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G U I E L I N E S F O R
FACILITY SITING
AND LAYOUT
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Thisbook is one of aseriesof publications
available from
the
Center
for
Chemical ProcessSafety.
A complete
catalog
ofavailabletitlescan be found
on the
AIChEweb
site,www.aiche.org.
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G U I D E L I N E S F O R
FACILITY SITING
AND LAYOUT
CENTER FOR
CHEMICAL
PROCESS
SAFETY
V
An lChE
Industry
Technology Alliance
Center
for Chemical Process Safety
of
the
AmericanInstitute
ofChemicalEngineers
3
ParkAvenue,N ewYork, NewYork
10016-5991
W1LEY
INTERSCIENCE
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Copyright 2003
AmericanInstituteofChemicalEngineers
3 ParkAvenue
New
York,
NewYork10016-5991
All
rights reserved.
N opart
of
this
publication may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording,or otherwise without the prior permission of the copyrightowner.
AlChE and
CCPS are
trademarks
owned by the
AmericanInstitute
of
Chemical
Engineers. These
trademarksmay not be used without the prior express written consent of theAmerican
Instituteof
Chemical
Engineers. The use ofthisproduct inwholeor inpartfor commercial
use is prohibited without prior express written consent of theAmericanInstituteof Chemical
Engineers.Toobtain appropriate license and permission for
such
use contact Scott Berger,
212-591-7237,scotb@AIChE.org.
CCPSPublicationNumberG 84
Library
of Congress Cataloging in Publication Data:
Guidelines forfacilitysiting and layout /
Th e
Center for Chemical Process
Safety,
p. cm.
Includes bibliographical references and index.
ISBN0-8169-0899-0
Hardcover)
1. Chemical plants Design and construction. 2. Chemical
industry Safety measures.
1.
American
Institute
of Chemical Engineers.
Center for Chemical Process Safety.
TP155.5.G7662003
660 dc22 2003015938
II is sincerely hoped that the Information presented in this volume will lead toan even mo re impressive
safety record for the entire industry. However, the American Institute of Chemical Engineers, its
consultants, CCPS Subcommittee mem bers, their employers, and their employers officers and d irectors
and Baker Engineering and Risk Consultants Cheryl A. Grounds and JosephR.Natale disclaim makingor
giving any warrantiesorrepresentations, exp ressor implied, including with respect to fitness, intended
purpose, use or merchantability, and/or correctness
or
accuracy
of
the content
of
the inform ation
presented in this document. As between (1) American institute of Chemical Engineers, its consultants,
CCPS Subcomm ittee m embers, their employers, and their emp loyers officers and directors and B aker
Engineering and Risk Consultants Cheryl A. Grounds and JosephR.Natale (2) the userofthis do cument
accepts any leg al liability
or
responsibility whatso ever
for
the consequences of its use
or
misuse.
This
book is available at a special discount when ordered in
bulk quantities. For information, contact the Center for
ChemicalProcess Safety at the address shown above.
PRINTED N THE
UNITED
STATES
OF
AMERICA
10 9 8
mailto:scotb@AIChE.orgmailto:scotb@AIChE.org7/24/2019 Guidelines for Facility Siting & Layout
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ents
Preface
ix
Acknowledgments xi
1
INTRODUCTION
1.1. Objec tives 1
1.2. How
To
Use This Book 2
1.3. Layers of Safety 4
1.4. References 6
2
M N GEMENT OVERVIEW
2 1 Implications of Siting and Layout 7
2.2. Management of Risks 8
2.3. Basis for Facility Siting and Layout 8
2.4. ChangingWorld 10
3
PREP RING FOR THE SITE SELECTION PROCESS
3 1 Project Description 14
3.2. Assembling a Site Selection Team 16
3.3. Prel iminary Site Size Determination 19
3.4. Preliminary Hazard Screening 20
3.5. Guidelines for the Survey andDataCollection Effort 26
3.6. Environmental Control
Issues
29
V
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vi
Contents
4
SITE SURVEY AND SELECTION
4 . 1 . Information Required to Se lect a Site 33
4 . 2 .
Transportation
Issues
39
4 . 3 .
Utilities 44
4.4. Electrical and Communications Systems 47
4.5. Environmental Controls 49
4.6. Fire , Safety, and Security 51
4.7. Site
Features
53
4.8. Multi-Chapter Example 55
5
SITE AND PLANT LAYOUT
5 . 1 .
General 64
5.2. The Site 66
5.3. Block Layout
Methodology
71
5.4. Spacing Tables 72
5.5. Utilities 74
5.6. Electrical and Control Facilities 80
5.7. Process 82
5.8. Outside Battery Limits
( O S B L )
85
5.9. Tank Storage 92
5.10. Occupied and CriticalStructures 94
5 . 1 1 . Multi-Chapter Example 97
6
EQUIPMENT LAYOUT AND SPACING
6 . 1 . Spacing Tables 101
6.2. General 103
6.3. Single-andMultilevelStructures 104
6.4. Enclosed Process Units 105
6.5. Layout and Spacing to Minimize
VaporCloud Explosion Effects 105
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Contents vii
6.6.
