1. EQUIPMENT LAYOUT FOR ONSHORE PLANT
BY: Haryono WB

2. REFERENCES
API RP 14J Design & Hazard Analysis for Offshore production Facilities
API 521 Guide for Pressure Relieving & Depressuring Systems
API RP 2001 Fire Protection in Refineries
API RP 752 Management of Hazards Associated with Location of Process Plant Building
NFPA 30 Flammable and Combustible Liquids Code
NFPA 58 Liquefied Petroleum Gas Code
NFPA 59A Standard for the for the Production, Storage, and Handling of Liquefied Natural Gas (LNG)
IRI IM Oil & Chemical Plant Layout
IRI IM A Hazard Classification of Process Operations for Spacing Requirements
PIP PNC 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 Prevailing Wind
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: Brown 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 Paving Primary Roads Secondary 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

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. Plant Layout 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

19. Plant Layout 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: Details:
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