C-170 Plant Layout
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TRAINING MANUAL- PIPING PLANT LAYOUT Uhde India Limited
DOC No. : 29040-PI-UFR-0017 Rev.
: R0
Page
: 1
CONTENTS Page 0.0
Cover Sheet
1
1.0
Introduction
2
2.0
Concept of Plant Layout
3–5
Applicable Revision: Prepared:
Checked:
Approved:
Date: First Edition: R0 Prepared: DNL
Date:
Date:
Checked: AKB
Approved: RUD
Date: File Name: C- 17
Date: Server:
PUNE: KUMUS 207
Directory: PUNE: Refer \ Pi \ Training Manual
Date: VKO: KUMUS 209
VKO: Refer \ Training Manual
TRAINING MANUAL- PIPING PLANT LAYOUT Uhde India Limited
1.0
DOC No. : 29040-PI-UFR-0017 Rev.
: R0
Page
: 2
INTRODUCTION: Today’s trend at large and complex plants presents substantial risk potential. In order to minimize the risks, certain norms are developed and practiced with respect to space allocations & relative locations and some specified distances are to be taken care of while a plant is designed. Many times, existing plants are modified to increase the capacity by change/addition of certain equipment whereas the original space designs may not be sufficiently cater for such changes. This also calls for a detailed analysis of the space allocation and consideration of any new additions. Generally, the basis of keeping specific inter distances depends on the lessons learnt during the past years from accidents which occurred in various plants throughout the world. Accordingly, the specified minimum distances and the specified relative locations are undergoing a continuous updation as new datas are generated and experiences increase. A few of the major points to be born in mind while venturing into plant layouts are explained here. The various process plants we come across are Petroleum refineries, Petrochemical complexes. Fertilizer plants, and Chemicals and Pharmaceutical plants, which need special attention due to the nature of the materials and products handled in those plants. All these plants involve various facilities such as raw material storage; intermediate and finished product storage, Process units and Control rooms; Flare System, Raw material/Product loading and unloading facilities; Utilities generation and distribution; Waste water treatment facilities; Non plant facilities such as Administration Buildings, Canteen, Workshops, Laboratory, Security arrangements, Vehicle Parking space, Stores, Fire station, and Township. Space allocation need to be provided to accommodate all these facilities. Before starting the development of Plant Layout the following information is a must. • • • • • • • • • •
Process Units and Capacities. A flow diagram indicating the process flow sequence. Utility requirements. Number of storage tanks and also open storage area. Raw material/Product receipt and dispatch philosophy. Covered storage required. Number of Flares. Grouping philosophy for utilities. Non plant Buildings. Environmental Considerations.
The data collected during the site selection stage shall be given due consideration at the time of plant layout. A few of the points are: • • • • • • • • •
Site location map and Area topography contour map for the plot size, shape and the nature of the land. Prevailing wind direction. Source of water supply and the supply point with respect to the plot. Electric supply point with respect to the plot. Effluent disposal point and the other drainages. Railway entry point. Approach roads to the plant. Raw material/Product movement by rail/road. Surrounding areas of the plot and considerations to be given to the neighborhood.
TRAINING MANUAL- PIPING PLANT LAYOUT Uhde India Limited
2.0
DOC No. : 29040-PI-UFR-0017 Rev.
: R0
Page
: 3
CONCEPT OF THE PLANT LAYOUT:
A process plant, which consists of the various different sections mentioned earlier should be arranged so as to follow the general route of raw material to process, to Intermediate/Finished product storage, to dispatch. Generally block concept is prevalent for the Plant Layout wherein the entire plot area is divided into blocks. The sizes of the blocks depend on the facilities to be accommodated. While locating the blocks and further sub blocks within them, the following points are to be considered.
