10/2 PLANT SITING AND LAYOUT 10.1 Plant Siting Salety is a prime consideration in plant siting. Other ‘important factors include: access to raw materials and to sarkets, avalabiity of land, labour and. cooling water reans of eluent disposal iateinking with other plants find government poiice, incudiag planning permission ‘nd investment incentives. ILis only safely aspects which fate considered ete, ‘As far as safety of the public is concerned, the most Important feature of siting is the distance between the site and buillup areas, Stes range {fom rural to urban, te population densities varying trom virtually zero to "Separation between a hazard and the public 1 Dbenedcial in mitigating the eects of a major accident ‘An area of low population density around the site wil help to reduce casualties. In the ideal case the works is surrounded by fields or waste land forming a complete ‘cordon sanitaire. Tn many siations, however, i ‘unattractive fo ‘serie’ large amount of land in this vay, particularly in an urban area, where. land is senerally at a premiun, “The physical eifects of a major accident tend to decay quite rapidly with distance. Models for fre give an Inverse ‘square law decay, as do many of the simpler rodels for explosion and foxic release, though other fexplosion and toxic release models give dierent decay fedatons, some with Tess rapid decay. Decay laws were Aiseusted in Chapter 9 and further Weatments are given tn Chapters 15-17 Information on the potential effets of a major accident on the surrounding ‘area is one of the main results ‘obtained from a hazard assessment and such an fassessmeat is of assistance in making ‘decisions on lant sting. Shing is aot a substitute for high standards of design and operation of the plant. I should never be forgotten ‘hat the people most at risk are the people on site, and standards should be such as to safeguard this workforce. 1s sometimes argued in fact that standards should be suficietly high thet separation between site and public Js not necessary. Such standards, however, are essen- ually a form of tetive protection, which depends ervelally fon, the qualiy” of management, In “most counties, Including the UK. the view is taken that it is prudent nevertheless. to have “a degree of separation. The provision of a separation distance is a form of passive protection which provides a further mitigating factor and ‘which i relatively robust nthe event of deterioration sn the plant management In terms of hazard warning, separation tends to create hazard, which wil give more warnings abd which i ‘hereore less unforgiving “Topography is another relevant feature, Mis desirable to. avoid terrain where hazardous fide, whether liquids or dense gases, can flow down into Dopulated areas. Another consideration to be taken into account is contamination of water courses by liquid Sls: In selcting a site, allowance should be made for ste emergencies One factor is the avalabliy of emergency ltliies such ay electrical power and water. Another i the availability and experience of outside emergency services, particularly the fire service. Ard is access for these services Table 10.1 Selected references on plant sting NRC (Appendix 26 Shing); Cremer G945), Moiman (4850); Blewert and Krone (1955); Greeabut 1986); von Allmen (1960); ].A Gray (960); Anon. (19640); Risinger (0964); Liston (1965) Fryer (1965); Farmer (9672, 1969a,));R Reed (1957); Fowler and Spiegelman (1968) Kaltenecker 1968); GD. Bell (1970); Otway and Erdmann (1970): Spir (1870): Tucker and Cline (1970); Yocom, Colins and Bowne (1971); Gronow and Gausdea (0975); Balemans etal. (187i); Cross and Simons (1575); Roskil (1976); Welsmantel (1977) Cremer and Warner (4978); Slater (1878); Dalal 4980); Klets (19804: Granger (1881) Coasidine, Grint and Holden (1982) Lovett Swiggett and Cobb (1882) Ramsay, Sylvester vans and English (1982); Landphairand Motioch (1985) A discussion of sting for high toxic hazard materials GHTHM:) is given in the “CPS HTHM Storage Guidelines 1988/2). Sting policy for major hazard plate im the UK was diecussed in Chapter 4 Selected feferences on plant siting are given in Table 101 102 Plant Layout Plant layout is a crucial ctor in the econ salety of process plant. Some of the ways i Iayout contributes to safety and loss prevention are mics and plant (0) segregation of diferent risks; (@) minimization of vulnerable pipework ©) eftcien (6). edicient and sate operation ()elicient and sale maintenance; (@) fale control room design (©). emergency contro facies; (Go) fire ghting faces; GU) access for emergency services; (02) security. Plant layout can have a large impact on plant economics. Aliitional space. tends. to increase. safely but is expeasive in terms of land and also in addtional pipework and operating costs. Space needs to. be provided where tis necessary for safety, but not wasted ‘The topics considered under’ the heading of “plant Jayout? are traditenaly rather wide ranging. Many of these eubjects are treated here in separate chaplere and only a brief teatment is given in this one. This applies in paticular to sich topics at hasard_ assessment, emission and dispersion, fire and fre protection, exple- Sion and explosion protection. storage, and emergeacy planning. ‘A general gui to the subject is given in Process Flant Layout Mecklenburg, 1985), Tis is based on the work of an Insitaton of Chemical Engineers (ChemE) work- lng party and expands an earlier guide Plan? Layout (lecklenburgh, 1973). The treatment of hazard assess sent in particular is much expanded inthis later volume. ‘The loss prevention aspects of plant layout have also been considered specifically by Mecklenburg (876)PLANT SITING