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Design guides Checking of Plot Plans and Plant layouts.

https://abcengineering.wordpress.com/2012/03/15/design-guides-checking-plot-plans-plant-layout/

Table of content

1. Purpose
2. Checking of Plotplans
3. Recording of Changes
4. References
5. Attachments

1. Purpose
This procedure, by the application of checklists, describes the safeguarding of quality
aspects of engineering work in the development of plotplans and plant layouts. It
covers the requirements to ensure that the applicable specified design basis, regulatory
requirements, codes and standards are correctly translated in their development within
the Engineering Department.

2. Checking of Plotplans
The plotplans and plant layouts shall be verified as a minimum against four lists, as
follows:
2.1 Checklist for Administration
All changes on the plotplans shall be recorded properly on the revision lists and the
marked-up issues filed. Attachment 1 contains checklist that covers the administrative
aspects of plotplan control.
2.2 Safety Checklists for Plotplans
All questions of the safety checklist shall be verified against the plotplan, see
Attachment 2.
2.3 Checklist for Technical Content of Plotplans
All questions of the checklist will be verified against the plotplan drawing, see
Attachment 3.
2.4 Equipment Clearance GuidelineGenerally, clients have their guidelines on
clearances between equipment and or local regulations exist. In absence of this data,
the figures mentioned in Attachment 4 shall be used as a guide.

3. Recording of Changes
The recording of changes and the filing of the associated documents shall be in
accordance with the relevant sections of ref. 4.4, 4.3 and 4.4. These files shall be
maintained as part of the project file. To each document a “ List of Revisions “ shall
be attached ( ref. 4.7 ).

4. References

Document Number Title Level


4.1 CM-MA-101 The Numbering of Documents 2

4.2 CM-MA-102 Document Issue Code and Change Identification 2

4.3 CM-PE-504 The Production of Engineering Documents 2

4.4 CM-PE-110 Project File Coding and Maintenance 2

4.5 BN-DG-C1 Design Guide for Plant Layout 5

4.6 BN-S-UK004 Checklist Design Review Technical Disciplines (later) 5

4.7 BN-UE(I)-10 List of Revisions 4

5. Attachments

1. Checklist for Administration


2. Safety Checklist for Plotplans
3. Checklist for Technical Content of Plotplans
4. Equipment Clearance Guideline

1. CHECKLIST FOR ADMINISTRATION


1. Was a listing prepared of regulations to be followed ?
2. Does a list of the plotplans exist ?
3. Is this list kept up-to-date with number of drawings and issues ?
4. Do any alternative lists exist ?
5. What is the type of list ( Manual, Printout ) ?
6. What is frequency of updating of plotplan ?
7. Do large deviations exist in updating periods of each unit ?
8. Was client approval

 obtained formally ?
 properly recorded ?

9. Does a market-up master copy exist ? Is it kept up-to-date /


10. Are changes

 recorded on revision lists ?


 are revision lists orderly filed ?
 properly referenced to plotplan
 referenced to potential change order ?

11. Are these revision lists orderly filed ?


12. Is origin of change and impact properly indicated on revision list ?
13. Are market-up master copies properly filed in numerical order ?
14. Are revisions properly indicated on plotplan ?
15. Authorized signatures? (Refer to relevant procedure, ref. 4.3). Location for ”
certified ” signature.
2. SAFETY CHECKLIST FOR PLOTPLANS
CHECKLIST QUERIES
1. Identify Codes of Practice, Statutory Legislation or Client’s requirements
determining.
1.1 Overall plant layout, proximity to public access, parking places at safe
locations.
1.2 Minimum spacing between adjacent plants, interrelated plants and on-plot
equipment.
1.3 Spacing and bunding of storage areas and units.
1.4 Minimum spacing between buildings and hazardous areas.
1.5 Location and design of Control Building.
1.6 Atmospheric conditions, e.g. wind direction.
1.7 Soil conditions and topography. High points, slopes.
2. Identify potential hazards from highly flammable or toxic, or corrosive
materials. Do these affect layout or impose restrictions ? Identify requirements.
2.1 High or low temperatures.
2.2 High or low pressures.
2.3 Chemical reactions.
2.4 Flammable explosive substances.
2.5 Risk of dust explosions.
2.6 Toxic corrosive substances.
2.7 Radiation emission.
2.8 Start-up situations (covered in procedures ?).
2.9 Shutdown situations (covered in procedures ?).
3. Identify Codes determining Flare Location ( if included ).
4. Identify fire fighting and protection requirements together with applicable
codes and laws/review with local specialists required ?
4.1 Firewater, foam, dry powder location.
4.2 Fire and gas detection, location of equipment.
4.3 Location of utility stations.
4.4 Fire protection of structures and equipment.
5. Identify means of access and egress.
5.1 Overall road access requirements.
5.2 Fire access requirements.
5.3 Means of escape from areas at grade and bunds.
5.4 Means of escape from elevated areas.
5.5 Have alternative means of access and egress been developed wherever
practicable ?
6. Establish safe location of vents and drains.
6.1 Atmospheric relief valve discharges.
6.2 Steam and gas vents/drains.
6.3 Continuous process vents/drains.

