Location&Layout

Localizacin y distribucin en plantas qumicas
Felipe Bustamante
Departamento de Ingeniera Qumica

Facultad de Ingeniera
Universidad de Antioquia
Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 1 / 53

Localizacin de Plantas Qumicas Evaluacin cualitativa
Localizacin

Factores a considerar
Resumen

Resumen
Tomado de: Kirk & Othmer. Plant Location. En: Encyclopedia of Chemical Technology

Importancia para compaas de Estados Unidos establecidas en otros pases
Characteristic Accessibility
Factor
- Access to markets Characteristic Area Reputation
Characteristic Industry in Area
- Location of supplier Factor
Factor
- Quality of roads and railroads - General reputation
- Level of industrialization
Characteristic Basic Services - Points of unusual interest
- Potential for industrial growth
Factor - Contributions of area to community
- Trends in U.S. and other foreign
- Communication Characteristic Host Government
investment
- Transportation services Factor
Characteristic Labor and Staff Availability
- Advertising agencies - Cooperation with foreign investors
Factor
- Police and fire protection - Political structure
- Wage rates
- Mass media - Stability
- Income distribution
Characteristic Site Costs - Honesty
- Commuting radius
Factor - Staffing
- Personnel policies
- Relative cost of site development - Involvement of local industry in politics
- Size of local labor force
- Land and construction costs - New services made necessary by your
- Potential employables by skills
Characteristic Environment industry
- History of labor problems
Factor Characteristic Host Government Policies
Characteristic Host Taxes and Incentives
- Pollution regulations Factor
Factor
- Quality and type of schools - National policies
- Corporate and personal tax structure
- Housing - Shared ownership
- Labor and welfare legislation
- Absence of social or ethnic conflicts - Exchange controls
- Tax agreements
- Attitude toward foreign investors - Quality of service
- Conveniences of living (shopping,
recreational, cultural)
B.M. Bass, D.W. McGregor, J.L. Walters Selecting Foreign Plant Sites: Economic, Social and
Political Considerations, The Academy of Management Journal, Vol. 20, No. 4 (Dec., 1977),
pp. 535-551

Factores a considerar (cont.)

Ranking
Factor Calificacin
Factor Calificacin
Labor and welfare legislation 1.6
Land and construction costs 2.6
General reputation 1.6
National policies 2.6
Political structure 1.6
Access to markets 2.5
Quality of service 1.6
Transportation services 2.5
Conveniences of living (shopping, recre-
Relative cost of site development 2.5 1.5
ational, cultural)
Tax agreements 2.5
Potential for industrial growth 1.5
Attitude toward foreign investors 2.4
History of labor problems 1.5
Exchange controls 2.4
New services made necessary by your in-
Pollution regulations 2.3 1.3
dustry
Stability 2.3
Housing 1.2
Cooperation with foreign investors 2.2
Absence of social or ethnic conflicts 1.2
Shared ownership 2.2
Trends in U.S. and other foreign investment 1.2
Size of local labor force 2.1
Quality and type of schools 1.1
Location of supplier 2
Income distribution 1.1
Quality of roads and railroads 2
Personnel policies 1.1
Level of industrialization 2
Commuting radius 0.9
Potential employables by skills 2
Involvement of local industry in politics 0.9
Communication 1.8
Police and fire protection 0.8
Wage rates 1.8
Contributions of area to community 0.6
Corporate and personal tax structure 1.8
Points of unusual interes 0.5
Honesty 1.8
Advertising agencies 0
Staffing 1.8
Mass media 0

Localizacin de Plantas Qumicas Evaluacin cuantitativa
Mtodo de Brown & Gibson
Etapas
1 Asignar un valor relativo a cada factor objetivo en cada
localizacin posible (FOi )
2 Estimar un valor relativo para cada factor subjetivo en cada
localizacin posible (FSi )
3 Combinar los factores objetivos y subjetivos, asignndoles una
ponderacin relativa (K ) y obtener una Medida de Preferencia de
Localizacin (MPL)
4 Seleccionar la localizacin con el mximo valor de MPL


Cuantificacin de factores objetivos
Debe determinarse el costo anualizado de los factores objetivos en

cada localizacin posible.
El valor del factor objetivo en la localizacin i ser
1
c
FOi = Pn i 1
i=1 ci
Donde ci representa el valor anual total objetivo en la localizacin i


Cuantificacin de factores objetivos
Tomado de: Sapag y Sapag. Preparacin y evaluacin de proyectos. 5a. ed.


