LAYOUT &

INTRODUCTION TO PROCESS AREA

PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

PIPING AND LAYOUT

Document Title: LESSON 01 –INTRODUCTION TO PROCESS AREA

PRELIMINARY PLOT PLAN

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 LAYOUT &
LESSON 01 - INTRODUCTION TO PROCESS AREA
PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

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 LAYOUT &
LESSON 01 - INTRODUCTION TO PROCESS AREA
PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

Executive Summary

These design guides have been compiled to assist plant design engineers and designers in the
development of Plot Plans for actual jobs and estimates.

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 LAYOUT &
LESSON 01 - INTRODUCTION TO PROCESS AREA
PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

Contents
1. INTRODUCTION................................................................................................................... 5
2. CONTENTS OF A PROPOSED PLOT PLAN ...................................................................... 5
2.1 SCALE......................................................................................................................... 5
2.2 BLOCK MODEL - (Electronic) ................................................................................... 5
2.3 ISSUE .......................................................................................................................... 5
3. PLOT PLAN DEVELOPMENT OF UNIT WITHIN AN EXISTING COMPLEX...................... 6
3.1 GENERAL INFORMATION REQUIRED BY PLANT DESIGN ................................... 6
4. LAYOUT OF PLOT PLAN AREA ......................................................................................... 7
5. FLOW DIAGRAMS ............................................................................................................. 10
6. PREPARATION FOR DEVELOPMENT OF PLOT PLAN.................................................. 12

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 LAYOUT &
LESSON 01 - INTRODUCTION TO PROCESS AREA
PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

1. INTRODUCTION
These guides have been compiled to assist the plant design engineer when plot plans
are to be developed either for actual jobs or estimates.
Do not consider that these guides are mandatory or assume that the contents can
influence any requirement laid down by the clients standards and layout procedures.
The clients procedures will always override these design guides, unless a mutual
agreement is obtained.
The important function of these guides is to aid in the preparation of a plot plan in the
quickest time possible.
Enclosed in these guides are some typical approaches on the preparation of plot plans,
these include step by step accounts of how a plant design engineer could approach
and develop a plot plan.
It is impossible to show every kind of unit in a refinery or chemical plant in these design
guides, but however, the enclosures will give basic information to give a plant design
engineer the initiative and confidence to tackle most requirements for plot plan
development.

2. CONTENTS OF A PROPOSED PLOT PLAN

The contents of the plot plan should indicate all major equipment items, buildings in
outline, battery limits, area limits for which the company's responsibility ceases and
starts, pipe exit and entry points, access ways, roadways, stairways, structures and
steelwork in sufficient details so as not to obscure its message.
Dimensions should be kept to a minimum on the development plot plan. Dimensions
that need to be shown should be limited to the location of battery limit, overall
dimensions, main pipe rack spans, northings/eastings, elevations of major structure
levels and pipe rack levels (if known). Do not dimension locations of equipment items.

2.1 SCALE
The scale of the proposed plot plan should be as large as the drawing sheet can
permit, and if necessary two or more drawing sheets may be used providing the match
lines are well defined. Do not risk illegibility, by using too small a scale.

2.2 BLOCK MODEL - (Electronic)

When the preliminary layout sketch of the plot has been completed to the satisfaction
of plant design group it must then be distributed to all sections or departments of the
company which are concerned with the physical arrangement and, assuming that the
layout has been developed using a 3D CAD drafting package (PDMS or equal), a block
model can be constructed to give the best possible information for the various
engineers to make comments. The plot plan drawing proper can commence after the
block model has been reviewed.

2.3 ISSUE
After reviews have been made on the plot plan and or block model, the plant design
group should issue the proposed plot plan for approval to the client.
The block model is also used as an assistance for obtaining client approvals.

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 LAYOUT &
LESSON 01 - INTRODUCTION TO PROCESS AREA
PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

3. PLOT PLAN DEVELOPMENT OF UNIT WITHIN AN EXISTING COMPLEX

This section has been compiled to show step by step how the plant design engineer
can approach the development of a plot plan within an existing complex.
The unit chosen for this subject is a simplified crude unit, this is only an example and
the data specified relates to the example.
However, in the absence of specific project requirements this example will serve as
good industry practice.

