PLANT LAYOUT

1. Equipment Arrangement

4.1 Pumps4.1.1 Suction pompa harus diletakkan sedekat mungkin dengan

Vessel, dengan posisi suction pompa yang dekat dengan Vessel dapat mengurangi kerugian akibat friction dan pressure drop sehingga NPSH pompa tetap mencukupi.Rumus NPSH :

NPSHa = Ha + Hs – Hvp – Hfs

Hfs = ( fs x Ls x Vs2 ) / ( 2 x g x di )

P = ρ x g x h

NSPHa > NPSHr

Ha  =  Atmospheric Head Hs  =  Suction Head Static (level fluida,positif atau negative)Hvp =  Vapor Head fluida (head = pressure)Hfs =  Friction Head Losses dalam suction piping dan konektor-

konektornya (Hfs ≈ panjang pipa, jumlah fitting, 1/ Pipe Ø)

Fs  = Friction factor ( pipe roughness )Ls =  Total panjang pipaVs = Velocity (kecepatan aliran fluida)di = Inside Diameter

NPSHa = Absolute pressure available at Suctiom PumpNPSHr = Minimum required absolute pressure at Suction Pump

to prevent Cavitation.Cavitation = Formation of vapour cavities in a liquid. It is

happen when the liquid pressure drop below vapour pressure.

4.1.2 Pompa yang berbahaya (hazard pump) yang mengalirkan cairan mudah terbakar (liquefied flammable gas) yang dapat terbakar sendiri (autoignition) diatas temperature 260 C atau bertekanan diatas 34.5 bar tidak diperbolehkan dipasang di bawah piperack (lihat Gb.1).Sedangkan untuk pompa jenis lain (non-hazard pump) harus diletakkan tepat dibawah piperack untuk menghemat tempat (lihat Gb.2).

Gb1. Hazard Pump Gb 2. Other Pump

Hs

Hfs

Ha

NPSHa

Piperack Piperack

Not OK OK

Liquid :- Liquified Flammable gas- Flammable&Combustible

liquid (autoignition temperature > 260C or operated above 34.5 bar).

Liquid :- Other Liquid (Non-Flammable)

4.1.3 Pompa harus disusun secara parallel dengan piperack agar penempatannya seragam dan rapi.

4.1.4 Untuk maintenance pompa yang terletak dibawah piperack atau steel structure, pemasangan maintenance beam atau hook diatas pompa harus sudah direncanakan, kecuali :(1) Tersedia akses jalan untuk maintenance vehicle (cth. forklift

dll.)(2) Akses untuk mobil crane memungkinkan.

Maintenance beam or hook (1) Tersedia akses jalan untuk maintenance vehicle

(2) Tersedia akses mobil crane

PLANT ROAD

Piperack

Maintenance beam

Piperack

Maintenance vehicle

4.2 Compressor

4.2.1 Compressor harus diletakkan di ground ( tanah ) beserta dengan pipa dan pendukungnya (oil unit) dan didesain agar akses dan maintenance senyaman mungkin.

( Plan View )

( Section A- A )Namun ada beberapa kondisi yang tidak memungkinkan untuk meletakkan Compressor di ground yaitu untuk Compressor dengan arrangement sebagai berikut :(1) Jika pipa yang terkoneksi ke nozzle Compressor terletak di

bagian bawah Compressor, maka Compressor harus

PLANT ROAD Mobil Crane

M

C

A

A Maintenance access

Oil unit = auxiliaries

M CGL. El. 00

Oil unit = auxiliaries

L = Close Distance

Slope requirement for return line (see vendor print)

#Suct #Disch

dinaikkan (diletakkan di atas) dengan mempertimbangkan jarak yang cukup untuk memasang pipa dan pendukungnya di bawah platform.

