An Overview Of

PLANT
LAYOUT
AND
REAL - a member of Reliance Group
PIPING
 Piping Concepts
Site Plan
Considerations
 All aspects of safety, operability, maintenance, constructability and
economics.
 Layout and spacing of the roads, process plants, tanks and piperacks.
 Equipment location & spacing, associated piping, controls & maintenance
& constructability
 Good accessibility to valves and instruments, avoiding hazardous
obstructions like misplaced manifolds, valve stems & support columns.
 Constructability to ensure no obstruction to transportation, lifting &
erection of equipment due to adjacent plant, structures or equipment and
compliance to sequenced construction plan.
 Potential late delivery of large equipment items to avoid serious impact on
construction schedule.
 Piping Concepts
Site Plan
 One overall site plan for the entire complex, interconnecting piperacks
and their relative locations to be made.
 Process units and offplot facilities, to be constructed to common
schedule to be grouped and located to ensure minimum impact from
and to the operating plant during construction for later phases.
 Prevailing wind direction to be considered for special cases.

For e.g., Flares for the refinery to be located upwind of the process units.

 Layout of the tankage area to suit the flow of products and feed stocks
with the pumps stations located outside of the bunded area.
 Roads to be provided around the tanks for access to all areas for
maintenance & fire fighting.
 Piping Concepts
Unit Plot Plan
 One unit plot plan for each process unit.
 Equipment layout & spacing to allow for maintenance & constructability
 Air coolers to be on top of a pipe rack. No equipment is to be located
above or below coolers to facilitate access to place the air coolers and
remove the tube bundle for maintenance.
 Furnaces and boilers to be located at plot boundaries for ease of access.
Adequate dropout and swinging space for tube pulling by mobile crane.
 Fired heaters to be located upwind of process units. In congested
process areas, heater locations to provide the lowest risk of fire or
explosion.
 Exchangers to be with channel end away from piperacks to facilitate
tube bundle removal
 Pumps handling flammable materials not to be located below piperacks
but to be placed with centreline of discharge at min. 1.5 m from the
centre line of pipework column.
 Piping Concepts
Unit Plot Plan
 Compressors to be located adjacent to roadway and downwind from
heaters & to be in shelters to provide protection for equipment &
personnel. Bridge or gantry crane for removal of compressor
components.

 Vertical vessels to be placed on a common centreline parallel to the

main piperack USO.

 Horizontal vessels to be located to minimise piping runs & to be lined

up with their tangents on a common locating line.

 Reactors to be located for ease of access during catalyst unloading and

loading operations. Space to be provided for cranes and storage of
spent and new catalyst.
 Stress Analysis
 Pipe Stress Analysis
Purpose
 To ensure that piping is routed and supported so that no damage occurs
to either the pipe or associated equipment due to the effects of thermal
expansion or contraction, or loads resulting from weight, pressure, wind
earthquake, pulsation, shock, foundation settlement, etc.
Procedure
 Ensuring compliance to all Code, Client and Inspection Authority
requirements pertaining to Piping Stress Analysis.
 Establishing all operating functions including start-up, shutdown,
steam-out, various combinations of equipment working and idle,
bypasses in and out of use, de-coking, etc., for lines to be analyzed.
 Stress Critical Line List Review.
 Nozzle loads calculations.
 Stress Analysis
 Pipe Stress Analysis
 Check for flange leakage where bending moments are large, including
flanged connections at equipment.
 Anchor loads on structures and/or foundations.
 Finalising the location of spring supports with required loads and
movements on the Stress sketch.
 Analysing requirement of reinforcement at branch connections, (other
than for internal/external pressure considerations covered by the Piping
Material Specification), or at concentrated loading points.
 Considering expansion joints in stress analysis
 Checking position of fixed and sliding supports of heat exchangers,
horizontal drums, etc.
 Review of vendor drawings for equipment nozzle loadings.
 Piping Layout & Isometrics
Piping Layout (GA)
Purpose
 For piping installation within a construction area.
 Information for construction planning.
 Information for testing and pre-commissioning.
 Information for Plant Operators.

Methodology
 Piping arrangement drawings produced in two stages:
– Planning drawing (study sketches / 2D CAD )
 To solve major design problems, transmit information & co-ordinate
activities of the different design departments.
 Preliminary piping arrangement for inter-discipline review & comment.
– Final drawings (3D CAD model or Non-CAD manual drawing)
 For 2" and larger lines with dimensions and labelling
 Piping Layout & Isometrics
Piping Layout (GA)- Methodology
 GA Using 3D CAD Model
– G.A. drawings to be extracted from 3D CAD model.
– All verification, geometric & clash checks to be completed (including
equipment checks to vendor data) before IFC GA extraction.
 Non-CAD GAs
– Additional Pipe support GA’s issued for construction to reflect pipe support
requirements only.
 Piping Layout & Isometrics
Piping Layout (GA)
Design Data
 High point of grade.
 Column and vessel orientation design sketches including:
– nozzles and manways
– column and vessel piping
– platform and ladder size
– instrument orientation and location
– height of tower and vessel skirts
 Orientation of major equipment nozzles, i.e. pumps, exchangers, compressors, etc.
 Top of grout for all equipment foundations & pads.
 Pipe rack widths, bent spacing and top of support elevation of main pipe racks.
 Allocation of space for electrical, instrument racks, analyser houses, switchgear,
and utility hose stations.
 Location of all main structural columns.
 Elevations of structural levels and extent of platforms, ladders and stairs required.
 Piping Layout & Isometrics
Piping Layout (GA)
Contents of Piping Layout
 Equipment co-ordinates.
 Elevations (Piping, Equipment, Platforms, etc.).
 Line No. Identification and Flow Arrow.
 Instrument Identification
 Match lines.
 Drawing Continuation References.
 Key Plan Identification.
 Complete "Holds" List.
 Reference Drawings.
 Structural Column Identification.
 Piping Layout & Isometrics
Piping Layout (GA)
Piping Layout - Checkpoints
 Conformance with P&ID's for
 Line number, size, classification, direction of flow.
 Instrument connections and numbers (long form).
 Piping material classification changes.
 Drawing "Holds" list.
 Drawing title block & Drawing key plan.
 Compliance with standard drawings and plot plan.
 Adjacent drawings & key plans for correct co-ordinates & drawing references.
 Fire & Safety requirements & location of fire fighting equipment.
 Location of Drain hubs, Utility stations, safety showers, eyewashes, drinking
fountains & ladders.
 No fouling of piping with structures, equipment and other lines.
 Requirements for operating aisles, headway and roadway clearances and other
mandatory dimensional clearances.
 Piping Layout & Isometrics
Piping Isometrics
Purpose
 Adequate information to fabricate shop pipework.
 Adequate information to field run small bore piping.
 Adequate information to erect the pre-fabricated pipe spools.
 Adequate means of identifying materials for above mentioned isometrics.
 Adequate information for locating & identifying pipe supports welded to shop
fabricated pipework.

