2015 Herv Baron

HERVE BARON

Engineering Training

Welcome to this presentation.

It is part of a suite of Engineering training modules.

It shows the activities and deliverables of the Plant Layout discipline.

Comments are most welcome (herve.baron@gmail.com), which I will incorporate for the benefit of all.

Please download this file so that you can see my trainers notes in the top left corner latest Acrobat Pro feature.

Herv

2015 Herv Baron

HERVE BARON

Engineering disciplines: activities and deliverables

PROCESS

PLANT LAYOUT

EQUIPMENT

SAFETY & ENVIRONMENT

CIVIL

PIPING

PIPELINE

INSTRUMENTATION

ELECTRICAL

2015 Herv Baron

HERVE BARON

Piping discipline

Plant Layout & Piping discipline

Plant Layout Piping installation Piping

materials Piping stress

analysis

2015 Herv Baron

HERVE BARON

Plant layout

What has to be considered in the layout of a plant?

PresenterPresentation NotesExternal interfaces: pipelines, utilitiesTraffic of plant personnel: parking etc.Prevailing windAccess / Exit

2015 Herv Baron

HERVE BARON

Layout/principles

From which direction comes the prevailing wind?

PresenterPresentation NotesFrom North West

2015 Herv Baron

HERVE BARON

Layout/principles

The wind rose shows the frequency of winds blowing from particular directions. The length of each "spoke" around the circle is related to the frequency that the wind blows from a particular direction per unit time, emanating from zero at the center to increasing frequencies at the outer circles.

2015 Herv Baron

HERVE BARON

Plant layout

The first step of Plant layout is to divide the Plant area into separate blocks and units. Why is this done? How?

PresenterPresentation Notesto reduce escalation of fire and explosion hazardsit is done by respecting minimum space between units

2015 Herv Baron

HERVE BARON

The Block Flow Diagram (BFD)

2015 Herv Baron

HERVE BARON

Plant layout

Minimum distances between Process Units are determined according to GE GAP 2.5.2/2A Classify Units in terms of Fire and

Explosion Hazard into 3 categories:

Moderate Hazard (MH) Intermediate Hazard (IH) High Hazard (HH)

Apply the following minimum distances

between units of various hazard category:

2015 Herv Baron

HERVE BARON

Plant layout

The first step of Plant layout is to divide the Plant area into separate blocks and units. The second step of Plant layout is to locate Equipment within each unit. Which document are used as starting points by Plant Layout?

PresenterPresentation NotesThe PFD and the Equipment list

2015 Herv Baron

HERVE BARON

Plot Plan

PresenterPresentation NotesFunctional sub-systems are identified on the PFD

2015 Herv Baron

HERVE BARON

Plant layout

What else shall be taken into account to locate equipment?

PresenterPresentation NotesAlloy and heavy wall piping whose runs length shall be minimized and minimum safety distances between equipment

2015 Herv Baron

HERVE BARON

Layout Requirements from Process

REFLUX CONDENSER

REFLUX ACCUMULATOR

REFLUX PUMP

COLUMN

What shall be the respective elevation of these equipment?

PresenterPresentation NotesReflux condenser above reflux accumulator above reflux pump. No other constraint (except no pocket in overhead line).

2015 Herv Baron

HERVE BARON

Layout Requirements from Process

REFLUX CONDENSER

REFLUX ACCUMULATOR

REFLUX PUMP

COLUMN

What shall be the respective elevation of these equipment?

PresenterPresentation NotesReflux condenser above reflux accumulator above reflux pump. No other constraint (except no pocket in overhead line).

2015 Herv Baron

HERVE BARON

On-shore plant: Equipment spacing recommendations as per GE GAP Guidelines .2.5.2

Clear horizontal distance, in meters, between adjacent edges of equipment

PresenterPresentation NotesGE GAP: GE Asset Protection GuidelinesTable does not apply to equipment in similar service, e.g. pump and spare./ means provide spacing based on access for operation and maintenance

2015 Herv Baron

HERVE BARON

Layout Requirements from Process

What shall be the respective elevation of the column and reboiler?

REBOILER

COLUMN

PresenterPresentation NotesIt depends on process requirements: refer to PDS

2015 Herv Baron

HERVE BARON

Layout Requirements from Process

REBOILER

COLUMN

PresenterPresentation NotesIt depends on process requirements: refer to PDS

2015 Herv Baron

HERVE BARON

Layout/principles Accesses

2015 Herv Baron

HERVE BARON

Layout principles: provision for piping flexibility

2015 Herv Baron

HERVE BARON

Layout principles: typical Unit Layout

PresenterPresentation NotesThe Equipment are arranged along a backbone = piperack. Connecting pipes run on the pipe-rack.This grade-mounted horizontal equipment arrangement is suitable when there enough real estate for the Plant. The advantage is ease of access for operation and maintenance as well as safety. The disadvantage is high real estate use and long runs of pipes, cables etc.