RelativeLocation
of Equipment 106
6.7. Equipment withA i rIntakes 107
6.8. Equipment-to-Equipment Separation Distances 108
6.9. Multi-Chapter Exampl e 116
7
OPTIMIZE
THE
L YOUT
7 . 1 . Layout MethodReview
7 . 2 . Layout
Issues
Resolution
7.3. The Right
Answer
8
C SE HISTORIES 127
PPENDIXA.TYPIC L SP CING T BLES 139
PPENDIX
B.
SITE SELECTION D T REQUIREMENT LIST 151
REFERENCES 179
GLOSS RY 183
INDEX 191
121
123
125
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ce
TheCenter for Chemical Process Safety
CCPS)
The Center for ChemicalPro
cess Safety CCPS) was established in 1985 by the American
Institute
of
Chemical Engineers for the express purpose of assisting
industry
in avoiding
or
mitigating catastrophic chemical accidents. To achieve
this
goal, CCPS
has focused its work on four areas:
Establishing and publishing the latest scientific, engineering and
management practices for prevention and mitigation of incidents
involving toxic,
flammable, and/or reactive materials
Encouraging the use ofsuch information by dissemination through
publications, seminars, symposia, and continuing education pro
grams for engineers
Advancing thestateof the art in engineering practices and technical
management through research in prevention and mitigation of
cata
strophic events
Developing
and encouraging the use of
undergraduate
engineering
curricula
that
will
improve
the safety
knowledge
and consciousness
of
engineers
This
book outlines a process for finding an optimal location for a chemi
cal or petroleum processing site and
then
arranging the units and equip
ment. It provides comprehensive guidelines on how to select a site, how to
recognizeand assess long-term risks, and how to lay out the facilities and
equipment withinthatsite. A survey guide is provided to aid site selection
teams in obtaining necessarydatato select a new site. Site layout and equip
ment spacing guidelines are provided based on historical and
current data
including industry practices and standards. Spacing tables are provided
which can be used as a
starting
point in laying out a site. Case histories and
examples are included to illustrate both the appropriate manner in which to
addressfacilitysiting and layout as
well
as the consequences when the effort
is inadequate.
ix
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owledgments
The American
Institute
of Chemical Engineers and the Center for Chemical
Process Safety express their gratitude to all the members of the Facility
Siting and Layout Subcommittee for their generous
efforts
and valuable
technical contributions in the preparation ofthisGuidelines book.
Chairs:
Ephraim
A .
Scheier BPAmerica,Inc.
Frank
Worley,
II I
Rohm
Haas
Company
Authors:
Cheryl
A.
Grounds Baker
EngineeringandRisk
Consultants
Joseph R. Natale BakerEngineering
and
Risk
Consultants
CCPS
Staff Consultant:
John
A .
Davenport
SubcommitteeMembers:
John
A .Alderman
Richard L. Alexander, Jr.
MichaelR Broadribb
Chris R. Buchwald
Christopher R
Devlin
Brian R. Dunbobbin
Rodger
Ewbank
William
Hague
Andrew
R Hart
John
Marshall
MichaelD.Moosemiller
Henry Ozog
RRS
Engineering
formerlywithSolutia
BP
America
ExxonMobil
Celanese
ChemicalsDivision
AirProducts Chemicals
Rhodia
HoneywellSpecialtyChemicals
NovaChemicals
Dow
Chemical
formerlywithD etNorskeVeritas DNV)
ioMosaic Corporation
xi
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xii
Acknowledgments
Vanessa
Rodriguez
USEnvironmentalProtection
Agency
JohnR Sharland FM Global
William
E.
Thornberg
formerly
with GE
Global
Asset
ProtectionServices
Tracy Whipple
formerlywithDet
Norske Veritas
DNV)
Before
publication, all
CCPS
books are subjected to a through peer
review
process. CCPSalso gratefully acknowledges the thoughtful comments and
suggestions of the peer reviewers.
Don
Connolley
Akzo
Nobel
Chemicals
Inc.
KieranJ. Clynn
BritishPetroleum
Hal
Johnson
ConocoPhillips
Neal
WJohnson ConocoPhillips
Neil
Macnaughton
BritishPetroleum
Jack
McCavit
Celanese
LisaMorrison
NOVA
Chemicals,Inc.
TimOverton
DowChemicalCompany
PhilPartridge
Dow
ChemicalCompany
JanetL. Rose
BayerPolymersLLC
Scott Schiller
ConocoPhillips
OrvUleM.Slye,Jr., PE
Loss
ControlAssociates
Anthony Thompson
MonsantoCompany
Jan Windhorst
Nova
Chemicals,Inc.
JeffYuill
StarrTechnical
Risks
Agency,
Inc