IMPLEMENTATION OF EQUIPMENT

IN PETROCHEMICAL PLANTS
RECOMMENDATIONS FOR THE DESIGN OF THE 'PLOT-PLAN'

The distribution of the equipment 1. INTRODUCTION body a series of important factors

and the machinery in the area many. It can be said that as
In the arrangement of the equipment (ins- that the conditions have changed,
work is a problem facilities, machines, etc.) and area the concept of distribution has evo-
inevitable in the design of of work, the distribution is a constantly deluded and everything
industrial plants. This problem that cannot be avoided. this has come to provide a series of
physical arrangement of the The mere act of placing equipment basic principles, which when being
industrial elements inside an area already re- well applied give rise to a
include minimal spaces it is a sorting problem. good plant layout.
among teams, machinery, The work of plant location Thus, the location plan
storage and others involves the physical ordering of the of the team is related to the
industrial elements; this orders- spatial arrangement and has a
activities or services. action already practiced or in project, vital influence on efficiency and
The location of the equipment includes necessary spaces, mini- utility of chemical plants.
it has a vital influence mos for the maintenance of the equi- Good distribution practices
in the efficiency of the for the machinery, storage, they achieve an economic balance
chemical plants. services and other activities. smallrequirementsof
safety, construction, maintenance
In this article, there The work of designing a distri-
lie, operation, future expan-
summary of practices plant distribution covers a wide
field. It can understand, alone- sessions and the process variables
usual designs in the mind, a workplace indi- as gravity or height flow
petrochemical industry. individual or the complete arrangement of positive suction of pumps.
many areas of industrial property Theaimofthisarticleis
trial; but in all cases it try to be a guide for cons-
must plan to achieve a distri- carry out a good distribution of
efficient distribution, which will be plasma- team on site.
inthelocationmap
team leader. 2. PLAN
During these years, the various ideas OF LOCATION
ALEJANDRO that the production men and TEAM GENERAL
ANAYADURAND other leaders had this respect
Mexican Institute of Petroleum they have been clarified; they have taken The general location plan of the
CHEMICAL ENGINEERING - MAY 1998 113
team is a critical document in Soil conditions. can achieve the following benefits-
the design and construction of a Basic information about the contract. cios:
process plant; it is a drawing of Specifications and standards of
Reductionofriskforthe
the unit in the plant, in which it work.
health and increased security to
they are found distributed and locating Client requirements.
the operators.
of all and each of the equi- Process flow diagrams. Enhancement of morale and satisfaction
also presented in it are the Preliminary dimensions of
operator faction.
buildings, main structures, team
Increase in usable capacity
roads and railways; systems of Electrical equipment and substations. of the land.
access to the plant, adjacent structures- Location of connections of
Reduction of delays in the
centers, storage areas and servicesincludingcurrent operation of the process.
administration, as well as the rack of electric. Maintenance is facilitated
pipes and the necessary for a Preliminary dimensions of edi-
team, etc.
efficient operation of the plant. fictitious.
The 'plot-plan' is the initial drawing. Information on similar plants.
6. CONSIDERATIONS
produced for the plan arrangement From this necessary information FOR LOCALIZATION
process heap. All the specia- ria to start a 'plot-plan', is OF THE TEAM
design lists use this plan fundamental the flowchart
for the development of the required of the process, and as information Knowingthelimitationsof
necessary elements and the drawings basic of the project, the "foundations of place, the applicable regulations
for construction, operation, man- design", since in this document and the standards, it will be in with-
maintenance of the plant. The econo- all are defined decisions to make the plan of
mine in the realization of a projec- requirements of the plant, so [Link]
it depends largely on the dis- like the location of the shells What should be done the same
distributionandlocalizationofthe climatic characteristics of the place. considerations that were made
teams; of their interdependence and for the preliminary location plan
freedom to combine. 5. OTHER BENEFITS minar: the distribution of the process
FROM A GOOD from the plant by material flow
3. CRITERIA FOR DISTRIBUTION with the position of the services and
DESIGN THE buildings added later
PLOT-PLAN A good distribution of the team mind.