Cuantificacin de factores subjetivos
Primero hay que determinar una calificacin para cada factor subjetivo
(Wj ) mediante comparacin pareada de los factores: uno de los
factores puede ser ms importante que el otro, o los dos ser
igualmente importantes. Despus, se evala cada factor subjetivo en
las diferentes localizaciones (Rij ). Finalmente, el valor del factor
subjetivo en la localizacin i ser
n
X
FSi = Rij Wj
j=1


Calificacin de factores subjetivos (Wj )
Tomado de: Sapag y Sapag. Preparacin y evaluacin de proyectos. 5a. ed


Ponderacin de factores subjetivos en cada localizacin (Rij )
En resumen . . .


Calificacin de Factores Subjetivos


Evaluacin de la Medida de Preferencia de Localizacin
La MPL depende del valor relativo de los factores objetivos y

subjetivos, y de la importancia relativa de cada uno (K ):
MPLi = K FOi + (1 K ) FSi


Evaluacin de la Medida de Preferencia de Localizacin
Si K = 0.75:
MPLA = (0.75)(0.34195) + (0.25)(0.2500) = 0.31895

MPLB = (0.75)(0.33319) + (0.25)(0.4575) = 0.36427
MPLC = (0.75)(0.32485) + (0.25)(0.2925) = 0.31678

Una observacin

Distribucin en Plantas Qumicas
Distribucin en Planta

Antes . . .
Tomado de: Guidelines for Facility Siting and Layout - AICHE (2003)

Despus . . .

Riesgos en la Industria Qumica
14 For the majority of businesses carrying out chemical reaction

processes, there are four main events that individually, or jointly,
have the potential to cause significant harm or damage:
(a) fire;
(b) explosion;
(c) release of a toxic substance; and
(d) release of a corrosive substance.
38 There are essentially four major hazards in chemical

processing:
(a) chemical reactions hazards;
(b) fire and explosion hazards;
(c) health hazards; and
(d) environmental hazards.
Tomado de: Designing and operating safe chemical reaction processes - HSE (2000,2008)

Risk assessment
9 A risk assessment is an organised study of your work

activities using the following five steps:
Step 1 Look for the hazards.
Step 2 Decide who may be harmed and how.
Step 3 Evaluate the risks arising from the hazards and decide
whether existing precautions are adequate or if you need to
do more.
Step 4 Record your significant findings.
Step 5 Review your assessment from time to time and revise
it if necessary.
Tomado de: Designing and operating safe chemical reaction processes - HSE (2000,2008)

Objetivos de la Distribucin en Planta
The plant layout shall be arranged for:

a) maximization of safety;
b) prevention of the spread of fire and also ease of operation;
c) maintenance consistent with economical design and future
expansion.
Tomado de: Engineering Standard for Layout and Spacing, Mar. 1996 - Iranian Petroleum Standard

OIL AND CHEMICAL PLANT LAYOUT AND SPACING

Loss experience clearly shows that fires or explosions in
congested areas of oil and chemical plants can result in extensive
losses. Wherever explosion or fire hazards exist, proper plant
layout and adequate spacing between hazards are essential to
loss prevention and control. Layout relates to the relative
position of equipment units within a given site. Spacing
pertains to minimum distances between units of equipment.
IRI layout and spacing recommendations are for property loss
prevention purposes only and are intended for existing and new oil
and chemical facilities. These guidelines are intended to limit
explosion overpressure and fire exposure damage. They do not
address shrapnel damage. If these guidelines cannot be
followed, then additional control measures, such as fire
proofing, waterspray or blast hardening will be necessary.
IM.2.5.2 . September 3, 2001 - Published as a part of GE Global Asset Protection Services by Industrial Risk Insurers.

