Plant Lay out

Introduction

Before getting started, I would like to discuss the differences between the Code, the standard, and the recommended practices.

A code is a collection of general principles or systematic norms for design, materials, manufacture, installation, and inspection that has been constructed with the intention of being adopted by a legal jurisdiction and then enacted into law. The ASME B31.1 Power Piping and the ASME B31.3 Process Piping documents are examples of documents that fall within this category.

Documents that are considered to be standard are drafted by a professional group with requirements that are considered to be excellent and proper engineering practice. These documents are also created with the required requirements (that is, the verbs shall be used).

The term "recommend practice" refers to documents compiled by a professional group that indicate acceptable engineering practices. However, these materials are available for use, and the verbs should be utilized. 

Various engineering procedures that are deemed to be good practice are enumerated in guides and guidelines, which are publications that are produced by agencies, organizations, and committees. These documents do not include any specific recommendations or requirements. The engineer has the authority to decide whether or not to use these guides.

Engineers must have the information described above before beginning to work on plant layouts. The terms "shall," "may," "should," and "could" are essential to comprehend in the context of terminology.

Plot plan

Generally speaking, plot plans may be broken down into two primary categories: general plot plans and unit plot plans, which are also referred to as equipment layouts. Plot plans are fundamental designs that are utilized in engineering projects. Various design inputs are utilized in the preparation of these blueprints, which serve a variety of unique objectives. An overview of each category has been provided below, along with the potential design inputs:

Plot plan categories

1. General Plot Plan:

   • Purpose: Provides a comprehensive overview of the entire project site, including the arrangement of buildings, roads, major equipment, and utility systems.
   • Scope: Encompasses the overall layout and spatial relationships of all major elements on the site.

2. Unit Plot Plan (Equipment Layout):

   • Purpose: Focuses on the detailed arrangement of individual units or systems within the larger site.
   • Scope: Includes the precise location and orientation of equipment, piping, instrumentation, and other components within a specific area.

Design Inputs for Plot Plan Preparation

1. ITB/Contract Documents:

   • Client’s standards and related documents that provide specific requirements and guidelines for the project.
   • Ensure compliance with contractual obligations and client preferences.

2. Basic Engineering Design Data:

   • Initial design parameters and criteria that form the foundation of the project.
   • Includes information on process design, capacity, and overall plant configuration.

3. Process Flow Diagram (PFD) and/or Piping & Instrumentation Diagram (P&ID):

   • PFD: Represents the process flow of the plant, showing major equipment and the flow of materials.
   • P&ID: Provides detailed schematics of the piping, instrumentation, and control devices in the plant.
   • Crucial for understanding the process and instrumentation layout.

4. Design Basis for Plant Layout:

   • The document outlines the fundamental design principles, objectives, and constraints for the plant layout.
   • Includes considerations for safety, operability, maintainability, and accessibility.

5. Detailed Engineering Design Data:

   • Comprehensive engineering information is required for the detailed design phase.
   • Covers aspects such as mechanical, electrical, civil, and structural engineering.

6. Utility Flow Diagram:

   • Diagram showing the flow and distribution of utilities (e.g., steam, water, air, electricity) throughout the plant.
   • Essential for planning the utility systems and their integration with process equipment.

Preparation of Plot Plans

The preparation of plot plans involves several steps, often requiring close collaboration between different engineering disciplines:

1. Data Collection:

   • Gather all relevant design inputs, including client standards, engineering data, and diagrams.

2. Initial Layout:

   • Develop a preliminary layout based on the design basis and spatial constraints.
   • Ensure that the layout accommodates process requirements, safety considerations, and future expansions.

3. Review and Iteration:

   • Conduct reviews with stakeholders, including engineers, clients, and regulatory authorities.
   • Iterate the design based on feedback and new information.

4. Finalization:

   • Finalize the plot plan with detailed dimensions, equipment locations, and utility connections.
   • Ensure that all design criteria are met and that the plan is ready for implementation.

And what happens if there is some consistency between the documents? When inconsistencies are found between related documents, prioritizing them helps ensure clarity and consistency in the engineering and construction process. Here is the priority order typically followed:

1. Basic Engineering Design Data (BEDD):

   • This foundational data sets the overall design criteria and parameters, providing the primary guidance for the project. It includes essential information such as process design, operating conditions, and equipment specifications.

2. Detailed Engineering Design Data (DEDD):

   • This data builds on the BEDD and provides more specific and detailed information necessary for the final design and construction phases. It includes detailed schematics, equipment details, and comprehensive engineering calculations.

3. Client’s Standards and Related Documents:

   • These documents outline the specific requirements and guidelines set by the client, including industry standards and any client-specific preferences or regulations.

4. Process Flow Diagram (PFD) and/or Piping and Instrument Diagram (P&ID):

   • These diagrams provide crucial information on the process flow, piping arrangements, and instrumentation details. They are essential for understanding how the process operates and how various components are interconnected.

5. Contractor Individual Project Documents:

   • These documents include the contractor's project-specific plans, drawings, and specifications. They are tailored to the particular project but should align with the higher-priority documents listed above.

Data requirements for Plot plan

Designing a plant layout requires a comprehensive set of data to ensure that all aspects of the project are considered and integrated effectively. Here is a detailed list of the requirement data typically needed for the design of a plant layout:

1. Terrain, Climate, and Related Laws and Regulations:

   • Terrain Information: Topography, soil characteristics, drainage, and site accessibility.
   • Climate Data: Temperature ranges, precipitation, humidity, wind patterns, and seismic activity.
   • Laws and Regulations: Local, regional, and national regulations, zoning laws, environmental regulations, and building codes.

