Good Plant Layout

1.0 1.1 INTRODUCTION A plant layout shows all equipment, pipe rack, buildings, major structures, electrical and instrument cable rack, roads, access ways and any other item of importance. The plant layout of process unit is the most critically scrutinized drawing. A cautious thought in the beginning will avoid many problems during operation and maintenance. A well laid out plant reduces overall plant cost as well as plant down time. The plant may be divided into two area, onsite and off-site. Onsite plant consists of process units. This is the area of highest concentration of loads and should be located in the area of best soil characteristics. The off-site plant consist of steam generation, boiler feed water treatment, cooling towers, storage tanks, electrical power generation, loading and unloading facilities, waste disposal etc.

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2.0 SITE SELECTION 2.1 The first thing a designer should know is the plot area and its topography. The grade level of the entire area should preferably be same. If the plot area is not flat, the land should be leveled because this eliminates lot of problems during piping design with respect to level matching, underground pipe routing and drainage. 2.2 Load bearing characteristics of the soil plays an important role in site selection. Natural soil has got more load bearing capacity compared to filled soil. The cost of civil foundation will be less in natural soil because piling to support the heavy loads may not be required in this case where as in case of filled soil, piling may be required which is very expensive. Piling has to be avoided as far as possible. The onsite plant where heaviest load shall be coming shall be located on the best soil of the plot area. Offsite plants may be thereafter located suitably. 2.3 In case of hilly sites, the load bearing capacity of the soil is very good. Onsite plants shall be located at higher elevations and offsite plants al lower grades. The higher elevation provides a head for natural flow of products into storage tanks. 2.4 The sewer system is greatly simplified with waste treatment section located at the lowest elevation. This eliminates the need of waste handling pumps. 2.5 Following site data are also required for the layout development; Magnetic North Surveying Bench Mark Prevailing Wind Direction Climatic Conditions Rail / Road Approach Barge / Ship Docks Location Incoming Utilities i.e. Power, water etc. 3.0 DEVELOPMENT OF PLOT PLAN & PLANT LAYOUT
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3.1. The space required for a process unit depends upon its capacity and the nature of process it carries out. It requires a fairly good knowledge and experience of plant and processes, basic safety, maintenance, layout rules and statutory regulations to decide the equipment plot plan. 3.2. The following data will be required by a plot plan designer from the process designer; Process and enginnering flow diagram of the unit Plot Shape and size Equipment Sizes Stainless Steel, Alloy Steel or any other piping which must be kept as short as possible without affecting the flexibility of the piping due to thermal expansion Restrictions, if any, on the equipment layout in view of the process considerations 3.3. As far as possible the equipment shall be located as per flow diagram sequence to minimize the pipe length and to ensure a neat and clean layout. 3.4. 3.5. 4.0 It is imperative that the connected equipment are placed near by, such as storage tank and transfer pumps, tower and its reboiler etc. A plot plan designer will come across with different types of equipments requiring varied considerations in the layout. EQUIPMENT LAYOUT

Following guidelines shall be followed for the few important equipment layout; 4.1. Tall Tower, Reactor, vertical Vessel: All the tall towers and vertical vessels shall be located on a common line. The position of the largest diameter vessel shall be fixed judiciously and it will guide the line up and location of other vessels. Space around the tower shall be adequate for ladders and platforms, catalyst loading or unloading and pipe davit operation. Provision for crane or derrick approach shall be kept which may be required during erection or maintenance. Generally, tall towers are assembled at site. This may require a clear space in and around the plant for field construction and erection of the towers or large vertical vessels. 4.2. Fired Heaters: Fired heaters shall be kept at a considerable distance from an equipment handling hydrocarbons. The normal recommended distance is 15 to 18 meters. Reactors may be kept at shorter distance of 7 to 10 meters to optimize the alloy steel piping lengths. Crane approach and space provision shall be kept for tube removal for repairs and maintenance. It is advisable to provide approach road.

4.3. Heat Exchangers: Back head of heat exchangers will be set on one line, which is called the equipment line. Tube pulling or rod cleaning area must be provided at the channel end. This length will be tube
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length plus two meters from the tube sheet. This area shall be clearly marked on equipment layout. Adequate space around the equipment shall be provided to attend the flanged end covers. 4.4. Pumps & Compressors: Pumps and compressors are roto-dynamic machines. Spacing between two such equipment shall be done in a way that vibration of one is not transmitted to the other. Control panels and local gage boards should have free access. Normally, compressors are housed in a building with its own maintenance crane. Maintenance space shall be provided at he end of the building. Compressor building must have truck access. Pumps and compressors shall be located to keep the suction as short as possible. Pumps shall be located, preferably, under pipe rack with discharge centre line one meter out from the centre line of rack column. 4.5 Reboilers : Reboilers shall be located next to the tower they serve. Kettle type reboiler elevation is determined by the tower liquid level. Reboilers may be supported with the tower or else a separate structure shall be made. 4.6 Cooling Towers : Cooling tower should be located at a considerable distance from flare stack, fired heaters or any other heat producing unit. Pump house serving cooling tower should be located to keep the piping run minimum. Orientation of cooling tower shall be such that the shorter side faces the prevailing wind direction. This allows both long sides to intake an equal amount of circulating fresh air. 4.7 Control Building : Control building should be centrally located and well connected thorough plant roads. The central location will minimize the length of lead cables. Control building should be away from equipment handling toxic or enflamable liquid. 4.8 Air Coolers : Air cooler, fin type, shall be located on the pipe rack top. 4.9 Piping : Piping is the most important consideration in equipment layout. In case stainless steel, alloy steel or any other costly pipes the equipment location may be suitably changed to keep the piping length minimum. 5.0 PIPING LAYOUT :

Process and utility lines shall, preferably, be run and supported on pipe racks following north south, east west directions. In a bigger plant with many equipment and inter connected piping it is advisable to keep the pipe rack in the middle portion of the plant for a better and economic piping layout.

