6/8/2015 VariousConsiderationsinEquipmentLayoutintheEquipmentandPlotPlan|PIPINGGUIDE

VariousConsiderationsinEquipmentLayoutintheEquipment
andPlotPlan
PostedbyAnkitChughon9:51AM 0Comments

LearningObjectives

Equipment layout is based on certain considerations.

The final plant design is executed on the this drawing
and it should be seen that plant should be safe and
economical. This equipment layout is very important
becausethisisusedfortheexecutionofplant.

The piping engineer has to understand the concept of

equipment layout and consideration. While preparing
layout, the piping engineer should design a steady
process,nonhazardousutilityandfacility.

Introduction

In general the various process plants we come across are petroleum refineries, petrochemical complexes,
fertiliserplants,andchemicalandpharmaceuticalplantswhichneedspecialattentionduetothenatureof
materialsandproductshandled.

Beforestartingthedevelopmentoftheplantlayout,thefollowinginformationisrequired.

i.Processunitsandcapacities.

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ii.Aflowdiagramindicatingtheprocessflowsequence.

iii.Utilityrequirement.

iv.Numberofstoragetanksandalsoopenstorageareas.

v.Rawmaterial/productreceiptanddispatchphilosophy.

vi.Coveredstoragerequired.

vii.Numberofflares(Asapplicable).

viii.Groupingphilosophyforutilities.

ix.Nonplantbuildingi.e.Administrativeblock,laboratory,securityworkshop,parkingspace,firestation,
canteen,etc.

Ideally, before site selection, a preliminary layout should be made. The data collected during the site
selection stage shall be given due consideration at the time of the equipment layout. A few points to be
consideredare:

i.Sitelocation,mapandareatopography,geologicalandmeteorologicaldata

ii.Environmentconditionrelativetoadjacentpropertiesi.e.proximitytoairport

iii.Soilconditions,prevailingwinddirection.

iv.Sourceofwatersupplyandthesupplypointwithrespecttotheplot.

v.Electricsupplypointwithrespecttotheplot.

vi.Effluentdisposalpointandotherdrainages.

vii.Materialtransportationrailwayentrypointapproachroadsbargeorshipdocketc.

viii.Geographicalfactorsi.e.winddirection,temperature,rain,frequentthunderstormandearthquake
susceptibleareas.

MajorConsiderationinPlantLayout

The most economical plant layout is that in which the spacing of the main equipment is such that it
minimises interconnecting pipe work and structural steel work. Normally equipment should be laid out in
sequence to suit the process flow but exception to this arises from the desirability to group certain tanks,
pumps or perhaps to isolate hazardous operations according to statutory rules and regulations. The use of
thesinglestreamormultiplestreamflowpatternwillaffectthelayout.

The major variables affecting the final layout are interconnected pipe sizes, insulation thickness, steel work
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spacing, matters of operational convenience, safety, ease of erection and maintenance which calls for
expiriesofcriticaljudgmentontheexperienceandthestudyofexistingandknowlimitation.

Economic

Basicallyeconomicconsiderationmeansinstallingtheunitinthesmallestpossiblespace,consistentwiththe
operabilityeaseofpipingmaterial,structuralsheetsandconcretewiththeproperlayoutconsideringfurther
economieswhichcanbeachievedinwayofpumpingandutilities.

Safety

Where toxic or hazardous materials are handled, layout may be needed to isolate a section of the plan
equipment, which could be a possible source of hazard. It should be grouped together and where possible
located separately from other areas of the plant. i.e. furnaces, flare stacks or other equipment containing
naked flares. Mechanical equipment handling flammable or volatile liquids which could easily leak or spill
out of the equipment thus causing flammable conditions. However such consideration should not override
considerationsofcost.Forinstance,theprocessheatermustnecessarilybelocatedclosetootherequipment
to conserve expensive alloy piping. Furnaces using gas as a feedstock do not normally constitute hazards.
Due consideration shall be given for fire hazardous areas and isolated by providing firewall, fire door, etc.
The BOCA (Building official and code administration) published by the National Building Code shall be
followed.

Theareaequipmentareahandlingacidsorothertoxicmaterial,whichcausedamageorendangerpersonnel
bytheirspillageshouldingeneralbegroupedtogetherandisolated.

To isolate hazardous areas it may be necessary to build walls with selfclosing doors. Definitions of
hazardousareasaregiveninNFPA,NEC,andthePetroleumActOISDorlocalstandards.

