1.3 Layout Design - General Philosophy and Principles

8/8/2017
1.3 Layout Design – General

Philosophy and Principles
• Goals of plant layout design
• Site location, layout and conditions
• Separation distances – standards and
best practices: API, CCPS, GE-GAP
Main Objective of Plant Layout

• The main objective of a plant layout is to find the
most economical spatial arrangement of process
vessels and equipment and their connection by pipes,
while satisfying requirements of
– construction,
– operation,
– maintenance,
– safety, and
– compliance with applicable regulations.
The layout objective is finding the best arrangement
of process equipment and associated piping so that
the total life cycle cost (LCC) is a minimum and the
minimum required distances between components
and clearances are satisfied.
Nabil Al-Khirdaji, M.Eng., P.Eng. 1

8/8/2017
An Applied Guide to Process

and Plant Design
The book covers plant layout and
the use of spreadsheet programs
and key drawings produced by
professional engineers as aids to
design; subjects which are usually
learned on the job rather than in
education.
The book includes a wealth of
selection tables, covering the key
aspects of professional plant
design.
* Chapter 14: How to Lay Out
a Process Plant
Process Plant Layout

Operational & Maintenance Considerations
Parallel Tasks improve final design
Plant Plant
Layout Layout
Process Structural
Operation Maintenance
Design Design

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Layout Modeling – Objective Function

The objective is to minimize the cost associated
with the layout !
Land Cost
+
Piping Cost
+
Safety Cost (function of distance vs. cost)
+
Protection devices Cost
* Constraints : Land Restriction, non-overlapping
Definitions
• Plant – A general term used to describe anyone or all
of the units on a given site.
• Plot – An area of the site containing one or more
processing units, or tankage.
• Process Unit – A main production component of a
plant, consisting of groups of equipment arranged to
perform one or more process operations
• Non-Severe Service Equipment – Equipment
operating below 410°F and 500 psig.
• Severe Service Equipment – Equipment operating at
or above 410°F or 500 psig.

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Site Layout
Flare
Process Utilities Effluent Storage Bldgs Future
Siting Consideration
Siting of a proposed expansion or new plant should
consider the following factors:
– Buffer zones between the plant and the public;
– Worst credible scenarios for release of a toxic
chemical, explosion or fire, and effect(s) on exposed
groups;
– Exposure hazard to / from adjacent plants or facilities;
– Possible exposures due to natural events such as
earthquake, flood, tornado, etc.; and
– Effects of transportation of hazardous material
feedstocks or products through local communities.

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Plant Engineer’s Handbook

The Plant Engineering Handbook offers
comprehensive coverage of an enormous range
of subjects which are of vital interest to the
plant engineer and anyone connected with
industrial operations or maintenance.
This handbook is packed with indispensable
information including selection of a suitable
site for a factory and provision of basic
facilities (including boilers, electrical systems,
water, HVAC systems, pumping systems and
floors and finishes) to issues such as
lubrication, corrosion, energy conservation,
maintenance and materials handling as well as
environmental considerations, insurance
matters and financial concerns.
One of the major features of this volume is its
comprehensive treatment of the maintenance
management function.
1/3
Fire and Explosion Hazard
Reduction Measures for Piping
CONCEPTUAL Phase
Minimize inventory of combustible material
Process and compress gas onshore to reduce processing risks offshore
Avoid high energy systems
Select less hazardous materials
Hold materials in a form, or under conditions, to render them non/less
hazardous
Use less hazardous materials
Include systems for flaring
Provide a TR on an adjacent bridge linked structure
Promote permit to work culture
Build accommodation platform separate from production platform
Separate personnel from process hazards
Improved means of escape