AND LAYOUT 10/3 ‘Cremer (1945) Malick and Gaudreau (931), Shubin and Madeheim (1951); Muther (985, 1961 1873) MeGarry (1958); Armistead (1959) Reed (1961, 1967); RUA (1962 Document 12, 1973 Handbook 7); 1M Moore (1962); ABCM (1964/3); Dow Chemical Co (G964, 1966, 197, 1980, 1987, 1994); Duggan (1964); Feneti (19640): Landy (642-0): Risinger (864); R ‘Wilson (19646): Eston (1965, 1982): IP (1880 Bur. MCSP PLZ, 1981 MCSP Pt, 1957 SICSP Pt 9, 1990 MCSP PL 15); R Ker (1965, 1977 series, 1978)" MW. Kellore Co. 496i); BCISC (1968/7); Fowier and Spiegelman (4968); Katenecker (1968); House 1850) Proctor (0968); Bash Cryogenics Council (1970); 1. Hughes (0970); IC1/RoSPA (1970 18/71); Kaess (1970); Sac (G97; Tucker and Cline (1970; Bash and Wells (197 1872); Simpson (1971): Gill (1972); Mecklenburgh (0973, 1976, 1982, 1989); Pemberton (87H); RB. Robertson (974ab, 1975a}); Unwin, Robins and Page (0970); Falconer and Drury (1975); Beddows (1976) Harvey (1975, 1979); Spitago (1978): Rigby (197?) aura (19808): Klete (880, 19876); FV Anderson (0882); O'Shea (1882); Goodieliow and Berry (1985); Brandt e al. 1992); Meissner and Shelton (1992) Bausbacher and Hust (1993); Madden (199); Briggs (0994) ANST A, AIO, A37 and D series, BS 5930: 1981 Layout techniques ‘Mecilenburgh (1573, 1876, 1985); Sprocsser (1881); Nolan and Bradley (1987); Madden, Pulford and Shadbolt (4990); Madden (195). Virtual reality: IEE (1992 College Digest 92/98) Civil engineering, including foundations ASCE (Appendix 27, 28); Urquhart (1989); Biggs (1964); ASTM (1967); MacNesh (1968), Benjamin and Cornell (0970); Tomaisoa (i880); Carmichael (1982); M. Schwartz (882e-c, 19822-e, 1964); Pathak and Rattan (0885); Blenkinsop (1982): BS (Appendix 27 Cie Engineering, Construction), BS S031: 1981, BS 8004: 1985, BSCOP 2010; 1970-, BS COP 2012: 1974, Equipment weights: ELRiti (1979) Hazardous area classification (ee Table 16.2) Materials handling Woodley (1958); Smego (1955); R Reed (1959) Departmeat of Employment and Prodictvity 1970); Brook (871): DTY (974); Pemberton (G87); Sussams (G87; Chemical Engineering (19780) In-works transport, roads HSE (1973 TDN 14); Meckleaburgh (1973, 1985); HSE {4985 IND (G) 220), 1982 G8 9) jon distances CW. Bradley (a, 1985); Armistead (1959); Dow {Chemical Co. (196, 1965, 1975, 1980, 1987, 1994) Scharle 0965); Home Office (1968/1, 1971/3, 1973/4; ‘Masso and Rudé (1868); Goller (1970): 1. Hughes (0870); ICL/RoSPA (1870 18/74); Laska (1970); Simpson (G97)! OIA (1872 Pubteation 681), HSE (1373 BSW Booklet 30); Mecklenburgh (1973, 1976, 1985); Unwin, Robins and Page (197); Butraueno and Costello (1978); IP (1980 Fu. MCSP Pt 2, 1981 MCSP Pt 3, 1987 MCSP Pro), API (981 Refinery Inspection Guide Chapter 13, 1880 Sid 620, 1983 Si 650); Nolan and Bradley 1887) DJ Lewis (19895); Martinsen, Johnsen and Millsap (0985), NEPA (1989 NEPA OA, SOB, 1992 NFPA 38,50 TRI (198i, 1982); LPGITA (1991- LPG Code) rk 1. Kern (1966); MecKlenburgh (1973, 976, 1985): Clarke (0966 BRE/1) Corrosion Mears (860); ABCM (1984/3) Buildings BRE (Appendix 28,1983 CP2/83, P8/83); Beigler (0985); Crosses and Crowther (1992) BS (Appendix 27 Buildings, CoP Buildings), BS Handbook 201985 Structures and access RUA (1962 Document 12,1973 ‘Mecklenburgh (1973, 1976, 1988) ndbook 9 Floors, ABCM (1964/3): Steinberg (1964); Pierce (185): Friedrich (1974), ASTM (1978 688), EEMUA (1983, Publication 105), Escape and rescue FPA (CFSD FPDG 4); HSE (ISW Booklet 40); ERU (0962 Document 12); Webber and Hallman (1988) Lighting laminating Engineering Society (ad): Electricity Council and Bris Lighting Council (1967); Maxon (G967; Rowe (1979); HSE. (1987 HS(G) 38) BS 5266 1g8i-; UL $44-1990, UL 924-1990, UL 781-1992 Emergency lighting: UL (1990 824) Ventilation (ee Table 25.1) Wind resistance BRE (1872 BR 8, 1975 CP 36/75, $0 8, 1978 cP 25/78, 1885 EP); Simi and Scanlan (1978); ASCE (1980/0, 1985/12, 1987/34, 35) Resistance fo flood, hurricane Fulton (1960): Labine (961); Neil and Bethel 1962); Weismantl (9682); Marlar (1972) Blast resistance (ce Table 1738) Earthquake resistance (se Table A151) Compressor houses DILA Moms (1979) Prestice, Smith and Virtwe (1974) Control rooms Bradford and Culbertson (1967); Burns (1967); Prescott (4967) Schmidt (1971): E. Edwards and Lees (1973) ‘Mecilenburgh (1973, 1976, 1985): Vic. Marshall (1974, 1876); Klee (8%5e); Anon. (976 LPB 11 p. 16)10/4 PLANT SITING AND LAYOUT ‘Gugan (1976); Harvey (1976, 19796); Langeveld (1976); ‘Anon. (1977 LPB 16, p. 24); Balemans and van de Putte (G97H; CIA (979); Cannabce et a 193) Emergency shelters Johnston (968); Lynskey (1985) Indoor plants Kern (1978); Musson (1980) Storage FPA G864/1): IP (1980 Bur, MCSP PL 2, 1981 MCSP Pt 3.1987 MCSP PLS): Home Otfce (2968/1, 1971/2, 1973/ 4), JR Hughes (1970); C1/RoSPA (1970 18/74); HSE. (0973 HSW Booklet 30); Wirth (1975); Heyeek 1978), DW, Johnson and Welker (1978); Aarts and Mortison (G98i); NFPA (986 NFPA 43C, 1989 NFPA SOA. SOB, 1800 NFPA 42A. 50, 58A_ 1982 NFPA 58, 59, 1995 NFPA {3B); LPGITA (1991 LPG Code 1 Pt 1) Fire prevention and protection FPA (CFSD FPDG 2): IRI (1964/5); BCISC (1968/7): P (G90 Eur. MCSP Py 2, 1881 MCSP P13, 987 MCSP 9, 1985 MCSP Pt 19); Home Otice (1971- Manual of Firemanship); LR. Hughes (1870); IC1/RoSPA (1970 18/ 14), Simpson (1970); Meckdenburgh (1973, 1976, 1985); RB Robertson (19743, 1976): Klootwik (1975); Kaura (19802), Chimneys BBS 40761989 Drains ‘ED. Brown and Shannon (19632,8); Seppa (1960); ICE (0968); Mecklenburg (1973, 1975, 1985); Klootwiie (09765); Anon, (1978 LPB 19, p, 10), Bton (1980), Gallagher (1980); . Stephenson (1981); Easterbrook and Gagliardi (98); Mason and Armold (1984); Chieu ‘and Foster (1993); Crawley (1993 LFB 111); BS 8005: