01c.- general layout considerations

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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 – [email protected]

• 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



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



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



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



Example Layouts

http://www.airproducts.com/PhotoLibrary/restricted/photo-plant.asp

Open Single-Level Plant(Source: Air Products)


Open Single-Level Plant with Multiple Pipe Racks(Source: Air Products)


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)




Open Multilevel Plant with Multiple Racks & Underground Piping(Source: Air Products)


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



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


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



Routing Lines by System not Singly


Minimized Elevations in Plant


Change Diagonal Elevation to Cross

Multiple Lines


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



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)


Inline vs Non-Inline Items


Their length

becomes part

of the pipelength

calculation

Generally attachto the pipe run

with a branchfitting, tap or

similar branchingarrangement.



Elevate &

Slope for

Gravity

Flow(Source:

Bausbacher

and Hunt)

Open vs Closed Systems


Allow for Thermal Expansion

through Built in Flexibility



Open Plant with

Expansion Loops at

Kettle Reboiler (Source: Air Products)

Support Pipe thatExpands

Thermally

(Source:

Bausbacher and

Hunt)

Allow for Installation Variations




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




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.)


Pulling Equipment(Source: Midwest Maintenance & Industrial, Inc.)


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



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)


Example:

Madden Methodology

Steps to Creating Layout

Review available process data:

• Flowsheet

• Equipment specifications

• Process description• Mass/energy flows

• Plant site information



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



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



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



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)

01c.- general layout considerations

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