Hazard Identification and Evaluation Program

Determine the plant layout and spacing necessary to limit loss size
based on worst case scenarios for vapor cloud, vessel and building
explosions, and for fires. Calculate overpressure circles.
Duplication of Facilities
For large-scale chemical and petrochemical plants, provide
multiple process trains. In large scale plants, duplicate, with
installed spares, equipment that is highly susceptible to loss or
important for continued operations. For smaller scale or batch type
plants, install process important to production in the form of multiple
small-scale units rather than a single large unit.
Physically separate duplicated units, process trains or equipment
with adequate spacing in accordance with this section or
compartmentalize with blast resistant construction.

Aspectos claves a considerar preliminarmente
Terrain
In the first place, considerations should be given to the physical setting. It should not
automatically be assumed that it is necessary to level the site. There may instead be
ways that the process can take the advantage of whatever slopes are present.
With respect to terrain, assess should be made, whether, there is adequate space in
general. If not, ingenuity will be required to meet such requirements as those for
flares. Available space can help to govern whether the plant can be located on one
floor or instead occupy several stories. The physical setting shall also be considered
in light of the Transportation requirements for raw materials, products, wastes and
supplies.

Safety and Environment

1 Familiarization with pertinent Environmental Regulations, (Local, National and
International), and how they might change is essential prior to conclusion of
pre-project studies.
2 Attention shall be given to the pertinent safety regulations, including health and
welfare needs. Hazardous and flammable materials require special handling, which
can take up layout space.
3 If the process fluids are especially toxic, layout is affected by the need for close
chemical sewers and other protection measures. Security requirements may require
special layout design when the plant produces a high-value product.
4 If a plant site is governed by particular building, piping, plumbing, electrical and other
codes, these can affect plant layout. Similar governing standards and regulation in
plant site affects the layout concept.

Throughput
1 It is important not only to know the initial capacity but also to have a good feel for
how much the plant might be expanded in the future, as well as how likely the
process technology is to be modernized. These factors indicate how much space
should be left for additional equipment.
2 Multiple processing lines (trains), are often required for the plant. Pairs of trains can
either be identical or be mirror images. The former option is less expensive. But the
mirror image approach is sometimes preferable for layout reasons.

Factores a considerar en la distribucin
High hazard operations Market share concerns

Grouped operations Fire and explosion exposures
Critical operations Vapor cloud explosions
Number of personnel at risk Sources of ignition
Concentration of property and Maintenance and emergency
bussiness interruption values accesibility
Equipment replacement and Drainage and grade sloping
installation time Prevailing wind conditions
Interdependency of facilities Natural hazards and climate
Critical customer or supplier Future expansions
relationships External exposures

Clasificacin de riesgo
Moderado

Intermedio

Alto

Overall Plant Layout
Initially, base site selection on exposure from uncontrollable factors, such as floods,
earthquakes, tidal waves, subsidence, hurricanes, and adjacent oil and chemical
plants.
Once a site has been selected, arrange layout and spacing to reduce the effect of
some of the following controllable and uncontrollable factors that contribute to losses:
Uncontrollable factors include site slope, climate, exposure to natural hazards,
wind direction and force. However, locating ignition sources upwind of
potential vapor leaks or locating the tank farm downhill of essential units may
reduce the loss potential from an explosion or fire.
Controllable factors include process design parameters, maintenance, spare
parts supply, control logic and automation, fire protection design, spare
production capacity, flammable liquid holdups, spill control and the type of
process. Use proper drainage and separation to control spills and fire spread.
Use a hazard assessment of each plant operation to help establish the layout or
orientation of blocks or unit battery limits within the plant. Review the possible loss
events and the consequences for each proposal. Select a layout which will minimize
the overall property damage and related business interruption should an incident
occur.

