Guidelines for Facility Siting & Layout

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G U I E L I N E S F O R

FACILITY SITING

AND LAYOUT


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Thisbook is one of aseriesof publications

available from

the

Center

for

Chemical ProcessSafety.

A complete

catalog

ofavailabletitlescan be found

on the

AIChEweb

site,www.aiche.org.


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G U I D E L I N E S F O R

FACILITY SITING

AND LAYOUT

CENTER FOR

CHEMICAL

PROCESS

SAFETY

V

An lChE

Industry

Technology Alliance

Center

for Chemical Process Safety

of

the

AmericanInstitute

ofChemicalEngineers

3

ParkAvenue,N ewYork, NewYork

10016-5991

W1LEY

INTERSCIENCE


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Copyright 2003

AmericanInstituteofChemicalEngineers

3 ParkAvenue

New

York,

NewYork10016-5991

All

rights reserved.

N opart

of

this

publication may be reproduced, stored in a retrieval

system, or transmitted in any form or by any means, electronic, mechanical, photocopying,

recording,or otherwise without the prior permission of the copyrightowner.

AlChE and

CCPS are

trademarks

owned by the

AmericanInstitute

of

Chemical

Engineers. These

trademarksmay not be used without the prior express written consent of theAmerican

Instituteof

Chemical

Engineers. The use ofthisproduct inwholeor inpartfor commercial

use is prohibited without prior express written consent of theAmericanInstituteof Chemical

Engineers.Toobtain appropriate license and permission for

such

use contact Scott Berger,

212-591-7237,[email protected].

CCPSPublicationNumberG 84

Library

of Congress Cataloging in Publication Data:

Guidelines forfacilitysiting and layout /

Th e

Center for Chemical Process

Safety,

p. cm.

Includes bibliographical references and index.

ISBN0-8169-0899-0

Hardcover)

1. Chemical plants Design and construction. 2. Chemical

industry Safety measures.

1.

American

Institute

of Chemical Engineers.

Center for Chemical Process Safety.

TP155.5.G7662003

660 dc22 2003015938

II is sincerely hoped that the Information presented in this volume will lead toan even mo re impressive

safety record for the entire industry. However, the American Institute of Chemical Engineers, its

consultants, CCPS Subcommittee mem bers, their employers, and their employers officers and d irectors

and Baker Engineering and Risk Consultants Cheryl A. Grounds and JosephR.Natale disclaim makingor

giving any warrantiesorrepresentations, exp ressor implied, including with respect to fitness, intended

purpose, use or merchantability, and/or correctness

or

accuracy

of

the content

of

the inform ation

presented in this document. As between (1) American institute of Chemical Engineers, its consultants,

CCPS Subcomm ittee m embers, their employers, and their emp loyers officers and directors and B aker

Engineering and Risk Consultants Cheryl A. Grounds and JosephR.Natale (2) the userofthis do cument

accepts any leg al liability

or

responsibility whatso ever

for

the consequences of its use

or

misuse.

This

book is available at a special discount when ordered in

bulk quantities. For information, contact the Center for

ChemicalProcess Safety at the address shown above.

PRINTED N THE

UNITED

STATES

OF

AMERICA

10 9 8
mailto:[email protected]:[email protected]


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ents

Preface

ix

Acknowledgments xi

1

INTRODUCTION

1.1. Objec tives 1

1.2. How

To

Use This Book 2

1.3. Layers of Safety 4

1.4. References 6

2

M N GEMENT OVERVIEW

2 1 Implications of Siting and Layout 7

2.2. Management of Risks 8

2.3. Basis for Facility Siting and Layout 8

2.4. ChangingWorld 10

3

PREP RING FOR THE SITE SELECTION PROCESS

3 1 Project Description 14

3.2. Assembling a Site Selection Team 16

3.3. Prel iminary Site Size Determination 19

3.4. Preliminary Hazard Screening 20

3.5. Guidelines for the Survey andDataCollection Effort 26

3.6. Environmental Control

Issues

29

V


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vi

Contents

4

SITE SURVEY AND SELECTION

4 . 1 . Information Required to Se lect a Site 33

4 . 2 .

Transportation

Issues

39

4 . 3 .

Utilities 44

4.4. Electrical and Communications Systems 47

4.5. Environmental Controls 49

4.6. Fire , Safety, and Security 51

4.7. Site

Features

53

4.8. Multi-Chapter Example 55

5

SITE AND PLANT LAYOUT

5 . 1 .

General 64

5.2. The Site 66

5.3. Block Layout

Methodology

71

5.4. Spacing Tables 72

5.5. Utilities 74

5.6. Electrical and Control Facilities 80

5.7. Process 82

5.8. Outside Battery Limits

( O S B L )

85

5.9. Tank Storage 92

5.10. Occupied and CriticalStructures 94

5 . 1 1 . Multi-Chapter Example 97

6

EQUIPMENT LAYOUT AND SPACING

6 . 1 . Spacing Tables 101

6.2. General 103

6.3. Single-andMultilevelStructures 104

6.4. Enclosed Process Units 105

6.5. Layout and Spacing to Minimize

VaporCloud Explosion Effects 105


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Contents vii

6.6.