They must be taken into account. [Link]

following criteria: a guide to training ionic exchange reactors
Scale and scope of the operation
Existing location limitations
Security considerations
Operation supervision.
Supply of services
Management requirements
materials.
Convenience in maintenance.
Economy in construction.
Future expansion or possible additions
actions.
The focus of this article is that of
indicate how to create a plan
general equipment localization
(plot-plan)

4. INFORMATION FOR
START THE 'PLOT-PLAN'
The following information is required
tion:
Location of the geographical place
for the plant.
Topographic map.
Location of roads and highways
access terraces to the place.
Climatic data, winds
dominant and reigning.
114 CHEMICAL ENGINEERING - MAY 1998
However, the restrictions of minimum permissible elevation by mind in the thickeners. In this
place can help with the location on top of the floor, for which it case, the differences in elevation
connection of the service line they must take into account the characters between the first and the subsequent ones
roads (paths, railway tracks, operational and maintenance characteristics thickeners are agreed upon
electricity supply and I lie. the arrangement to allow flow through
drainage, drinking water and of pro- gravity from one to the
The minimum elevations are:
cleavage). next. Regarding the costs
Containers: 0.9 to 1.5 m from the civilworksmustbeused
6.1. RECIPIENTS bottom to the ground. natural variations in the level of
Torres: 0.9 to 1.5 m in height of floor.
The process and system containers skirt.
more service is used for Exchangers: 0.7 to 1.3 m 6.2. EVAPORATORS
maintain fluid volumes from the bottom to the ground.
for a specific period of time The minimum height of an evaporator
pos and for the separation of liquid- 6.1.3. TANKS is determined by the requirements
two immiscible with different den- OF STORAGE NPSH requirements of the pump
These containers can [Link]
are of two types: vertical and horizontal The intermediate storage in place the bomb in a local pit
horizontal. containers are frequently carried out dropped directly under the evaporator-
fearful in areas adjacent to the pain to obtain said requirement
6.1.1. RECIPIENTS process units with the bom- lie, since in some occasions
VERTICALS localized transfer bases to it is necessary to lower the calan-
along this area (Fig. 1). The dria.
The large vertical containers, final storage tanks
like the towers, they must be they are usually far from The barometric legs must
process area. have at least 10 m from the base
located from 2.5 to 3 diameters
distant from each other, from center to center from the container to the level inside
6.1.4. SEPARADORES from the barometric trough, normal-
tro. The vertical accumulators
mind situated on the floor. The sec-
small ones should be spaced out
The minimum distance to the units horizontal actions must be avoided
3 to 4 diameters apart
(center to center). The tanks of processes can be 100 feet long in the barometric legs and the
to try to locate far from the legsshouldideallybe
surge must align with towers.
main buildings and roads verticals.
6 1.2. RECIPIENTS subject to heavy traffic. Platforms will also be provided.
HORIZONTAL forcleaningpurposes
6.1.5. THICKENERS
each manual mouth, allowing 4
The horizontal containers and tan- The thickeners are horizontal tanks m 2from free platform for each
questions of surge must be aligned with opening,alsotheplatform
large diameter horizontal that have-
regarding the accumulators mon- rotary agitators for sludge. may be necessary for cleaning-
tados at floor level, looking for The sludge is fed through piping. for the tube welding and repair
as long as there is harmony with it towards the feeding well in the deé[Link]
process flow and that the lines of center of the tank, the clear liquor for the use of mechanical cleaners
pipes are shortened. removethroughperipheralwashingand pipe fittings and for removal
The accumulators are located together outletpipe,whilethe [Link]
and close to the assembly level mud or settled is taken or is it can mean having a board
of the capacitors. The end they take from the center at the back removable above the evaporator.
the accumulator is located below from the tank, usually by means of There should be spacing provided.
ofthecapacitoranditisnecessary from a screw conveyor. necessary to add pipe and
do it through a structure. Duetoitslargediameter,the additional valves, so that
The horizontal accumulators of thickeners are normally lo each evaporator can be removed
ofoperationwithoutinterruptingthe
refluxshouldbespaced carried out outside closed spaces
around 2 diameters apart and far from the process areas, of process.
between each other. so they don't take or occupy the
valuable process space. The 6.3. CRISTALIZADORES
The containers with large volu-
liquid volumes must be ins- thickeners have a structure
at the top of the tank to give The distribution requirements
cut down to a small pre- height for the crystallizers are similar-
preferably at floor level. From supportandallowaccesstothe
actuating mechanisms and of ali- to those, described for the
Indeed, all containers included
maintenance of the well, while the evaporators.
going towers and exchangers
they must be located at ground level- maintenance of the stirrers of The use should be taken into account
but if it is considered that there are no fa- The mud takes away in situations- of long radio elbows and provide
