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BY: Haryono WB EQUIPMENT LAYOUT FOR ONSHORE PLANT.

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Presentation on theme: "BY: Haryono WB EQUIPMENT LAYOUT FOR ONSHORE PLANT."— Presentation transcript:

1 BY: Haryono WB EQUIPMENT LAYOUT FOR ONSHORE PLANT

2 REFERENCES  API RP 14JDesign & Hazard Analysis for Offshore production Facilities  API 521Guide for Pressure Relieving & Depressuring Systems  API RP 2001Fire Protection in Refineries  API RP 752Management of Hazards Associated with Location of Process Plant Building  NFPA 30 Flammable and Combustible Liquids Code  NFPA 58Liquefied Petroleum Gas Code  NFPA 59AStandard for the for the Production, Storage, and Handling of Liquefied Natural Gas (LNG)  IRI IM.2.5.2Oil & Chemical Plant Layout  IRI IM AHazard Classification of Process Operations for Spacing Requirements  PIP PNC00003 Process Unit and Offsites Layout Guide  Project Specification  Peraturan Pemerintah / Peraturan Daerah

3 PLOT PLAN

4 PLANT LAYOUT  Basic Considerations  Plant Layout ○ Layout in Process Unit ○ Layout in Offsite Unit

5 BASIC CONSIDERATION  General  Blocking  Terrain & Weather  Hazard Classification / Safety  Maintenance  Future Expansion  Aesthetic  Construction

6 BASIC CONSIDERATION  General Public areas Convenient area Safety / emergency escape Containment / environment Operation / maintainability Economic Future Expansion

7 BASIC CONSIDERATION  Blocking Area formed in square (if possible) Equipment spacing Access for maintenance Prevailing wind Areas are divided by roads A block may contain more than one process unit or section Administration & service area & storage area Future expansion

8 Basic Consideration  Terrain & Weather Ground contour ○ Process unit located on highest elevation ○ Effluent treatment unit located at the lowest elevation Prevailing Wind

9 Basic Consideration  Hazard Classification / Safety Layout shall be determined in consideration of classified hazardous area ○ High Hazard - LPG ○ Intermediate Hazard - Condensate ○ Moderate Hazard - All other process gas Consider locations of catch basins & other flammable fluid spill collection Escape route

10 Basic Consideration  Maintenance / maintainability Provide space for maintenance of the facility ○ Heat exchangers ○ Reactors ○ Compressors ○ Pumps, etc Define the equipment that will be used and the space required to operate it

11 Basic Consideration  Future Expansion Consider future expansion ○ Future process plant ○ Future piping space on pipe ways ○ Future instrument & electrical cable ways Installation of future expansion shall not disturbing existing facility

12 Basic Consideration  Aesthetic Apply single centered pipe rack Towers and large vertical vessels arranged in rows Arrange pumps by aligned discharge nozzle Arrange exchangers by aligned discharge nozzle Duplicate streams for similar equipment sequences within the process stream

13 Basic Consideration  Construction Green area: ○ Provide adequate space and access for lifting ○ Review crane position for lifting in case late equipment delivery Brown area : ○ Able to separate from operating units ○ Consider additional problems ○ More stringent safety requirement in existing ○ Hot work should be able to be stopped should a major gas release occur ○ Provide a suitable access route to the construction site should be ○ Review crane position for lifting in operating area

14 Plant Layout  Blocked Area Arrangement Process unit shall be located in most convenient place Equipment should be laid out in a sequence to suit the process flow Storage located as far as possible form buildings, but near to process area Utility facility located beside process Administration & service located in safe area Flare stack located at the end of the site

15 Plant Layout  Roads & Paving Roads ○ Primary Roads Road width 6mtr, between block Sufficient clearance Run down the center of plant & between blocked areas ○ Secondary Roads 4mtr wide road Within block ○ Minimum (edge of road) 3mtr from processing equipment ○ Ensure sufficient road / access available during the construction phase Paving ○ Around pumps ○ Around catalyst, toxic, etc containing equipment ○ Curbing required to retain spilled material

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17 Plant Layout  Access, Platforms, Ladders Designed in accordance with SID Access required for operators Stair, primary access & egress to main operating level Stairway shall have sufficient clearance Ladder, access to vessel platforms, ACHE walkways, etc. Stair & ladders shall not obstruct instrumentation Maintenance Access around valves, CV’s, PSV’s etc. Operation & orientations of equipments, cabinets and valves

18  Piping & Pipe ways Pipe ways for process units ○ Usually pipe racks (max 10mtr wide) ○ Width shall consider length of ACHE ○ Limited to three stages Pipe sleepers for offsite facility Piping shall not obstruct access way Pipe spacing shall consider insulation thickness Plant Layout

