Course Information

General Plant Layout Considerations

Copyright , 2008, William G. Beazley, PhD All Rights Reserved Other Copyrights Apply as Noted

Contact
William G. Beazley Cell: 713-443-9914 wbeazley@infoassets.com

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 Outline
03 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 09 Nov 06 Nov 06 16 Nov 06 28 Nov 06 30 Nov 06 05 Dec 06 07 Dec 06 12 Dec 06 Review 15 Dec 06 Exam Pumps Compressors 14 Furnaces Reactors Exchangers Storage Tanks Instrumentation SPED Ann Meeting PPD Level III PPD Level I & III

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 BLEVEs 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

Principal Functions of Plant Layout Designer

Layout of equipment and its associated infrastructure.
Conceptual process unit plot plans AKA equipment arrangements; Tradeoff of many macro considerations

Plant Layout:
Significant Driver Of Project Engineering Costs, Focal Point For Clients, Project Management, Construction, Engineering, And Supporting Disciplines.

Success Metrics:
Economy, Constructability, O&M Efficiency

Routing of major above- and below-grade piping 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

Typical Plant: Oakville Refinery Petro-Canada, Oakville, Ontario

(Source: Ventech Process Equipment, Inc.)

Good basic rule: avoid designing one line at a time

Routing a line from 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
http://www.ventechequipment.com/oakville.htm

Typical Plant: Oakville Refinery Petro-Canada, Oakville, Ontario

(Source: Ventech Process Equipment, Inc.)

Explicit Requirements: Process Design Site Topography Site Environment

http://www.ventechequipment.com/oakville.htm

Plot Plan Information

Pipe Racks Layout of the Equipment in the PFD Layout of Major Equipment
Tankage Other areas shown as blocks Access via 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

Preliminary Information Sketches

(Source: Bausbacher and Hunt)

Final certified drawings usually not required until detail phase.

Site Information Required

On-Site Features

Floor Space Sizes

(Source: Bausbacher and Hunt)

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)
STONEFI ELD

Mars Ice Island, Beaufort Sea Alaska

A Street

Unified Oil Company

Direction of drainage

http://www.epa.gov/oilspill/guidance.htm

http://www.mms.gov/alaska/kids/shorts/iceislnd/iceislnd.htm

Access by Sea FCC Regenerator

Access by Road FCC Regenerator

Types of Guidance
(Source: James Madden)
Equipment Spacing and orientation Lining-up and grouping similar items Equipment Features Foundations and supports Dynamic loads Vibration Enclosures Transport Road widths and clearances Vehicle size and turning circles (similar data for rail traffic) Site Facilities Offices, laboratories, carparks Amenities - canteens, washrooms, Messrooms Utilities and effluent plants Fire and medical centres Workshops, stores Access Removal/lifting/laydown Maintenance/operating space Structures Floor heights Stairs/ladders Gangways Platforms/handrails Standards and Good Practice Equipment sizing procedures, catalogues, plant records Space allowances for operation, maintenance Gangway, stair, ladder standards Plant and equipment spacing standards Allowances and reserved space for piping, ducting, cabling Road, rail, pipetrack standards Control room, switch room areas and spacing

Storage and Tanker Access

http://cgvi.uscg.mil/media/main.php?g2_itemId=116706

(US Coast Guard, PA2 James Dillard)

Open Single-Level Plant

(Source: Air Products)

Example Layouts

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

Open Single-Level Plant with Multiple Pipe Racks

(Source: Air Products)

Multilevel Plant
(Source: Air Products)

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

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

Multilevel Plant with Multilevel Rack

(Source: Air Products)

Multilevel Plant with <hopefully> Normally Unoccupied Bldg.

(Source: Air Products)

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

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

Open Multilevel Plant with Multiple Racks & Underground Piping

(Source: Air Products)

Open Plant with Central Rack and Room for Expansion

(Source: Air Products)

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

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

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:

Layout Techniques and Methods

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

Physical Plant Model

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

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 is easier Agreed layout ready captured in CAD database for later development

Conceptual Layout Studies

(Source: Bausbacher and Hunt)

Disadvantages
Model set-up more expensive. Higher cost

Planning Study: Key Data for Other Disciplines (Source: Bausbacher and Hunt)

Layout Considerations

Piping Layout

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
Source: Design Power, Inc.

