhereoperatorsaresubjecttohazardousspraysorspills.
Breathingairstationsinthefacilitieshandlingextremelytoxicgases/fluids.
Fig.3showsatypicalplantlayout.
Fig.3:Typicalplantlayout
WhatisHazardClassification?
Hazardousareaclassificationistherisklocatingplanforeachunit/facilitywithintheplotboundaryforaprocessindustry.
ThePlotplanwillbeusedbyindicatingboundariesofriskarea.
HACdrawingsaregenerallyusedbyoperatorwhileissuingworkpermits.
HACStandard
HAZARDOUSAREA:Anareainwhichanexplosivegasatmosphereispresent,ormaybeexpectedtobepresent,inquantitiessuch
astorequirespecialprecautionsfortheconstruction,installationanduseofapparatus.
NONHAZARDOUSAREA:Anareainwhichanexplosivegasatmosphereisnotexpectedtobepresent,inquantitiessuchasto
requirespecialprecautionsfortheconstruction,installationanduseofapparatus.
ProcessRequirement
Properinterconnectionbetweenequipmenttoachieveintendedprocessparameters.
Normallyequipmentisarrangedintheprocessfluidflowsequence.Requirementlikegravityflow(EquipmentDrainpiping),Thermo
syphonsystemshouldbeconsidered,Limitationofpressure&temperature(processparameters)tobeconsidered
Requirementofupstreamanddownstreampipelengthsforinstruments.
Hazardous&Toxicfluidshallbeidentified.(H2S,Cyanide,Methanoletc.)
Equipmenthandlinghazardousfluidslikeflareanddirectfiredequipmentcontainingopenflameshallbelocatedseparately.
Similarlyequipmenthandlingtoxicmaterialshallbelocatedwiththerestrictedaccessorinaccordancewithlocalstatutoryregulation.
EconomicConsiderations
Equipmentshallbelocatedwithoutaffectingtheprocessrequirementformaximumeconomyofpipework&supportingsteelwith
consistentstandardclearances,construction,andmaintenance&safetyrequirements.
Runsofexoticmaterial&largeborepipingshallbeminimized.
Optimumutilizationofthestructuretobeensured.
Erection&Construction
Roadaccessforerectionofpipesupport/pipesandequipment.
Clearareaforcranetoerectequipmentonthelocationfromthetrucks.
Minimumonesideofpiperackshallbekeptclear.

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04/07/2016

ConsiderationsfordevelopmentofPlantLayout:AbriefpresentationWhatisPiping

Fig.4showsrelativelocationsforareaLayout.
Fig.4:RelativelocationsforareaLayout.

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