Note : H1 = Min. straight length ( min 6D or as per vendor confirmation)

H2 = Height of pipe support + CL pipe + elbow + reducer H3 = Nozzle projection length

Desain Compressor yang diletakkan di atas (elevated), yang paling penting bagi Disiplin Piping adalah menentukan/mengoptimasi elevasi (H) BOC (Bottom of Concrete) yang harus sudah dilakukan di awal ( P&ID AFP) dan sebisa mungkin data yang diberikan sudah akurat, karena data tersebut sangat dibutuhkan Disiplin Civil Structure untuk mendesain size dan dimensi RC Deck. Untuk itu agar dalam optimasi bisa mendapatkan angka yang akurat hal-hal berikut harus dilakukan oleh Piping Design :1. Collect correct info (data) / Mengumpulkan informasi atau

data yang benar, misalnya : Mechanical : Dibutuhkan data Vendor untuk

kebutuhan minimum Straight Length2. Jika Vendor Print belum ada, maka Piping harus meminta

advice dari Mechanical.

GL. El. 00

MC

Oil Unit

H1

H2

H3

Elevated (Platform)

RC Deck ( Reinforced Concrete)

BOC

H = H1+H2+H3

L= Close distance

C

(2) Jika Compressor menggunakan penggerak Steam Turbine dengan Steam Condenser, maka kompressor harus diletakkan di atas (elevated) dengan mempertimbangkan jarak yang cukup untuk memasang Steam Condenser di bawah Steam Turbine dan juga perpipaannya.

Note : (1) Hmin = Nilai terbesar dari Hc dan HST

(2) Ketinggian “A” karena mempertimbangkan NPSHa Suction Pompa.

CompSteam Turbine

BOC

B

A (2)

C

H1

H2

H3

PM

Condenser Hc = H1+H2+H3HST = A+B+C Hmin (1)

GL. El. 00

4.2.2 Untuk perawatan compressor dan pendukungnya, pada saat mendesain Plant Layout harus sudah direncanakan akses untuk mobile crane atau overhead traveling crane agar dapat memindahkan komponen-komponen compressor dan pendukungnya (oil unit) dengan mudah.For maintenance of compressor and their auxiliaries, overhead traveling crane or unobstructed access for a mobile crane shall be planned to easy removal of each components of the compressors and auxiliariey unit (oil unit)

( Shelter Plan View )

M

C

A

A

Oil unit = auxiliaries

Drop Area

Overhead traveling crane

Plant Road Mobile Crane

Access for Mobile Crane

Shelter

Maintenance access

( Section A- A )

4.2.3 Menghadapi kondisi perubahan cuaca/iklim (hujan-kemarau), maka harus dipertimbangkan kebutuhan shelter untuk melindungi equipment dan operator. Kebutuhan akan shelter ini tergantung dari ITB (Invitation to Bid) atau permintaan klien. Jika tidak dinyatakan dalam ITB maka kontraktor hanya perlu menyiapkan akses mobil crane untuk maintenance, hal ini dilakukan untuk menghemat biaya.Based on climatic condition, necessity of shelter shall be considered to protect equipment and operator. The requirement to provide shelter depend on ITB or owner request. Otherwise just provide mobile crane access for maintenance for cost down.

M C

Oil unit = auxiliaries

Overhead crane

Shelter

Overhead crane

Shelter

Access for maintenance & operation

Tower/Vessel

Centerline Lined Up

Paralel with piperack

50m 60m

Not practical, too far away

Tower/Vessel

Centerline Lined Up

Paralel with piperack

50m10m

OK

( Section A- A )4.3 Tower and Vessel4.3.1 Tower dan vessel vertical termasuk tangki-tangki kecil umumnya

harus diletakkan secara parallel dengan piperack, dan jika memungkinkan center line nya harus segaris.Vertical tower & vessel including small tanks shall generally be placed in parallel with the piperack. Where practical, the center lines shall be lined up.

M C

Oil unit = auxiliaries

Minimum Pipe Run

25m

10m

Lined up with saddle CL

Lined up with Tangent Line

Pipe Run

4.3.2. Horizontal vessel harus diletakkan dengan meminimalkan panjang pipa dan jika memungkinkan sejajar antara tangent line atau saddle center dengan sisi piperack.Horizontal vessel shall be located in order to minimize piping runs and where practical be lined up with their tangent line or saddle center line of vessel on piperack side.

