plant layout engineering tutorial

© 2015 – Hervé Baron

HERVE BARON

Engineering Training

Welcome to this presentation.

It is part of a suite of Engineering training modules.

It shows the activities and deliverables of the Plant Layout discipline.

Comments are most welcome ([email protected]), which I will incorporate for the benefit of all.

Please download this file so that you can see my trainer’s notes in the top left corner – latest Acrobat Pro feature.

Hervé


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Engineering disciplines: activities and deliverables

PROCESS

PLANT LAYOUT

EQUIPMENT

SAFETY & ENVIRONMENT

CIVIL

PIPING

PIPELINE

INSTRUMENTATION

ELECTRICAL


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Piping discipline

Plant Layout & Piping discipline

Plant Layout Piping installation

Piping materials

Piping stress analysis


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Plant layout

What has to be considered in the layout of a plant?

Presenter

Presentation Notes

External interfaces: pipelines, utilities Traffic of plant personnel: parking etc. Prevailing wind Access / Exit


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Layout/principles

From which direction comes the prevailing wind?

Presenter

Presentation Notes

From North West


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Layout/principles

The wind rose shows the frequency of winds blowing from particular directions. The length of each "spoke" around the circle is related to the frequency that the wind blows from a particular direction per unit time, emanating from zero at the center to increasing frequencies at the outer circles.


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Plant layout

The first step of Plant layout is to divide the Plant area into separate blocks and units. Why is this done? How?

Presenter

Presentation Notes

to reduce escalation of fire and explosion hazards it is done by respecting minimum space between units


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The Block Flow Diagram (BFD)


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Plant layout

Minimum distances between Process Units are determined according to GE GAP 2.5.2/2A Classify Units in terms of Fire and

Explosion Hazard into 3 categories:

• Moderate Hazard (MH) • Intermediate Hazard (IH) • High Hazard (HH)

Apply the following minimum distances

between units of various hazard category:


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Plant layout

The first step of Plant layout is to divide the Plant area into separate blocks and units. The second step of Plant layout is to locate Equipment within each unit. Which document are used as starting points by Plant Layout?

Presenter

Presentation Notes

The PFD and the Equipment list


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Plot Plan

Presenter

Presentation Notes

Functional sub-systems are identified on the PFD


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Plant layout

What else shall be taken into account to locate equipment?

Presenter

Presentation Notes

Alloy and heavy wall piping whose runs length shall be minimized… and minimum safety distances between equipment


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Layout Requirements from Process

REFLUX CONDENSER

REFLUX ACCUMULATOR

REFLUX PUMP

COLUMN

What shall be the respective elevation of these equipment?

Presenter

Presentation Notes

Reflux condenser above reflux accumulator above reflux pump. No other constraint (except no pocket in overhead line).


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On-shore plant: Equipment spacing recommendations as per GE GAP Guidelines .2.5.2

Clear horizontal distance, in meters, between adjacent edges of equipment

Presenter

Presentation Notes

GE GAP: GE Asset Protection Guidelines Table does not apply to equipment in similar service, e.g. pump and spare. / means provide spacing based on access for operation and maintenance


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What shall be the respective elevation of the column and reboiler?

REBOILER

COLUMN

Presenter

Presentation Notes

It depends on process requirements: refer to PDS


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REBOILER

COLUMN

Presenter

Presentation Notes

It depends on process requirements: refer to PDS


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Layout/principles Accesses


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Layout principles: provision for piping flexibility


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Layout principles: typical Unit Layout

Presenter

Presentation Notes

The Equipment are arranged along a backbone = piperack. Connecting pipes run on the pipe-rack. This grade-mounted horizontal equipment arrangement is suitable when there enough real estate for the Plant. The advantage is ease of access for operation and maintenance as well as safety. The disadvantage is high real estate use and long runs of pipes, cables etc.


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Structured-mounted vertical vs grade-mounted horizontal Equipment arrangement

Presenter

Presentation Notes

An alternative if the structured-mounted vertical equipment arrangement where equipment are stacked on each other, on a multilevel steel or concrete structure. The advantage is less use of plant area, suitable for housing as required by environmental or process conditions. The disadvantage is less convenient access/egress for operating personnel as well as for maintenance (monorails, drop zones to grade lay down area have to be provided) and less easy, i.e., longer construction.


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Presenter

Presentation Notes

The Equipment are arranged along a backbone = piperack. Connecting pipes run on the pipe-rack.


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Unit Layout

What type of equipment has a large impact on the layout?

Presenter

Presentation Notes

Air coolers – their size must be estimated with the greatest possible accuracy


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Layout / Equipment size by vendors

˜ 14 meters

˜ 8 meters

Duty spec

Waste Heat

Boiler

Presenter

Presentation Notes

for the same duty one vendor comes up with a 8 meter long equipment, another with a 14 meters long!