3.1 GENERAL INFORMATION REQUIRED BY PLANT DESIGN

When the plant design group is required to start layout and development of the unit plot
plan, certain information must be made available to the group by the projects or
process groups. The list below gives some indication of the requirements of plant
design and may be useful as a punch list.
site plans of existing refinery showing the vicinity of area proposed for the new unit.
Project design information.
Prevailing wind direction.
Equipment fist and sizes.
Process flow diagram(s) or preferably - P and I flow diagrams.
Utility conditions, such as: cooling water, steam etc.
Preferred locations of exit/entry piping points whether overhead, sleepers or
underground.
Electrical cables - entry points, above or below ground.
Pertinent data such as site clearance problems, underground sewers (existing) or
existing equipment within plot area.
Client preference or Company Standards for the safety distances from battery limits to
roadways, railroads, other units, etc.
Client preference or Company Standards for specific items of equipment
locations.
Grade levels of unit area and plant in general (roadways, railroads or access ways
adjacent to unit area).
Details of existing roadways, railroads or access ways around plot area (widths, etc.).
Plant bench marks (for Northings/Eastings).
Plant North or unit North.
Size and capacity of maintenance crane(s). Fire fighting data.
Associated engineering groups should also make available the following information to
the plant design group, items such as:
Storage tanks - diameter and height or capacity.
Heaters - diameter of shell and height, note whether cabin type or cylindrical type with
convection section or not.
Stack - diameter, note whether independent of heaters or mounted integral with each
heater.

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 LAYOUT &
LESSON 01 - INTRODUCTION TO PROCESS AREA
PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

Compressors - size of base plate area and type of compressor i.e. centrifugal or
reciprocating, seal oil/lube oil console floor space.
Details of oily water separator.
Control building data.
Specialist equipment - de-salter, package units, centrifuges, conveyors, boilers,
deaerator, coalescers, dryers, cold boxes, (aluminium exchangers) etc.
Tower bottom tangent line minimum heights from grade. Drum heights from grade
whether to bottom of drum or to the bottom tangent line.
Critical elevation requirements for all equipment.
Relative data sheets on towers and drums, including diameter and Tan to Tan.
Exchanger tube lengths and diameters. Fixed tube-sheets.
Withdrawal of tube bundle requirements. Number of shells for each item.
Parallel or in series. Finned tube exchangers. Kettle or conventional type exchangers.
Vertical or horizontal position.
Rotating equipment floor space requirements.
All of the above basic information influences the plot plan layout.
It is sometimes necessary to consult the Mechanical group regarding air cooler lengths
and widths, as in many cases pipe racks are sized to suit widths and lengths of air
coolers.
Check with clients procedures as to permissible location of air coolers. If they are
placed above pipe racks certain conditions are required and reference to future lesson
3 will be required.
For pump base sizes, it is usual to assume certain pump sizes. The approximate
suction and discharge pipe sizes, if given, will automatically give a design engineer a
feel for the size using his past experience, otherwise reference to future lesson 4 will
be required.
Mechanical group should attempt to pass information to plant design on sizes, but it is
more important to know the type of pump, such as: side and side inlet and outlet,
multistage, reciprocating, centrifugal, vertical, rotary, etc.
Steam driven pumps should also be well defined and the pressure of steam required at
turbine given. This could be important to the design engineer, when considering utility
layout.

4. LAYOUT OF PLOT PLAN AREA

The plant design engineer who has been assigned to develop the plot plan, should
proceed to analyse information received to build up a picture in his mind of the existing
refinery, in respect of: existing units, tankage area, pipe racks, in the vicinity of the unit
area, roadways, railroads or access ways etc. It is therefore advantageous if the design
engineer is permitted to visit the site.
The next phase would be to start laying out the plot plan area, first by building in the 3D
model of drafting the roadways/access ways around the unit area, and adding the co-
ordinates. Add new periphery roads or access ways as deemed necessary to fit in with
the plant (Fig. 1).

