4/26/2017 ConsiderationsfordevelopmentofPlantLayout:AbriefpresentationWhatisPiping

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BASICSOFPIPESTRESS

ConsiderationsfordevelopmentofPlant ANALYSIS:A
PRESENTATION-Part1of
Layout:Abriefpresentation 2
(http://www.whatispiping.com/bas
December 9, 2016No Comment (http://www.whatispiping.com/development-of- of-pipe-stress-analysis)
plant-layout#respond) PipingElbowsand
Bends:Ausefuldetailed
literatureforpiping
64 1 engineers
(https://www.linkedin.com/cws/share? (https://plus.google.com/share? (http://www.whatispiping.com/pip
elbows-and-bends)
Thisarticleprovidesthebasicconsiderationsforthedevelopmentofplant
url=http://www.whatispiping.com/development
url=http://www.whatispiping.com/development
StepbyStepMethodsfor
layoutinapresentationform.Formoredetailsinanyofthelistedpointsyou
ofplantlayout) ofplant WRC107andWRC297
canrefertoanystandardpipingbooks.Thispresentationwillprovidean
CheckinginCaesarII
overviewonbasicconsiderations. layout)
(http://www.whatispiping.com/wrc
BasisofSiteSelection: 107-and-wrc-297)
BALLVALVEDESIGN
Location FEATURES:ALiterature-
AreaAllocation Part-3of4
TransportFacilities (http://www.whatispiping.com/bal
Manpoweravailability valve-design-features-
IndustrialInfrastructure literature-part-3)
CommunityInfrastructure Top12musthavePiping
AvailabilityofWater booksforabegineerinto
AvailabilityofPower Pipingindustry
EffluentDisposal (http://www.whatispiping.com/pip
AvailabilityofIndustrialGas books)
SiteSize StressAnalysisofPSV
Ecology connectedPiping
Pollution systemsusingCaesarII
WhatisPlotPlan&itsrequirement? (http://www.whatispiping.com/ste
analysis-of-psv-
Plotplanisthemasterplanlocatingeachunit/facilitywithintheplotboundary connected-piping-
foraprocessindustrysuchas systems)
Refinery MusthaveLoadcasesfor
Chemical/AgroChemical/PetroChemical/OrganicChemical/ stressanalysisofa
InorganicChemical typicalpipingsystem
Fertilizer usingCaesarII
Pharmaceutical (http://www.whatispiping.com/loa
Metallurgical cases)
PowerGeneration FlangeLeakagechecking
inCaesarIIusingASME
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4/26/2017 ConsiderationsfordevelopmentofPlantLayout:AbriefpresentationWhatisPiping

Itisusedtolocatetheunit/facility. SectionVIIImethod
(http://www.whatispiping.com/flan
Thefollowingmainaspectsshallbeconsideredduringdevelopmentofthe
leakage-checking-in-
layout.
caesar-ii-using-asme-
Processrequirement section-viii-method)
Economyofpipingmaterialandcables
Erection&Constructionrequirements
Safetyrequirements.
PREVIOUSPOSTS
OperationandMaintenancerequirements.
Groupingofsimilarequipmentforconvenienceofmaintenance&safety
whereverpossible.
SelectMonth
Datatobecollectedbeforestarting:

Civil

Planetablesurveymap. SELECTCATEGORYOF
Contoursurveymap.
Soilbearingcapacity.
NatureofSoil INTEREST
Rail/RoadAccess.

Electrical SelectCategory

LocationofElectricSupplyPoint.
Supplyvoltagelevels.
FaultLevels. SITEMAP
VoltageLevelsrequiredwithintheunit.
Proposeddistributionscheme.
SiteMap
NonPlantFacilities (http://feeds.feedburner.com/whatispipin
AdministrativeBlock
Canteen
Workshop
R&D,QCLabandPilotPlant
GateHouse/Timeoffice
SecurityArrangements
VehicleParking
MedicalCentre
WareHouse
CoveredArea
OpenArea
SolidWarehouse
LiquidWarehouse
Steel/ScrapYard
FireStation
WeighBridge
StaffColony

MeteorologicalData

Minimum,MaximumandNormalTemperatureduringtheyear
Rainfall
IntensityandDirectionofthewind(windrose)
Seismiczone
WetandDryBulbtemperatures
Relativehumidity
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4/26/2017 ConsiderationsfordevelopmentofPlantLayout:AbriefpresentationWhatisPiping

Floodlevel

ProcessData

Size/Capacityoftheprocessunit
Knowledgeonthetypeofplant
Sequenceofprocessflow
Hazardousnatureoftheplant
TheOveralloperatingphilosophy
FullyAutomatic
PartiallyAutomatic
Manual
Batch/Continuous
Rawmaterialreceiptandproductdispatchphilosophy
StoragePhilosophy
Effluentplantcapacityanddischargepoints,incinerationrequirements,
etc.
TypeofHazard
Noofflares

DataonUtilities

Sourceand/orsupplypointofrawwater
QualityofWateravailable
WaterConsumptionfortheprocess
RequirementofdifferenttypesofutilitiessuchasSteam,Air,Nitrogen,
DMwater,Firewater,Brine,etc.
CapacitiesandGroupingphilosophy.