Routing Lines by System not Singly

(Source: Bausbacher and Hunt)

Minimized Elevations in Plant

(Source: Bausbacher and Hunt)

Change Diagonal Elevation to Cross Multiple Lines (Source: Bausbacher and Hunt)

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)

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

http://www.raking.com/articles/Constructability.htm

Use Manifolds and Standard Configurations

Steam Tracing Uses Manifolds to Distribute and Collect Steam Heat Lines
(Source: Bausbacher and Hunt)

Steam Tracing Manifolds (Source: Spirax Marshall)

Vertical Stacking to Minimize Footprint

http://www.forbesmarshall.com/spirax/paref1.htm

Inline vs Non-Inline Items

(Source: Bausbacher and Hunt)

Standardization
(Source: RAKI)
Generally attach to the pipe run with a branch fitting, tap or similar branching arrangement.

Their length becomes part of the pipe length calculation

http://www.raking.com/articles/Constructability.htm

Elevate & Slope for Gravity Flow

(Source: Bausbacher and Hunt)

Open vs Closed Systems

(Source: Bausbacher and Hunt)

Allow for Thermal Expansion through Built in Flexibility (Source: Bausbacher and Hunt)

Open Plant with Expansion Loops at Kettle Reboiler

(Source: Air Products)

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

Allow for Installation Variations

(Source: Bausbacher and Hunt)

Support Pipe that Expands Thermally (Source: Bausbacher and Hunt)

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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 to access abnormal or malfunctioning equipment.

Millwright Equipment Setting

(Source: Warfab)

Block Valves not Provided Regular Access

(Source: Bausbacher and Hunt)

http://www.warfab.net/

11

Walkway Access to Valve Manifolds (Source: shiptechnology.com)

Hard to Access Valves

(Source: Midwest Maintenance & Industrial, Inc.)

http://www.ship-technology.com/projects/amoretti/index.html#amoretti7

http://www.midwestmaintenance.net/pictures.htm

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

In-Place Repair
http://www.midwestmaintenance.net/pictures.htm http://www.warfab.net/

(Source: Warfab)

Extreme Access
(Source: Fire & Rescue)

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 gasoline fuel, elevated pressurized flammable liquid fire, flammable liquid 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 the multi-fueled pipe rack fire.

http://www.nfrmag.com/backissues/MayJun2003/default.asp

http://www.cdc.gov/niosh/fire/reports/face200615.html

12

Layout Interactions with Business Case and Design Baseline

Business Opportunity

Conflicting Layout Constraints

(Source: Jame Madden)
Large Space - Safer

Select Process Route

Less Space - Cheaper (a) Furnace and Flammable Storage

Evaporator

Process Design

Boiler

Good boiler plant, Big heat loss

Ancillaries

Evaluate:Safety Environment Operability

Plant Layout

Boiler

Evaporator

Evaluate Costs:Capital Operating

Good heat conservation, Awkward boiler plant

Ancillaries

(b) Boiler to Evaporator Steam Constraint

Stacked Equipment Layout (Source: RAKI)

Example: Madden Methodology

http://www.raking.com/articles/Constructability.htm

Review available process data:

Flowsheet Equipment specifications Process description Mass/energy flows Plant site information

Steps to Creating Layout

13

Acetone in Monomer in Water in T101 T102 T103 Recycle Acetone

Batch Plant Process Flowsheet

T126

H125

H105

H109

H113

Catalyst Bags T106

R104 T110

R108 T114

R112 C124 P128 Polymer Slurry P116

Raw Matl IN

R
Product OUT

Hold

Hold

P107

P111

P115

Exhaust Air

Polymer Paste F119 X132 Polymer Powder V130 Air In D129 H134 T120 H127 P121 HP Steam P118 X131 Condensate To Effluent P122 Water to Effluent T117 H123

Air Out

Bagged Polymer Out

P133

Block Diagram - Batch Polymer Plant

Water to Drain

Air In

Process Variables
Item Number Description Number Off Dimns. rate or capacity Analysis of material handled Mass % Material Working pressure Working temp. degrees C Services Remarks T101 Water weigh tank 1 1700 dia x 2000 water 100% T102 Monomer weigh tank 1 1700 dia x 1600 Monomer 100% T103 Acetone weigh tank 1 1900 dia x 2100 Acetone 84% Monomer 16% R104,108,112 Polymerisation reactors 3 2700 dia x 3000 Acetone 50% Monomer 10% Polymer 10% Water 30% Stainless Atmos 30 Cooling water power H105,109,113 Reflux condensers 3 tube length 5.0 m shell dia. 1.14 m Acetone 100% T106,110,114 Initiator make-up tanks 3 400 dia x 1200 Water 90% Initiator 10%

