plant layout design for safety aspect
TRANSCRIPT
A PRESENTATION ON
PLANT LAYOUT DESIGN FOR SAFETY ASPECT
ENVIRONMENTAL ENGINEERING AND SCIENCES
ANURAG SINGHMT/ENV/10005/2013
2ST SEMESTER
Plant layout refers to the arrangement of physical facilities
such as machinery, equipment, furniture. within the
factory building in such a manner so as to have quickest
flow of material at the lowest cost and with the least
amount of handling in processing the product from the
receipt of material to the shipment of the finished product.
PLANT LAYOUT
Meet quality and capacity requirement in the most
economical manner
Minimize unit costs and optimize quality
Promote effective use of people, equipment, space and
energy
Provide for employee safety and comfort
Control project costs
Achieve production deadlines
GOALS OF PLANT LAYOUT DESIGN
New site development or addition to previously
developed site.
Type and quantity of products to be produced,
Possible future expansion,
Operational convenience and accessibility,
Type of process and product control,
Economic distribution of utilities and services,
PLANT LAYOUT BASED ON
Type of building and building code requirements,
Guidelines related to health and safety,
Waste-disposable problems,
Space available and space requirement,
Auxiliary equipment, and
Roads and railroad.
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22
12 11
5 5
1
Mechanical OperatorError
Unknown ProcessUpsets
NaturalHazards
Design Sabotageand Arson
Acc
iden
ts (
%)
CAUSES OF LOSSES IN LARGE PLANT ACCIDENTS
ProcessDesign
Procedure of Plant Layout Design
Information Gathering
Determine what will be produced Determine how many will be
produced Determine what components will
be made or purchased Determine required operations
Determine sequence of operations
Production and Flow AnalysisDetermine the
plant rate
Determine the number of machines
Study the flow requirement
Determine activity
relationships
Support Services
Identify needs for personal
and plant services
Identify office
needs
Develop total space
requirements
EQUIPMENT LAYOUT METHOD
STRAIGHT LINE
FIXED POSITION LAYOUT
COMBINED LAYOUT
FLOW CHART OF LINE LAYOUT
FIXED POSITION LAYOUT
COMBINED LAYOUT GROUP TECHNOLOGY LAYOUT OR HYBRID LAYOUT)
Forging Press
Forging Press
Gear Cutting Machine
Gear cutting Machine
Gear cutting Machine
Heat Treatment
Heat Treatment
Gear Grinding Machine
Gear Grinding Machine
Finished Output
RawMat.
Prevent, limit and mitigate escalation of adjacent
events
Ensure safety within on-site occupied buildings
Control access of unauthorized personnel
Facilitate access for emergency services
IMPORTANT FACTORS OF PLANT LAYOUT AS FAR AS SAFETY ASPECTS
Fig. Steps of a safety and risk analysis
PLANT LAYOUT FOR SEAFTY
General
Location of Buildings and Structures
Control Facilities
Escape
Flow Sheet
Layout of Equipment
Electrical Equipment
Ventilation, Heating and Air Conditioning
Storage
Receiving and Dispatching
Transportation system
Road and footpaths
Railway
Parking Areas
Fig. Layout System in the Process Area of a Petrochemical Plant
Fig. Layouts of Parking
An ideal plant layout should provide the optimum relationship among
output, floor area and manufacturing process. It facilitates the
production process, minimizes material handling, time and cost, and
allows flexibility of operations, easy production flow, makes
economic use of the building, promotes effective utilization of
manpower, and provides for employee’s convenience, safety, comfort
at work, maximum exposure to natural light and ventilation. It is also
important because it affects the flow of material and processes, labor
efficiency, supervision and control, use of space and expansion
possibilities
CONCLUSIONS
Plant location and layout by Abha Kumar
Bausbacher, E.F. & Hunt, R.W. 1993. Process Plant
Layout and Piping Design. Englewood Cliffs: Prentice
Hall.
Inherent safety in process plant design by AnnaMari
Heikkilä
Indian standard for Industrial plant layout - code of
safe Practice
Principles of Inherent Safe Design by Jo Fearnley
REFERENCE
THANK YOU“THE TIME SPENT ON
PLANNING WILL M
AKE
FOR A SAFER SITE AND
SAVE MONEY”