Bioethanol Plant in a Sugar Factory: Equipment Layout and Piping Design

Planning for the replacement of a distillation column with piping design, steel structure adaptation and update of the approval-stage structural design

In a bioethanol plant within a sugar factory, a distillation column was to be replaced and supplemented with additional equipment. INOPCO provided the equipment layout and piping design as well as the structural and constructive integration into the existing facility.

Specific requirements resulted from the interfaces between the process licensor, the existing steel structure, new equipment, modified piping and the roof penetration for a vertical DN900 vapour line.

Update of the P&ID and extension of the planning scope to 15 lines
3D modelling of equipment, steel structures and piping
Piping isometrics, material lists and pipe stress calculation for DN900
Update of approval-stage structural design, connection calculations as well as installation and workshop planning

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Equipment layout and piping design for a distillation column in a bioethanol plant

Industry

Sugar / Bioethanol

Facility

Bioethanol plant

Focus

Structural, Piping design

Interface

Steel structure / statics

Planning Task

The column and additional equipment were designed, manufactured and supplied by the process licensor. The structural and planning task was to integrate the new equipment into the existing facility, modify or newly route piping and update the required steel structure and structural design documentation.

Process Interfaces

Adoption and update of the P&ID based on the available handwritten mark-ups.

3D Plant Model

Modelling of the new equipment based on dimensional data sheets and update of the steel structure and plant model.

Piping Design

Design of new and modified piping including isometrics and material lists.

Structure and Steelwork

Update of the approval-stage structural design and constructive integration of the new equipment into the steel structure.

Scope Modules

Two planning levels, one integrated plant concept

The planning was divided into two technically linked scopes: equipment layout and piping design on the one hand, and structural and steelwork design on the other.

Part 1: Layout and Piping

Review of project, existing and supplier documentation
Update of the P&ID in AutoCAD
Extension of the planning scope to 15 lines
Equipment layout drawings from the 3D model
Piping isometrics and material lists
Pipe stress calculation for the DN900 vapour line

Part 2: Structure and Steelwork

Integration of the planning into the structural concept
Update of the approval-stage structural design
Constructive solution for the DN900 roof penetration
Update of existing connection calculations
Installation and workshop planning for steel structures
Steel and parts lists as well as steel quantity determination

DN900 roof penetration and steel structure design for a bioethanol plant

Roof Penetration and DN900 Vapour Line

Constructive solution for a vertical line in the existing steel structure

A key planning aspect was the modification of the roof for the penetration of a vertical DN900 line. The necessary information for the executing trade was prepared in sketch form and linked to the updated approval-stage and connection calculations.

Result: Updated P&ID, equipment layout drawings, piping isometrics, material lists, pipe stress calculation DN900, updated approval-stage structural design, connection calculations and installation and workshop planning for the steel structure.