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2/3
FEED Phase
Maximize ventilation including use of blow out panels
Ensure adequate supply of deluge systems
Divide the inventory to reduce the amount with a potential to ignite
Reduce the number of flanges
Design for maximum pressure
Ensure critical pipelines do not rupture when subjected to blast pressure
Increase flange rating for critical piping
Use welding rather than bolting
Adopt pipe routes that will avoid drag loads
Adopt pipe routes that avoid large Δ displacement between supports
Adopt pipe routes with shielding and running behind beams
Adopt pipe routes avoiding vent areas
Optimize location and level of piperacks
3/3
DESIGN Phase
Improve layout of equipment and minimize congestion
Design blast walls for high over pressures
Minimize penetrations through blast walls, and provide seals where
required to avoid transferring blast loading to penetrating services
Deluge system feeders and their manual bypass lines should be protected
by providing PFP cladding or coating to piping and where necessary to
supports, or by extended deluge cover.
Main blowdown header to be protected from fire in high hazard areas.
Specifically relevant to header in vicinity of gas export metering
package
All Emergency shutdown valves which are recognized to be critical in
isolating major inventories will satisfy fail to safe condition
Optimize equipment fixings and piping supports

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Handbook of Fire and Explosion

Protection Engineering Principles
This publication is intended as a
general engineering handbook and
reference guideline for those
personnel involved with fire and
explosion protection aspects of
critical hydrocarbon facilities.
Design guidelines and specifications
of major, small and independent oil
companies as well as information
from engineering firms and
published industry references have
been reviewed to assist in its
preparation.
Plot Plan Consideration

A plot plan review should include:
– Congestion, e.g. overlapping hazard zones, difficult access,
possible confinement of vapour release, etc.;
– Location of control rooms, offices and other buildings;
– Storage areas;
– Loading and unloading areas;
– Drainage and containment;
– Other process areas;
– Insurance requirements;
– Federal, provincial and local regulations; and
– Company/industry spacing guidelines.

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Safety Issues in Plant Layout

• Accident containment and avoidance of “domino”
effects
• High hazard operations
• Segregation of different risks
• Exposure to possible explosion overpressure
• Exposure to fire radiation
• Minimizing vulnerable piping
• Drainage and grade sloping
• Prevailing wind directions
• Provision for future expansion
Plant Layout & Siting

• “Siting” means conducting a review of the location of
equipment and piping with regard to:
1) possible impact on human or environmental receptors, or
2) where other plant operations could have impact on the
new equipment.
• In case one, design layout might consider such items
as predominant wind direction and populated areas
down wind.
• In case two, the considerations might include such
items as any flammable or potential explosive
processes.

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Process Plant Layout Hierarchy

Plot Plan (Overall Site)
-Roads
-Access
-Storage
Process Plant
-Admin -Roads
-Utilities -Access
-Units
Process Unit
-Buildings -Access
-Equipment Process
Equipment
-Spacing
-Arrangement
Performance Shaping Factors PSF

(Performance Influencing Factors PIF)
• Any factor that influences human performance
of a task within the process system is a
performance-shaping factor (PSF) [also
referred to as performance influencing factor
(PIF)]. PSFs (PIFs) include:
– factors intrinsic to an individual (personality,
skills, etc.) and
– factors in the work situation (task demands, plant
policies, equipment design and layout, etc.).

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Poor Layout »» Error-Likely Situations

• Anything that must be monitored or manipulated by
workers should be located in convenient, accessible
locations that make sense in relation to the tasks that
must be performed and their frequency.
– In control rooms, designers often stick instruments, controls,
and annunciator lights wherever there is space, regardless of the
position of related devices.
– In the field, control valves and bypasses may be located in
elevated pipe racks, or drain valves may be stuck underneath
vessels with insufficient clearance.
• It is unrealistic to expect humans to reliably use
equipment that is inconveniently located.
Impact of Layout on Project Costs

• Project costs tend to increase due to additional:-
(i) Foundations and structural steelwork
(ii) Piping
(iii) Land requirements
(iv) Energy requirements
• Significant cost savings can therefore be achieved by
minimising the plot area providing safety,
operational and maintenance requirements are met.

