piping equipment layout
Piping equipment layout, also known as piping arrangement or pipe rack design, is a critical aspect of industrial and plant engineering. It involves the strategic positioning and arrangement of various piping components, equipment, instruments, and support structures within a facility. Proper piping equipment layout is essential to ensure the efficient operation, safety, and maintainability of a plant or facility. Here are some key considerations and principles in piping equipment layout:
Safety: Safety is paramount in piping equipment layout. Ensure that piping routes and equipment placement comply with safety codes and regulations. Maintain safe distances between equipment to allow for maintenance and emergencies.
Flow and Accessibility: Design the layout to optimize the flow of materials and fluids throughout the facility. Ensure that equipment is easily accessible for operation, maintenance, and inspection.
Spatial Planning: Consider the available space and spatial constraints when arranging equipment. Efficient space utilization is crucial for maximizing the facility's productivity.
Zoning: Divide the facility into functional zones based on the nature of operations or processes. For example, separate areas for storage, production, utilities, and offices. This helps in organizing the layout effectively.
Piping Routing: Plan the routing of pipes and pipelines to minimize bends, turns, and pressure losses. Consider the use of pipe racks or elevated platforms to keep pipes organized and accessible.
Equipment Spacing: Ensure adequate space between equipment to accommodate maintenance activities, equipment replacement, and the installation of new equipment.
Equipment Elevation: Elevate certain equipment or systems, such as pumps, compressors, or tanks, to optimize space and simplify maintenance access.
Support Structures: Design and install support structures, such as pipe racks, cable trays, and equipment foundations, to secure and organize piping and equipment.
Instrumentation and Control: Integrate instrumentation and control systems into the layout to monitor and manage equipment and processes effectively.
Flexibility: Plan for future expansions and modifications by leaving space for additional equipment or pipelines. Ensure that the layout allows for flexibility and scalability.
Clearances: Maintain appropriate clearances around equipment to accommodate ventilation, cooling, and safety requirements.
Utility Connections: Ensure that utility connections, such as electrical, water, gas, and steam, are easily accessible and properly integrated into the layout.
Material Handling: Consider the movement of materials, equipment, and personnel within the facility. Design pathways and access points for material handling equipment.
Compliance: Adhere to industry standards, building codes, and regulatory requirements when designing the layout.
Communication: Promote effective communication by considering the placement of control rooms, offices, and communication equipment within the layout.
Piping equipment layout is a complex and multidisciplinary task that requires collaboration among engineers, architects, and various stakeholders. It plays a crucial role in the overall efficiency and functionality of industrial facilities, ensuring that processes run smoothly, maintenance is manageable, and safety is maintained.
Steps involve in plant design, conceptual layout design and equipment layout design
1. What are the steps involve in plant design?
The mechanical design and development of the plant has three major steps as:-
A. Conceptual layout design.
B. Equipment layout design.
C. Piping layout design..
2. What is conceptual layout design?
It is the part of basic engineering package. It consists of following information:-
A. Essential process design requirement such as horizontal & vertical relationship of equipment.
B. Space allocation for basic plant requirement (space required for laboratories, office, storage etc.)
C. Planning for control room, motor control center room etc.
3. What is equipment layout design?
It is the detailing of conceptual layout. It is the basic document of mechanical engineering design or in other words this document is the basis for development of construction drawing by all disciplines. It is sometimes also referred as plot plan for large outdoor plant. It consists of following information:-
A. Floor space needed for the equipment and other facilities are shown.
B. Access, removal space, cleaning area, storage space and handling facilities are outlined.
4. What are the essential data/ documents required for preparation of equipment layout?
The essential data or documents required for preparation of equipment layout is as:-
A. Process Flow Diagrams (PFD) and Piping & Instrument Diagrams (P&ID).
PFD/P&ID indicates the interconnectivity of each equipment, information regarding solid handling, gravity feed, line slopes, loop sizes, venting requirement, special piping materials etc. which in turns governs the equipment location to a great extent.
