EQUIPMENT LAYOUT

A Good layout takes into account of the most important features of the plant such as economy, appearance & arrangement of the equipment from aesthetic point of view, proper maintenance facilities, and safety considerations and to facilitate the movement of erection machinery during the construction activities. Plant layout designer has to consider carefully all the above aspect to arrive at an optimum layout.

An Equipment layout shows the following:

1. 2. 3. 4. 5. 6. 7. All Equipments Major Structures. Main and Sub Pipe racks Access Way Control Room Space for future expansion and Any other item of importance

Reference Drawings / Documents:

1. 2. 3. 4. 5. 6. 7. Available plot area Process Flow diagram & P&IDs Line list for sizing rack Dimension of equipments / data sheet for equipment Type of building, structures & foundations Wind direction Equipment erection, maintenance and operation requirements

CONCEPTS IN EQUIPEMT LAYOUT

There are several concepts in equipment layout but normally a combination of the following three concepts are followed

IN-LINE LAYOUT
1. 2. 3. 4. All equipments are placed in a process flow sequence. Most economical arrangement for large number of equipments. Equipments are arranged on both sides of the pipe rack in the process flow sequence. pumps are placed near to the point of suction and lined up under the pipe rack. Parallel roads is arranged for convenience of construction and maintenance on the other side.

5.

SIMILAR EQUIPMENT GROUPING 1. 2. 3. 4. 5.

Operating and Maintenance convenience and safety considerations for groups similar type of equipments. Tall column grouping are grouped for common access platform. Housed compressors are grouped for common building and maintenance facilities. Exchangers are grouped for providing common gantry crane for maintenance. Pumps are grouped for common battery limit.

FUNCTIONAL EQUIPMENT GROUPING

1. For cost consideration, all Equipment connected to alloy steel pipes and pipes may be placed near each other. 2. All Equipments on pile foundation may be grouped together. 3. For safety and good house keeping Equipment containing acids/toxic materials are grouped with a paved and curbed area that is drained towards a neutralizing pit.

CONSIDERATIONS IN EQUIPMENT LAYOUT

PLANT ECONOMY Plant economy means installing a plant in the smallest possible space, consistent with operability safety and law maintenance and using the smallest possible amount of piping material structural steel and concrete - saving cost. ERECTION / CONSTRUCTION REQUIREMENT Erection scheme of all equipments should be considered during equipment layout Adequate clearance and open access should be provided for erection of tall columns and heavy equipments with available construction machinery like crane / derrick / lifting gear at project site. Cut outs / removable panels and removable structures should be provided at different elevations in technological building and other structures. The area surrounding the proposed plot should also be investigated for laying of tall columns before erection. SAFETY REQUIREMENT Petroleum rules 1976, OISD std 118 and other international regulations. Guidelines and safety practices to maintain minimum distances between different type of equipments. OPERATION AND MAINTENANCE REQUIREMENT Accessibility requirement to valves and instruments for operation. Maintenance clearance, Overhead clearance, Horizontal clearance. Clearance for exchangers and pumps, Road access, Tube-bundle removal, Lower tray removal, crane truck access e.t.c.

LAYOUT OF MAJOR EQUIPMENT / ITEMS

PIPE RACK

Starting point in the preparation of the layout is the arrangement of pipe rack with relation to equipment. Pipe rack in middle and equipment on both sides and access roads parallel to the row of equipment on both sides needs a long plot area. Other types L TYPE T TYPE U TYPE H TYPE DOUBLE H TYPE

Pipe rack portal spacing is generally 6M. Clearance beneath pipe rack shall be 3M,hence top of steel of first tier of pipe rack becomes 3.8m minimum. Road clearance should be 7m for a min road and 5m for secondary road. Headroom clearance of minimum 2.2m is provided for all lines within building, running over passage and platform.

