Plant Layout
Plant Layout
Plant Layout
Purpose
Checking of Plotplans
Recording of Changes
References
Attachments
1. Purpose
This procedure, by the application of checklists, describes
the safeguarding of quality aspects of engineering work in the
development of plotplans and plant layouts. It covers the
requirements to ensure that the applicable specified design
basis, regulatory requirements, codes and standards are
correctly translated in their development within the
Engineering Department.
2. Checking of Plotplans
The plotplans and plant layouts shall be verified as a
minimum against four lists, as follows:
2.1 Checklist for Administration
All changes on the plotplans shall be recorded properly on
the revision lists and the marked-up issues filed. Attachment
1 contains checklist that covers the administrative aspects of
plotplan control.
2.2 Safety Checklists for Plotplans
All questions of the safety checklist shall be verified against
the plotplan, see Attachment 2.
2.3 Checklist for Technical Content of Plotplans
All questions of the checklist will be verified against the
plotplandrawing, see Attachment 3.
2.4 Equipment Clearance GuidelineGenerally, clients have
their guidelines on clearances between equipment and or
local regulations exist. In absence of this data, the figures
mentioned in Attachment 4 shall be used as a guide.
3. Recording of Changes
The recording of changes and the filing of the associated
documents shall be in accordance with the relevant sections
4. References
4.
1
4.
2
4.
3
4.
4
4.
5
4.
6
4.
7
Document Number
Title
Level
CM-MA-101
CM-MA-102
CM-PE-504
CM-PE-110
BN-DG-C1
BN-S-UK004
BN-UE(I)-10
List of Revisions
5. Attachments
1.
2.
3.
4.
18. Are all open pits, floor openings etc. fenced or provided with guard rails ?
3. CHECKLIST FOR TECHNICAL CONTENT OF PLOTPLANS
GENERAL
Nearest geodetic starting point noted ?
Are battery limits indicated ? Block valves foreseen ?
Are access roads suitable ? Headroom clearance ? What rules ?
Access road to discharge and loading points walkway segregated from road traffic ?
Supply points for chemicals, catalysts ? Access roads for hazardous chemicals ?
Is plot broken up in units ? Flow pattern between units ?
Location of interconnecting pipe racks ? Room for future extension ?
Have locations of future equipment been indicated ?
What rules for equipment clearance (refer to guideline) ?
Location of maintenance shop/access roads or maintenance and equipment replacement ?
Close watch equipment defined and listed ?
NOTE :
Following items have been listed in sequence of the Company
Cost Code.
1.
2.
3.
4.
A. TOWERS.
Was grouping of distillation towers foreseen ?
Overhead condensers and reboilers grouped on common structure ?
Verify sectional drawings for elevation.
Lightning protection ?
B. BUILDINGS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
C. PIPING
Emergency shutdown and isolation block valves to be checked for all lines and plant limits.
Verify use of ROV and accessibility. Use of other isolating devices ?
Where are spectacle blinds to be foreseen ?
Location of anchors/pipe supports to be adequate for allowable stress and nozzle load /
Locking device on critical valves ?
Insulation for personnel protection ?
Protection against static electricity ?
Vibration bracing foreseen/installed ?
Location of isolation push buttons ?
Expensive alloy piping layout for minimum length ?
Fire stops for piping passing through concrete floors and walls ?
D. STRUCTURES
Use of concrete or steel/fire proofing ?
Use of fire decks ?
Rules for stacking of equipment ?
Standards for stairs, platforms, ladders and handrailings ? Grating ?
Lightning protection ?
Nor exposed to process equipment ?
Stairs, platforms, ladders for access to operating valves ?
Use of non-slip surfaces on stairs, platforms, access ways.
E. ELECTRICAL
1. Hazardous area
classification
Critical equipment -Power supply (transformers, switchgear) located separately and protected.
Oil containment dikes around transformers.
2. Earthing
3. Cathodic
protection
4. Fire protection
- Adequate illumination.
- Lights correctly positioned.
- Avoidance of too much glare or reflection.
- Adequate emergency lighting.
- Possibility of maintenance lighting.
6. Cabling
- Accessibility.
- Ease of maintenance
8. Control failure
9. Switchgears
locations.
Check that clear escape routes at grade have been provided.
Check that ladders and stairs are positioned at grade leading to clear escape routes.
Water flooding/sprinkling for spheres.
Stairways must be the primary access to main operating or service platforms.
Auxiliary exits by ladders to be provided.
No dead end platform to be longer than 8 meters.
Horizontal walking distance to primary or auxiliary exit must not exceed 25 meters.
Check on flame trap requirements for vent pipes.
Check on vent requirements for underground drainage systems.
Check that all vent pipes and relief valve manifolds discharging to atmosphere are at least 3
all relief system arrangements. Particular attention shall be given to possibility of pockets/vapor locks
and discharge requirements and use and/or need of closed systems.
Check locations of sniffers if provided on the plant.