Classof Firelode(Btu/sq.ft) RequiredfireResistance

Hazardous RatingforFireWalls(hr)
Laws 0to100,000 1
Moderate 100,000to200,000 2
High Over200,000 4
Requiredfireresistanceratingfirewallsandfirepartitions

Explosionhazard Minimumclearspace
(ft)
E1:Minimum,noneorslightconsider NonerequiredNone
negligibleE2:Moderatelimitedtosmall required
areapromptrestoration
E3:Intermediateappreciablemajor 50ft
equipments
E4:Highconsiderablepotentialor 75ft
probabilityseriesdelays
E5:Extremeunpredictablehigh 100ft
potentialdisruption
Clearspacerequiredwhenfirewallsorfirepartitionsareexposedtoexplosionhazards

Material Btu/lb
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Teflon 6,000
Rubber 7,500
Wood,paper 8,000
Polyvinylchloride 10,000
Polyurethane 11,000
Polyvinylalcohol 12,000
Methanol,ethanol 12,000
Acrylicplastics 12,500
Polystyrene 18,000
Oil 18,000
Gasoline 21,000
Typicalheatsofcombustion

Proccess

Process considerations may require some items be elevated to provide gravity flow of materials to
accommodatepumpsuctionrequirementforNPSH.Theotherprocessconsiderationcouldbethelimitation
of pressure or temperature drop in the transfer lines deciding the proximity of the furnace, reactors and
columns.

Operational

Thoughtshouldbegiventothelocationofequipmentrequiringfrequentattendancebyoperationpersonnel
andtherelativepositionofthecontrolroomtoobtaintheshortestandmostdirectrouteforoperator.When
on routine operation however the control room should be placed so that they are easily accessible and the
indicatorsareeasilyreadable.Generallyabatchorsemibatchprocessneedsmoreattentionbytheoperator
andthereforemoreconsiderationhastobepaidtotheergonomicsofthelayout.

Maintenance

Theneedtoremoveforservicing,retuningorreplacements,theheavy,servicingequipment.Theindivisible
plantwilldictatetheirlocationwhenaccessforcranesiscalledforregularorrotatingandothermachinery
callingfordismantling.Thisoftenmakestheirgroupingwithinthemachinehousedesirable.Thepositionof
items needing replacement of internal spent catalyst etc. or frequent internal cleaning has to be carefully
considered.

Constructional

The plot should be so designed that adequate access is available to lift the large items of equipment or
columns into place. Such equipment is positioned close to the boundary limits so that erection must take
place from outside these limits. A careful check must be undertaken to ascertain whether space will be
availableatthetimeoferectionforpositioningthecraneorliftingthedeliveryequipmentwhichisknown,
may well arrive fairly late in the construction programme and therefore have to be fitted into place after
most of the surrounding equipment has already been installed. It is important that the insulation
requirementbeconsideredduringthelayoutoftheplant.

Appearance:Aesthetic

An attractively laid out plant with the equipment in rows also economically laid out gives an aesthetic

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appearance. The building structure and groups of equipment should form a neat, symmetrical balanced
layoutconsistentwithkeepingthepiperuntoaminimumandallowingproperaccessformaintenance.The
tower and large vertical vessels should be arranged in rows with a common centreline. They should be of
similarsizebutifthediametervaries,duenotemustbetakenofthebuildinglinemanholesontheadjacent
tower should be at a similar elevation and orientation to streams. These as far as possible should be made
identical. Such arrangement for parallel streams or similar groups of process equipment require much the
design work and also for construction and subsequently operation but help in reducing the amount of
standbyequipment.

FutureExpansion

Thoughtshouldbegiventothelikelyexpansionofbothequipmentandpipework,sothatadditionscanbe
erectedandtestedwiththeminimuminterferencetoplantoperations.Onmainpiperuns,itisdesirableto
leave 30% space. At least 30 m distance from flame proof plant area is needed for safe welding where no
specialprecautionareneeded.

Buildings
Plant buildings should be kept to a minimum on the basis that most of equipment including pumps, heat
exchangerboilers,cyclones,etc.maybesafelyinstalledintheopen.Thephilosophyshouldbethattheplant
issupportedonanopensteelstructureunlessthereisgoodreasonnottodoso.Thusitistobeinstalledin
theopenwithcentralisedcontrolfacilitieshousedinbuildings.