2015 Herv Baron

HERVE BARON

Structured-mounted vertical vs grade-mounted horizontal Equipment arrangement

PresenterPresentation NotesAn alternative if the structured-mounted vertical equipment arrangement where equipment are stacked on each other, on a multilevel steel or concrete structure. The advantage is less use of plant area, suitable for housing as required by environmental or process conditions. The disadvantage is less convenient access/egress for operating personnel as well as for maintenance (monorails, drop zones to grade lay down area have to be provided) and less easy, i.e., longer construction.

2015 Herv Baron

HERVE BARON

Layout principles: typical Unit Layout

PresenterPresentation NotesThe Equipment are arranged along a backbone = piperack. Connecting pipes run on the pipe-rack.

2015 Herv Baron

HERVE BARON

Unit Layout

What type of equipment has a large impact on the layout?

PresenterPresentation NotesAir coolers their size must be estimated with the greatest possible accuracy

2015 Herv Baron

HERVE BARON

Layout / Equipment size by vendors

14 meters

8 meters

Duty spec

Waste Heat

Boiler

PresenterPresentation Notesfor the same duty one vendor comes up with a 8 meter long equipment, another with a 14 meters long!

2015 Herv Baron

HERVE BARON

Layout / package arrangement

PresenterPresentation NotesDimensions from Vendors are specially important for packages, that involve auxiliaries etc.

2015 Herv Baron

HERVE BARON

Layout principles: pipe routing

There are 2 ways to run pipes. Name them.

2015 Herv Baron

HERVE BARON

Layout principles: typical Unit Layout

B/L(Battery limit)

C/L of Road

R

Min. 7.5 m

PresenterPresentation NotesThe Equipment are arranged along a backbone = piperack. Connecting pipes run on the pipe-rack.

2015 Herv Baron

HERVE BARON

Layout principles: typical Unit Layout

What is the purpose of leaving 3 meters distance between the 2 vessels??

PresenterPresentation NotesThe Equipment are arranged along a backbone = piperack. Connecting pipes run on the pipe-rack.

2015 Herv Baron

HERVE BARON

Layout principles: typical Unit Layout

PresenterPresentation NotesThe Equipment are arranged along a backbone = piperack. Connecting pipes run on the pipe-rack.

2015 Herv Baron

HERVE BARON

Layout principles: typical Arrangement of Air-coolers

PresenterPresentation NotesThe Equipment are arranged along a backbone = piperack. Connecting pipes run on the pipe-rack.Access are provided to:motor, fan and bearing for maintenance: motors are dismantled and dropped on a four-wheel trolley at service platform level then brought up to a dvait from service platform to grade.Both headers for cleaning and instrument access

2015 Herv Baron

HERVE BARON

Plant Layout Job specification for design / Plant layout guidelines

Site elevation (s)

Minimum distances between units, equipment, buildings: applicable code + supplementary information

Clearance around equipment

Road width, clearance

Headroom clearance

B/L(Battery limit)

C/L of Road

R

Min. 7.5 m

A

Line Up C/L of Equipment

Pipe Rack of Structure

Min. 3 m

2015 Herv Baron

HERVE BARON

Interfaces between Engineering disciplines Plot Plan

Plot Plan

Process design & simulations

Process eqt specs

Process Flow diagrams

Process eqt sizing

Eqt sizing by vendors

Equipment dimensions

Piping routing

Fire water network routing

Electrical distribution & cable routing

Instrument JB & cable routing

Sewage sizing & layout

2015 Herv Baron

HERVE BARON

Overall Site plan

PresenterPresentation NotesDefines the location of a complex and of its environment 1:5000 scale

2015 Herv Baron

HERVE BARON

General plot plan

PresenterPresentation NotesShows the entire Plant and the arrangement of the various units (process, utility), storage facilities, buildings and other facilities 1:1000 scale

2015 Herv Baron

HERVE BARON

Unit plot plan

PresenterPresentation NotesShows location of equipment, pipe-racks, structures, with co-ordinates and elevation 1:200 scale

2015 Herv Baron

HERVE BARON

Unit plot plan Elevation view

2015 Herv Baron

HERVE BARON

Unit plot plan Plan view

PresenterPresentation NotesShows location of equipment, pipe-racks, structures, with co-ordinates and elevation

2015 Herv Baron

HERVE BARON

3D modelling

2015 Herv Baron

HERVE BARON

3D model clash check

2015 Herv Baron

HERVE BARON

3D model review

3 model reviews are usually done

2015 Herv Baron

HERVE BARON

3D model review

3 model reviews are usually done:

What is the scope of the first model review?