iss Earthing, grounding TEBE (962 IEEE 1); UL (1984 UL 457: BS 7430: 1991, Winterisation JC: Davis (1979); Facer and Rich (1984); Fisch (1988) Modular plants Armstrong (1872); Glaser, Kramer and Causey (1979) IMechE (1980); Sats (1860) Bolt and Arzymanow (0982); HR_ James (1982); Marein and Schulte (1982); Parkiasos, Short and Ushio (1982), Zarshon and Hull (0882); Glaser and Kramer (1989): Hulme and La Trobe Bateman (1889); Kiewer (1880); Tan, Kumar and Kullanoff (1984); Whitaker (1984); Tarakad, Durr and Hust (1987); Clement (1889); Hesler (1990); Shelley (4990); Daty, Fisher and Lewis (1995) Barge mounted and ocean-borne plants Birkeland ef al (1979); Charpentier (1979): Glaser, Kramer and Causey (1978); TL. Howard and Andersen (0979; Jackson (1879); Jansson etal (1978); Shimpo (4979); Rice! G88); HR James (1982); de Vilder (1842) Plant identification [NEPA (1990 NFPA S01); APT (1998 RP 1109), BS (Appentix 27 Identification of Equipmend, BS 1710 1964, BS S378: 1980- Hazard assessment ‘Mecklenburg (1982, 1985) Other work on plant layout, and in particular saety and loss prevention (SL), snchides that of Armistead 4959), R Kern G977e-f 1978-0, and Brausbacher and ust (1999) oa genera aspects and spaciag recommes- dations; Simpsoa (871) and RB. Robertson (74a, 18760), on. ite protection) Fowler and Spiegelman (0968), the Manuftcuring Chemists Association (CA, 1970/18), Balemans ef al. 1974) and Drewitt (1975), on checklists: and’ Madden. (2989), o synthesis techniques. Plant layout is one of the principal aspects treated in vatious versions of the Dow Guide by the Dow Chemical {Company (19940). Tee also dealt within the Engineering Design Guidelines of the. Center for Chemical Process Salety (CCPS, 1993/13). There are aso a large number of codes relevant to” plant. layout. and. particularly Separation distances and’ area cassiation. These are described below “The treatment given here for the most part follows that, of Mecklenburg except where otherwise indicated. 1 is appropriate to repeat ere his caution thatthe practice described should be regarded ony as typical nd that it wy need to be modified ia the light of leal conditions, legislation and established sale practices. in particular, the account given generally assumes a ‘greemield’ ste, fand some compromise is normally necessary for an existing ste Selected references on plat layout are sven in Table 102 1043 Layout Generation 10.3.1 Factor layout For lactones generally there are 2 sumber of diferent principles on Which plant layout may be based QMuther, 1961). Thus in Hight engineering use is made of layouts jx which the materia Gabricated.remaine ia a Gxed postion and others. in which @ particular process or function is performed at 2 xed point 103.2 Flow principle For ‘process plants. however, the most_ appropriate ethod is generaly to lay the plant out so that the atrial Now follows the process ow diagram. This is the process Dow priacple: This arrangement minimizes the transler of materials, which is desirable both for economics and safety. Is dificult to overemphasize the {importance of eficient materials handing. It har been estimated by the Department of Tvade and Tndusty (TT, 1974) that about a quarter of the production costs of manufacturing inéustey generally are for materiale handing, an activity which in eet is totally unproduce Likewise, long runs of pipework with vulnerable features are an undesirable sddtion to the hazards of the plant. There are features which can lead to thePLANT SITING AND LAYOUT 10/5 layout sequence diverging ftom the process sequence. ‘They relate paticlarly to: requirement for gravity flow. equipment needing specially strong founatoas, access {or construction, commissioning, operation and minle- ‘nance; future extension: operator protection; escape and fre Sighting, containment of aeldents; and environmental 10.2.8 Corelation and compatbilty ‘There are certain other layout approaches which are used for factory. layouts “generally and which merit renton. Correlation and compatibility techniques. are Used for the elimination of layout arrangements which are incompatible or impossible, and also. for the ‘elininary formblation of compatible arrangements In the correlation chart method, for example, the procedure is 2s follows. The constraints and) objectives are sted. The floor space is subdivided into a grid and for cach item the grid divisions which violate the constraints are deleted, The permissible layouts are thea determined There is a corresponding. algebraic method Proximity and sequencing techsiques are available for the determination of the costs of material wanser with Aifzent layouts ‘These general factory layout techniques are described fn more delal by Meckleaburgh (1973), but he states ‘hat they appear to have found litle’ application in process plant layout 10.3.4 Process plant layout As with design general, the design of a process plant avout involves fst ayaesis and then analysis. Despite As importance, there is relatively [ile written on the generation of the layout. An indication of some of the Principles which guide the designer hae been given by Madden (1993). He describes a suctured approach to the generation of the layout which bas ow sages (I) tnreedimensional model, @) flow, @) relationships and groups. 