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Spacing (Separation Distances)

• Spacing – The clear unobstructed horizontal and vertical
distance between adjacent edges of equipment or plots.
– Spacing requirements may be specified in terms of
vessel, exchanger, or other equipment diameters or
straight-line distances. When different diameters of
like equipment are considered for determining space
requirements, the larger diameter shall be used.
– Spacing requirements to rotating equipment shall be
measured to the equipment base.
– Spacing requirements between plots shall be measured
to and from the plot battery limit.
Typical Spacing Between Units

Based on Hazard Category (GAP.2.5.2A)
• 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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Typical
Examples
of
Minimum
Plot
Separation
Distances
Typical
Separation
Distances
Between
Non-severe
Equipment
Within a
Plot

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Typical
Separation
Distances
Between
Severe and
Non-severe
Equipment
Within a Plot
Typical
Separation
Distances
Between
Severe
Equipment
Within A Plot

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Equipment Spacing Guidelines

• Safe equipment spacing requirements for process and
petrochemical plants are given in various standards
and guidelines including:
– CCPS (Center For Chemical Process Safety)
– GE GAP Standards [IRI Guidelines IM2.5.2]
– NFPA Fire Protection Handbook, and
– NFPA Standard 30.
– PIP PNC00003
– API standard 2510 - Specific requirements for
spacing vessels containing pressurized LPG.
Equipment Spacing Guidelines

The most important of these include the following:
– There should be at least two entrances to the plant;
– The overall site should be subdivided into general
areas (blocks) with a maximum size of 300 feet x 600
feet;
– Access roadways should be provided between the
blocks to allow access to each block from at least two
directions; and
– Road widths and clearances should be sized to handle
large moving equipment and emergency vehicles

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Some Fire Protection Standards & Codes

Code/Standard Description
ASME B31.3 Process Piping
API RP 500 Classification of Hazardous Areas in Petroleum Pipeline
Facilities
API Pub 2510A Fire-Protection Considerations for the Design and
Operation of LPG Storage Facilities
GE GAP (IRI IM) 2.5.2 Plant Layout and Spacing for Oil and Chemical Plants
NFPA Standard 11 Low Expansion Foam and Combined Agent Systems
NFPA Standard 15 Water Spray Fixed Systems
NFPA Standard 22 Water Tanks for Private Fire Protection
NFPA Standard 24 Installation of Private Fire Service Mains and Their
Appurtenances
NFPA Standard 25 Inspection, Testing and Maintenance of Water-Based
Fire Protection Systems
NFPA Standard 30 Flammable and Combustible Liquids Code
NFPA Standard 70 National Electric Code
Minimum Distance Between

Equipment within Process Units
(GE Insurance Solutions, GAP. 2.5.2 & 2.5.2a)
Notes
All dimensions are in metres
/ = No spacing requirements
High Hazard pumps handle
flammable, combustible liquids
operating at ≥ 260oC and >34.5 bar

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Storage Tanks and Offsite Facilities

Storage Tanks and Offsite Facilities
Table 7

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Applicable NFPA, API and GAP

Equipment Spacing Requirements
Inter-Unit Spacing
Loading Racks
Service Buildings
Process Units High Hazards

Requirements (feet)
Flares
Control Rooms
Fire Water Pumps
Atmospheric Storage Tanks

Pressure storage Tanks
Flares ---
Loading Racks 300 50
Service Buildings 300 200 ---
Control Rooms 300 200 --- ---
Fire Water Pumps 300 200 50 50 ---
Process Units High Hazards 300 200 400 300 300 200
Pressure Storage Tanks 400 350 350 350 350 350 *
Atmospheric Storage Tanks 300 250 250 250 350 350 * *
--- = there is no spacing requirement; * = see table “Storage Tanks Spacing Requirements”

Intra-Unit Spacing
Compressors
Requirements (feet)
Pipe Racks
Fired Heaters
Heat exchangers
High Hazard Pumps
Emergency Controls
Compressors 30
Pipe Racks 50 ---
Fired Heaters 50 50 25
Analyzer Rooms
Heat Exchangers 30 10 50 5
High hazard Pumps 30 15 50 15 5
Emergency Controls 50 50 50 50 50 ---
Analyzer Rooms 50 50 50 50 50 --- ---

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3,000 < C < 10,000 bbls

Storage Tanks Spacing
Floating Roof Tanks

Requirements (feet)
3,000 < C < 300,000 bbls

(Source IRI IM2.5.2)
Floating Roof Tanks
Pressure Storage Vessels -

Drums and Bullets
Floating Roof Tanks 0.5 D
3,000 < C < 10,000 bbls
Floating Roof Tanks D D
3,000 < C < 300,000 bbls
Pressure Storage Vessels - 1.5 D 1.5 D D
Drums and Bullets 100’ min 100’min.
C = tank capacity; D = tank diameter

