1.

The Basics Of Plant Layout Design

Plant layout design plays an important part in the design and engineering
phases of any industrial facility. This chapter discusses the role and
responsibilities of the plant layout designer, provides advice on how to use
project data, describes the timing of various activities, offers an approach to a
basic piping design layout and lists abbreviations and common terminology.
Subsequent chapters cover plant layout specifications, major equipment
layouts commonly found in such facilities, pipe rack layout, underground
design, and instrumentation.

2.The Plant Layout Designer

The plant layout designer is skilled primarily in the development of equipment
arrangements and piping layouts for process industries. The position offers an
opportunity to demonstrate technical ability along with a creative talent
and common-sense approach to problem solving. Process facilities must be
designed while adhering to maintenance, safety and quality standards;
moreover, the design must take constructability, economics and operations into
account. Although the tools to achieve these goals are changing from pencil
and paper to computer graphics terminals the responsibilities of the plant
layout design remain the same.

The plant layout designer must develop layout documents during the
conceptual and study phases of a project. The skills needed include:
∙Common sense and the ability to reason.
∙Knowledge of what a particular plant is designed to do.

∙A general understanding of how process equipment is maintained and

operated.
∙The ability to generate a safe , comprehensive layout within a specified time
and with consideration toward constructability and cost-effectiveness.
∙Creativity .
∙Sufficient experience to avoid reinventing the wheel.
∙Knowledge of the principal roles of other design and engineering groups and

∙The ability to resolve unclear or questionable data .

∙Willingness to compromise in the best interest of the project.
∙The ability to generate clear and concise documents.
∙The ability to defend designs when challenged.

3.Principal Functions
The principal functions of the plant layout designer include the conceptual and
preliminary development of process unit plot plans , sometimes referred to as
equipment arrangements ; the routing of major above and below-grade piping
systems ; and the layout of equipment and its associated infrastructure. Plot
plans show the positions of major units and equipment within units and their
associated infrastructure. Creating a well-designed facility involves meeting
all client specifications and local government codes and regulations and
adhering to design engineering practices with the planning plot plan as a basis
, the following functions are a standard part of the plant layout designer’s
activities :

∙Setting all equipment locations – This activity includes input from

construction on erection sequences or on special problems associated with
setting large pieces of equipment. Choosing equipment locations includes
setting coordinates in two directions and finalizing equipment elevations ,
whether they are centerline , tangent line , or bottom of base plate .
∙Designing all structures and positioning the associated stairways , ladders ,

∙Planning unobstructed areas for necessary steel members or structures that

facilitate all plant maintenance requirements.
∙Establishing all equipment nozzle locations satisfy all process , utility and
instruments equipments.
∙Locating all safety items (e.g. fire hydrants monitors , and safety shower
stations).
∙Locating all miscellaneous items (e.g. , filter silencers , and analyzer houses).

These activities must be closely coordinated all the plant design and
construction participant volved in the engineering and construction phase
project to reduce costly rework and enable the layout designer to generate the
optimum design schedule.

4.Project Input Data

Although there is a vast amount of input data throughout the life of a project ,
the data basically follow three distinct categories :
∙Project design data – Is supplied by the client or project engineering.
∙Vendor data – Pertains to equipment and specialty bulk items.
∙Internally generated engineering data.
These are discussed in the following sections.

Project design data This includes the geographic location of the plant ; its
proximity to roads , railways and waterways ; local codes and regulations .
Topography ; and climatic conditions. The project design data also specifies
whether the project is within an existing facility or is a new site. This
information is generally required during the project’s plot plan development
phase.

Vendor data All purchased equipment and specially bulk items (e.g. , pumps ,
compressors , air coolers , furnaces , control and safety valves , level
instruments , strainers , and silencers) require preliminary vendor drawings for
the development of piping layouts . Final certified drawings are usually not
required until the detail phase.
Internally generated engineering data This data is typically generated by the
supporting disciplines within the designer’s organization. An example of such
information is shown in Fig.LPP 1. This information is eventually superseded
by certified vendor drawings but is of sufficient quality and definition to use
during the study phase of the project.

5.The Logic Diagram

The design of any processing plant is usually accomplished in three phases:

conceptual, study, and detail conceptual designs are made when sketchy or

minimal information is used to prepare an abstract arrangement of a plot plan

or an equipment and piping layout. Preliminary, or study phase, designs are
made with unchecked or uncertified data to design a facility in sufficient detail
so that the documents produced can be used for detail design, confirmation of
purchased equipment, and the purchase of bulk materials. In the detail phase,
all designs are finalized. The designs use such checked data as steel and
concrete drawings, hydraulics and certified vendor drawings for equipment,
valves, and instruments.

