Guidelines for Siting and Layout of Facilities

By CCPS (Center for Chemical Process Safety)

This book has been written to address many of the developments since the 1st Edition which have improved how companies survey and select new sites, evaluate acquisitions, or expand their existing facilities. This book updates the appendices containing both the recommended separation distances and the checklists to help the teams obtain the information they need when locating the facility within a community, when arranging the processes within the facility, and when arranging the equipment within the process units.

• Language: English
• Publisher: Wiley
• Release date: Apr 20, 2018
• ISBN: 9781119474760

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PUBLICATIONS AVAILABLE FROM THE

CENTER FOR CHEMICAL PROCESS SAFETY OF

THE

AMERICAN INSTITUTE OF CHEMICAL

ENGINEERS

GUIDELINES FOR SITING AND LAYOUT OF FACILITIES

SECOND EDITION

CENTER FOR CHEMICAL PROCESS SAFETY OF

THE

AMERICAN INSTITUTE OF CHEMICAL

ENGINEERS

New York, NY

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This edition first published 2018

© 2018 the American Institute of Chemical Engineers

Edition History

The American Institute of Chemical Engineers (1e, 2003)

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ISBN: 978-1-119-47463-0

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This book is one in a series of process safety guidelines and concept books published by the Center for Chemical Process Safety (CCPS). Please go to www.wiley.com/go/ccps for a full list of titles in this series.

It is sincerely hoped that the information presented in this document will lead to an even more impressive process safety record for industry; however, neither the American Institute of Chemical Engineers, its consultants, CCPS Technical Steering Committee and Subcommittee members, their employers, their employers officers and directors, nor BakerRisk® and its employees warrant or represent, expressly or by implication, the correctness or accuracy of the content of the information presented in this document. As between (1) American Institute of Chemical Engineers, its consultants, CCPS Technical Steering Committee and Subcommittee members, their employers, their employers officers and directors, and BakerRisk® and its employees, and (2) the user of this document, the user accepts any legal liability or responsibility whatsoever for the consequence of its use or misuse.