Atmospheric Storage Tanks Spacing Required Distance (feet)
Requirements (Source NFPA 30)
Between Adjacent Tanks (Shell-to-Shell) 1/6 sum of adjacent tank
diameters but not less than 3 feet
From Property Line that Is or Can be Built ½ times diameter of tank or 175
Upon, Including the Opposite Side of a feet for tanks over 3,000,000 gal
Public Way – With Protection for (72,000 bbls) capacity
Exposures
From Property Line that Is or Can be Built Diameter of tank but need not to
Upon, Including the Opposite Side of a exceed 175 ft but no less than 5
Public Way – No Protection for Exposures ft.
From Nearest Side of any Public Way or 1/6 times diameter of tank but no
from Nearest Important Building on the less than 5 feet or 60 feet for
Same Property tanks over 3,000,000 gal capacity

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Pressurized LPG Tanks
Required Distance (feet)
Spacing Requirements
(Source: API Standard 2510)
Between Adjacent Tanks (Shell-to-Shell) 5 feet or ¾ of larger tank diameter
Adjoining Property Line 75 feet (for 30,000-70,000 gallon
tanks)
Control buildings 50 feet
Other buildings 100 feet
Process vessels 50 feet
Flares and other equipment with open flames 100 feet
Fired equipment including process furnaces 50 feet
Rotating equipment, 50 feet
except pumps taking suction from LPG tanks 10 feet
Loading facilities 50 feet
Recommended Inter-Unit
Equipment Separation Distances for
Traditional Chemical/Oil Plants
30
(Distances in ft.)
30 5
50 5 5 Ref: Guidelines for Engineering Design
50 10 25 25 for Process Safety, CCPS, 1993
50 10 15 25 15
50 10 15 25 15 15
50 10 15 50 25 25 15
100 100 100 100 100 100 100 100
50 50 50 50 50 50 50 100 25
30 15 15 25 15 15 15 100 50 1
30 10 15 25 15 10 10 100 50 15 5
30 10 15 25 15 10 10 100 50 1 50 1
50 50 50 100 50 50 50 100 50 50 50 50 1
50 50 50 100 50 50 50 100 50 50 50 50 1 1
50 50 50 50 50 50 50 100 50 50 50 50 1 1 1

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Minimum Spacing for Refineries

The spacing (m) and Petrochemical Plants
between specific
items can be found Legend:
at the crossing of na = not applicable, no
vertical and distance can be determined
horizontal lines of nm = no minimum spacing
the two items under requirements, use engineering
judgment for spacing
consideration.
For example: the
distance between
'Tank truck loading'
and 'Process unit
battery limits' is 45
m meters.
See Notes next slide
Notes: Minimum Spacing for

Refineries and Petrochemical Plants
Notes:
1. Distances are in meters.
2. Minimum distances between buildings, process equipment and property are
shown and apply to edge distances. Additional spacing may be required for high
hazard petrochemical classifications
3. Top entry in each column represents the spacing between alike items (i.e. two
cooling towers)
4. Where unusual conditions require closer spacing, fire protection exceeding the
standard requirements shall be provided subject to approval of the owner.
5. Main plant roads are defined as roads normally open to thru traffic. Roads
which are normally used only for maintenance access, etc. are considered as
secondary plant roads.
6. Monitor locations shall be selected to protect specific items of equipment.
7. Additional spacing may be required to maintain the flare radiation intensity
within the requirements of API RP-520 and RP-521.
Legend:
na = not applicable, no distance can be determined
nm = no minimum spacing requirements, use engineering judgment for spacing