B. Project design data.
This consists of following information as:- Geographic location, proximity to roads and railway, topography and local codes and regulations, weather conditions such as rainfall records, seasonal temperature differences, wind direction, outlet points for drains etc. The above information such as wind direction influences the location of cooling towers, furnaces, stacks etc. Similarly, the information regarding outlet drain points affects the design of storm water drains and requirements of enclosures.
C. Equipment sizes and building.
This includes fabricated equipment such as vessels, heat exchangers, reactors, tanks and proprietary equipment like pumps, compressors, furnaces etc. For locating the above, the equipment is grouped to have optimum location for minimum pipe run as well as fallow the process flow sequence.
5. What are the two basic configurations for the equipment layout (unit plot plan )?
The equipment layout can basically be divided into two configurations:
A. The grade mounted horizontal arrangement as seen in the refineries and petrochemical plants.
B. The vertical arrangement as seen in many chemical process industries.
6. What is grade mounted horizontal arrangement of equipment layout?
In the grade mounted horizontal arrangement, the equipment is placed on the either side of the central pipe rack with auxiliary roads. Advantage of this arrangement is that the equipment is located at grade level, which makes it easier to construct, operate and maintain. Disadvantage is that it takes lot of ground area.
7. What is vertical arrangement of equipment layout?
The structure mounted vertical arrangement has equipment located at multilevel in steel or concrete structure. This could be indoor or outdoor. Advantage is of small coverage area and ability to house the facility to suit process requirement or climate conditions.
9. What is line routing diagram?
A line routing diagram is a schematic representation of all process and utility - piping system drawn on a copy of plot plan. This diagram does not show the exact locations, elevations or interference but it locates the most congested area.
calculate the width of pipe rack
10. How do you calculate the width of pipe rack?
W = (f X n X s) + A + B.
…Where, f : safety factor
= 1.5 if pipes are counted from PFD.
= 1.2 if pipes are counted from P&ID.
n : number of lines in the densest area up to size 450NB.
= 300 mm (estimated average spacing)
= 225 mm (if lines are smaller than 250 NB )
A : additional width for: –
: lines larger than 450 NB.
: For instrument cable tray / duct.
: For electrical cable tray.
s : 300 mm (estimated average spacing)
: 225 mm (if lines are smaller than 250 NB)
B : future provision
= 20% of (f X n X s) + A
headroom clearance and drawing / layout is required for piping layout?
13. At which location the wide spacing (spacing more than the normal) in between the column is necessary?
Wide spacing is necessary at road crossing or where loading or access space is needed.
14. How much headroom clearance is required under the following type of crossing?
A. Structures / pipe lines inside operating area.
B. From top of the rail.
C. Above crest of road for crane movement.
D. Above crest of road for truck movement.
E. Above crest of road between process units.
The headroom normally provided is as: -
A. Structures / pipe lines inside operating area. : 2200
B. From top of the rail. : 7000
C. Above crest of road for crane movement. : 7000
D. Above crest of road for truck movement. : 6000
E. Above crest of road between process units. : 4500
15. What sort of drawing / layout is required for piping layout?
The following drawing / layout are required for piping layout.
A. Piping & instrumentation diagram (P& ID).
B. Equipment layout.
C. Piping specification.
D. Equipment drawing.
E. Vendor requirement for proprietary equipment.
16. What care shall be taken while routing piping for instruments?
Following points shall be taken care of while routing piping for instruments.
A. Flow measuring instrument needs certain straight length on upstream & downstream of the instruments. Normally, 15D on the upstream and 5D on the downstream is kept.
B. The pipe line in which flow meters such as magnetic flow meters, vortex meters, turbinemeters etc are located shall be routed in such a way that the line must be filled with liquid all the time. The pipe line shall be supported with robust support on both side of the meter.
