Plant Layout Specification

Plant Layout Specification

• Definitions
• Uses
• Ownership
• Impact on Equipment
• Construction & Logistics Access (Roads,
Railroads, etc.)
• O&M Access
Copyright ©, 2010,
William G. Beazley, PhD
All Rights Reserved
Other Copyrights Apply as Noted

Outline of Typical Spec Document Plant Layout (Plot Plan) Drivers

1. Modifications to the Spec Document
2. Terms used in the Document • Site Topography
3. General Equipment Arrangements • Nature of the Planned Facility
4. Equipment Elevations • Surrounding Environment
5. Roads, Paving, and Railroads
• Noise Levels
6. Use of Platforms, Ladders, and Stairs
• Prevailing Winds
7. Maintenance (Constraints on Layout & Piping)
8. Plant Operations (Constraints on Layout & Piping) • Plans for Future Expansion
9. Above-Ground Piping (Routing Strategy and
Protection)

Plant Layout Groupings Plant Layout Considerations

• By function and impact
• Likely Sources of Fire and Toxic Release
• Inside Battery Limit (ISBL)
• Noise
– Process facilities
• Access and Workspace for Operations,
– One or more plants in one geographical area
Maintenance and Fire Fighting
• Outside Battery Limit (OSBL)
• Escape Routes for Personnel Safety
– Bulk storage of flammable materials remote from
• On-plot areas and support facilities such as utilities, • Risk Assessment
fire pumps and buildings • Operational Housekeeping
• Hazardous operating facilities.
• Environmental Controls and Restrictions
– Flares - located separately from other areas
(Source: Prof. Alfred M. Center, Cornell) (Source: Prof. Alfred M. Center, Cornell)

1
 Inherently Safer Plant Designs
(Quentin Baker / John F. Murphy) Recommended Equipment Spacing
• Minimizing
– Inventories of flammable and toxic materials • Insurers may set requirements or use AIChE
– Congestion and confinement Spacing Guidelines
– Building infiltration
• Industrial Risk Insurers (IRI)
• Controlling or Attenuating
– Hazardous material with refrigeration or dilution
– Entitled "General Recommendations for Spacing
– Ignition sources in Refineries, Petrochemical Plants, Terminals, Oil
• Providing adequate Pump Stations and Offshore Properties“
– Spacing between equipment and buildings • AIChE/Center for Chemical Process Safety
– Structural design for buildings
– Drainage for flammable liquids
– Guidelines for Facility Siting and Layout
• Design with – Covers siting and layout of process plants,
– Proper mechanical integrity design including both new and expanding facilities
– Unit layout and orientation to prevailing wind
– Air intakes in safer locations with gas absorbent capabilities
http://psc.tamu.edu/symposium/1999/Papers/inherently_safer_design_in_plant.htm

Sample Safety Spacing Requirements Equipment Spacing in Imperial Units

(Source: Bausbacher and Hunt) (Source: Bausbacher and Hunt)

Equipment Spacing in Metric Units

Furnaces Upwind of Fuel Sources
(Source: Bausbacher and Hunt) (Emerson Process Management)

http://www.emersonprocess.com/home/news/resources/morephotos.html

2
 Equipment Pipe Headroom
Elevation (Source: Automatic Fire Protection Design)
Requirements
(Source:
Bausbacher and
Hunt)
• Baseline Ground Level:
– 100 Feet (English
– 100,000 mm (Metric)
• POS – Point of Support

http://www.autofire.com.au/

Roads, Paving and Railroads Secondary Roads

(Source: Bausbacher and Hunt) (Source: StrangePolice.com)

http://www.strangepolice.com/content/item/108349.html

Truck Truck Headroom

(Source: StrangePolice.com)
Headroom
(Source:
StrangePolice.com)

http://www.strangepolice.com/content/item/107907.html http://www.strangepolice.com/content/item/109761.html

3
 Vehicle Impacts Valve at Point Std Flatcar Dimensions and Typ Load
Comfort Formosa Plastics Plant (Source: US Army)
• 68-foot, Wooden decks
• Used for both chain tie-downs and blocking and bracing
• No sides (accommodate almost any width)

http://www.csb.gov/index.cfm?folder=completed_investigations&page=info&INV_ID=55

Railcar Clearances Typical bulk chemical storage and transfer facility

(Source: Savannah Environmental Consulting, Inc.)
(Source: Genquip)

http://www.genquip.com/tech%20sheets/FIF116R001.pdf
http://www.savannahenvironmental.com/CERCLA.html

Railcar Loading Roads, Paving and Railroads

(Source: Savannah Environmental Consulting, Inc.)
• Roads serve:
– Process Units
– Utility plants,
– Materials-Handling and loading areas
– Off-site equipment requiring access for
maintenance and firefighting
– Secondary roads for construction and
maintenance
• Pave under all units and pipe racks and
sloped for drainage
• Earthen Dikes used to contain dangerous
http://www.savannahenvironmental.com/index.htm spills