Methodology
 Shop and field isometrics to be extracted/drawn & self-contained within a model
base, plant or unit as defined at start of job.
 Shop isometrics to be adequately dimensioned to enable spooling
and/or shop fabrication.
 Field isometrics to be extracted/drawn with overall dimensions only for
material purposes & to assist field erection.
 Piping Layout & Isometrics
Piping Isometrics - Methodology
 Isometrics using 3D CAD Model
– Isometrics to be extracted from 3D CAD model.
– Isometrics need not be fully checked dimensionally.
– P & ID check of the isometric and yellow off to be done.
– Material to be downloaded from model.
– Isometric to be downloaded for piping spool drawings.
 Non-CAD Isometrics
– Manually prepared on Isometric Sheet.
– Both dimensional and P&ID checks to be done.
– Material to be manually entered.
 Piping Layout & Isometrics
Piping Isometrics
Contents of Piping Isometrics
 Line Number & Size
 Pipe Classification
 Direction of Flow
 Equipment Reference & Nozzle Identification
 Structural Number Identification
 Isometric Drawing Continuation References
 All Valving (except vent and drain valves)
 Strainers, Traps & Flexible Hoses
 Break with Shop and Field
 Field Welds (but not shop welds)
 Vents (as V) & Drains (as D)
 Orifice Assemblies
 Piping Layout & Isometrics
Piping Isometrics - Contents
 Spectacle Blinds and Spacers
 Instrument Numbers, such as PI, TIs, TWs, etc.
 Instrument Connections
 Out of Specification Items
 Sample Points
 Special Shop Attachment of Pipe Support
 Dummy Legs
 Cold Pull
 Special Line Features, such as Fall, Reinforcing Pads, Weep Holes, Welded
Lugs, etc.
 Spool Identification (suffix letter only)
 Insulation (include limit)
 Piping Materials
 Scope
 Material take-off
 Updating & control of material quantities with design
 Monitoring of material requisitions.
 Method
 Automated Material Control
– MTO download from 3D CAD Model
– Manual Material Entry (for non-modelled items).
 Link to Procurement Tracking System

 Piping Stock Code

 Project Stock Code Index generated by Piping Material Classes to be
issued as a project specification.
 Piping Materials

 Responsibility
 Lead Piping Engineer to schedule and co-ordinate all piping material
take-off activities and material requisitioning.
 Civil Group to give take-off of underground carbon steel non-
pressure piping using the appropriate piping class.
 Instrument Group to give take-off of all instrument piping beyond the
primary (root) block valve (except at level instruments).
 Electrical Group to give take-off of all electrical cable duct piping.
 Piping Materials Engineer to transmit a summary of all tubing and
tubing fittings requirements to Instrument Group for requisitioning.
 Piping Materials

 Material Control
 Initial material take off from :
– Completed preliminary line routings in the CAD model
– Manual take off from P&IDs
 Total forecast material requirements including working surplus and
contingency form the basis of the Bulk Material Requisitions.
 Frequency & timing of material extractions from CAD model & manual
MTO ensure that bulk material status is concurrent with design.
 Field material control is possible as the data within the piping material
control programme is downloaded to Procurement Tracking System.
 Material requisitions issued to procurement for enquiry/ purchase.
 MR quantities issued for purchase (initial & at each revision) are
downloaded to Procurement Tracking System.
 Statutory Requirements
 Applicable Codes
 International piping codes and standards accepted in India
– ASME/ANSI B31.1, “Power Piping”
– ASME/ANSI B31.3, “Chemical Plant and Petroleum Refinery Piping”
 Oil Industry Safety Directorate,Standard 118.
– Layout & spacing of roads,buildings,storage tanks and all equipment

 Authority Approval
 Indian Boiler Regulations (IBR)
– Materials and fabrication associated with steam and boiler feed systems.
 Chief Controller of Explosives. (CCOE)
– All Plot Plans for approval together with safety radii from various sources.
(Hazardous Area Drawings).
 Tariff Advisory Committee (TAC)
– Fire protection system & material selection.
 THAT’S ALL ABOUT

Plant Layout & Piping