103.5 Tiwee-dmensional model ‘The first step is to produce a three dimensional (6D) model of the space occupied by each item of equipment ‘This 2D envelope should ince space for (1) operations access, (2) maintenance access, and (6) piping connec Sons: ‘The effect of allowing for these aspects is generally to increase eeverabold the volume of the envelope 10.3.6 Flow ‘The concept of ‘Dow! as used by Madden as two saeanings: (2) progression of materials towards a higher degree of completion, and 2) mass fows of process or Utlty materials Often the two coincide, but where there fi a featre sich at a recycle the relationship is less slraighllorward 103.7 Relationships Arrelationship exists between two items when they share some common factor. Relatonships may be identiied by Considering the plant from the ‘viewpoint of ezch Aisipine in turn, Broad clases of relationship. are () process, @) operations, (@) mechasical, (@) electrical, @) Structural and’ (@) safety. Process relationships are exemplified by: dest flow diagram connectivity’ between ites, gravity Dow, hydra lice and net positive suction head (NPSID requirements and heat iblerchange and. conservation. Operations Felationships ince muliple items ‘with ssilar fea ates, ef batch reactors and centrifuges, Examples of mechanical relationships are the space needed between tems for piping and. transmission or isolation of vibrations. Hlectical relationships may be associated vith electrical area classieation and mith high voltage ‘F power features. Stuctural features include the grou fg together of heavy items and the location of heat lems on good ground, Some safely features are separation between potential leak sources and ignition sources and the provision of a sterile area auch a8 that found a fare 1028 Groups From the relationships identified it is then necessary to select those which are to be given priosity. It is then possible to arrange the iems int groups Tis found by experience that a group size of about seven items isthe largest which a layout designer can realy han; above {his number the arrangement of items within the group Decomes excessively complex. Atypical group is a Aislition column group consisting of the cobsmn felt and its associated eat exchangers, ete 10.3.9 Segregation A relationship of particular importance in plant layout is that between a hazard and_a_ potential Target of that hazard. The minimisation of the risk lo the target #8 lected by segregating the hazard from the target. The fequirement for segregation therefore places constraints oon the Layout 104 Layout Techni ‘There are a auimber of methods avaiable for layout design. These ae generally more applicable (0 the fnalysis rather than the syathesis of layouts, but some hhave elements of both, They include: )classcation rating and ranking: @) crea examination: (@) hazard assessment economic optinszation ‘There ae also various aids, including: ©). visualization aids: (computer aids 8 and Aids 10.443 Classitestion, rating and ranking ‘There ate several methods of clasifcation, rating and ranking which are used in yout design. The muain fechnigues are those used for the classiacation of (1) hazardous areas, (2) storage, G) fre Uighting faces and (0) access aones, together with methods dased on hazard indices Tazardovs area clasifcation is aimed at the exchision of ignition sources trom the vicinity of potential Tele Sources and involves the definition of zones in which Control of gation sources is exercised to. difering degrees Iie described in Section 10.12 and Chapter 16,10/6 PLANT SITING AND LAYOUT Storage classification is based on the classification of ‘the Tguide stored, Accounts are piven in Section 10.10 and Chapter 22 ‘Closely related is classification based om fre fighting requirements, since this is applicable particularly to storage TResrcton of access may be required near maior hazard plants or commercially sensive processes. Areas ae thereiore classiied by the need to control access. ng methods such as those ofthe Dow Index and lex may also be used as a means of growing similar hazards together, 10.42 Chica examination Citic examination, which is part of the techsique of snethod study (Carte, 1960), may be applied to. plant layout. This application has been described by Eliot and (Gwen. 1968). In critical examination of plant layout, ‘ypicel questions asked are: Where is the plant eat sent placed? Why ist placed there? Where else could, 20? "The technique therefore stats with and involves analysis of a. proposed layout, but insolar as other possible solutions are suggested it may be regarded sso as 2 method forthe geieration of alternatives which ‘an then be evaluated ‘As alteady mentioned in Chapter, ei document im an early hazard study ia plant layout diagram, and to this extent such a hazard study may be regarded as form of eritcal examination of layout 10.43 Hazard assessment Hazard assessment of plant layout is practised both in respect of malor hazards which affect the whole ste, and of lesser hazatds, notably leaks, and their escalation’ The ‘waditional method of dealing with the latter has bees the tse of minimum safe separation distances, but there has been an increasing trend to supplement the latter with hazard assessment. An account of hazard assessment it sven. in Chapter 9 and its role in. plant layout is Aiseuseed in Sections 105 and 10.1. 