special process stores that after emptying the tank. many cleaning conveniences.
they require the elevation of the equipment, Continuous counter-decantation Such pipes must have pen-
inwhichcaseitmustbedecidedthe current is often carried out teeth for ease of drainage.
CHEMICAL ENGINEERING - MAY 1998 115
6.4. OVENS 6.6. TOWERS It is advisable to have the condenser-
AND TEAMS WITH FIRE gold above the dome of the column
For the location of towers to minimize the steam piping
Thefirstconsiderationinthe processinplant,itisnecessary and provide gravity reflux.
distribution of equipment with fire consider three types of lines: This arrangement requires support ade-
it is the security, and it must be carried out when for the reflux tank and
Main process lines.
a complete study of the codes requires a proper head in the
These lines will be shorter if they
[Link] circuit in the center between the columns
towers are arranged in the sequence-
The general is that the team with fire nas,whichmustbe7.5
process flow chart, and so close-
it must be located at least sometimes the average of the diameters of
each other like the
15 m away from process equipment the columns.
dimensions of equipment and space
dangerous or equipment that could for access to allow it. If access to the system is required
be a source of splatter or leak
capacitors,sincesome
of gases. Lines between associated teams. The sometimes they are supported on the tower,
the spacing of the towers depends space must also be provided
Theprocessequipment(suchas of the number and of the dimensions of
such as reactors, fractionators and for the removal of the tubes or of the
other devices connected to it.
distillation columns) that same exchangers. The spa-
This leads to the second group of line-
find connected to the output network of platforms for access
as in the flow diagram of proce-
from the furnaces, they must be located to the valves and instruments aso-
so:linesthatconnectwitheachother
ascloseaspossibleto tied with the exchangers
closely related team, it must also be considered.
so that the transfer lines such as fund withdrawals to bom-
the references should be as brief and simple as possible
bas, reflux circuit to the heater Provisions must be made for
it is possible; moreover, it is convenient internal access, in order to allow
or power supply lines and of pro-
consider you a chi policy terminal ducts. cleaning, placement of dishes, ins-
commonthreats,takingintoaccount
corrosion inspection, leveling
count, for security, the distances- Feeder lines of pro- of packaging supports, and for
minimum charges towards other teams small diameter duct. The other maintenance work.
recommended. Other factors that towers (fractionators, dehydrators- In diameters smaller than 0.5 m the
affectthelocationarethe doors,etc.)thustheymustbe internal access is not practical and the
management of liquid effluents, locatedascloseaspossible the column must be built in
the gaseous effluents relate possible from the pipe rack. sections of approximately 2.5 m
two with other plants and the approx- of height for maintenance.
The front side of the towers must-
service formation for teams
with fire. toremainfreetohave The centerline of the records
access. The front side must be of man (access to the interior of
The distance from the oven to the alignedwhilemaintainingaclear the tower) will normally be 1 m
nearest process equipment between this and the pipe rack. above the platform, but it can
son: 6 a l0 m for circular ovens towers located on lines with be varied between 0.5 m and 1.3 m.
from 12 to 18 m. for type ovens connected platforms
Generally, the columns are
Box. The pipe rack will be are sometimes preferred for
to be located within these dis- access, maintenance and operation considerably higher than the
majorityofotheraccessoriesor
safety measures. It should be suitable.
equipment, and in the cases where
provide a free space between hours
no and oven; these spaces should The fractionation towers are deliver complete, it must
be twice its width (from the center to located in a line of centers to foresee adequate access to the
common from 3.5 to 4.5 m away from the same, space for download and
center).
rack of columns. [Link]
Theyshouldbearrangedina reason are better located when-
common line based on the chi- 6.6.1. CONSIDERATIONS it is possible at one end of the
I walk, whenever possible, and OF ELEVATION process area.
the chimneys must be located
you give on the side or at the far end The height-to-column ratio 6.6.2. CONSIDERATIONS
away from unity. the reheater (thermosyphon type), and OF SPACING
from the column to the pump of
6.5. TORCHES two for NPSH requirements, A mini space must be provided.
are determined by the flow of 3 m between columns, which
The required localization is precise fluid. This height varies from 0.9 to it can increase if it is likely
may the prevailing winds blow in 1.5 m for towers with diameters of the frequent replacement of the pla-
oppositedirectiontowhereitis 0.6 to 5 m and bottom temperature to. For extremely end columns-
the units are located from 100 to 400°[Link] temperatures you high, for which it is required-
ofprocessandonland can this be increased ran special designs of cimen-
high, if it is on accidental ground height of 0.3 to 0.6 m, to avoid the you, the area required for the
tado. The minimum distance between the transmission of high temperatures to foundation can be the criterion