4
Plant Roads & Walkways Construction Access by Road & Rail
(Source: Air Products)
(Source: Air Products)

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

Dual Crane LNG Heat Exchanger Loading

LNG Heat (Source: Air Products)
Exchanger Is
Loaded For
Ocean Shipment
(Source: Air
Products)

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

Iraqi Tanker Dock Facility

Barge Loading (US SIGIR)
and CG Issues
(Source:
StrangeDangers.com)

http://www.strangepolice.com/content/item/109375.html
http://www.sigir.mil/reports/quarterlyreports/Jul07/pictures.aspx

5
 Platforms
Valve (Source: Bausbacher and Hunt)
Accessibility
Description ft mm
and
Headroom 7’ 2,100
Clearance -
Width of walkways (grade or elevated) 3’ 900
Vertical
Maximum variance between platforms 9” 230
Stem
(Source: without an intermediate step
Chevron Width at vertical vessels 3’ 900
Technology)
Distance between inside radius and inside 10” 250
of platform on vertical vessels
Maximum distance of platform or grade 5’ 1,500
below centerline of maintenance access
Maximum length of dead ends 20’ 6,000

Railing Standards
Stairway, (Source: Chevron Technology)
Grates,
Rails
(Source:
MMS)

Handrails are required on

open sides of platform
http://www.mms.gov/mmskids/explore/explore.htm
areas and stairways.

Stairway, OSHA Approved

Grates, Ladder?
Rails (Source:
(Source: StrangeDangers.com)
MMS)

http://www.mms.gov/mmskids/explore/explore.htm http://www.strangepolice.com/content/item/109375.html

6
 OSHA on Ladders
Ladders (Source: Bausbacher and Hunt)
Description ft mm
Width of ladders 1 ‘ 6” 450
Diameter of cage 2’4” 710
Extension at step-off platforms 4’ 1,200
Distance of bottom hoop from grade or platform 8’ 2,400
Distance between inside radius of vertical vessels to 1’2” 350
centerline of ladder rung
Maximum vertical rise of uninterrupted ladder run 30’ 9,150
Maximum slope from vertical axis 15°
Toe clearance 8” 200

Ladder Enclosure & Platform Extreme Ladder Access

(Source: Engineered Storage Products Company) (Source: Trellchem®)

Self-closing gates at
ladder openings and all
platforms are required

http://www.slurrystore.com/40/AgiNozzl.html
http://www.geocities.com/CapeCanaveral/Lab/3518/SH-Wallpapers.htm

Stairs
(Source: Bausbacher and Hunt) Width of
Walkways
Description ft mm (Source: Center for
Width (back-to-back of stringer) 2 ‘6” 750 Environmental
Maximum vertical one-flight rise 18’ 5,500
Research Education)
Maximum angle 50°
Headroom 7’ 2,100 • 2'6" is OSHA
Width of landings 3’ 900 • 3' is more realistic

http://dep.state.ct.us/educ/cere/schoolprograms.htm

7
 Ladder and Ladders
(Source: The Grating Company)
Platform
Examples
(Source: Tsukishima
Kikai Co.,Ltd.)

Ladders that extend more than 20ft above

grade must have safety cages - OSHA

http://www.tsk-g.co.jp/en/tech/ind/ind1.html
http://www.fibreglassgrating.com/

Fixed and Ladder &

Temporary Platform
Ladder Access Clearances
to Vessels (US DOE)
(US DoE)

http://www.nrel.gov/data/pix/
http://www.eia.doe.gov/kids/energyfacts/sources/non-renewable/refinery.html

Handrails & Stairs

Platforms & Bridges (Source: The Grating Company)
(Source: The Grating Company)

http://www.fibreglassgrating.com/

http://www.fibreglassgrating.com/

8
 Valve Maintenance
(Source: ABB, Weir Valves & Controls)

Maintenance
Requirements
(Source: Bausbacher
http://www.abb.com
and Hunt) http://www.offshore-technology.com/contractors/valves/hopkinsons/hopkinsons5.html

Flat Plate Heat Exchanger Maintenance Tube Pulling Machine

(Source: Black Cat Construction) (Source: Cevisa Bevelling
Machines)

http://www.bcc-qatar.com/projectgallery.htm http://www.bevelling.net/pulling%20sequence.htm

Compressor Maintenance
Compressor Maintenance (Source: Capital Machinery Systems, Inc.)
(Source: Texas Compressor Corporation)

http://www.texascompressor.com/fieldservice.htm

http://www.texascompressor.com/fieldservice.htm

9
 Turbine Bearing Removal Dry Gas Cooler Vessel Installation
(Source: Yonden, Nuclear News) (Source: Black Cat Construction)

http://www.nucleartourist.com/systems/tb.htm http://www.bcc-qatar.com/projectgallery.htm

