CH3029 Plant Layout Syllabus:
CH3029 Plant Layout Syllabus – Anna University Regulation 2021
COURSE OBJECTIVES:
To understand the importance of plant layout in mitigating risk on people, plant, planet
To apply knowledge in placing equipment for ease of operability & maintainability
UNIT I STANDARDS FOR AREA CLASSIFICATION
Standards for area classification–Electrical Area classifications, OSHA (Occupational Safety and Health Administration) regulations, National Fire Protection Association (NFPA), Petroleum Hazards Classification, IP15 Petroleum classification based on flash point, OISD standards (Oil Industry Safety Directorate), API Codes (American Petroleum Institute), PESO (Petroleum and Explosives Safety Organization) guidelines, Investigations Reports & Best practices data Chemical Safety Board, USA Case Studies – From Industries on Lessons from Incidents from Environmental Protection Agency (EPA), Safety & Environmental Incidents, etc.
UNIT II INTER UNIT DISTANCES
Distance between plants, substation, centralized control room, utilities sections / captive power plants; Inter-distance between adjacent Columns, Storage tanks, Tank dykes; Flare stack location (based on Prevailing up-wind direction), Design to keep it smokeless, Sterile zone/area – Governing API /OISD Standards, Field cabins. Access to firefighting facilities, Fire tank capacity, Foam need assessment, Design to tackle simultaneous fire incidents, Protection of fire network and ensuring availability on demand, Risk evaluation(arising from inventory of inflammable liquid, potential formation of explosive mixture, operation above auto-ignition temperature, toxic release, etc.) based on credible scenario;3D models used in equipment & piping isometric, Maintenance accessibility, Safe work place specially at elevated platform, Ease of emergency evacuation; Bow Tie Analysis to mitigate risk right at design stage, Blast proof design of control room, Minimize employee occupancy at a given time in risk zone. Case Studies – From Industries on operations & maintenance aspects viz. Trouble shooting, Efficiency / Effectiveness tracking, Debottlenecking, Design tips, Safety & Environmental Incidents, etc.
UNIT III STORAGE TANKS
Storage Tanks – Fixed or Floating roof, Mounded Bullet tanks, Cryogenic storage tanks & their special design requirements, Special designs along with breather systems, Lightening arrestors, Earth pits, other appurtenances –Manways for roofs or tank sidewalls, Catwalks, Roof vents, Roof hatches, Nozzles, Roofs (flat-style, knuckle-style, or pitched), Aluminium geodesic domes, Ladders, etc. Comfort factors Vs Inventory carrying cost, Safe operation of floating roof travel, breather sizing, steam coils design, rainwater drains, dyke capacity, inter tank distance based on
product hazard classification, tank inspection schedule, ease of cleaning, confined place entry, water spray and other firefighting feature, fugitive emission control, etc. Case Studies – From Industries on operations & maintenance aspects viz. Trouble shooting, Water traps and roof collapse, safe filling height, Design tips, Safety & Environmental Incidents, etc.
UNIT IV AT RISK SYSTEMS AND EQUIPMENT
At-risk systems and equipment: Fuel gas systems, Fuel oil network, Hydrogen gas for generator cooling in power plants; Plant battery systems, Ammonia systems, Solid handling of coal and coke dust, Sulphur yard, Toxic gas loss of containment, etc, MSDS of every stream being handled / processed, Spent catalyst safe disposal ;Safe at Risk Assessment: Overall risk assessment using credible scenario along with preventive measures &systems to be in place to eliminate / minimize loss of containment. Case Studies – From Industries on operations & maintenance aspects viz. Trouble shooting, Process Control, Early event detection, Debottlenecking, Design tips, Safety & Environmental Incidents, etc.
UNIT V BASIC ENGINEERING DESIGN PACKAGE
Basic Engineering Design Package (BEDP): First document to be prepared and approved between Process Engineering Team and Owner’s representative. It shall cover not limited to – Site Conditions (weather, wind rose, seismic activity, water table, etc.); System of measurement (in FPS or MKS for flow of gas / liquid / steam, temperature, pressure, heat duty, inferential properties, etc.), Design considerations and margins, Design philosophies such as Operating & Control philosophy, Vent & Drain philosophy, Isolation philosophy, sparing philosophy etc. Raw material details (Capacity, conditions, logistics including receipt modes & storage criteria) Product offtake plans and modes of distribution, environmental norms, Levels of power & utilities that would be available for safe and hassle free operations ; Green belt cover, use of renewables, zero liquid discharge, maximum air cooling / condensing, storm water channel considerations, rain water harvesting ; Flare gas recovery, flight path and tall structures in industry premises, MIQA (mechanical integrity and quality assurance) considerations, equipment designed life ; Feed definition / variability / flexibility, product mix& swings, product quality, custody transfer design basis, turnaround plans ; Energy & loss targets and best in class design considerations, criteria for smooth and faster start-up, onstream factor, spinning margin, applicable codes, built in features for continual improvement, advanced process control and other s/w deployment for SCM (Supply Chain Mgt) and O&M (Operation and Maintenance) excellence. Case Studies – Lessons learnt from Industries viz. examples of regret investment, deviations from original design & impact thereof, market forces & design adaptability, challenges in product quality, etc.
TOTAL: 45 PERIODS
OUTCOMES:
On completion of the course, the students will be able to
CO1 – understand the importance of plant layout in mitigating risk on people, plant, planet
CO2 – understand the knowledge in placing equipment for ease of operability & maintainability
CO3 – understand the storage tanks operation and usage at safety level
CO4 – knowledge on usage of equipment at safety levels and their risk assessment
CO5 – understand the basic engineering design package
TEXTBOOKS
1. Chemical Engineering Design Principles, Practice and Economics of Plant and Process Design – GAVIN TOWLER and RAY SINNOTT
REFERENCE BOOKS
1. OISD Guideline on Plant Layout – OISD-STD-118
2. OSHA Guidelines on Plant Layout
3. API Guidelines on Plant layout