Process Plant Layout

Process Plant Layout

2nd Edition - November 16, 2016

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  • Author: Sean Moran
  • Paperback ISBN: 9780128033555
  • eBook ISBN: 9780128033562

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Process Plant Layout, Second Edition, explains the methodologies used by professional designers to layout process equipment and pipework, plots, plants, sites, and their corresponding environmental features in a safe, economical way. It is supported with tables of separation distances, rules of thumb, and codes of practice and standards. The book includes more than seventy-five case studies on what can go wrong when layout is not properly considered. Sean Moran has thoroughly rewritten and re-illustrated this book to reflect advances in technology and best practices, for example, changes in how designers balance layout density with cost, operability, and safety considerations. The content covers the ‘why’ underlying process design company guidelines, providing a firm foundation for career growth for process design engineers. It is ideal for process plant designers in contracting, consultancy, and for operating companies at all stages of their careers, and is also of importance for operations and maintenance staff involved with a new build, guiding them through plot plan reviews.

Key Features

  • Based on interviews with over 200 professional process plant designers
  • Explains multiple plant layout methodologies used by professional process engineers, piping engineers, and process architects
  • Includes advice on how to choose and use the latest CAD tools for plant layout
  • Ensures that all methodologies integrate to comply with worldwide risk management legislation


Process design engineers, chemical engineers, design engineers, chemical engineering students, mechanical engineers, manufacturing engineers

Table of Contents


    1 Introduction

    2 Layout in context

    3 Site layout principles

    4 Plot layout principles

    5 Planning of layout activities

    6 Methods for layout, conception and development

    7 Layout analogues and visual aids

    8 Hazard assessment of plant layout


    9 Transportation

    10 Bulk Fluid storage

    11 Bulk solids storage

    12 Warehouse storage

    13 Pollution Control

    14 Utilities I : General

    15 Utilities II : Water and Steam

    16 Central services

    17 Construction and layout

    18 Details of plot layout

    19 Layout within buildings


    20 Tanks and Drums

    21 Furnaces and fired equipment

    22 Distillation columns and towers

    23 Heat exchangers

    24 Reactors

    25 Mixers

    26 Filters

    27 Centrifuges

    28 Solids handling plant

    29 Dryers

    30 Filling and packaging

    PART IV: Detailed Layout: Materials Transfer Systems

    31 Pumps

    32 Compressors

    33 Conveyors

    34 Piping

    PART V: Detailed Layout: Other

    35 Pipe Stress Analysis

    36 Instrumentation

    Part VI APPENDICES       

    A. CAD

    B. Hazard assessment calculations

    C. Typical data for preliminary layouts

    D. Variants on the methodology

    E. Masterplanning

    F. Conversion factors for some common units

    G. Consolidated Terminology / Glossary

    H. Consolidated Standards and Codes of Practice

Product details

  • No. of pages: 756
  • Language: English
  • Copyright: © Butterworth-Heinemann 2016
  • Published: November 16, 2016
  • Imprint: Butterworth-Heinemann
  • Paperback ISBN: 9780128033555
  • eBook ISBN: 9780128033562

About the Author

Sean Moran

Sean Moran
Eur Ing Dr Seán Moran CEng is a practising chemical engineer with over thirty years of experience in process design, commissioning, and troubleshooting. He started his career with international process engineering contractors before setting up his own consultancy in 1996, specializing in process and hydraulic design for water, sewage and industrial effluent treatment plants. Sean spent several years in academia, where he held positions including a Royal Academy of Engineering Visiting Professorship, and is a strong advocate for the overhaul of traditional university chemical engineering curricula. He is the author of three textbooks and many articles on process plant design and layout, and has an international portfolio of design and forensic engineering projects.

Affiliations and Expertise

Engineering Consultant, Expertise Limited, Wirksworth, UK

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  • RafaelSequeira Mon Jul 23 2018

    Very good reference book

    Very good reference book