CONTENTS

ACRONYMS AND ABBREVIATIONS

GLOSSARY

ACKNOWLEDGMENTS

FOREWORD

PREFACE

1 INTRODUCTION

1.1 OBJECTIVES

1.2 A SITING AND LAYOUT APPROACH

1.3 HOW TO USE THIS GUIDELINE

1.4 THE PROTECTION LAYERS

1.5 TERMINOLOGY

1.6 GUIDELINE REFERENCES

1.7 SEPARATION DISTANCES BASED PRIMARILY ON FIRE CONSEQUENCES

2 OVERVIEW OF BENEFITS

2.1 IMPLICATIONS OF SITING AND LAYOUT

2.2 MANAGEMENT OF RISKS

2.3 IMPLEMENTING A STEP-WISE APPROACH FOR THE SITING AND LAYOUT OF FACILITIES

2.4 ANTICIPATING THE CHANGING WORLD

2.5 SUMMARIZING THE BUSINESS CASE FOR PROPER SITING OF A FACILITY

3 IDENTIFYING THE PROCESS HAZARDS AND RISKS

3.1 INTRODUCTION

3.2 DESCRIBING THE FACILITY’S SCOPE

3.3 SCREENING FOR PRELIMINARY HAZARDS

3.4 EVALUATING THE RISKS

3.5 CHECKLIST FOR IDENTIFYING THE PROCESS HAZARDS AND RISKS

3.6 SUMMARY

4 SELECTING A FACILITY LOCATION

4.1 INTRODUCTION

4.2 ADDITIONAL INFORMATION ON THE FACILITY

4.3 SELECTING A TEAM TO LOCATE THE FACILITY

4.4 GUIDELINES WHEN SURVEYING POTENTIAL FACILITY LOCATIONS

4.5 DETERMINING THE LOCATION PLOT SIZE

4.6 CONSTRUCTION AND TURNAROUND ISSUES

4.7 MAPS AND INFORMATION

4.8 GEOLOGICAL ISSUES

4.9 WEATHER ISSUES

4.10 SEISMIC ISSUES

4.11 OFF-SITE ISSUES

4.12 SECURITY ISSUES

4.13 ENVIRONMENTAL ISSUES

4.14 INFRASTRUCTURE ISSUES

4.15 BUILDING AND STRUCTURE ISSUES

4.16 MATERIAL HANDLING ISSUES

4.17 COMMUNICATIONS ISSUES

4.18 ENGINEERING DESIGN ISSUES

4.19 UTILITIES ISSUES

4.20 OTHER CHARACTERISTICS

4.21 PREPARING THE INFORMATION WHEN COMPARING LOCATIONS

4.22 A SITING AND LAYOUT ILLUSTRATION

4.23 CHECKLIST FOR SELECTING A FACILITY LOCATION

4.24 SUMMARY

5 SELECTING THE PROCESS UNIT LAYOUT WITHIN A FACILITY

5.1 INTRODUCTION

5.2 BLOCK LAYOUT METHODOLOGY OVERVIEW

5.3 HOW THE BLOCK LAYOUT INTEGRATES WITH THE FACILITY LOCATION

5.4 APPLYING PREVENTIVE MEASURES WHEN ARRANGING PROCESS UNITS

5.5 APPLYING MITIGATIVE MEASURES WHEN ARRANGING PROCESS UNITS

5.6 CONSTRUCTION AND TURNAROUNDS

5.7 THE BLOCK LAYOUT APPROACH: STEP 1 - EVALUATING THE LOCATION’S CHARACTERISTICS

5.8 OFF-SITE ISSUES

5.9 SECURITY ISSUES

5.10 ENVIRONMENTAL ISSUES

5.11 INFRASTRUCTURE ISSUES

5.12 THE BLOCK LAYOUT APPROACH: STEP 2 - EVALUATING THE SEPARATION DISTANCES BETWEEN BLOCKS

5.13 CRITICAL AND OCCUPIED STRUCTURES

5.14 MATERIAL HANDLING

5.15 PROCESS UNITS

5.16 TANK FARMS

5.17 OTHER AREAS

5.18 UTILITIES

5.19 OPTIMIZING THE LOCATIONS OF THE PROCESS UNITS

5.20 RESOLVING BLOCK LAYOUT OPTIMIZATION ISSUES

5.21 CONTINUING THE SITING AND LAYOUT ILLUSTRATION

5.22 CHECKLIST FOR SELECTING THE LAYOUT OF PROCESS UNITS WITHIN A FACILITY

5.23 SUMMARY

6 SELECTING THE EQUIPMENT LAYOUT WITHIN A PROCESS UNIT

6.1 INTRODUCTION

6.2 EQUIPMENT LAYOUT METHODOLOGY OVERVIEW

6.3 HOW THE EQUIPMENT LAYOUT INTEGRATES WITH THE BLOCK LAYOUT

6.4 APPLYING PREVENTIVE MEASURES WHEN ARRANGING EQUIPMENT

6.5 APPLYING MITIGATIVE MEASURES WHEN ARRANGING EQUIPMENT

6.6 CRITICAL AND OCCUPIED STRUCTURE DESIGN

6.7 EQUIPMENT

6.8 RESOLVING EQUIPMENT LAYOUT OPTIMIZATION ISSUES

6.9 CONTINUING THE SITING AND LAYOUT ILLUSTRATION

6.10 CHECKLIST FOR SELECTING THE EQUIPMENT LAYOUT WITHIN A PROCESS UNIT

6.11 SUMMARY

7 MANAGING CHANGES

7.1 INTRODUCTION

7.2 ADDRESSING SURROUNDING COMMUNITY AND INDUSTRIAL EXPANSIONS

7.3 A SITING AND LAYOUT APPROACH WHEN MANAGING CHANGES

7.4 MAINTAINING FACILITY INTEGRITY DURING ITS LIFE CYCLE

7.5 MANAGING EXPANSIONS AT AN EXISTING FACILITY

7.6 MANAGING PURCHASES OF EXISTING FACILITIES

7.7 MONITORING CHANGES WITH PERIODIC REVIEWS

7.8 ADDRESSING SITING AND LAYOUT ISSUES WHICH ARE IDENTIFIED DURING EXPANSIONS

7.9 SUMMARY

8 CASE HISTORIES

9 REFERENCES

10 APPENDICES

APPENDIX A. ADDITIONAL SITING AND LAYOUT REFERENCES

APPENDIX B. CCPS RECOMMENDED DISTANCE TABLES FOR SITING AND LAYOUT OF FACILITIES