The total width of pipe rack shall be, W meters

W=(fxnxs)+a
f = factor of safety n = no. of lines up to 450mm OD s = 300 mm a = additional width required

TOWER AND VERTICAL VESSELS

Columns towers and vertical vessels are arranged with common centerline, decided by larger vessels, placing O.D. of the vessel 3m away from the pipe rack. A minimum space of 3m allowed between tower shells, adjacent tower should be checked so that adjacent platforms do not overlap. Tower piping is concerned with proper orientation of nozzles and provision of access points of operation and maintenance. common structure with central stairway is justified for operation/ maintenance from economy point of view. Even lift can be provided if client requires. To handle heavy items a davit is usually needed .the davit Should be on the vessel away from the rack .the area at grade should be kept clear from a dropout. Circular segmental platforms with cat ladders are supported directly from the column shell for the maximum allowable straight run of cat ladder (9m) before a break platform. Platforms on towers should be provided for all valve of 3 or above for instrument controllers or transmitters, relief vales, man holes and blinds. Access to small valves, indicating instruments etc, is acceptable directly from cat ladder. Platforms for access to level gauges and controllers should not be provided if the underside of the supporting steel work is less than normal headroom clearance. Manholes are preferably placed outward from the central pipe way or structure and dropping area to allow for the removal of tower internals or packing or attachments and should be on the side of the tower away from the pipe way.

The centerline of the manhole should normally be 750mm to 1220mm above platform to allow easy access. Adequate clearance should be left for the swing of the manhole cover on its davits and entrance to the man hole must not be obstructed by piping. Access can be made to tower platform from a platform level in the pipe rack in the structure, but the tower platform should also be provided with its own means of escape. The height of the towers and vessels providing suction to pumps, particularly handling hot or boiling liquids should be given special attention to ensure there is a adequate height to cover the pump n.p.s.h. requirements. Depending on the nature of the plant arrangement, towers may have to be elevated to a height in excess of the normal requirements to allow for headroom clearance from low level piping off takes. This is to avoid undesirable pockets formed due to off-take piping from column / vessel have to rise before entering another item of equipment and to pipes on racks.

REBOILER Reboilers are located next to the tower they serve except the fired heater type. Kettle type reboiler elevation is determined by the tower liquid level. Horizontal thermosyhpon (shell and tube) type exchangers are located at a minimum elevation. Vertical thermosyphon are supported by the tower and are located on the back side for accessibility and Maintenance.

HORIZONTAL VESSELS

Horizontal vessels are laid perpendicular to the pipe rack and are placed 2.4m away from the pipe rack. Access platforms on vessels and drums shall be kept to a minimum and should be supported from the vessel. Horizontal vessels, drums, subject to expansion should be arranged so that the nozzles connecting to the pump suction is near to the fixed supports. Vessel or Drums should not be located so that the vessel or any part thereof passes through the floor level unless particularly required to do so by the process or operational requirements. Clearance between small vertical / Horizontal vessels should be 1500mm measured between vessel shell or insulation and piping. where space is limited the distance can be reduced to 900mm provided no piping or instruments located between vessels. The channel end of the tubulant heaters should face towards an open access. the distance provided for bundle withdrawal should be minimum bundle length + 1000mm. Adequate clearance should be provided for agitator / mixer removal. Routing of motor cables should be kept clear of nozzles, open vents and hinged tops.

EXCHANGERS Floating head of exchanger are place on a line 2.4m away from the pipe rack. Adequate clearance should be provide for the removal of shell cover with flanged head of shell and tube type exchanger. Tube pulling and rod cleaning area must be allowed at the channel end. tube bundle length + 1m.

PUMPS Pumps should be arranged in row with the centerline of discharge of a common line 700mm from the centerline of the rack column. Pump houses / Shelters depend on the client requirements. If pumps are located under the pipe rack motor should be located towards the center of the rack and motor cable entry should be on the same side. Clearance between pumps / piping for access should be minimum 900mm.A clear working passage of 3m should be provide between the edges of two rows of pimps on the either side of the center of the pipe rack.