Overall Plant Layout

Subdivide the overall site into general areas dedicated to process units, utilities,
services and offices. Since each area or unit block generally has a rectangular
shape, keep the maximum unit size to 300 ft 600 ft (92 m 183 m) for firefighting
purposes.
Provide access roadways between blocks to allow each section of the plant to be
accessible from at least two directions.
Avoid dead end roads.
Size road widths and clearances to handle large moving equipment and
emergency vehicles or to a minimum of 28 ft (8.5 m), whichever is greater.
Maintain sufficient overhead and lateral clearances for trucks and cranes to
avoid hitting piping racks, pipe ways, tanks or hydrants.
Do not expose roads to fire from drainage ditches and pipeways.
Slightly elevate roads in areas subject to local flooding.
Locate hydrants and monitors along roads to allow easy hook-up of firefighting
trucks.
Provide at least two entrances to the plant for emergency vehicles to prevent
the possibility of vehicles being blocked during an incident, e.g., open bridge,
railway.
Plan and implement a Roadway Closure permit system authorized and
controlled by site Emergency Response personnel as part of the site
impairment handling system.

Process Units
Evaluate the process hazards and, depending on the results of such review, classify
them in high, intermediate and moderate hazard groups as shown in GAP.2.5.2.A.
Consult the table in this section to determine the spacing required between the
various blocks based upon the relative hazard of each process.
Separate hazardous units from other hazardous units to avoid fire spread.
Separate or buffer high hazard units by using moderate or even lower hazard
units as a way to reduce such exposure, e.g., separate a DNT plant from a TDA
plant by placing a sulfuric or nitric acid unit between them.
Locate equipment or structures common to multiple process units, such as large
compressors and turbines, central control rooms and fired heaters, so as to prevent
a single event from impairing the overall operation and causing extensive business
interruption.

Process Units
Lay out the equipment within a unit in one of two general ways.
Use grouped layout, where similar equipment is grouped together to ease
operation, maintenance and control.
Use flow line layout, where equipment is arranged in a sequence similar to the
process flow diagram.
Wherever it does not conflict with loss control, consider accessibility for maintenance
and operations in determining spacing and layout. Locate equipment needing
frequent overhaul, maintenance or cleaning at unit boundaries. Locate large vessels
or equipment close to unit boundaries to allow easy access of cranes.

Layout de equipos
Consideraciones particulares
Tomado de: Process Industry Practices PNE00003 - Process Unit and Offsites Layout Guide, 2007

Metodologa de Bloques macrodistribucin

Metodologa de Bloques mesodistribucin

Un ejemplo
Tomado de: Process Plant Layout and Piping Design (1993)

Un ejemplo (cont.)

Un ejemplo (cont.)

Un ejemplo (cont.)

Un ejemplo (cont.)

Tuberas

Diagrama de flujo para Metodologa de Bloques

Un problema de optimizacin
Facility layout is a challenging problem due to its relationship with

safety, operational procedures and plant cost, which are often in
conflict. This work addresses the optimal layout of a chemical plant
considering a complete QRA. The resulting MINLP model is based on
CCPS guidelines for facility siting and layout alternative methodology.
The problem for a specified chemical process can be stated as follows:
Tomado de: N. Medina-Herrera et al. Computers and Chemical Engineering 68 (2014) 165181

Given
Most common failures within the process and their failure rates and expert judgment for
environmental conditions.
Wind direction probability analysis of the site (wind rose).
The amount of mass released, flowrate and physical and chemical properties.
A flat land area chosen by a siting analysis with a maximum length Lx and depth Ly .
A set of hazardous units H at fixed location (xH , yH ) and their dimensions in x axis, LH ,
and y axis, WH .
A set of facilities or units U and their dimensions in x axis, LU , and y axis, WU .
i
The average number of workers near unit i, Nworkers for i U.
Economic data on costs for units interconnections, equipment, life prevention, and land.
Average environmental parameters such as humidity and air molecular weight.

Determine
The set of potential catastrophic events E and their probability of occurrence PE .
All units center locations (xi , yi ) for i U.
Total occupied area Aland .
Optimal distances Di,j between units i U and dangerous units j H.
Optimal distances Dui,k between units, i, k U.
Final cost related to interconnection, equipment damage, workers injured and land.
With the goal to minimize the plant layout cost, PLC.