10.4.4 Economie optimization ‘The process of layout development generates alternative candtlale layouts and economic optimization ita Principal method of selection from among these. The points at which such economic optimization is performed fre described in Section 105, Some factors which are of importance forthe ‘cost of a plant. layout. include foundations, structures, piping and pipetracks, and pumps and power consumption, 10.45 Vieualzation aids ‘There are various methods of representing the plant to assist in layout design. These ince drawings. cutouts, Flock models and piping models. Cutouts area two: dimensional (2D) layout aid consisting of sheets of paper, ‘cardboard or plastic which represent item in. plan, Whether whole plots or items of equipment, and. are overlaid on the ste or lot plan, asthe case may be. The bother main physical sids are 3D. Block models are very Simple models made ffom Wood blocks or the lke which show the main items of equipment and are used to Aevelop plot. aad foor plans and. elevations. Piping models include the pipework, are more elaborate, and can constitute up to 05% of the total installed plant cost ‘They are useful as an ald to: doing layout. drawings determining piping layout and avoiding pipe fouls positioning: valves, insirumeals, ele: checking. access for operation. and maintenance; planning. construction and eneculing it and operator taining 10.46 Computer akis Plant layout is one of the areas in which computer sided design (CAD) methods are now widely used. One pe of code gives vsualzation of the layout. This may take a eof forms. One is a 2D layout visualization equivalent to cutouts. Another is a 3D_ visualization fequalent to eilher a block model or a piping model, but much more powerful. The visualization packages avaiable have become very sophisticated abd it is possible in effect for the user to sit at the display and fake a ‘wall through the plant. A recent development is eahancement by the use’ of the techniques of vistual Fealiy. Typically such CAD packages aot only give 3D Aisplay but hold a large amoat of iformaton about the plant such as the co-ordinates of the main lems and Branches, the piping routes, the materials list, ete ‘A particular application of 3D visualization codes is as ‘aputto other computer programs such as computational ‘id dynamies codes fot explosion simulation. The 3D Jayout required for the laler is provided by the 3D visualization code, which then forma the front end of the total package. “Another type of code tackles the synthesis of layouts, ‘The general approach isto deine a priority sequence for locating items of equipment inside 2 block and thea for the location of the block The pipework is then added fand costed. Such a method hat been described by Shocair (1978). A thied ype of code deal with the analysis of layouts fo oblain an economic optimum. Typical factors taken Ito account in such programs incide the costs of piping, space and buldings. A program of this type has been described by Guna (1970) “The extent to which computer aids are wsed in the design of plat layout is ot great but some visualization packages are very powerfil and are Ukely tnd Increasing applicaton. Computer techniques for'plant layout ate described in more detall in Chapter 28, 105 Layout Planning and Development 105.1 Layout actwties and stages Plant layout is sally divided into the following activities: ) ste layout Q)_ plot avout, @)cquipmeat layout ‘The layout developed typical goes through three stages: (Q). Stage One layout @) Stage Two layout, @) Final layout. ‘The sequence of layout development described by Mecklenburg is:Table 10.3. Typical stages in the development of a lant layout fafter Meckienburgh, 1985) (Courtesy ofthe Insttation of Chemiea Engineers) A. Stage One plot layout Thal plot data rst plot layout Elevation Pt plan Pot buldinge Second plot plan Hazard assessment of plot layout Layout of piping and other connections Coca examination of pot layout B_ Stage One site layout 10 Taal ste data 11 Fist ete layout 12 Hazard assessment of ste layout 18 Site layout optimization 14 Critical examination of site layout 15 Site selection © Stage Two site layout 16 Stage Two site data 17 Stage Two site layout tage Two plot layout IF Stage Two plot layout data 19 Stage Two plot layout ). Stage One plot layout, @). Stage One ste layout; @)_ Stage Two site layout (@) Stage Two plot layout ‘Typical sages in the development ofa plant layout are given in Table 103. The Stage Two and Final Stage Glesign network. is shown in simpliied form in Figure 101. Tye process of layout development makes consider- able use of gusdelines for separation distances. These are Aesribed in Section 10:11, ‘Slage One is the preliminary layout, also known as the conceptual, defistion, proposal or font end layout. In {his stage consideration is given to the various factors ‘which aze important in the layout, which may threaten the vibility of the project if they are not satislactorly resolved and which are relevant to ate selection, 105.2 Stage One plot layout In the Siage One plot layout, the information available should include preiinary ow sheets showing the rigor iteme of equipment and major pipework with an indication of equpment elevations, and process enginect= fing designs for the equipment. The plot layouts ate Uaen Aeveloped following the process ow principle and usin guidance on preliminary separation distances. The ple Sze generally recommended is 100m x 200% with plots Separated rom each other by roads 15m wide For each plot layout the clevation and plan are farther Aeveloped. The proposed elevation layouts ae subjected PLANT SITING AND LAYOUT 10/7 to a review such a8 critical examination which generates alternatives, and these alternatives are costed, Silay, {iterative plan layouts are generated accommodating the ain lems of equipment, pipework, buildings and cable fins, and are reviewed to ensure that they meet the brincipal constraints. These include construction, op on, maintenance, safely, environment and eikents, The pla layouts are then costed. The justiation forthe use of buldinge is examined. The civ engineering aspects fare then considered, including foundations and support dnd access structures, “The outcome of this process for each plot is a set of candidate layouts, These are then presented for view as layout models in block model ot coniputer graphics form, ‘The diferent disciplines can then be invited comm ‘These plot layouts are then costed again and & short Ist is selected, preferably of one ‘The plot layouts are then subjected to hazard assess- ent. Thie assessment ie concemed largely with the smaller, more irequent leaks which may occur and with Sources of igation for sich leaks. The process of hhazardous area classiication is also performed. Hazard assessment and hazardous area. claeecation are Aegerined in Sections 1012 and 1013 ‘Studies are caried out to fm up of piping and piping routes and on electrical mains routes, Finally, each plot Tayout is subjected to a critical examination, typically using 2 model and following a checkist. 