Layout planning shall be in sequential order of process flow so that piping are also minimum. The blocks shall be so arranged considering the prevalent wind direction that flammable gases should not be carried by wind on to source of ignition. Process unit block shall be centrally located with straight approach from main gate. Storage tanks shall be grouped according to product classification. In undulating areas, storage tanks shall be located in lower elevations. Utility blocks shall be located adjacent to unit blocks. Main blocks shall be located adjacent to unit blocks. Main power receiving station shall be close to the boundary line so that minimum overhead power lines pass through the plant. The electric sub stations in the plant shall be located in such a way that the cabling to major load centers are minimum. The location of power plants shall be near to the process/utility blocks and close to main receiving station. Flare shall be located upwind of process units so that the inflammable gas from plant is not carried towards flare. Truck loading facilities shall be located close to product movement gate. Rail loading facilities are arranged generally at the periphery of the plant. Effluent plant shall be located away from the other units on the down wind location. The preferred location is at lower elevation than the other plant units in order to facilitate gravity flow. Fire station and fire water pump house shall be at a safe place away from hazardous areas. Fire station shall be near to the main gate with straight approach to process units and other critical areas. Two adjacent process unit location shall be decided based on the annual shut down philosophy for the maintenance of the units. If the shut downs will be at different times, it is preferable to increase the distance between the two points so that the risk for operating units due to hot jobs in the units under shut down can be minimized. Also this will facilitate easy maintenance.
TRAINING MANUAL- PIPING PLANT LAYOUT Uhde India Limited
DOC No. : 29040-PI-UFR-0017 Rev.
: R0
Page
: 4
Process units shall be located on the high ground. The adjacent neighbourhood installations, if any, shall be taken into consideration before fixing the plant layout. The limitations imposed by the neighbourhood facilities cannot be ignored, e.g. an ignition source. Flares, Furnaces/Heaters, Dusty operations and Cooling towers shall be oriented depending on the prevailing wind direction. The first two shall be located upwind of Process units and the last two on the down wind directions of process units. Due consideration of construction and erection of the plant shall be given while deciding the plant layout, especially Tall Towers, Reactors, Furnaces, etc. shall not be at congested areas and sufficient open space shall be provided to have erection at any stage. Equipment requiring frequent maintenance shall have easy accessibility. So also equipment having removable parts shall have free access for removal of the part and also for the free access for hoisting equipment. Provisions for future expansion shall be considered. It is preferable to have similar type of facilities in adjacent space for expansion. Care shall be given to give the expansion facilities without any disturbance to the existing facility. Care shall be given to give the expansion facilities without any disturbance to the existing facility. The blocks developed are separated by roads in between for purpose of access and safety. The fire fighting facilities are to be provided on these roads. There shall always be an alternative approach for fire fighting and maintenance in case one route is blocked. The layout shall be so designed that truck traffic inside the plant is minimized. Boiler house, Air compressors, Fuel oil facilities shall be grouped into one block adjoining the Process unit blocks, so that spreading of various utilities can be avoided and also to facilitate easy operation. The layout shall be designed so as to minimize capital cost for earthwork and pavements, special foundations and extent of vacant plot as waste land. Some of the major distances to be considered during plant layout are given in Table A. The plant layout needs statutory approvals before implementation. Some of the statutory approving codes are • • • • • •
Indian Factory Act. Indian Explosives Act. Petroleum and Carbide of Calcium Manual. Indian Electricity Rules. Insurance Association of India Fire Protection Manual. NFPA Code of Practice / TAC Rules.
The oil industry safety directorate gives some guidelines for plant layouts but does not overrule the existing statutory requirements.
TRAINING MANUAL- PIPING PLANT LAYOUT Uhde India Limited
DOC No. : 29040-PI-UFR-0017 Rev.
: R0
Page
: 5
The environmental/security requirements now demand that a Green Belt area around the plant boundary shall be provided. This is a belt of width 30m to 40m around the plant boundary where no construction will be done. TABLE A 1.
Process Units to Flare
90 M
2.
* Storage tank ‘Class A’ to Class B’ or ‘Class A’ to Class A’
3.
* Storage tank ‘Class Flameproof Pump
A’
to
Minimum of : 15 M from Perimeter or 0.5 D or d where, D=Dia. of Large tank d=Dia. of small tank 8M
4.
* Storage Boundary
A’
to
20 M
5.
15 M
8.
Loading / Unloading Tank Vehicle to Tank or Boundary Non-Flameproof Electric Pump to tank Class A/B Electrical Sub stn. to Process units Fire stations to Process Units
9.
Boiler House to Process Units
45 M
10.
Cooling Towers to Boundary
30 M
11.
Service Buildings to Process Units
60 M
12.
Control Room to Process Unit
30 M
13.
Process Unit to Process Unit
30 M
14.
