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Onshore Gathering Station Layout Design Fundamentals
Presentation · July 2021
DOI: 10.13140/RG.2.2.16727.19364
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Muhammad Riandhy Anindika Yudhy
Universitas Gadjah Mada
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Onshore Gathering Station
Layout Design Fundamentals
SPE UIR SC Guest Lecture
25 July 2021
Ir. Muhammad Riandhy Anindika Yudhy, M.Eng, IPM
Facility Engineer – Process Safety Management
Short Intro for Muhammad Riandhy
7+ years experience in oil & gas industry
Wireline & Borehole
Seismic Field Engineer
(2014)
Project Engineer
(2015 – 2016,
2018 – 2020)
Notable Achievements:
1. Top 10 Graduates in Eastern Hemisphere at
Halliburton Technical Training Program Cairo
Education Background
B.Eng
Engineering
Physics
M.Eng
Mechanical
Engineering
© 2020 PT. Chevron Pacific Indonesia
Reliability Engineer
(2016 – 2018)
Process Safety
Engineer
(2018 – 2021)
Notable Achievements:
1. Cumulative cost savings from implementation of Lean
Six Sigma > USD 25 MM
2. Lead multiple digital transformation initiatives:
a. Digital Operational Discipline Metric Monitoring
(Improve Operational Discipline by 32%)
b. Drone Smart Detection of Vegetation and
Insulator Failure in Power Line
c. Live One Line Diagram (Reduce Response Time
for Well Downtime by 50%)
d. Digital Pigging Procedure
e. Decision Support Centers (Integrated Operations,
Alarm, Equipment Reliability)
3. Recipient of more than 30 Awards for outstanding
support to Operations.
Executive Summary
Discussion






Introduction to Onshore
Surface Facilities
Basic Surface Facilities
Process
Basic Facility Layout
Design
Standards Governing
Equipment Layout in Oil
and Gas Industries
Design Basis for Facility
Layout
General Guidance in
Developing Facility Layout
Key Messages From the Discussion
 The basic process for surface facilities
is separation of the production fluid
into gas phase, oil phase, water phase
and solid/sand phase
 The facility layout shall satisfy the
requirement for safety, operability,
maintainability, constructability and
cost-effectiveness
 Guidance in developing facility plan
lay out shall refer to Industry
Standards as well as accommodate
the stakeholders concern
Desired Outcomes
Refresh the audience of the concept to design the appropriate lay out of gathering station facility
to meet the requirement set by industrial, local and national regulations
Introduction to Onshore Surface Facilities
The main purpose of a surface facility is to
separate the well stream into three
components, typically called “phases” (oil, gas,
and water), and process these phases into some
marketable product(s) or dispose of them in an
environmentally acceptable manner.
Basic surface facilities process and its target:
• Oil dehydration and degasification 
impurities in form of Basic Sediment &
Water (BS&W) < 1%
• Water treatment  water meet regulatory
spec
• Associated gas treatment  gas meet power
generator fuel spec
Basic Process in Surface Facilities
Gas is flashed from
the liquids and “free
water” is separated
from the oil.
Dry glycol is pumped to the large vertical contact tower,
where it strips the gas of its water vapor
Production header
heater-treaters that are used for removing
water from the oil and emulsion being
treated
Water-flood injection
Water from the separators must be treated to remove small quantities of produced oil.
If the water is to be injected into a disposal well, facilities may be required to filter
solid particles from it.
So many equipment, how do we arrange it
for optimum impact?
