Guidelines for Siting and Layout of Facilities

Since 1985, the Center for Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology. The CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 90 books in its process safety guidelines and process safety concepts series, and over 100 training modules through its Safety in Chemical Engineering Education (SAChE) series.

• List of Figures xiiiList of Tables xviiAcronyms and Abbreviations xixGlossary xxiAcknowledgments xxxiiiForeword xxxvPreface xxxvii1 Introduction 11.1 Objectives 11.2 A Siting and Layout Approach 31.3 How to Use This Guideline 41.4 The Protection Layers 71.5 Terminology 121.6 Guideline References 151.7 Separation Distances Based Primarily on Fire Consequences 152 Overview of Benefits 172.1 Implications of Siting and Layout 172.2 Management of Risks 182.3 Implementing a Step-wise Approach for the Siting and LayOut of Facilities 232.4 Anticipating the Changing World 252.5 Summarizing the Business Case for Proper Siting of a Facility 253 Identifying the Process Hazards and Risks 273.1 Introduction 273.2 Describing the Facility’s Scope 283.3 Screening for Preliminary Hazards 293.4 Evaluating the Risks 403.5 Checklist for Identifying the Process Hazards and Risks 403.6 Summary 414 Selecting a Facility Location 424.1 Introduction 424.2 Additional Information on the Facility 434.3 Selecting a Team to Locate the Facility 434.4 Guidelines when Surveying Potential Facility Locations 464.5 Determining the Location Plot Size 474.6 Construction and Turnaround Issues 514.7 Maps and Information 524.8 Geological Issues 544.9 Weather Issues 594.10 Seismic Issues 624.11 Off-site Issues 624.12 Security Issues 654.13 Environmental Issues 674.14 Infrastructure Issues 744.15 Building and Structure Issues 744.16 Material Handling Issues 744.17 Communications Issues 834.18 Engineering Design Issues 854.19 Utilities Issues 884.20 Other Characteristics 944.21 Preparing the Information when Comparing Locations 964.22 A Siting and Layout Illustration 974.23 Checklist for Selecting a Facility Location 1054.24 Summary 1065 Selecting the Process Unit Layout within a Facility 1075.1 Introduction 1085.2 Block Layout Methodology Overview 1105.3 How the Block Layout Integrates with theFacility Location 1185.4 Applying Preventive Measures when Arranging Process Units 1185.5 Applying Mitigative Measures when Arranging Process Units 1205.6 Construction and Turnarounds 1235.7 The Block Layout Approach: Step 1 – Evaluating the Location’s Characteristics 1285.8 Off-site Issues 1315.9 Security Issues 1345.10 Environmental Issues 1345.11 Infrastructure Issues 1345.12 The Block Layout Approach: Step 2 - Evaluating the Separation Distances between Blocks 1355.13 Critical and Occupied Structures 1395.14 Material Handling 1555.15 Process Units 1625.16 Tank Farms 1655.17 Other Areas 1695.18 Utilities 1745.19 Optimizing the Locations of the Process Units 1825.20 Resolving Block Layout Optimization Issues 1845.21 Continuing the Siting and Layout Illustration 1855.22 Checklist for Selecting the Layout of Process Units within a Facility 1905.23 Summary 1916 Selecting the Equipment Layout within a Process Unit 1936.1 Introduction 1936.2 Equipment Layout Methodology Overview 1946.3 How the Equipment Layout Integrates with the Block Layout 1986.4 Applying Preventive Measures when Arranging Equipment 1996.5 Applying Mitigative Measures when Arranging Equipment 2096.6 Critical and Occupied Structure Design 2196.7 Equipment 2286.8 Resolving Equipment Layout Optimization Issues 2336.9 Continuing the Siting and Layout Illustration 2346.10 Checklist for Selecting the Equipment Layout within a Process Unit 2396.11 Summary 2407 Managing Changes 2417.1 Introduction 2417.2 Addressing Surrounding Community and Industrial Expansions 2447.3 A Siting and Layout Approach when Managing Changes 2457.4 Maintaining Facility Integrity during its Life Cycle 2467.5 Managing Expansions at an Existing Facility 2507.6 Managing Purchases of Existing Facilities 2517.7 Monitoring changes with Periodic Reviews 2527.8 Addressing Siting and Layout Issues which are Identified During Expansions 2627.9 Summary 2628 Case Histories 2659 References 30110 Appendices 315Appendix A Additional Siting and Layout References 319Appendix B CCPS Recommended Distance Tables for Siting and Layout of Facilities 335Appendix C Checklist for Identifying the Process Hazards and Risks 338Appendix D Checklist for Selecting a Facility Location 342Appendix E Checklist for Selecting the Process Unit Layout within a Facility 347Appendix F Checklist for Selecting the Equipment Layout within a Process Unit 349Index 351