APPENDIX C. CHECKLIST FOR IDENTIFYING THE PROCESS HAZARDS AND RISKS

APPENDIX D. CHECKLIST FOR SELECTING A FACILITY LOCATION

APPENDIX E. CHECKLIST FOR SELECTING THE PROCESS UNIT LAYOUT WITHIN A FACILITY

APPENDIX F. CHECKLIST FOR SELECTING THE EQUIPMENT LAYOUT WITHIN A PROCESS UNIT

INDEX

EULA

List of Tables

Chapter 1

Table 1.1

Table 1.2

Chapter 3

Table 3.1

Chapter 4

Table 4.1

Table 4.1

Chapter 5

Table 5.1

Table 5.2

Table 5.3

Table 5.4

Table 5.5

Table 5.6

Table 5.7

Table 5.8

Table 5.9

Table 5.10

Chapter 6

Table 6.1

Chapter 7

Table 7.1

Table 7.2

Chapter 8

Table 8.1

Appendices

Table 10.1

Appendix A

Table A.1

Table A.2

Table A.3

Table A.4

Table A.5

Table A.6

Table A.7

Table A.8

Appendix C

Table C.1

Appendix D

Table D.1

Appendix E

Table E.1

Appendix F

Table F.1

List of Illustrations

Chapter 1

Figure 1.1. A Siting and Layout Approach

Figure 1.2. A Facility’s Protection Layers

Figure 1.3. Guideline Terminology

Chapter 2

Figure 2.1. The Effect of Time on the Options for Reducing Process Safety Risks

Figure 2.2. Life cycle Phases for a Facility, a Process Unit, or the Equipment

Figure 2.3. The Chapters Corresponding to the Steps for Siting and Laying out of Facilities

Chapter 3

Figure 3.1. An illustration of potential flammability limit contours for flash fires

Figure 3.2. An illustration of potential thermal radiation contours from pool or jet fires

Figure 3.3. An illustration of potential blast overpressure contours

Figure 3.4. An illustration of potential toxic release endpoint contours from a small leak using the ERPG guidance

Figure 3.5. An illustration of potential toxic release endpoint contours from a small leak using probits

Chapter 4

Figure 4.1. Typical Land Use Guidance for the Land Surrounding a Facility

Figure 4.2. Characteristics Considered when Selecting a Facility Location

Figure 4.3. A Southeast Prevailing Wind Direction shown on a Wind Rose Diagram

Figure 4.4. Location 1-Proposed Inland Site in Remote Area

Figure 4.5. Location 2-Proposed Inland Site with Nearby Development

Chapter 5

Figure 5.1. Flowchart used to Determine the Process Unit Layout Distances at a Facility

Figure 5.2. An Example of a Modeled Dispersion Profile

Figure 5.3. How Layout Distances are Measured at a Facility

Figure 5.4. Blast Overpressure Contours for the Proposed Site

Figure 5.5. Block Layout Diagram for the New Low Hazard Operation

Figure 5.6. Block Layout Diagram with Layout Distances for the New Low Hazard Operation

Figure 5.7. Building Damage Levels as a Function of Pressure-Impulse Curves

Figure 5.8. Rail Car Fragment thrown from the Crescent City BLEVE

Figure 5.9. Location 3 Facility Layout for its Structures and Process Unit Blocks

Chapter 6

Figure 6.1. Flowchart used to Determine Equipment Layout Distances within a Process Unit

Figure 6.2. Computer Aided Design (CAD) Image Depicting a Proposed Layout of Equipment within a Process Unit

Figure 6.3. Traditional Pump Row / Pipeway Arrangement when Transferring Materials in Overhead Piping

Figure 6.4. A Safer Process Unit Pump Row / Pipeway Arrangement when Transferring Flammable Materials in Overhead Piping

Figure 6.5. An Example Hazardous Area / Zone Classification Drawing using a 3D Facility Plot Plan

Figure 6.6. The DuPont Brandywine Powder Mills

Figure 6.7. Layout of the Ethylene Unit’s Process Unit Blocks for Location 3

Figure 6.8. Layout of the Equipment in the Cracking Furnace Unit for Location 3

Chapter 7

Figure 7.1. A Siting and Layout Approach when Managing Changes

Figure 7.2. Managing Siting and Layout Changes within the Equipment, Process Unit, and Facility Life Cycles

Figure 7.3. The Separation Distances at the Existing Process Unit

Figure 7.4. The Proposed Layout for the Expansion Project at an Existing Facility