Process Unit to ADM Building
60 M
6. 7.
tank
* Petroleum Storage Tank
‘Class
15 M 15 M 60 M
DOC No. : 29040-PI-UFR-0017 Rev.
: R0
Page
: 1
CONTENTS Page 0.0
Cover Sheet
1
1.0
Introduction
2
2.0
Concept of Plant Layout
3–5
Applicable Revision: Prepared:
Checked:
Approved:
Date: First Edition: R0 Prepared: DNL
Date:
Date:
Checked: AKB
Approved: RUD
Date: File Name: C- 17
Date: Server:
PUNE: KUMUS 207
Directory: PUNE: Refer \ Pi \ Training Manual
Date: VKO: KUMUS 209
VKO: Refer \ Training Manual
TRAINING MANUAL- PIPING PLANT LAYOUT Uhde India Limited
1.0
DOC No. : 29040-PI-UFR-0017 Rev.
: R0
Page
: 2
INTRODUCTION: Today’s trend at large and complex plants presents substantial risk potential. In order to minimize the risks, certain norms are developed and practiced with respect to space allocations & relative locations and some specified distances are to be taken care of while a plant is designed. Many times, existing plants are modified to increase the capacity by change/addition of certain equipment whereas the original space designs may not be sufficiently cater for such changes. This also calls for a detailed analysis of the space allocation and consideration of any new additions. Generally, the basis of keeping specific inter distances depends on the lessons learnt during the past years from accidents which occurred in various plants throughout the world. Accordingly, the specified minimum distances and the specified relative locations are undergoing a continuous updation as new datas are generated and experiences increase. A few of the major points to be born in mind while venturing into plant layouts are explained here. The various process plants we come across are Petroleum refineries, Petrochemical complexes. Fertilizer plants, and Chemicals and Pharmaceutical plants, which need special attention due to the nature of the materials and products handled in those plants. All these plants involve various facilities such as raw material storage; intermediate and finished product storage, Process units and Control rooms; Flare System, Raw material/Product loading and unloading facilities; Utilities generation and distribution; Waste water treatment facilities; Non plant facilities such as Administration Buildings, Canteen, Workshops, Laboratory, Security arrangements, Vehicle Parking space, Stores, Fire station, and Township. Space allocation need to be provided to accommodate all these facilities. Before starting the development of Plant Layout the following information is a must. • • • • • • • • • •
Process Units and Capacities. A flow diagram indicating the process flow sequence. Utility requirements. Number of storage tanks and also open storage area. Raw material/Product receipt and dispatch philosophy. Covered storage required. Number of Flares. Grouping philosophy for utilities. Non plant Buildings. Environmental Considerations.
The data collected during the site selection stage shall be given due consideration at the time of plant layout. A few of the points are: • • • • • • • • •
Site location map and Area topography contour map for the plot size, shape and the nature of the land. Prevailing wind direction. Source of water supply and the supply point with respect to the plot. Electric supply point with respect to the plot. Effluent disposal point and the other drainages. Railway entry point. Approach roads to the plant. Raw material/Product movement by rail/road. Surrounding areas of the plot and considerations to be given to the neighborhood.
TRAINING MANUAL- PIPING PLANT LAYOUT Uhde India Limited
2.0
DOC No. : 29040-PI-UFR-0017 Rev.
: R0
Page
: 3
CONCEPT OF THE PLANT LAYOUT:
A process plant, which consists of the various different sections mentioned earlier should be arranged so as to follow the general route of raw material to process, to Intermediate/Finished product storage, to dispatch. Generally block concept is prevalent for the Plant Layout wherein the entire plot area is divided into blocks. The sizes of the blocks depend on the facilities to be accommodated. While locating the blocks and further sub blocks within them, the following points are to be considered.