C. Control valves are located at grade e.g. at about 500mm height from finished ground to provide convenient access for operation and maintenance. Block and bypass valve shall be located to have easy operation/access from the grade. Locating control valve on the vertical line shall be avoided.
D. Isolation valves for level gauges and pressure gauges shall be made accessible. All primary and secondary indicators of pressure, temperature, flow, level, positioners etc shall be visible from the operating area.
E. Rotameter shall be placed on vertical line and the inlet shall be from the bottom of the instrument.
Economic piping, Process requirement, Common operation, Underground facilities
8. What are the basic principles of locating the equipment irrespect of the type of arrangement?
The certain basic principles to be followed while locating the equipment is as:-
A. Economic piping :
In order to minimize the cost of piping, the equipment should be located in process sequence and close enough to suit safety needs, access requirements and flexibility. The equipments are identified which forms the subsystem within the unit. The component within the subsystem to be arranged to have most economical piping and the whole subsystem to be arranged within the unit to have most economic interconnection.
B. Process requirement:
The equipment layout should support requirement like minimum pressure drop, gravity feed and loop.
C. Common operation:
The equipment that requires common maintenance facilities, common utility and continuos operator attention shall be located the same area.
D. Underground facilities:
Before deciding the equipment location, the facilities such as storm water drain, effluent drain, fire water, cooling water to be placed underground.
column of pipe rack
11. Up to what limit the width of pipe rack is restricted? What type of arrangement shall be done if the width of rack calculated is more then the restricted limited?
Normally pipe rack width is limited to 6.00 Mtrs. If the width of rack calculated is more then the arrangement shall be done in multiple layers. The arrangements adopted are: -
A. Single column rack ‘T’ type.
B. Double column rack with a single tier.
C. Double column rack with a double tier.
12. How much space is kept in between column of pipe rack?
Normally, 5 to 6 mtrs. spacing is kept in between the column of pipe rack.
piping layout guidelines
Here are some piping layout guidelines:
- Simplicity: The piping layout should be as simple as possible, with minimal bends, fittings, and valves. This will reduce the cost of the system and make it easier to maintain.
- Accessibility: The piping layout should be designed to allow for easy access to valves, flanges, and other components for maintenance and inspection.
- Safety: The piping layout should be designed to minimize the risk of leaks, spills, and fires. This includes using appropriate materials and valves, and installing the piping in a way that protects it from damage.
- Efficiency: The piping layout should be designed to minimize the pressure drop and maximize the flow rate of the fluid or gas being transported.
- Cost: The piping layout should be designed to minimize the cost of the system, while still meeting all of the other requirements.
In addition to these general guidelines, there are a number of specific factors that should be considered when designing a piping layout, such as the type of fluid or gas being transported, the operating pressure and temperature, and the environmental conditions.
Here are some additional tips for designing a piping layout:
- Use a scale drawing or 3D model to plan the layout. This will help to ensure that the piping fits properly and that there are no conflicts with other equipment.
- Consider the thermal expansion and contraction of the piping. This is especially important for piping systems that transport fluids or gases at high temperatures.
- Design the piping system to withstand the forces of vibration and shock. This is important for piping systems that are installed in industrial environments.
- Use appropriate supports and hangers to support the piping. This will help to prevent the piping from sagging or vibrating.
- Label all of the pipes and valves clearly. This will make it easier to identify and maintain the system.
By following these guidelines, you can design a piping layout that is safe, efficient, and cost-effective.
what is equipment layout
Equipment layout, also known as plant equipment layout or facility layout, is the systematic arrangement and positioning of machinery, equipment, tools, workstations, storage areas, and other physical assets within a facility or industrial plant. The goal of equipment layout is to create an efficient, safe, and productive environment that optimizes the use of space and resources.
Key aspects of equipment layout include:
Space Utilization: Effective equipment layout ensures the efficient utilization of available space, allowing for the smooth flow of materials, products, and personnel within the facility.