7. Noise profiles.

8. Construction aspects.

9. Sampling and analyzer points.

10. Drainage/collecting in sewer. Accessibility of sample point.


11. Plant security.
12. Check suitability of safety shower location. Verify that water supply cannot freeze.
13. Special plant situations, e.g. offshore.
14. Has Process Department identified and listed all equipment and lines subject to lethal
or toxic rules or requiring special attention for safety reasons ? Emergency showers and
eye washers foreseen ?
15. Has Process Department identified and listed all equipment and lines involved in
extreme design conditions ?
16. Rules for guarding of moving machinery ?
17. Any hazards to the public. (Release of toxic gases or wastes, fire, explosion under
misoperation, malfunction, equipment failure ?).
18. Are all open pits, floor openings etc. fenced or provided with guard rails ?
3. CHECKLIST FOR TECHNICAL CONTENT OF PLOTPLANS
GENERAL
 Nearest geodetic starting point noted ?
 Are battery limits indicated ? Block valves foreseen ?
 Are access roads suitable ? Headroom clearance ? What rules ?
 Access road to discharge and loading points walkway segregated from road traffic ?
 Supply points for chemicals, catalysts ? Access roads for hazardous chemicals ?
 Is plot broken up in units ? Flow pattern between units ?
 Location of interconnecting pipe racks ? Room for future extension ?
 Have locations of future equipment been indicated ?
 What rules for equipment clearance (refer to guideline) ?
 Location of maintenance shop/access roads or maintenance and equipment replacement ?
 Close watch equipment defined and listed ?

NOTE :
Following items have been listed in sequence of the Company Cost Code.

A. TOWERS.

1. Was grouping of distillation towers foreseen ?


2. Overhead condensers and reboilers grouped on common structure ?
3. Verify sectional drawings for elevation.
4. Lightning protection ?

B. BUILDINGS

1. Use of safety glass (for windows) ?


2. Fire stops in pipe passages through concrete walls ? Idem for cables ?
3. Buildings codes written and listed ?
4. Protection of lunch heating devices ?
5. Type of heating/air conditioning ?
6. Ventilation and air intake points ?
7. Sanitary facilities/first-aid facilities ?
8. Lightning protection ?
9. Exits identified/integrated in emergency lighting
10. Orientation of buildings/sun shades foreseen ?

C. PIPING

 Emergency shutdown and isolation block valves to be checked for all lines and plant
limits. Verify use of ROV and accessibility. Use of other isolating devices ?
 Where are spectacle blinds to be foreseen ?
 Location of anchors/pipe supports to be adequate for allowable stress and nozzle load /
 Locking device on critical valves ?
 Insulation for personnel protection ?
 Protection against static electricity ?
 Vibration bracing foreseen/installed ?
 Location of isolation push buttons ?
 Expensive alloy piping layout for minimum length ?
 Fire stops for piping passing through concrete floors and walls ?

Safety Relieving Devices

 Layout of flare header/slope


 Atmospheric release ( steam etc. ) away from platform.

D. STRUCTURES

 Use of concrete or steel/fire proofing ?


 Use of fire decks ?
 Rules for stacking of equipment ?
 Standards for stairs, platforms, ladders and handrailings ? Grating ?
 Lightning protection ?
 Nor exposed to process equipment ?
 Stairs, platforms, ladders for access to operating valves ?
 Use of non-slip surfaces on stairs, platforms, access ways.

E. ELECTRICAL

1. Hazardous area
classification -Identification of source of hazards.
-Identification of substances released.
-Establishment of risk zones.
-Establishment of temperature class and gas groups.
-Selection of certified equipment.
-Power supply (transformers, switchgear) located separately and protected.
Critical equipment
Oil containment dikes around transformers.
2. Earthing -Protection against lightning
-Discharge of static electricity.
-Dispersal of fault currents.
-Limiting step and touch potentials to safe levels.
-Protection of earthing conductors against corrosion.
3. Cathodic
– Protection of buried metals.
protection
– Interference with earthing system.
4. Fire protection – Fire alarm call points.
– Fire alarm bells/sirens.
– Sprinkler/cloud systems.
– Fire resistance of materials.
5. Area & road – Adequate illumination.
lighting
– Lights correctly positioned.
– Avoidance of too much glare or reflection.
– Adequate emergency lighting.
– Possibility of maintenance lighting.
6. Cabling – Compliance with regulations.
– Correct conductor sizing.
– Adequate protection for cables.
7. Equipment – Accessibility.
– Ease of maintenance
Emergency power – Is emergency generator foreseen/located in safe area?
– Use of diesel drives/turbines ?
Power connections – Distances.
– Failure of electrical controls to be considered in design.Foresee fail/safe
8. Control failure
equipment
9. Switchgears – Are lockout facilities foreseen ?

