What is Plant Design?

Plant design is the creation and optimization of efficient and safe processes for constructing and operating plant facilities. Successful plant design ensures the seamless flow of materials, equipment and personnel at the facility, while maximizing productivity, safety and cost-efficiency.

What is a Plant?

A plant is a physical location where industrial, manufacturing or energy production processes take place. Plants are typically equipped with specialized machinery, equipment and technology tailored to the specific needs of the industry they serve. 

Plant facilities can vary in size and complexity, ranging from small factories to sprawling industrial complexes. Key elements of a plant include utilities to support operations, as well as safety measures to ensure compliance with regulations and the well-being of workers. Other elements depend on the type of facility. 

Industrial Plants

Industrial plants transform raw materials into finished goods for consumers and businesses. They typically include areas for raw material storage, production lines, quality control, packaging and distribution. These plants may also house administrative offices, research and development labs and maintenance workshops. 

Industrial plants have a strong focus on efficiency, safety and sustainability. They often require stringent operational controls to meet production targets while adhering to environmental and regulatory standards. 

Power Plants

Power plants generate electricity by converting energy from various sources into electrical power. They operate using specialized equipment such as turbines, solar,  generators and transformers to produce and distribute electricity. Depending on the energy source, power plants may also incorporate systems for emissions control and environmental protection. 

The Importance of Plant Design

In sectors like manufacturing, oil and gas, pharmaceuticals and food and beverage , effective plant design directly influences productivity and profitability. A well-designed plant layout reduces material handling time, eliminates bottlenecks and optimizes resource use, leading to higher output and cost savings.

Moreover, plant design is essential for workplace safety. Properly planned layouts and systems help minimize hazards, prevent accidents and promote a safe working environment.

The Plant Design Process

The plant design process includes the following stages:

Conceptual Design

The conceptual design is the first step in developing a new plant. It establishes a preliminary design and determines if it is feasible to build the plant. This Front-End loading (FEL) step  includes determining the site master plan, size, location and configuration of key functional and non-functional areas and optimizing critical operational processes including equipment. The conceptual design also considers space utilization, material handling and workforce ergonomics.

When large capital expenditures are required, a Front-End Engineering Design (FEED) study is often used. This iterative process evaluates various alternatives for each component and system in the conceptual design before making significant investments in construction.

Detailed Design

The detailed design phase leverages the content and layout of the conceptual design and involves developing drawings and defining specifications and plans of the plant. This stage includes 3D CAD modeling of the plant including piping, electrical and instrumentation required for monitoring operations within the plant facility and designing facilities such as storage tanks and utility systems (e.g., water supply lines). Essentially building a digital twin of the proposed facility, both stages are crucial for the successful development of an industrial plant, with conceptual design setting the stage and detailed design ensuring that the project can be built and operated effectively.

Procurement 

The majority of the materials, including pipe, steel, etc., will be purchased based on the estimates from the conceptual and detailed phases of the project. Any specialized equipment may also be ordered based on the conceptual design due to the time it takes to manufacture. The procurement department uses bills of materials, materials take-offs and materials requisitions to establish transmittals for vendor/supplier bids and manage eventual material fulfillment.

Fabrication and Construction 

Fabrication involves the manufacturing and assembly of components and equipment that will be used in the industrial plant. This includes producing components, such as steel structures, piping, tanks and machinery, according to design specifications. The most cost-effective project approach is to perform as much assembly and welding of components at the fabricator/supplier as conditions are more controlled. Some parts may be made from scratch, depending on need and availability.

Construction is building the physical facility as detailed in a planned sequence that groups teams, tools, material availability and other constraints into an efficient actional plan to ensure optimum erection of the facility. The physical construction of the plant includes site preparation, equipment installation and infrastructure development. This phase requires collaboration among architects, engineers, contractors and project managers to ensure the facility meets operational, safety and environmental standards. 

Plant Design Teams

Plant design often involves professionals specializing in process, mechanical, electrical, instrumentation and control engineering. Process engineers design the process flow, mechanical engineers handle equipment selection and layout, electrical engineers manage electrical systems and instrumentation and civil and structural engineers ensure infrastructure and structural safety.

Collaboration and coordination are crucial in plant design projects to ensure seamless integration of different disciplines. Regular meetings, clear communication channels and collaborative software tools facilitate a smooth project.

Onshore vs Offshore Plant Design

There are two main categories of plant design: onshore and offshore. Understanding the differences, challenges and considerations in each type is crucial for successful project execution.