The major activities of the plant layout designer to achieve an optimum plant
configuration taken place during the study phase of a project. Although project
schedules often dictate variations in this approach, it is intended to be an
optimum condition for the most effective use of staff time. The study phase
can make or break a project. Working out of sequence is acceptable within
reason, but if it is overdone, a project will never recover during the detail
phase. The ideal situation for speed and quality is to do the job right the first
time.

6.Project Input Data

Each plant layout designer develops an individual layout philosophy. Although
conditions (e . g.,client specifications , schedule constrains , and availability
information) may change significantly among projects designer’s style
remains consistent . One basic remember is to avoid designing one line at a
member that is , routing a line from one piece of equipment to another before
thinking about the next one. Although it is possible to complete an area design
useing approach
, the result is a lack of consistency.
An overview of all the piping within a given area should be completed before
the designer proceeds with the final arrangement. This can be achieved through
close review of the piping and instrumentation diagrams and freehand
sketching of major piping configurations to ensure that the piping will be
routed in an orderly manner.

7.Plan View Layout

Both arrangements shown in Fig.LPP 2 are workable piping layout for the
given

equipment. The design in plan A is the one-line-at-a-time approach. Along

with requiring more pipe fittings and steel in support 1 , it lacks consistency.
Plan B was developed as a whole unit. Lines running to the nozzles on drums
D and E are on the outside of the pipe rack and peel off first with flat piping
turns . The lines to exchangers A, B, and C are located to the center of the rack
and can also peel off in most cases.
This approach saves fittings and requires a shorter steel beam to support the
piping . It should be noted that the use of flat turns in piping is not
recommended if there is a likelihood of future expansion in an area. The
alternative to accommodate future piping running north at the same elevation
is to change elevation for the piping running east and west to the drums.
Although it is not always necessary to plan for future expansion , it can often
be done with very little additional effort and cost. Each area should be the
through on a case- by-case basis.
8.Elevation Layout
Fig.LPP 3 Shows two workable piping layouts key difference is that the
arrangement on the shows piping running at too many elevation with little
effort , this can be corrected , as shown in right-hand view. Adding support
steel for this preferred design would require only minimal effort. The view on
the left , however , would require additional engineering time and additional
steel cost .

9.Diagonal Piping Runs

When lines are run in a congested area , a basic rule to follow is to change the
elevation to avoid interference with other lines when lines are to be routed
perpendicular to most adjacent piping. The arrangement shown in plan A of
Fig.LPP 4 has a minimal offset dimension , X. Running the line at the same
elevation is acceptable if it does not block the passage of a large number of
other lines. In plan B , dimension Y would interfere with too many lines and
should run at a different elevation , as shown. There is no absolute rule except
that judgment should be used to produce a neat and orderly layout as well as
to occasionally save pipe fittings when possible.
10.Valve Manifolds
The layout of valve manifolds is another opportunity to exercise consistency
of design. Layout A of Fig.LPP 5 uses an excessive number of fittings and
indicates a lack of proper planning . With a little thought and extra effort , a
less expensive and more practical design can be generated , as shown in layout
B. Certain piping specification may restrict the use of branch connections in
lieu of reducers , but this option should be considered if at all possible .

11.Use of Space
The effective use of plant real estate provides plant operations and
maintenance personnel with the maximum amount of room in a plant. Which
in most cases can be very congested Fig.LPP 6 shows some typical misuses of
valuable real estate.

For example, the steam trap assembly shown on the left is commonly designed
in the engineering office. This arrangement for a thermodynamic steam trap is
spread out over an area of approximately 27 in (690 mm) in length. Although
this area may not seem excessive for one trap assembly, it can be avoided
completely by installing the trap and strainer in the vertical leg of the piping,
as shown on the right. An additional drain may be required, but this
arrangement should be considered as a space-saving alternative. The steam
tracing manifold in the left-hand sketch is another common engineering office
approach that wastes valuable plant space. If a vertical manifold that is
supported from the column is used, additional space is available for other
piping systems or operator access.

The client must live with the plant long after the engineering and construction
phases are over. The operators will be walking through the facility each day
and will be continually reminded of who took the time and effort to plan the
project thoroughly, and they will keep that in mind when the next expansion
planned.