Page 59 - APPLIED PROCESS DESIGN FOR CHEMICAL AND PETROCHEMICAL PLANTS, Volume 1, 3rd Edition

46 Applied Process Design for Chemical and Petrochemical Plants

Table 1-11
Layout and Process Development Engineering Check-List

SITE (ASSUMES SITE SELECTED) and methods of shipment (trailer truck, box car, tank car, hop-
1. Ground contour and its relation to general orientation of build- per or special car). Consider in-transit and turnaround time
to determine number in use.
ings and equipment.
2. Drainage and waste disposal, details to prevent erosion. GENERAL LAYOUT
3. Set plant elevations: floor elevations of buildings and bottom of
steel footings for equipment and large storage tanks. 1. Use of models.
4. Location of any existing or probable locations for new railroads, 2. Maintenance considerations associated with each building,
roads, power lines and power sources, telephone lines, water sup- process area and equipment. Consider (a) access for cranes and
ply, residential and/or industrial buildings or structures. trucks (b) work space for local repairs (c) operating conditions
5. Legal Requirements and Permits. of adjacent parts of process to allow local repairs.
a. Rights of way for pipe crossing of road, highway, railroad, 3. Initial construction sequence and problems.
rivers, canals, etc. 4. Materials of construction for buildings.
b. Easements for pipe lines, power lines, etc. 5. Roads: paving, width.
c. C.A.A. approval on airports, and for construction and paint- 6. Basic pattern for concrete, gravel or asphalt paving or work
ing of structures in certain areas in airport vicinity.
d. Underground storage wells for chemical and hydrocarbon floors in operating and adjacent areas.
products. 7. Fencing.
e. Railroad approval of road crossings, additions to existing 8. Plant pard or security system.
facilities, automatic railroad gates, required state and railroad
clearances.
AND FIRE HAZARDS
f. Navigable stream requirements and permits. ELECTRICAL
1. Define plant areas handling hazardous and lethal materials and
CLIMATE set rules for design considerations, such as ventilation, explosion
I. Prevailing wind; locate hazardous vents, burning flares, waste walls, etc. Flammable storage materials may require enclosed
dikes, foam systems and the like. Refer to National Board of
burning pits, waste settling ponds down-wind of plant proper. Fire Underwriters or specific insurance company to coordinate
2. Nature of climate. Consider seasonal and daily temperature recommended protection. Attawayl has details on many points
variations, dust, fog, tornados, hurricanes, earthquakes. Define to consider.
duration of conditions for design. Determine from U.S. Weather 2. Define plant areas requiring explosion-proof, drip-proof and
Bureau yearly statistics for above, as well as rainfall. Establish open motor and associated electrical components. Refer to Na-
if conditions for earthquakes, hurricanes prevail. For stormy tional Electrical Code and National Electrical Manufacturer’s
conditions, structural design for 100 miles per hour winds Association Standards.
usually sufficient. For hurricanes, winds of 125 miles per hour
may be design basis. 3. Define areas and buildings to use wet and dry sprinkler systems,
3. Corrosion. Plants located close (within 100 feet) to seas, oceans, foam systems, location of hand and hose fire extinguishers, fire
carts, fire engines.
bays, lakes encounter more severe corrosion than if located one-
fourth mile or more away. Some highly industrial areas are 4. Define location of fire walls, fire hydrants.
more corrosive than rural or non-industrial locations. Additional 5.Review layout for fire equipment access, and secondary and
details are presented by Mears.15 emergency exit roads from each area.
4. Pollution of Air and water. Determine allowable limits for 6. Review entire fire and other hazards program with insurance
atmospheric vent as well as liquid wastes. Consider neutraliza- representatives. Industrial insurance companies have excellent
tion. Determine federal, state and local regulations and effect of facilities for evaluating the associated problems.
climatic conditions on dispersion.
UTILITIES AND RAW MATERIALS SAFETY REQUIREMENTS
1. Special design problems for emergency handling of dangerous
1. Sources and methods of transportation and packaging. or lethal materials.
a. Water: potable, service, brackish, sea or ocean, cooling tower.
b. Steam: condensate disposal, feed-water make-up 2. Safety as it is reflected in factors of safety in design of pressure
vessels, pressure testing of piping and vessels, etc. Use of A.P.I.,
c. Gas: (1) Process; may not be odorized A.S.M.E. and ASA Codes; Code Stamps on equipment.
(2) Fuel; odorized 3. Areas requiring safety showers and eye wash stations.
d. Oil: fuel, lubrication (or Liquefied Petroleum Gas)
e. Air, (1) Utility 4. Design and selection philosophy for use of safety devices for
pressure relief and alarm.
(2) Instrument; must be dry below lowest equivalent
dew. point to prevent moisture condensation and 5. Inside block valves on acid and caustic storage vessels.
freezing. 6. Emergency power and other facilities to control safe operation
f. Power or shut-down.
2. Warehouse receiving and storage: drums, boxes, carboys for raw
processing materials as well as laboratory control and testing
chemicals. FUTURE GROWTH
1. Define areas of future growth and associated space requirements.
PRODUCT SHIPMENTS 2. Correlate future expansion plans to required utilities and raw
1. Conditions for pipe line transfer of product to user or customer. materials as related to economics of required installation.
2. Warehouse conditions for bagging, boxing, crating, palletizing 3. Consider spare equipment, present and future.