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Legend: Minimum Spacing for

Refineries and Petrochemical Plants
1 Administration and office building 20 Desalter
2 Shops, warehouses, shipping building,
laboratories, etc. 21 Internally insulated reactors (above
ignition temperature)
3 Main plant substation 22 Externally insulated reactors (above
ignition temperature)
4 Fire pumps and fire station
23 Reactors (below ignition temperature)
5 Tank truck and rail car loading racks, piers
24 Heat exchangers (above ignition
temperature)
6 Boilers and power generation, instrument
air compressors 25 Heat exchangers (below ignition
temperature)
7 Cooling towers
8 Main process control house 26 Process pumps handling LPG products
9 Process unit control house 27 Process pumps handling HC above auto
ignition temperature
10 Process unit battery limits
11 Main plant roads (see note 5) 28 Process pumps handling HC below auto
ignition temperature
12 Property boundary and public roads
13 Hydrants and fire monitors (see note 6) 29 Fractionation towers, absorbers, drums,
accumulators, KO ports, etc.
14 Process unit substation 30 Air coolers
15 Explosion proof electrical switch racks 31 Pipe ways
16 Water spray control valves and emergency 32 Equipment handling non flammables
shutdowns 33 Atmospheric storage tanks
17 Unit isolation, depressurizing, control and
snuffing steam valves 34 Low pressure storage tanks (≤ 15 psig)
18 Fired process heaters and open flame
equipment 35 High pressure storage tanks (spheres and
bullets)
19 HC compressors and expanders 36 Flare (see note 7)
PIP PNE00003-2013: Process

Unit and Offsites Layout Guide
• This Process Industry Practice (PIP) describes the
guidelines for the layout of plot areas, equipment,
pipe racks, piping, platforms, roads, and other
miscellaneous items.
• Layout includes
– equipment location,
– access and egress for personnel safety,
– access for operations and maintenance, and
– provisions for operational housekeeping and
constructability.

8/8/2017

• This guide does not cover any requirements for owner
safety and property protection needs such as loss
prevention, vapor cloud explosions, or environmental
or flare/vent stack requirements.
• Spacings in the "Recommended Equipment Spacing
Charts" are based on industry experience
predominantly from a fire exposure/asset loss stand
point and are generally applicable for facility
processing flammable and combustible gases and
liquids.

Purpose
• This Practice provides guidance for engineers for the
design and layout of process units and offsites.
• This guide should be used as a starting point for the
development of plans, electronic models, and
working drawings for process units and offsites.
• This Practice should be coordinated with the overall
site and offsites layout for geotechnical, grading,
zoning, building codes, life safety, fire codes, and
owner's and insurer's risk assessment requirements

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PIP PNE00003
Minimum Requirements
Item Description Dimension
Roads Clearance over primary access roads where major 18'-0"
maintenance vehicles are expected to pass
Clearance over electrical transmission and distribution lines 22'-0"
Width of primary access roads 20'-0"
Clearance over secondary access roads and pump access roads 10'-0"
Width of secondary access roads and pump access roads 10'-0"
Railroads Clearance over through-railroads (from top of rail) 22'-0" (check local regulations)
Clearance over dead ends and sidings (from top of rail) 16'-0" (check local regulations)
Horizontal clearance from track centerline to obstructions 8'-6"
Clearance under electrical lines Check applicable regulations
Access Clearance height for projections over platforms, working 7'-6” (6’-8” for bottom of valve
Walkways areas, walkways handwheels)
Width of stairways (unobstructed width) 3'-0"
Width of landings (in direction of stairways) 3'-0"
Width of walkways 3'-0"
Maximum vertical rise of one flight of stairway 18'-0"
Maximum horizontal distance from any point on platform to 7 5'-0"
an emergency exit
Maximum length of dead-end platforms 20'-0"
PIP PNE00003
Minimum Requirements
Item Description Dimension
Ladders Maximum vertical rise of ladders in a single run 30'-0"
Maximum allowable slope of ladders from vertical 15 degrees
Minimum toe clearance from centerline of rung to obstruction 7"
Platforms Maximum variance in platform elevations without an 1'-0"
intermediate step
Minimum unobstructed width of platforms 2'-6"
Occasional obstructions ( level glass, transmitter, etc.) 1’-6”
Minimum width of manhole platforms on vertical vessels 3'-6"
Minimum platform extension beyond centerline of manhole 2'-6"
flange on vertical vessels
Minimum width of platform from three sides of manhole on 2'-6"
vessel top head platforms
Minimum width of platforms at ends of horizontal tube 3'-6"
furnaces
Operation Minimum clearance in front of channel end of horizontal Tube bundle length plus 5 ft.
and exchanger for tube removal or cleaning
Maintenance Minimum clearance around exchanger body flanges 1'-6"
Vertical exchangers Unobstructed vertical access