Factorswhichdeterminetheselectionofenclosedbuildingsare

a)Natureandfrequencyoftheoperator'sworkEquipment,whichrequiresfrequentmaintenancein
adverseweatherconditions.

b)ClimateExtremeclimateconditionsmaydeterminethattheplantistobekeptinabuilding.

c)TypeofequipmentExpensiveequipmentandcomplexmachineryshouldhavesomedegreeof
weatherproofing.

d)NatureofprocessPlantshandlingdustexplosiveandcombustiblesolidmaterialsrequireabuilding.To

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preventcontamination,food,pharmaceuticalandbiochemicalplantsrequiretobeinabuilding.

e)ProximityofhazardsTopreventthepossiblespreadoffireandexplosion,abuildingmaybedesirable.

f)Ifenclosedbuildingsareplanned,thenconsiderationmustbegiventothefollowingfactors:

i)Fireprotection/ExplosionProtectionapprovalbythelocalfireauthoritymustbeobtainedonfire
fightingequipmentandlayout.

ii)Illumination.

Natural illumination may be obtained by the use of patent glazing windows or translucent sheets in the
sidewalls or the roof. Artificial lighting must be arranged to give adequate illumination where physical
andchemicalhazardexists

iii)FireproofingDeterminestheplantarrangementandswitchroom.

iv)VentilationAirintakeshouldbepositionedinsuchawaythatitshouldavoidtheriskofdrawingtoxic
orhazardousfumes.Exhaustmayberequiredfortreatmentoffilterwasher,separation.

v)Heating

vi)AccessProperaccessformaintenanceandoperationpurposestobeconsidered.

vii)Roofing.

TechniquesforLayout

Thereisnosingletechniqueleadingtothebestarrangementinanyproblem.Layoutmaybeconsideredat
several stages from the selection of the site and arrangement of the plant on it through block layout. The
threebasicprinciplesoflayoutplanningare:

1)Planthewhole,thenthedetail,Individualaspectsmustbesubservienttothewholeandsuboptimisation
avoided.

2)Plantheideal,thenthepractical.Theideallayoutisfreefromrestrictionsandgivesadatum.

3)Planmorethanonelayout.Itisseldomthatasinglelayoutis"BEST"foreachcriterion.Planningmore
thanonepermitscomparisonandleadstogreaterconfidenceinmakingthefinalselection.

4) Sequence of activities in layout. A simplified network showing the integration of the plant layout and
designactivitiesshouldbegiven.

DetailsofTechniquesforLayout
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1)Initialdevelopmentofthelayout.

Layoutisbyprocessflow,inthesequenceofoperationandmaterialsmoved.

CriticalExaminationquestion

Whereistheplantitemplaced?

Thesteamejectoratelevation.

Whyitisplacedthere?

Convenientforbarometricleg.

Whereelsecoulditbe?

Nearthegroundlevelwiththecondenserandthevacuumpump.Correlationandcompatibilitywhatis
impossibleorinadmissible.

2) Techniques of correlation and compatibility. The correlation chart is a diagrammatic method of

determiningtheeffectofconstraints.

3)ProximityandsequencingTravelchart.Thesimplestmanualmethodisprobablyoneoftrialanderror
inwhichitemsaresituatednearoneanotherassuggestedbysignificantcostsandthearrangementmodified
withreferencetothetravelchart.

LayoutAnalogues

1) Cut outTo visualise plant layout 2 dimensional scale templates or scale cutouts of unit areas and
equipmentlayoutareprepared.

2) Block models These models are chiefly used to develop the plot plan, floor plan, elevation, major
equipmentandmajorpiperacksinthecorrectcorelationwitheachother.

3)Drawingsforthedevelopmentandevaluationofthelayoutitcorelatesthebasicprojectinformationon
theequipmentandsiteconditionandprovidessourceofdataforthefinallayout.

4)Pipingmodelsforaccuratedetailedlayoutoftheprocesspipingutilityandcontrolfacilities.

Computers

Iftherearesixalternatepositionsforeachofoneofthesixblocksthenthereare720feasiblecombinations
of these six blocks. In general, for a computerised plant layout, the judgment of the engineer has to be
combined with the calculation power of the computer. Usage of the computer is on the evaluation of
systematic techniques. Small problems can be handled manually with various corelation and compatibility
methods.