10.5.8 Stage Ore site layout The Stage One plot layouts provide the information necessary for the Stage One site layout. These include the size and shape of each plot the desirable separation distances, the access requirements and trafic character- fatce, The flow of materials and uiiiies on the se are represented inthe form af site Nowsheets ‘The site layout is now developed to accommodate not only the process plots but also storage and terminals, lilies, process ‘and control buildings, ‘nonprocest buildings and car parks, and the road and rail systems ‘The flow principle is again followed in laying out the plots, but may need to be modiied to meet constraints Guidance is avalable on separation distances for this preliminary site avout, Hazard assessment is then performed on the site layout with particular reference to escalation of incidents and to vulnerable featares such a8 service buildings and buldings suet over the ste boundary. I allenative site layouts have been generated, they are then costed and the moet economic identified, The Ste layout is then subjected to a critical examination, If there is @ choice of ste, the selection is made at this 10.54 Stage Two ste layout Stage Two layout is the secondary, intermediate or Sanction layout. As the later term implies, it i carried fut to provide 2 layout which is sulictenty detalled for tsmclion purposes, I starts withthe site layout and then proceeds to the pot layout "At this stage information om the specific characteristics of the ste is brought to. bear, such as the legal Fequirements, the soil and drainage, the meteorological Conditions, the environs, the environmental aspects and10/8 PLANT SITING AND LAYOUT Stas 2 08516 aaa gy om sapcton ld Rosel yea wos [ sem a ate S$ a Figure 10.1 Simpitied Stage Two and Final Stage design network (Mecklenburgh, 1985). ELD, engineering ne siagram (Courtesy of the insituton af Chemical Engineers) the services, Site standards are set for Dullng lines and finishes, service corridors, pipetracks and road, ‘Stage Two layout involves reworking the Stage One site layout in more detail and for the specific ste, and fepeating the hazard assessmest, economic optimization Sand criial examination, Features of the speciic site which may well infuence this stage are: planning mutters; environmental aspects acighbouring plats, which may constitute hazards and/ for targets other targets such as public bullings: and toad, ral and service access points ‘A this stage there should be fall consultation with the various regulatory authorities, insurers and emergency services, including the police and fre services ‘final site plan is drawn up in the form of drawings and models, both ‘physical and computerbased ones, showing in particular the layout of the plots within the Site, the main buildings and roads, railways, service comidors,pipetacks and drainage. 4105.5 Stage Two plot layout There then follows the Stage Two plot layout The Information avalable for this phase indudes (1) stas- dards, Q) site data, @) Stage ‘Two. site layout, @) process engineering design and () Stage One’ plot layout. The standards inchide international and national sandards and codes of practice, company standards and Contractor standards. The process engineering. design data include the fowsheets, ow diagrams, equipment lists and drawings, process design data sheets and pipework line lists “The Slage Two plot layout involves reworking in more etait and subject to the site constraints the plot plans fand layouts and repeating the hazard assessment, piping layout and eitieal examination, The reworking of the plot Tayout which occurs at node 7 in Figure 101. is a citical phase, requising good co-ordination between the ‘arious disciplines. By the end of Stage 2 an assessment should have ‘been caried ou! of hazard and environmental problems ‘This sseecement is sed to obtain detaledplansing penisson 10,6 Site Layout Features 40.6.1 Ste constraints and standards Once a site has been selected the next step is to establish the site constraints and standards The cor SirsntsiachadePLANT SITING AND LAYOUT 10/9 (Q) topography and geology Q) weather ©) eavironment transport (@) senices (6) legal constrains Topographical and geological features are those such as the lie of the land and ie loatbearing capabilities, Weather includes temperatures, wind conditions, solr radiation, and thunderstorms. Btvitonment covers people, aeivties and buldings inthe vicinity. Services are power, vater and eluents. Legal constraints include Planning and bulding, efuent and pollution, tac, fre and other safety laws, bylaws and regulations ‘Site standards should also. be established covering such matlrs a8 ) separation distances; @) building ines; (@)_ building construction, fins @ road dimensions; (G)_ service comidors; © divebridges. Road dimensions include width, radius and gradient. 