burner and the processing units the concrete foundation or in spacing. The interac-
it is 60 m. structure. the action of the wind could also
116 Chemical Engineering - May 1998
influence the location of ["The exchangers, cooled-"] se ajustan para diferentes distribu-
adjacent columns. productnetwork,forexample, plant actions. Plants do not
theymustbeplacedbetweenthe very big usually have
6.7. HEAT EXCHANGERS process team and the limit of a simpler type of support structure.
OF HEAT battery of the unit, with the aim of
Inlargeplants,therackof
minimize the pipe run pipes will be more complicated
The grouped exchangers at high temperatures.
when the raw materials, serve-
they must be in line with the axes
One step further in distribution is auxiliary cios or thermal products
from the mouths of the channels, in the location of those inter- They enter or exit the limit of
a common vertical plan, for pre-
toestablishanaestheticappearanceand
stackable changers battery on the different sides, by
striking a balance in order to simplify arrangements. what should be of type T.
to facilitate the details of tube- pipe fittings and space saving.
river. The exchangers can U-type supports are used in
to pile up, but they should never be The design specifications, plants where it is required that to
more than three if they support each other theyusuallylimittheheight along the pipelines there are connections
mind. The exchangers maximum of exchangers, that from the process on each side; this is
connected in series or in parallel it is 1.5; m. to the upper part of the it also applies to the support
they can be located one on top armor,insuchawaythattheteam type Z, which can be a combination-
from the other up to heights of approximately mobile can handle conveniently L-type and T-type support structure.
mind 4 m. lie the beam of tubes in case of The U-type support is also used
its extraction is necessary.
When required for a cam- Liza when some type is required
the heat sink should be removed as for loading and unloading, as they can
6.8. PUMPS to be vans or tank trucks
a complete unit for cleaning
and dragging, it must be provided with a Of course, the configuration of
Normally the pumps are located
adequate space at the ends get as close as possible and to rack, results from a plane of inte-
for dismantling. The majority- floor level of the containers of gracing, of terrain conditions,
the gear changers are located those who suck. client requirements and about
satisfied with the base more or less 1 all about the economy of the plant.
m above floor level. The Generally the elevation will be
level battery exchangers governed by the type of pump The elevation is determined by the
they are usually spaced out selected, and in relation to being- mostcriticalrequirementsof
0.9 m between them. vice and pumped liquid. In the agreement to the following:
to the extent possible, it should Minimumheightrequiredfor
In the distribution, the towers of preventing the bombs from being crazy
cooling must be fixed crossroads.
lowered below floor level, already Minimum height required above
the first one and the rest of the team that this involves civil work
after. The position of an inter- access to equipment located under the
expensive (for support structures rack.
heat exchanger in chemical plants involved) and problems of dre-
normalmicaandpetrochemicals Heightforinterconnectionof
naje. The bombs located in lines that are located in the
Mind depends on location raised points generally cau-
from the distillation columns. pipe bed to local equipment
there will be vibration problems in the given to the sides of the rack.
In the placement of exchanges- structural design.
The height of the rack should be
hot flashes, should be taken in Centrifugal pumps of type
consideration the following points more than necessary for mini-
cans require space in the part measure the length of vertical pipes
tos: frontal for arrow removal scales.
The exchangers must and for maintenance in the impulse-
sor. The length of the pipe rack is
to be immediately adjacent to others governed by the number and dimension
equipment such as reboilers and When there are several bombs teams sessions, structures and
they should be located near they must be located in such a way that
buildings located on both sides
their respective towers; the condemned remain aligned and aesthetically pleasing
delrack. It is required as an average-
sponsors should be close to their well distributed. Normally god, around 3 m in length
reflux tanks, and at the same time, cer- under the pipe rack. unrack each piece of equipment
pipes to the towers.
Ingeneral,themechanicalteam (exchangers, tanks, towers)
The exchangers must it should be placed in such a way compressors,etc.)forplants
to be close to other teams of that its maintenance and operation petrochemicals.
process, for example, the exchanges do not be interfered with by problems
With good distribution practices
bypass in closed circuits with of access.
thecostoftherackcanbe
pumps (recirculation circuits) in the considerably reduced.
case of an outflow through [Link] RACKS
from an exchanger from the fon- The pipe supports must be
from a container, with the purpose of The plant layout determines sized to allow
to have the suction lines to the in the piping route and the future expansions of the plant and
bombs, of shorter length. typical pipe rack arrangements they must run in parallel to the system of