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

GRP Atmos Ambient None Mounted on load cells

Stainless Atmos Ambient None Mounted on load cells

Stainless Atmos Ambient None Mounted on load cells

Mild steel Atmos 30 Cooling water

Stainless Atmos Ambient Power

Make notes of relationships for each item

Acetone in Monomer in Water in T101 T102 T103 Recycle Acetone

Batch Plant Main Relationships

T126

Fig. 2

Find Dominant Relationships

Ruthlessly eliminate all but the one or two most important relationships Mark these on Flowsheet Multiple copies marked with different combinations may help to clarify alternatives in more complex cases Decide for each item which is its single most important relationship which must be satisfied. Mark up on final copy of Flowsheet

H125

H105

H109

H113

Catalyst Bags T106

R104 T110

R108 T114

R112 C124 P128 Polymer Slurry P116

P107

P111

P115

Exhaust Air P133 X132 D129 Polymer Powder V130 Air In

Polymer Paste F119 T117 H134 T120 H127 P121 HP Steam P118 X131 Condensate To Effluent P122 Water to Effluent H123

Process Proximity Gravity NPSH

Bagged Polymer Out

BPFSHT2

14

Acetone in Monomer in Water in T101 T102 T103 Recycle Acetone

BATCH PLANT GROUPING DECISION

Fig. 3
H12 5 T126

Possible Groups
H113

Assemble into Groups of 5-7 related items

If a Group exceeds 7 items, divide it by choosing which relationship can be broken. Some items may possibly belong to two (or more) Groups and a choice must be made, When this has been done, the major and minor groups can be shown on the Flowsheet as in Figs 4 and 5. Some items may not belong to any Group and can be treated as infill items when final group assembly is carried out.

H105

H109

Catalyst Bags T106

R104 T110

R108 T114

R112 C124 P128 Polymer Slurry P116

P107

P111

P115

Exhaust Air

Group chosen
X132 Polymer Powder V130 Air In P133 D129

Polymer Paste F119 T117 H134 T120 H127 P121 HP Steam P118 H123

Bagged Polymer Out

X131 Condensate To Effluent P122

Water to Effluent

FormMethAnsFig03

Acetone in Monomer in Water in T101 T102 T103 Recycle Acetone

BATCH PLANT SELECT 4 MAJOR GROUPS

Fig. 4
H125 T126

Acetone in Monomer in Water in T101 T102 T103 Recycle Acetone

BATCH PLANT MINOR GROUPS

Fig. 5
H125 T126

H105

H109

H113

H105

H109

H113

Catalyst Bags T106

R104 T110

R108 T114

R112 C124 P128 Polymer Slurry

Catalyst Bags T106

R104 T110

R108 T114

R112 C124 P128 Polymer Slurry P116

P107

P111

P115

P116

P107

P111

P115

Exhaust Air D129 Polymer Powder V130 Air In P133 Bagged Polymer Out

Polymer Paste F119 X132 T117 H134 T120 H127 P121 HP Steam P118 X131 Condensate To Effluent P122 Water to Effluent H123

Exhaust Air

Polymer Paste F119 X132 Polymer Powder V130 Air In P133 D129 H134 T120 H127 P121 HP Steam P118 X131 Condensate To Effluent P122 Water to Effluent T117 H123

Bagged Polymer Out

FLOW
FormMethAnsFig04

FormMethAnsFig05

MAIN GROUPS ONLY (Minor Groups Similar)

From the Flowsheet, form picture of Flow:

Within the groups For the whole plant
Raw Matl IN

Sketch each Group as a network of items ordered along the group flow line
P107 T117 T120 F119 D129 Exhaust X132 V130 X131 Product Out