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 LAYOUT &
LESSON 01 - INTRODUCTION TO PROCESS AREA
PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

Battery limits with their co-ordinates are then defined on the proposed areas as in
Figure 1.
Existing pipe racks should then be added. These are normally found on the site plan,
but if they are not indicated the design engineer should check with Projects to define
incoming and outgoing pipe racks. In Figure 1 the existing pipe racks have been
shown. Any other existing conditions should be shown i.e. buildings etc.
North arrow and prevailing wind direction should be added. The plant boundary fence
and any other miscellaneous information such as an adjacent river should be added to
the plot plan as reference. The plant area should now be well defined with all known
outside conditions.
Finally the plant area should be cleared of all obstructions but should it necessitate
leaving an existing underground line the new plant will be designed with it remaining.
The plot plan is now ready for detailed investigation.

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 LAYOUT &
LESSON 01 - INTRODUCTION TO PROCESS AREA
PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

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 LAYOUT &
LESSON 01 - INTRODUCTION TO PROCESS AREA
PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

5. FLOW DIAGRAMS
The process flow diagram (Figure 2) should be made available for use in developing
the plot plan.
The first step would be to follow and familiarise the main flow patterns through the unit
with the process engineer and as a result there are several points which should be
taken into account and could affect layout of equipment, these typically would be:
The crude charge from storage to charge pumps GA-101, needs to be close to the
incoming line from battery limit.
Pumps should be located near the respective equipment to avoid excessive pressure
drop in suction lines.
The feed lines to heaters, will need manifold stations which split the line into several
manifolds depending on the number of passes in the heater, so it is recommended that
sufficient room should be allowed around the heater. Refer to Lesson 7
The transfer line from the heaters needs to be kept as short as possible and routed
without pockets. Flexibility should be taken into account at Plot Plan Stage.
Lines to and from strippers DA-102 and DA-103 and flare systems should be kept to a
minimum.
Bottoms line out of DA-101 needs investigation as to flexibility, as the temperature
would be on the high side. Also consider hot and cold conditions of spare pump.
The overhead line from DA-101 should be run without pockets to condenser EC-101,
and kept as direct as possible taking flexibility and growth of the tower into account.
The condensate line from condenser EC-101 to FA-101 again should be run without
pockets.
The off gas line from FA-101 to GB-101 should be kept short and also without pockets.
Many of the above statements will apply to most situations in Process Plant layouts

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 LAYOUT &
LESSON 01 - INTRODUCTION TO PROCESS AREA
PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

Figure 2

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 LAYOUT &
LESSON 01 - INTRODUCTION TO PROCESS AREA
PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

6. PREPARATION FOR DEVELOPMENT OF PLOT PLAN

Having completed the flow diagram investigation, a further inspection of information
received may reveal other design considerations necessary before equipment is placed
on the Plot Plan.
Check that the client has no design and layout requirements. If not basic CB&I good
practice should prevail resulting in the following:
The provision of adequate access to the unit for maintenance.
Headroom clear over railroads to be 7000 minimum.
Headroom clear over roads to be 6000 minimum.
Clearances over access ways to be 4000 minimum.
Pumps operating above their auto ignition temperature should not be located within
3000 mm (ground distance) of overhead air coolers.
Agreement on the location of pumps under structure.
Pumps operating below their auto ignition temperature are generally acceptable under
pipe racks, although many clients request them to be located away.
Air cooler locations are generally acceptable above pipe racks.
Provide suitable access to pumps and drivers for ease of maintenance.
Minimum clearance over pumps to be 3000 mm.
For layout purposes assume fireproof steelwork up to the first 8000 mm, and fireproof
up to all equipment (supports) containing hydrocarbons.
Pipe racks to be fireproofed when carrying process equipment and piping.
Construction considerations:
An area to be allocated for construction facilities.
Review roadway and access points for adequate space to permit the arrival, and
erection of heavy and large equipment (such as the fractionation tower Da-101).
Pipes entering and leaving the plant at the battery limits to be established by the client
and forwarded for use on the plot plan.
Having analysed the flow diagrams and the various design considerations, it is now
advisable to plot the anticipated equipment locations in rough block form manner.
Reference to the various equipment arrangements included in this design guide is
recommended at this stage, as certain design conditions could apply.
Having already plotted the area allocated for the unit (Fig. 1), use this layout as a guide
when plotting the equipment in block fashion (Fig. 3)
The following lessons will enable the design engineer establish definitive locations of
the equipment included in the Plot Area.

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LESSON 01 - INTRODUCTION TO PROCESS AREA
PIPING DESIGN
PRELIMINARY PLOT PLAN
COURSE

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