F. FIRE FIGHTING ( see also K, item 3 )

 Check suitability of fire fighting equipment, location of hydrants and adequacy of water
supply.
 Check to ensure that adequate access for fire tender has been provided to all relevant
plant locations.
 Check that clear escape routes at grade have been provided.
 Check that ladders and stairs are positioned at grade leading to clear escape routes.
 Water flooding/sprinkling for spheres.
 Stairways must be the primary access to main operating or service platforms.
 Auxiliary exits by ladders to be provided.
 No dead end platform to be longer than 8 meters.
 Horizontal walking distance to primary or auxiliary exit must not exceed 25 meters.
 Check on flame trap requirements for vent pipes.
 Check on vent requirements for underground drainage systems.
 Check that all vent pipes and relief valve manifolds discharging to atmosphere are at least
3 meters above any platform within a radius of 15 meters.
 Check that suitable interlocking has been called for at multiple relief valve assemblies.
 Have smoking regulations been determined ?
 Design Engineering Supervisor in conjunction with Process and Project shall check
suitability of all relief system arrangements. Particular attention shall be given to
possibility of pockets/vapor locks and discharge requirements and use and/or need of
closed systems.
 Check locations of sniffers if provided on the plant.
 Monitors and hydrants guarded against vehicle damage ?
 Reliability of firewater pump in case of power failure. Auxiliary drive.

G. GENERAL

 Handling devices required for handling weights over…….kg.


 Space for material storage.
 Have weight and size of containers been considered/listed ? Equipment foe handling of
containers, bins.
 Loading piers : accessibility to emergency shut-off valves.
 Communications between shipping pump and loading point.
 Flare well segregated ? Area protected against radiation. Extent of radiation zone.
 Distance between utility stations.
 Accessibility of utility stations and composition.

H. HEATERS/BOILERS

 Located in separate area. Well segregated.


 Distance to process units : minimum 15 meters to hydrocarbon bearing equipment.
 Sufficient inspection openings to verify the internals visually.
 Anchoring of inlet and outlet lines.
 Located upwind of operating units.
 Air intake locations.
 Remotely operated/accessible shutdown valves on fuel supply lines.
 What in case of tube burst ?
 Access for emergency equipment ?
 Diversion walls foreseen ?

J. CIVIL

 Have underground services been marked ?


 Marking also in case of excavation ( warning strips )?
 Standard for roadways ?
 Consider risk of settlements of foundations.
 Are all open pits, floor openings etc. fenced or provided with guard rails ?

K. CONTROL SYSTEMS
Specific reference shall be made to “ Checklist Design Review Technical
Disciplines,” section 9 (ref. 4.6) and shall include :

1. Hazardous areas: – Design philosophy.


– Selection of certified equipment.
– Compliance with area classification drawing
– Installation to code and specific certificate requirements
2. Earthing. – Limiting touch potential to safe levels.
– Protection of earthing conductors against corrosion.
3. Fire protection – Fire alarm bells/sirens.
– Smoke/fire detection. (Instrument equipment)
– Shutdown, interlock and alarms.
– Fire resistance of materials.
– Operational implications of a fire.
– Fire fighting system. (Instrument equipment).
– High fire risk areas.
4. Fail/safe design – Shutdown systems/emergency depressurizing system.
– Fail safe features affecting plant safety.
– Effect of failure or loss of electricity, and all utilities.
– Burner management systems.
5. Safety relieving
– Sizing criteria.
devices
– Safety factors.
– Calculations approval.
6. Equipment
– Maintenance
location
– Accessibility
7. Cabling – Compliance with regulations.
– Correct conductor sizing.
– Adequate protection for cables
– Segregations.
8. Electrical supply
– Correct type and sizing of fuses and circuit breakers.
system
– Extent of equipment of uninterruptable power supply system.
– Alarms.
– Overall power consumption.
9. Air supply – Instrument air consumption.
– Security of supply.
– Operational and design conditions.
– Is an audible alarm included to warn for release of flammable vapors?
10. Alarming
Release of lethal gas. Fired heater flame failure.

M. VESSELS ( TANKS )

 Protection in case of leakage (bundwalls).