19  Control Room & Substation Location: ○ As close as possible to plant equipment ○ Up wind of process and storage tanks (flammable) ○ Minimum 15mtr to the nearest process equipment Shall consider convenience in daily operation Shall consider cable length (electric / instrument)

20 Plant Layout  Building Kept to a minimum based on equipment Factors which determine the selection of enclosed building are: ○ Nature & frequency of the operator’s work ○ Climate ○ Type of equipment ○ Nature of process ○ Proximity of hazards ○ Consideration on enclosed building: Fire protection Illumination Fire proofing Ventilation Access Roofing

21 Layout in Process (Unit) Area  General  Reactors / Towers / Drums  Heat Exchangers  Compressors / Blowers  Pumps  Cooling Towers

22 Layout in Process (Unit) Area  General Arrangement shall minimize runs Layout along with the process flow diagrams Access around equipment (i.e. 600 mm min) Roads shall be outside area classification Utility area shall be outside classified area Equipment layout shall consider spacing requirement

23 Layout in Process (Unit) Area  Reactors / Towers / Drums Space for catalyst loading / unloading Periodic maintenance Drop space for internal removal / safety valves Related equipment shall be located as close as possible

24 Layout in Process (Unit) Area  Heat Exchangers Shell & Tube ○ Space & access for bundle removal ○ Located on grade / ground ○ Shall be grouped ○ Space for cleaning Air Cooled ○ Close to hydrocarbon pumps ○ Far from high temp equipment to minimize hot air circulation ○ Mobile access for maintenance

25 Layout in Process (Unit) Area  Compressor / Blower Minimum suction pressure drop Sufficient space around and between compressors for maintenance Air intake location shall be in safe area Personnel access on compressor deck Equipment shall not be located over gas compressor Access for fire fighting Down wind of fired heater, if practical

26 Layout in Process (Unit) Area  Pumps Laid out in groups Access to pump auxiliaries Access around and between pumps Provide overhead clearance (vertical pumps) Consider space for maintenance, emergency Good ventilated shelter for large pumps that need in situ maintenance Located outside pipe rack

27 Layout in Offsite Area  Tank Farms Tank spacing & location shall comply with IP Refining Safety Code, NFPA 30 (liquid) Location of LPG storage tanks shall be in accordance with API Std 2510A Pumps shall be located outside dike Consider to provide dike around tank yard for spill control Consider distance between tank to nearest process / utility unit Spill control shall be accomplished by dike enclosure

28 Layout in Offsite Area  Loading / Unloading Facility Located at near plant gate Located at remote area on periphery Distance from Process Area depend on type of commodity to be handle Consider prevailing wind and ignition source Consider space for loading / unloading Ensure access for fire fighting vehicles

29 Layout in Offsite Area  Cooling Towers Consider prevailing wind (downwind or cross wind process plant, sub station, etc) Consider noise that arise from Cooling Tower Located to optimise maintenance access Minimise any nuisance Cooling towers shall be placed clear of process areas susceptible to fire risk Source of hydrocarbon release Consider water source

30 Layout in Offsite Area  Effluent treatment facility Collect contaminated water prior send the water to water outfall Located away from other units Downwind from ignition source (prevailing wind) Preferred location is at lower elevation than others (maximize gravity flow)

31 Layout in Offsite Area  Flare Provide sufficient space to keep heat radiation low Located at remote from the offsite & process facility (outside Hazardous Area Classification) Consider prevailing wind (upwind / crosswind process plant) KO drum & its accessories should be at periphery Elevated (15mtr or more) flare should be located 60mtr & burn pit should be located 150mtr If more than 1 flare, location of each flare shall be based on operation

32 Layout in Offsite Area  Fired Heater / Boiler Provide sufficient space to keep heat radiation low Located at a safe distance from other hydrocarbon containing equipment Consider prevailing wind (upwind / crosswind process plant) Consider space for tube replacement and ample access for mobile equipment Sufficient access for firefighting equipment Provide paved and curbed areas under or around heaters No low points in the paving or grading these are spots for hydrocarbon liquids trapping

33 Operability  Means of egress, stairs vs ladders.  Orientations of equipment, cabinets and valves.  Clearances around valves, CV’s, PSV’s etc.  Instrument stand – “it’s just a stand, it can go anywhere” wanna bet?  Know the cycle of daily operational routines – “somebody tell me again why we put the CV way up there on top of what structure?”  Put yourself in their place – can you reach it, can you see it, can you put a valve wrench on it.

34 Layout Tip  Layout method  Basic Principles:  Plan the whole, than the detail  Plan the ideal, than the practical  Plan more than one layout  Sequence of activities in layout  Details:  Layout based on process flow  Techniques of correlation and compatibility  Proximity and sequencing


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