2015 Herv Baron

HERVE BARON

First model review: Scope: finalize the Plot Plan Content: Equipment + 30% of piping is modelled, i.e. all ines on PFDs Outcome: after incorporation of COMPANYs comments, the Plot plan is released as the base for the design (IFD). Aspects reviewed: Unit location, equipment location, main access and escape routes to facilities, major piping routes indicated on PFDs, arrangement around LLI, location of main manifolds, space around equipment for maintenance, platforms for main operation access

3D model review

2015 Herv Baron

HERVE BARON

30% model review

2015 Herv Baron

HERVE BARON

Air-Cooled Heat Exchangers In which case would you install the ACHE at grade vs on pipe-rack?

PresenterPresentation NotesInstall on pipe-rack when you lack real estate

2015 Herv Baron

HERVE BARON

Air-Cooled Heat Exchangers In the case of installation on top of pipe-rack, what extra access shall be provided?

PresenterPresentation NotesService platform for maintenance of motor, fan and bearing motors are dismantled and dropped on a four-wheel trolley at service platform level then brought up to a dvait from service platform to grade.

2015 Herv Baron

HERVE BARON

Plot Plan review Hands-on exercise

Please review and comment the Plot Plan

PresenterPresentation NotesComment: off-spec tanks located upwind of furnaces: to be relocated

2015 Herv Baron

HERVE BARON

Piping Layout Modular plants

In which cases is a modular plant preferable vs a stick built?

PresenterPresentation NotesConstruction not easy of costly (extreme wetaher: Siberia, Canada, remote area, high labour cost)Revamping: to minimize SIMPOS

2015 Herv Baron

HERVE BARON

Design development

This is the Plot at FEED stage. Which parts of it do you expect will change at EPC stage?

2015 Herv Baron

HERVE BARON

Incinerator Package

Design development

FEED stage EPC Stage

2015 Herv Baron

HERVE BARON

Combustion Air blowers + heater

Plant layout evolution

FEED EPC - IFD EPC - IFC

2015 Herv Baron

HERVE BARON

The Oil & Gas Engineering Guide 2nd edition

Do you want to know more... Much more?

2015 Herv Baron

HERVE BARON

The Oil & Gas Engineering Guide - 2nd edition

Table of Contents

2015 Herv Baron

HERVE BARON

The Oil & Gas Engineering Guide 2nd edition

Order direct from the publisher:

http://www.editionstechnip.com/en/catalogue-detail/1111/oil-gas-engineering-guide-the.html

Engineering TrainingEngineering disciplines: activities and deliverables Piping disciplineSlide Number 4Layout/principlesLayout/principlesSlide Number 7The Block Flow Diagram (BFD)Slide Number 9Slide Number 10Plot PlanPlant layoutLayoutRequirements from ProcessLayoutRequirements from ProcessOn-shore plant: Equipment spacing recommendations as per GE GAP Guidelines .2.5.2LayoutRequirements from ProcessLayoutRequirements from ProcessLayout/principlesAccessesLayout principles: provision for piping flexibilityLayout principles: typical Unit LayoutStructured-mounted vertical vs grade-mounted horizontalEquipment arrangementLayout principles: typical Unit LayoutUnit LayoutLayout / Equipment size by vendorsLayout / package arrangementLayout principles: pipe routingLayout principles: typical Unit LayoutLayout principles: typical Unit LayoutLayout principles: typical Unit LayoutLayout principles: typical Arrangement of Air-coolersPlant LayoutJob specification for design / Plant layout guidelinesInterfaces between Engineering disciplinesPlot PlanOverall Site planGeneral plot planUnit plot planUnit plot planElevation viewUnit plot planPlan viewSlide Number 383D model clash check3D model review3D model review3D model review30% model reviewAir-Cooled Heat ExchangersAir-Cooled Heat ExchangersPlot Plan reviewHands-on exercisePiping LayoutModular plantsDesign developmentDesign developmentPlant layout evolutionThe Oil & Gas Engineering Guide2nd editionThe Oil & Gas Engineering Guide - 2nd editionThe Oil & Gas Engineering Guide2nd edition