Safety Considerations for Plant Layout Levels

This article is about chemical Plant Layout Levels guidelines, plant safety pdf, safety in plant design and layout pdf, plant layout pdf and plant layout spacing standards.

Plant layout design is an essential step in the construction of any industrial facility. It involves arranging machines, equipment, and other resources in the most efficient and productive manner. However, safety considerations should also be taken into account, especially in multi-level facilities.

One of the primary concerns in multi-level plant layouts is the risk of falls from heights. Workers and visitors should be protected from falls by the installation of guardrails, handrails, and other fall protection systems. Additionally, any openings in floors or walls should be securely covered or fenced off to prevent accidental falls.

Safety Considerations for Plant Layout Levels

1. SCOPE
2. REFERENCES [Codes and Standards for Plant Layout Levels]
3. DEFINITIONS (Definitions for Plant Layout)
4. GENERAL REQUIREMENTS
   1. General
   2. Terrain
   3. Prevailing Wind
   4. Life Safety Code
   5. Cost Benefit Analysis
5. ROADS AND ACCESS
   1. Access for Maintenance.
   2. Access for Fire Fighting.
6. PLOT PLAN LAYOUTS
   1. Spacing Recommendations.
   2. Process Unit Arrangement.
7. LAYOUT AND SPACING OF PROCESS EQUIPMENT
   1. Process Unit Spacing
   2. Fired Heaters
   3. Pumps
   4. Exchangers
   5. Air Cooled Exchangers
   6. Towers and Vessels
   7. Compressors, Turbines, Expanders, Power Generators
   8. Cogeneration facilities
   9. Air Intakes
   10. High Skin Temperature Equipment
   11. Equipment Handling Nonflammables, Non combustibles, or Nontoxics
   12. Extruders
   13. Radioactive Sources
8. LAYOUT AND SPACING OF BUILDINGS AND SUBSTATIONS
   1. Buildings Outside Process Units.
   2. Control Houses and Operator Shelters.
   3. Remote Instrument Enclosures (RIEs).
   4. Electrical Substations.
   5. Fire Stations.
9. UTILITY FACILITIES
   1. Boilers and Utility Equipment
   2. Plant Air Instrument Air Compressors
10. OFFSITE TANK STORAGE
    1. General
    2. Access
    3. Tanks and Pipeway Protection
    4. Drainage and Dikes
    5. Storage tanks with High Flash point Lube Oil
    6. High Pressure Storage Tanks and Spheres (In Excess of 103.4 kPag)
    7. High Pressure Storage in Cylindrical Vessels (Bullets)
    8. Underground Storage Tanks
    9. Refrigerated and Cryogenic Storage.
11. LOADING AND UNLOADING FACILITIES
    1. Truck Loading Racks
    2. Tank Car Loading Racks
    3. Petroleum Piers and Wharves
    4. Drainage, Bonding and Grounding
12. FLARES
    1. Siting Elevated Flares
    2. Distance From Process Units
    3. Ground Flares
13. OTHER OFFSITE FACILITIES
    1. Wastewater separators
    2. Blowdown Drums
    3. Fire Training Areas
    4. Ethylene Vaporizers
    5. Compressed and Liquefied Gas Storage
    6. Fuel Dispensing Facilities
    7. Safe Assembly Areas
    8. Smoking Zones
14. PROCESS EQUIPMENT SPACING TABLES
15. PRODUCTION BUILDINGS AND WAREHOUSES
    1. Exposure Protection
    2. Life Safety
    3. Construction and Waste Materials Areas
16. STRUCTURAL AND PLATFORM REQUIREMENTS
    1. Platform Requirements
    2. Walking and Working Surfaces
    3. Pipeways and Structure Clearances
17. PAVING AND DRAINAGE
    1. Paving Hydrocarbon Spill Areas
    2. Road and Accessways
    3. Polyethylene and Polypropylene Units
    4. Drainage and Sewer Systems
    5. Sewer Design
    6. Administrative and Shop Area Drainage
    7. Open Drainage Ditch Design
18. FENCES
19. MAINTENANCE EQUIPMENT

Procedure for Determining Alternative Spacing Requirements

FIGURES:

TABLE I Spacing of Pumps to Fireproofed Elevated Process Area Pipe ways and Structurally Supported Air Coolers.

TABLE IA Minimum Spacing for Operating Facilities SI (Metric) Units.

TABLE IIA Minimum Spacing for Control Houses, RIEs and Substations.