2. Client’s Standards, Regulations, and Requirements:

   • Client’s Standards: Specific standards and guidelines provided by the client.
   • Regulations and Requirements: Compliance with the client’s operational and safety requirements.

3. Safety Requirements:

   • Safety Standards: OSHA regulations, safety codes, and best practices for safe plant operation.
   • Hazard Analysis: Identification of potential hazards and implementation of mitigation measures.

4. Fire Fighting Requirements:

   • Fire Safety Standards: Codes and regulations for fire prevention and control.
   • Fire Fighting Systems: Requirements for fire detection, suppression systems, and emergency response plans.

5. General Plot Plan:

   • Overall Layout: The spatial arrangement of all major components, including buildings, roads, utilities, and green spaces.

6. Equipment Layout of Adjacent Process Units:

   • Adjacent Units: Layouts and data for existing or planned adjacent units to ensure integration and compatibility.

7. Process Requirements:

   • Process Flow: Detailed process flow diagrams (PFDs) and piping and instrumentation diagrams (P&IDs).
   • Process Conditions: Operating conditions, material balances, and energy balances.

8. Erection and Maintenance Requirements:

   • Construction Requirements: Guidelines for the construction and installation of equipment and structures.
   • Maintenance Access: Provisions for maintenance, including space for equipment access and removal and safety considerations.

9. Operational Requirements:

   • Operational Efficiency: Layout considerations to optimize workflow and efficiency.
   • Accessibility: Ensuring easy access to all areas for operation, monitoring, and control.

10. Economic Requirements:

    • Cost Considerations: Budget constraints and cost-effective design choices.
    • Economic Analysis: Cost-benefit analysis and lifecycle costing.

11. Equipment List:

    • Equipment Inventory: A comprehensive list of all equipment, including specifications, quantities, and locations.
    • Data Sheets: Detailed equipment data sheets with technical specifications and requirements.

By systematically gathering and analyzing this data, engineers can develop a plant layout that meets all technical, safety, regulatory, and economic requirements, ensuring efficient and safe operation. 

What is the plant design engineering?

Introduction

For some companies, the plant design function may be integrated within the piping and layout department, reflecting the interconnected nature of these areas. In certain contexts, plant design is synonymous with 3D Layout, emphasizing the critical role of three-dimensional modeling in modern engineering practices. Consequently, plant design engineering emerges as a specialized discipline focused on multidisciplinary design within a 3D environment, requiring expertise in various engineering domains to ensure cohesive and efficient plant operations.

Plant designers and engineers are responsible for the comprehensive development of 3D models, which serve as the blueprint for the entire plant layout. Their role encompasses integrating various components, such as piping, equipment, structural elements, and electrical systems, into a unified model. This model not only facilitates visualizing the final design but also allows for simulations and analyses to optimize the plant's functionality and safety.

Moreover, plant designers and engineers collaborate closely with other departments, including process engineering, construction, and maintenance, to ensure that the design meets all operational requirements and standards. They use advanced software tools to create detailed and accurate representations of the plant, enabling stakeholders to make informed decisions throughout the project lifecycle. Their expertise ensures that the plant layout is both practical and efficient, ultimately contributing to the successful execution and operation of the facility.

The following are the main activities/tasks of the Plant Design Team:

• Ensure consistent development of 3D models
• Assuring Ergonomic, Safe, Operable, and Maintainable Design
• Ensure the constructability of all components of the project
• Disciplines design input in 3D is in accordance with project requirements
• A customer-oriented approach is applied during the design development
• Maximize the use of clash detection to help minimize site clashes
• Reduce design modifications and avoid rework
• Eliminates field reworks
• Optimize the design to reduce overall project cost
• Maximize the use of drawings, MTO, and reports extracted from 3D models to save time and avoid incoherent design deliverables.
• Meeting Project schedule and milestones
• Meeting required model content for stage reviews
• Ensuring progress of the 3D model
• Review, supervise, and monitor multidiscipline activities during design development. 
• Progress monitoring, reporting the status of model reviews and comment closeouts
• Facilitating 3D model review meetings 

 Function

The plant Design function covers any item, such as

• Plot Plans – layout for the on-plot facilities “Inside Battery  Limits” (ISBL).
• Site Plans – layout for the off-plot facilities “Outside Battery  Limits” (OSBL).
• Plant layout and layout criteria.
• Equipment segregation, separation, and arrangement
• Plant safety, maintenance, and operation.
• Construction issues affecting plant layout.
• Aspects of piping routing and arrangement affecting plant layout.
• Aspects of Electrical and Instruments functions
• Equipment and piping arrangements are interlinked and cannot be considered in isolation.
• Plant layout, however, also includes other issues, such as;
• Plant access – roads, paths, platforms, stairways.
• Drainage.
• Structures, buildings, shelters.
• Constructability and construction facilities.
• Impact on local communities and environment.
• The piping layout must be integrated with the equipment layout to produce the final plant layout.

Summary

Thus, what kinds of skills are required to become a plant design engineer?

Plant Design must be carried out by an Engineer/Designer  with the right skills:

• Must be aware of safety and ergonomic issues.
• Common sense and reasoning.
• Understand the plant design intent.
• Overall understanding of how the plant will operate and be maintained.
• Cost-conscious.
• Good understanding of construction issues.
• Creative, open-minded, multidiscipline background.
• Probing nature, able to question the reliability of information or data and resolve issues.
• Must be able to defend the chosen design but able to compromise while still achieving acceptable results

So, ready to expand your skills and knowledge?

Never ending Studies.

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