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Layout / package arrangement

Presenter

Presentation Notes

Dimensions from Vendors are specially important for packages, that involve auxiliaries etc.


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Layout principles: pipe routing

There are 2 ways to run pipes. Name them.


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B/L(Battery limit)

C/L of Road

R

Min. 7.5 m

Presenter

Presentation Notes



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What is the purpose of leaving 3 meters distance between the 2 vessels??

Presenter

Presentation Notes



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Presenter

Presentation Notes



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Layout principles: typical Arrangement of Air-coolers

Presenter

Presentation Notes

The Equipment are arranged along a backbone = piperack. Connecting pipes run on the pipe-rack. Access are provided to: motor, fan and bearing – for maintenance: motors are dismantled and dropped on a four-wheel trolley at service platform level then brought up to a dvait from service platform to grade. Both headers for cleaning and instrument access


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Plant Layout Job specification for design / Plant layout guidelines

Site elevation (s)

Minimum distances between units, equipment, buildings: applicable code + supplementary information

Clearance around equipment

Road width, clearance

Headroom clearance

B/L(Battery limit)

C/L of Road

R

Min. 7.5 m

A

Line Up C/L of Equipment

Pipe Rack of Structure

Min. 3 m


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Interfaces between Engineering disciplines Plot Plan

Plot Plan

Process design & simulations

Process eqt specs

Process Flow diagrams

Process eqt sizing

Eqt sizing by vendors

Equipment dimensions

Piping routing

Fire water network routing

Electrical distribution & cable routing

Instrument JB & cable routing

Sewage sizing & layout


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Overall Site plan

Presenter

Presentation Notes

Defines the location of a complex and of its environment 1:5000 scale


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General plot plan

Presenter

Presentation Notes

Shows the entire Plant and the arrangement of the various units (process, utility), storage facilities, buildings and other facilities 1:1000 scale


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Unit plot plan

Presenter

Presentation Notes

Shows location of equipment, pipe-racks, structures, with co-ordinates and elevation – 1:200 scale


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Unit plot plan Elevation view


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Unit plot plan Plan view

Presenter

Presentation Notes

Shows location of equipment, pipe-racks, structures, with co-ordinates and elevation


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3D modelling


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3D model clash check


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3D model review

3 model reviews are usually done


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3D model review

3 model reviews are usually done:

What is the scope of the first model review?


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First model review: Scope: finalize the Plot Plan Content: Equipment + 30% of piping is modelled, i.e. all ines on PFDs Outcome: after incorporation of COMPANY’s comments, the Plot plan is released as the base for the design (IFD). Aspects reviewed: Unit location, equipment location, main access and escape routes to facilities, major piping routes indicated on PFDs, arrangement around LLI, location of main manifolds, space around equipment for maintenance, platforms for main operation access

3D model review


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30% model review


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Air-Cooled Heat Exchangers In which case would you install the ACHE at grade vs on pipe-rack?

Presenter

Presentation Notes

Install on pipe-rack when you lack real estate


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Air-Cooled Heat Exchangers In the case of installation on top of pipe-rack, what extra access shall be provided?

Presenter

Presentation Notes

Service platform for maintenance of motor, fan and bearing –motors are dismantled and dropped on a four-wheel trolley at service platform level then brought up to a dvait from service platform to grade.


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Plot Plan review Hands-on exercise

Please review and comment the Plot Plan

Presenter

Presentation Notes

Comment: off-spec tanks located upwind of furnaces: to be relocated


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Piping Layout Modular plants

In which cases is a modular plant preferable vs a stick built?

Presenter

Presentation Notes

Construction not easy of costly (extreme wetaher: Siberia, Canada, remote area, high labour cost) Revamping: to minimize SIMPOS


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Design development

This is the Plot at FEED stage. Which parts of it do you expect will change at EPC stage?


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Incinerator Package

Design development

FEED stage EPC Stage


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Combustion Air blowers + heater

Plant layout evolution

FEED EPC - IFD EPC - IFC


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The Oil & Gas Engineering Guide 2nd edition

Do you want to know more... Much more?


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The Oil & Gas Engineering Guide - 2nd edition

Table of Contents


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The Oil & Gas Engineering Guide 2nd edition

Order direct from the publisher:

http://www.editionstechnip.com/en/catalogue-detail/1111/oil-gas-engineering-guide-the.html




plant layout engineering tutorial

Education

plant layout discipline

step of plant layout

plant area

process units

presenterpresentation

equipment list

minimum safety distances

following minimum distances