StatutoryRequirements

StateIndustrialDevelopmentCorporation(SIDC)
Central/StateEnvironmentalPollutionControlBoards(PCBS)
FactoryInspectorate
StateElectricityBoards(SEB)
ChiefControllerofExplosives(CCOE)
StaticandMobilePressureVesselRules(SMPV)
TariffAdvisoryCommittee(TAC)
NationalFireProtectionAssociation(NFPA)
AviationLaws
ChiefInspectorofBoilers(CIB)
OilIndustrySafetyDirectorate(OISD)
FoodandDrugAdministration(FDA)
MinistryofEnvironmentandForest(MoEF)

ExpansionPhilosophy

Withintheunit
AdditionalUnits
Nearfutureexpansion
Farfutureexpansion

PointstoNote

NormallyConstructionispermittedonmaximum50%oftheplotarea
withtotalbuiltupareaequaltoareaoftheplot(i.e.F.S.I.=1(Depending
upontheregulationgoverningtheareaandthetypeofindustry))
Areareservedfortreeplantationshallbe1/3oftheareaoccupied.

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4/26/2017 ConsiderationsfordevelopmentofPlantLayout:AbriefpresentationWhatisPiping

Waterstoragecapacity24hr.minimum.
Domesticwater100litresperpersonperday
WaterrequirementforBoilerSteamratingxWorkingfactor
Coolingtower11/4%ofcapacityasdriftandblowdownlosses
Washing10-15litresperdaypersq.ft.offloorareaoftheplant
Gardening5litresperdaypersq.ft.ofgardenarea
Parkingspace10%oftheplotarea

Roads&Paving

Roadsintheplantshallbeplannedforeffectivemovementofthetrucks,
cranes&emergencyvehiclesetc.Roadwidth(Blacktop)shallbe
generallyasfollowsunlessspeciallyrequested.
Mainplantroad&roadsconnectingtoPlantboundaries,roadsforfire
fightingaccessis6meterswide(Min)
Secondaryroads4meterswide(Min)
Turningradiusoftheroadshallbeadequateforthemobileequipment
&shallclearofanyobstruction.Minimumturningradiustobesameas
thelengthofvehicle.
Thefinishofroadi.e.gradedorblacktopshallbedecidedinthe
beginningwhiledevelopingplotlayout.
Pavingshouldbeprovidedaroundtheequipmentswherespillageis
likelyoccurring.Forexample:Pumpsormachineries,belowfurnaceor
fireheaters,compressoretc.
AlsopavingshouldbeprovidedbelowAirfincoolerthosearelocatedat
grade.
Areahandlingacids,alkalisortoxicmaterialshallbepavedandbunded.
Propersurfacetreatmentshallbeprovidedtopavingtomeetservice
requirement.

Thebelowsketch(Fig.1)showsminimumdistancerequiredbetweentheroad
andthefacility.Thisdistanceshallbereviewedtocasetocasebasisforthe
project.

(http://www.whatispiping.com/wp-content/uploads/2014/11/Minimum-
distance-required-between-the-road-and-the-facility.jpg)
Fig.1:Minimumdistancerequiredbetweentheroadandthefacility

Elevations

Belowdatafortheelevationsshouldbegenerallyfollowed.

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4/26/2017 ConsiderationsfordevelopmentofPlantLayout:AbriefpresentationWhatisPiping

UndersidethebaseplateofStructuralsteel:Min150mm.aboveHPof
finishedgrade/paving.
Stairorladderpads:Min75mm.aboveHPoffinishedgrade/paving.
TopofPedestalofVessel&Tower:Min300mm.aboveHPoffinished
grade/paving.
TopofPumppedestal:Min200mm.aboveHPoffinishedgrade/paving.

Insulation&FireProofing

Fireproofingrequirementsforpiperack,vesselsupports,process
structureshouldbeconsideredasthesereducestheclearanceswith
access,pipework,instrument&electricalequipment.
Properinsulationthicknessshouldbeconsideredforpipework&
equipmentclearances.