Process Piping Installation Manway Access from Scaffolding

(GCPTA)
(Source: Black Cat Construction)

http://www.gcpta.org/
http://www.bcc-qatar.com/projectgallery.htm

Manways
(Douglas Bros.) Hydraulic Lid and
Swing Davit
(Source: Auxill UK Ltd)

http://www.douglasbrothers.com/manway.html http://www.filtrationandseparation.co.uk/market/oil_gas.htm

10
 Typical Davit Hatches Davit Cranes
(Source: NMW, Inc., and Juniper Industries, Inc.) (Source: Engineered Maintenance Equipment)

http://www.nowata.com/Liquid_Strainer_Filter_Vessel.htm
http://www.filtrationandseparation.co.uk/market/oil_gas.htm
http://www.easilymovedequipment.com/PRODUCT%20REVIEW.html

I-Beam Trolley Operator

(Source: Global Equipment Company Inc.) Access to
Controls
(Source:
Bausbacher
and Hunt)

http://www.globalindustrial.com/

Adjustment in View of Indicator Operator Access to Valves

(GCPTA)
(Source: Air Products)

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

11
 Extreme Operator Access Atmospheric Vents Near Platforms
(http://www.hazmat.tripod.com) (Shell)

http://www.hazmat.tripod.com/id4.html

Atmospheric Underground Elevations

Vents (Source: Bausbacher and Hunt)
(Source:
Bausbacher and
Hunt)

• Top of Stacks
& Continuously
Operating
Vents - 10ft
(3m) above any
platform within
35ft (10.5m)
radius
• Vertical
distance may
be reduced by
same distance
is outside
safety radius

Grade Mounted Horizontal In-Line Arrangement

(Source: Bausbacher and Hunt)

Plot Plan Development

12
 Structure Mounted Vertical Arrangement Subdivided Process Flow Diagram
(Source: Bausbacher and Hunt) (Source: Bausbacher and Hunt)

Subsystem Arrangement & Interconnections Typical Gravity Feed Arrangement

(Source: Bausbacher and Hunt) (Source: Bausbacher and Hunt)

Typical Compressor Area Arrangement Floor Space

(Source: Bausbacher and Hunt) Minimization
(Source:
Bausbacher and
Hunt)

13
 Fluid Catalytic Cracking Unit Plot Plan Typical Access Requirements in a Vertical Arrangement
(Source: Bausbacher and Hunt) (Source: Bausbacher and Hunt)
Place Large, Big
Equipment First

Typical Access Requirements in an Inline Arrangement

(Source: Bausbacher and Hunt) Total Unit Encasement
(Source: Bausbacher and Hunt)

Individual Equipment Houses Typical Pipe Rack Elevation

(Source: Bausbacher and Hunt) (Source: Bausbacher and Hunt)

14
 Pipe Rack Configurations
(Source: Bausbacher and Hunt)

Typical Pipe
Rack in a Vertical
Arrangement
(Source: Bausbacher
and Hunt)

http://www.nrel.gov/data/pix/

Typical Process Unit Road and Paving Arrangement

(Source: Bausbacher and Hunt)
Building Locations
(Source: Bausbacher and Hunt)

Typical Typical Compressor

Tower Area Area Spacing
(Source: Bausbacher and Hunt)
Spacing
(Source:
Bausbacher
and Hunt)

15
 Typical Furnace Area Spacing
(Source: Bausbacher and Hunt)

Typical Air
Cooler
Spacing
(Source:
Bausbacher and
Hunt)

Subsystems within Types of Plot Plans

Process Flow
(Ross Van Wormer)
Diagram
(Source: Bausbacher and • Proposal Plot Plan - used to establish the basis
Hunt) of bid work.
• Approval Plot Plan - offered to the client for his
concurrence of available space, perimeter
roads, adjacent inhabited areas and interface
points with the remainder of the complex.
• Overall Plot Plan - a small scale depiction of
utility, storage, and loading facilities as
associated with the process plant.

Types of Plot Plans (cont’d) Types of Plot Plans (cont’d)

(Ross Van Wormer) (Ross Van Wormer)
• Sectional Plot Plans - the overall plot plan • Construction Plot Plan - releases the
broken into manageable size drawings. constructor to begin activities related to
• Planning Plot Plan - an agreed-upon equipment location, such as roads, pile driving,
arrangement which usually starts the work of underground piping, foundations, etc. It is the
most groups that rely on equipment positioning. single document containing all equipment,
• Production Plot Plan - an update of the structure and road locations.
planning plot plan after enough study work has • Final or "As Built" Plot Plan - a plot plan
been completed to establish firm location of normally provided by the responsible
equipment. This plot plan is the basis for engineering company that reflects the completed
beginning detailed design work. project as constructed. This plot plan is
maintained by the client for future expansion
work requirements or other business needs.

16
Initial Arrangement Sketch Line Run Check
(Source: Bausbacher and Hunt) (Source: Bausbacher and Hunt)

Final Plot Plan

(Source: Bausbacher and Hunt)

17