Electrical and instrument cable rack shall be routed along the pipe rack. Position and elevation of the electrical and instrument cable rack shall be marked in the beginning itself to avoid fouling with the piping later on. Pipe rack column shall be, preferably spaced at 6M interval. The vertical distance between two parallel layers shall be 2400 mm and crossing layer will pass at 1200mm. Spacing of the pipe on the shall be such that the application of paint, and insulation on the pipe and support is permitted easily. The minimum head room under the pipe rack shall be as follows: - Above main plant road and public thorough fare. - Above secondary plant road - Above platform, gengway & maintenance area

- 7.5M - 4.5M - 2.2M

In case of hot lines provision shall be made for thermal expansion by providing loops or expansion joint. As far as possible the expansion loops shall be grouped together Hot lines connected to pumps, compressors and turbines shall be adequately anchored or guided so that no undue forces and moments are transmitted to pump, compressor or turbine nozzle. The routing of the piping shall be such that pocket, where liquidor gas collect, is avoided. If it can not be avoided, provision for draining and venting shall be made. Valves requiring frequent operation and adjustment shall be operatable from grades, platform or building floor. Valves shall not be installed with the stem below horizontal. Piping around equipment shall be arranged to permit access to the equipment and removal of equipment for maintenance and inspection. 6.0 6.1. WORKING PROCEDURE FOR DRAWING DEVELOPMENT : PLOT PLAN DRAWING :

A plot plan is drawn always with reference to a plant north. The plant north may nor be true or magnetic north. It is decided as per designers convenience. A rough sketch of the plot plan is made to show the relative locations of plants. This will be primarily a sequence layout. The scale may be choosen as 1:50 or 1:100. Ince the plot plan is completed it is circulated for coments and discussions. A best plot plan is decided by concensous.

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PLANT PAYOUT AND EQUIPMENT LAYOUT DRAWINGS :

On the basis of finalized plot plan the plant area is divided into the subplant sections. Each subplants are further developed for equipment layouts. The steps involved are as follows; 6.2.1. Pipe Rack layout : Main pipe rack and secondary pipe rack will be decided. The width of the pipe rack will be decided on the basis of the size and the number of pipes to run on the pipe rack. If the number of pipe lines are more a double or triple tier rack will be selected. The line feeding and equipment on the left side of rack shall be kept on the left portion of the rack and similarly, a line feeding an equipment on right side will be placed on the right potion of the pipe rack. This arrangement will minimize the pipe length and avoid piping juggalary. Electrical cable rack shall be routed along the pipe rack. The orientation shall be decided on the basis of maxm. Concentration of electrical motors. Similarly, instrument cable rack should also be decided, care will be taken to see that electrical and instrument cable racks are not very close to each other otherwise H.T. electrical cable will affect the instrument cable. Therefore, it is advisable to keep electrical and instrument cable rack on the opposite sides. 6.2.2. Ladders and Platform Layouts: Ladders and platforms will be provided for operation and maintenance of valves and equipment. Attempts shall be made to provide a common platform for the two adjesently located equipment. This aspect should not be overlooked because this results in initial saving as well as operators convenience. Platform area will be decided in view of locating the manifold any other piping which is connected to the equipment and likely to be located on the platform. Care shall be taken to ensure that the space around the equipment is free for easy access to the equipment. 6.2.3. Road Layout: Approach road to the plant will be decided. If crane will required in the unit either during erection or maintenance, suitable approach shall be provided and for crane mivement adequate space should be available. Control building be well connected from main road. 6.2.4. Piping Layout: Now the sequence layout as developed above shall be critically examined in view of the shorter length of stainless steel, alloy steel and hot lines without affecting the flexibility of hot lines due to thermal expansion. If necessary, the position of the equipment may altered to keep the costly pipes shorter in length and pipe elbows less in number. This may also be checked that the process restrction, if any, on the layout are compiled with.

6.2.5. Equipment layouts and Dimensioning: Dimensioning of equipment layout shall be done very carefully. It requires a fairly good experience and knowledge of plant and equipment. As a general guideline the following factors shall be considered while fixing the distance between two equipment. - Size of the equipment - Spread foot of the foundation - Structural i.e. ladders, platforms etc. - Maintenance space around the equipment - Space for catalyst loading and unloading in case of packed towers. - Space for the valve manifold in the piping connected to equipment - Space for internal removal in case of reactors etc. - Space for crane or derrick required during erection and maintenance - Vibration transmission from one equipment to other. - Space for the tube bundle removal in case of heat exchangers. 7.0 FUTURE EXPANSION PROVISION: Provision for future expansion shall be kept.