Equipmentlocations

Pumps:LocatepumpsclosetosuctionsourceconsideringNPSH
requirement.Pumps&driveraxisshouldbelocatedperpendicularto
piperackorotherequipmenttominimizefireexposureincaseofpump
sealfailure.
GascompressororExpanders:Gascompressorsshouldbelocated
downwindofthefiredheaters,flareoranyopenflameequipment.They
maybegroupedtogetherformaintenance&operations(CommonEOT
/dropdownarea,singlesunshadecanbemade)
PlantAir&Instrumentaircompressors:Plantair&instrumentairisvital
servicefortheplant.Theseunitsshouldbelocatednearthecontrol
room&shallbekeptinsafeareasufficientlyawayfromHACof
equipment.
HeatExchangers:Heatexchangersaregenerallyplacedongradeunless
otherwiseduetoprocessortechnicalreasons.(Platformforverticalheat
exchangers,Tubebundleremovalarea,accesstomobilecraneor
monorailwithhoistshallbeconsidered)
Aircooler:Aircoolerlocatedsuchawaytoallowtheaccesstomobile
liftingequipment.Preferablyaircoolerislocatedinamainequipment
rowinaccordancewithprocessrequirement.
CoolingTowers:Coolingtowersshallbelocatedawayfromtheprocess
equipment&downwindofprocessequipment,substation,mainpipe
rack.
OffsiteTanks:Storagetanks(Groupedandshallbesurroundedbydike
wall,Primary/secondaryroadsforadequatefirefightingaccessibility,
Lowerelevationsthantheotheroccupanciesanddownwindofflares,
furnaceheaters).Emergencyshutdownvalve,pumps,manifold&
transferpipingshallbeoutsidedikearea.

Pipeways/Piperacks

Pipewaysorpiperacksshouldbeoverheadinprocessmainunitandat
gradeinoffsite.
Widthisdeterminedbasedonpresentneed+10%atoutsetthejob+
15%forfuturerequirementorasspecifiedbyclient.
Requirementofexpansionbays,anchorbays&bracingshallbechecked
withstress/structuralengineeratthebeginningoftheracklayout.

ReliefvalveandFlaresystems

Closedreliefvalvesystem

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4/26/2017 ConsiderationsfordevelopmentofPlantLayout:AbriefpresentationWhatisPiping

Self-draining
Nopockettoavoidcondensation&backpressure.
Flareshallbelocatedupwindprocessunit&storage.

ClearanceatPigReceiver

AreaattheendclosureofReceivershallbekeptfreetoavoidany
incident.
Provideconcretewallminimum20meteraway(Fig.2)fromtheend
closureifareaneedstobeutilizedforanyequipment.

(http://www.whatispiping.com/wp-content/uploads/2014/11/Clearance-at-Pig-
Launcher.jpg)
Fig.2:ClearanceatPigLauncher

Personalprotection

Eyewashandemergencyshowersshallbeprovidedinareawhere
operatorsaresubjecttohazardousspraysorspills.
Breathingairstationsinthefacilitieshandlingextremelytoxicgases/
fluids.

Fig.3showsatypicalplantlayout.

(http://www.whatispiping.com/wp-content/uploads/2014/11/Typical-plant-
layout.jpg)
Fig.3:Typicalplantlayout

WhatisHazardClassification?

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4/26/2017 ConsiderationsfordevelopmentofPlantLayout:AbriefpresentationWhatisPiping

Hazardousareaclassificationistherisklocatingplanforeach
unit/facilitywithintheplotboundaryforaprocessindustry.
ThePlotplanwillbeusedbyindicatingboundariesofriskarea.
HACdrawingsaregenerallyusedbyoperatorwhileissuingwork
permits.

HACStandard

HAZARDOUSAREA:Anareainwhichanexplosivegasatmosphereis
present,ormaybeexpectedtobepresent,inquantitiessuchasto
requirespecialprecautionsfortheconstruction,installationanduseof
apparatus.
NON-HAZARDOUSAREA:Anareainwhichanexplosivegasatmosphere
isnotexpectedtobepresent,inquantitiessuchastorequirespecial
precautionsfortheconstruction,installationanduseofapparatus.

ProcessRequirement

Properinterconnectionbetweenequipmenttoachieveintendedprocess
parameters.
Normallyequipmentisarrangedintheprocessfluidflowsequence.
Requirementlikegravityflow(EquipmentDrainpiping),Thermosyphon
systemshouldbeconsidered,Limitationofpressure&temperature
(processparameters)tobeconsidered
Requirementofupstreamanddownstreampipelengthsfor
instruments.
Hazardous&Toxicfluidshallbeidentified.(H2S,Cyanide,Methanoletc.)
Equipmenthandlinghazardousfluidslikeflareanddirectfired
equipmentcontainingopenflameshallbelocatedseparately.
Similarlyequipmenthandlingtoxicmaterialshallbelocatedwiththe
restrictedaccessorinaccordancewithlocalstatutoryregulation.

EconomicConsiderations

Equipmentshallbelocatedwithoutaffectingtheprocessrequirement
formaximumeconomyofpipework&supportingsteelwithconsistent
standardclearances,construction,andmaintenance&safety
requirements.
Runsofexoticmaterial&largeborepipingshallbeminimized.
Optimumutilizationofthestructuretobeensured.

Erection&Construction

Roadaccessforerectionofpipesupport/pipesandequipment.
Clearareaforcranetoerectequipmentonthelocationfromthetrucks.
Minimumonesideofpiperackshallbekeptclear.

Fig.4showsrelativelocationsforareaLayout.

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4/26/2017 ConsiderationsfordevelopmentofPlantLayout:AbriefpresentationWhatisPiping

(http://www.whatispiping.com/wp-content/uploads/2014/11/Relative-
locations-for-area-Layout..jpg)
Fig.4:RelativelocationsforareaLayout.

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