10.62 Site services ‘The site ceniral services such asthe boiler house, power slation, switch station, pumping stations, etc, should be placed in suitable locations. This means that they should fot be put out of action by such events a8 fre or flood and, if possible, “not. by other accidents such as explosion, and that they should not constitute sources of ignition for fammables. Electrical substations, pimping stations, etc, should be located in areas where nozlameproof equipment can be tused, except where they ate a iategal pact ofthe past Factors in sting the boiler house are that it shoul not constitute 2 source of ignition, that emissions from the Stack should not give rise to nuisance and that there Should be ready access for fuel supplies. 10.6.3 Use of bullings Some plant may need to be locted inside «bailing, but the se of a building is always expensive and it can create hazards and needs to be justiied. Typical a Dullding’ is used where the process, the plant, the raterals processed and/or the associated activities are sensiive to exposure. Thus the process may need a Stable environment not subject to extremes of heat oF ‘old or it may need to be sterile. The plant may contain Wulnerable ems stich a8 igh speed. or precision tachinery. The. process. material may need to. be protected. against coataminaion or damage, including Fin The activities which the operators have to under fake may be delicate of skilled, or simpy very frequent ‘Thss a building” may be used. to encourage more frequeat inspection of the plant. Similarly, there may be raintenance activities which are debate or skiled or ‘Smpy frequent. In some cases where there are high elevations an indoor structure may be, or may feel, sae. ‘The nee to stisly customers ofthe prodiet aad to keep unsightly plant out of view are other reasons. Examples ofthe use of buildings are the housing af batch reactors, ‘entrifiges and analyse instruments Since ventilation is a building is generally lese than ‘hat outdoors, a lea of Jammable or foie material tends to disperse more slowly and a hazardous concentration is sare Hkely to bud up. Moreover, fan explosion of a ammable gas or dst occuts the overpressure generated tends to be much higher. These are major disadvantages of the use of s building 10.64 Location of bullings Buildings which are the work base for a number of people should be located 0 as to limit their exposure to Raaards, Analytical laboratories should be in a safe area, but otherwise as close as possible to the plants served. So Should workshops and general stores. The laller also Fequire ready access for stores materials. ‘Mmiaistation buldinge shoul be situated in a safe acea on the public side of the security point. The main Slice block should always be near the main entrance ard ther administration buildings. should. be near this fentrance if possible. Other buildings such at medical centres, canteens ete, should also be ina aie area and ‘he Inter should have realy access Tor food supplies ‘A buildings should be upwind of plants which may ave rise to abjectionable features ‘Water ditt from cooling tovvers can restrict visibly and cause corrosion ot ice formation on. planls of fransport routes, and towers should be sted to minimize this. Another problem is. recycling of air fom. the discharge of one tower to the suction of another, hich is countered by placing towers cross-ise to the prevailing wind. The entrainment of efuents from stacks and of corrosive vapours from plants into the cooling fowers should be avoided. as" should. the ‘sling of huldings near the lower intakes. The positioning of tural draught cooling towers should also take into account resonance caused by wind between the towers ‘The problem of sir reerelation shosld also be borne nd'in sling aircooled heat exchangers. 10.65 Limitation of exposure ‘An aspect of segregation which is of particular impor- tance is the limitaton of exposure of people to the hhazards. The measures required to elect Such linstation ate location of the workbase outside, and contol of enty fo, the high hazard zone, The contribution of plat layout {o limitation of exposure therefore hes largely in work- base location. Limitation of exposure is coasdered more fully in Chapter 20. 10.8 Segregation Although a layout which is economical in respect of land, piping and wansport is in general desirable, in process late itis ssually necessary to provide some adational space and to practise a degree of segregation. The site Feyout should aim to contain an accident at source, to prevent escalation and” avoid hazarding vulnerable fargets. A block layout is appropriate with each. plot containing simular and compatble types of hazard and srt dllereat types segregated in separate plots10/10 PLANT SITING AND LAYOUT Face STE I Roadie yt eaniat puto a me, Figure 10.2 Compact block layout system in the process area of a petrochemical plant with 4.5m reads (Simpson, 1971) (Courtesy of the nsblution of Chemical Engines) 108.7 Fite containment ‘The site layout should contribute to the containment of any fre which may occur and to combating the fre. Features of the site layout relevant to fire hazard are Austrated in Figures 102 and 103 Ginpson, 1970) Figure 102 shows a compact ayott, which minimizes Jand usage and. pipework, for & petrochemical plant Va consisting of a major process with several stages and a umber of subsidiary: processes. There are (Wo min process areas and alright angles to these isan area with {vow of fired heaters, and associated reactors, steam Boilers and a stack, ‘This layout has several weaknesses. The lack of firebreaks in the main process blocks would allow a pce =I Figure 10.3. Block layout system in the process area ofa petrochemical plant with 6 m roads (Simpson, 1971) (Courtesy ofthe nsttution af Chemical Engineers)PLANT