4.3.3 Dibutuhkan tempat/area yang cukup di bagian access side (manhole) untuk loading/unloading internal atau katalis.Adequate space on the access side for loading/unloading catalyst and internal.

Vessel/Column

Mobile Crane

Free space For maintenance

Manhole = Access Side

4.3.4. Vessel harus diletakkan di ground (tanah) kecuali jika ada kebutuhan proses atau alasan teknikal lainnya (contoh kebutuhan slope berdasarkan P&ID).Vessel to be located on ground unless there is process requirements or other technical reason (ex. indicated in P&ID slope requirement).

Example II : Highly elevated vessel due to high pressure pump suction head requirement.

Plant Road Plant Road

GR El. 0

GR El. 0

Vessel on Ground

Elevated Vessel

Slope Requirement

35000

El.35000

High Pressure Pump

4.3.4. Tower dengan ketinggian lebih dari 30 meter harus diletakkan sedekat mungkin dengan jalan ( Plant Road) untuk kemudahan konstruksi dan maintenance.Tower taller than 30m should be placed near the plant road from the point of view of construction and maintenance.

GR El. 0

V-101(H=50m)

Plant Road

Plant Road

L= min

4.4 Heat ExchangerType of Heat Exchanger :

A. Shell and Tube Heat Exchanger

How Shell and Tube Heat Exchanger Works :

The hot fluid entering the shell from shell inlet nozzle, at the same time the cold fluid entering thetube from the tube inlet nozzle. The heat exchange happen when the cold fluid at inside tube meet with hot fluid inside the shell, so the temperature at each outlet nozzle will be change due to the heat transfer ( see the illustration above).

Tube inlet Shell Shell outlet

T=30C

T=50C

T=100C

T=80C

Shell cover

Tube outlet Shell inlet

Baffle plate

Tube bundle

Channel cover

B. Plate Heat Exchanger

How Plate Heat Exchanger Works :

The hot fluid entering the PHE from hot stream in nozzle at the top, the hot fluid will go down through the plate. At the same time the cold fluid entering the PHE from the cold stream in nozzle at bottom side and will go up through the plate that can only be passed by cold fluid. The heat exchange happen when the plate with hot fluid and cold fluid touch each other, so that the temperature at each outlet nozzle will be change due to the heat transfer ( see the illustration above).

4.4.1 Heat Exchanger shall generally be placed on the groundHE on Ground

Elevated HE due to ACES21 Design

Shell cover

4.4.2 Shell and Tube Heat Exchanger shall be located with channel nozzle away from piperack due to tube bundle removal works.

4.4.3 For Heat Exchanger located under structure or piperack, overhead clearance should be provided for maintenance by mobile crane, but if not feasible maintenance beam or lifting hook shall be provided upward of the Heat Exchanger

GR El. 0

GR El. 0

Piperack

Shell

Channel

Maintenance Space for Tube Bundle Take Out

MTube Bundle Extractor

H

Overhead clearance for Mobile Crane Access

Structure

Structure

Lifting Hook

4.4.4 Tube Bundle shall be removed with a mobile crane. But if it impractical, the permanent monorail with enough length to permit pull the tube bundle can be provided.

Mobile Crane H If Mobile Crane Access

Not Feasible

M

Mobile Crane

Remove the Tube Bundle

Permanent Monorail shall be provide if the mobile crane impractical to used.

4.4.5. Heat Exchanger can be Stacked

H.E. can be stacked with maximum 2 stages if the shell Diameter is 600mm and over (see drawing A).

If the Diameter less than 600mm, you may stages with more than 2 stage (see drawing B).