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PIP PNE00003 Table 1 -

Recommended Offsites Equipment Spacing
PIP PNE00003 Table 2 -

Recommended Process Unit Equipment Spacing

8/8/2017
Surface Equipment Spacing: Oil & Gas Plants
Positioning of Portable Buildings

on Chemical Sites
On March 23, 2005, the
BP Texas City refinery
experienced a
catastrophic process
accident.
During the investigation
it was found that the main
area of destruction
occurred in and around a
group of trailers involved
in maintenance work
unrelated to the
restart.
Some trailers were
located very close to the
process unit, and more
than 40 trailers were
damaged in the incident.

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Consequences of Inappropriate Spacing

Many people died because the location of the control room and parking
lot were too close to hazardous facilities (Details in Workshop I)
BP Texas city disaster (2005) Pasadena (1989)

parking lot control room
API RP 752 - Management of

Hazards Associated With Location of
Process Plant Permanent Buildings
Chemical Manufacturers
Association (CMA) and American API CMA
Petroleum Institute (API)
established RP752 in May 1995.
RP 752 is enforced by OSHA
API RP 752
API RP 753 Management of API RP 753
Hazards Associated with Location
of Process Plant Portable
Buildings was published in July
2007 following CSB (Texas OSHA
Incident) Recommendation

8/8/2017
API RP 752
According to RP 752, there are several types of buildings commonly
used in process areas. These building types and the effects of
explosion overpressure on each are as follows:
Building Type Overpressure (psi) Consequences

Wood-frame trailer 2.0 Complete collapse
Steel frame/metal siding 2.5 All walls destroyed
Unreinforced masonry building 1.5 Complete collapse
Steel frame with reinforced 2.5 Complete frame
masonry collapse
Reinforced concrete 4.0 Complete collapse
6.0
API RP 753 “Management of Hazards

Associated with Location of Process Plant
Portable Buildings”
• What is API RP 753? It is a new recommended
practice that provides guidance for reducing the risk to
personnel located in portable buildings from potential
explosion, fire and toxic release hazards.
• Why was API RP 753 developed? The fatal incident
on March 23, 2005 at the BP Texas City Refinery
prompted investigations into facility siting, specifically
addressing portable buildings located near process
plants. API RP 753 is one of the outcomes of this
investigation

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API RP 753 “Management of Hazards

Associated with Location of Process Plant
Portable Buildings”
Figure 2: Blast proof portable building
API RP 753 - Objectives

• There are four objectives for API RP-753:
1. Provide guidance on the safe placement of
portable buildings.
2. Minimize the presence of personnel in refinery
process areas.
3. Minimize the use of occupied portable buildings
in refinery process areas.
4. Design, construct and install these buildings or
trailers to better protect occupants.

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API RP 753 - Simplified Method

• To aid operators, API RP 753 provides a simplified
blast zone approach, which is based upon plant
layout and size (see Figure 1, next slide).
• Based upon the data within Figure 1, zones around
process plant can be plotted based upon the volume of
any congested volume within the process plant.
• These zones are then used to determine where
portable buildings or non-essential personnel (e.g.
administration staff) should or should not be located.
API RP 753 – Standoff Distance Criteria

“Congested Volume”
refers to the volume
(ft3) of a collection of
closely spaced objects
that have the potential
to increase flame
speed to an extent to
generate a damaging
blast wave, such as an
area populated with
pipes, pumps, valves,
vessels and other
process equipment and
supporting structures.