SITING AND LAYOUT 10/11 fire to propagate right along these, particularly if the wind i blowing along them, which, on the site Considered it does for 13% of the year There is entry fo the plant area from the 6m roads from opposite comers, which allows for all wind dictions. But the only access for vehicles to the process plots is the 45m ras. Tn the case of a major fre, appliances might well fel trapped by an escalation ofthe bre. The 45m roads ive a total clearance of about 10m alter allowance ‘or equipment being set back from the road, but this is Darely adequate as a frebreak. The layout is also Hikely to crise dilicubies in mnfenance work The altemative layout shown in Figure 103. avoids these problems. The process areas are divided by Srebreaks. There are more entry points oa the site and dead ends ate eliminated. The roads are 6m wide with fan ellective clearance of 15m, The crane access azeas provide additional clearances for the fred beaters Other aspects of fire protection are described in Section 10.15 and Chapter 16 10.68 Eftuents ‘The ste Tavout must accommodate the systems for hhanding the efuents ~ gaseous. liquid and sold ~ and storm vealer and Gre water. The ellen systems are Considered. ia Section 10.16 and the drain” system in Section 10.7 10.68 Transport Tis prime aim of plant layout to minimise the distances! travelled by ‘materids. This is generally achieved by following the ow principle, modified as Aecessary 19 minimize hazards Aecess is required to plots for wansport of materiale and equipment, maintenance operations and emergencies. ‘Works roade should be laid out to provide this to plant plots, ideally on all four sides. Roads should be suitable for the largest vehicles which may have to use them ia respect of width, radius, gradient, bridges and. pipe bridges. Recommended dimensions for works roads are given by Meckleaburgh (1973). Road widths of 10m and Tm are suggested for works! main and side roads, respectively. Standard road signs should be used. A road ‘with of 7.5m with the adaition of tree space and/or a pipe teach on the verges may be used to give a Separation distance of 151 between unit. ‘There are various types of tralic in a works, including snaterials, fuel, wastes, sore, food and personel. These Twatie ows should” be estimated and. thelr rostes planned. Incompatible types of trafic should be segre- ited as far et possible ‘Road and ail walfic should not go through process areas except to ite destination and even thea should not violate hazardous area classications. Tn this connection, A should be borne in mind that some counties sll wae open firebox engines. Railway lines should not cross the fain entrance and’ should not box plants in, There should be as few railway crossings, crossroads, right angle bends, dead ends, ete. as possible There should be adequate road tanker parking and rail tanker sidings af the unloading and loading terminals, so ‘hat vehicles can wait their turn atthe loading ganty or weighbridge without causing congestion at entrances, or fon works oF public roads Pedestian pathways should be_ provided. alongside ads where there are many people and much trafic Bridges may need to be provided at busy intersections (Car and bus parks and access roads to these should be situated in a safe afen and outside security points, The Dirk for nightshit workers should be observable by the Aatekeeper. There shouldbe gates. sted. so that the lect of shit change on outside trafic is minimized 106.10 Emergencies There should be an emergency plan for the ste. This is discussed in deta in Chapter 21. Here consideration is limited to aspects of layout relevant to emergencies, "The fist ep in emergency planning is t0 study the scenarios of the potential hazaris and of their develop- feat Plant layout diagrams are essential for such studies. Emergency arrangements should. include an fmergency contol centre. This should. be a specially Alesignated and signed room in 4 sale area, accessible from the public roads and. with space around it for emergency service vehicles “Assembly points should also be designated and signed in safe areas at least 100m from the plants In some cases it may be appropriate to buld refuge room a assembly points. A contl room should not be used Gither as the emergency control centre or as 3 reluge "The maintenance of road access to all points in the site is important in an emergency. The site should have 4 road round the periphery wih access to the public oads at two points at least ‘The vulnerability of the ‘works road system to blockage should be as low as possible. Data on fypieal fre services appllance dimes Sons aad weights are given by Mecklenburgh (1889) For several of these the turning circle exceeds 15m. “hurangements should be made to safeguard supple of services such as electricity, water and steam to pants ia fan emergency. Electricity cables ate partcaary vulner= able to Gre and, if possible, important equipment should be provided with alternative supplies run through the plant by separate routes. 106.11 Securty ‘The site should be provided with 2 boundary fence and all entrances should have a gatehouse. The number of entrances should be kept to & minimus, construction ‘ror is going on in part of the works, this building site Should Rave its own boundary fence and a separate entrance and gatehouse. Ifthe works boundary fence is used a8 part of this enclosure, movement between the building ‘ste andthe works should be through an entrance with ls own gatehouse, 10,7 Plot Layout Consi Some considerations which bear upon plot layout are: rations, process considerations @) economic considerations @) construction: operations )_ maitenance; rds