600mm

600mm

500mm

500mm

500mm

(Drawing A)

(Drawing B)

4.5 Air Cooler Air coolers shall generally be located on top of piperacks

How does Air Cooler Works :

The hot fluid entering the header from inlet nozzle than will flow through the tube bundle, at the same time the fresh air will enter the cooler because it sucked /forced by the fan. The heat exchange happen when the Tube Bundle contact to the Fin with the airflow, so the temperature at outlet nozzle will be change (decrease) due to

Air flow

Nozzle InletT=60C

Induce Draught Fan Type

T=27C

Air flow T=40C

Nozzle OutletT=40C

Top of Piperack

the heat transfer ( see the illustration above).

The other type of Air Cooler is Force Draught Fan Type as described bellow :

And the assemlby of header, tubes and frame as described bellow :

Why the Air Cooler should be located at the top of piperack ?

From the illustration above, this is an example for the Air Cooler that placed on the ground. There are several matters of this arrangement :1. With this arrangement the Air Cooler performance will be drop because the

inlet air already has a high temperature due to hot surface. Automatically the heat transfer can’t work as expected.

2. By placing Air Cooler on the ground, it is feared there would be a lot of dust that will be inhealed into the Cooler and attached to the Fin. In this

T= 40C

Hot Surface

Gr. El. +0

Dust

situation, the Air Cooler performance will also drop.

Concern of locating Air Cooler on top of Piperack :

1. Hot pipe under Air Fin Cooler ( AFC Performacne) 2. Air Fin Cooler Weight (Seismic)3. Wind Speed4. Piperack Column Span

4.6 Direct Fired Equipment

4.6.1 Direct Fired Equipments shall be placed on the windward side of other equipment and shall be grouped in one area as much as possible.

Hot Line

L (to be consider)

WIND

Civil matters to design Piperack

WIND

Reactor with Flammable Gas

Fired Heater

Leakage Gas

WIND

4.6.2 Direct Fired Equipment shall be located near plant road for easy access and shall have secure enough space for maintenance.

4.7 Storage Tank 4.7.1 Storage Tank should be grouped, separate from process unit

Reactor with Flammable Gas

Leakage Gas Fired Heater Shall be

Grouped

WIND

Fired Heater

Reactor with Flammable Gas

Plant Road

Tanks should be surrounded by dike

Note :- Inside W or Inside L : by Piping considering layout

availability/space- H : by Piping calculated from the volume of spillage- t : by Civil from strength calculation

Work Flow of Civil Information of Dike1. Calculate capacity/volume of spillage2. Decide total inner area of dike (considering available

Utility AreaTank Yard

BuildingProcess Unit

Process Unit

Tank grouped in this area

Dike

Inside Length (L)

Inside Width (W)

Inner Area

Inside W or Lt

H

space/layout) Inside L & Inside W3. Calculate required dike height H4. Inform Civil dimension of inside L, Inside W, and H. Than Civil will

calculate thickness dike -- t5. After receive information “t” from Civil, Piping inform final/fixed

dike information to Civil, include all dimension.

4.7.2 Storage Tank shall be arranged in an orderly manner

5. PIPEWAYS AND ROADS5.1 Pipeways5.1.1Pipeways shall generally be overhead in process main unit (on-site) and at grade (on the sleeper) in off-site

Tank Area Tank Area

Orderly Manner Not Orderly Manner

Piperack

Pipe

Main Beam/GirderIntermediate Beam

5.1.2 Pipeways width determined based on present needs plus contingency of 10% at the outset job.

ColumnSpandrel/Longitudinal Beam

Piperack – On Site

Sleeper

H = 3m (max)

M- Posh Sleeper

Embeded Plate

Concrete Sleeper

H = 300mmOr Mention on ITB

L = Present needs during preliminary P&ID/preliminary Plot Plan. At preliminary P&ID the main pipe size shall be fixed.

Total L = 6600 mm

L = 6000 mm10% L = 600mm

10% x L is outset of the job/contigency

L = 6000 mm10% L

20% L”

Future needs required by ITB (ex. 20%)

L’ = L + 10%L = 1.1 L = 6.600 mmL” = 20% x L’ = 1.320 mmL total = 6.600+1.320 = 7.920 mm

L total = 7920 mm

If in P&ID AFD Process team change the main pipe size that required additional space of piperack, the cantilever beam can be added.