Chapter 8

Figure 8.1. Layout of the area surrounding the ISOM unit at Texas City

Figure 8.2. Image of PEPCON after Initial Explosion

Figure 8.3. Aerial View of the Explosion Damage in Danvers

Figure 8.4. Area Plot Plan and Impacted Areas Surrounding the PEMEX LPG Facility

Figure 8.5. Growth of the Community Surrounding the PEMEX LPG Facility

Figure 8.6. Images after the Explosion at the Little General Store

Figure 8.7. Flames Developing and Impinging on valero’s No. 1 Extractor Piping

Figure 8.8. The Pipe Bridge after the Incident at Valero

Figure 8.9. Range of Off-site Damage at Praxair in St. Louis

Figure 8.10. Range of the Vapor Cloud at Amuay

Figure 8.11. Range of the Blast Radius at West Fertilizer Company

Figure 8.12. Image of Damage from the West Fertilizer Company Explosion

Figure 8.13. Damage to the Concept Sciences Inc. Facility

Figure 8.14. T2 Laboratories, Inc., after the Explosion

Figure 8.15. Fragment of the T2 Laboratories 3-inch (7.6 cm) Thick Reactor

Figure 8.16. The Imperial Sugar Facility after the Explosions and Fires

Appendix D

Figure D.1. The Conservation Balance Across a Facility’’’s Property Line

Acronyms and Abbreviations

Glossary

This Glossary contains the terms specific to this Guideline and process safety related terms from the CCPS Process Safety Glossary. The specific CCPS process safety related terms in this Guideline are current at the time of publication; please access the CCPS website for potential updates to the CCPS Glossary.

Acknowledgments

The American Institute of Chemical Engineers (AIChE) and the Center for Chemical Process Safety (CCPS) express their appreciation and gratitude to all members of this CCPS Subcommittee for Project 246 and their CCPS member companies for their generous support and technical contributions in the preparation of these guidelines. The AIChE and CCPS also express their gratitude to the team of authors from BakerRisk®.

CCPS Subcommittee Members:

CCPS wishes to acknowledge the many contributions of the BakerRisk® staff members who contributed to this edition, especially the principal author Bruce K. Vaughen and his colleagues who contributed to portions of this manuscript (listed in alphabetical order): Ray Bennett, David Black, David Bogosian, Mike Broadribb, Adam Connor, Philip Hodge, David Kirby, John Lira, Michael Moosemiller, Joe Natale (Co-author of the 2003 Edition), Doug Olson, Phil Parsons, Adrian Pierorazio, Kelly Thomas, Karen Vilas, David Wechsler, and Joe Zanoni. Editing assistance from Moira Woodhouse, BakerRisk®, is gratefully acknowledged, as well.

Additional acknowledgement is extended to Reid McPhail, CNRL, for his significant and thorough reviews of the manuscript and updating of the tables provided in Appendix B, and to Annette Kyle, for her contributions during the initial stages of this work.

Before publication, all CCPS books are subjected to a thorough peer review process. CCPS gratefully acknowledges the thoughtful comments and suggestions of the peer reviewers. Their work enhanced the accuracy and clarity of these guidelines.

Peer Reviewers:

Foreword

I appreciate the leadership of the Center for Chemical Process Safety and their work with process safety professionals to advance a culture of ongoing improvement to process safety. It is important to ensure that lessons learned regarding proper siting of facilities, and the layout of process units and equipment within the facility, are identified to enable better evaluations and decisions. As a tri-chair of the Obama Administration Chemical Facility Safety and Security Working Group, these issues were raised during listening sessions held across the United States. Much progress can be made in this area by improving safety, and reducing the impact of incidents and the loss of lives, if facility siting is done in a responsible and effective manner.

Mathy Stanislaus - December 2016

Assistant Administrator in EPA’s Office of Land and Emergency Management

Preface

The American Institute of Chemical Engineers (AIChE) has been closely involved with process safety, environmental and loss control issues in the chemical, petrochemical and allied industries for more than four decades. Through its strong ties with process designers, constructors, operators, safety professionals, and members of academia, AIChE has enhanced communications and fostered continuous improvement between these groups. AIChE publications and symposia have become information resources for those devoted to process safety, environmental protection and loss prevention.

AIChE created the Center for Chemical Process Safety (CCPS) in 1985 soon