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API RP 753 Blast Zone Diagram
EXAMPLE
API RP 753
Allowable Locations and Personnel for Portable Buildings
Intended for Occupancy
Portable Buildings
Light Wood Occupancy
other than Light
Trailers Restrictions
Wood Trailers
Detailed analysis House only
Zone 1 Not allowed
required essential personnel
Detailed analysis Detail analysis
Zone 2 No restrictions
required required
Zone 3 No restrictions No restrictions No restrictions

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Access and Safety

• Inadequate access (or lack of direct access) to
operating and work areas around equipment could
compromise personnel safety and plant integrity.
• Equipment/components which are hard to reach or
which do not have adequate work areas will not get
the necessary attention.
• Compliance with related safety regulations is the
minimum requirement.
Recommended Minimum Clearance in

Access Ways and Work Areas
Topic Vertical Horizontal Comments
Main walkways 2100 mm minimum 1000 mm
2300 mm recommended
Access ways 2100 mm 600 mm Min. width 900 mm for
access to manned
workplaces
Access ways for 2100 mm minimum, Trolley width +
trolley/truck 2300 mm recommended 300 mm; Truck
width +900 mm
Work areas 2300 mm Min 2100 mm in parts
Access to fixed 700 mm
equipment
Pipe bottom to floor 150 mm N/A to drain pipes
Flange OD to fixed 250 mm 250 mm Applies to flange
obstruction OD>100 mm

8/8/2017
Unit Layout – Internal Elevation
Unit Layout – External Elevation

1.3 Layout Design - General Philosophy and Principles

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8/8/2017

1.3 Layout Design – General

Main Objective of Plant Layout

Nabil Al-Khirdaji, M.Eng., P.Eng. 1

An Applied Guide to Process

Process Plant Layout

Parallel Tasks improve final design

Nabil Al-Khirdaji, M.Eng., P.Eng. 2

Layout Modeling – Objective Function

* Constraints : Land Restriction, non-overlapping

Nabil Al-Khirdaji, M.Eng., P.Eng. 3

Process Utilities Effluent Storage Bldgs Future

Nabil Al-Khirdaji, M.Eng., P.Eng. 4

Plant Engineer’s Handbook

Nabil Al-Khirdaji, M.Eng., P.Eng. 5

Nabil Al-Khirdaji, M.Eng., P.Eng. 6

Handbook of Fire and Explosion

Plot Plan Consideration

Nabil Al-Khirdaji, M.Eng., P.Eng. 7

Safety Issues in Plant Layout

Plant Layout & Siting

Nabil Al-Khirdaji, M.Eng., P.Eng. 8

Process Plant Layout Hierarchy

Performance Shaping Factors PSF

Nabil Al-Khirdaji, M.Eng., P.Eng. 9

Poor Layout »» Error-Likely Situations

Impact of Layout on Project Costs

Nabil Al-Khirdaji, M.Eng., P.Eng. 10

Spacing (Separation Distances)

Typical Spacing Between Units

• Apply the following

Nabil Al-Khirdaji, M.Eng., P.Eng. 11

Nabil Al-Khirdaji, M.Eng., P.Eng. 12

Nabil Al-Khirdaji, M.Eng., P.Eng. 13

Equipment Spacing Guidelines

Equipment Spacing Guidelines

Nabil Al-Khirdaji, M.Eng., P.Eng. 14

Some Fire Protection Standards & Codes

Minimum Distance Between

Nabil Al-Khirdaji, M.Eng., P.Eng. 15

Minimum Distance Between

Minimum Distance Between

Nabil Al-Khirdaji, M.Eng., P.Eng. 16

Applicable NFPA, API and GAP

Process Units High Hazards

Fire Water Pumps

Atmospheric Storage Tanks

Applicable NFPA, API and GAP

High Hazard Pumps

High hazard Pumps 30 15 50 15 5

Emergency Controls 50 50 50 50 50 ---

Analyzer Rooms 50 50 50 50 50 --- ---

Nabil Al-Khirdaji, M.Eng., P.Eng. 17

Applicable NFPA, API and GAP

3,000 < C < 10,000 bbls

Floating Roof Tanks

3,000 < C < 300,000 bbls

Floating Roof Tanks

Pressure Storage Vessels -

Applicable NFPA, API and GAP

Nabil Al-Khirdaji, M.Eng., P.Eng. 18

Applicable NFPA, API and GAP

Nabil Al-Khirdaji, M.Eng., P.Eng. 19