The pile are already driven at P&ID (90% 3D review) so there is no change to change the piperack width

Piping can claim to Process if the information given late ( main pipe size shall be fixed during P&ID AFD).

5.1.3 Height of lowest piperack stage shall be determined to satisfy the following condition :1. To keep overhead clearance for hanging equipment (pumps,

channel cover of HE, etc.) to removed for the maintenance.

Additional Space if Required

Pile

Hh = overhead clearence

Manual Chain Block

TOS ElevationH = TOS of lowest beam

Electric Chain Hoist

2. To keep space for piping to be connected to vessel and heat exchangers installed under the piperack.

3. To keep access space for maintenance vehicle under the piperack.

OARH = Over All Raised Height

Removed Channel Cover to maintenance internal tube

TOS Elevation

H

Clearence to install pipe connected to equipment

H = 6m

TOS Elevation

H = 3.5mOARH

Contractor shall request information the height of maintenance vehicle to the owner

Correct information of equipment height.

4. To keep access space of automobile (mobile crane) over plant roads.

Request to the owner of information the highest maintenance Automobile/Mobile Crane.

5.2 Roads

5.2.1 Roads in the plant area shall be planned to realize pass through of truck, truck crane, emergency vehicle, etc.

TOS Elevation

Add clearance space

Plant Road

Automobileex. Mobile Crane

H

PLANT AREA

8m

Truck Crane

5.2.2 Plant Road width shall generally be as follows :1. Primary roads which handle large moving equipment : Min

8m2. Plant main road within the plant complex : Min. 6m3. Plant roads or branch road within the plant complex : Min.

4m

8m

Emergency Vehicle

Truck

AMMONIA AREA (Plant Complex)

UREA AREA (Plant Complex)

Primary Road

5.2.3 For both side of plant road, free space of 1 m from road edges shall be provided for fire fighting equipments.

UTILITY AREA (Plant Complex)

Primary Road

8m

8m

6m

6m

4m

Plant Main Road

Branch/Plant Road

Plant Main Road

Plant Road

1m

Fire Hydrant

5.2.4 Turning radius for roads shall allow adequate space for mobile equipment to clear pipe support.

Notes: Civil will decide the turning radius of the road

based on information of the longest distance of vehicle with equipment

Piping to conform to Civil about the turning radius of the road before applied it in plot plan.

R2>R - Depend on the length of the vehicle with equipment that pass through the bend of the road.

6. ACCESSABILITY6.1 Overhead Clearence

1. Over public roads and rail roads : min. 6.7 m2. Over plant roads in the process plant (on-site) / : min.

4.5 m3. Over plant roads outside the process plant boundary : min.

5.5 m4. Over access ways for maintenance vehicle at

pump row piperack, etc.5. Over access ways and platforms (except at dead end) : min.

R = Turning Radius of the Road

R2R2>R

: min. 3.5 m

2.1 m

( Drawing above for describe No 1,2 and 3)

- Over access ways for maintenance vehicle at pump under piperack shall be minimum 3.5 m.

AMMONIA AREA (Plant Complex)

UREA AREA (Plant Complex)

UTILITY AREA (Plant Complex)

Primary Road

Primary Road

8m

8m

6m

6m4

m

Plant Main Road

Branch/Plant Road

Plant Main Road

Public Road

H = 3.5m

BOS El. +3500

Piperack

Maintenance Vehicle

OARH = Over All Raised Height

- Over access ways and platform shall be minimum 2.1 m

6.2 Access Clearence

6.2.1 Operator access width shall be minimum 750 mm , but for operator’s daily access route shall be 900 mm

H = 2.5mOARH

H = 2.1m

BOS El. +2100

Piperack/Platform

Plant Road

Daily Operator access

6.2.2 For maintenance vehicle such as forklifts, the access way width shall be minimum 3 m.

7. STAIRS AND LADDERS

7.1 Stairs Access to Platform Stairs shall be provided for :1. The top of platforms of the structure is located 10m and over

and has an area of 50m2 and larger.