CHEMICAL ENGINEERING - MAY 1998 117

 Fgi2.E
. xampelofgeneraolcazilaoitnpalnT
.ream
t entpalntandrecycnilgofcondensaets

paths to keep clear team 1=10 or 20 or 33 1/3 (area of regarding the light towers,
the process areas. If the support- process) since in case of escape, it must
river crosses an area that later prevent light vapors from being
With the information from the area dis-
willhavespaceforservicesof available, we proceed to the preparation
driven by the winds to the fire.
process will be severely restricted Delimitation of the plan. It is defined to scale.
Thus, in fractionated plants-
the available space for the equi- ras, the process equipment that
by process. the area available for the plant theydeterminethelocationofthe
with clearly defined lines the remaining team consists of towers and
The number of lines to be located battery limit calls of the
the bed can be estimated ovens, given that these devices
unit. This is done to define theyarethereferenceaxisforthe
by the drawing of the lines in a in addition the responsibility of the
printing of the "plot-plan" with the
location of the remaining equipment.
engineering firm. The minimum separation that reco-
flowchart assistance. By
the estimate of the number of lines Theareamustbeorientedtowards Iputtheliteratureamongthese
plant that is going to be drawn, of the equipment is 25 m. The separation
in the densest section of the rack,
so that the north is preferred minimum recommended between towers
the total width can be obtained from
towards the upper part or the light ones are 3 m; or if it exists
rack.
the left side. If the north see- team among them, such as reher-
true deviates from any of viewers,itwillbetherequiredfor
7. PREPARATION maintenance and operation.
the two previous addresses the
OF THE PLAN OF declination should be indicated in the
GENERAL LOCATION The floor level is another of the
integration plan.
data that must be indicated in the
Select the appropriate scale. The direction of the winds is a general localization plans
Thelocationplansof important factor that must be taken ofteams,theyareusually
teammustbedrawnin is taken into account when the referring to a pre-level bank
engineering scale. The scales Team plot-plan. Power cone- clearly fixed within the compl-
what is recommended to use for the to go where they can be sent the refinery. The floor level ter-
general location plan are ofthevaporsbythewind, mining (N.P.T.) is important for
the following: when there is a leak or simple- the location of equipment and structure
aventing,itisofutmostimportance heavy loads. An elevation of
Generallocationplan
importance. Based on this, it 0,0 should be avoided, as this
(master) 1=100 or 200
willdeterminethelocationof could lead to requiring levels
General localization plan of burner and oven equipment negatives for all jobs
118 CHEMICAL ENGINEERING - MAY 1998
 which shows the required area for
Fgi3.G
. eneraolcaoitnpalnR
. eacoitnsecoitnandrteam
t ent- to place the process equipment and
condensedmnit servicesaswellastheroomof
control. Figure 2 shows
an example of a plot plan.