Espaciado mnimo
Tomado de: Kirk & Othmer. Plant Layout. En: Encyclopedia of Chemical Technology

Espaciado mnimo
Tomado de: Kirk & Othmer. Plant Layout. En: Encyclopedia of Chemical Technology

Ejemplo (parcial) de checklist para una distribucin

ideal
Spacing between process components
have adequate provisions been made for relieving explosions in process components?
are operating units and equipment within units spaced to minimize potential damage from
fires or explosions in adjacent areas?
are there safe exit routes from each unit?
has equipment been adequately spaced and located to safely permit anticipated
maintenance (e.g., pulling heat-exchanger bundles, dumping catalyst, lifting with cranes)
and hot work?
are vessels containing highly hazardous chemicals located sufficiently far apart? if not,
what hazards are introduced?
is there adequate access for emergency vehicles, e.g., fire trucks?
can adjacent equipment or facilities withstand the overpressure generated by potential
explosions?
can adjacent equipment and facilities, e.g., support structures, withstand flame
impingement?


ideal
Location of large inventories
are large inventories of highly hazardous chemicals located away from the process area?
is temporary storage provided for raw materials and finished products at appropriate
locations?
are the inventories for highly hazardous chemicals held to a minimum?
where applicable, are reflux tanks, surge drums, and rundown tanks located in a way that
avoids large-volume concentration of highly hazardous chemicals in any one area?
where applicable, has special consideration been given to storage and transportation of
explosives?
have the following been considered in the location of material handling areas: fire hazards
location relative to important buildings safety devices, e.g., sprinklers slope of area (is it
level?)


ideal
Location of engineering, lab, administration, or other buildings
are administration buildings located away from inventories of

highly hazardous chemicals?
are administration buildings located away from release points for
highly hazardous chemicals?
are workers in administration buildings protected from all of the
following:
toxic, corrosive, or flammable sprays, fumes, mists, or vapors
thermal radiation from fires (including flares)
overpressure and projectiles from explosions contamination of
utilities, e.g., water contamination of spills or runoff noise
transport of hazardous materials from other sites
flooding, e.g., ruptured storage tank odors

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Localizacin y distribucin en plantas qumicas

Departamento de Ingeniera Qumica

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 1 / 53

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 2 / 53

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 3 / 53

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 4 / 53

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 5 / 53

Factores a considerar (cont.)

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 6 / 53

Mtodo de Brown & Gibson

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 7 / 53

Mtodo de Brown & Gibson

Debe determinarse el costo anualizado de los factores objetivos en

Donde ci representa el valor anual total objetivo en la localizacin i

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 8 / 53

Mtodo de Brown & Gibson

Tomado de: Sapag y Sapag. Preparacin y evaluacin de proyectos. 5a. ed.

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 9 / 53

Mtodo de Brown & Gibson

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 10 / 53

Mtodo de Brown & Gibson

Tomado de: Sapag y Sapag. Preparacin y evaluacin de proyectos. 5a. ed

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 11 / 53

Mtodo de Brown & Gibson

Tomado de: Sapag y Sapag. Preparacin y evaluacin de proyectos. 5a. ed

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 12 / 53

Mtodo de Brown & Gibson

Tomado de: Sapag y Sapag. Preparacin y evaluacin de proyectos. 5a. ed

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 13 / 53

Mtodo de Brown & Gibson

La MPL depende del valor relativo de los factores objetivos y

MPLi = K FOi + (1 K ) FSi

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 14 / 53

Mtodo de Brown & Gibson

MPLA = (0.75)(0.34195) + (0.25)(0.2500) = 0.31895

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 15 / 53

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 16 / 53

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 17 / 53

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 18 / 53

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 19 / 53

Riesgos en la Industria Qumica

14 For the majority of businesses carrying out chemical reaction

38 There are essentially four major hazards in chemical

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 20 / 53

9 A risk assessment is an organised study of your work

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 21 / 53

Objetivos de la Distribucin en Planta

The plant layout shall be arranged for:

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 22 / 53

OIL AND CHEMICAL PLANT LAYOUT AND SPACING

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 23 / 53

Hazard Identification and Evaluation Program

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 24 / 53

Aspectos claves a considerar preliminarmente

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 25 / 53

Aspectos claves a considerar preliminarmente

Safety and Environment

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 26 / 53

Aspectos claves a considerar preliminarmente

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 27 / 53

Factores a considerar en la distribucin

High hazard operations Market share concerns

Felipe Bustamante (Dpto. IQ- UdeA) Localizacin & distribucin 28 / 53