 Lightning protection.
 Distances between tanks/diked areas. What rules to be followed?
 Protection against static electricity.
 Special rules for cold storage defined.
 Accessibility of tank gauging device/suitable for pressure and temperature.
 Minimum flanged connections within diked areas.
 Use of flow limiting devices.
 Tank farms at lower level than process units.
 Siting of tanks in groups; consider API rules.
 Icing protection for refrigerated storage protection for spontaneous warming.
 Protection of gas storage tanks against sun radiation.

N. INSULATION

 Resistance of insulation against fire.


 Personnel protection insulation foreseen (verify along access roads).
 If insulation foe personnel protection is not foreseen, protect by open guards, shields,
railings.

P. PUMPS/COMPRESSORS

 Location separately for noise limitation. Compressors upwind from fired equipment.
 Grouped under pipe rack (separate rows). Separate high pressure pumps.
 Possibility of sprinkler installation/common loops.
 Accessibility of rotating equipment for operation and maintenance (equipment
replacement).
 All rotating equipment adequately guarded.
 Noise protection in rotating equipment. What rules imposed ?
 Air intake location for compressors.
 What is risk in case of seal leakage ? What protection foreseen ?
 Equipment clearance/removal possibility of defective equipment.
 Installation of lifting equipment.
 Lubrication points defined. Accessible for operating and maintenance personnel ?
 High pressure charge pumps to be isolated.
 Location of seal oil units.

Q. SEWERS

 Check area classification for pits and other catchment devices.


 How is sealing and venting of catch basins done ?
 Verify removal of releases and drips from under equipment.
 Consider use of separate sewer and toxic sewer. Oily sewer required ?
 Pollution risk. Waste water collection and treatment. Location of discharge point.
 Special precautions for highly toxic highly flammable products.

T. EXCHANGERS

 Accessibility for cleaning rodding.


 Space for bundle pulling device.
 Location of airfin coolers (no pumps underneath).
 Are fire decks foreseen ?

4. EQUIPMENT CLEARANCE GUIDELINES


ITEMS

Overhead clearance Meters


Equipment, structures, platforms, piping and pipe supports shall provide the following
clearance overhead:
– Railroads, top of rail to bottom of any obstruction 7
– Plant roads for major mobile equipment 6
– Secondary roads and access ways for mobile equipment 5
– Grades at pump row access way inside battery limits 3
– Walk-ways, pass-ways, platforms and inside buildings 2
– Exchangers at grade, shell cover channel end 1.5

Horizontal clearances
– Between exchangers (aisles between piping) 0.9
– Around pumps (aisles between piping) 0.9
– Fired heaters to pumps handling flammable stocks 15
– Fired heaters to other flammable containing equipment not closely
8
associated with heaters
– Driver end of pumps where truck access is required 3
– Driver end of pumps where truck access is not required 1.8
– Shell cover end of exchangers at grade for access 1.3
– Between shells of adjacent horizontal vessels 1.2

Pipe berths
– Underground, minimum clear gap between pipes (300 mm) 0.3
– Aboveground, normal, between flanges and bare pipe or surface
0.025
of insulation and plugs (25 mm)

Equipment spacing
– Small pumps, 3.75 kW or smaller, mounted on common foundations,center to center suitable
distance
– Medium pumps, 22.5 kW or smaller, clear aisle 0.9
– Large pumps, larger than 22.5 kW, clear aisle 0.9
– Exchangers and other equipment on structures, minimum clear aisle 0.9

Platforms
Vessels (vertical and horizontal) and towers
– Side platform distance below centerline of manhole flange 0.9-1.05
– Side platform width from manhole cover to outside edge of platform 0.9
– Side platform extension beyond centerline of manhole 0.9
– Head platform distance below underside of flange 0.175
– Head platform width from three sides of manhole 0.75

Exchangers (horizontal)
– Clearance in front of channel or bonnet flange 1.2
– Exchanger tube bundle removal space bundle length
– Minimum clearance from edge of flanges 0.3
Exchangers (vertical)
– Distance of platform below top flange of channel or bonnet 1.5
Furnaces
– Width of platform at sides of horizontal and vertical tube furnaces, minimum 0.75
– Width of platform at ends of horizontal tube furnaces, minimum 1.0
Control room
– Distance of control room to process equipment 25

SUGGESTED SPACINGS FOR LPG STORAGE

Minimum distances
Vessel capacity From buildings Between vessels
imp. gallons cubic meters feet meters feet meters
up to 100 up to 0.45 – – – –
101-500 0.45-2.3 10 3 3 1
501-2,000 2.3-9.1 25 7.5 3 1
over 2,000 over 9.1 50 15 5 1.5