R104 H105

Access

Water

PLANT FLOW
Hold

Product OUT Hold

Reactor Group
Treat as 3 identical Groups

Dryer Group

HP Steam

F119

Water

T120

H125 T126
H123 F119

Air Out

P121 Seal Tank

P122 P122

C124 H127

P128
Power

Water to Drain
FormMethAnsFig06

Air In

Effluent

Steam

Vacuum Group Block Diagram - Batch Polymer Plant

FormMethAnsFig07

Column Group

15

Treat Groups as Super Items - Arrange into Super Groups of 5-7 Groups,
According to the strength of inter group relationships. The network of Groups should be arranged around the Plant Flow line If the plant is not covered by 5-7 Groups, arrange the Super Groups into Meta Groups of 5-7 Groups, using similar reasoning in prior steps

PLANT AS SET OF GROUPS

Fig. 8

FEED

Two logical structures showing networks of Plant items in CATALYST Groups Groups within the whole plant, on which the 3D layout operation can start.
AIR

REACTORS COLUMN

T117 H123

DRYER

VACUUM

PRODUCT
FormMethAnsFig08

Build 3-D Models of Equipment Items

Allow for access, etc using equipment data and sketches Note regions where main pipes should be connected.

MAJOR ITEM SKETCHES R104 - C124 - F119

1000

750

550 Dia
11500

2000 2700 Dia

3000

R-104/-108/-112

500

Filter F119

1000

2200

Column C124

MAJOR ITEM SKETCHES R104 - C124 - F119

Outlet Box 900 X 2600 Inlet Box 1100 X 2600 1000 Dia
1500

9300 Long

Roughly 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
3500

1500

1500 Dia Drive Unit below Drum Dryer D129

1800

Cyclone X132

2800

2000 Dia

3800

4000 Hopper V130

2000

2500

Bagger X131

Bagged Polymer Out

16

REACTOR GROUP ELEVATIONS

H105 (1140 DIA)
1000 6670 el 1500 5600 el 3000

COLUMN GROUP ELEVATIONS

500

19570 el

H125 540 dia 1000 piping T126 1400 dia

T101/2/3

2500 to drive Control Valve 14400 el

9000 Packed Height

C124

R104

2000 Ground Level 600

P106

1000 2400 Tubes 1500

Liquid level 3900 el 500 Liquid Depth H12 7 Ground level

DRYER GROUP ELEVATIONS F119 X132 10500 el 400 D129 1000 Min 500 V130 3800 500 X131 2500 Ground Level Minimum pipe angle 45. Note effect of horizontal offsets from sloped pipes. 1800 10100 el

F119 10200 el P121 T120

10600 el 800 for good pipe slope 700 Dia 9100 el

7300 el

VACUUM GROUP ELEVATIONS

Presure 0.27 Bar Abs 9000 Min Barometric Seal 8500 Min Barometric Seal

P122 Ground Level Ht 1200 Seal Tank 600

GROUP and LAYOUT EXAMPLE

Apply inter-item spacings:
To meet safety or similar needs, From good practice guides, For access within the group,

Atmos

H134

Power

P118

From Column Group (as before):-

X132 V130

Powder Flow

D129

Paste Flow

F119

Powder Flow

Building Up the Layout

H125 T126

C124

P128

H127

X131

Product Store

Power

Dryer Group

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
To Plant:-

3-D Kernels

Do not attempt to orient the whole group along NS or E-W axes at this stage. This step establishes the overall 3-D shape of the Group Repeat for each Group to provide a set of 3-D kernels of the whole plant

Access and Maintenance

Bagger Hopper X131 V130 Cyclone X132

Dryer D129

Filter F119

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

Group Perimeter

Layout of Dryer Group

17

ASSEMBLING GROUP LAYOUTS INTO PLANT

Check elevations of all items and normalize to common set of levels Levels will become Flows or combined platforms. Add in any lone items, filling in any spare spaces. Nest all Groups as possible
Reasonable rectilinear shape

RAW MATLS IN

Generated Layout
First, logical layout concept Layout evaluated, agreed, passed to detailed engineering

FEED TANKS R104 R108 R112

COLUMN

DRYER

F119

Target aspect ratio in plan between, say, 1 and 2.5 Check inter Group access line up accessways Add space for stairwells, ladders, pipetracks, etc.

AIR (Under) VACUUM PRODUCT OUT

GROUP ASSEMBLY - Not to scale

CAD Model of Layout

Questions?

Steam Tracing Lines

Valve Manifold Panel (Source: Ziptronix )

(Source: Tyco Thermal Controls)

http://www.ziptronix.com/equipment/tools/valve_manifold.html http://www.tycothermal.com/usa/english/services/images/fig-2.jpg

18