Monitors and hydrants guarded against vehicle damage ?
Reliability of firewater pump in case of power failure. Auxiliary drive.
G. GENERAL
Handling devices required for handling weights over.kg.
Space for material storage.
Have weight and size of containers been considered/listed ? Equipment foe handling of
containers, bins.
Loading piers : accessibility to emergency shut-off valves.
Communications between shipping pump and loading point.
Flare well segregated ? Area protected against radiation. Extent of radiation zone.
Distance between utility stations.
H. HEATERS/BOILERS
Located in separate area. Well segregated.
Distance to process units : minimum 15 meters to hydrocarbon bearing equipment.
Sufficient inspection openings to verify the internals visually.
Anchoring of inlet and outlet lines.
Located upwind of operating units.
Air intake locations.
Remotely operated/accessible shutdown valves on fuel supply lines.
What in case of tube burst ?
Access for emergency equipment ?
Diversion walls foreseen ?
J. CIVIL
Have underground services been marked ?
Marking also in case of excavation ( warning strips )?
Standard for roadways ?
Consider risk of settlements of foundations.
Are all open pits, floor openings etc. fenced or provided with guard rails ?
K. CONTROL SYSTEMS
Specific reference shall be made to Checklist Design Review
Technical Disciplines, section 9 (ref. 4.6) and shall include :
1. Hazardous areas: - Design philosophy.
- Selection of certified equipment.
- Compliance with area classification drawing
- Installation to code and specific certificate requirements
2. Earthing.
3. Fire protection
4. Fail/safe design
5. Safety relieving
- Sizing criteria.
devices
- Safety factors.
- Calculations approval.
6. Equipment
location
- Maintenance
- Accessibility
7. Cabling
8. Electrical supply - Correct type and sizing of fuses and circuit breakers.
system
- Extent of equipment of uninterruptable power supply system.
- Alarms.
- Overall power consumption.
9. Air supply
10. Alarming
M. VESSELS ( TANKS )
Protection in case of leakage (bundwalls).
Lightning protection.
Distances between tanks/diked areas. What rules to be followed?
Protection against static electricity.
Special rules for cold storage defined.
Accessibility of tank gauging device/suitable for pressure and temperature.
Minimum flanged connections within diked areas.
Use of flow limiting devices.
Tank farms at lower level than process units.
Siting of tanks in groups; consider API rules.
Icing protection for refrigerated storage protection for spontaneous warming.
Protection of gas storage tanks against sun radiation.
N. INSULATION
Resistance of insulation against fire.
Personnel protection insulation foreseen (verify along access roads).
If insulation foe personnel protection is not foreseen, protect by open guards, shields, railings.
P. PUMPS/COMPRESSORS
Location separately for noise limitation. Compressors upwind from fired equipment.
Grouped under pipe rack (separate rows). Separate high pressure pumps.
Possibility of sprinkler installation/common loops.
Accessibility of rotating equipment for operation and maintenance (equipment replacement).
All rotating equipment adequately guarded.
Noise protection in rotating equipment. What rules imposed ?
Air intake location for compressors.
What is risk in case of seal leakage ? What protection foreseen ?
Equipment clearance/removal possibility of defective equipment.
Installation of lifting equipment.
Lubrication points defined. Accessible for operating and maintenance personnel ?
High pressure charge pumps to be isolated.
Location of seal oil units.
Q. SEWERS
Check area classification for pits and other catchment devices.
How is sealing and venting of catch basins done ?
Verify removal of releases and drips from under equipment.
Consider use of separate sewer and toxic sewer. Oily sewer required ?
Pollution risk. Waste water collection and treatment. Location of discharge point.
Special precautions for highly toxic highly flammable products.
T. EXCHANGERS
Accessibility for cleaning rodding.
Space for bundle pulling device.
Location of airfin coolers (no pumps underneath).
Are fire decks foreseen ?
1.5
Horizontal clearances
- Between exchangers (aisles between piping)
0.9
0.9
15
1.8
1.3
1.2
Pipe berths
- Underground, minimum clear gap between pipes (300 mm)
0.3
0.9
0.9
0.9
Platforms
Vessels (vertical and horizontal) and towers
- Side platform distance below centerline of manhole flange
0.9-1.05
0.9
0.9
0.175
0.75
Exchangers (horizontal)
- Clearance in front of channel or bonnet flange
1.2
bundle length
0.3
Exchangers (vertical)
- Distance of platform below top flange of channel or bonnet
1.5
Furnaces
- Width of platform at sides of horizontal and vertical tube furnaces, minimum 0.75
- Width of platform at ends of horizontal tube furnaces, minimum
1.0
Control room
- Distance of control room to process equipment
25
Minimum distances
Vessel capacity
From buildings
Between vessels
imp. gallons
cubic meters
feet
meters
feet
meters
up to 100
up to 0.45
101-500
0.45-2.3
10
501-2,000
2.3-9.1
25
7.5
over 2,000
over 9.1
50
15
1.5