Onshore Plant Design

Onshore plants are typically located near raw material sources, markets and infrastructure. They benefit from easy access to resources, transportation networks and skilled labor. They are also generally more cost-effective to build and operate than offshore plants. Examples include refinery complexes, power plants and chemical manufacturing facilities.

Offshore Plant Design

Offshore plants are located in marine environments and are often used for extracting seabed oil and gas reserves. They face unique challenges because of harsh conditions, including extreme weather, corrosive environments, limited access and overall space and weight limitations. Offshore plant design requires specialized expertise, advanced technologies and stringent safety measures.

When designing offshore plants, teams must consider factors such as platform or floating structure selection, corrosion and erosion protection, transportation logistics and environmental impact assessments. Offshore projects also require adherence to specific regulations and standards set by governing bodies.

Examples of offshore plant design projects include offshore oil rigs, floating liquefied natural gas (LNG) facilities and subsea production systems.

Visualization in Plant Design and Engineering

Visualization is another critical component of plant design, enabling engineers and designers to create, analyze and communicate complex concepts effectively. By representing design ideas visually, it becomes easier to understand and evaluate various aspects of plant design, leading to better decision-making and improved project outcomes.

Tools for Plant Visualization

Industrial facilities have unique visualization requirements in that the space volume of the components is much more important than the internal workings of the equipment or device, as the focus is on the safe operation and maintenance of the facility. Several tools and technologies are available for plant design visualization, each serving a specific purpose. Computer-aided design (CAD) software allows designers to create detailed 2D schematic layouts and 3D models that can form a digital twin of plant layouts, equipment and piping systems. These models can be visualized and manipulated in virtual environments, providing a realistic representation of the final plant and allowing teams to test various layouts and configurations.

Virtual reality (VR) and augmented reality (AR) technologies are increasingly utilized in plant design visualization. These technologies leverage the 3D detailed model to simulate a virtual environment for users to provide a sense of scale and spatial awareness. AR overlays digital information onto the physical world, enabling designers to visualize plant components in their real-world context and potentially help train users on the safe operation of many aspects of the facility. 

Benefits of Plant Visualization

Visualization of plant designs improves collaboration between stakeholders because it removes the complexity of operating engineering software and provides a simple and direct way to view and orient the detailed information for review and collaboration with team members. By using visualization to review and analyze designs almost in real-time, these individuals can identify potential issues such as potential bottlenecks, optimize layouts and make informed decisions regarding equipment placement and process flow. Visualizations can also aid engineers in ensuring the plant is efficient, safe and meets required compliance, maintenance accessibility and production specifications.

Choosing the Right Plant Design Software

When choosing plant design software for your organization, consider the following:

Visibility and Workflow

One of the biggest challenges for plant project teams is the numerous silos of critical engineering, vendor/supplier and legacy (if required) information. With so many unique disciplines working in specialized solutions, having an easy way to link and visualize all this information in a simple environment is a real challenge. In many cases, industrial facility engineering teams have replicated old paper-based work processes into newer database solutions and have not taken full advantage of the technologies at hand. This results in inefficient workflows and continues to hamper the ability to break the information silos. 

To avoid these complications, look for software that gives you the necessary visibility and flexibility for your process.

File Compatibility   

There are several industrial plant design software solutions on the market today, but they all have their data formats and file types. When you work with multiple solutions to complete your project, you may need to convert files from one format to another. This can be time-consuming and frustrating for users trying to get their job done efficiently. Avoid this problem by selecting software that brings siloed information into a transparent and collaborative environment.

Industry Requirements 

Project teams often find it challenging to find solutions that meet industry requirements. Look for software that complies with any necessary standards. Even better, look for software that will help ensure your designs meet regulatory and safety requirements. 

Ability to Collaborate in 2D and 3D     

Plant designers require the ability to visualize the proposed design in both 2D and 3D formats.  That means the designer needs the ability to quickly switch back and forth with a simple user environment tailored for design review or comparison. 

Closing Statement     

 At Hexagon, we understand the complexities of both onshore and offshore plant design. Our comprehensive software solutions, including CAD, CAE and project management tools, empower engineers and designers to optimize plant design processes, enhance collaboration and ensure compliance with industry standards. With Hexagon’s advanced technologies, you can achieve efficient and cost-effective plant design, regardless of the project’s location or complexity.

Learn more about Intergraph Smart® 3D and CADWorx® Plant Professional - our industry-leading solutions for plant design.