ConceptofthePlantLayout

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Aprocessplantwhichconsistsofthevariousdifferentsectionsmentionedearliershouldbearrangedsoasto
followthegeneralrouteoftherawmaterial,toprocess,tointermediate/finishedproductstagetodispatch.
The entire plot area will be divided into blocks, the size of the blocks depend on the facilities to be
accommodated.

While locating the blocks and further subblocks within them, the following points runs should also be
minimum.

1)Thelayoutplanningshallbeinthesequentialorderoftheprocessflowsothatthepipingrunisalso
minimum.

2)Theblockshallbearrangedconsideringtheprevalentwinddirectionsuchthatflammablegasesshould
notbecarriedbythewindontoasourceofignition.

3)Theprocessunitblockshallbecentrallylocatedwithastraightapproachfromthemaingate.

4) Storage tanks shall be grouped according to product classification. In undulating areas, storage tanks
shallbelocatedatlowerelevations.

5)Utilityblocksshallbelocatedadjacenttotheunitblock.

6)Themainpowerreceivingstationshallbeclosetotheboundarylinesothattheminimumoverheadpower
linespassthroughtheplant.

7)Theelectricsubstationsintheplantshallbelocatedinsuchawaythatcablingtomajorloadcentresare
minimum.

8)Thelocationofpowerplantsshallbeneartheprocess/utilityblockandclosetothemainreceivingstation.

9)Flaresshallbelocatedupwindoftheprocessunitssothattheinflammablegasfromtheplantarenot
carriedtowardstheflares.

10)Truckloadingfacilitiesshallbelocatedclosetotheproductmovementgate.Railloadingfacilitiesare
arrangedgenerallyattheperipheryoftheplant.

11) The effluent plant shall be located away from the other units on the down elevation. The preferred
locationisatthelowerelevationthantheotherplantunitsinordertofacilitategravityflow.

12)Thefirestationandfirewaterpumphouseshallbeatasafeplaceawayfromhazardousareas.Thefire
stationshallbenearthemaingatewithastraightapproachtotheprocessunitsandothercriticalareas.

13)Twoadjacentprocessunitlocationsshallbedecidedbasedontheannualshutdownphilosophyforthe
maintenanceoftheunits.Iftheshutdownsarebeatdifferenttimes,itispreferabletoincreasethedistance
betweenthetwounitssothattheriskfortheoperatingunitsduetoheatjobsintheunitsundershutdown
canbeminimised.Alsothiswillfacilitateeasymaintenance.

14)ProcessUnitsshallbelocatedonthehighground.

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15)Theadjacentneighbourhoodinstallations,ifany,shallbetakenintoconsiderationbeforefixingtheplant
layout.Thelimitationsimposedbytheneighbourhoodfacilitiescannotbeignored,e.g.anignitionsource.

16) Flares, furnaces/heater, dusty operations and cooling towers shall be oriented depending on the
prevailingwinddirection.ThefirsttwoshallbelocatedupwindoftheProcessunitsandthelasttwoonthe
downwinddirectionsoftheprocessunits.

17) Due consideration to the construction and erection of the plant shall be given while deciding the plant
layout, especially tall towers, reactors, furnaces, etc. shall not be in congested areas and sufficient open
spacesshallbeprovidedforerectionatanystage.

18)Equipmentrequiringfrequentmaintenanceshallhaveeasyaccessibility.Soalsoequipmentwhichneed
removalofpartsandalsoforfreeaccessforhoistingequipment.

19)Provisionsforfutureexpansionshallbeconsidered.Itispreferabletohavesimilartypeoffacilitieswith
adjacent space for expansion adjacent. Care shall be taken to install the expansion facilities without any
disturbancetotheexistingfacility.

20) Roads in between for the purpose of access and safety should separate the blocks developed. Fire
fightingfacilitiesaretobeprovidedontheseroads.

Thereshallalwaysbeanalternativeapproachforfirefightingandmaintenanceincaseonerouteisblocked.
Thelayoutshallbesodesignedthattrucktrafficinsidetheplantisminimized.

21)Boilerhouse,aircompressors,fueloilfacilitiesshallbegroupedintooneblockadjoiningtheprocessunit
blocks,sothatspreadingofvariousutilitiescanbeavoidedandalsofacilitateeasyoperation.