RelativeLocation

of Equipment 106

6.7. Equipment withA i rIntakes 107

6.8. Equipment-to-Equipment Separation Distances 108

6.9. Multi-Chapter Exampl e 116

7

OPTIMIZE

THE

L YOUT

7 . 1 . Layout MethodReview

7 . 2 . Layout

Issues

Resolution

7.3. The Right

Answer

8

C SE HISTORIES 127

PPENDIXA.TYPIC L SP CING T BLES 139

PPENDIX

B.

SITE SELECTION D T REQUIREMENT LIST 151

REFERENCES 179

GLOSS RY 183

INDEX 191

121

123

125


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ce

TheCenter for Chemical Process Safety

CCPS)

The Center for ChemicalPro

cess Safety CCPS) was established in 1985 by the American

Institute

of

Chemical Engineers for the express purpose of assisting

industry

in avoiding

or

mitigating catastrophic chemical accidents. To achieve

this

goal, CCPS

has focused its work on four areas:

Establishing and publishing the latest scientific, engineering and

management practices for prevention and mitigation of incidents

involving toxic,

flammable, and/or reactive materials

Encouraging the use ofsuch information by dissemination through

publications, seminars, symposia, and continuing education pro

grams for engineers

Advancing thestateof the art in engineering practices and technical

management through research in prevention and mitigation of

cata

strophic events

Developing

and encouraging the use of

undergraduate

engineering

curricula

that

will

improve

the safety

knowledge

and consciousness

of

engineers

This

book outlines a process for finding an optimal location for a chemi

cal or petroleum processing site and

then

arranging the units and equip

ment. It provides comprehensive guidelines on how to select a site, how to

recognizeand assess long-term risks, and how to lay out the facilities and

equipment withinthatsite. A survey guide is provided to aid site selection

teams in obtaining necessarydatato select a new site. Site layout and equip

ment spacing guidelines are provided based on historical and

current data

including industry practices and standards. Spacing tables are provided

which can be used as a

starting

point in laying out a site. Case histories and

examples are included to illustrate both the appropriate manner in which to

addressfacilitysiting and layout as

well

as the consequences when the effort

is inadequate.

ix


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owledgments

The American

Institute

of Chemical Engineers and the Center for Chemical

Process Safety express their gratitude to all the members of the Facility

Siting and Layout Subcommittee for their generous

efforts

and valuable

technical contributions in the preparation ofthisGuidelines book.

Chairs:

Ephraim

A .

Scheier BPAmerica,Inc.

Frank

Worley,

II I

Rohm

Haas

Company

Authors:

Cheryl

A.

Grounds Baker

EngineeringandRisk

Consultants

Joseph R. Natale BakerEngineering

and

Risk

Consultants

CCPS

Staff Consultant:

John

A .

Davenport

SubcommitteeMembers:

John

A .Alderman

Richard L. Alexander, Jr.

MichaelR Broadribb

Chris R. Buchwald

Christopher R

Devlin

Brian R. Dunbobbin

Rodger

Ewbank

William

Hague

Andrew

R Hart

John

Marshall

MichaelD.Moosemiller

Henry Ozog

RRS

Engineering

formerlywithSolutia

BP

America

ExxonMobil

Celanese

ChemicalsDivision

AirProducts Chemicals

Rhodia

HoneywellSpecialtyChemicals

NovaChemicals

Dow

Chemical

formerlywithD etNorskeVeritas DNV)

ioMosaic Corporation

xi


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xii

Acknowledgments

Vanessa

Rodriguez

USEnvironmentalProtection

Agency

JohnR Sharland FM Global

William

E.

Thornberg

formerly

with GE

Global

Asset

ProtectionServices

Tracy Whipple

formerlywithDet

Norske Veritas

DNV)

Before

publication, all

CCPS

books are subjected to a through peer

review

process. CCPSalso gratefully acknowledges the thoughtful comments and

suggestions of the peer reviewers.

Don

Connolley

Akzo

Nobel

Chemicals

Inc.

KieranJ. Clynn

BritishPetroleum

Hal

Johnson

ConocoPhillips

Neal

WJohnson ConocoPhillips

Neil

Macnaughton

BritishPetroleum

Jack

McCavit

Celanese

LisaMorrison

NOVA

Chemicals,Inc.

TimOverton

DowChemicalCompany

PhilPartridge

Dow

ChemicalCompany

JanetL. Rose

BayerPolymersLLC

Scott Schiller

ConocoPhillips

OrvUleM.Slye,Jr., PE

Loss

ControlAssociates

Anthony Thompson

MonsantoCompany

Jan Windhorst

Nova

Chemicals,Inc.

JeffYuill

StarrTechnical

Risks

Agency,

Inc

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