Layout planning shall be in sequential order of process flow so that piping are also minimum. The blocks shall be so arranged considering the prevalent wind direction that flammable gases should not be carried by wind on to source of ignition. Process unit block shall be centrally located with straight approach from main gate. Storage tanks shall be grouped according to product classification. In undulating areas, storage tanks shall be located in lower elevations. Utility blocks shall be located adjacent to unit blocks. Main blocks shall be located adjacent to unit blocks. Main power receiving station shall be close to the boundary line so that minimum overhead power lines pass through the plant. The electric sub stations in the plant shall be located in such a way that the cabling to major load centers are minimum. The location of power plants shall be near to the process/utility blocks and close to main receiving station. Flare shall be located upwind of process units so that the inflammable gas from plant is not carried towards flare. Truck loading facilities shall be located close to product movement gate. Rail loading facilities are arranged generally at the periphery of the plant. Effluent plant shall be located away from the other units on the down wind location. The preferred location is at lower elevation than the other plant units in order to facilitate gravity flow. Fire station and fire water pump house shall be at a safe place away from hazardous areas. Fire station shall be near to the main gate with straight approach to process units and other critical areas. Two adjacent process unit location shall be decided based on the annual shut down philosophy for the maintenance of the units. If the shut downs will be at different times, it is preferable to increase the distance between the two points so that the risk for operating units due to hot jobs in the units under shut down can be minimized. Also this will facilitate easy maintenance.
TRAINING MANUAL- PIPING PLANT LAYOUT Uhde India Limited
DOC No. : 29040-PI-UFR-0017 Rev.
: R0
Page
: 4
Process units shall be located on the high ground. The adjacent neighbourhood installations, if any, shall be taken into consideration before fixing the plant layout. The limitations imposed by the neighbourhood facilities cannot be ignored, e.g. an ignition source. Flares, Furnaces/Heaters, Dusty operations and Cooling towers shall be oriented depending on the prevailing wind direction. The first two shall be located upwind of Process units and the last two on the down wind directions of process units. Due consideration of construction and erection of the plant shall be given while deciding the plant layout, especially Tall Towers, Reactors, Furnaces, etc. shall not be at congested areas and sufficient open space shall be provided to have erection at any stage. Equipment requiring frequent maintenance shall have easy accessibility. So also equipment having removable parts shall have free access for removal of the part and also for the free access for hoisting equipment. Provisions for future expansion shall be considered. It is preferable to have similar type of facilities in adjacent space for expansion. Care shall be given to give the expansion facilities without any disturbance to the existing facility. Care shall be given to give the expansion facilities without any disturbance to the existing facility. The blocks developed are separated by roads in between for purpose of access and safety. The fire fighting facilities are to be provided on these roads. There shall always be an alternative approach for fire fighting and maintenance in case one route is blocked. The layout shall be so designed that truck traffic inside the plant is minimized. Boiler house, Air compressors, Fuel oil facilities shall be grouped into one block adjoining the Process unit blocks, so that spreading of various utilities can be avoided and also to facilitate easy operation. The layout shall be designed so as to minimize capital cost for earthwork and pavements, special foundations and extent of vacant plot as waste land. Some of the major distances to be considered during plant layout are given in Table A. The plant layout needs statutory approvals before implementation. Some of the statutory approving codes are • • • • • •
Indian Factory Act. Indian Explosives Act. Petroleum and Carbide of Calcium Manual. Indian Electricity Rules. Insurance Association of India Fire Protection Manual. NFPA Code of Practice / TAC Rules.
The oil industry safety directorate gives some guidelines for plant layouts but does not overrule the existing statutory requirements.
TRAINING MANUAL- PIPING PLANT LAYOUT Uhde India Limited
DOC No. : 29040-PI-UFR-0017 Rev.
: R0
Page
: 5
The environmental/security requirements now demand that a Green Belt area around the plant boundary shall be provided. This is a belt of width 30m to 40m around the plant boundary where no construction will be done. TABLE A 1.
Process Units to Flare
90 M
2.
* Storage tank ‘Class A’ to Class B’ or ‘Class A’ to Class A’
3.
* Storage tank ‘Class Flameproof Pump
A’
to
Minimum of : 15 M from Perimeter or 0.5 D or d where, D=Dia. of Large tank d=Dia. of small tank 8M
4.
* Storage Boundary
A’
to
20 M
5.
15 M
8.
Loading / Unloading Tank Vehicle to Tank or Boundary Non-Flameproof Electric Pump to tank Class A/B Electrical Sub stn. to Process units Fire stations to Process Units
9.
Boiler House to Process Units
45 M
10.
Cooling Towers to Boundary
30 M
11.
Service Buildings to Process Units
60 M
12.
Control Room to Process Unit
30 M
13.
Process Unit to Process Unit
30 M
14.
Process Unit to ADM Building
60 M
6. 7.
tank
* Petroleum Storage Tank
‘Class
15 M 15 M 60 M
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