22) The layout shall be designed so as to minimise the capital cost for earthwork and pavement, special
foundationsandtheextentofavacantplotaswasteland.

For the major distances to be considered during plant layout OISD (Oil Industries Safety Directorate)
Standardsshallbereferredto.

Plantlayoutneedsstatutoryapprovalsbeforeimplementation.Someofthestatutoryapprovingcodesare:

1.IndianFactoriesAct
2.IndianExplosivesAct
3.PetroleumAct
4.Central/StatePollutionControlBoardLaw
5.IndianElectricityRules
6.CIVILaviationruleNationalAirportsAuthority
7.InsuranceAssociationofIndiaFireProtectionmanual.
8.N.F.P.A.CodeofPractice.

The oil industry safety directorate (OISD) gives some guidelines for plant layout but does not overrule the
existingstatutoryrequirements.

The environment/security requirements now demand that a Green Belt area around the plant boundary

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shallbeprovided.Thisisabeltofwidth50mto100maroundtheplantboundarywherenoconstructionwill
bedone.

ThePresentFact Alternatives Selectionfor

Development
Whatisachieved? why?whatelse whatshouldbeachieved?
couldbeachieved?
Howitisachieved? Whythat Howelsecoulditbe Howshoulditbeachieved?
way? achieved?
Whenitisachieved? Whythen? Whenelsecoulditbe Whenshoulditbe
achieved? achieved?
Whereisitachieved? Whythere? Whereelsecoulditbe Whereshoulditbe
achieved? achieved?
Whoachievesit? Whythat Whoelsecould Whoshouldachieveit?
persion? achieveit?
(a)Criticalexaminationsheet

Stagesinthedevelopmentofthe UsefulTechnique
layout
1)Thelayoutbeginswiththecollectionand Criticalexaminationisusedtoquestionthe
assessmentoftheflowsheet(whichmust elevationlayoutassumptionsmadeintheflow
showmaterialofconstruction,sizeofpipe sheet.Thismethodenablestheobjectivesand
workandsuggestedelevation),equipment constraintstobedefined.Techniquesof
datasheets,resultofsitesurvey correlationandcompatibilityareusedtosort
(incorporatingrelevantdataonsite andlistthevariousalternatives.
boundaries,topography,soilstructure,
weatherconditions,utilityterminalsand
siteaccesspoints).
2)Thecostofeachelevationalternationis Simpleelevationdrawingsarepreparedforthe
examinedfordifferencesonlye.g.inthe alternativesshowingheightsandrelative
numberofplantitemsneededtoachieve positionsonlyofplantitemsonly,Nostructure
theobjectivesinthematerialtransfercosts orfloorlevelsareaddedyetasthesemay
suchaspipingelevation,power dependonplanlayout.
consumption.
3)PlantitemsandbuildingsarelaidoutinCriticalexaminationisusedtoquestionthe
theplanensuringthatalllayoutconstrains
planlayoutassumptionsmadeinthedefined
(e.g.relatingtooperation,maintenance, OncetheconstraintsaredefinedTechniques
safetycostingenvironmentandexpansion ofcorrelationandcompatibilityareagainused
)areappliedAsimilarcostingmadeof tosortandlistthevariousalternatives.Layout
eachplanlayoutismade analogoussuchascutoutshelpinthe
visualizationofthelayoutandinthe
examinationofplotsizeandexternal
constraints.
4)Theselectedplanandelevationlayout Thelayoutalternativeispresentedbyblock
arenowcombinetodeterminethepossible models.Thisstagewillhelppeopletovisualise
positionsofsupportingandaccess thenonquantifiableandsafetyaspects.
structures,andtostudythecivil
requirements.Thesemayforcethe
relaxationofearlierconstraints.
5)Finalalternatiresareagaincostedfor Thefinallayoutisdrawn(optionsmaystillbe
differencesandaselectionismade. leftopenfordetailedstudy)
6)Preparationofpipingmodelsnow Pipingmodelsarenowprepared.
commences.Thesearefurtherusedto
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optimizepipework.Acheckshouldbe
madethatallconstraintsareobeyed
particularlythoseforoperation.
(b)Typicalstagesinplantlayout

SummingUp

Understandingofequipmentlayoutisveryimportantandisbasedoncertainconsiderationsandguidelines.
Theconceptbehindthepreparationandapplicationofthelayoutareveryimportant.Theplantis
executablebasedonthisimportantlayout.

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