8. FOOTNOTES
OF TEAM
AND INSTALLATIONS

The notes for recipients

vertical roofs, towers, heating
they should refer to the centers
(Fig. 3).
The specifications for containers
horizontals refer to the cen-
tropos and to the tangent line. Also
the elevation must be indicated to the line-
center lanes.
Annotations for changers
of heat shield and tubes, it refers to
go to the lines of the center of the crown
for the center lines of the nozzle
of the tubes. It also indicates the
elevation to center lines.
The annotations for engine of
compressors and control rooms,
they are at the center of columns.

The specifications for bombs are

undergrounds and lead to a confu- but they should be the minimum possible, to the center lines of the nozzle
unnecessary level session. especiallythefillings,since download.
Another point to consider these require slow work and
expensive, as the specifications The piping support, also
it is the entry of inputs and the exit denominadarack,itwillbelimitedto
of earthworks compaction and
of products, since this determines way that the main columns
tell the type of main support its control must be very strict.
A bad foundation can cause they will be indicated with numbers and the
to use (rack). There are several types columns inside the plant
settlement in the teams
of pipe supports depend on they will indicate with letters.
oftheinputentriesand and serious problems, mainly-
product outputs, in addition to the in the pipes; for that reason, if
the process allows it, it must be avoided 9. CONCLUSIONES
process, capacity, type and need
data of the plant; being able to be until the heavy teams or that
vibrant, are located in areas Inaworldofcompetition
these typeY, type T, type U, type Z as is the case in the industry, they must
filler.
and type L. analyze all possible ones
Next, the following are prepared
They must be ready by now. roadstowardsreductionof
schemes, locating first-
have the templates ready cost. In many industries, it is already
the individual areas it occupies lie to the teams that require difficult, if not impossible, to ensure
specialattentionsuchas
ran each of the indi teams- an advantage over the competition
towers, furnaces, pipe supports,
fallen in the Flow Diagram of Hi, in any of the factors
Process, as well as the team of quarter of control, which is the axis [Link],the
for location reference
ordinary services for the my- machinery, the distribution methods
of the remaining team.
moreneedsoftheprocess. distribution and even the salaries, have led
Thesetemplatesmustbefrom Once it has been located the to be more and more standardized
according to the dimensions indicates- oven,thetowers,thesupports [Link],theaddress
they are on the equipment and scale list main and control room, the mustincreasinglyensure,to
selected. remaining team templates are through the details (details that
They locate in the available area. affectthecostprice),their
It is also required in this
profit margins. One of
moment the configuration plan Selectedtheschemewith
topographic section, where it can be templates that present the arrangement these important details are the
plant layout.
studied the location of the of the most convenient team, it is brought
teams, taking into account the on a paper a location map The approach and resolution of the pro-
earthworks, such that preliminary general team formation distribution problems are so
CHEMICAL ENGINEERING - MAY 1998 119
important in scope and variety To achieve this, the engineer of Approach to Plan Layout, Chemical Engineering
which can only be compared to the distribution must be sure of Engineering, December 28 (1959).
process design. that has not gone unnoticed any Kern, R. "How toArrange The Plot"
element of physical particularity Plan for Process Furnaces, Hoffmann-La
The activities of the design of the pro- Roche Inc. Chemical Engineering, May 8
what should have been anticipated
and those of the distribution design inthedistribution,andatthesame
(1978).
are closely related. In Notes from the Engineering class
time, you must ensure that
the process design can be applied has recognized and investigated everything
Projects, Faculty of Chemistry, University
National Autonomous University of Mexico.
drive more quickly the principles
consideration that could influence
from engineering to a specific problem
in it. And for each consideration
I fit. In the design of the distribution,
ration must evaluate its meaning
all their activities are exceeded exact action or measure in which it
with the areas of all the disciplines affect its distribution. Each dis-
design tray bringing with it a distribution has certain elements or
great complexity. Many principles particularities that are very much
pious and requirements have to importance.
to conjugate in order to be applicable
two, and finally get a 10. BIBLIOGRAPHY
economic plant distribution and
aesthetics. [1] Conn, D. and Thompson, D. “Rational

120 CHEMICAL ENGINEERING - MAY 1998