Process Area

Control room

SGSG

900mm

750mm

Operator access

Maintenance Vehicle

Lmin = 3m

Access way

A ≥ 50m2

2. The platform on which equipment or instrument requiring operation at emergency.

H ≥ 10m

Equipment requiring operation at emergency :

- Furnace

Furnace

15m Valve on platform for fuel gas inlet to furnace

3. Platform for equipment which require frequent opening and/or

closing of some part once or more per day.4. The elevated platform more than 1.5m height on which a

sample nozzle requiring sampling once or more per day.

Note :*If the platform height is less than 1500mm, we can provide ladder.

1.8m

TANK

Cl El.+2900

Gr.El. +0

Gr.El. +0

1300

1600

Operator

Sample connection (required frequent operation/daily

Platform Height ≥ 1500mm*

If the Sample Connection (SC) located on the Tank in high elevation, stairs shall be provided (see picture above).

For Vessel/Tower shall be provided by ladder to reach Sample Connection (SC) at high elevation. Except for Carbamate Condenser that still use stairs.

SC

Stairs to be provided by Mechanical

Gr.El. +0

12500

Gr.El. +0

SC

25000

Ladder

TOWER

(Prilling Tower)

Stairs

Lift

7.2 Ladder Access to Platform

Ladder access shall be provided for following cases :1. Platform other than par. 7.12. Platform with stair which requires one escape way

3. Platform height is 1.5m and lower even though frequent operation is required

15 m

8 m

Stair P/F El. +3000 Position of ladder

for escape way

TANK

Cl El.+2700

Gr.El. +0

1300

1400

Operator

Sample connection (required frequent operation/daily

Platform Height < 1500mm

4. Platform attach directly to equipment

7.3 Dual Access Requirements

For following cases, two way access shall be provided :1. When the platform has more than 20 m travel from a main

access ladder or stair, an escape ladder shall be provided.

Note : If L ≤ 20 m - No need two way access L = Travel from main access ladder or stairs.

P/F El. +6000

P/F El. +12000

P/F El. +18000

TOWER

P/F El. +4000

Note : If L > 20 m - Need two way access ( main access stair + one

escape ladder) L = Travel from main access ladder or stairs.

Note : If travel from main access stair or ladder more than 20m, then add one “escape ladder”.

P/F El. +4000

2. Access ladder for walk way on the piperack shall be required at intervals of a maximum of 60 m in process plant area (on-site) and maximum of 100 m in off site.

3. Crossover access way to another platform or floor may be planned in place of a leader or stair.

P/R Process Plant Area (on-site)

P/R Process Plant Area (off-site)

300m

60m (max)

60m (max)

60m (max)

60m (max)

60m (max)

300m100m

100m

100m

Ladder

Ladder

10m

10m

8. SAFETY DISTANCE

(1) Pumps and compressor handling flammable material shall be located a minimum 15 m far away from fired equipment.

If pumps and compressor handling non-flammable material the distance may be reduce to a minimum 8 m

Fired Heater

Min. 15 m

Min. 8 m

(2). Tower, vessel taller than the end points of the flare stack should not be located within 50 m radius of such discharge end.

(3). Equipment and piping handling flammable materials shall not be placed within 15m of building such as control room, switch room, etc.

50 m

30 m

R=More than 50 mTower

Discharge End

Piping handling flammable gas

Equipment handling flammable gas

Control Room /Switch Room

>15 m

>15 m

(4). Oxygen manufacturing unit shall be away 10 m or more from equipment handling flammable material.

(5). Large Electrical equipment such as Switch Gear, should not be placed in hazardous area.

Oxygen manufacturing unit

Equipment handling flammable gas

>10 m

Not OK

OK

Hazardous Area

Hazardous Area

Switch Gear

Switch Gear

Code of Hazardous Area :NFPA : National Fire Protection Association