Workflow Optimization: The arrangement of equipment is designed to minimize material handling, reduce bottlenecks, and improve the overall flow of work processes. It considers the sequence of operations and minimizes unnecessary movement.
Safety: Safety is a top priority in equipment layout. Proper spacing and safety clearances are maintained to prevent accidents, facilitate emergency evacuation, and ensure compliance with safety codes and regulations.
Ergonomics: Equipment is positioned to promote ergonomic work conditions, reducing physical strain on operators and workers. This includes considering factors like reachability, accessibility, and workstation design.
Maintenance Access: Easy access to equipment and machinery for maintenance and repairs is a critical consideration. Maintenance personnel should be able to reach and service equipment without major disruptions to operations.
Flexibility: Layouts should allow for adaptability to changing production requirements, expansion, and the addition of new equipment. Flexibility is essential for long-term operational efficiency.
Energy Efficiency: The positioning of equipment can impact energy consumption. Equipment layout should take into account energy efficiency measures, such as optimizing the placement of heating, cooling, and ventilation systems.
Material Handling: Considerations for material handling equipment, such as conveyor systems, forklifts, and cranes, are integrated into the layout to ensure efficient movement of raw materials and finished products.
Regulatory Compliance: Layouts must adhere to industry-specific regulations and standards, including safety, environmental, and zoning regulations.
Communication: Effective communication systems, control rooms, and monitoring stations may be integrated into the layout to facilitate coordination and information exchange.
Equipment layout is a critical aspect of facility planning, particularly in industries such as manufacturing, warehousing, logistics, and industrial production. Efficient equipment layout can significantly impact productivity, safety, and the overall success of an operation. It is typically a collaborative effort involving engineers, architects, facility managers, and other professionals to create an optimized and functional work environment.
Equipment layout in piping
Equipment layout in piping is the process of arranging piping equipment in a way that is safe, efficient, and cost-effective. There are a number of factors to consider when designing an equipment layout, such as:
- The type of fluid or gas being transported
- The flow rate of the fluid or gas
- The pressure of the fluid or gas
- The temperature of the fluid or gas
- The distance between the different pieces of equipment
- The accessibility of the equipment for maintenance and inspection
- The safety of the equipment and personnel
When designing an equipment layout, it is important to consider the following guidelines:
- Simplicity: The equipment layout should be as simple as possible, with minimal bends, fittings, and valves. This will reduce the cost of the system and make it easier to maintain.
- Accessibility: The equipment layout should be designed to allow for easy access to valves, flanges, and other components for maintenance and inspection.
- Safety: The equipment layout should be designed to minimize the risk of leaks, spills, and fires. This includes using appropriate materials and valves, and installing the equipment in a way that protects it from damage.
- Efficiency: The equipment layout should be designed to minimize the pressure drop and maximize the flow rate of the fluid or gas being transported.
- Cost: The equipment layout should be designed to minimize the cost of the system, while still meeting all of the other requirements.
In addition to these general guidelines, there are a number of specific factors that should be considered when designing an equipment layout for a piping system, such as the type of fluid or gas being transported, the operating pressure and temperature, and the environmental conditions.
Here are some additional tips for designing an equipment layout for a piping system:
- Use a scale drawing or 3D model to plan the layout. This will help to ensure that the equipment fits properly and that there are no conflicts with other equipment.
- Consider the thermal expansion and contraction of the equipment. This is especially important for piping systems that transport fluids or gases at high temperatures.
- Design the equipment layout to withstand the forces of vibration and shock. This is important for piping systems that are installed in industrial environments.
- Use appropriate supports and hangers to support the equipment. This will help to prevent the equipment from sagging or vibrating.
- Label all of the equipment clearly. This will make it easier to identify and maintain the system.
By following these guidelines, you can design an equipment layout for a piping system that is safe, efficient, and cost-effective.