COMPRESSORS Centrifugal / Reciprocating compressors should all be of a raised floor design, to eliminate the problem of dismantling and realigning of large piping for maintenance and to reduce vibrations. Foundations should be extended to the floor height, without structural or foundation ties to the floor or building with chequer plate flooring at the level of the top of the foundation for operation and maintenance. The height of the compressor is set by the physical space and the access required by the bottom suction and discharge piping. The point to be aware of is the height required for gravity flow for degassing and lube oil. The control valves and coolers for lube oil packages is generally mounted on top of the reservoir and therefore necessitates walking on top of the reservoir for normal operation and maintenance. When compressors are steam driven, condensers and pumps NPSH determine the height of the table. The required foundation mass of an unbalanced reciprocating compressor resting on the poor soil can increase to four or five times the height. Therefore house keeping and maintenance is sacrificed to obtain a low floor with its reduced vibration and opportunity to guide or anchor from grade. Intercoolers and pulsation dampers are placed near the compressor, knock out pots and after coolers may be kept outside compressor house. Spacing of compressors depend upon the withdrawal of the engine, compressor piston, cam shaft, crank shaft and lube oil bundle cooler withdrawal with least obstruction from piping supports.

Electric operated traveling crane, hand operated traveling crane or mono rail should be provided which can handle heavier removable piece. Traveling crane should extend past he building to lay down or dropout area from where it can be loaded into a truck or maintenance / repair can be carried out.

CHECKLIST FOR THE REVIEW OF EQUIPMENT LAYOUT 1. 2. Whether process units have been located on relative high ground in the plant. Whether equipment layout has been developed considering the process sequence. Whether equipment layout has been developed considering type of design of foundations. Whether layout has been developed in process flow sequence. Whether furnace / furnaces have been located at the out skirts of the process unit. Whether process equipments such as reactors, primary fractionators, distillation columns connected to furnace outlets are located as close as possible to furnaces so that transfer lines are short and simple. Whether furnace tubes cleaning and removal space as well as access for mobile crane has been provided. There should be no encroachment on the main road. Whether furnace have been located on upward direction with respect of the other equipments so that flammable gases or vapors are less likely to be blown towards the furnace. Whether common platform for a group of towers is provided. If so allowable for differential expansion between the towers have been considered and design is provided accordingly. Whether for packed towers a permanent trolley over the filling manhole is provided.

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Whether manhole on columns are aligned in the direction facing the access way. Whether large size safety valves are located so that their removal is possible. Whether safety valves discharging to atmosphere are placed on the higher platform or other meeting the safety standard. Whether safety distances are provided between equipment as well as for the purpose of maintenance and operational cases. Whether gas compressors are located down wind the furnace so that leaks e.t.c. Are less likely to be blown towards the furnace. Whether gas compressors are provided with shelter and open from sides. It would avoid accumulation of heavier gases. Whether air fin coolers are located above pipe racks. If so whether hydrocarbon pumps are kept away underneath the pipe rack. Whether pumps in the hydrocarbon service are located underneath the pipe rack. Whether pumps are clustered in the area. Whether there is any damage vapor cloud burst and a blast. If so control room design has been designed accordingly. Whether control room has been located in the safe area. If not an adequate pressurization system has been provided and adequate fresh air supply requirement has been taken into an account. Whether vessels of large hydrocarbon holdup, If any are located on pipe rack / overhead structure. If so, nature of protection provide need to be ascertained. Whether suitable facility for loading the catalyst has been provided.

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Whether fire proofing has been specified for all levels of pipe racks and legs of the fin fan coolers for at least two hours rating in case fin coolers are located above pipe rack. Whether fireproofing has been specified for all levels of pipe racks, supports and full load bearing height of the vessel supports. Whether safety chambers have been provide at strategic point / points.

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OPERABILITY 1. Does the layout result in high cost to a. Flexibility provided for operation. b. Additional access to operating area. c. Additional pavements. MAINTENANCE 1. 2. 3. Whether plan preventive maintenance have been provided as per clients philosophy nearby. Whether mobile crane can approach heavy overhead equipments without any obstruction. Whether maintenance aids like overhead crane davits e.t.c. has been provided.

EXPANSION 1. 2. Whether any provision is made for known expansion & unknown expansion i.e. additional pumps, exchangers & vessels. Whether provision for additional lines has been made on the pipe rack.

CONSTRUCTION 1. Whether layout has been developed after considering the erection scheme of tall columns & heavy equipments to be installed at elevated supports. Whether layout is good for erection of equipments delivery of erection equipment is delayed and no hold up is affected.

2.

CAPITAL COST 1. whether the layout minimize capital cost for each work and pavements. Whether optimization of pipe runs particularly for alloy steel & other costly piping has been made a. Need for special foundation & structure. b. Extent of vacant plot as well as waste land.

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