Basic Facility Layout Design
•
•
Definition: Arrangement of equipment and piping in a process plant that satisfy the 5 main
principles within the specified project schedule and budget
– Safety : Maximize safety & prevents spread of fire
– Operability & Maintainability: Facilitate easy Operations & Maintenance of the
facility
– Constructability: Facilitate easy construction
– Cost – effectiveness: Economize project
– Facilitate future expansion
The layout design must take into account the requirements from each of the disciplines
involved in the facility design
Facility Layout Design Flowchart
Conceptual
plot plan
study
•
•
•
•
Preliminary locations
of
• Major
equipment
• Access roads
• Major and
minor roads
• Buildings
• Fencing
• Flare location
Pipe racks and
sleeper ways
Wind rose (wind
direction)
True North
Plant North
Discipline
Engineering
Requirement
•
All equipment
nozzles must be
established in
accordance with the
proper elevation
and orientation to
satisfy process,
utility and
instrumentation
requirement
Constructa
bility
assessment
•
•
•
Erection
sequences
Accessibility of
construction
heavy equipment
Other special
construction
challenges that
might occur
Operability &
Maintainability
assessment
•
•
•
•
•
Locations of stairways,
ladders and operating
platform
Access requirement
around equipment for
Operations &
Maintenance Personnel
Egress and escape
routes around and from
equipment and
hazardous area
Access for plant
maintenance
requirement
Location of safety
equipment
Industry Standards Governance for
Petroleum Facility Layout Design
Several industry standard that is used in Facility Layout design:
•
•
•
•
•
•
•
•
•
•
ASME B31.3 Chemical Plant and Petroleum Refinery Piping
ASME B31.4 Petroleum Pipeline
ASME B31.8 Gas Transmission Pipeline
NFPA 30 Tank Storage
NFPA 58 Liquefied Petroleum Gas Storage and Handling
NFPA 59A Liquefied Natural Gas Storage and Handling
OSHA 1910 – 27 Fixed Stairs
OSHA 1910 – 24 Fixed Ladders
API RP 500 Recommended Practice for Classification of Locations for
Electrical Installations at Petroleum Facilities Classified as Class 1,
Division 1 and Division 2
PIP (Process Industry Practice)
Design Basis for Facility Layout
Facility Layout Plan is developed based on the information given by:
– PFD/P&ID/Hazardous Classification Area  Set the flow directions and the order of
equipment placement. This includes equipment spacing based on the major and critical lines
and the requirement of hazardous classified area
– Land, survey maps, geotechnical data and available real estate drawings  shows
available plot space to work with and the locations of roads, railroads and local housing and
buildings
– Local & National Regulations
– Soil and Climate Conditions
– Client philosophies and needs
Design Basis for Facility Layout
•
•
•
Hazardous classification area  A
location where fire/explosion hazards may
exist due to flammable gas/vapor,
flammable liquids, combustible dust or
ignitable fibers/flying (API RP 500 Definition)
– Class 1 Division 1  A location in which
ignitable concentrations of flammable
gas/vapors are expected to exist
under normal operating conditions
– Class 1 Division 2   A location in
which ignitable concentrations of
flammable gas/vapors may be present,
but normally are confined within a
closed system
The area classification is based on the
“hazard radius”. A function of:
– Volatility of the material being released
– Rate of material release
Hazard radius will influence the spacing
requirement of the equipment
General Guidance in Developing Facility
Layout
•
Some general guidance in developing facility layout summarized from the industry standards:
– The process area shall be located in the most convenient place for operating the process Unit.
– The storage area shall be located as far as possible from buildings occupied by personnel at the
site, but should be located near the process area for ready operation of the feed stocks and product
run-downs.
– The utilities area shall be located beside the process area for ready supply of utilities.
– Loading and unloading area shall be located on a corner of the site with capable connection to
public road directly, for inland traffics. For marine transportation, the area shall be located on the
seaside or riverside in the plant site.
– The administration and service area shall be located at a safe place on the site in order to protect
personnel from hazards. It shall preferably be located near the main gate alongside the main road
of the plant.
– Flare and burn pit shall be located at the end of the site with sufficient distance to prevent personnel
hazard.
– Waste water treating Unit shall be located near at the lowest point of the site so as to collect all of
effluent streams from the processing Unit.
– The process Unit to which the feed stock is charged first, shall be located on the side near the feed
stock tanks, to minimize the length of the feed line.
– The process Unit from which the final product(s) is (are) withdrawn, shall be located on the side
near the products tanks to minimize the length of the product run-down line.
– Process Units in which large quantities of utilities are consumed, should be preferably located on
the side near the utility center
General Guidance in Developing Facility
Layout
General Guidance in Developing Facility
Layout
General Guidance in Developing Facility
Layout
General Guidance in Developing Facility
Layout
Example of Plot Plan
Produced fluid coming in, the yellow arrow
follows the PFD mass and energy flow
Adequate space and access for
construction, maintenance and
operational activities
Water treatment facility located at
the low point of the area
Control
room
located far
from highly
reactive
area near
the road
and gate
Elevation
high to low
Major line located in
unobstructed area
Elevation
high to low
Flare and open pit
located far away
from personnel and
process area
Safe distance and spacing between equipment
Fixed Roof Flammable Liquid
Storage Tank
•
Class 1 Div 1 Radius 5’
•
Class 1 Div 2 Radius 10’
•
Distance between tanks as
per PIP 100’
Unit Separator
•
Class 1 Div 1 Radius 10’ – 25’
•
Class 1 Div 2 Radius 20’ – 35’
•
Distance between separators as per PIP 25’
•
Distance between separator & tanks as per PIP 200’
Q&A
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